CAUTION

In order to reduce the chance of personal injury and/or property damage, carefully observe
the in stru ction s that follow :

S ervice in fo rm a tio n pro vide d by General M otors C orporation is intended fo r use by

professional, qualified technicians. A ttem pting repairs or service w ith o ut the appropriate
training, tools, and equipm ent could cause injury to you or others. This could also damage
the vehicle, or cause the vehicle to operate im properly.

Proper vehicle service and repair are im portant to the safety of the service technician and to
the safe, reliable operation of all m otor vehicles. If you need to replace a part, use the same
part num ber or an equivalent part. Do not use a replacement part of lesser quality.

The service procedures we recommend and describe in this manual are effective m ethods of
perform ing service and repair. Some of the procedures require the use of tools that are
designed fo r specific purposes.

A ccordingly, any person who intends to use a replacem ent part, a service procedure, or a
tool that is not recommended by General Motors, m ust firs t establish that there is no
jeopardy to personal safety or the safe operation of the vehicle.

This manual contains CAUTIONS that you m ust observe carefully in order to reduce the risk
o f injury to yourself or others. This manual also contains NOTICES that m ust be carefully
follow ed in order to avoid im proper service that may damage the vehicle, or damage too ls or
equipm ent. These CAUTIONS and NOTICES are not exhaustive. General Motors can not
p ossibly warn of all the potentially hazardous consequences of your failure to fo llo w these
in structions.

If the vehicle being serviced is equipped with a Supplem ental Inflatable Restraint (SIR), refer
to the CAUTIONS in the follow ing service manual section/service category type before
perform ing a service on or around SIR Components or w iring:

• S u b -S e ctio n 9J - S u p p le m e n ta l In fla ta b le R e stra in ts, re fe r to CAUTIONS u n d e r

On-Vehicle Service and the SIR Com ponent W iring Location view, or,
• Section - Body and Accessories, Sub-Section - Restraints, refer to CAUTIONS under
On-Vehicle Service and the SIR Com ponent W iring Location view.

Failure to follo w these CAUTIONS could cause air bag deployment, personal injury, or
otherw ise unneeded SIR repairs.

In 1order to help avoid accidental air bag deploym ent and personal injury, whenever you
service a vehicle that requires repair of the SIR and another vehicle system , we recommend
that you firs t repair the SIR, then go on to the other system.
 Mixed Style Service Manual Structure
This service manual is a mix of the old style GM service manual and the new style that
will be completely transitioned for the 1999 model year. For 1998 this manual consists
of three volumes. The following table shows the section content by volume and the
style the information was written in.

Volum e 1 Volum e 2 Volum e 3

0 - General Information New 2 - Steering Old 6 - Engine New
1 - HVAC Old 3 - Suspension New Volum e 4
8 - Chassis/Body Electrical Old 4 - Driveline/Axle New 6 - Engine - Continued New
9 - Accessories Old 5 - Brakes New 7 - Transmission/Transaxle New
10 - Body Old

Another change to the old style sections is that all of the sub-section Table of Contents
have been brought forward to the front of the section and the information is listed in
book order for that section. These Table of Contents have been enhanced and are to
be used to locate information in those sections as there are not index entries in the
Index for the old style sections.

The following table gives the previous service manual sub-sections with the name of
the new section and sub-section. If a section is new style, it will contain the diagnosis
that was previously in Section 8A. Also, Seat Belts and SIR is found in Sub-Section 9J
in Accessories this year.

Please bear with us through this transition year. We hope the information found in the
following tables and the enhanced Table of Contents will enable you to more easily find
the information you need.
 Truck Service Manual Sub-Section to Section
and Sub-Section Conversion Table
O ld New
Sub-Section O ld Sub-Section Section Section Nam e Sub-Section Name
OA General Information Preface Cautions and Notices Cautions and Notices
OA General Information 0 General Information General Information
OB Maintenance and Lubrication 0 General Information Maintenance and Lubrication
OC Vibration Diagnosis 0 General Information Vibration Diagnosis
1A Heating and Ventilation 1A HVAC Heating and Ventilation
Heating, Ventilation, and Heating, Ventilation, and
1B Air Conditioning 1B HVAC Air Conditioning
1D2 A/C Compressors 1D2 HVAC A/C Compressors
2A Frame and Bumpers 10A5 Body Frame and Bumpers
2B Sheet Metal 10A6 Body Sheet Metal
3A Front Wheel Alignment 3 Suspension Wheel Alignment
Power Steering Gear Power Steering Gear and
3B and Pump 2B Steering Pump
Power Steering Gear Unit Power Steering Gear Unit
3B1A Repair 2B1A Steering Repair
Power Steering Pump Unit Power Steering Pump Unit
3B1B Repair 2B1B Steering Repair
3B3 Steering Linkage 2B3 Steering Steering Linkage
3C Front Suspension 3 Suspension Front Suspension
3D Rear Suspension 3 Suspension Rear Suspension
3E Tires and Wheels 3 Suspension Tires and Wheels
3F Steering Columns 2F Steering Steering Wheel and Column
4A Propeller Shaft 4 Driveline/Axle Propeller Shaft
4B1, 4B2,
4B3, 4B4,
4B5, 4B7 Rear Axle and Differential 4 Driveline/Axle Rear Drive Axle
Front Drive Axles Front Wheel Drive Shafts
4C, 4C2 and Differential 4 Driveline/Axle and Front Drive Axle
4D1 Drive Axle Unit Repair 4 Driveline/Axle Rear Drive Axle
5A Hydraulic Brakes 5 Brakes Hydraulic Brakes
5A1, 5A1A Master Cylinder 5 Brakes Hydraulic Brakes
5B1 Front Disc Brakes 5 Brakes Disc Brakes
5B2 Rear Disc Brakes 5 Brakes Disc Brakes
Leading/Trailing Drum
5C1 Brakes 5 Brakes Drum Brakes
5C2 Duo-Servo Brakes 5 Brakes Drum Brakes
5D1, 5D2,
5D2A Hydraulic or Vacuum Booster 5 Brakes Hydraulic Brakes
5F Parking Brake 5 Brakes Parking Brake
5E Anti lock Brakes 5 Brakes Antilock Brakes
 Truck Service Manual Sub-Section to Section
and Sub-Section Conversion Table (cont’d)
Old New
Sub-Section Old Sub-Section Section Section Nam e Sub-Section Name
6, 6A Engine Mechanical 6 Engine Engine Mechanical
6B Engine Cooling and Radiator 6 Engine Engine Cooling
6D Engine Electrical 6 Engine Engine Electrical
— Driveability and Emissions 6 Engine Engine Controls
6F Exhaust System 6 Engine Exhaust System
6H Vacuum Pump 6 Engine Vacuum Pump
6J Turbocharger 6 Engine Turbocharger
Automatic Transmission, and
Transmission/Transfer Case
7A Automatic Transmission 7 T ransmission/T ransaxle Unit Repair Manual
Manual Transmission, and
Transmission/Transfer Case
7B Manual Transmission 7 T ransmission/T ransaxle Unit Repair Manual
7C Clutch 7 Transmission/Transaxle Clutch
Transfer Case, and
Transmission/Transfer Case
7D Transfer Case 4 Driveline/Axle Unit Repair Manual
8A Electrical Diagnosis 8A Electrical Diagnosis Electrical Diagnosis
8B Lighting Systems 8B Body Lighting Systems
Instrument Panel and Instrument Panel and
8C Gauges 8C Body Gauges
8D Chassis Electrical 8D Body Chassis Electrical
8E1 Windshield Wiper/Washers 8E1 Body Wiper/Washer Systems
Rear Window Wiper Washer Rear Window Wiper Washer
8E2 System 8E2 Body System
9A Audio Systems 9A Body Audio Systems
9B Cruise Control 9B Body Cruise Control
9E Engine Coolant Heater 9E Engine Engine Cooling
9F Luggage Carrier 9F Body Luggage Carrier
Supplemental Inflatable Supplemental Inflatable
9J Restraint 9J Restraints Restraints
9K Remote Keyless Entry 9K Body Remote Keyless Entry
10A1 Doors 10A1 Body Doors
10A2 Body Seats
10A2 Seats 9J Restraints Seat Belts
10A3 Stationary Windows 10A3 Body Windows
10A4 Interior Trim 10A4 Body Interior Trim
10A5 Endgate 10A7 Body Body Rear End
10B Cab and Body Maintenance 10B Body Sheet Metal
BLANK
 1LJ8 C/K THic'
Service Manual
Volume 4

This manual provides information on the diagnosis, the service procedures, the adjustments, and the
specifications for the 1998 C/K Truck.

Information on transmission unit repair (overhaul) can be found in the 1998 Transmission/Transaxle/Transfer Case
Unit Repair Manual (TURM), GMPT/98-TURM, available seperately. The TURM manual contains information on
automatic and manual transmissions and transaxles, and transfer cases for all GM passenger cars and light duty
trucks, including the fluid flow and circuit description information.

The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better
service the vehicle owners.

When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in
place of the recommended item. All information, illustrations and specifications in this manual are based on the
latest product information available at the time of publication approval. General Motors reserves the right to make
changes at any time without notice.

Published by

NORTH AMERICAN OPERATIONS

General Motors Corporation
Warren, Michigan 48090

©1997 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

The information cutoff date is 3/26/97. LITHO IN U.S.A.

No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means
(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of
General Motors Corporation. This applies to all text, illustrations, and tables.
BLANK
 Table of Contents
V o lu m e 1
P re fa c e
Cautions and Notices................................................ 1
G e n e ra l I n f o r m a t io n ............................................0-1
General Information................................................0-3
Maintenance and Lubrication..............................0-41
Vibration Diagnosis and Correction................... 0-85
H V A C ..............................................................................1
Heater and Ventilation......................................... 1A-1
Heater, Ventilation and Air Conditioning............1B-1
HD6/HT6 Air Conditioning Compressor
Service or Unit Repair R-134a..................... 1D2-1
E le c tr ic a l...................................................................... 8
Electrical Diagnosis............................................. 8A-1
Lighting Systems................................................. 8B-1
Instrument Panel and Gauges........................... 8C-1
Chassis Electrical................................................ 8D-1
Windshield Wiper/Washer System..................... 8E-1
Rear Window Wiper/Washer System.................8E-2
A c c e s s o r ie s ................................................................9
Audio Systems..................................................... 9A-1
Cruise Control.......................................................9B-1
Passlock System ................................................. 9D-1
Engine Coolant Heater........................................ 9E-1
Luggage Carrier....................................................9F-1
Running Boards................................................... 9G-1
Restraints...............................................................9J-1
Seat Belts.......................................................... 9J-1
Supplemental Inflatable Restraints (SIR).... 9J-47
Remote Keyless Entry......................................... 9K-1
B o d y ............................................................................ 10
Doors................................................................. 10A1-1
Seats................................................................ 10A2-1
Windows............................................................ 10A3-1
Interior Trim....................................................... 10A4-1
Frame and Bumpers........................................ 10A5-1
Sheet Metal....................................................... 10A6-1
Endgate..............................................................10A7-1
Cab and Body Maintenance..............................10B-1
Volume 2
Preface
Cautions and Notices................................................ 1
Steering ........................................................................ 2
Power Steering Gear and Pump....................... 2B-1
Power Steering Gear Unit Repair..................2B1A-1
Power Steering PumpUnit Repair................. 2B1B-1
Steering Linkage.................................................2B3-1
Speed Dependent Steering Electronic
Variable Orifice (EVO)...................................2B5-1
Steering Wheel and Column On Vehicle
Service............................................................... 2F-1
Supplemental Inflatable Restraint (SIR)
Standard Steering Column Unit Repair...... 2F4-1
Supplemental Inflatable Restraint (SIR)
Tilt Steering Column Unit Repair................. 2F5-1
Suspension ..............................................................3-1
Suspension General Diagnosis............................. 3-3
Wheel Alignment.................................................. 3-17
Front Suspension................................................. 3-35
Rear Suspension.................................................. 3-93
Tires and W heels............................................... 3-113
Driveline/Axle ......................................................... 4-1
Propeller Shaft........................................................ 4-5
Wheel Drive Shafts..............................................4-29
Front Drive A x le ................................................... 4-49
Rear Drive A xle.................................................. 4-103
Rear Drive Axle - Locking/Limited Slip
Rear A xle ........................................................ 4-169
Transfer Case..................................................... 4-181
Brakes ....................................................................... 5-1
Hydraulic Brakes.................................................... 5-5
Disc Brakes............................................................5-89
Drum Brakes....................................................... 5-123
Park Brake...........................................................5-145
Antilock Brake System...................................... 5-163
 Table of Contents - Continued

Volume 3 Volume 4
Preface Preface
Cautions and Notices............................................... 1 Cautions and Notices............................................... 1
Engine............................................................ 6-1 Engine ........................................................................6-1
Engine Mechanical - 4.3L....................................6-23 Engine Controls - 6 .5 L .................................... 6-2279
Engine Mechanical - 5.0L,5.7L......................... 6-237 Engine Controls - 7.4L.................................... 6-2677
Engine Mechanical - 6.5L..................................6-455 Turbocharger.....................................................6-3239
Engine Mechanical - 7.4L..................................6-687 Vacuum Pump...................................................6-3253
Engine Cooling....................................................6-927 Engine Exhaust.................................................6-3259
Engine Electrical................................................ 6-991 Transmission/Transaxle...............................7-1
Engine Controls - 4 .3 L ....................................6-1089 Manual Transmission -New Venture..................... 7-7
Engine Controls - 5.0, 5.7L............................ 6-1643 Automatic Transmission - 4L60-E...................... 7-39
Automatic Transmission - 4L80-E.................... 7-269
Clutch.................................................................. 7-593
 REPORTING ERRORS AND SUGGESTIONS
If you find an error in a GM Service manual, or if you have a suggestion about a GM service manual, we
want to hear from you.

When calling, be prepared with the following information:

• Your name
• Your dealership’s name
• Your dealership’s phone number
• The model year and the vehicle line
• The publication part number (if present)
• The vehicle identification number of the vehicle being worked on
• The service manual section and page number(s)
• Any applicable electronic information element identification numbers
• A descriptive explanation of your concern

The GM service manual phone personnel will respond to your concerns in the following ways:
• By delivering your concern to the manual’s author.
• By eliciting a response from the author.
• By supplying you with an answer to your concerns.

For paper manual users: The GM service manual phone personnel will also explain how to send in examples
or marked-up pages.

For electronic manual users: Be prepared to provide any applicable identification numbers pertaining to the
electronic information that you are questioning.

The GM service manual comment telephone numbers do not provide technical assistance. For technical
assistance, contact your regular technical assistance source.

United States and Canada General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-828-6860,
fax number 810-265-9327, 8:00 a.m.-8:00 p.m. Eastern Time Zone.

Canada, French Speaking General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-503-3222,
fax number 810-265-9327, 8:00 a.m.-6:00 p.m. Eastern Time Zone.

International English Speaking General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 810-265-0840,
fax number 810-265-9327, 8:00 a.m.-6:00 p.m. Eastern Time Zone.

United States and Canadian Vehicle Owner/Operator

Vehicle owners or operators are encouraged to address their comments and concerns to the applicable
Customer Assistance Center. The phone number and address of the Customer Assistance Centers are in the
Owner’s Manual.

GM I ServiceTechnology Group
BLANK
Preface
Preface
Cautions and Notices ............................................3
Definition of Caution, Notice, and Important..... 3
ABS Handling Caution......................................... 3
Battery Disconnect Caution................
Brake Dust Caution...............................................3
Brake Fluid Caution..............................................4
Clutch Dust Caution..............................................4
Electric Coolant Fan Caution............................... 4
Fuel and EVAP Pipe Caution.............................. 4
Fuel Pipe Fitting Caution..................................... 4
Fuel Storage Caution............................................4
Gasoline/Gasoline Vapors Caution......................4
Lower O-Ring Removal Caution..........................4
Moving Parts and Hot Surfaces Caution........... 4
Relieving Fuel Pressure Caution.........................4
Road Test Caution................................................4
Safety Glasses and Compressed Air Caution ...5
Safety Goggles and Fuel Caution.......................5
Seat Belt Replacement Caution..........................5
Shop Towel Fuel Link Caution............................5
SIR Caution........................................................... 5
SIR Handling Caution...........................................5
Table of Contents -1
SIR Inflator Module Disposal Caution................ 5
SIR Inflator Module Handling and
Storage Caution................................................5
3 SIR Special Tool Caution..................................... 5
Vehicle Lifting Caution.... ..................................... 5
Window Removal Caution................................... 5
Window Retention Caution.................................. 6
Work Stall Test Caution....................................... 6
o> o> o> o>
Defective Scan Tool Notice
Fastener Notice...................
Fuel Pressure Notice.........
Handling ESD Sensitive Parts Notice
Handling IAC Valve Notice.................................. 7
Ignition OFF When Disconnecting Battery
Notice.................................................................7
Latched DTC B1018, B1024 Notice
(SDM-RSD)....................................................... 7
Nylon Fuel Lines Notice...................................... 7
OBDII System Description Notice.......................7
PCM and ESD Notice.......................................... 7
Servicing and Replacing Seat Belts Notice...... 7
Single Cylinder Flooding Notice..........................7
 Preface

BLANK
Preface
Cautions and Notices
Definition of Caution, Notice, and
Important
Cautions, N otices, and Im portants in the
Service Manual
The diagnosis and repair procedures in the GM
Service Manual contain both general and specific
Cautions, Notices, and Importants. GM is dedicated
to the presentation of service information that helps
the technician to diagnose and repair the systems
necessary for the proper operation of the vehicle,
however, certain procedures may present a hazard
to the technician if they are not followed in the
recommended m anner. Cautions, Notices, and
Importants are elements designed to prevent these
hazards, however, not all hazards can be foreseen.
This information is placed at strategic locations within
the service manual. This information is designed to
prevent the following from occurring:
• Serious bodily injury to the technician
• Damage to the vehicle
• Unnecessary vehicle repairs
• Unnecessary component replacement
• Improper repair or replacement of vehicle
components. Any caution or notice that appears
in general information is referenced from the
individual service categories.
CAUTION Defined
When encountering a CAUTION, you will be asked
to take a necessary action or not to take a
prohibited action. If a CAUTION is not heeded, the
following consequences may occur:
1. Serious bodily injury to the technician
2. Serious bodily injury to other technicians in the
workplace area
3. Serious bodily injury to the driver and/or
passenger(s) of the vehicle, if the vehicle has
been improperly repaired
NOTICE Defined
Notices call special attention to a necessary action
or to a prohibited action. If a NOTICE is not heeded,
the following consequences may occur:
• Damage to the vehicle
• Unnecessary vehicle repairs
• Unnecessary component replacement
• Improper operation or performance of the
system or component under repair
• Damage to any systems or components which
are dependent upon the proper operation of the
system or component under repair
• Improper operation or performance of any
systems or components which are dependent
upon the proper operation or performance of
the system or component under repair
Cautions and Notices - 3
• Damage to fasteners, basic tools, or
special tools
• The leakage of coolant, lubricant, or other vital
fluids
IMPORTANT Defined
IMPORTANT statements emphasize a necessary
characteristic of a diagnostic or repair procedure.
IMPORTANT statements are designed to do the
following:
• Clarify a procedure
• Present additional information for accomplishing
a procedure
• Give insight into the reason or reasons for
performing a procedure in the manner
recommended
• Present information that will help to accomplish
a procedure in a more effective manner
. Present information that gives the technician
the benefit of past experience in accomplishing
a procedure with greater ease
ABS Handling Caution
Caution: Certain components In the Antilock
Brake System (ABS) are not intended to be
serviced individually. Attempting to remove or
disconnect certain system components may
result In personal injury and/or Improper system
operation. Only those component with approved
removal and installation procedures should be
serviced.
Battery Disconnect Caution
Caution: Disconnect the negative battery cable
under the following circumstances:
• When Installing an electrical unit.
• When a tool or equipment could easily come
into contact with "live" exposed electrical
terminals.
Failure to disconnect the negative battery
terminal may result in personal Injury or damage
to the vehicle’s components. Turn OFF the
vehicle ignition, unless instructed otherwise.
Brake Dust Caution
Caution: Avoid taking the following actions when
you service wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry
brush or with compressed air.
Many earlier model or aftermarket brake parts
may contain asbestos fibers which can become
airborne in dust. Breathing dust with asbestos
fibers may cause serious bodily harm. Use a
water-dampened cloth in order to remove any
dust on brake parts. Equipment is available
4 - Cautions and Notices
commercially In order to to perform this washing
function. These wet methods prevent fibers from
becoming airborne.
Brake Fluid Caution
Caution: Brake fluid may be Irritating to the skin
or eyes. In case o f contact, take the following
actions:
• Eye contact - rinse eyes thoroughly with
water.
• Skin contact - wash skin with soap and
water.
Clutch Dust Caution
Caution: Avoid taking the following actions when
you service wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry
brush or with compressed air.
Many earlier model or aftermarket brake parts
may contain asbestos fibers which can become
airborne in d u st Breathing dust with asbestos
fibers may cause serious bodily harm. Use a
water-dampened cloth In order to remove any
dust on brake parts. Equipment Is available
commercially in order to to perform this washing
function. These wet methods prevent fibers from
becoming airborne.
Electric Coolant Fan Caution
Caution: An electric fan under hood can start
even when the engine Is not running and can
injure you. Keep hands, clothing and tools away
from any underhood electrical fan.
Fuel and EVAP Pipe Caution
Caution: In order to Reduce the Risk o f Fire and
Personal Injury observe the following items:
• Replace all nylon fuel pipes that are nicked,
scratched or damaged during Installation, Do
Not attempt to repair the, sections o f the
nylon fuel pipes
• Do Not hammer directly on the fuel harness
body clips when installing new fuel pipes.
Damage to the nylon pipes may result In a
fuel leak.
• Always cover nylon vapor pipes with a wet
towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115°C (239°F) for more than one
hour, o r more than 90'C (194'F) for any
extended period.
• Apply a few drops o f clean engine oil to the
male pipe ends before connecting fuel pipe
fittings. This w ill ensure proper reconnection
and prevent a possible fuel leak. (During
normal operation, the O-rings located in the
female connector w ill swell and may prevent
proper reconnection if not lubricated.)
Preface
Fuel Pipe Fitting Caution
Caution: Always apply a few drops o f clean
engine oil to the male pipe ends before
connecting fuel pipe fittings In order to reduce
the risk o f fire and personal injury.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the O-rings located in
the female connector will swell and may prevent
proper reconnection If not lubricated.
Fuel Storage Caution
Caution: Do not drain the fuel into an open
container. Never store the fuel in an open
container due to the possibility o f a fire or an
explosion.
Gasoline/Gasoline Vapors Caution
Caution: Gasoline or gasoline vapors are highly
flammable. A fire could occur If an ignition
source Is present. Never drain or store gasoline
or diesel fuel In an open container, due to the
possibility of fire or explosion. Have a dry
chemical (Class B) fire extinguisher nearby.
Lower 0-Ring Removal Caution
Caution: Verify that the lower (small) O-ring o f
each injector does not remain in the lower
manifold in order to reduce the risk o f fire and
personal Injury.
If the O-ring is not removed with the injector, the
replacement injector with new O-rings will not
seat properly in the injector socket. Improper
seating could cause a fuel leak.
Moving Parts and Hot Surfaces Caution
Caution: While working around a running engine,
avoid contact with moving parts and hot surfaces
to prevent possible bodily Injury.
Relieving Fuel Pressure Caution
Caution: Relieve the fuel system pressure before
servicing fuel system components in order to
reduce the risk o f fire and personal injury.
After relieving the system pressure, a small
amount o f fuel may be released when servicing
the fuel lines or connections. In order to reduce
the chance o f personal Injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This w ill catch any fuel that may
leak out. Place the towel In an approved
container when the disconnection is complete.
Road Test Caution
Caution: Road test a vehicle under safe
conditions and while obeying all traffic laws. Do
not attempt any maneuvers that could jeopardize
vehicle control. Failure to adhere to these
precautions could lead to serious personal injury.
Preface
Safety Glasses and Compressed Air
Caution
Caution: Wear safety glasses when using
compressed air in order to prevent eye injury.
Safety Goggles and Fuel Caution
Caution: Always wear safety goggles when
working with fuel in order to protect the eyes
from fuel splash.
Seat Belt Replacement Caution
Caution: Replace belts, retractors, and hardware
in use during all but a minor collision. Also,
restraint systems should be replaced and
anchorage’s properly repaired if they were in
areas damaged by collision, whether the belt was
in use or not. If there is any question, replace
the belt system. Damage, whether visible or not,
could result in serious personal injury in the
event o f an accident.
Shop Towel Fuel Link Caution
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk
o f fire and personal Injury. The towel will absorb
any fuel leakage that occurs during the
connection o f the fuel pressure gauge. Place the
towel in an approved container when the
connection o f the fuel pressure gauge is
complete.
SIR Caution
Caution: This vehicle has a Supplemental
Inflatable Restraint (SIR) System. Refer to SIR
Component Location View In order to determine
whether you are performing service on or near
the SIR components or the SIR wiring. When you
are performing service on or near the SIR
components or the SIR wiring, refer to SIR
On-Vehlcle Service Information. Failure to follow
the CAUTIONS could cause air bag deployment,
personal Injury, o r unnecessary SIR system
repairs.
SIR Handling Caution
Caution: When you are carrying an undeployed
inflator module:
• Do not carry the inflator module by the
wires or connector on the inflator module
• Make sure the bag opening points away
from you
When you are storing an undeployed Inflator
module, make sure the bag opening points away
from the surface on which the inflator module
rests. When you are storing a steering column,
do not rest the column with the bag opening
facing down and the column vertical. Provide free
space for the air bag to expand In case o f an
accidental deployment. Otherwise, personal Injury
may result.
Cautions and Notices - 5
SIR Inflator Module Disposal Caution
Caution: In order to prevent accidental
deployment o f the air bag which could cause
personal injury, do not dispose o f an undeployed
inflator module as normal shop waste. The
undeployed inflator module contains substances
that could cause severe illness or personal injury
if the sealed container is damaged during
disposal. Use the following deployment
procedures to safely dispose o f an undeployed
inflator module. Failure to dispose o f an inflator
module as instructed may be a violation o f
federal, state, province, or local laws.
SIR Inflator Module Handling and Storage
Caution
Caution: When you are carrying an undeployed
inflator module:
• Do not carry the inflator module by the
wires or connector on the inflator module
• Make sure the bag opening points away
from you
When you are storing an undeployed Inflator
module, make sure the bag opening points away
from the surface on which the inflator module
rests. When you are storing a steering column,
do not rest the column with the bag opening
facing down and the column vertical. Provide free
space for the air bag to expand In case o f an
accidental deployment. Otherwise, personal injury
may result.
SIR Special Tool Caution
Caution: In order to avoid deploying the air bag
when troubleshooting the SIR system, use only
the equipment specified In this manual and the
instructions given in this manual. Failure to use
the specified equipment as Instructed could
cause air bag deployment, personal injury to you
or someone else, or unnecessary SIR system
repairs.
Vehicle Lifting Caution
Caution: To help avoid personal injury, when a
vehicle Is on a hoist, provide additional support
for the vehicle a t the opposite end from which
you are removing components. The additional
support will reduce the possibility o f the vehicle
falling off the hoist. When you are removing
major components from the vehicle while the
vehicle is on a hoist, chain the vehicle frame to
the hoist pads at the same end from which you
are removing the major components to prevent
tip-off. If you fail to follow these precautionary
measures, vehicle damage, serious personal
injury, or death may result.
Window Removal Caution
Caution: When working with any type o f glass,
use approved safety glasses and gloves to
reduce the chance o f personal injury.
6 - Cautions and Notices Preface

Window Retention Caution locking compound or sealant are identified in the

service procedure. Do not use paints, lubricants, or
Caution: When replacing stationary windows, corrosion inhibitors on fasteners or fastener joint
Urethane Adhesive K it GM P/N 12346284, or a surfaces unless specified. These coatings affect
urethane adhesive system meeting GM fastener torque and joint clamping force and may
Specification GM3651M, must be used to damage the fastener. Use the correct tightening
maintain original installation integrity. Failure to sequence and specifications when installing fasteners
use the urethane adhesive kit will result in poor in order to avoid damage to parts and systems.
retention o f the window which may allow
unrestrained occupants to be ejected from the Fuel Pressure Notice
vehicle resulting in personal injury.
Notice: Do not allow the fuel pressure to exceed the
Work Stall Test Caution specified value because damage to the fuel pressure
regulator or the fuel pressure gauge may result.
Caution: One or more o f the following guidelines
may apply when performing specific required Handling ESD Sensitive Parts Notice
tests in the work stall:
1. When a test requires spinning the drive
wheels with the vehicle jacked up, adhere to
the following precautions: N O TICE
• Do not exceed 56 km/h (35 mph) when
spinning one drive wheel with the other
drive wheel stopped. This lim it is
necessary because the speedometer
indicates only one-half the actual vehicle
speed under these conditions. Personal
injury may result from excessive wheel
spinning.
• If all o f the drive wheels are spinning at
the same speed, do not exceed 112 km/h
(70 mph). Personal injury may result from
excessive wheel spinning. CONTENTS SENSITIVE
• A ll persons should stay clear o f the TO
rotating components and the balance STATIC ELECTRICITY
weight areas in order to avoid possible
personal injury. 6392
• When running an engine in the repair stall
Electrostatic discharge (ESD) can damage many
for an extended period o f time, use care
solid state electrical components. Not all components
not to overheat the engine and the
that are susceptible to damage from ESD are
transmission.
labeled with the ESD symbol. Exercise caution when
2. When a test requires Jacking up the vehicle handling all solid state electrical components.
and running with the wheels and brake
Avoid damaging solid state electrical components by
rotors removed, adhere to the following
taking the following precautions:
precautions:
• Discharge personal electricity by touching a
• Do not apply the brake with the brake
metal ground point after each of the following
rotors removed.
activities:
• Do not place the transmission in Park
- sliding across the vehicle seat
with the drive wheels still spinning.
- sitting or rising
• Turn Off the ignition in order to stop the
powertrain components from spinning. - walking
• Do not touch the exposed electric terminals on
Defective Scan Tool Notice a component with your finger or a tool. The
Notice: Do not use a scan tool that displays faulty connector that you are checking may be tied
data. Report the scan tool problem to the into a circuit that is susceptible to damage by
manufacturer. Use of a faulty scan tool can result in ESD.
misdiagnosis and unnecessary parts replacement. • Do not allow a screwdriver or a similar tool to
contact exposed terminals when disconnecting
Fastener Notice a connector.
Notice: Use the correct fastener in the correct • Do not remove the protective packing of the
location. Replacement fasteners must be the correct solid state component until you are ready to
part number for that application. Fasteners requiring install the solid state component.
replacement or fasteners requiring the use of thread
Preface
• Unless specified in a particular diagnostic
procedure, avoid the following activities:
- jumpering components or connectors
- grounding components or connectors
- using test equipment probes on components
or connectors
. When a diagnosis requires the use of test
equipment probes, connect the ground
lead first.
. Touch the solid state component’s package to a
ground before opening.
• Do not lay the solid state component in any of
the following locations:
- On a metal work bench
- On top of an electrically operating appliance
or piece of equipment, like a TV, radio or
oscilloscope
• Do not drop the solid state component.
Handling IAC Valve Notice
Notice: If the IAC valve has been in service: DO
NOT push or pull on the IAC valve pintle. The force
required to move the pintle may damage the threads
on the worm drive. Also, DO NOT soak the IAC
valve in any liquid cleaner or solvent, as damage
may result.
Ignition OFF When Disconnecting Battery
Notice
Notice: Always turn the ignition OFF when
connecting or disconnecting battery cables, battery
chargers, or jumper cables. Failing to do so may
damage the Powertrain Control Module (PCM) or
other electronic components.
Latched DTC B1018, B1024 Notice
(SDM-RSD)
Notice: When DTC B1018 or B1024 has been set it
is necessary to replace the inflatable restraint
Sensing and Diagnostic Module (SDM). Setting DTC
B1018 or B1024 will also cause DTC B1071 to set.
When a scan tool clear codes command is issued
and the malfunction is no longer present, DTC
B1018 or B1024 and DTC B1071 will remain current.
Make sure that the short to ground condition is
repaired prior to installing a replacement SDM to
avoid damaging the SDM.
Nylon Fuel Lines Notice
Notice: Do not attempt to straighten the kinked
nylon fuel lines. Replace any kinked nylon fuel feed
or return pipes in order to prevent damage to the
vehicle.
Cautions and Notices - 7
OBDII System Description Notice
Notice: The OBD II symbol is used on the circuit
diagrams in order to alert the technician that the
circuit is essential for proper OBD II emission control
circuit operation. Any circuit which, if it fails causes
the Malfunction Indicator Lamp (MIL) to turn on, is
identified as an OBDII circuit.
PCM and ESD Notice
Notice: Do not touch the connector pins or soldered
components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage to
the PCM.
Servicing and Replacing Seat Belts Notice
Notice: To prevent possible seat belt damage, refer
to the following items before servicing or replacing
lap and shoulder belts, including single loop belt
systems:
1. Lap and shoulder belts will be serviced as
follows:
1.1. Replace only the part in question.
1.2. All belts need to be serviced as a set to
assure the belt components are from the
same supplier.
1.3. Do not intermix standard and deluxe
belts on front or rear seats.
1.4. All attachment hardware must be
replaced, not reused.
2. Keep sharp edges and damaging objects away
from belts.
3. Avoid bending or damaging any portion of the
belt buckle or latch plate.
4. Do not bleach or dye belt or strap webbing.
Clean with a mild soap solution and water.
5. When installing lap or shoulder belt anchor
bolts, start the bolts by hand to ensure that the
bolts are threaded straight.
6. Do not attempt repairs on lap or shoulder belt
retractor mechanisms to lap belt retractor
covers. Replace defective assemblies with new
service replacement parts.
7. Do not attempt to remove the seat belt retractor
cover. The cover and the long rivet securing the
cover to the retractor are not available as
service replacement parts.
Single Cylinder Flooding Notice
Notice: In order to prevent flooding of a single
cylinder and possible engine damage, relieve the fuel
pressure before performing the fuel injector coil test
procedure.
 Preface

BLANK
Engine
Section 6
Engine
E n g in e M e c h a n ic a l - 4 .3 L ..............................6-23
S pecifications...................................................... 6-23
Fastener Tightening Specifications................ 6-23
Engine Mechanical Specifications................. 6-25
GM SPO Group Numbers............................... 6-28
Sealers, Adhesives, and Lubricants.............. 6-29
Diagnostic Information and P rocedures...... 6-30
Base Engine Misfire Diagnosis...................... 6-30
Engine Compression Test...............................6-32
Engine Noise Diagnosis.................................. 6-32
Valve Train Diagnosis..................................... 6-32
Oil Consumption Diagnosis.............................6-35
Oil Pressure Diagnosis and Testing.............. 6-35
Oil Leak Diagnosis.......................................... 6-36
Drive Belt Diagnosis (2nd)..............................6-37
Drive Belt Tensioner Diagnosis.......................6-41
Visual Ide n tification............................................6-42
Disassembled V iew s....................................... 6-42
Repair In s tru ctio n s.............................................6-47
Drive Belt Replacement.................................. 6-47
Drive Belt Tensioner Replacement................ 6-48
Drive Belt Idler Pulley Replacement............. 6-49
Engine Mount Inspection (Front)................... 6-50
Engine Mount Inspection (Rear).................... 6-50
Engine Mount Replacement (Front).............. 6-51
Engine Mount Replacement (Rear RWD).....6-53
Engine Mount Replacement (Rear 4W D ).....6-55
Intake Manifold Replacement (Upper)........... 6-57
Intake Manifold Replacement (Lower)........... 6-60
Valve Rocker Arm Cover Replacement
(Left Side)..................................................... 6-64
Valve Rocker Arm Cover Replacement
(Right S ide).................................................. 6-66
Valve Rocker Arm and
Push Rod Replacement..............................6-68
Valve Stem Oil Seal and
Valve Spring Replacement.........................6-69
Valve Lifter Replacement................................ 6-72
Exhaust Manifold Replacement......................6-74
Cylinder Head Replacement...........................6-76
Crankshaft Balancer Replacement................ 6-80
Engine Front Cover Replacement................. 6-82
Crankshaft Position Reluctor Ring
Replacement................................................ 6-86
Timing Chain and Sprockets
Replacement................................................ 6-87
Balance Shaft Replacement...........................6-90
Table of Contents 6-1
Balance Shaft Bearing and/or
Bushing Replacement................................. 6-94
Camshaft Replacement................................... 6-95
Oil Filter Adapter and
Valve Assembly Replacement................. 6-102
Oil Pan Replacement.................................... 6-103
Oil Level Indicator and
Tube Replacement.................................... 6-104
Oil Pump Replacement................................. 6-106
Crankshaft Rear Oil Seal and
Housing Replacement (Housing)............. 6-107
Crankshaft Rear Oil Seal and
Housing Replacement (Seal)....................6-110
Engine Flywheel Replacement
(Manual Transmission)...............................6-111
Engine Replacement......................................6-112
Engine Oil and Oil Filter Replacement...... 6-123
Draining Fluids and Oil Filter Removal...... 6-123
Engine Flywheel Removal............................6-124
Exhaust Manifold Removal (Left S ide)...... 6-125
Exhaust Manifold Removal (Right Side).... 6-125
Water Pump Removal................................... 6-126
Crankshaft Balancer Removal......................6-126
Valve Rocker Arm Cover Removal............. 6-128
Distributor Removal....................................... 6-129
Throttle Body Removal................................. 6-129
Intake Manifold Removal..............................6-130
Valve Rocker Arm and
Push Rod Removal................................... 6-130
Cylinder Head Removal................................ 6-131
Valve Lifter Removal..................................... 6-132
Oil Pan Removal............................................6-133
Oil Pump Removal.........................................6-134
Oil Level Indicator and Tube Removal...... 6-134
Engine Front Cover Removal...................... 6-135
Timing Chain and Sprockets Removal....... 6-135
Balance Shaft Removal................................6-136
Camshaft Removal........................................ 6-138
Piston, Connecting Rod, and
Bearing Rem oval...................................... 6-139
Crankshaft Rear Oil Seal and
Housing Removal...................................... 6-140
Crankshaft and Bearings Removal.............. 6-141
Oil Filter Adapter and
Valve Assembly Removal.........................6-141
Engine Block Plug Removal.........................6-142
Engine Block Clean and Inspect..................6-145
6-2 Table of Contents
Cylinder Boring and Honing......................... 6-146
Crankshaft and Bearings
Clean and Inspect..................................... 6-147
Crankshaft Balancer Clean and Inspect......6-154
Engine Flywheel Clean and Inspect...........6-155
Piston and Connecting Rod
Disassemble.............................................. 6-156
Piston, Connecting Rod and
Bearings Clean/lnspect............................ 6-157
Piston Selection............................................. 6-160
Piston and Connecting Rod Assemble........6-161
Camshaft Bearing Removal
(Removal Procedure)................................6-162
Camshaft Bearing Removal
(Tool Instructions)...................................... 6-164
Camshaft and Bearings
Clean and Inspect..................................... 6-165
Camshaft Bearing Installation...................... 6-167
Balance Shaft Bearing and/or
Bushing Removal..................................... 6-168
Balance Shaft Clean and Inspect...............6-169
Balance Shaft Bearing and/or
Bushing Installation..................................6-170
Timing Chain and Sprockets
Clean and Inspect....................................6-171
Valve Rocker Arm and
Push Rods Clean and Inspect...............6-171
Valve Lifters and Guides
Clean and Inspect....................................6-172
Cylinder Head Disassemble........................ 6-173
Cylinder Head Clean and Inspect............. 6-174
Valve Guide Reaming/Valve
and Seat Grinding....................................6-176
Cylinder Head Assemble............................. 6-178
E n g in e M e c h a n ic a l - 5 .0 L , 5 .7 L ................ 6-237
Oil Pump Disassemble................................ 6-180
Oil Pump Clean and Inspect.......................6-182
Oil Pump Assemble......................................6-182
Valve Rocker Arm Cover
Clean and Inspect....................................6-184
Oil Pan Clean and Inspect..........................6-185
Intake Manifold Disassemble......................6-185
Intake Manifold Clean and Inspect............ 6-189
Intake Manifold Assemble...........................6-190
Exhaust Manifold Clean and Inspect.........6-194
Water Pump Clean and Inspect................ 6-195
Service Prior to Assembly...........................6-196
Engine Block Plug Installation................... 6-196
Oil Filter Adapter and
Valve Assembly Installation................... 6-199
Crankshaft and Bearings Installation.........6-200
Crankshaft Rear Oil Seal
and Housing Installation......................... 6-201
Piston, Connecting Rod,
and Bearing Installation......................... 6-202
Camshaft Installation................................... 6-203
Balance Shaft Installation........................... 6-204
Timing Chain and Sprockets Installation....6-206
Engine
Engine Front Cover Installation................... 6-208
Oil Level Indicator and Tube Installation.... 6-208
Oil Pump Installation..................................... 6-209
Oil Pan Installation........................................ 6-209
Valve Lifter Installation.................................. 6-211
Cylinder Head Installation.............................6-212
Valve Rocker Arm and
Push Rod Installation................................ 6-213
Intake Manifold Installation (Upper).............6-214
Intake Manifold Installation (Lower).............6-215
Throttle Body Installation...............................6-217
Crankshaft Balancer Installation.................. 6-218
Distributor Installation.................................... 6-219
Valve Rocker Arm Cover Installation...........6-220
Water Pump Installation................................ 6-221
Exhaust Manifold Installation (Left Side).... 6-222
Exhaust Manifold Installation
(Right S ide)................................................6-223
Engine Flywheel Installation..........................6-223
Engine Set-Up and Testing...........................6-225
Description and O pe ra tio n............................. 6-226
Engine Component Description................... 6-226
New Product Information............................... 6-226
Engine Identification...................................... 6-227
Lubrication....................................................... 6-229
Thread Repair.................................................6-229
Cleanliness and Care.................................... 6-230
Replacing Engine Gaskets............................ 6-230
Use of RTV and Anaerobic Sealer.............. 6-231
Separating Parts.............................................6-231
Tools and Equipment..................................... 6-232
Special Tools and E quipm ent........................6-233
S pe cifica tio ns.................................................... 6-237
Fastener Tightening Specifications.............. 6-237
Engine Mechanical Specifications (L30)......6-239
Engine Mechanical Specifications (L31)......6-241
GM SPO Group Numbers.............................6-243
Sealers, Adhesives, and Lubricants............6-245
Diagnostic Information and Procedures......6-246
Base Engine Misfire Diagnosis.................... 6-246
Engine Compression Test.............................6-248
Engine Noise Diagnosis................................ 6-248
Valve Train Diagnosis.................................... 6-248
- Oil Consumption Diagnosis...........................6-251
Oil Pressure Diagnosis and Testing............6-251
Oil Leak Diagnosis.........................................6-251
Drive Belt Diagnosis (Rev 2 ) ...................6-253
Drive Belt Tensioner Diagnosis............... 6-257
Visual Ide n tificatio n......................................... 6-258
Disassembled Views...................................... 6-258
Repair In stru ctio n s...........................................6-263
Drive Belt Replacement............................... 6-263
Drive Belt Tensioner Replacement......... 6-264
Engine
Drive Belt Idler Pulley Replacement...........6-265
Engine Mount Inspection (Front)................. 6-266
Engine Mount Inspection (Rear).................. 6-266
Engine Mount Replacement
(Front C Model)......................................... 6-267
Engine Mount Replacement
(Front K Model)......................................... 6-268
Engine Mount Replacement
(Rear C Model Manual Trans)................ 6-270
Engine Mount Replacement
(Rear C Model Auto Transmission)........6-271
Engine Mount Replacement
(Rear 15k GVW 4WD Auto).................... 6-272
Engine Mount Replacement
(Rear 15k GVW 4WD Manual)............... 6-273
Intake Manifold Replacement (Lower)........6-274
Intake Manifold Replacement (Upper)........6-282
Valve Rocker Arm Cover Replacement.......6-285
Valve Rocker Arm and
Push Rod Replacement............................6-288
Valve Stem Oil Seal and
Valve Spring Replacement.......................6-290
Valve Lifter Replacement..............................6-294
Exhaust Manifold Replacement
(Left Side)...................................................6-297
Exhaust Manifold Replacement
(Right Side)................................................6-299
Cylinder Head Replacement.........................6-301
Crankshaft Balancer Replacement.............. 6-307
Crankshaft Front Cover
Oil Seal Replacement............................... 6-309
Engine Front Cover Replacement............... 6-310
Crankshaft Position Reluctor
Ring Replacement..................................... 6-314
Timing Chain and Sprockets
Replacement..............................................6-315
Camshaft Replacement................................. 6-317
Oil Filter Adapter and
Valve Assembly Replacement................. 6-326
Oil Pan Replacement.................................... 6-327
Oil Level Indicator and
Tube Replacement.................................... 6-331
Oil Pump, Pump Screen
and Deflector Replacement..................... 6-333
Crankshaft Rear Oil Seal and
Housing Replacement (Housing)............. 6-335
Crankshaft Rear Oil Seal and
Housing Replacement (Seal)....................6-338
Engine Flywheel Replacement
(Manual Transmission).............................. 6-339
Engine Flywheel Replacement
(Automatic Transmission).........................6-340
Engine Replacement..................................... 6-341
Engine Oil and Oil Filter Replacement...... 6-351
Draining Fluids and Oil Filter Removal...... 6-351
Engine Flywheel Removal............................6-352
Exhaust Manifold Removal (Left Side)....... 6-352
Table of Contents 6-3
Exhaust Manifold Removal (Right Side).....6-353
Water Pump Removal................................... 6-353
Crankshaft Balancer Removal..................... 6-354
Valve Rocker Arm Cover Removal
(Left S ide).................................................. 6-355
Valve Rocker Arm Cover Removal
(Right Side)................................................ 6-356
Distributor Removal........................................6-356
Throttle Body Removal................................. 6-356
Intake Manifold Removal.............................. 6-357
Valve Rocker Arm and
Push Rod Removal................................... 6-358
Cylinder Head Removal (Left S ide)............ 6-359
Cylinder Head Removal (Right Side).......... 6-359
Valve Lifter Removal......................................6-360
Oil Pan Removal............................................6-361
Oil Pump, Pump Screen and
Deflector Removal.................................... 6-362
Oil Level Indicator and Tube Removal.......6-362
Engine Front Cover Removal.......................6-363
Timing Chain and Sprockets Removal........ 6-364
Camshaft Removal.........................................6-365
Piston, Connecting Rod, and
Bearing Removal...................................... 6-366
Crankshaft Rear Oil Seal and
Housing Removal...................................... 6-367
Crankshaft and Bearings Removal.............. 6-368
Oil Filter Adapter and
Valve Assembly Removal.........................6-369
Engine Block Plug Removal.........................6-369
Engine Block Clean and Inspect..................6-372
Cylinder Boring and Honing.........................6-373
Crankshaft and Bearings
Clean and Inspect..................................... 6-374
Crankshaft Balancer Clean and Inspect.... 6-382
Engine Flywheel Clean and Inspect........... 6-382
Piston and Connecting Rod
Disassemble............................................... 6-383
Piston, Connecting Rod and
Bearings Clean/lnspect............................. 6-384
Piston Selection.............................................. 6-388
Piston and Connecting Rod Assemble...... 6-389
Camshaft Bearing Removal..........................6-390
Camshaft and Bearings
Clean and Inspect......................................6-391
Camshaft Bearing Installation.......................6-393
Timing Chain and Sprockets
Clean and Inspect..................................... 6-394
Valve Rocker Arm and
Push Rods Clean and Inspect................ 6-395
Valve Lifters and Guides
Clean and Inspect..................................... 6-395
Cylinder Head Disassemble..........................6-396
Cylinder Head Clean and Inspect............... 6-397
Valve Guide Reaming/Valve
and Seat Grinding......................................6-400
6-4 Table of Contents
Valve Rocker Arm Stud Removal................6-402
Valve Rocker Arm Stud Installation.............6-402
Cylinder Head Assemble...............................6-403
Oil Pump Disassemble................................. 6-404
Oil Pump Clean and Inspect........................ 6-406
Oil Pump Assemble......................................6-407
Valve Rocker Arm Cover
Clean and Inspect..................................... 6-409
Oil Pan Clean and Inspect........................... 6-409
Intake Manifold Disassemble....................... 6-409
Intake Manifold Clean and Inspect..............6-412
Intake Manifold Assemble............................ 6-413
Exhaust Manifold Clean and Inspect...........6-415
Water Pump Clean and Inspect.................. 6-416
Service Prior to Assembly.............................6-417
Engine Block Plug Installation..................... 6-417
Oil Filter Adapter and
Valve Assembly Installation.................... 6-420
Crankshaft and Bearings Installation.......... 6-421
Crankshaft Rear Oil Seal and Housing
Installation.................................................. 6-421
Piston, Connecting Rod, and Bearing
Installation.................................................. 6-422
Camshaft Installation.................................... 6-424
Timing Chain and Sprockets Installation....6-424
Engine Front Cover Installation................... 6-426
Oil Level Indicator and Tube Installation.... 6-426
Oil Pump, Pump Screen and Deflector
Installation.................................................. 6-427
Oil Pan Installation.......................................6-428
Valve Lifter Installation................................. 6-430
Cylinder Head Installation (Left Side).........6-430
Cylinder Head Installation (Right S ide)..... 6-431
Valve Rocker Arm and
Push Rod Installation...............................6-432
Valve Lash Adjustment.................................6-433
Intake Manifold Installation...........................6-434
Throttle Body Installation..............................6-436
Crankshaft Balancer Installation................. 6-436
Distributor Installation................................... 6-438
Valve Rocker Arm Cover
Installation (Left Side)................... .......... 6-439
Valve Rocker Arm Cover Installation
(Right Side)................................................6-439
Water Pump Installation...............................6-440
Exhaust Manifold Installation (Left Side).... 6-440
Exhaust Manifold Installation
(Right Side)............................................... 6-441
Engine Flywheel Installation........................ 6-441
Engine Set-Up and Testing......................... 6-443
Description and O peration........................... 6-444
Engine Component Description..................6-444
New Product Information............................. 6-445
Engine Identification...... .............................. 6-446
Lubrication......................................................6-446
Thread Repair............................................... 6-447
Engine
Cleanliness and Care.................................... 6-448
Replacing Engine Gaskets............................6-448
Use of RTV and Anaerobic Sealer..............6-448
Separating Parts.............................................6-449
Tools and Equipment..................................... 6-450
Special Tools and E quipm ent........................6-451
E n g in e M e c h a n ic a l - 6 . 5 L ............................6-455
S pe cifica tio ns....................................................6-455
Fastener Tightening Specifications.............. 6-455
Engine Mechanical Specifications................ 6-456
GM SPO Group Numbers.............................6-460
Sealers, Adhesives, and Lubricants............ 6-461
Diagnostic Information and Procedures.... 6-462
Engine Cranking Speed Test........................6-462
Engine Compression Test............................ 6-462
Engine Noise Diagnosis............................... 6-462
Valve Train Diagnosis................................... 6-463
Oil Pressure Diagnosis and Testing........... 6-464
Oil Leak Diagnosis....................................... 6-464
Drive Belt Diagnosis..................................... 6-466
Drive Belt Tensioner Diagnosis................... 6-470
Visual Ide n tificatio n .........................................6-471
Disassembled Views..................................... 6-471
Repair in s tru c tio n s ....................................... . 6-477
Drive Belt Replacement............................... 6-477
Drive Belt Tensioner Replacement............. 6-478
Drive Belt Idler Pulley Replacement...........6-479
Engine Mount Inspection............................... 6-481
Engine Mount Replacement (Front)............ 6-482
Engine Mount Replacement (Rear)............. 6-484
Intake Manifold Replacement (Upper).........6-489
Intake Manifold Replacement (Lower).........6-492
Oil Pump Drive Replacement..................... 6-496
Oil Level Indicator and
Tube Replacement................................... 6-500
Valve Rocker Arm Cover Replacement..... 6-502
Valve Rocker Arm, Shaft, and
Push Rod Replacement...........................6-507
Exhaust Manifold Replacement (L e ft)....... 6-511
Exhaust Manifold Replacement (Right)..... 6-514
Cylinder Head Replacement....................... 6-517
Valve Stem Oil Seal and
Valve Spring Replacement...................... 6-529
Valve Lifter Replacement............................ 6-533
Crankshaft Balancer Replacement........ . 6-538
Crankshaft Front Oil Seal Replacement.... 6-542
Engine Front Cover Replacement..............6-545
Timing Chain and Sprockets
Replacement............................................. 6-553
Camshaft Replacement................................6-560
Crankshaft Rear Oil Seal Replacement.... 6-566
Engine Flywheel Replacement....................6-570
Oil Filter Adapter and
Valve Assembly Replacement................ 6-572
Oil Pan Replacement...................................6-574
Engine
Oil Pump Replacement................................. 6-578
Engine Replacement..................................... 6-580
Engine Oil and Oil Filter Replacement.......6-590
Accessory Removal....................................... 6-590
Engine Flywheel Removal............................6-591
Oil Fill Tube Removal................................... 6-591
Oil Level Indicator and Tube Removal.......6-592
Thermostat Removal..................................... 6-592
Intake Manifold Removal (L56)................... 6-593
Intake Manifold Removal (L 6 5)................... 6-594
Intake Manifold Removal (L56, L65)........... 6-595
Engine Wiring Harness
Assembly Removal (Engine Wiring
Harness-Removal)..................................... 6-596
Turbocharger Removal.................................. 6-598
Oil Pump Drive Removal..............................6-600
Exhaust Manifold Removal...........................6-600
Water Pump Removal................................... 6-601
Fuel Injection Pump Removal (L65)............ 6-602
Crankshaft Balancer Removal..................... 6-604
Engine Front Cover Removal.......................6-605
Timing Chain Wear Check............................6-605
Timing Chain and Camshaft
Sprocket Removal..................................... 6-606
Valve Rocker Arm Cover Removal.............. 6-607
Valve Rocker Arm, Shaft, and
Push Rod Removal................................... 6-607
Cylinder Head Removal................................ 6-608
Valve Lifter Removal..................................... 6-609
Camshaft Removal.........................................6-610
Oil Pan Removal............................................ 6-611
Oil Pump Removal.........................................6-611
Piston, Connecting Rod, and
Bearing Removal........................................6-612
Crankshaft Rear Oil Seal Removal............. 6-613
Crankshaft and Bearings Removal.............. 6-614
Oil Filter Adapter and
Valve Assembly Removal.........................6-615
Engine Block Plug Removal.........................6-615
Piston Oil Cooling Nozzle Removal............ 6-616
Engine Block Clean and Inspect................. 6-617
Cylinder Boring and H oning.........................6-618
Crankshaft and Bearings
Clean and Inspect..................................... 6-621
Crankshaft Balancer Clean and Inspect.... 6-625
Engine Flywheel Clean and Inspect............ 6-625
Piston and Connecting Rod
Disassemble...............................................6-626
Piston, Connecting Rod and
Bearings Clean/lnspect............................. 6-627
Piston Selection.............................................. 6-629
Piston and Connecting Rod Assemble...... 6-629
Camshaft Bearing Removal..........................6-631
Camshaft and Bearings
Clean and Inspect......................................6-632
Camshaft Bearing Installation.......................6-632
Table of Contents 6-5
Timing Chain and Sprockets
Clean and Inspect..................................... 6-634
Valve Rocker Arm and Shaft
Disassemble............................................... 6-634
Valve Rocker Arm and Shaft
Clean and Inspect......................................6-635
Valve Rocker Arm and Shaft Assemble.....6-635
Valve Lifters and Guides
Clean and Inspect......................................6-636
Cylinder Head Disassemble..........................6-636
Cylinder Head Clean andInspect............... 6-637
Valve Guide ReamingA/alve
and Seat Grinding......................................6-639
Cylinder Head Assemble.............................. 6-640
Oil Pump Disassemble.................................. 6-642
Oil Pump Clean and Inspect........................6-643
Oil Pump Assemble.......................................6-644
Engine Front Cover Clean and Inspect......6-646
Valve Rocker Arm Cover
Clean and Inspect......................................6-646
Oil Pan Clean and Inspect........................... 6-646
Intake Manifold Clean and Inspect............. 6-646
Exhaust Manifold Clean and Inspect.......... 6-646
Water Pump Clean and Inspect...................6-646
Fuel Injection Pump Clean and Inspect......6-646
Service Prior to Assembly............................ 6-647
Piston Oil Cooling Nozzle Installation......... 6-648
Engine Block Plug Installation......................6-648
Oil Filter Adapter and Valve
Assembly Installation................................ 6-649
Crankshaft and Bearings Installation.......... 6-649
Crankshaft Rear Oil Seal Installation.......... 6-653
Piston, Connecting Rod, and
Bearing Installation....................................6-653
Oil Pump Installation......................................6-655
Oil Pan Installation.........................................6-656
Camshaft installation......................................6-656
Valve Lifter Installation.................................. 6-657
Cylinder Head Installation............................. 6-658
Valve Rocker Arm, Shaft, and
Push Rod Installation................................ 6-659
Valve Rocker Arm Cover Installation.......... 6-660
Timing Chain and Sprockets Installation.... 6-661
Engine Front Cover Installation....................6-662
Crankshaft Balancer Installation.................. 6-663
Fuel Injection Pump Installation (L65)........ 6-664
Water Pump Installation................................ 6-666
Exhaust Manifold Installation........................6-667
Oil Pump Drive Installation........................... 6-668
Turbocharger Installation............................... 6-668
Engine Wiring Harness
Assembly Installation................................ 6-670
Intake Manifold Installation (L56)................ 6-672
Intake Manifold Installation (L65)................ 6-672
Intake Manifold Installation (L56, L65)........ 6-673
Thermostat Installation.................................. 6-674
6-6 Table of Contents
Oil Level Indicator and Tube Installation.... 6-675
Oil Fill Tube Installation.................................6-676
Engine Flywheel Installation......................... 6-676
Accessory Installation..... .............................. 6-677
Engine Set-Up and Testing...........................6-678
Description and O pe ra tio n .............................6-679
Engine Component Description....... ........... 6-679
New Product Information...............................6-679
Engine Identification...................................... 6-679
Lubrication........................ 6-680
Thread Repair.................................................6-680
Cleanliness and Care.................................... 6-681
Replacing Engine Gaskets............................6-681
Use of RTV and Anaerobic Sealer..............6-682
Separating Parts.............................................6-682
Tools and Equipment..................................... 6-683
Special Tools and E quipm ent....................... 6-684
E n g in e M e c h a n ic a l - 7 . 4 L ............................6-687
S p e cifica tio n s.................................................... 6-687
Fastener Tightening Specifications.............6-687
Engine Mechanical Specifications............... 6-688
GM SPO Group Numbers............................6-691
Sealers, Adhesives, and Lubricants...........6-692
D iagnostic Inform ation and Procedures.... 6-693
Base Engine Misfire Diagnosis................... 6-693
Engine Compression Test........................... 6-695
Engine Noise Diagnosis...............................6-695
Valve Train Diagnosis (Valve Lifter)............6-698
Oil Consumption Diagnosis......................... 6-700
Oil Pressure Diagnosis and Testing...........6-700
Oil Leak Diagnosis....................................... 6-700
Drive Belt Diagnosis (1998).........................6-702
Drive Belt Tensioner Diagnosis................... 6-706
Visual Id e n tifica tio n ........................................ 6-707
Disassembled Views.....................................6-707
Repair In s tru c tio n s ......................................... 6-711
Drive Belt Replacement................................ 6-711
Drive Belt Tensioner Replacement.............6-712
Drive Belt Idler Pulley Replacement........... 6-713
Engine Mount Inspection...............................6-715
Engine Mount Replacement (Front)............6-716
Engine Mount Replacement (Rear)............6-718
Intake Manifold Replacement (Upper).........6-723
Intake Manifold Replacement (Lower).........6-729
Valve Rocker Arm Cover Replacement..... 6-733
Valve Rocker Arm and
Push Rod Replacement..........................6-737
Valve Stem Oil Seal and
Valve Spring Replacement......................6-740
Valve Lifter Replacement............................ 6-744
Oil Level Indicator and
Tube Replacement.................................. 6-750
Exhaust Manifold Replacement................. 6-752
Cylinder Head Replacement...................... 6-757
Engine
Crankshaft Balancer Replacement..............6-764
Crankshaft Front Cover
Oil Seal Replacement...............................6-769
Engine Front Cover Replacement............... 6-771
Crankshaft Position Reluctor
Ring Replacement..................................... 6-775
Timing Chain and Sprockets
Replacement.............................................. 6-778
Camshaft Replacement.................................6-785
Oil Filter Adapter and Valve
Assembly Replacement.............................6-796
Oil Pan Replacement.................................... 6-798
Oil Pump Replacement................................. 6-804
Crankshaft Rear Oil Seal Replacement......6-807
Engine Flywheel Replacement..................... 6-809
Engine Replacement......................................6-811
Engine Oil and Oil Filter Replacement........6-820
Draining Fluids and Oil Filter Removal.......6-821
Engine Flywheel Removal.............................6-821
Oil Level Indicator and Tube Removal........6-822
Exhaust Manifold Removal (L e ft)................ 6-822
Exhaust Manifold Removal (Right).............. 6-824
Water Pump Removal................................... 6-825
Crankshaft Balancer Removal......................6-825
Valve Rocker Arm Cover
Removal (Left)............................................6-826
Valve Rocker Arm Cover
Removal (Right)........................................ 6-827
Distributor Removal....................................... 6-827
Throttle Body Removal.................................. 6-828
Intake Manifold Removal............................... 6-829
Valve Rocker Arm and
Push Rod Removal................................... 6-830
Cylinder Head Removal (Left Side)............. 6-831
Cylinder Head Removal (Right S ide)..........6-831
Valve Lifter Removal..................................... 6-832
Oil Pan Removal............................................6-833
Oil Pump, Pump Screen and
Deflector Removal..................................... 6-834
Engine Front Cover Removal...................... 6-834
Timing Chain and Sprockets Removal...... 6-835
Camshaft Removal........................................ 6-836
Piston, Connecting Rod, and
Bearing Removal....................................... 6-837
Crankshaft Rear Oil Seal and
Housing Removal...................................... 6-839
Crankshaft and Bearings Removal.............. 6-839
Oil Filter Adapter and
Valve Assembly Removal.........................6-839
Engine Block Plug Removal.........................6-840
Engine Block Clean and Inspect................. 6-843
Cylinder Boring and Honing..........................6-844
Crankshaft and Bearings
Clean and Inspect..................................... 6-846
Crankshaft Balancer Clean and Inspect.... 6-854
Engine
Engine Flywheel Clean and Inspect............ 6-855
Piston and Connecting Rod
Disassemble...............................................6-856
Piston, Connecting Rod and
Bearings Cleari/lnspect.............................6-857
Piston Selection..............................................6-860
Piston and Connecting Rod Assemble.......6-861
Camshaft Bearing Removal..........................6-862
Camshaft and Bearings
Clean and Inspect..................................... 6-864
Camshaft Bearing Installation.......................6-865
Timing Chain and Sprockets
Clean and Inspect..................................... 6-866
Valve Rocker Arm and
Push Rods Clean and Inspect................ 6-867
Valve Lifters and Guides
Clean and Inspect..................................... 6-868
Cylinder Head Disassemble..........................6-869
Cylinder Head Clean and Inspect............... 6-870
Valve Guide Reaming/Valve
and Seat Grinding..................................... 6-873
Cylinder Head Assemble..............................6-875
Oil Pump Disassemble.................................. 6-876
Oil Pump Clean and Inspect........................6-878
Oil Pump Assem ble...................................... 6-878
Valve Rocker Arm Cover
Clean and Inspect..................................... 6-880
Oil Pan Clean and Inspect...........................6-881
Intake Manifold Disassemble........................6-881
Intake Manifold Clean and Inspect.............. 6-884
Intake Manifold Assemble.............................6-886
Exhaust Manifold Clean and Inspect.......... 6-889
Water Pump Clean and Inspect.................. 6-891
Service Prior to Assembly............................6-892
Engine Block Plug Installation..................... 6-892
Oil Filter Adapter and Valve
Assembly Installation................................ 6-895
Crankshaft and Bearings Installation........... 6-896
Crankshaft Rear Oil Seal and
Housing Installation................................... 6-898
Piston, Connecting Rod, and
Bearing Installation................................... 6-898
Camshaft Installation..................................... 6-900
Timing Chain and Sprockets Installation.... 6-900
Engine Front Cover Installation................... 6-902
Oil Pump, Pump Screen and
Deflector Installation........................ 6-903
Oil Pan Installation........................................ 6-903
Valve Lifter Installation.................................. 6-904
Cylinder Head Installation (Left).................. 6-905
Cylinder Head Installation (Right)................ 6-906
Valve Rocker Arm and
Push Rod Installation................................ 6-907
Intake Manifold Installation...........................6-907
Throttle Body Installation.............................. 6-909
Table of Contents 6-7
Distributor Installation.................................... 6-910
Valve Rocker Arm Cover
Installation (Left Side)............................... 6-912
Valve Rocker Arm Cover
Installation (Right S ide)............................ 6-912
Crankshaft Balancer Installation...................6-913
Water Pump Installation................................ 6-914
Exhaust Manifold Installation (Left Side) ....6-914
Exhaust Manifold Installation
(Right Side)................................................ 6-916
Oil Level Indicator and Tube Installation ....6-917
Engine Flywheel Installation.........................6-917
Engine Set-Up and Testing........................... 6-918
Description and Operation............................. 6-919
Engine Component Description....................6-919
'New Product Information.............................. 6-920
Visual Identification..........................................6-921
Engine Identification.......................................6-921
Description and Operation............................. 6-922
Lubrication...................................................... 6-922
Thread Repair................................................ 6-922
Cleanliness and C a re ................................... 6-922
Replacing Engine G askets........................... 6-923
Use of RTV and Anaerobic Sealer.............. 6-923
Separating Parts............................................. 6-924
Tools and Equipment.................................... 6-924
Special Tools and Equipment........................6-925
Engine Cooling ................................................. 6-927
Specifications.................................................... 6-927
Fastener Tightening Specifications.............. 6-927
GM SPO Group Numbers............................6-927
Schematic and Routing Diagram s............... 6-929
Cooling System Schematic References..... 6-929
Cooling System Schematic Icons................ 6-929
Cooling Fan Schematics............................... 6-930
Component Locator..........................................6-931
Cooling System Component Views............. 6-931
Cooling System Connector End Views...... 6-932
Diagnostic Information and Procedures.... 6-933
Auxiliary Cooling Fan Inoperative................ 6-933
Auxiliary Cooling Fan Runs
Continuously............................................... 6-934
Engine Overheating...................................... 6-935
Loss of Coolant..............................................6-936
Thermostat Diagnosis (Off-Vehicle)............. 6-938
Thermostat Diagnosis (On-Vehicle)............. 6-939
Fan Clutch Diagnosis.................................... 6-940
Coolant Concentration Testing......................6-941
Cooling System Leak Testing
(Radiator Leak Test)................................. 6-942
Cooling System Leak Testing
(Radiator Cap Leak Test)......................... 6-943
Cooling System Leak Testing
(Exhaust Gas Leak Test)..........................6-944
6-8 Table of Contents
Repair In s tru c tio n s .......................................... 6-945
Draining and Filling Cooling
System........................................................ 6-945
Flushing........................................................... 6-947
Surge Tank (Diesel) Replacement............... 6-947
Coolant Recovery Reservoir
Replacement.............................................. 6-948
Radiator Hose Replacement
(4.3L and 5.0L).......................................... 6-949
Radiator Hose Replacement (5.7L).............6-950
Radiator Hose Replacement (7.4L).............6-951
Radiator Hose Replacement
(6.5L Diesel)...............................................6-951
Engine Oil Cooler Line Replacement.........6-952
Fan Clutch Replacement
(4.3L, 5.0L, 5.7L, and 6 .5 L ).................... 6-959
Fan Clutch Replacement (7.4L)................... 6-960
Auxiliary Cooling Fan and
Motor Replacement................................... 6-961
Auxiliary Cooling Fan
Relay Replacement................................... 6-963
Thermostat Replacement
(Gasoline Engines).................................... 6-963
Thermostat Replacement
(Diesel Engines)........................................ 6-965
Thermostat Housing
Crossover Replacement............................6-967
Water Pump Replacement
(Gasoline Engines).................................... 6-968
Water Pump Replacement
(Diesel Engines)........................................ 6-971
Drain Cock Replacement..............................6-974
Fan Shroud Replacement (Upper)............... 6-975
Fan Shroud Replacement (Lower)............... 6-978
Radiator Replacement................................... 6-981
Description and O p e ra tio n .............................6-985
Cooling System Description..........................6-985
Coolant Recovery System
Description..................................................6-986
Radiator Assembly Description.................... 6-986
Radiator Filler Cap Assembly
Description..................................................6-987
Electric Engine Cooling Fan
Description.................................................. 6-988
Water Pump Description...............................6-989
Thermostat Description.................................. 6-989
Special Tools and E quipm ent........................6-990
Special Tools...................................................6-990
Engine Electrical...............................................6-991
S p e c ific a tio n s .................................................... 6-991
Fastener Tightening Specifications..............6-991
Battery Usage.................................................6-992
Battery Temperature vs Voltage D rop....... 6-992
Starter Motor Usage
(28-MT Starter Motor)............................... 6-992
Spark Plug Wire Resistance.........................6-992
Engine
Schematic and Routing Diagram s................ 6-993
Starting and Charging Schematic
References.................................................6-993
Starting and Charging Schematic Icons.... 6-993
Starting and Charging Schematics.............. 6-994
Component L ocator......................................... 6-998
Starting and Charging Components............6-998
Starting and Charging Component
Views........................................................ 6-1000
Starting and Charging Connector
End View s................................................6-1002
Diagnostic Inform ation and
P rocedures..................................................6-1004
Starting System Check................................6-1004
Charging System C heck.............................6-1005
Starter Solenoid Does Not Click................ 6-1005
Starter Solenoid Clicks,
Engine Does Not Crank..........................6-1007
Engine Cranks/Cranks Slowly,
but Does Not Start.................................. 6-1008
Starter Motor Noise Diagnosis
(General Diagnosis)................................ 6-1008
Starter Motor Noise Diagnosis
(Pinion Clearance)................................... 6-1010
Starter No Load Test................................... 6-1010
Battery Hydrometer Displays
Dark or Yellow Dot.................................. 6-1011
Battery Load Test........................................ 6-1012
Parasitic Load Test...................................... 6-1012
Charge Indicator Always O n.......................6-1014
Charge Indicator Inoperative...................... 6-1014
Voltmeter Reading High/Low.......................6-1015
Noisy Generator...........................................6-1016
Generator Electrical Test.............................6-1016
Generator Assembly Bench
Check (CS-130)....................................... 6-1017
Generator Assembly Bench
Check (CS-144)....................................... 6-1018
Ignition Coil Test...........................................6-1018
Spark Plug Visual Diagnosis.......................6-1019
Spark Plug Wire Harness...........................6-1021
Repair In s tru c tio n s ........................................ 6-1022
Starter Motor Replacement
(Gasoline Engines).................................. 6-1022
Starter Motor Replacement
(Diesel Engines)...................................... 6-1022
Starter Motor Overhaul (SD Series).........6-1023
Starter Motor Overhaul (MT Series).........6-1026
Starter Motor Inspection (SD Series)...... 6-1034
Starter Motor Inspection (MT Series)...... 6-1037
Starter Pinion Clearance Check................ 6-1038
Battery Charging...........................................6-1039
Charging Low or Completely
Discharged Battery.................................. 6-1040
Jump Starting in Case of Emergency..... 6-1041
Battery........................................................... 6-1043
Engine
Battery Cable................................................6-1044
Battery Tray Replacement
(Battery Tray Replacement - LH)..........6-1045
Battery Tray Replacement (Battery
Tray Replacement - R H )....................... 6-1047
Ground Strap Replacement................ 6-1049
Generator Replacement
(Gasoline Engines).................................. 6-1049
Generator Replacement
(Diesel Engines)...................................... 6-1051
Generator Overhaul (CS-144).................... 6-1052
Spark Plug Wire Harness
Replacement............................................6-1059
Spark Plug Replacement............................6-1059
Distributor Replacement (VINW, M, R)....6-1060
Distributor Replacement (VIN J)...............6-1066
Distributor O verhaul.................................... 6-1068
Distributor Inspection................................... 6-1076
Ignition Coil and ICM Replacement
(VIN W, M, R )..........................................6-1077
Ignition Coil and ICM Replacement
(VIN J )...................................................... 6-1077
Description and O pe ra tio n ...........................6-1079
Battery........................................................... 6-1079
Battery Tray and Hold-Down
Retainer Description................................ 6-1079
Starting System Operation..........................6-1079
Starting System Circuit Description...........6-1079
Battery Description...................................... 6-1080
Battery Operation (Undercharged or
Overcharged)............................................6-1082
Battery Operation
(Causes of Battery Failure)................... 6-1084
Charging System Description.................... 6-1084
Charging System Operation........................6-1085
Ignition System Description........................6-1086
Special Tools and Equipm ent..................... 6-1087
Special Tools................................................6-1087
E n g in e C o n tr o ls - 4 .3 L ................................ 6-1089
S pecifications.................................................. 6-1089
Temperature vs Resistance........................6-1089
Fastener Tightening Specifications............6-1089
Engine Scan Tool Data List........................6-1090
Engine Scan Tool Data Definitions............6-1096
DTC List................................................... .....6-1108
GM SPO Group Numbers........................... 6-1112
Schematic and Routing Diagrams...............6-1114
Emission Hose Routing Diagram................6-1114
Engine Controls Schematic
References............................................... 6-1114
Engine Controls Schematic Icons............. 6-1115
Engine Controls Schematics....................... 6-1116
Component L ocator........................................6-1128
Engine Controls Components.....................6-1128
Engine Controls Component Views........... 6-1133
VCM Connector End Views (8 )..................6-1144
Table of Contents 6-9
Engine Controls Connector End
Views (Connector End Views)............... 6-1148
Diagnostic Information and Procedures ...6-1153
Powertrain OBD System Check.................6-1153
Malfunction Indicator Lamp
Circuit Check............................................ 6-1156
Data Link Connector Diagnosis..................6-1159
Engine Cranks but Does Not R un............ 6-1162
Fuel Pump Relay Circuit Diagnosis.......... 6-1164
Fuel System Diagnosis
(System Check)......................................6-1167
DTC P0101 Mass Air Flow System
Performance............................................. 6-1177
DTC P0102 MAF Sensor Circuit
Low Frequency........................................6-1182
DTC P0103 MAF Sensor Circuit
High Frequency........................................6-1186
DTC P0106 MAP System Performance....6-1189
DTC P0107 MAP Sensor Circuit
Low Voltage............................................. 6-1192
DTC P0108 MAP Sensor Circuit
High Voltage............................................. 6-1196
DTC P0112 IAT Sensor Circuit
Low Voltage.............................................6-1200
DTC P0113 IAT Sensor Circuit
High Voltage.............................................6-1203
DTC P0117 ECT Sensor Circuit
Low Voltage.............................................6-1206
DTC P0118 ECT Sensor Circuit
High Voltage.............................................6-1208
DTC P0121 TP Sensor Performance........ 6-1211
DTC P0122 TP Sensor Circuit
Low Voltage.............................................6-1214
DTC P0123 TP Sensor Circuit
High Voltage.............................................6-1217
DTC P0125 ECT Excessive
Time to Closed Loop.............................. 6-1220
DTC P0131 H02S Circuit
Low Voltage Bankl S en so r!................. 6-1222
DTC P0132 H02S Circuit
High Voltage Bankl S e n so rl................ 6-1225
DTC P0133 H02S Slow Response
Bankl S e n s o rl........................................6-1228
DTC P0134 H02S Insufficient
Activity Bankl S ensorl...........................6-1231
DTC P0135 H02S Heater
Circuit Bankl S ensorl............................6-1234
DTC P0143 H02S Circuit
Low Voltage Bankl Sensor3................. 6-1237
DTC P0144 H02S Circuit
High Voltage Bankl Sensor3................ 6-1240
DTC P0146 H02S Insufficient
Activity Bankl Sensor3........................... 6-1243
DTC P0147 H02S Heater
Circuit Bankl Sensor3................. 6-1246
DTC P0151 H02S Circuit
Low Voltage Bank2 S en so rl................. 6-1249
6-10 Table of Contents
DTC P0152 H02S Circuit
High Voltage Bank2 S e n s o r!................ 6-1252
DTC P0153 H02S Slow Response
Bank2 S en so rl........................................ 6-1255
DTC P0154 H02S Insufficient
Activity Bank2 S e n so rl...........................6-1258
DTC P0155 H02S Heater
Circuit Bank2 S e n s o rl............................6-1261
DTC P0171 Fuel Trim System
Lean B a n k l............................................. 6-1264
DTC P0172 Fuel Trim System
Rich B a n k l...............................................6-1268
DTC P0174 Fuel Trim System
Lean Bank2............................................. 6-1272
DTC P0175 Fuel Trim System
Rich Bank2...............................................6-1276
DTC P0300 Engine MisfireDetected........ 6-1280
DTC P0325 Knock Sensor
Module Circuit.......................................... 6-1283
DTC P0327 Knock Sensor
Noise Channel Low Voltage.................. 6-1286
DTC P0336 CKP Sensor
Circuit Performance...... .......................... 6-1290
DTC P0337 CKP Sensor
Circuit Low Frequency............................6-1293
DTC P0338 CKP Sensor
Circuit High Frequency...........................6-1296
DTC P0339 CKP Sensor
Circuit Intermittent................................... 6-1299
DTC P0340 CMP Sensor Circuit............... 6-1302
DTC P0341 CMP Sensor
Circuit Performance................................. 6-1305
DTC P0401 EGR System
Flow Insufficient................................... ...6-1307
DTC P0404 EGR Valve Open
Pintle Position...........................................6-1311
DTC P0405 EGR Pintle Position
Circuit Low Voltage................................. 6-1315
DTC P0420 TWC System
Low Efficiency B a n k l..............................6-1319
DTC P0440 EVAP System..........................6-1323
DTC P0442 EVAP Control System
Small Leak Detected...............................6-1328
DTC P0446 EVAP Vent Valve
Performance.............................................6-1332
DTC P0452 Fuel Tank Pressure
Sensor Low Voltage................................6-1336
DTC P0453 Fuel Tank Pressure
Sensor High Voltage (8 ).........................6-1340
DTC P0461 Fuel Level Sensor
Circuit Performance................................. 6-1343
DTC P0462 Fuel Level Sensor
Circuit Low Voltage.................................6-1346
DTC P0463 Fuel Level Sensor
Circuit High Voltage................................6-1349
DTC P0500 Vehicle Speed
Sensor Circuit.......................................... 6-1352
Engine
DTC P0506 Idle Control System
Low RPM..................................................6-1355
DTC P0507 Idle Control System
High RPM.................................................6-1357
DTC P0601 VCM Memory..........................6-1359
DTC P0602 VCM Not Programmed..........6-1361
DTC P0603 VCM Memory Reset..............6-1363
DTC P0604 VCM Random
Access Memory (RAM).......................... 6-1365
DTC P0605 VCM Read Only
Memory (ROM)........................................ 6-1367
DTC P0704 Clutch Switch C ircuit.............6-1369
DTC P1106 MAP Sensor CKT
Intermittent High Voltage....................... 6-1372
DTC P1107 MAP Sensor CKT
Intermittent Low Voltage.................. .....6-1376
DTC P1111 IAT Sensor CKT
Intermittent High Voltage....................... 6-1379
DTC P1112 IAT Sensor CKT
Intermittent Low Voltage.........................6-1382
DTC P1114 ECT Sensor CKT
Intermittent Low Voltage.........................6-1385
DTC P1115 ECT Sensor CKT
Intermittent High Voltage........................6-1388
DTC P1121 TP Sensor CKT
Intermittent High Voltage........................6-1391
DTC P1122 TP Sensor CKT
Intermittent Low Voltage.........................6-1394
DTC P1133 H02S Insufficient
Switching Bankl S e n s o rl........................6-1397
DTC P1134 H02S Transition
Time Ratio Bankl S e n s o rl................... 6-1400
DTC P1153 Insufficient Switching
Bank2 S en so rl........................................ 6-1403
DTC P1154 H02S Transition
Time Ratio Bank2 S e n s o rl................... 6-1406
DTC P1336 CKP System
Variation Not Learned.............................6-1409
DTC P1345 CKP/CMP Correlation............ 6-1413
DTC P1351 IC Circuit High Voltage..........6-1415
DTC P1361 IC Circuit Low Voltage...........6-1418
DTC P1380 EBCM DTC Rough
Road Data Unstable............................... 6-1421
DTC P1381 Misfire Detected
No EBCM/VCM Serial Data................... 6-1423
DTC P1404 EGR Valve Closed
Pintle Position...........................................6-1425
DTC P1441 EVAP System Flow
During Non-Purge................................... 6-1428
DTC P1508 IAC System Low R P M ..........6-1432
DTC P1509 IAC System High RPM..........6-1435
DTC P1621 VCM EEPROM
Performance.............................................6-1438
DTC P1626 Loss of Serial
Communication with V T D .......................6-1440
DTC P1630 Theft Deterrent
VCM in Learn M ode............................... 6-1444
Engine
DTC P1631 Theft Deterrent
Password Incorrect................................. 6-1445
DTC U1026 Loss of ATCM
Communication.........................................6-1450
DTC U1041 Loss of EBCM
Communication.........................................6-1453
DTC U1192 Loss of VTD
(Passlock)/EVO Communication............ 6-1456
DTC U1193 Loss of VIM
Communication.........................................6-1459
Symptoms..................................................... 6-1462
Hard Start..................................................... 6-1464
Surges/Chuggles..........................................6-1465
Lack of Power, Sluggishness,
or Sponginess..........................................6-1467
Detonation/Spark Knock.............................. 6-1467
Hesitation, Sag, Stum ble............................6-1468
Cuts Out, Misses..........................................6-1469
Poor Fuel Economy.................................... 6-1470
Rough, Unstable, or Incorrect
Idle, Stalling..............................................6-1472
Dieseling, Run-On........................................6-1474
Backfire......................................................... 6-1474
Restricted Exhaust System Check............ 6-1476
Vehicle Control Module Diagnosis............. 6-1477
A/C Compressor Control Circuit
Diagnosis.................................................. 6-1478
Manual Transmission Shift Light............... 6-1482
Fuel Injector Balance Test..........................6-1484
Fuel Injector Coil Test................................. 6-1488
Fuel Injector Circuit Diagnosis................... 6-1490
Fuel Tank Pressure Sensor
Diagnosis.................................................. 6-1492
Alcohol/Contaminants-in-Fuel
Diagnosis.................................................. 6-1494
EVAP Control System Diagnosis............... 6-1494
Enhanced Ignition System Diagnosis....... 6-1499
Knock Sensor System Diagnosis.............. 6-1502
EGR System Diagnosis.............................. 6-1503
Crankcase Ventilation System
Diagnosis.................................................. 6-1506
Idle Air Control System Diagnosis............6-1507
Inspection/Maintenance Status
Reset Procedures................................... 6-1510
Repair In s tru ctio n s.........................................6-1511
VCM Replacement/Programming............... 6-1511
CKP System Variation
Learn Procedure..................................... 6-1513
Password Learn Procedure........................6-1513
ECT Sensor Replacement..........................6-1515
MAF Sensor Replacement..........................6-1516
MAP Sensor Replacement..........................6-1517
H02S Replacement.................................... 6-1518
TP Sensor Replacement............................. 6-1521
IAT Sensor Replacement............................6-1522
IAC Valve Replacement.............................. 6-1523
Table of Contents 6-11
Accelerator Controls Cable
Replacement........................................... 6-1525
Accelerator Controls Pedal
Replacement........................................... 6-1529
Throttle Body Assembly Replacement..... 6-1529
Fuel Pressure Relief Procedure............... 6-1533
Quick Connect Fitting(s) Service
(Metal Collar)...........................................6-1533
Quick Connect Fitting(s) Service
(Plastic Collar).........................................6-1536
In-Line Fuel Filter Replacement
(Exc. Cart, type)..................................... 6-1538
In-Line Fuel Filter Replacement
(Exc. Cart, type 4DR Utility)................. 6-1539
Fuel Filter Element Replacement
(Cartridge Type)..................................... 6-1540
Fuel Tank Draining Procedure.................. 6-1541
Fuel Tank Replacement
(Extended Cab - Side Tank)................ 6-1541
Fuel Tank Replacement
(Pick-up-Side Tank)................................ 6-1545
Fuel Tank Replacement
(Cab and Chassis - Side Tank)...........6-1550
Fuel Tank Replacement
(Cab and Chassis - Rear Tank)...........6-1555
Fuel Tank Pressure Sensor
Replacement.......................................... 6-1558
Filler Tube Replacement (Fleetside)........ 6-1559
Filler Tube Replacement (Stepside)......... 6-1560
Fuel Sender Assembly Replacement....... 6-1562
Fuel Pump Replacement (Main)................6-1563
Fuel Hose/Pipes Replacement
(Engine Compartment)........................... 6-1565
Fuel Hose/Pipes Assembly Replacement
(Steel Fuel Line Repair)........................ 6-1568
Fuel Hose/Pipes Assembly Replacement
(Fuel Pipes)............................................. 6-1569
Fuel Hose/Pipes Assembly Replacement
(Vapor Pipes)..........................................6-1571
Fuel System Cleaning (Fuel Tank)........... 6-1573
Fuel System Cleaning (Fuel Pipes)......... 6-1573
Fuel Pressure Connection
Valve Replacement................................ 6-1575
Fuel Pressure Regulator
Replacement (CSFI).............................. 6-1576
Fuel Meter Body Assembly
Replacement...........................................6-1578
Fuel Injector Replacement................... ......6-1582
Fuel Pump Relay Replacement................ 6-1582
Fuel Pump and Engine Oil PRESS
Sensor Replacement.............................6-1583
EVAP Canister Purge Solenoid
Valve Replacement................................6-1584
EVAP Vent Valve Replacement................6-1586
EVAP Canister Replacement.................... 6-1587
EVAP System Cleaning............................ 6-1587
Crankshaft Position Sensor
Replacement.......................................... 6-1588
6-12 Table of Contents
Camshaft Position Sensor Replacement.... 6-1591
Knock Sensor Replacement....................... 6-1592
EGR Valve Replacement............... 6-1593
Air Cleaner Element Replacement...........6-1595
Air Cleaner Assembly Replacement.........6-1596
Air Cleaner Intake Duct Replacement..... 6-1598
Intake Air Resonator Replacement...........6-1599
Wiring Repairs............................................ 6-1601
Description and O p e ra tio n .......................... 6-1607
Vehicle Control Module Description..........6-1607
Serial Data Communications.......................6-1611
Information Sensors/Switches
Description................................................6-1613
Fuel System Description - CSFI................ 6-1619
Fuel Supply Component Description....... 6-1621
Fuel Metering System Component
Description................................................6-1623
Short Term Fuel Trim Description.............6-1627
Long Term Fuel Trim Description..............6-1628
Speed Density System Description...........6-1628
EVAP Control System Description.............6-1628
Enhanced Ignition System Description.... 6-1633
Knock Sensor System Description............6-1635
EGR System Description.............................6-1636
Crankcase Ventilation System
Description................................................6-1637
Air Intake System Description.................... 6-1637
Special Tools and E quipm ent..................... 6-1639
Special Tools.................................................6-1639
E n g in e C o n tr o ls - 5.0, 5 .7 L ...................... 6-1643
S p e cifica tio n s..................................................6-1643
Temperature vs Resistance........................ 6-1643
Fastener Tightening Specifications............6-1643
Engine Scan Tool Data List....................... 6-1644
Engine Scan Tool Data Definitions............6-1651
DTC List........................................................ 6-1662
GM SPO Group Numbers...........................6-1671
Schematic and Routing Diagram s..............6-1673
Emission Hose Routing Diagram............... 6-1673
Engine Controls Schematic References... 6-1673
Engine Controls Schematic Icons..............6-1674
Engine Controls Schematics...................... 6-1675
Component L o ca to r....................................... 6-1691
Engine Controls Components.................... 6-1691
Engine Controls Component Views...........6-1696
VCM Connector End Views....................... 6-1709
Engine Controls Connector End
Views (Connector End Views)............... 6-1713
Diagnostic inform ation and
P ro ce d u re s..................................................6-1719
Powertrain OBD System Check................. 6-1719
Malfunction Indicator Lamp
Circuit Check........................................... 6-1722
Data Link Connector Diagnosis................. 6-1725
Engine Cranks but Does Not Run.............6-1728
Engine
Fuel Pump Relay Circuit Diagnosis......... 6-1730
Fuel System Diagnosis (System Check) .....6-1733
DTC P0101 Mass Air Flow
System Performance...............................6-1743
DTC P0102 MAF Sensor Circuit
Low Frequency........................................ 6-1748
DTC P0103 MAF Sensor Circuit
High Frequency....................................... 6-1752
DTC P0106 MAP System Performance... 6-1755
DTC P0107 MAP Sensor Circuit
Low Voltage............................................. 6-1758
DTC P0108 MAP Sensor Circuit
High Voltage.............................................6-1761
DTC P0112 IAT Sensor Circuit
Low Voltage............................................. 6-1765
DTC P0113 IAT Sensor Circuit High Voltage
6-1767
DTC P0117 ECT Sensor Circuit
Low Voltage..............................................6-1770
DTC P0118 ECT Sensor Circuit
High Voltage.............................................6-1773
DTC P0121 TP Sensor Performance...... 6-1776
DTC P0122 TP Sensor Circuit
Low Voltage..............................................6-1778
DTC P0123 TP Sensor Circuit
High Voltage.............................................6-1781
DTC P0125 ECT Excessive Time
to Closed Loop........................................ 6-1784
DTC P0131 H02S Circuit Low
Voltage Bankl S e n so r!..........................6-1786
DTC P0132 H02S Circuit High
Voltage Bankl S e n s o rl..........................6-1789
DTC P0133 H02S Slow Response
Bankl S ensorl............................ 6-1792
DTC P0134 H02S Insufficient
Activity Bankl S en so rl...........................6-1795
DTC P0135 H02S Heater Circuit
Bankl S ensorl.........................................6-1798
DTC P0137 H02S Circuit Low
Voltage Bankl Sensor2..........................6-1801
DTC P0138 H02S Circuit High
Voltage Bankl Sensor2..........................6-1805
DTC P0140 H02S Insufficient
Activity Bankl Sensor2...........................6-1808
DTC P0141 H02S Heater
Circuit Bankl Sensor2............................ 6-1811
DTC P0143 H02S Circuit
Low Voltage Bankl Sensor3................. 6-1815
DTC P0144 H02S Circuit
High Voltage Bankl Sensor3................ 6-1819
DTC P0146 H02S Insufficient
Activity Bankl Sensor3...........................6-1822
DTC P0147 H02S Heater Circuit
Bankl Sensor3........................................ 6-1826
DTC P0151 H02S Circuit Low
Voltage Bank2 S e n s o rl..........................6-1830
DTC P0152 H02S Circuit High
Voltage Bank2 S e n s o rl..........................6-1833
Engine
DTC P0153 H02S Slow Response
Bank2 S ensorl.........................................6-1836
DTC P0154 H02S Insufficient
Activity Bank2 S en so rl...........................6-1839
DTC P0155 H02S Heater Circuit
Bank2 S ensorl.........................................6-1842
DTC P0157 H02S Circuit Low
Voltage Bank2 Sensor2..........................6-1845
DTC P0158 H02S Circuit High
Voltage Bank2 Sensor2..........................6-1848
DTC P0160 H02S Insufficient
Activity Bank2 Sensor2...........................6-1851
DTC P0161 H02S Heater Circuit
Bank2 Sensor2........................................ 6-1854
DTC P0171 Fuel Trim System
Lean B a n k l..............................................6-1858
DTC P0172 Fuel Trim System
Rich B a n k l...............................................6-1862
DTC P0174 Fuel Trim System
Lean Bank2.............................................. 6-1866
DTC P0175 Fuel Trim System Rich
Bank2....................................................... 6-1870
DTC P0300 Engine Misfire Detected....... 6-1874
DTC P0325 Knock Sensor Circuit............. 6-1877
DTC P0327 Knock Sensor Noise
Channel Low Voltage.............................. 6-1880
DTC P0336 CKP Sensor Circuit
Performance.............................................6-1884
DTC P0337 CKP Sensor Circuit
Low Frequency.........................................6-1887
DTC P0338 CKP Sensor Circuit
High Frequency........................................6-1890
DTC P0339 CKP Sensor Circuit
Intermittent................................................6-1893
DTC P0340 CMP Sensor Circuit............... 6-1896
DTC P0341 CMP Sensor Circuit
Performance.............................................6-1899
DTC P0401 EGR System Flow
Insufficient................................................ 6-1901
DTC P0404 EGR Valve Open
Pintle Position..........................................6-1905
DTC P0405 EGR Pintle Position
Circuit Low Voltage................................. 6-1909
DTC P0410 AIR System............................. 6-1912
DTC P0420 TWC System Low
Efficiency B a n k l.......................................6-1917
DTC P0430 TWC System Low
Efficiency Bank2.......................................6-1921
DTC P0440 EVAP System .........................6-1924
DTC P0442 EVAP Control System
Small Leak Detected.............................. 6-1929
DTC P0446 EVAP Vent Valve
Performance............................................. 6-1933
DTC P0452 Fuel Tank Pressure
Sensor Low Voltage................................ 6-1937
DTC P0453 Fuel Tank Pressure
Sensor High Voltage............................... 6-1940
Table of Contents 6-13
DTC P0461 Fuel Level Sensor Circuit
Performance (Single Fuel Tank)...........6-1943
DTC P0461 Fuel Level Sensor Circuit
Performance (Dual Fuel Tanks)............ 6-1945
DTC P0462 Fuel Level Sensor Circuit
Low Voltage (Single Fuel Tank)............ 6-1947
DTC P0462 Fuel Level Sensor Circuit
Low Voltage (Dual Fuel Tanks)............. 6-1949
DTC P0463 Fuel Level Sensor Circuit
High Voltage (Single Fuel Tank)........... 6-1952
DTC P0463 Fuel Level Sensor Circuit
High Voltage (Dual Fuel Tanks)............ 6-1955
DTC P0500 Vehicle Speed Sensor
Circuit....................................................... 6-1958
DTC P0506 Idle Control System
Low R P M ................................................. 6-1961
DTC P0507 Idle Control System
High RPM................................................. 6-1963
DTC P0601 VCM Memory.......................... 6-1965
DTC P0602 VCM Not Programmed.......... 6-1967
DTC P0603 VCM Memory Reset.............. 6-1969
DTC P0604 VCM Random Access
Memory (RAM).........................................6-1971
DTC P0605 VCM Read Only Memory
(ROM)....................................................... 6-1973
DTC P0704 Clutch Switch Circuit............. 6-1975
DTC P1106 MAP Sensor CKT
Intermittent High Voltage........................ 6-1978
DTC P1107 MAP Sensor CKT
Intermittent Low Voltage......................... 6-1981
DTC P1111 IAT Sensor CKT
Intermittent High Voltage........................ 6-1984
DTC P1112 IAT Sensor CKT
Intermittent Low Voltage.........................6-1987
DTC P1114 ECT Sensor CKT
Intermittent Low Voltage........................ 6-1989
DTC P1115 ECT Sensor CKT
Intermittent High Voltage.......................6-1991
DTC P1121 TP Sensor CKT
Intermittent High Voltage.......................6-1994
DTC P1122 TP Sensor CKT
Intermittent Low Voltage........................6-1997
DTC P1133 H02S Insufficient
Switching Bankl S e n so rl.......................6-2000
DTC P1134 H02S Transition Time
Ratio Bankl S ensorl............................. 6-2003
DTC P1153 Insufficient Switching
Bank2 S e n s o rl...................................... 6-2006
DTC P1154 H02S Transition Time
Ratio Bank2 S ensorl.............................6-2009
DTC P1336 CKP System Variation
Not Learned........................................... 6-2012
DTC P1345 CKP/CMP Correlation...........6-2015
DTC P1351 IC Circuit High Voltage.......6-2018
DTC P1361 IC Circuit Low Voltage.......6-2021
DTC P1380 EBCM DTC Rough
Road Data Unstable............................. 6-2024
6-14 Table of Contents
DTC P1381 Misfire Detected
No EBCM/VCM Serial Data................... 6-2026
DTC P1404 EGR Valve Closed
Pintle Position.......................................... 6-2028
DTC P1415 AIR System B a n k l................6-2031
DTC P1416 AIR System Bank2................6-2034
DTC P1441 EVAP System Flow
During Non-Purge...................................6-2037
DTC P1508 IAC System Low RPM...........6-2040
DTC P1509 IAC System High RPM..........6-2043
DTC P1621 VCM EEPROM
Performance............................................ 6-2046
DTC P1626 Loss of Serial
Communication with V T D ...................... 6-2048
DTC P1630 Theft Deterrent
VCM in Learn Mode................................6-2052
DTC P1631 Theft Deterrent
Password Incorrect..................................6-2053
DTC U1026 Loss of ATCM
Communication........................................ 6-2057
DTC U1041 Loss of EBCM
Communication........................................ 6-2060
DTC U1192 Loss of VTD
(Passlock)/EVO Communication............6-2063
DTC U1193 Loss of
VIM Communication..... ..........................6-2066
Symptoms..................................................... 6-2068
Hard S ta rt..................................................... 6-2070
Surges/Chuggles.......................................... 6-2072
Lack of Power, Sluggishness,
or Sponginess......................................... 6-2073
Detonation/Spark Knock..............................6-2074
Hesitation, Sag, Stumble.............................6-2075
Cuts Out, Misses......................................... 6-2076
Poor Fuel Economy..................................... 6-2077
Rough, Unstable, or Incorrect
Idle, Stalling..............................................6-2078
Dieseling, Run-On....................................... 6-2080
Backfire......................................................... 6-2081
Restricted Exhaust System C heck............6-2082
Vehicle Control Module Diagnosis.............6-2083
A/C Compressor Control
Circuit Diagnosis...................................... 6-2084
Electric Cooling Fan Diagnosis.................. 6-2088
Manual Transmission Shift Light................6-2091
Fuel Injector Balance Test......................... 6-2093
Fuel Injector Coil Test.................................6-2097
Fuel Injector Circuit Diagnosis................... 6-2099
Fuel Tank Pressure Sensor Diagnosis.... 6-2101
Alcohol/Contaminants-in-Fuel
Diagnosis..................................................6-2104
EVAP Control System Diagnosis............... 6-2105
Enhanced Ignition System Diagnosis...... 6-2109
Secondary Air Injection System
Diagnosis.................................................. 6-2113
EGR System Diagnosis (sys)..................... 6-2117
Idle Air Control System Diagnosis.............6-2120
Engine
Inspection/Maintenance Status
Reset Procedures.................................... 6-2123
Repair In stru ctio n s........................................ 6-2124
VCM Replacement/Programming............... 6-2124
CKP System Variation Learn
Procedure.................................................6-2128
Password Learn Procedure.........................6-2128
ECT Sensor Replacement......................... 6-2130
MAF Sensor Replacement..........................6-2131
MAP Sensor Replacement..........................6-2132
H02S Replacement..................................... 6-2133
TP Sensor Replacement.............................6-2135
IAT Sensor Replacement........................... 6-2136
IAC Valve Replacement..............................6-2137
Accelerator Controls Cable
Replacement............................................ 6-2140
Accelerator Controls Pedal
Replacement.............................................6-2143
Throttle Body Assembly Replacement.... 6-2143
Camshaft Retard Offset Adjustment..........6-2148
Fuel Pressure Relief Procedure................ 6-2148
Quick Connect Fitting(s) Service
(Metal Collar)............................................6-2149
Quick Connect Fitting(s) Service
(Plastic Collar)..........................................6-2152
In-Line Fuel Filter Replacement
(Exc. Cart, type)...................................... 6-2154
In-Line Fuel Filter Replacement
(Exc. Cart, type 4DR Utility).................. 6-2154
Fuel Filter Element Replacement
(Cartridge Type)...................................... 6-2155
Fuel Tank Draining Procedure................... 6-2156
Fuel Tank Replacement (Suburban)..........6-2156
Fuel Tank Replacement (2DR Utility)........6-2160
Fuel Tank Replacement
(Extended Cab - Side Tank).................. 6-2164
Fuel Tank Replacement
(Pick-up - Side Tank)..............................6-2168
Fuel Tank Replacement
(Cab and Chassis - Side Tank).............6-2173
Fuel Tank Replacement
(Cab and Chassis - Rear Tank)............6-2177
Fuel Tank Replacement (4DR Utility)........6-2181
Fuel Tank Pressure Sensor
Replacement.............................................6-2184
Filler Tube Replacement (Fleetside)..........6-2185
Filler Tube Replacement (Stepside)..........6-2187
Fuel Sender Assembly Replacement........6-2188
Fuel Pump Replacement (Main)................ 6-2190
Fuel Balance Pump Replacement
(Balance)..................................................6-2191
Fuel Hose/Pipes Replacement
(Engine Compartment)............................6-2193
Fuel Hose/Pipes Assembly Replacement
(Steel Fuel Pipe Repair).........................6-2196
Fuel Hose/Pipes Assembly Replacement
(Vapor Pipe - 4DR Utility).......................6-2197
Engine
Fuel Hose/Pipes Assembly Replacement
(Vapor Pipe - Ex. 4DR Utility)............... 6-2198
Fuel Hose/Pipes Assembly Replacement
(Fuel Pipes - 4DR Utility).......................6-2199
Fuel Hose/Pipes Assembly Replacement
(Fuel Pipes - Ex. 4DR Utility)................ 6-2201
Fuel System Cleaning (Fuel Tank)............ 6-2203
Fuel System Cleaning (Fuel Pipes)..........6-2203
Fuel Pressure Connection
Valve Replacement................................. 6-2205
Fuel Pressure Regulator Replacement
(CSFI)....................................................... 6-2206
Fuel Meter Body Assembly
Replacement............................................6-2208
Fuel Injector Replacement (CSFI)............. 6-2212
Fuel Pump Relay Replacement................. 6-2212
Fuel Pump and Engine Oil PRESS
Sensor Replacement............................... 6-2213
EVAP Canister Purge Solenoid
Valve Replacement................................. 6-2214
EVAP Vent Valve Replacement................. 6-2216
EVAP System Hoses/Pipes
Replacement............................................6-2217
EVAP Canister Replacement......................6-2217
Crankshaft Position Sensor
Replacement............................................6-2218
Camshaft Position Sensor
Replacement............................................6-2220
Knock Sensor Replacement.......................6-2221
Secondary Air Injection Pump
Replacement............................................6-2221
Sec Air Injection Check
Valve/Pipe Replacement.........................6-2222
EGR Valve Replacement.......................... 6-2225
Air Cleaner Element Replacement...........6-2227
Air Cleaner Assembly Replacement........ 6-2228
Air Cleaner Intake Duct Replacement......6-2230
Intake Air Resonator Replacement........... 6-2231
Wiring Repairs.............................................. 6-2233
Description and O peration...........................6-2239
Vehicle Control Module Description...........6-2239
Serial Data Communications......................6-2243
Information Sensors/Switches
Description................................................ 6-2247
Electric Engine Cooling Fan
Description................................................6-2253
Fuel System Description - CSFI................ 6-2254
Fuel Supply Component Description......... 6-2256
Fuel Metering System Component
Description................................................ 6-2259
Short Term Fuel Trim Description............. 6-2263
Long Term Fuel Trim Description.............. 6-2264
Speed Density System Description........... 6-2264
EVAP Control System Description............. 6-2264
Enhanced Ignition System Description..... 6-2269
Knock Sensor System Description............ 6-2271
Table of Contents 6-15
Secondary Air Injection System
Description...............................................6-2272
EGR System Description...........................6-2273
Crankcase Ventilation System
Description...............................................6-2274
Air Intake System Description.................. 6-2274
Special Tools and Equipm ent.................... 6-2276
Special Tools...............................................6-2276
E n g in e C o n tr o ls - 6 . 5 L ..............................6-2279
S pecifications.................................................6-2279
Temperature vs Resistance...................... 6-2279
RPM vs Hertz (Hz)..................................... 6-2279
Fastener Tightening Specifications...........6-2280
Engine Scan Tool Data List...................... 6-2281
. Engine Scan Tool Data Definitions..........6-2284
DTC L is t........................................................ 6-2287
Fuel System Specifications..........................6-2290
GM SPO Group Numbers.........................6-2290
Schematic and Routing D iagram s............6-2291
Emission Hose Routing Diagram.............6-2291
Engine Controls Schematic References....6-2291
Engine Controls Schematic Icons............. 6-2292
Engine Controls Schematics....................... 6-2292
Component Locator......................................6-2305
Engine Controls Components.....................6-2305
Engine Controls Component Views........... 6-2309
PCM Connector End Views........................6-2325
Engine Controls Connector End Views.....6-2331
Diagnostic Inform ation and
P rocedures................................................ 6-2333
Powertrain OBD System Check..................6-2333
No Malfunction Indicator Lamp...................6-2335
Data Link Connector Diagnosis................6-2338
Engine Cranks but Does Not R un.......... 6-2340
Fuel Pump Relay Circuit Diagnosis........ 6-2343
DTC P0101 Mass Air Flow System
Performance............................................. 6-2346
DTC P0102 MAF Sensor Circuit
Low Frequency........................................ 6-2349
DTC P0103 MAF Sensor Circuit
High Frequency........................................6-2353
DTC P0112 IAT Sensor Circuit
Low Voltage.............................................6-2356
DTC P0113 IAT Sensor Circuit
High Voltage.............................................6-2359
DTC P0117 ECT Sensor Circuit
Low Voltage.............................................6-2362
DTC P0118 ECT Sensor Circuit
High Voltage.............................................6-2365
DTC P0121 APP Sensorl Circuit
Performance.............................................6-2368
DTC P0122 APP Sensorl Circuit
Low Voltage.............................................6-2371
DTC P0123 App Sensorl Circuit
High Voltage............................................ 6-2374
6-16 Table of Contents
DTC P0126 Insufficient ECT
for Stable Operation................................6-2377
DTC P0182 Fuel Temperature
Sensor CKT Low Voltage...................... 6-2380
DTC P0183 Fuel Temperature
Sensor CKT High Voltage...................... 6-2383
DTC P0215 Engine Shutoff
Control Circuit.......................................... 6-2386
DTC P0216 Injection Timing
Control Circuit.......................................... 6-2389
DTC P0219 Engine Overspeed
Condition...................................................6-2393
DTC P0220 APP Sensor2 Circuit..............6-2395
DTC P0221 APP Sensor2 Circuit
Performance............................................ 6-2397
DTC P0222 APP Sensor2 Circuit
Low Voltage............................................. 6-2400
DTC P0223 APP Sensor2 Circuit
High Voltage............................................ 6-2403
DTC P0225 APP Sensor3 Circuit..............6-2406
DTC P0226 APP Sensor3 Circuit
Performance............................................ 6-2408
DTC P0227 APP Sensor3 Circuit
Low Voltage..............................................6-2411
DTC P0228 APP Sensor3 Circuit
High Voltage............................................ 6-2414
DTC P0231 Fuel Pump Feedback
Circuit Low Voltage.................................6-2417
DTC P0236 TC Boost System................... 6-2420
DTC P0237 TC Boost Sensor
Circuit Low Voltage.................................6-2423
DTC P0238 TC Boost Sensor
Circuit High Voltage................................6-2426
DTC P0251 Injection Pump Cam
System...................................................... 6-2429
DTC P0263 Cylinder 1 Balance
System...................................................... 6-2433
DTC P0266 Cylinder 2 Balance
System...................................................... 6-2435
DTC P0269 Cylinder 3 Balance
System......................................................6-2437
DTC P0272 Cylinder 4 Balance
System...................................................... 6-2439
DTC P0275 Cylinder 5 Balance
System...................................................... 6-2441
DTC P0278 Cylinder 6 Balance
System......................................................6-2443
DTC P0281 Cylinder 7 Balance
System...................................................... 6-2445
DTC P0284 Cylinder 8 Balance
System...................................................... 6-2447
DTC P0300 Engine Misfire Detected...... 6-2449
DTC P0301 Cylinder 1 Misfire
Detected....................................................6-2452
DTC P0302 Cylinder 2 Misfire
Detected....................................................6-2454
DTC P0303 Cylinder 3 Misfire
Detected....................................................6-2456
Engine
DTC P0304 Cylinder 4 Misfire
Detected...................................................6-2458
DTC P0305 Cylinder 5 Misfire
Detected...................................................6-2460
DTC P0306 Cylinder 6 Misfire
Detected...................................................6-2462
DTC P0307 Cylinder 7 Misfire
Detected...................................................6-2464
DTC P0308 Cylinder 8 Misfire
Detected...................................................6-2466
DTC P0335 Crankshaft
Position (CKP) Sensor C K T.................. 6-2468
DTC P0370 Timing Reference
High Resolution....................................... 6-2471
DTC P0380 Glow Plug Circuit
Performance.............................................6-2475
DTC P0400 EGR System...........................6-2478
DTC P0401 EGR System Flow
Insufficient................................................. 6-2481
DTC P0402 EGR Flow Excessive............. 6-2483
DTC P0404 EGR System Performance... 6-2485
DTC P0405 EGR Sensor Circuit
Low Voltage..............................................6-2487
DTC P0406 EGR Sensor Circuit
High Voltage.............................................6-2490
DTC P0501 Vehicle Speed
Sensor Circuit...........................................6-2493
DTC P0567 Cruise Resume C ircuit..........6-2496
DTC P0568 Cruise Set C ircuit.................. 6-2498
DTC P0571 Cruise Brake
Switch Circuit............................................6-2501
DTC P0601 PCM Memory..........................6-2504
DTC P0602 PCM Not Programmed..........6-2505
DTC P0604 Control Module
Random Access Memory.......................6-2506
DTC P0606 PCM Internal
Communication Interrupted................... 6-2507
DTC P1125 APP System...........................6-2508
DTC P1191 Intake Air Duct Leak............. 6-2510
DTC P1214 Injection Pump
Timing Offset...........................................6-2512
DTC P1216 Fuel Solenoid Response
Time Too Short....................................... 6-2514
DTC P1217 Fuel Solenoid Response
Time Too Long....................................... 6-2517
DTC P1218 Injection Pump
Calibration Circuit................................... 6-2520
DTC P1406 EGR Valve Position..............6-2522
DTC P1409 EGR Vacuum
System Leak............................................6-2524
DTC P1621 EEPROM W rite..................... 6-2527
DTC P1626 VTD Controller
Serial Data Circuit.................................. 6-2528
DTC P1627 A/D Performance.................. 6-2530
DTC P1630 Theft Deterrent
PCM in Learn M ode..............................6-253
DTC P1631 Theft Deterrent
Password Incorrect.................................6-2532
Engine
DTC P1635 5 Volt Reference Low............ 6-2536
DTC P1641 MIL Control C ircuit................ 6-2539
DTC P1643 Wait to Start Lamp
Control Circuit..........................................6-2541
DTC P1653 EGR Vent Solenoid
Control C ircuit..........................................6-2543
DTC P1654 Service Throttle Soon
Lamp Control CKT.................................. 6-2547
DTC P1655 EGR Solenoid Control
C ircuit....................................................... 6-2549
DTC P1656 Wastegate Solenoid
Control Circuit..........................................6-2553
DTC U1026 Loss of ATC Class 2
Communication........................................ 6-2557
DTC U1192 Loss of VTD (Passlock)/EVO
Communication.........................................6-2558
Symptoms..................................................... 6-2559
Intermittent Condition.................................. 6-2559
Hard Start..................................................... 6-2560
Surges/Chuggles..........................................6-2561
Lack of Power, Sluggishness,
or Sponginess..........................................6-2562
Fuel Knock/Combustion Noise................... 6-2562
Hesitation, Sag, Stumble............................6-2563
Cuts Out, Misses..........................................6-2563
Poor Fuel Economy.................................... 6-2564
Excessive Smoke.........................................6-2564
Restricted Exhaust System Check............ 6-2565
A/C Request Circuit Diagnosis.................. 6-2565
Cruise Control Diagnosis............................6-2566
Fuel Tank Leak Check................................ 6-2569
Contamination Testing................................. 6-2569
Fuel Quality Diagnosis................................ 6-2570
Specific Gravity Testing............................... 6-2570
Fuel Sender Diagnosis................................ 6-2570
Fuel Supply System Check........................6-2571
Fuel Manager/Filter Diagnosis................... 6-2572
Fuel Heater Functional Diagnosis............. 6-2573
Water-in-Fuel Lamp Circuit Diagnosis...... 6-2575
Fuel Injection System Diagnosis............... 6-2577
Injection Nozzle(s) Diagnosis......................6-2577
Fuel Return System Diagnosis.................. 6-2578
Glow Plug System Check........................... 6-2578
CDR Valve Test............................................6-2580
Air Cleaner Diagnosis................................. 6-2580
Repair In s tru ctio n s.........................................6-2581
Description and Operation........................... 6-2658
PCM Replacement/Programming............... 6-2581
Password Learn Procedure........................6-2583
ECT Sensor Replacement..........................6-2584
MAF Sensor Replacement..........................6-2585
IAT Sensor Replacement............................ 6-2588
APP Module Replacement..........................6-2589
Fuel Filter Element Replacement.............. 6-2591
Fuel Manager/Filter Replacement.............. 6-2594
Fuel Manager/Filter Water
Draining Procedure................................. 6-2596
Table of Contents 6-17
Water-in-Fuel Sensor Replacement........... 6-2597
Fuel Heater Replacement.......................... 6-2601
Fuel Tank Draining Procedure................... 6-2603
Fuel Tank Replacement (Suburban).......... 6-2603
Fuel Tank Replacement (Tahoe/Yukon) ....6-2607
Fuel Tank Replacement
(Pickup Side Tank).................................. 6-2610
Fuel Tank Replacement
(Cab and Chassis Side Tank)............... 6-2615
Fuel Tank Replacement
(Cab and Chassis Rear Tank).............. 6-2620
Fuel Tank Replacement
(Extended Cab Side Tank).....................6-2623
Fuel Sender Assembly Replacement........ 6-2627
Fuel Sender Assembly Service..................6-2629
Fuel Lift Pump Replacement......................6-2629
Fuel Hose/Pipes Assembly
Replacement............................................6-2631
Fuel System Cleaning................................. 6-2631
Fuel Feed and Fuel Return
Pipe Purge Procedure............................ 6-2632
Fuel Injection Pump Replacement............ 6-2633
Injection Timing Adjustment........................6-2636
TDC Offset Adjustment............................... 6-2636
Injection Line(s) Replacement....................6-2637
Injection Nozzle(s) Replacement................6-2638
Fuel Pump Relay Replacement..................6-2638
Engine Oil Pressure
Sensor/Switch Replacement...................6-2639
Crankshaft Position Sensor
Replacement............................................6-2639
Glow Plug Relay Replacement...................6-2641
Glow Plug(s) Replacement.........................6-2644
EGR Valve Replacement............................ 6-2647
EGR Solenoid Replacement.......................6-2648
EGR Vent Solenoid Replacement............. 6-2649
EGR Solenoid Filter Replacement............ 6-2649
EGR Control Pressure
Sensor Replacement............................. .6-2650
Vehicle Speed Signal
Buffer Replacement................................ 6-2651
Boost Sensor Replacement........................6-2651
Wastegate Solenoid Replacement............. 6-2652
CDR Valve and Hoses Replacement........ 6-2652
Air Cleaner Element Replacement............ 6-2653
Air Cleaner Assembly Replacement.......... 6-2656
Powertrain Control Module Description.... 6-2658
Serial Data Communications......................6-2659
Information Sensors/Switches
Description................................................ 6-2662
APP Module Description............................. 6-2666
Fuel System Description............................. 6-2666
Fuel Supply Component Description.........6-2670
Glow Plug System Description...................6-2672
EGR System Description............................ 6-2673
6-18 Table of Contents
Crankcase Ventilation
System Description.................................6-2673
Air Intake System Description.................... 6-2674
Special Tools and E quipm ent..................... 6-2675
Special Tools.................................................6-2675
E n g in e C o n tr o ls - 7 .4 L ................................6-2677
S p e cifica tio n s..................................................6-2677
Temperature vs Resistance........................ 6-2677
Fastener Tightening Specifications...........6-2677
Engine Scan Tool Data List....................... 6-2678
Engine Scan Tool Data Definitions............6-2684
DTC List........................................................ 6-2695
GM SPO Group Numbers.......................... 6-2698
Schematic and Routing Diagrams..............6-2700
Emission Hose Routing Diagram............... 6-2700
Engine Controls Schematic
References................................................6-2700
Engine Controls Schematic Icons..............6-2700
Engine Controls Schematics...................... 6-2701
Component L o ca to r....................................... 6-2714
Engine Controls Components.................... 6-2714
Engine Controls Component Views...........6-2719
VCM Connector End Views....................... 6-2730
Engine Controls Connector End
Views (Connector End Views)............... 6-2734
Diagnostic Inform ation and
P ro ced u re s..................................................6-2737
Powertrain OBD System Check
(OBD System Check)..............................6-2737
Malfunction Indicator Lamp
Circuit Check........................................... 6-2739
Data Link Connector Diagnosis................. 6-2742
Engine Cranks but Does Not Run.............6-2744
Fuel Pump Relay Circuit Diagnosis...........6-2746
Fuel System Diagnosis................................6-2749
DTC P0101 Mass Air Flow System
Performance............................................ 6-2759
DTC P0102 MAF Sensor Circuit
Low Frequency (P0102 MAF Low ).......6-2763
DTC P0103 MAF Sensor Circuit High
Frequency (MAF Sensor High)..............6-2767
DTC P0107 MAP Sensor Circuit
Low Voltage............................................. 6-2770
DTC P0108 MAP Sensor Circuit
High Voltage............................................ 6-2773
DTC P0112 IAT Sensor Circuit
Low Voltage............................................. 6-2777
DTC P0113 IAT Sensor Circuit
High Voltage............................................ 6-2779
DTC P0117 ECT Sensor Circuit
Low Voltage............................................. 6-2782
DTC P0118 ECT Sensor Circuit
High Voltage (98).................................... 6-2785
DTC P0121 TP Sensor Performance....... 6-2788
DTC P0122 TP Sensor Circuit
Low Voltage............................................. 6-2790
Engine
DTC P0123 TP Sensor Circuit
High Voltage............................................ 6-2793
DTC P0125 ECT Excessive
Time to Closed Loop..............................6-2796
DTC P0131 H02S Circuit
Low Voltage Bankl S e n s o rl................. 6-2798
DTC P0132 H02S Circuit
High Voltage Bankl S e n s o rl................ 6-2801
DTC P0133 H02S Slow Response
Bankl S en so rl........................................ 6-2804
DTC P0134 H02S Insufficient
Activity Bankl S e n so rl.......................... 6-2807
DTC P0135 H02S Heater Circuit
Bankl S en so rl........................................ 6-2810
DTC P0137 H02S Circuit Low
Voltage Bankl Sensor2..........................6-2813
DTC P0138 H02S Circuit High
Voltage Bankl Sensor2..........................6-2817
DTC P0140 H02S Insufficient
Activity Bankl Sensor2...........................6-2820
DTC P0141 H02S Heater
Circuit Bankl Sensor2............................6-2823
DTC P0151 H02S Circuit
Low Voltage Bank2 S e n s o rl................. 6-2827
DTC P0152 H02S Circuit
High Voltage Bank2 S e n s o rl................ 6-2830
DTC P0153 H02S Slow
Response Bank2 S e n s o rl..................... 6-2833
DTC P0154 H02S Insufficient
Activity Bank2 S e n so rl...........................6-2836
DTC P0155 H02S Heater
Circuit Bank2 S e n s o rl............................6-2839
DTC P0157 H02S Circuit
Low Voltage Bank2 Sensor2................. 6-2842
DTC P0158 H02S Circuit
High Voltage Bank2 Sensor2................ 6-2845
DTC P0160 H02S Insufficient
Activity Bank2 Sensor2...........................6-2848
DTC P0161 H02S Heater
Circuit Bank2 Sensor2............................6-2851
DTC P0171 Fuel Trim System
Lean B a n k l..............................................6-2855
DTC P0172 Fuel Trim System
Rich B a n k l...............................................6-2859
DTC P0174 Fuel Trim System
Lean Bank2..............................................6-2863
DTC P0175 Fuel Trim System
Rich Bank2...............................................6-2867
DTC P0300 Engine Misfire Detected...... 6-2871
DTC P0325 Knock Sensor
Module C ircuit......................................... 6-2874
DTC P0327 Knock Sensor
Noise Channel Low Voltage.................. 6-2877
DTC P0336 CKP Sensor
Circuit Performance................................. 6-288'1
DTC P0337 CKP Sensor
Circuit Low Frequency............................6-288-r
DTC P0338 CKP Sensor
Circuit High Frequency...........................6-2887
Engine
DTC P0339 CKP Sensor
Circuit Intermittent................................... 6-2890
DTC P0340 CMP Sensor Circuit............... 6-2893
DTC P0341 CMP Sensor
Circuit Performance................................ 6-2896
DTC P0401 EGR System
Flow Insufficient...................................... 6-2898
DTC P0404 EGR Valve Open
Pintle Position..........................................6-2902
DTC P0405 EGR Pintle Position
Circuit Low Voltage................................. 6-2906
DTC P0410 AIR System............................. 6-2909
DTC P0420 TWC System
Low Efficiency B a n kl.............................. 6-2913
DTC P0430 TWC System
Low Efficiency Bank2..............................6-2917
DTC P0440 EVAP System .........................6-2920
DTC P0442 EVAP Control System
Small Leak Detected..............................6-2925
DTC P0446 EVAP Vent Valve
Performance.............................................6-2929
DTC P0452 Fuel Tank Pressure
Sensor Low Voltage................................ 6-2933
DTC P0453 Fuel Tank Pressure
Sensor High Voltage............................... 6-2937
DTC P0461 Fuel Level Sensor
Circuit Performance................................ 6-2940
DTC P0462 Fuel Level Sensor
Circuit Low Voltage................................. 6-2943
DTC P0463 Fuel Level Sensor
Circuit High Voltage................................ 6-2946
DTC P0500 Vehicle Speed
Sensor Circuit...........................................6-2949
DTC P0506 Idle Control System
Low RPM.................................................. 6-2952
DTC P0507 Idle Control System
High RPM................................................. 6-2954
DTC P0601 VCM Memory..........................6-2956
DTC P0602 VCM Not
Programmed.............................................6-2957
DTC P0603 VCM Memory Reset.............. 6-2959
DTC P0604 VCM Random
Access Memory (RAM)...........................6-2960
DTC P0605 VCM Read Only
Memory (ROM )........................................6-2961
DTC P0704 Clutch Switch Circuit............. 6-2962
DTC P1106 MAP Sensor CKT
Intermittent High Voltage........................6-2965
DTC P1107 MAP Sensor CKT
Intermittent Low Voltage.........................6-2968
DTC P1111 IAT Sensor CKT
Intermittent High Voltage........................6-2971
DTC P1112 IAT Sensor CKT
Intermittent Low Voltage.........................6-2974
DTC P1114 ECT Sensor CKT
Intermittent Low Voltage.........................6-2976
DTC P1115 ECT Sensor CKT
Intermittent High Voltage........................6-2979
Table of Contents 6-19
DTC P1121 TP Sensor CKT
Intermittent High Voltage........................6-2982
DTC P1122 TP Sensor CKT
Intermittent Low Voltage.........................6-2985
DTC P1133 H02S Insufficient
Switching Bankl S e n so rl........................6-2988
DTC P1134 H02S Transition
Time Ratio Bankl S e n s o rl....................6-2991
DTC P1153 Insufficient Switching
Bank2 S e n s o rl........................................6-2994
DTC P1154 H02S Transition Time
Ratio Bank2 S ensorl.............................. 6-2997
DTC P1336 CKP System Variation
Not Learned.............................................6-3000
DTC P1345 CKP/CMP Correlation............ 6-3003
DTC P1351 IC Circuit High Voltage.........6-3005
DTC P1361 IC Circuit Low Voltage.......... 6-3009
DTC P1380 EBCM DTC Rough
Road Data Unstable............................... 6-3012
DTC P1381 Misfire Detected
No EBCM/VCM Serial Data...................6-3014
DTC P1404 EGR Valve Closed
Pintle Position........................................ 6-3016
DTC P1415 AIR System B a n k l............... 6-3019
DTC P1416 AIR System Bank2............... 6-3021
DTC P1441 EVAP System Flow
During Non-Purge..................................6-3023
DTC P1508 IAC System Low RPM .........6-3026
DTC P1509 IAC System High R PM .........6-3030
DTC P1626 Loss of Serial
Communication with VTD..................... 6-3034
DTC P1630 Theft Deterrent
VCM in Learn Mode............................. 6-3036
DTC P1631 Theft Deterrent
Password Incorrect................................6-3037
Symptoms................................................... 6-3041
Hard Start....................................................6-3043
Surges/Chuggles........................................6-3044
Lack of Power, Sluggishness,
or Sponginess........................................6-3045
Detonation/Spark Knock........................... 6-3046
Hesitation, Sag, Stumble.......................... 6-3047
Cuts Out, Misses........................................6-3047
Poor Fuel Economy.................................. 6-3049
Rough, Unstable, or Incorrect
Idle, Stalling...........................................6-3050
Dieseling, Run-On..................................... 6-3052
Backfire....................................................... 6-3053
Restricted Exhaust System Check.......... 6-3054
Vehicle Control Module Diagnosis........... 6-3055
VCM Outputs Diagnosis
(IAC System Check).............................6-3056
A/C Compressor Control
Circuit Diagnosis................................... 6-3059
Electric Cooling Fan Diagnosis............... 6-3062
Manual Transmission Shift Light............. 6-3065
Fuel Injector Balance Test........................6-3067
6-20 Table of Contents
Fuel Injector Coil Test.................................6-3071
Fuel Injector Circuit Diagnosis................... 6-3073
Fuel Tank Pressure Sensor Diagnosis.... 6-3075
Alcohol/Contaminants-in-Fuel
Diagnosis................................................. 6-3077
EVAP Control System Diagnosis..... ......... 6-3078
Enhanced Ignition System Diagnosis...... 6-3081
Knock Sensor System Diagnosis...............6-3085
Secondary Air Injection System
Diagnosis (overview)...............................6-3085
EGR System Diagnosis...............................6-3088
Crankcase Ventilation System
Diagnosis..................................................6-3091
Idle Air Control System Diagnosis.............6-3092
Inspection/Maintenance Status
Reset Procedures.................................... 6-3095
Repair in s tru c tio n s ........................................ 6-3096
VCM Replacement/Programming............... 6-3096
CKP System Variation Learn
Procedure.................................................6-3099
Password Learn Procedure........................ 6-3099
ECT Sensor Replacement.......................... 6-3100
MAF Sensor Replacement......................... 6-3100
MAP Sensor Replacement........................ 6-3101
H02S Replacement..................................... 6-3102
TP Sensor Replacement............................ 6-3104
IAT Sensor Replacement........................... 6-3106
IAC Valve Replacement..............................6-3106
Accelerator Controls Cable
Replacement............................................ 6-3109
Accelerator Controls Pedal
Replacement.............................................6-3112
Throttle Body Assembly Replacement...... 6-3113
Camshaft Retard Offset Adjustment.......... 6-3117
Fuel Pressure Relief Procedure................. 6-3117
Quick Connect Fitting(s) Service
(Metal Collar)............................................6-3118
Quick Connect Fitting(s) Service
(Plastic Collar)......................................... 6-3121
In-Line Fuel Filter Replacement
(Exc. Cart type)....................................... 6-3123
In-Line Fuel Filter Replacement
(Exc. Cart, type 4DR Utility)........ ......... 6-3123
Fuel Filter Element Replacement............. 6-3124
Fuel Tank Draining Procedure.................. 6-3125
Fuel Tank Replacement (Suburban).........6-3125
Fuel Tank Replacement (2DR Utility)...... 6-3129
Fuel Tank Replacement
(Extended Cab - Side Tank).................. 6-3133
Fuel Tank Replacement
(Pick-up - Side Tank)..............................6-3137
Fuel Tank Replacement
(Cab and Chassis - Side Tank).............6-3142
Fuel Tank Replacement
(Cab and Chassis - Rear Tank)............6-3146
Fuel Tank Replacement (4DR Utility)...... 6-3150
Engine
Fuel Tank Pressure Sensor
Replacement............................................ 6-3153
Filler Tube Replacement (Fleetside)........ 6-3154
Filler Tube Replacement (Stepside)........ 6-3156
Fuel Sender Assembly Replacement........6-3157
Fuel Pump Replacement (Main)................6-3159
Fuel Balance Pump Replacement
(Balance)................... 6-3160
Fuel Hose/Pipes Replacement
(Engine Compartment)........................... 6-3162
Fuel Hose/Pipes Assembly Replacement
(Steel Fuel Pipe Repair)........................ 6-3165
Fuel Hose/Pipes Assembly Replacement
(Vapor Pipe - 4DR Utility)...................... 6-3165
Fuel Hose/Pipes Assembly Replacement
(Vapor Pipe - Ex. 4DR Utility)............... 6-3166
Fuel Hose/Pipes Assembly Replacement
(Fuel Pipes - 4DR Utility)...................... 6-3167
Fuel Hose/Pipes Assembly Replacement
(Fuel Pipes - Ex. 4DR Utility)................ 6-3169
Fuel System Cleaning (Fuel Tank)............6-3171
Fuel System Cleaning (Fuel Pipes)...........6-3171
Fuel Pressure Connection Valve
Replacement.............................................6-3173
Fuel Rail Assembly Replacement..............6-3174
Fuel Pressure Regulator Replacement
(SFI).......................................................... 6-3176
Fuel Injector Replacement (SFI)................ 6-3177
Fuel Pump Relay Replacement................. 6-3178
Fuel Pump and Engine Oil PRESS
Switch Replacement................................ 6-3178
EVAP Canister Purge Solenoid
Valve Replacement................................. 6-3179
EVAP Vent Valve Replacement................. 6-3180
EVAP Canister Replacement..................... 6-3180
Crankshaft Position Sensor
Replacement.............................................6-3181
Camshaft Position Sensor
Replacement..................... 6-3183
Knock Sensor Replacement....................... 6-3184
Secondary Air Injection Pump
Replacement.............................................6-3185
AIR Check Valve/Pipe Replacement -
Bank 1 ...................................................... 6-3188
EGR Valve Replacement (DR Utility)...... 6-3191
Air Cleaner Element Replacement...........6-3192
Air Cleaner Assembly Replacement.........6-3192
Air Cleaner Intake Duct Replacement..... 6-3194
Intake Air Resonator Replacement............ 6-3196
Wiring Repairs..............................................6-3198
Description and O p e ra tio n ...........................6-3204
Vehicle Control Module Description...........6-3204
Serial Data Communications...................... 6-3209
Information Sensors/Switches
Description................................................6-321C
Electric Engine Cooling Fan
Description................................................6-3218
Engine
Fuel System Description - S F I.................. 6-3219
Fuel Supply Component Description......... 6-3222
Fuel Metering System
Component Description........................... 6-3225
Short Term Fuel Trim Description............. 6-3229
Long Term Fuel Trim Description.............. 6-3229
Speed Density System Description........... 6-3229
EVAP Control System Description............. 6-3229
Enhanced Ignition System Description..... 6-3230
Knock Sensor System Description............ 6-3232
Secondary Air Injection
System Description................................. 6-3233
EGR System Description............................6-3233
Crankcase Ventilation
System Description................................. 6-3235
Air Intake System Description................... 6-3235
Special Tools and E quipm ent......................6-3236
Special Tools................................................ 6-3236
T u r b o c h a r g e r .................................................... 6-3239
S pecifications.................................................. 6-3239
Fastener Tightening Specifications............ 6-3239
Diagnostic Information and Procedures..... 6-3240
Lacks Power, No Black Smoke
at WOT..................................................... 6-3240
Lacks Power, Black Smoke at W OT.........6-3240
Turbocharger Noise......................................6-3240
Blue Exhaust Smoke, Warm
Engine Only.............................................. 6-3240
Turbocharger................................................ 6-3241
Wastegate Actuator......................................6-3243
Repair In stru ctio n s.........................................6-3244
Turbocharger................................................ 6-3244
Wastegate Actuator......................................6-3249
Table of Contents 6-21
Description and O peration.......................... 6-3251
Turbocharger............................................... 6-3251
Vacuum Pump ................................................ 6-3253
S pecifications................................................. 6-3253
Fastener Tightening Specifications........... 6-3253
Vacuum Pump Specifications....................6-3253
Diagnostic Inform ation and
P rocedures................................................. 6-3254
Vacuum Pump Diagnosis........................... 6-3254
Repair Instructio n s........................................6-3255
Vacuum Pump Replacement.....................6-3255
Special Tools and Equipm ent.....................6-3257
Engine Exhaust.............................................. 6-3259
S pecifications................................................. 6-3259
Fastener Tightening Specifications........... 6-3259
GM SPO Group Numbers.........................6-3259
Diagnostic Information and
P rocedures................................................. 6-3260
Vibration or Rattling................................... 6-3260
Restricted Exhaust..................................... 6-3260
Exhaust Leakage (Not OBD II)................ 6-3260
Repair In stru ctio n s....................................... 6-3262
Exhaust System Inspection...................... 6-3262
Catalytic Converter Replacement
(Gasoline Below 8600 lb GVWR).........6-3262
Catalytic Converter Replacement
(Gasoline Above 8600 lb GVWR).........6-3264
Catalytic Converter Replacement
(Diesel)....................................................6-3266
Catalytic Converter Replacement
(Export)....................................................6-3268
Description and O peration..........................6-3270
Exhaust System Description..................... 6-3270
BLANK
Engine Engine Controls - 6.5L 6-2279

Engine Controls - 6.5L

Specifications

Temperature vs Resistance
*c *F OHMS
Temperature vs Resistance Values (Approximate)
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700

RPM vs Hertz (Hz)

RPM vs Hertz (Hz) for High Resolution Signal

RPM Hertz (Hz) RPM Hertz (Hz) RPM Hertz (Hz)
700 2987 1600 6827 2500 10667
800 3413 1700 7253 2600 11093
900 3840 1800 7680 2700 11520
1000 4267 1900 8170 2800 11947
1100 4693 2000 8533 2900 12373
1200 5120 2100 8960 3000 12800
1300 5547 2200 9387 3100 13227
1400 5973 2300 9813 3200 13653
1500 6400 2400 10240 3300 14080
6-2280 Engine Controls - 6.5L Engine
RPM vs Hertz (Hz) for CAM and Crank Signal
RPM Hertz (Hz) RPM Hertz (Hz) RPM Hertz (Hz)
700 47 1600 106 2500 166
800 53 1700 113 2600 173
900 60 1800 120 2700 180
1000 67 1900 126 2800 186
1100 73 2000 133 2900 193
1200 80 2100 140 3000 200
1300 89 2200 147 3100 207
1400 93 2300 153 3200 213
1500 100 2400 160 3300 220

Fastener Tightening Specifications

Application N-m Lb Ft Lb In
Crankshaft Position Sensor Mounting Bolt 25 18 —
EGR Control Pressure/BARO Sensor 35 — 27
Boost (BARO) Sensor Mounting Bolts 3.5 — 27
Fuel Manager/Filter to Intake Manifold Bolts 25 18 —
Water in Fuel Sensor Mounting Screws 2 — 24
Injection Lines to Nozzle Fittings 25 18 —
Fuel Feed Pipe and Suction Pipe to Fuel Pump 30 22 —
Injection Pump Flange Nuts 40 30 —
Driven Gear to Injection Pump Bolts 25 18 —
Injection Nozzle 70 50 —
Engine
Engine Scan Tool Data List
Use the scan tool data listed in this table for
comparison after the On-Board Diagnostic system
check and finding the on-board diagnostics function
properly with no diagnostic codes displayed.
The Typical Scan Tool Data Values are an average
of display values recorded from normally operating
vehicles. The Typical Scan Tool Data Values are
intended to represent what a normally functioning
system would display. The values you get may vary
due to a low battery charge or other reasons. But
they should be very close.
Engine Controls - 6.5L 6-2281
Do not use a scan tool that displays faulty data.
Report the problem to the manufacturer. The use of
a faulty scan tool can result in misdiagnosis and
unnecessary parts replacement.
Use only the parameters listed in the tables for
diagnosis. If a scan tool reads other parameters, the
values are not recommended by General Motors for
use in diagnosis. For more description on the values
and the use of the scan tool diagnosis the PCM
inputs, refer to the applicable diagnosis. If all values
are within the range illustrated, refer to Driveability
Symptoms.

Engine Scan Tool Data List

Engine Idling/Lower Radiator Hose Hot/Closed Throttle/Park or Neutral/Accessories Off
Scan Tool
Parameter Data List Units Displayed Typical Data Value Reference
Engine Data 1, MAF ±100 RPM from
Engine Speed RPM Engine Scan Tool Data Definitions
EGR Data desried
Engine Data 1, MAF
Desired Idle Speed RPM 630 - 650 Engine Scan Tool Data Definitions
EGR Data
85’ C - 105*C
Engine Data 1, MAF /185"F - 220-F
ECT *C/ *F Information Sensors
EGR Data (varies with
temperature)
Engine Data 1, MAF varies (ECT at time
Startup ECT *C/ *F Engine Scan Tool Data Definitions
EGR Data of engine startup)
Engine Data 1, MAF
ECT Sensor Volts 2-3 Information Sensors
EGR Data
Engine Data 1, MAF 65 - 104 (varies
BARO kPa Information Sensors
EGR Data with altitude)
10*C - 90'C
/50'F - 194*F
Engine Data 1, MAF
IAT *C/ *F (temperatures may Information Sensors
EGR Data
increase under
heavy engine loads)
20 - 35 g/s (Idle)
MAF MAF EGR Data g/s 120 - 140 g/s Information Sensors
(2500 RPM)
4000 - 4500 Hz
(Idle)
MAF Frequency MAF EGR Data Hz Information Sensors
7200 - 7800 Hz
(2500 RPM)
Engine Data 1, MAF
ESO Solenoid On/Off On Engine Scan Tool Data Definitions
EGR Data
Engine Data 1, MAF 50 - 70 (Idle)
Wastegate Solenoid % Engine Scan Tool Data Definitions
EGR Data 20 - 40 (2500 RPM)
Engine Data 1, MAF 60 - 170 kPa
Boost Pressure kPa/PSI Information Sensors
EGR Data (All RPMs)
Engine 1 Data, MAF 80 - 104 kPa
Actual EGR kPa Engine Scan Tool Data Definitions
EGR Data (All RPMs)
Engine 1 Data, MAF 80 - 104 kPa
Desired EGR kPa Engine Scan Tool Data Definitions
EGR Data (All RPMs)
Engine 1 Data, MAF
j EGR Duty Cycle kPa 0 kPa (All RPMs) Engine Scan Tool Data Definitions
EGR Data
6-2282 Engine Controls - 6.5L____________________________ Engine
Engine Scan Tool Data List (cont’d)
Engine Idling/Lower Radiator Hose Hot/Closed Throttle/Park or Neutral/Accessories Off
Scan Tool
Parameter Data List Units Displayed Typical Data Value Reference
Engine 1 Data, MAF 4.60 - 4.85 volts
EGR Sensor Volts Information Sensors
EGR Data (All RPMs) ,
Engine 1 Data, MAF
EGR Vent Sol. On/Off Off Information Sensors
EGR Data
EGR Adaptive
MAF EGR Data Counts 0 Information Sensors
Leam Matr.
0.30 - 1.00 g/cyl
Cylinder Air MAF EGR Data g/cyl Information Sensors
(All RPMs)
0.30 - 1.00 g/cyl
Desired Cylinder Air MAF EGR Data g/cyl Information Sensors
(All RPMs)
Engine Data 1, MAF
Vehicle Speed MPH/km/h 0 Engine Scan Tool Data Definitions
EGR Data
Fuel Temperature Engine Data 1, MAF 10'C - 90’ C
'C/ *F Information Sensors
Sensor EGR Data /50 ’ F - 194'F
Engine Data 1, MAF
Fuel Rate mm3 7 - 1 5 (All RPMs) Engine Scan Tool Data Definitions
EGR Data
Glow Plug Engine Data 1 Volts 0.0 Engine Scan Tool Data Definitions
Enabled on key up
Engine Data 1, MAF
Glow Plug System Disable/Enabled (times varies with Engine Scan Tool Data Definitions
EGR Data
temperature)
Desired Inj. Pump Engine Data 1, MAF • 4 - 1 0 (Idle)
Engine Scan Tool Data Definitions
Timing EGR Data 14 - 20 (2500 RPM
Actual Inj. Pump Engine Data 1, MAF 4 - 1 0 (Idle)
• Engine Scan Tool Data Definitions
Timing EGR Data 14 - 20 (2500 RPM
Engine Data 1, MAF 0 (Idle)
APP Angle % Engine Scan Tool Data Definitions
EGR Data 4-8 (2500 RPM)
0.44 - 0.95 (Idle)
Accelerator Pedal Engine Data 1, MAF
Volts 0.75 - 1.25 Information Sensors
Pos. 1 EGR Data
(2500 RPM)
3.9 - 4.5 (Idle)
Accelerator Pedal Engine Data 1, MAF
Volts 3.7 - 4.3 Information Sensors
Pos. 2 EGR Data
(2500 RPM)
3.6 - 4.1 (Idle)
Accelerator Pedal Engine Data 1, MAF
Volts 3.5 - 4.0 Information Sensors
Pos. 3 EGR Data
(2500 RPM)
Inj. Pump Sol. Engine Data 1, MAF 1.70 - 1.90
mS Engine Scan Tool Data Definitions
Closure Time EGR Data (All RPMs)
+0.75 to -1.75
Engine Data 1, MAF •
TDC Offset (factory setting Engine Scan Tool Data Definitions
EGR Data
varies per engine)
Engine Data 1, MAF 1 2 - 1 4 (accuracy
Ignition Voltage Volts Engine Scan Tool Data Definitions
EGR Data ±0.4 volts)
Cruise Active Engine Data 1 On/Off Off Engine Scan Tool Data Definitions
Cruise Switch Engine Data 1 On/Off Off Engine Scan Tool Data Definitions
Brake Switch Engine Data 1 Open/Closed Open Information Sensors
Cruise Brake Switch Engine Data 1 Open/Closed Closed Information Sensors
Set Switch Engine Data 1 On/Off Off Engine Scan Tool Data Definitions
Resume Switch Engine Data 1 On/Off Off Engine Scan Tool Data Definitions
Engine________________________________________________ Engine Controls - 6.5L 6-2283
Engine Scan Tool Data List (cont’d)
Engine Idling/Lower Radiator Hose Hot/Closed Throttle/Park or Neutral/Accessories Off
Scan Tool
Parameter Data List Units Displayed Typical Data Value Reference
Crank Reference
Engine Data 1 Counts 0 Engine Scan Tool Data Definitions
Missed
Inj. Pump CAM
Engine Data 1 Counts 0 Engine Scan Tool Data Definitions
Reference Missed
1 2 - 1 6 (0.6 volts
Lift Pump Engine Data 1 Volts higher than Engine Scan Tool Data Definitions
ignition voltage)
Lift Pump System Engine Data 1 Disabled/Enabled Enabled Engine Scan Tool Data Definitions
Engine Load Engine Data 1 % 1-5 Engine Scan Tool Data Definitions
Engine Torque Engine Data 1 ft lb 3-8 Engine Scan Tool Data Definitions
Number Of DTCs Engine Data 1 Counts 0 Engine Scan Tool Data Definitions
DTC Set This Ignition Engine Data 1 Counts Yes/No Engine Scan Tool Data Definitions
Engine Data 1, MAF
MIL On/Off Off Engine Scan Tool Data Definitions
EGR Data
Service Throttle Engine Data 1, MAF
On/Off Off Engine Scan Tool Data Definitions
Soon Lamp EGR Data
VTD Fuel Disable Engine Data 1 Active/lnactive Inactive Engine Scan Tool Data Definitions
VTD Auto
Engine Data 1 Active/lnactive Inactive Engine Scan Tool Data Definitions
Learn Timer
PCM in VTD Fail
Engine Data 1 Yes/No No Engine Scan Tool Data Definitions
Enable
VTD Fuel Diasable
Engine Data 1 Yes/No No Engine Scan Tool Data Definitions
Until Ign. Off
Park/Neutra!/
Reverse/
Transmission Range Engine Data 1 Overdrive/ Park/Neutral Automatic Transmission 4L80E
Drive 3/
Drive 2/Drive 1
On On On/Off
A/B/C Range Switch Engine Data 1 On Off On Automatic Transmission 4L80E
Off Off
1 - 2 Sol. Engine Data 1 On/Off On Automatic Transmission 4L80E
2 - 3 Sol. Engine Data 1 On/Off Off Automatic Transmission 4L80E
50*C - 70*C
Trans. Fluid Temp. Engine Data 1 *C/ *F Automatic Transmission 4L80E
/12 2 'F - 158’ F
TFT Sensor Engine Data 1 Volts 1.8 - 2.2 Engine Scan Tool Data Definitions
Calc. A/C Load Engine Data 1 Counts 0 Engine Scan Tool Data Definitions
A/C Request Engine Data 1 On/Off 0 Engine Scan Tool Data Definitions
Engaged/
A/C Compressor Engine Data 1 Disengaged Engine Scan Tool Data Definitions
Disengaged
A/C Relay Engine Data 1 On/Off Off Engine Scan Tool Data Definitions
Varies with engine
Engine Run Time Engine Data 1 Hrs/Mins/Sec Engine Scan Tool Data Definitions
run time
6-2284 Engine Controls - 6.5L
Engine Scan Tool Data Definitions
A list of each data message displayed on the Scan
tool will be explained in two groups; Engine or
Transmission. This information will assist in emission
or driveability problems. The displays can be viewed
while the vehicle is being driven. Always perform the
Powertrain On-Board Diagnostic (OBD) System
Check first. The OBD System Check will confirm
proper system operation.
Engine Speed-Range 0-9999 RPM: Engine speed
is computed by the PCM from the crankshaft position
sensor. If the crankshaft position sensor is
inoperative, an rpm reading is taken from the
injection pump cam signal. It should remain close to
desired idle under various engine loads with engine
idling. Engine speed value is very accurate.
Desired Idle-Range 0-3187 RPM: The idle speed
that is requested by the PCM. The PCM will
compensate for various engine loads based on
engine coolant temperature to keep the engine at
the desired speed.
ECT-Range -40°C to 151°C, -4 0 T to 304°F: The
Engine Coolant Temperature (ECT) sensor sends a
signal to the PCM relative to engine coolant
temperature. The sensor is a thermistor which
changes internal resistance as temperature changes.
When the sensor is cold (internal resistance high),
the PCM monitors a high signal voltage and
interprets it as a cold engine. As the sensor warms
(internal resistance decreases), the voltage signal will
decrease and the PCM will interpret the lower
voltage as a warm engine.
Startup Coolant - Range -4 0 ’C to 15TC , -4 0 8F to
304°F: A reading of the vehicles coolant temperature
at startup. This will change every key cycle.
lAT-Range -40°C to 151°C, -40°F to 304°F: The
intake air temperature sensor sends a signal to the
PCM relative to the incoming air. The IAT is used by
the PCM to adjust fuel delivery.
MAF - Range 0-6553.5 g/s: The Mass Air Flow
sensor measures the amount of air entering the
engine during a given time. The PCM uses this
information to monitor the EGR flow rates only.
MAF Frequency - Range 0-65535 Hz: This is the
conversion of MAF from Grams per Second (g/s) into
a frequency (Hz).
ECT Sensor-Range 0 -5 Volts: The Engine Coolant
Temperature (ECT) sensor sends a signal to the
PCM relative to engine coolant temperature. The
sensor is a thermistor which changes internal
resistance as temperature changes. When the
sensor is cold (internal resistance high), the PCM
monitors a high signal voltage and interprets it as a
cold engine. As the sensor warms (internal
resistance decreases), the voltage signal will
decrease and the PCM will interpret the lower
voltage as a warm engine.
BARO-Range 10-105 kPa, 0 -5 Volts: The BARO
reading is determined from the Boost sensor at
ignition ON, engine OFF. The BARO reading display
represents barometric pressure and is used to
compensate for altitude differences.
Engine
ESO Solenoid-Range ON/OFF: The ESO is located
on the fuel injection pump. When the ignition switch
OFF, the ESO is in the NO FUEL position. It
prevents fuel from entering the fuel injection pump.
Boost Solenoid-Range 0-100%: The PCM cycles
the boost solenoid PWM ON and OFF. The ON time
(duty cycle) of the solenoid valve is expressed as a
percent. The Boost pulse width modulated solenoid
meters the vacuum level at the wastegate valve
actuator as commanded by the PCM.
Boost Pressure-Range 10-200 kPa, 0-5.0 Volts:
The amount of turbo boost pressure in the intake
manifold. This is measured in kPa and volts. True
boost pressure is determined by subtracting BARO
from the actual reading.
Actual EGR - Range 10-200 kPa, 0-5.0 Volts:
Actual EGR vacuum going to the EGR valve.
Desired EGR - Range 10-200 kPa, 0-5.0 Volts:
The PCM command for EGR vacuum.
EGR Duty Cycle-Range 0-100% : The PCM cycles
the EGR solenoid PWM ON and OFF. The ON time
(duty cycle) of the EGR solenoid valve is expressed
as a percent. The EGR pulse width modulated
solenoid meters the vacuum level at the EGR valve
actuator as commanded by the PCM.
EGR Sensor - Range 0 -5 Volts: The conversion of
Actual EGR into a voltage.
EGR Vent Sol. - Range ON/OFF: The PCM
commands the EGR vent solenoid to purge vacuum
to the atmosphere when there is a desire to quickly
turn off EGR flow.
EGR Adaptive Learn Matrix - Range 0-15: The
Adaptive Learn Matrix (ALM) bases itself on Mass
Air Flow (MAF) to adjust the EGR control vacuum.
As backpressure or other system variations increase
over the life of the vehicle the ALM will trim the EGR
control vacuum to compensate. The ALM has sixteen
cells in which each cell covers a range of engine
speed (RPM) and load (mm3).
Cylinder Air - Range 0.25-1.25 g/cyl: The actual
amount of air going through the MAF. The
conversion of the MAF sensor readings into Grams
per Cylinder (g/cyl).
Desired Cylinder Air - Range 0.25-1.25 g/cyl: The
requested Cylinder Air by the PCM. This is based on
engine load and speed.
Fuel Temp.-Range -2 8 #C to 140°C, -1 8 ‘F to
285*F: There is a thermistor located in the optical
sensor that determines fuel temperature. When the
sensor is cold (internal resistance high) the PCM
monitors a high signal voltage which it interprets as
low fuel temperature. As the sensor warms (internal
resistance low) the voltage signal will decrease and
the PCM will interpret the low voltage as warm fuel.
Fuel Rate-Range 0-80m m 3: This reading is
displayed in millimeters cubed (mm3). This is the
amount of fuel the PCM is requesting.
Engine
Glow Plug-Range 0-25.5 volts: The amount of
voltage the glow plug system is drawing. The scan
tool can be used to indicate if the glow plugs
actually turned ON by monitoring the voltage drop.
Also, a good functional check of the glow plug relay.
Glow Plug System -Range ON/OFF: Glow Plug
System-Range ON/OFF Indicates whether or not the
PCM has requested the glow plugs to be turned ON.
Des. Inj. Tim ing-Range 0-25.5 Degrees: The
amount of injection timing requested by the PCM.
Act. Inj. Tim ing-Range 0-25.0 Degrees: Current
actual injection timing.
APP Angle-Range 0-100%: Computed by the PCM
from APP module voltage (throttle position) and
should display 0% at idle and 100% at wide open
throttle.
APP 1-Range 0 -5 Volts: The PCM uses the
APP sensors to control fuel delivery as requested by
the driver. Three APP sensors are located in a
module at the base of the accelerator pedal. The
PCM only requires information from one sensor, the
other two serve as fail safes. APP 1 should read
about 0.35-0.95 volts at idle to above 4.0 volts at
wide open throttle.
APP 2-Range 0 -5 Volts: The PCM uses the
APP sensors to control fuel delivery as requested by
the driver. Three APP sensors are located in a
module at the base of the accelerator pedal. The
PCM only requires information from one sensor, the
other two serve as fail safes. APP 2 should read
about 4.5 volts at idle and steadily decrease to about
1.0 volt at wide open throttle.
APP 3-Range 0 -5 Volts: The PCM uses the
APP sensors to control fuel delivery as requested by
the driver. Three APP sensors are located in a
module at the base of the accelerator pedal. The
PCM only requires information from one sensor, the
other two serve as fail safes. APP 3 should read
about 4.0 volts at idle and steadily decrease to about
2.5 volts at wide open throttle.
Inj. Pump Sol. Closure Tim e-Range 0.0-4.0
milliseconds: Indicates the amount of time the fuel
solenoid takes to close. When engine load is
increased, closure time will fluctuate.
TDC OFFSET-Range -2 .50 to + 2.50 Degrees: The
PCM has the ability to determine the amount of
offset needed to bring the engine to top dead center.
This is used by the PCM to determine proper
injection timing and fuel delivery. This value may be
displayed as a positive or negative number.
MPH km/h-Range 0-98 mph: Vehicle speed is a
PCM internal parameter. It is computed by timing
pulses coming from the Vehicle Speed Sensor
(VSS). Vehicle speed is used in checking
TCC lock-up speed or speedometer accuracy.
Speed is displayed in both Miles Per Hour (mph)
and Kilometers Per Hour (km/h).
Cruise Switch-Range ON/OFF: Indicates if the
cruise switch (on turn signal lever) is in the
ON position.
Engine Controls - 6.5L 6-2285
Cruise Active-Range ON/OFF: Indicates if vehicle
is in cruise control.
Cruise Brake Sw.-Range open/closed: Is used for
stop lamps and a redundant cruise control
disengagement switch.
Brake Switch-Range open/closed: When the brake
pedal is applied, the switch sends a signal to the
PCM to disengage the cruise control.
Set Switch-Range ON/OFF: Indicates if the cruise
control set switch is activated. The scan tool may be
used to determine if the cruise control set switch is
functioning properly.
Resume Switch-Range ON/OFF: Indicates if the
cruise conrol resume switch is activated. The scan
tool may be used to determine if the cruise control
resume set switch is functioning properly.
TR Switch-Range Park/Neutral, Reverse, Drive 4,
Drive 3, Drive 2, Low and Invalid: These values
represent the decoded sequence of the transmission
range pressure switch assembly circuits and are to
determine manual valve position.
Crank Ref. Missed-Range 9 - 8: The scan tool will
display the number of crank pulses missed. At idle it
should read 0.
Inj. Pump Cam Reference Missed-Range 0-8: The
scan tool will display the number of cam pulses
missed. At idle it should read 0.
Lift Pump-Range 0-25.5 volts: The amount of
voltage the lift pump system is drawing. Also, a good
functional check of the lift pump relay and oil
pressure switch.
Lift Pump System-Range disabled/enabled:
Indicates weather or not the PCM has requested the
lift pump to be turned ON. This display can not be
used to determine if the lift pump is actually ON.
Engine Load-Range 0-100% : The amount of load
on the engine.
Engine Torque-Range 0-999 ft/lb: The amount of
engine torque.
# of Curr. DTCs-Range #: Indicates the total
number of current DTCs set. Does not necessarily
mean the MIL is illuminated.
DTC Set This Ign.-Range #: Indicates the total
number of current DTCs set this ignition cycle.
Ignition Volts-Range 0-25.5 volts: This represents
the system voltage measured by the PCM at its
ignition feed circuit. Ignition voltage is only present
when vehicle is running.
TFT Sensor-Range 0-5 volts: This value
represents the input signal of the transmission fluid
temperature sensor in voltage. Refer to section Refer
to Transmissions.
TFT-R ange- -4 0 #C to 151BC, -40°F to 304°F: This
value represents the input signal of the transmission
fluid temperature sensor. Refer to Transmissions.
Calc. A/C Load-Range: The amount of load the
A/C is putting on the engine.
6-2286 Engine Controls - 6.5L
A/C Compressor-Range engaged/disengaged:
Indicates weather or not A/C compressor is engaged.
The output test function in the scan tool can only
activated with the key ON, and the engine OFF.
A/C Request-Range ON/OFF: Represents the state
of the A/C request input from the control head.
A/C Relay-Range Disabled/Enabled: Represents
the commanded state of the A/C clutch control relay.
The A/C clutch should be engaged with ON
displayed.
MIL Lamp-Range ON/OFF: Represents the
commanded state of the Service Engine
Soon (MIL) lamp.
STS Lamp-Range ON/OFF: Represents the
commanded state of the Service Throttle Soon lamp.
4WDL Mode-Range: Indicates if vehicle is in the
four wheel drive mode.
Front Axle Switch-Range Engaged/Disengaged:
Indicates weather or not the front axle state is being
detected by the PCM.
VTD Fuel Disable: The scan tool display is Active or
Inactive. If the PCM has not received the correct
password from the Passlock module the PCM will
disable fuel to the fuel system, and Active will be
displayed on the scan tool.
PCM in VTD Fail Enable: The scan tool display is
Yes or No. This will indicate that the PCM received a
good password from the Passlock module and the
vehicle has started and a failure has occurred. The
PCM will continue to enable fuel.
VTD Auto Learn Timer: The scan tool display is
Active or Inactive. The Auto Learn Timer is will
indicate if the Vehicle Theft Deterrent (VTD) system
is in learn mode and has not timed out (10 min.)
VTD Fuel Disable Until Ign. Off: The scan tool
display is Yes or No. With the ignition ON and a
VTD code stored, the scan tool will display Yes.
A/B/C Range Sw.-Range On On On/Off Off Off:
They are used to detect which gear has been
manually selected. Engine must be running. Refer to
Transmissions.
Engine
1 - 2 Sol 2 -3 Sol-Range On Off/On Off: These
values are the command status of the 1-2 and the
2 - 3 shift solenoids. ON represents a commanded
energized state (current flowing through solenoid).
OFF represents a commanded non-energized state
(current not flowing through solenoid). Refer to
Transmissions.
TCC Enabled-Range disabled/enabled: Indicates if
TCC is engaged.
PC Solenoid-On/Off: This value is the commanded
state of the pressure control solenoid. Refer to
Transmissions.
Device Control-Range YES/NO: Indicates if the
scan tool has taken control of a system under
output tests.
Engine Run Tim e-Range 00:00:00 (HRS/MIN/SEC):
A measure of how long the engine has been
operating. When the ignition is cycled to OFF the
value is reset to zero.
Freeze Frame and Failure Record Data
Definitions: A freeze frame and failure record data
list consist of a many of the same parameters as in
a Engine data list. The list below defines the
parameters not found in a Engine data list.
First Odometer-Range miles (x16): The amount of
miles (in 16 mile increments) that the vehicle has
traveled since the freeze frame or failure record has
been stored.
Last Odometer-Range miles (x16): Every time a
failure occurs, last odometer will reset to zero. The
amount miles since the last failure (in 16 mile
increments).
Fail Counter-Range (decimal): The number of
ignition cycles that at test has ran and failed (at
least once).
Pass Counter-Range (decimal): The number of
ignition cycles that at test has ran and passed (at
least once).
No Results Counter: The number of ignition cycles
with out a result (pass or fail).
Engine Engine Controls - 6.5L 6-2287

DTC List
The service information contained in this manual
refers to the Federal calibration package. The export
change is NOT reflected in the service information
on the DTC’s diagnostic support information page or
in the Repair Instructions. Export vehicles may have
differences in DTC types that will affect Malfunction
Indicator Lamp (MIL) operation.
Type A: The PCM illuminates the Malfunction
Indicator Lamp (MIL) on the first drive trip that the
diagnostic runs and fails.
Type B: The PCM illuminates the Malfunction
Indicator Lamp (MIL) on the second consecutive
drive trip that the diagnostic runs and fails.
Type C: The PCM illuminates the Service Throttle
Soon lamp only when there is more than one DTC
(Type C) stored.
Type C*: The PCM will not illuminate a service lamp
but will store a Failure Record on the first drive trip
that the diagnostic runs and fails.
If a system is malfunctioning and the associated
DTC has been disabled (Type X), it may be
beneficial to use the diagnostic table as a guide to
aid in diagnosis. Many of the DTC tables include a
functional check of the system that may pinpoint a
problem. However, it is important to remember that
the DTC tables are specifically designed for use only
when a DTC is set. Therefore, a thorough
understanding of the normal operation of the system
being diagnosed is necessary and use of the tables
for this purpose is at the discretion of the technician.
Important: For Automatic Transmission DTC types,
refer to Automatic Transmission.

DTC List
Heavy Duty
DTC Description RPO L56 RPO L65 RPO L65
P0101 Mass Air Flow (MAF) System Performance B — —
P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency B — —
P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency B — —
Intake Air Temperature (IAT) Sensor Circuit Low
P0112 B B B
Voltage
Intake Air Temperature (IAT) Sensor Circuit High
P0113 B B B
Voltage
Engine Coolant Temperature (ECT) Sensor Circuit
P0117 B B B
Low Voltage
Engine Coolant Temperature (ECT) Sensor Circuit
P0118 B B B
High Voltage
Accelerator Pedal Position (APP) Sensor 1 Circuit
P0121 C C C
Performance
Accelerator Pedal Position (APP) Sensor 1 Circuit
P0122 C C C
Low Voltage
Accelerator Pedal Position (APP) Sensor 1 Circuit
P0123 C C C
High Voltage
P0126 Insufficient ECT for stable Operation B — —
P0182 Fuel Temperature Sensor Circuit Low Voltage B B B
P0183 Fuel Temperature Sensor Circuit High Voltage B B B
P0215 Engine Shut off Control Circuit C* C* C*
P0216 Injection Timing Control Circuit B B B
P0219 Engine Overspeed Condition C* C* C*
P0220 Accelerator Pedal Position (APP) Sensor 2 Circuit C C C
Accelerator Pedal Position (APP) Sensor 2 Circuit
P0221 C C C
Performance
Accelerator Pedal Position (APP) Sensor 2 Circuit
P0222 C C C
Low Voltage
Accelerator Pedal Position (APP) Sensor 2 Circuit
P0223 C C C
High Voltage
P0225 Accelerator Pedal Position (APP) Sensor 3 Circuit C C C
Accelerator Pedal Position (APP) Sensor 3 Circuit
P0226 C C C
Performance
6-2288 Engine Controls - 6.5L Engine
DTC List (cont’d)
Heavy Duty
DTC Description RPO L56 RPO L65 RPO L65
Accelerator Pedal Position (APP) Sensor 3 Circuit
P0227 C C C
Low Voltage
Accelerator Pedal Position (APP) Sensor 2 Circuit
P0228 C C C
High Voltage
P0231 Fuel Pump Feedback Circuit Low Voltage B B B
P0236 Turbocharger Boost System B B B
P0237 Turbocharger Boost Sensor Circuit Low Voltage B B B
P0238 Turbocharger Boost Sensor Circuit High Voltage B B B
P0215 Injection Pump Cam System A A A
P0263 Cylinder 1 Balance System C* C* C*
P0266 Cylinder 2 Balance System C* C* C*
P0269 Cylinder 3 Balance System C* C* C*
P0272 Cylinder 4 Balance System C* C* C*
P0275 Cylinder 5 Balance System C* C* C*
P0278 Cylinder 6 Balance System C* C* C*
P0281 Cylinder 7 Balance System C* C* C*
P0284 Cylinder 8 Balance System C* C* C*
P0300 Engine Misfire Detected B B B
P0301 Cylinder 1 Misfire Detected B B B
P0302 Cylinder 2 Misfire Detected B B B
P0303 Cylinder 3 Misfire Detected B B B
P0304 Cylinder 4 Misfire Detected B B B
P0305 Cylinder 5 Misfire Detected B B B
P0306 Cylinder 6 Misfire Detected B B B
P0307 Cylinder 7 Misfire Detected B B B
P0308 Cylinder 8 Misfire Detected B B B
P0335 Crankshaft Position (CKP) Sensor Circuit A A A
P0370 Timing Reference High Resolution A A A
P0380 Glow Plug Circuit Performance B B B
P0400 Exhaust Gas Recirculation (EGR) Flow Malfunction B — —
Exhaust Gas Recirculation (EGR) System Flow
P0401 B — —
Insufficient
Exhaust Gas Recirculation (EGR) System Flow
P0402 B — —
IExcessive
Exhaust Gas Recirculation (EGR) System
P0404 B — —
Performance
Exhaust Gas Recirculation (EGR) Sensor Circuit Low
P0405 B — —
Voltage
Exhaust Gas Recirculation (EGR) Sensor Circuit High
P0406 B — —
Voltage
P0501 Vehicle Speed Sensor Circuit C* C* C*
P0567 Cruise Resume Circuit C* C* C*
P0568 Cruise Set Circuit C* c* c*
P0571 Cruise Brake Switch Circuit C* c* c*
P0601 Internal Control Module Memory A A A
P0602 Control Module Programming C* C* C*
Engine Engine Controls - 6.5L 6-2289
DTC List (cont’d)
Heavy Duty
DTC Description RPO L56 RPO L65 RPO L65
P0604 Control Module Random Access Memory Check Sum C* C* C*
P0606 PCM Internal Communication Interrupted A A A
P1125 Accelerator Pedal Position System C C C
P1191 Intake Air Duct Leak B — —
P1214 Injection Pump Timing Offset B B B
P1218 Injection Pump Calibration Circuit B B B
P1406 Exhaust Gas Recirculation (EGR) Valve Position B — —
Exhaust Gas Recirculation (EGR) Vacuum
P1409 B — —
System Leak
Vehicle Theft Deterrent (VTD) Controller Serial Data
P1626 C* — —
Circuit
P1627 A/D Performance B B B
P1630 Theft Deterrent PCM in Learn Mode C* C* C*
P1631 Theft Deterrent Password Incorrect C* C* C*
P1641 Malfunction Indicator Lamp (MIL) Control Circuit C* C* C*
P1643 Wait To Start Lamp Control Circuit B B B
Exhaust Gas Recirculation (EGR) Vent Solenoid
P1653 B — —
Control Circuit
P1654 Service Throttle Soon Lamp Control Circuit C* C* C*
Exhaust Gas Recirculation (EGR) Solenoid Control
P1655 B — —
Circuit
P1656 Wastegate Solenoid Control Circuit B B B
6-2290 Engine Controls - 6.5L
Fuel System Specifications
Some states and provinces have restrictions on the
purchase of diesel fuel for light duty vehicles and
require you to buy permits or pay special taxes.
Some of these restrictions apply to residents, and
others apply to both residents and visitors. These
restrictions can change. To learn the current
restrictions in any state or province, contact your
auto club, the police or other officials.
What Fuel to Use in the United States
In the United States, for best results use Number
2-D diesel fuel year-round (above and below
freezing conditions) as oil companies blend Number
2-D fuel to address climate differences. Number 1-D
diesel fuel may be used in very cold temperatures
(when it stays below O'F or —18*C); however, the
fuel will produce a power and fuel economy loss.
The use of Number 1-D diesel fuel in warm or hot
climates may result in stalling, poor starting when the
engine is hot and may damage the fuel injection
system.
Diesel fuel may foam when filling the tank. This can
cause the automatic pump nozzle to shut off, even
though the tank isn’t full. If this happens, just wait for
the foaming to stop and then continue to fill the tank.
What Fuel to Use in Canada
Canadian fuels are blended for seasonal changes.
Diesel Type ’A’ fuel is blended for better cold
weather starting (when it stays below O’ F or - 1 8 ’ C);
however, the fuel will produce a power and fuel
economy loss. The use of Type ’A’ diesel fuel in
warmer climates may result in stalling, poor starting.
Diesel Type ’B’ fuel is blended for temperatures
above O’ F (-1 8 ’ C). The emission control system
requires the use of diesel fuel with low-sulfur (0.05%
by weight) content. Both low- and higher-sulfur fuels
GM SPO Group Numbers
Parts Name
Engine Control Modlue
Engine Coolant Temperature Sensor
C/Case Depression Regulator Valve
C/Case Depression Regulator Valve Hose
EGR Valve
EGR Solenoid Valve
EGR Vent Solenoid Valve
Glow Plug
Glow Plug Relay
Air Cleaner Assemblyl
Air Cleaner Filter
Fuel Filter
Fuel Tank
Engine
will be available in Canada. Only low-sulfur diesel
fuels are available in the United States. It is
important that diesel-powered trucks are refueled
only with low-sulfur fuel. Use of fuels with
higher-sulfur content will affect the function of the
emission components and may caused reduced
performance, excessive smoke and unpleasant odor.
Very Cold Weather Operation
If the vehicle is driven in very cold temperatures and
can’t get a ’winterized’ Number 2-D that has been
adapted to cold weather or a Number 1-D, use one
gallon of kerosine for every two gallons of diesel
fuel. Once you add kerosine, run the engine for
several minutes to mix the fuels. Only add kerosine
when the temperature falls below O’ F (-1 8 ’ C),
because the fuel economy and lubricating qualities of
kerosine isn’t as good as that of diesel fuel.
In cold w eather, the fuel filter may become clogged
(waxed). To unclog the filter, move the vehicle to a
warm garage area and warm the filter to a
temperature between 32*-50*F (0*-10’ C). Replacing
the filter is not necessary.
Water in Fuel
Sometimes, water can be pumped into the fuel tank
along with diesel fuel. This can happen if the service
station doesn’t regularly inspect and clean their fuel
tanks, or the fuel gets contaminated for the service
stations suppliers.
If water is pumped into the fuel tank, a Water In
Fuel light will illuminate. If the Water In Fuel light
illuminates, the excess water must be drained from
the fuel system on the vehicle.
The Water In Fuel light also should illuminate briefly
when the engine is started as a check. If the light
doesn’t illuminate, the problem should be fixed to
identify a Water In Fuel condition correctly.
Group
3.670
3.682
1.745
1.762
3.670
3.670
3.670
2.270
2.510
3.402
3.410
3.890
3.001
Engine________________________________________________ Engine Controls - 6.5L 6-2291

Schematic and Routing Diagrams

Emission Hose Routing Diagram

47227

Legend
(1) EGR Control Pressure/BARO Sensor
(2) EGR Vent Solenoid
(3) EGR Solenoid
(4) Wastegate Solenoid
(5) Vacuum Pump
(6) Turbo Charger Wastegate
(7) EGR Valve
6-2292 Engine Controls ■ 6.5L Engine
Engine Controls Schematic References
Service Category Type Number
Reference on Schematic - Service Category
Antilock Brakes - Cell 44 8A-44
Automatic Transmission Controls - Cell 39 7 - Automatic Transmission
Four Wheel Drive - Cell 38 7 - Automatic Transmission
Cruise Control - Cell 34 8A-34
Data Link Connector (DLC) - Cell 50 8A-50
Fuse Block Details - Cell 11 8A-11
Power Distribution - Cell 10 8A-10
Ground Distribution - Cell 14 8A-14
Sensors - Cell 21 6 - Engine Controls
Instrument Panel - Cell 81 8A-81

Engine Controls Schematic Icons

Icon Icon Definition
Refer to Electrostatic Discharge (ESD) Sensitive Devices in Section 8A-3 Symbols.

19384
Refer to On-Board Diagnostics II (OBD II) Circuits in Section 8A-5 Repair Procedures.

A
iO B D I lk
19385
 Engine________________________________________________ Engine Controls - 6.5L
Engine Controls Schematics (PWR, GND, and DLC)
(Hot In RunAndStart| j HotInRunAndStart! |HotAtAll Timesj
Power Power ” ” ■*Underhood Power Power ------ --------1,p
* Distribu
Cell 10
Distribution
Cell 10
ton H71 ^12°^1Fuse-Relay
J8 t Fuse 1Center
20A I
_ _ J
Cel10 I
Distribution H8 GAUGES
Fuse4
J7 10A
Distribution B6 aux pwr 1Fuse
Cell 10
C5 Fuse7
25A *Block
I
1 ORN 440 y m 0.8 PNK 39
Fuse&ock
S10I FuseBlock
S2131 Details
Cell 11
S166 (►- Details 0.35 PNK 39
CeilH
22.
■*Instrument
(Instrument ◄—♦---------- Malfunction
• Cluster
duster A Service Indicator ! Cluster
Cell 81 ( T ) Throttle 0 Lamp(MIL)
0.8 PNK 439 Soon y (ServiceEngine
Lamp I Soon) \ A PCM
j
21 23
C1= BRN
C2* BRN
0.8 ORN 440 0.8 PNK 439 0.35 WHT/BLK 176 0.5 BRN/WHT 1 ORN 840 C3- BLU
SP101 E*C200 V i C200 FuseBlock S272
Details
0.8 ORN 440 0.8 PNK 439 0.35 WHT/BLK 176 0.5 BRN/WHT 419 Cell11
C13 D13 C12 C11 D ll C14 . C3
Battery Battery Ignition Ignition ServiceThrottle MIL ^ Powertrain
Feed Feed Feed Feed SoonIndicator Control 1Control
Control Module (PCM)
PCM PCM Serial Data
Ground Ground (ClassII)
l A
D7 D6 C3 (Wind C8 ' C3
Distribution 0.5 PPL 1807
0.8 BLK/WHT 451 Cell 14
P101 P101
S150<
0.8 TAN/WHT 551 P101 l 0.5 PPL 1807
C200 1 BLK/WHT 0.5 PPL 1807
S103 1 BLK/WHT G Cl 1 ORN 840
—« — S215
I 451 K 451 B7; ,C100
I 0.5 PPL 1807 i serial Datai Electronic
0.5
I Mciassi«)_j Brake
BLK/WHT 451 £280
l Control A
0.35 Module
1
Ground
(Wind S204 PPL 1807 0.5 PPL 1807 (EBCM)
Distribution - *—
Distribution
Cell 14
Cel 14 B4 0.5 PPL 1807 E9
r“ 'EVO f " ” 1 Active Transfer
I |Passlock i __ J Case Control
1 BLK/WHT 451 1 BLK 150 3 BLK 150 0.5 BLK 150
Module Module
4. 16 Data Link

6-2293
IG 104 * G200 Connector (DLC)
185277
6-2294 Engine Controls - 6.5L ________________________________________________ Engine
185292
Engine Controls Schematics (Glow Plug Controls)
Engine________________________________________________ Engine Controls - 6.5L 6-2295
185296
Engine Controls Schematics (Fuel Controls)
 6-2296
Engine Controls Schematics (Fuel Controls)
|Hot in RunAndStart! |Hot InRunAndStart! | HotInRunAndStart (
Power ^ IP T Power -d--------T ■*Underhood
' Distribution
tlon H8 K GAUGES * Fuse ' Distribution * 7 1 ENG1
I Ce«10 lv ECM-1 1Fuse-Relay

Engine Controls - 6.5L ________________________________________________ Engine

| Cell 10 Fuse4 'Block J FU8S15
J 7 1 10A Q 2°A | Center
I I I L8> 20A

0.8 PNK 39
S213<
FuseBlock
Details
Cell 11
0.8 PNK 539 ^1186block
Details
Cell 11
0.8 PNK 439
- i >S166
F &C113
s
0.35 PNK 39 439 Fuel 0
____________ 22 , S190 Solenoid
Instrument 11nstrument
Cluster PNK 439
duster Water
Cell 81 Q ) in Fuel C k C117 B' PCM
inaicaior ■ , AA
Y Indicator PNK 439 RED BLK Cl - BRN
I J I C2= BRN
D. B .> C3= BLU
i i S108 F,
Ignition Fuel Fuel Fuel
Positive Solenoid Solenoid Solenoid
Voltage High Low
B 4, Fuel Driver
Injection Closure Closure
Control Signal Ground
0.8 PNK 439 A E'
539
0.8 RED 313
0.8 LT GRN 260 0.8 BLK 491
Fuel Engine
Heater ShutOff A i ............. D | _______ B | C117
Solenoid
0.8 LT GRN 260 0.8 BLK 491
►S191
0.8 LT GRN 260 0.8 RED 313
0.8 BLK 259 0.8 LT GRN 260
A i --------- M i L i ---------- P i C113 F$C112
0.8 DK P101
BLU/WHT 259
4 S269 0.8 LT GRN 260 0.8 BLK 491
0.8 DK 0.8 DK 0.8 LT GRN 260 0.8 RED 313
BLU/WHT 259 BLU/WHT 259
D15. C15 D3 C3 C3 C13 JLCl A1 C2
Powertrain f S ^ mm Engine Fuel Fuel Closure Closure
Control! shutoff ShutOff Injection Injection Signal Ground
Control Control Control
A Module 0aiiM
(PCM)!.____
# G105
185298
 En9»ne
Engine Controls Schematics (Ignition System)

__________________________ Engine Controls - 6.5L

I Signal Signal Signal rtgh Low Low High I Module A
[ ____________________________________________________________________________________________________________^ ( P C M ) ! ^

6-2297
185301
6-2298 Engine Controls - 6.5L __________________ ______________________________Engine
185303
Engine Controls Schematics (Engine Sensors)
Engine________________________________________________ Engine Controls - 6.5L 6-2299
Engine Controls Schematics (EGR, MAF and Accelerator Pedal Controls)
 6-2300
Engine Controls Schematics (4WD and Cruise Controls)

|Hot In RunAndStartj I” 5 * !
r r — r ~ "'Transfer r ~ Front r
“* Front ■*Transfer
I 1 IP 1 I

Engine Controls - 6.5L________________________________________________ Engine

Distribution M8 K CRUISE 1Axle 1 (Case • ( Axle 'Case
1 Cell 10 FuseS I Fuse 1 (Actuator * *Relay 1 1 Actuator I
I N7 10 A I Block ' Switch
L. __ J L _ J
I I AY 87 Y A B
j

0.35 BRN 41
0.8 BLK/WHT s
0.8 BLK/WHT 1695

A13: ; C266 »S314 0

0.35 BRN 41 0.8
GRY/BLK 1694
A
Cruise PCM
BRN
Control
/ On/Off / Set/Coast 7 Resume/
Accelerate
Switch
W/NP1 W /ONPI
BRN
BLU

0.8 GRY 397 0.35 GRY/BLK 87

0.35 DK BLU 84 0.8 BLK/WHT 1695

A12: ............. A14' A i5 fC 2 6 6 B & ____________________M c i2 0

0.8 GRY 397 0.35 GRY/BLK 87
0.35 DK BLU 84
f^our Wheel”
1 BLK/WHT 1695 Drive
P101 C el 38

S111< _________i
K?C204 C200
0.8 BLK/WHT 1695 0.5 GRY/BLK 1694
0.5 GRY 397 0.5 GRY/BLK 87
0.5 DK BLU 84 P101

O
O
CM

T*
A 1 1 ......... D101 Cl B31.C2
Cruise Set/Coast Resume/ 4WDLow 4WDFront Powertrain
On/Off Request Accelerate Indicator Wheel Lock Control
Request Signal Request Signal Feed Module
Signal Signal
(PCM)

L _______________________ ________________________________________________________________________ jA

185305
 Engine
Engine Controls Scnematics (VSS Controls)
|Hot in RunAnd Start!
PCM ■•IP J" "j Transfer [■ 1 Radio \ — -JEVO/
Cl= BRN Power ◄—
C2= BRN Distribution GAUGES * Fuse i vss * Case i vss i A i ^ |Passlock
C3- BLU Cel10 ! Fuse4 • Block
10A I
i input i Control A
J Module ild S
i input i Control
apV ” j M°du,e
—j D8 16 C2 A8Y A

__________________________________________ Engine Controls - 6.5L

Vehicle Speed
0.5 DK Sensor (VSS)
0.5
0.8 PNK 39 GRN/WHT 817 0.5 DK GRN/WHT 817
DK GRN/ 817
S221 WHT A"
S213 0.5
PPL/WHT 821
0.5 LT GRN/BLK 822
A/Tw/4WD |m/TW/4Wd| | 2WD |

<v n " T"

0.5 LT GRN/BLKJ822 PPU/WHt J821 0.5
AS215 0.5 0.5
, PPL/WHT 821
LTGI / 822 PPL/WHT 821
Vehicle Speed BLK
vss vss
Sensor (VSS) Low High
Adapter 0.5 LT GRN/BLK 822
1 BLK/WHT 451 B 0.5 Bi 0.5 A 5;
0.5 AY LT G / 822 PPL/WHT 821
0.5 LT GRN/BLK 822 PPL/WHT 821 BLK
0.5 DK
K ’ C200 GRN/WHT 817
0.5
Powertrain Control A Instrument A 0.5 LT PPL/WHT 821
1 BLK/WHT 451 0.35 PNK 39 Module (PCM) Cluster GRN/BLK 822
r ------ — — -------------------- 1 r — ----------- — i 1 Electronic
I A/TISS Vehicle I I Vehicle 1 r " ’ Over C5> 04^ ' C1001 1Brake
SP101 • Sensor Speed I I vss
Output Input 1 u - J Speed ' Input I Control
L _ _Input
——_ •* B Alarm «• - — J Module
A3 A6 C2 14 (EBCM)
r ------+ S103 0.5 (Export)
0.5
I 0.5 BRN 437 DK GRN 389 0.5 DK GRN 389
1827
1 DK GRN 389
diround
Distribution 0.5 G y C200 C9 C223
D2 $ C100
Cell 14 BLK/ 0.5 BRN 437 0.5 LT
0.5 DK GRN 389
WHT 451 GRN/BLK
1 S211 1827
BLK/ 451 0.5
DK GRN 389
WHT
0.8 9A 14 A 13 A 15
TAN/ 551 Ground Ignition Vehicle A/TISS Vehicle VSS VSS Vehicle Vehicle Speed
WHT Power Speed Sensor Speed Low High Speed Sensor (VSS)
Output Input Output Output Buffer A
#G104 4 A

6-2301
185306
6-2302 Engine Controls - 6.5L________________________________________________ Engine
185308
Engine Controls Schematics (Transmission and TCC Controls)
Engine________________________________________________ Engine Controls - 6.5L 6-2303
185309
Engine Controls Schematics (Transmission Controls)
6-2304 Engine Controls - 6.5L ________________________________________________ Engine
185307
Engine Controls Schematics (A/C Controls)
Engine______________ Engine Controls - 6.5L 6-2305

Component Locator

Engine Controls Components

Name Location Locator View Connector End View
At the front of the A/C compressor, at the
A/C Compressor Clutch 201-14 —
LF of the engine
In the underhood fuse-relay center, at the
A/C Compressor
LR of the engine compartment, on the 201-6 —
Clutch Relay
fender
On the top RH of the A/C accumulator, at
A/C Compressor Cycling
the RH of the engine compartment, on the 201-17 —
Switch
bulkhead
A/C Compressor High On the rear of the A/C compressor, at the
201-10 —
Pressure Cutout Switch LF of engine
A/C Compressor Low At the top of the A/C compressor, in the
201-10 —
Pressure Cutout Switch high pressure refrigerant line
Automatic Transfer Case
Under the LH of the IP, near the
Control Module, 201-34 202-23
convenience center
Connector C1
Camshaft (CMP) Position
In the distributor 201-12 —
Sensor
Clutch Pedal Position
At the top of the clutch pedal 201-41 202-61
(CPP) Switch
Crankshaft Position At the lower RF of the engine block, near
201-11 —
(CKP) Sensor the crankshaft
Cruise Control At the LR of the engine compartment, on
201-31 202-29
Module (CCM) the bulkhead
Under the LH of the IP, at the LH of the
Data Link
steering column, mounted at the bottom of 201-43 202-30
Connector (DLC)
the knee bolster
Electronic Brake Control Near the brake master cylinder, at the LF
201-6 —
Module (EBCM) wheelhousing
Electronic Variable
Orifice (EVO)/Passlock Under the center of the IP 201-40 202-31
Control Module
Engine Coolant
At the top RH of the engine, near the
Temperature (ECT) 201-10 —
thermostat housing
Sensor
Exhaust Gas
At the top LH of the engine, above the
Recirculation (EGR) 201-20 202-62
valve cover
Solenoid
Exhaust Gas
On top of the intake plenum 201-20 —
Recirculation (EGR) Vent
Front Axle Actuator At the RF of the front drive axle 201-19 202-62
Fuel Heater At the top rear of the engine 201-69 —
Fuel Pump Inside the LH frame rail, below the LF door 201-21 —
Fuel Pump, Secondary In the auxiliary fuel tank 201-21 —
Fuel Pump and Sender In the fuel tank 201-73 —
Fuel Pump Oil Pressure At the rear and top center of the engine,
201-12 202-63
Switch and Sender behind the distributor
Fuel Pump Prime In the IP harness, approximately 20 cm into
— —
Connector the underhood fuse- relay center breakout
At the top LR of the engine, near the
Glow Plug Relay 201-22 —
bulkhead
6-2306 Engine Controls - 6.5L________________________________________________ Engine
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
On the side of the engine, near the
Glow Plugs 201-19 —
exhaust manifold
Part of heater controls, in the center of the
HVAC Control Module 201-53 202-35
IP, under the radio
Under the LH end of the IP, above the
Instrument Cluster 201-32 202-38
steering column
Intake Air Temperature
In the air intake duct 201-21 —
(IAT) Sensor
At the LH of the IP, near the LF door
IP Fuse Block 201-32 —
jamb switch
Mass Air Flow (MAF) At the air intake duct, near the air filter, at
201-13 —
Sensor the RH of the engine
Under the RH end of the IP, above
Powertrain Control
the blower motor, behind the 201-37 —
Module (PCM)
IP compartment box
Radio In the center of the IP 201-35 202-43, 44
Part of the underhood fuse-relay center, at
Remote Battery Stud the LR of the engine compartment, on the 201-5 —
fender
Stoplamp Switch At the top of the brake pedal 201-44 202-70
Transfer Case Control Under the IP, on the steering column
201-38 202-46
Module (TCCM) support bracket
At the RR of the engine compartment, near
Transfer Case Relay 201-23 202-70
the center of the bulkhead
Transfer Case Switch At the top LH of the transfer case 201-24, 25, 27, 28 —
Underhood Fuse- At the LR of the engine compartment, on
201-5 —
Relay Center the fender
Vehicle Speed
At the LR of the transfer case 201-37 202-70
Sensor (VSS)
At the top LR of the engine, above the
Wastegate Solenoid 201-20 —
valve cover
Water-in-Fuel Sensor At the top rear of the engine 201-19 —
The engine harness to the IP harness, at
C100 the LR of the engine compartment, at the 201-4 202-0
bulkhead
The engine harness to the fuel pump
motor, at the LR of the engine
C103 201-14 202-49
comaprtment, near the underhood
fuse-relay center
C112 The engine harness to the engine sensors 201-20 202-4
C113 The engine harness to the engine sensors 201-20 202-5
C122 On the LH of the transmission 201-23 202-6, 7
Behind the RH of the IP, near the blower
C200 201-37 202-10
motor, in the foam wrap
C204 Behind the RH of the IP 201-37 202-12
C223 At the convenience center 201-36 202-53
C227 At the convenience center 201-44 202-70
The IP harness to the steering column
C266 harness, at the LH of the steering column, 201-32 202-14
near the bulkhead
Engine________________________________________________ Engine Controls - 6.5L 6-2307
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
The engine harness, approximately 16 cm
D104 201-10 —
from the A/C compressor clutch connector
G104 At the RH top center of the cylinder head 201-16 —
G105 At the RF of the engine block 201-13 —
Behind the LH of the IP, below the IP fuse
G200 201-32 —
block, on the tie bar
Inside the LH frame rail,near the rear
G404 201-73 —
crossmember
At the RR of the engine compartment, at
P101 201-7 —
the bulkhead
S100 The engine harness, approximately 31 cm
— —
(A/T) from the taillamp harness breakout

S100 The engine harness, approximately 37 cm

from the EBCM breakout, toward the — —
(M/T) taillamp harness
The engine harness, approximately 5 cm
S101 — —
from the starter solenoid breakout
The engine harness, approximately 12 cm
S103 — —
from the starter solenoid breakout
The engine harness, approximately 30 cm
S107 (HD) from the EBCM breakout, toward the EGR — —
valve breakout
The engine harness, approximately 24 cm
S107 (LD) from the EBCM breakout, toward the EGR — —
valve breakout
The engine harness, approximately 12 cm
S108 (A/T) — —
from the glow plugs breakout
The engine harness, approximately 5 cm
S108 (M/T) from the backup lamp switch harness — —
breakout
The engine harness, approximately 11 cm
S111 from the EBCM breakout, toward the — —
glow plugs
The engine harness, approximately 4 cm
S147 — —
from the starter solenoid breakout
The engine harness, approximately 13 cm
S150 — —
from the EBCM breakout
The engine harness, approximately 4 cm
S152 — —
from the IP harness breakout, toward P101
The engine harness, approximately 7 cm
S159 (A/T) — —
from the EGR valve breakout
The engine harness, approximately 31 cm
S159 (M/T-HD) — —
from the glow plugs breakout
The engine harness, approximately 6 cm
S159 (M/T-LD) — —
from the VSS breakout
The engine harness, approximately 8 cm
S166 (A/T) — —
from the fuel heater breakout
The engine harness, approximately 5 cm
S166 (M/T-HD) — —
from the glow plugs breakout
The engine harness, approximately 1 cm
S166 (M/T-LD) — —
from the fuel heater breakout
6-2308 Engine Controls - 6.5L________________________________________________ Engine
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
The engine harness, approximately 31 cm
S199 — —
from the taillamp harness breakout
The IP harness, approximately 10 cm from
S204 — —
the steering column harness breakout
The IP harness, approximately 16 cm into
S211 — —
the instrument cluster breakout
The IP harness, approximately 4 cm from
S213 — —
the steering column harness breakout
The IP harness, approximately 8 cm from
S215 the instrument cluster breakout, toward the — —
radio connectors breakout
The IP harness, approximately 6 cm from
S220 the steering column harness breakout, — —
toward C100
The IP harness, approximately 40 cm from
S221 — —
the instrument cluster breakout
The IP harness, approximately 20 cm from
S222 the inflatable restraint IP module switch — —
breakout
The IP harness, approximately 7 cm from
S268 the inflatable restraint IP module switch — —
breakout
The engine harness, approximately 29 cm
S269 (HD) — —
from the IP harness breakout
The engine harness, approximately 11 cm
S269 (LD) — —
from the IP harness breakout
The IP harness, approximately 5 cm from
S280 — —
the DLC breakout
The IP harness, approximately 24 cm from
S298 the instrument cluster breakout, toward the — —
radio breakout
The IP harness, approximately 4 cm from
S299 the steering column harness breakout, — —
toward P100
The selectable 4WD harness,
approximately 5 cm from the transfer
S314 — —
case relay breakout, toward the front
axle actuator
The taillamp extension harness,
approximately 10 cm from the fuel pump
S318 — —
balance module breakout, toward the
engine harness
The taillamp extension harness,
approximately 7 cm from the fuel pump
S319 — —
and sender breakout, toward the fuel
pump balance module breakout
Engine__________________________ Engine Controls - 6.5L 6-2309

Engine Controls Component Views

O verhead Engine View

192963

Legend
(1) EGR Valve (6) Glow Plug Relay
(2) Boost Pressure Sensor (7) EGR Vent Solenoid
(3) Turbocharger (8) EGR Solenoid
(4) CDR Valve (9) Wastegate Solenoid
(5) Fuel Manager/Filter
6-2310 Engine Controls - 6.5L Engine
Underhood Fuse Relay Center

192972

Legend
(1) Underhood Fuse Relay Center (5) Battery Cable
(2) Stop Lamp Relay (6) A/C Relay
(3) Electronic Brake Control Module (EBCM) (7) Fuel Pump Relay
(4) Glow Plug Relay Battery Feed
Engine Engine Controls - 6.5L 6-2311
Glow Plugs

192951

Legend
(1) Glow Plugs
(2) Cylinder Head
6-2312 Engine Controls - 6.5L Engine
Injection Nozzles

Legend
(1) Cylinder Head
(2) Injection Nozzles
(3) Seal
Engine Engine Controls - 6.5L 6-2313
Oil Pressure Switch (OPS)

(1) Oil Pressure Switch (OPS)

(2) Engine Block
6-2314 Engine Controls ■ 6.5L Engine
Air Cleaner and MAF Sensor

Legend
(1) Passenger Side Fender
(2) Air Cleaner (Element Inside)
(3) Turbocharger
(4) MAF Sensor
Engine Engine Controls - 6.5L 6-2315
Fuel Injection Pump and Lines

192955

Legend
(1) Optical/Fuel Temperature Sensor (4) Injection Lines
(2) Fuel Injection Pump (5) Fuel Solenoid Driver
(3) Fuel Solenoid (6) Engine Shut Off (ESO) Solenoid
6-2316 Engine Controls - 6.5L_______________________________________ Engine
ECT Sensor, ITS Motor, and Optical/Fuel Temperature Sensor

192956

Legend
(1) ECT Sensor
(2) Fuel Injection Pump
(3) Ignition Timing Stepper (ITS) Motor
(4) Fuel Solenoid
(5) Optical/Fuel Temperature Sensor
Engine __________ _________________ Engine Controls ■ 6.5L 6-2317
Crankshaft Position (CKP) Sensor

192948

Legend
(1) Front Engine Cover
(2) Crankshaft Position (CKP) Sensor
(3) Mounting Bolt
6-2318 Engine Controls - 6.5L Engine
IAT Sensor

Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Intake Manifold
Engine Engine Controls - 6.5L 6-2319
EGR Control Pressure/BARO Sensor

Legend
(1) EGR Control Pressure/BARO Sensor
(2) Engine/Passenger Compartment Divider
(Engine Cowl)
6-2320 Engine Controls - 6.5L Engine
Fuel Manager/Filter and Fuel Injection Pump

192944

Legend
(1) Fuel Injection Pump
(2) Intake Manifold
(3) Water in Fuel Sensor
(4) Fuel Heater
(5) Fuel Manager/Filter (Filter Inside)
Engine________________________________________________ Engine Controls - 6.5L 6-2321

192969

Legend
(1) Plenum Tray
(2) Instrument Panel Harness
(3) Instrument Panel
(4) Powertrain Control Module (PCM)
(5) Instrument Panel Lower Reinforcement Bar
(6) HVAC Module
6-2322 Engine Controls - 6.5L Engine
APP Module

Legend
(1) APP Module
(2) Accelerator Pedal
(3) Brake Pedal

VSS Buffer Module

Legend
(1) VSS Buffer Module
(2) Harness Connector
(3) Fastener
(4) Instrument Panel near Glove Box
Engine Engine Controls - 6.5L 6-2323
EVO Module

Legend
(1) Instrument Panel Conduit
(2) Instrument Panel Lower Reinforcement Bar
(3) EVO Module
(4) Radio Carrier (Instrument Panel)
6-2324 Engine Controls - 6.5L Engine
Fuel Lift Pump
1

193110

Legend
(1) Fuel Lift Pump (2) Frame Rail

Fuel Tank and Sender

Legend
(1) Frame Rail (4) Fuel Tank (Typical)
(2) Fuel Lines (5) Fuel Sender
(3) Ground
Engine__________________ Engine Controls - 6.5L 6-2325
PCM Connector End Views
PCM 32 Way Brown (C1) Connector

C16 11 m il Mi— I'Tnrn Cl

16 15 14 13 12 11 igSHHUIlllT a [i] tanii

D16 D1

31454

• 12110245
Connector Part Information
• PCM 32 Way Brown (C1) Connector
Pin Wire Color Circuit No. Function
C1 — — Not Used
C2 DK GRN/WHT 762 A/C Request
C3 YEL 492 Mass Air Flow Signal
C4 TAN 472 IAT Signal
C5 LT BLU 1162 APP (2) Signal
C6 YEL 505 Glow Plug Relay Control
C7 RED/BLK 1228 Pressure Control Solenoid Valve (Hi)
C8 YEL 1578 Fuel Temperature
C9 YEL/BLK 1227 TFT Sensor
C10 — — Not Used
C11 YEL 410 ECT Signal
C12 GRY/BLK 433 EGR Control Pressure/BARO Signal
C13 RED 313 Closure Signal
C14 LT GRN 432 Boost Sensor Signal
C15 LT BLU/WHT 1229 Pressure Control Solenoid Valve (Lo)
C16 — — Not Used
6-2326 Engine Controls - 6.5L Engine
PCM 32 Way Brown (C1) Connector

cie TT1r m ' □ t r U T 1 1 Cl

T 11 111 1 1I T
16 15 14 |13 R 2 i n r i i o i f 9 i [ 8 i f 7 i [ 6 i r 5 i f ? r 3 2 ft

16| 15| 14 |13 i0 |f9 ll8 lf7 ll6 ir 5 l 4 lf 3 l 2 H T

f i 111 Tn
D ie JJ_[
_LLL 11
31454

• 12110245
Connector Part Information
• PCM 32 Way Brown (C1) Connector
Pin Wire Color Circuit No. Function
D1 BLU/WHT 1231 Transmission Input Speed Signal
D2 GRY/BLK 1694 4WD Low Indicator Signal
D3 YEL/BLK 1275 APP (3) 5 Volt Ref.
D4 DK GRN 1163 APP (3) Signal
D5 GRY 120 Fuel Lift Pump Signal
D6 GRY 1273 APP (3) Ground
D7 BRN 507 Glow Plug Signal
D8 DK GRN/WHT 465 Fuel Lift Pump Control
D9 PNK/BLK 632 Pump CAM, High Res. and Fuel Temperature Ground
D10 GRY/BLK 87 Cruise Resume/Accel Request
D11 RED/BLK 1230 Transmission Input Speed Signal (Lo)
D12 WHT/BLK 1164 APP (1) 5 Volt Ref.
D13 GRY 416 Boost, CKP and EGR Cont/BARO 5 Volt Ref.
D14 GRY 474 Pump CAM and High Res. 5 Volt Ref.
D15 — — Not Used
D16 — — Not Used
Engine________________________ Engine Controls - 6.5L 6-2327
PCM 24 Way Brown (C2) Connector

I11I
r "
0

o>
00
o
12 7 ||e U L 4 L ? .I2J . 1 1

12 11 101| 9 8 7 6 S ||4|3|2|1

B
0
31460

• 12110244
Connector Part Information
• PCM 24 Way Brown (C2) Connector
Pin Wire Color Circuit No. Function
A1 BLK 491 Closure Ground
A2 ORN 1799 High Res. Signal
A3 BRN 437 Transmission Input Speed Signal
A4 BRN/WHT 633 Pump CAM Sensor Signal
A5 YEL 573 CKP Sensor Signal
A6 DK GRN 389 VSS Signal
A7 RED/BLK 1031 Injection Timing Stepper Motor (HI)
A8 TAN/BLK 1030 Injection Timing Stepper Motor (LO)
A9 ORN/BLK 1032 Injection Timing Stepper Motor (LO)
A10 YEL/BLK 1033 Injection Timing Stepper Motor (Hi)
A11 GRY 397 Cruise ON/OFF Signal
A12 PPL 1272 APP (2) Ground
6-2328 Engine Controls - 6.5L Engine

PCM 24 Way Brown (C2) Connector

A r ............
a
12 Ml
_ 0 |9

12 11 10 9
8

8
7 6

7 6
5 1| 4 | 3 H2 U 1 |

5 T |[3 i l l

111 B

31460

• 12110244
Connector Part Information
• PCM 24 Way Brown (C2) Connector
Pin Wire Color Circuit No. Function
B1 BRN 1271 APP (1) Ground
B2 DK BLU 1161 APP (1) Signal
B3 BLK/WHT 1695 Front Axle Switch Signal
B4 RED 1226 TR Switch C
B5 DK BLU 1225 TR Switch B
B6 PNK 1224 TR Switch A
B7 — — PTO (1360 RPM)
B8 — PTO (1070 RPM)
PPL (A/T) 420 (A/T) Cruise Control Brake Switch (A/T)
B9
BRN/WHT (M/T) 379 (M/T) Brake/CPP Switch (M/T)
B10 WHT 17 Brake Switch
B11 DK BLU 84 Cruise Set/Coast Signal
B12 BLK 452 Sensor Ground (Boost, EGR, ECT, IAT, Fuel Temp., TFT and CKP Sensor)
Engine______________________ Engine Controls - 6.5L 6-2329
PCM 32 Way Blue (C3) Connector

__________
Cl6
L, I
_ ______
II II II U r-3 U ITT - •,
Cl

BkU
0>|—
oi
14 |13 s n i m u l t i ] \h H \\k 1

TrrnT m
16 15 14 |13 12| 11 i 0 | | 9 l | 8 l f 7 l f 6 l [ 5 l 4 13 2 1

D1611111 l 11 l “
31454

• 12110207
Connector Part Information
• PCM 32 Way Blue (C3) Connector
Pin Wire Color Circuit No. Function
C1 — — Not Used
C2 TAN 1274 APP (2) 5 Volt Ref.
C3 LT GRN 260 Fuel Inject Control
C4 LT GRN 1222 Shift Solenoid (1-2)
C5 BRN 418 TCC PWM
C6 YEL7BLK 1223 Shift Solenoid (2-3)
07 DK BLU 507 Wait To Start Lamp Control
C8 PPL 1807 Class 2 Communication
C9 — — Not Used
C10 — — Not Used
C11 PNK 439 Ignition
C12 PNK 439 Ignition
C13 ORN 440 Battery
C14 BRN/WHT 419 MIL Control Control
C15 DK BLU/WHT 259 ESO Control
C16 GRY 435 EGR Solenoid Control
6-2330 Engine Controls - 6.5L Engine
PCM 32 Way Blue (C3) Connector

'TT1r m Q S T T ttt C l
C16
T 11 B12 1[ ll]1 l1 0 ll9 J L 8 J i7 jl6 j|5 J l4 [3J 2 1 ,
16 ie 14 [13
16|15 14||13 12| 11 10I19J18J17J16JL5J 4JL3 2J1
II II I I Tn f
D16 1 1111 1 11 l l D1

31454

• 12110207
Connector Part Information
• PCM 32 Way Blue (C3) Connector
Pin Wire Color Circuit No. Function
D1 — — Not Used
D2 — — Not Used
D3 LT GRN 260 Fuel Inject Control
D4 — — Not Used
D5 DK GRN/WHT 459 A/C Enable
D6 BLK/WHT 451 Ground
D7 TAN/WHT 551 Ground
D8 — — Not Used
D9 — — Not Used
D10 — — Not Used
D11 WHT/BLK 176 Service Throttle Soon Lamp Control
D12 WHT 257 EGR Vent Control
D13 ORN 440 Battery
D14 YEL 258 Wastegate Solenoid Control
D15 DK BLU/WHT 259 ESO Solenoid Control
D16 — — Not Used
Engine________________________________________________ Engine Controls - 6.5L 6-2331
Engine Controls Connector End Views EGR Pressure Sensor (Diesel)
Accelerator Pedal Position Module
Connector (Diesel)

95766

Connector Part • 12020403

Information • ASM 3M M/P 100 (GRN)
62472
Circuit
• 12065425 Pin Wire Color No. Function
Connector Part
Information • ASM 10F M/P 150 (BLACK) A BLK 452 Sensor Return
Circuit Barometric Pressure
B GRY/BLK 433
Pin Wire Color No. Function Sensor
A BRN 718 Sensor Return C GRY 416 Reference Voltage Feed
B PPL 719 Sensor Return
EGR Valve Solenoid (Diesel)
C LT BLU 486 TP Sensor Signal #2
D GRY 597 5 Volt Reference
E GRY 596 5 Volt Reference
F DK BLU 485 TP Sensor Signal #1
G GRY 598 5 Volt Reference
H — — Not Used
J GRY 720 Sensor Return
K DK GRN 487 TP Sensor Signal #3

38245

• 12052641
Connector Part
Information • ASM CONN 2F M/P 100
(BLACK)
Circuit
Pin Wire Color No. Function
A PNK 539 Ignition Fused Feed
B WHT 257 EGR Vent Solenoid Output
B ??? 435 EGR Vent Solenoid Output
6-2332 Engine Controls - 6.5L Engine

VSS Buffer Connector (Diesel) Glow Plug Relay Connector (Diesel)

n_q D _n
EDED ED EDEDHEOHCDCD
TZT TZT

• 12045636
• 12066130 Connector Part
Connector Part Information • CONN 4F M/P 280
Information • CONN 9F M/P 100 (MEDIUM GRAY)
(NATURAL)
Circuit
Circuit Pin Wire Color No. Function
Pin Wire Color No. Function
Fuse Output - Ignition 1 -
7 LT GRN/BLK 822 VSS Return A PNK 539
Type III Fuse
8 BLK/WHT 451 ECM Ground B YEL 505 Glow Plug Relay Feed
Fuse Output - Ignition 1 - C BLK 150 Ground
9 PNK 39
Type III Fuse
D — — Not Used
VSS Signal - 12800
10 YEL/BLK 1827
Pulses Per Mile
11 — — Not Used
12 PPL/WHT 821 VSS Signal
13 BRN 437 VSS Signal
DK VSS Signal - 4000 Pulses
14 817
GRN/WHT Per Mile
VSS Signal - 4000 Pulses
15 DK GRN 389
Per Mile
Engine
Diagnostic Information and
Procedures
Powertrain OBD System Check
Refer to Power, Ground, MIL and DLC.
Circuit Description
The On Board Diagnostic (OBD) System Check is
an organized approach in identifying a problem
created by an electronic engine system fault. The
OBD system check is the starting point for any
driveability diagnosis. The OBD system check directs
the service technician to the next step in diagnosing
the complaint. Do not perform this check if no
driveability complaint exists. Understanding the table
correctly reduces the diagnostic time. Understanding
the table correctly prevents the replacement of
good parts.
Diagnostic Aids
Important: Do not clear the DTCs unless directed
by a diagnostic procedure. Clearing the DTCs
will also clear valuable freeze frame and failure
records data.
Inspect all related wiring and connections including
the connections at the PCM. These may cause an
intermittent malfunction.
Check any circuitry that is suspected of causing an
intermittent problem for the following conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections
• Physical damage to the wiring harness
• Corrosion
Engine Controls - 6.5L 6-2333
Test Description
The numbers below refer to the step number in the
diagnostic table.
1. This step will check for power and grounds to
the Data Link Connector (DLC).
4. This step will determine if other modules on the
Class 2 circuit can communicate, if no
communication occurs, the class 2 circuit is
grounded, open, shorted to voltage or the
module is causing a communication problem.
5. This step will check for DTCs associated with
the Vehicle Theft Deterrent (VTD) which will
prevent the vehicle from starting.
6. Whenever multiple DTCs are stored, refer to
the DTC Tables in the following order:
1. PCM Error DTCs
2. System voltage DTCs
3. Component level DTCs (DTCs that
indicate a malfunctioning part)
4. System level DTCs (DTCs that indicate a
system fault)
7. Checking the sensors for proper operation
during warm up can be a crucial step in
correctly diagnosing any driveability concern.
Careful observation of these sensors during the
engine warm up may reveal a slow responding
sensor or a sensor that malfunctions only within
a small portion of its range.
After the engine is at the normal operating
temperature, a comparison of the actual control
system data with the typical values is a quick
way to determine if any parameter is not within
limits. Keep in mind that a base engine problem
(i.e. advanced cam timing) may substantially
alter sensor values.
Check the Engine Coolant Temperature (ECT)
sensor for initial coolant temperature reading at
ambient. Then observe the rise in the
temperature while the engine is warming up.
6-2334 Engine Controls - 6.5L Engine
Powertrain OBD System Check
Step Action Value(s) Yes No
Important: Check for applicable service bulletins before
proceeding with this diagnosis.
Important: Do not turn the ignition OFF when performing
this diagnostic.
1 —
1. Connect the scan tool to the Data Link
Connector (DLC).
Go to Data Link
2. Turn the ignition ON while leaving the engine OFF. Connector
Does the scan tool power-up? Go to Step 2 Diagnosis
1. Install the scan tool.
2. Turn ON the ignition.
2 —
3. Attempt to establish communications with the PCM.
Does the scan tool display PCM data? Go to Step 3 Go to Step 4
3 Does the engine start and continue to run? — Go to Step 6 Go to Step 5
Attempt to establish communications with other systems
connected with to the same serial data line (Passlock/EVO, Go to Data Link
4 ATC, ABS controllers). —
Connector Go to Body and
Does scan tool communicate with the other systems? Diagnosis Accessories
Is DTC 1626 or DTC P1631 stored? Go to the Go to Engine
5 — applicable Cranks but Does
DTC table Not Run
Check for PCM DTCs using the scan tool. Go to the
6 Were any last test failed, history, or MIL request — applicable
DTCs set? DTC table Go to Step 7
1. Turn ON the ignition leaving the engine OFF.
2. Check the ECT.
3. Start the engine.
4. Allow the engine temperature to reach operating
temperature.
7 —
5. While the engine is reaching the operating
temperature, check the ECT.
6. Compare the scan tool values of the sensors with Go to Diagnostic
the typical values shown in the Scan Tool Values. Aids and Test
Are thq displayed values normal or within typical ranges? Go to Symptoms Descriptions
Engine______________________ Engine Controls - 6.5L 6-2335
No Malfunction Indicator Lamp

|H o t In Run And S ta rt |

| P ow er
^ IP
Distribution GAGES *Fuse
Fuse 4
I Cel! 10 1Block
I 10 A
I

PNK 39
F u s e B lock
D etails PCM
C e ll 11 C l = 32 BRN
PNK 39 C 2 = 2 4 BRN
C 3 = 3 2 BLU
22 X
r n Instrument A
I In stru m e n t ◄— ♦------------------------ H i M alfunction
| Cluster
C lu s te r i t S E R V IC E Indicato r

I
C ell 81 (T )-T H R O T T L E ( j) Lamp(M IL) l
's ' soon (S E R V IC E
I T Lamp l
i. l E N G IN E S O O N )
j
21 ' 23
WHT/BLK 176 BRN/WHT 419

WHT/BLK 176 BRN/WHT 419

D11 C14 C3
r ---- ——— — ■* Powertrain
■ S e rv ic e T hrottle
Soon Lam p C o ntrol 1 Control ^
I C o n tro l
I Module (PCM)
u _» ____ _ _ __________ j

185027

Circuit Description Test Description

There should always be a steady Malfunction Number(s) below refer to the step number(s) on the
Indicator Lamp (MIL) when the ignition is ON and Diagnostic Table.
engine OFF. Battery ignition voltage is supplied to 5. This Step will isolate the problem in the MIL
the lamp. The PCM will turn the lamp ON by control circuit.
grounding the ignition feed circuit.
6. If the Battery Feed, Ignition Feed and
Diagnostic Aids Diagnostic Test circuits have voltage, the PCM
If the engine cranks but will not run, check: connections, grounds, or PCM are
malfunctioning.
• Continuous battery-fuse or fusible link for open.
8. Refer to PCM terminal end view in this section
• PCM ignition fuse for open. for PCM pin locations of ground circuits.
• Battery Feed circuit to PCM for open. 12. If the fuse/fusible link is open, refer to PCM
• Ignition Feed circuit to PCM for open. Wiring Diagram for complete circuit.
• Poor connection to PCM.
6-2336 Engine Controls - 6.5L Engine
No Malfunction Indicator Lamp
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Attempt to start the engine.
2 —
Does the engine start? Go to Step 3 Go to Step 6
Check the fuse number 4.
3 —
Is the fuse OK? Go to Step 4 Go to Step 14
Turn the ignition ON, probe the ignition feed circuit at the
4 cluster connector with a test light to ground. —
Is the test light ON? Go to Step 5 Go to Step 11
1. Turn the Ignition OFF.
2. Disconnect the blue PCM connector.
3. Turn the ignition ON.
5 4. With a fused jumper wire connected to ground, probe —
the MIL control circuit at the PCM connector.
5. Observe the MIL.
Is the MIL ON? Go to Step 9 Go to Step 10
Check the PCM Ignition Feed and Battery Feed fuses.
6 —
Are both of the fuses OK? Go to Step 7 Go to Step 13
1. Turn the ignition OFF.
2. Disconnect the PCM connectors.
3. Turn the ignition ON.
7 —
4. Probe the PCM harness ignition and battery feed
circuits with a test light to ground.
Is the test light ON both circuit? Go to Step 8 Go to Step 12
1. Check for a proper PCM ground or a proper PCM
ground connection.
8 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 20 Go to Step 9
1. Check for a proper connection at the PCM.
9 2. If a poor connection is found, repair as necessary. —
Was a problem found? Go to Step 20 Go to Step 15
1. Check the MIL control circuit for an open.
10 2. If the MIL control circuit is open, repair as necessary. —
Was a problem found? Go to Step 20 Go to Step 16
Repair open in the ignition feed circuit to the cluster
11 connector. — —
Is the action complete? Go to Step 20
Locate and repair open in the PCM battery feed circuit or
12 the PCM ignition feed circuit as necessary. — —
Is the action complete? Go to Step 20
Locate and repair short to ground in the PCM Ignition
13 Feed circuit or the PCM Battery Feed circuit as necessary. — —
Is the action complete? Go to Step 20
Locate and repair short to ground in the instrument cluster
14 Ignition Feed circuit. — —
Is the action complete? Go to Step 20
Engine Engine Controls - 6.5L 6-2337
No Malfunction Indicator Lamp (cont’d)
Step Action Values) Yes No
Replace the PCM.
Important: The new PCM must be programmed. Refer to
15 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 20
1. Check the MIL control circuit for a proper connection
at the instrument cluster connector.
16 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 20 Go to Step 17
1. Remove the instrument cluster.
17 2. Inspect the MIL bulb. —
Is the bulb OK? Go to Step 19 Go to Step 18
Replace the MIL bulb.
18 — —
Is the action complete? Go to Step 20
Replace the instrument cluster.
19 — —
Is the action complete? Go to Step 20
1. Using the Scan Tool, select DTC, Clear Info.
20 2. Attempt to start the engine. —
Does the engine start and continue to run? Go to Step 21 Go to Step 2
1. Allow engine to idle until normal operating
temperature is reached.
21 — Go to the
2. Select DTC, Failed This Ign. Applicable
Are any DTCs displayed? DTC Table Go to Step 22
Using the Scan Tool, select Capture Info, Review Info. Go to the
22 Are any DTCs displayed that have not been diagnosed? — Applicable
DTC Table System OK
6-2338 Engine Controls - 6.5L Engine

Data Link Connector Diagnosis Test Description

Refer to Power, Ground, MIL and DLC.
Circuit Description
There should always be a Malfunction Indicator
Lamp (MIL) when the ignition is ON and engine OFF.
Battery ignition voltage is supplied to the lamp. The
PCM will turn the lamp ON by grounding the ignition
feed circuit.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step verifies if the problem is in the Scan
tool or the vehicle.
6. This step will check the ground circuits at the
DLC connector.
9. The step will check for the battery and ignition
feeds to the PCM.

Data Link Connector Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Important: This table assumes that the scan tool you are
using is functional.
2 1. Turn ON the ignition leaving the engine OFF. —
2. Connect the scan tool to the DLC.
Does the scan tool power-up? Go to Step 3 Go to Step 5
1. Turn OFF the ignition for 15 seconds.
Go to Body and
3 2. Attempt to start the vehicle. — Accessories/Wiring
Does the engine start then stall? Systems Go to Step 4
4 Did the engine just crank over and not start? — Go to Step 9 Go to Step 13
1. Disconnect the scan tool from the DLC.
2. Turn ON the ignition leaving the engine OFF.
5 3. Probe the DLC terminal 16 using a test lamp —
connected to battery ground.
Does the test lamp illuminate? Go to Step 6 Go to Step 16
Probe the DLC terminals 4 and 5 using a test lamp
6 connected to B+. —
Does the test lamp illuminate on both circuits? Go to Step 7 Go to Step 8
1. Inspect the scan tool connections to the DLC.
2. Also inspect the terminals for proper tension at the Go to
7 — —
DLC. Refer to Body and Accessories. Powertrain OBD
Is action complete? System Check
Repair the open ground circuit to the DLC terminals 4 and Go to
8 5. Refer to Body and Accessories/Wiring Systems. — Powertrain OBD —
Is action complete? System Check
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the Battery
and Ignition feed circuits.
3. Turn the ignition ON.
9 —
4. Probe the Battery and Ignition feed circuits in the
PCM harness connectors with a test lamp connected
to battery ground.
Does the test lamp illuminate on each circuit? Go to Step 10 Go to Step 14
Measure the resistance between the battery ground and
the PCM ground circuits in the PCM harness connectors
10 using a DMM. 5Q
Does the DMM display the specified value (or lower) on
each circuit? Go to Step 11 Go to Step 15
Engine Engine Controls - 6.5L 6-2339
Data Link Connector Diagnosis (cont’d)
Step Action Value(s) Yes No
Inspect the PCM for proper connections. Refer to Body Go to
11 and Accessories/Wiring Systems. — Powertrain OBD
Was a repair performed? System Check Go to Step 12
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — Go to —
PCM Replacement/Programming.
Powertrain OBD
Is the action complete? System Check
Repair the Class 2 circuit for being open between the
splice and the DLC. Refer to Body and Accessories/Wiring Go to
13 Systems. — —
Powertrain OBD
Is the action complete? System Check
Repair the circuit that did not illuminate the test lamp. Go to
14 Refer to Body and Accessories/Wiring Systems. — Powertrain OBD —
Is the action complete? System Check
Repair the PCM ground circuit(s). Refer to Body and Go to
15 Accessories/Wiring Systems. — Powertrain OBD —
Is the action complete? System Check
Repair the B+ supply circuit. Refer to Body and Go to
16 Accessories/Wiring Systems. — Powertrain OBD —
Is the action complete? System Check
6-2340 Engine Controls - 6.5L Engine

Engine Cranks but Does Not Run

H o t In Run And Start

A
io e o n k .

PCM
= 3 2 BRN
= 2 4 BRN
= 3 2 BLU

E n g in e E n g in e Fue l Fuel C lo s u re C lo s u re
1 rowenrain
S h u tO ff S h u tO ff Injection In jec tion Signal G ro u n d 1 Control
I S o le n o id S o le n o id C o ntrol C o n tro l 1 Module Jk
| C o ntrol C o n tro l
l (PCM) I jA

185026

Circuit Description If the Crankshaft position sensor and the Optical/Fuel

This chart assumes that battery condition and engine Temperature are disconnected or malfunctioning at
cranking speed is OK, quantity and quality of fuel is the same time, a Engine Cranks But Will Not Run
OK and glow plug system is operating OK. condition will exist.

Diagnostic Aids Test Description

If no trouble is found and the cause of an Engine
Cranks But Will Not Run has not been found,
check for:
• Proper cranking speed, 100 RPMs cold -
180 RPMs hot (a scan tool can be used to
check cranking speed by pulling the FUEL SOL
fuse and monitoring Engine Speed on scan tool
while cranking).
• Water or foreign material in fuel system.
• Basic engine problem.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
6. This step checks for proper cranking speed
(see Diagnostic Aids).
8. This step will check the ground wire on the
injection pump (wire located on top of pump).
12. This step will determine if the injection pump or
wiring is at fault.
Engine________________________________________________ Engine Controls - 6.5L 6-2341
Engine Cranks but Does Not Run
Step Action Value(s) Yes No
Important: Before clearing DTCs use the Scan Tool
Capture Info to record freeze frame and failure records
for reference, as data will be lost when Clear Info function
1 is used. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Check for proper condition of batteries. Refer to Engine
2 Electrical. —
Is the condition of batteries OK? Go to Step 3 Go to Step 23
Check for adequate fuel in the tank.
3 —
Is the fuel at an adequate level? Go to Step 4 Go to Step 23
Check the quality of the fuel. Refer to Fuel Quality
4 Diagnosis. —
Is the fuel quality OK? Go to Step 5 Go to Step 23
Check the glow plug system operation. Refer to Glow Plug
5 System Check. —
Are the glow plugs operating OK? Go to Step 6 Go to Step 23
Check for the proper cranking speed. Refer to Engine
6 Electrical. —
Is the cranking speed OK? Go to Step 7 Go to Step 23
Check for a restriction in the fuel return system. Refer to
7 Fuel Supply System Check. —
Does the fuel return system operate properly? Go to Step 8 Go to Step 23
Check the injection pump ground wire (located on top of
8 the injection pump). —
Is the ground OK? Go to Step 9 Go to Step 23
Turn the ignition ON. Go to No
9 Does the MIL come ON? — Malfunction
Go to Step 10 Indicator Lamp
Install a scan tool. Go to Data Link
10 Does the scan tool display data? — Connector
Go to Step 11 Diagnosis
1. Loosen the injector line at the injector.
2. Crank the engine.
11 —
3. Repeat the procedure for the remaining injectors.
Is there fuel at each injection line? Go to Step 17 Go to Step 12
Disconnect the Optical/Fuel temperature sensor.
12 —
Does the vehicle start? Go to Step 16 Go to Step 13
1. Reconnect the Optical/Fuel temperature sensor.
2. Disconnect the fuel solenoid driver at the fuel
injection pump.
3. With J 39200 connected to ground, probe the fuel
13 1.2 V
injector control circuit at the harness terminal
(terminal A).
4. Crank the engine.
Is the voltage greater than or equal to the specified value? Go to Step 14 Go to Step 18
1. Verify the fuel solenoid driver is still disconnected.
2. Probe the fuel solenoid closure ground circuit
14 (terminal C) with a test light connected to B+ at the —
harness terminal.
Is the test light ON? Go to Step 15 Go to Step 19
6-2342 Engine Controls - 6.5L Engine
Engine Cranks but Does Not Run (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition ON leaving the engine OFF.
2. Verify the fuel solenoid is still disconnected.
15 3. Probe the ignition feed circuit (terminal D) at the fuel —
solenoid harness connector with a test light
connected to ground.
Is the test light ON? Go to Step 16 Go to Step 21
Replace fuel injection pump. Refer to Fuel Injection Pump
16 Replacement. — —
Is the action complete? Go to Step 25
The injection system is OK. Go to Driveability
17 — —
Is the action complete? Symptoms
Check the fuel inject control circuit for an open or ground
18 between the fuel solenoid driver and the PCM. —
Was a problem found? Go to Step 22 Go to Step 20
Check the closure ground circuit for an open between the
19 fuel solenoid driver and the PCM. —
Was a problem found? Go to Step 22 Go to Step 20
Inspect the fuel solenoid driver connector and the PCM
20 connector for a proper connection. —
Was a problem found? Go to Step 22 Go to Step 24
Repair the open in the ignition feed circuit.
21 — —
Is the action complete? Go to Step 25
Repair the circuit as necessary.
22 — —
Is the action complete? Go to Step 25
Make the appropriate repairs.
23 — —
Is the action complete? Go to Step 25
Replace the PCM.

24 Important: The new PCM must be programmed. Refer to — —

PCM Replacement/Programming.
Is the action complete? Go to Step 25
1. Using the Scan Tool, select DTC, Clear Info.
25 2. Attempt to start the engine. —
Does the engine start and continue to run? Go to Step 26 Go to Step 2
1. Allow the engine to idle until normal operating
temperature is reached.
26 — —
2. Select DTC, Fail This Ign.
Are any DTCs displayed? Go to Step 27
Using the Scan Tool, select Capture Info, Review Info. Go to the
27 Are any DTCs displayed that have not been diagnosed? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2343
Fuel Pump Relay Circuit Diagnosis Diagnostic Aids
Refer to Fuel Pump Controls. Possible long crank times or a poor performance
problem will exist.
Circuit Description
When the key is in turned ON, the PCM energizes Test Description
the fuel pump relay which sends voltage to the lift Number(s) below refer to the step number(s) on the
pump. The lift pump remains ON during the glow Diagnostic Table.
plug cycle. If the engine is not started immediately 2. Checks for proper operation of the fuel pump.
after the glow plug cycle, the PCM shuts the fuel lift
3. Checks the operation of the fuel pump by
pump OFF and waits until the engine starts. As a
supplying 12 volts to the fuel pump control
backup system to the fuel pump relay, the fuel lift
circuit.
pump can also be turned ON by the fuel pump/oil
pressure switch. When the engine oil pressure 5. Check the battery feed circuit to the fuel
reaches 28 kPa (4 psi), and the fuel pump relay pump relay.
does not complete the circuit, the fuel pump/oil 10. Checks for proper operation of the fuel
pressure switch will close and complete the circuit pump relay.
to run the fuel lift pump.

Fuel Pump Relay Circuit Diagnosis

Step Action Value(s) Yes No
Important: Before clearing DTCs use the Scan Tool
Capture Info to record freeze frame and failure records
for reference, as data will be lost when Clear Info function
1 is used. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition OFF for 10 seconds.
Go to Engine
2 2. Turn the ignition ON. — Cranks but Does
Does fuel pump operate during the glow plug cycle? Not Run Go to Step 3
Apply a 12 volt fused jumper to the fuel pump test
3 terminal. —
Does the fuel pump operate? Go to Step 4 Go to Step 12
1. Remove the 12 volt fused jumper from the test
terminal.
2. Turn the ignition OFF for 10 seconds.
4 —
3. Turn the ignition ON.
Does the fuel pump operate during glow plug cycle and
then stop? Go to Step 25 Go to Step 5
1. Disconnect the fuel pump relay.
2. Turn the ignition ON, engine OFF.
5 3. Probe the fuel pump relay battery feed terminal at —
the fuel pump relay harness connector with a test
light to ground.
Is the test light ON? Go to Step 6 Go to Step 14
Connect a test light between the fuel pump relay battery
6 feed circuit harness connector and ground. —
Is the test light ON? Go to Step 7 Go to Step 15
1. Connect a test light between the fuel pump relay
control circuit and ground.
7 2. Turn the ignition OFF for 20 seconds. —
3. Turn the ignition ON.
Is the test light ON during glow plug cycle and then OFF? Go to Step 8 Go to Step 16
Check for a proper connection at the fuel pump relay
8 control connector terminal. —
Was a problem found? Go to Step 11 Go to Step 9
6-2344 Engine Controls - 6.5L________________________________________________ Engine
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
Replace the fuel pump relay. Refer to Fuel Pump Relay
9 Replacement. —
Is the action complete? Go to Step 25 Go to Step 10
1. Start the engine and idle until normal operating
temperature is reached.
10 2. Verify the oil pressure is within normal range. —
3. Disconnect the fuel pump relay.
Does the engine continue to run? Go to Step 11 Go to Step 17
1. Reinstall the fuel pump relay.
2. Turn the ignition OFF.
11 3. Probe the fuel pump test connector with a test light —
to ground.
Is the test light ON? Go to Step 18 Go to Step 25
1. Disconnect the fuel pump harness connector at the
fuel lift pump.
2. Apply a 12 volt fused jumper to the fuel pump test
12 terminal. —
3. Probe the fuel pump feed circuit with a test light to
ground.
Is the test light ON? Go to Step 13 Go to Step 20
With a test light connected to B+ probe the fuel pump
ground terminal (vehicle side) of the chassis harness fuel
13 pump connector. —
Is the test light ON? Go to Step 19 Go to Step 21
Repair the open in the battery feed circuit to the fuel pump
14 relay harness connector terminal. — —
Is the action complete? Go to Step 25
Repair the open in the fuel pump relay ground circuit.
15 — —
Is the action complete? Go to Step 25
1. Check for a proper connection at the PCM fuel pump
relay control circuit.
2. Check for an open or short to ground in the harness
16 —
between the fuel pump relay control connector
terminal and the fuel pump relay control circuit.
Was a problem found? Go to Step 22 Go to Step 24
Check the oil pressure switch harness connector terminals
17 for a proper connection. —
Was a problem found? Go to Step 22 Go to Step 18
Replace the oil pressure switch. Refer to Engine Oil
18 Pressure Sensor/Switch Replacement. — —
Is the action complete? Go to Step 25
Replace the fuel lift pump. Refer to Fuel Lift Pump
19 Replacement. — —
Is the action complete? Go to Step 25
Repair the open between the fuel pump test terminal and
the fuel pump feed circuit at the fuel pump harness
20 — —
connector.
Is the action complete? Go to Step 25
Repair the open in the fuel pump harness ground circuit.
21 — —
Is the action complete? Go to Step 25
Engine Engine Controls - 6.5L 6-2345
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
Repair the circuit as necessary.
22 — —
Is the action complete? Go to Step 25
Repair the connection as necessary.
23 — —
Is the action complete? Go to Step 25
Replace the PCM.

24 Important: The new PCM must be programmed. Refer to

— —
PCM Replacement/Programming.
Is the action complete? Go to Step 25
1. Using the scan tool, select DTC, Clear Info.
25 2. Attempt to start the engine. —
Does the engine start and continue to run? Go to Step 26 Go to Step 2
1. Allow the engine to idle until normal operating
temperature is reached.
26 —
2. Select DTC, Failed This Ign. Go to Applicable
Are any additional DTCs displayed? DTC Table Go to Step 27
Using the scan tool, select Capture Info, Review Info.
27 Are any additional DTCs displayed that have not been — Go to Applicable
diagnosed? DTC Table System OK
6-2346 Engine Controls - 6.5L_______________
DTC P0101 Mass Air Flow System Performance
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air
entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates
deceleration or idle.
The MAF sensor produces a frequency signal.
DTC P0101 will be set if the signal from the MAF
sensor does not match a predicted value based on,
engine coolant temperature, throttle angle and
engine speed.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
. DTCs P0405, P0406, P0102 and P0103 are
not set.
Engine
• The Baro is greater than 75 kPa.
• Must fail 2 of the 5 EGR tests (these test are
performed internaly by the PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine
Conditions for Clearing the MIL7DTC
• The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the
diagnostic has been run and the fault condition
is no longer present.
• A history DTC P0101 will clear after
40 consecutive warm-up cycles have occurred
without a fault.
• DTC P0101 can be cleared by using the scan
tool Clear Info function.
Diagnostic Aids
Check for the following conditions:
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the scan tool while moving connectors
and wiring harnesses related to the MAF sensor.
A change in the display will indicate the location
of the fault.
• Plugged intake air duct or dirty air filter
element. A Wide-Open throttle acceleration from
a stop should cause the Mass Air Flow
displayed on a scan tool to increase. If not,
check for a restriction.
Engine Controls - 6.5L 6-2347
If DTC P0101 cannot be duplicated, the information
included in the Fail Records data can be useful in
determining vehicle mileage since the DTC was last
set. This may assist in determining how often the
DTC sets.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine
speed (RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. This step verifies that the problem is present
at idle.
5. A voltage reading of less than 4 or over 6V at
the MAF sensor signal circuit indicates a fault
in the wiring or a poor connection.
6. Verifies that ignition feed voltage and a good
ground are available at the MAF sensor.

DTC P0101 Mass Air Flow System Performance

Step Action Vaiue(s) Yes No
Important: Before clearing any DTCs, use the Scan tool
to save Freeze Frame and Failure Records for reference,
as the Scan tool loses data when using the Clear Info
1 function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. Review and record the scan tool Fail Records data.
3. Operate the vehicle within the Fail Records
2 conditions as noted. —
4. Using a scan tool, monitor the Specific DTC info for
DTC P0101. Refer to
Does the scan tool indicate DTC P0101 Failed This Ign? Go to Step 3 Diagnostic Aids
1. Check for the following conditions:
• Plugged intake air duct or dirty air filter element
• Intake manifold vacuum leaks
3 —
• Leaks at EGR valve flange and tower gasket.
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 17 Go to Step 4
1. Turn the ignition ON leaving the engine OFF with the
Go to DTC P0121
throttle closed.
4 0% APP Sensorl
2. Observe the APP Angle display on the scan tool. Circuit
Is the APP Angle near the specified value? Go to Step 5 Performance
1. Turn the ignition OFF.
2. Disconnect the MAF sensor connector.

5 3. Turn the ignition ON leaving the engine OFF.

5V
4. Using a DMM, measure the voltage between the
MAF signal circuit and chassis ground.
Is the voltage near the specified value? Go to Step 6 Go to Step 7
6-2348 Engine Controls ■ 6.5L________________________________________________ Engine
DTC P0101 Mass Air Flow System Performance (cont’d)
Step Action Value(s) Yes No
Connect a test light between the MAF sensor ignition feed
6 and ground circuits at the MAF sensor harness connector. —
Is the test light ON? Go to Step 10 Go to Step 9
7 Is the voltage less than the specified value? 4.5V Go to Step 11 Go to Step 8
1. Turn the ignition OFF, disconnect the PCM.
2. Turn the ignition ON leaving the engine OFF.
8 3. Measure the voltage between the MAF signal circuit OV
and ground.
Does the voltage measure near the specified value? Go to Step 15 Go to Step 13
Connect a test light between the MAF sensor ignition feed
9 circuit and the chassis ground. —
Is the test light ON? Go to Step 12 Go to Step 13
1. Check for a proper connection at the MAF sensor.
2. If a poor connection is found, replace the terminal(s)
10 —
as necessary.
Was a poor connection found? Go to Step 17 Go to Step 15
1. Check the MAF signal circuit between the PCM and
the MAF sensor for an open, short to ground, or
short to the MAF sensor ground circuit.
11 —
2. If the MAF signal circuit is open or shorted, repair it
as necessary.
Was the MAF sensor signal circuit open or shorted? Go to Step 17 Go to Step 16
Locate and repair the open in the ground circuit to the
12 MAF sensor. — —

Is the action complete? Go to Step 17

Locate and repair the open in the ignition feed circuit to
13 the MAF sensor. — —
Is the action complete? Go to Step 17
Locate and repair the short to voltage in the MAF sensor
14 signal circuit. — —
Is the action complete? Go to Step 17
Replace the MAF sensor. Refer to MAF Sensor
15 Replacement — —
Is the action complete? Go to Step 17
Replace the PCM.
Important: The new PCM must be programmed. Refer to
16 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 17
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
17 which was set. —
4. Operate the vehicle, within the Conditions for
Setting this DTC, until the Scan Tool indicates the
diagnostic Ran.
Does scan tool indicate the diagnostic Passed? Go to Step 18 Go to Step 2
Does the Scan tool display any additional Go to the
18 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________________
DTC P0102 MAF Sensor Circuit Low Frequency
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given time.
The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air entering
the engine indicates an acceleration, high load situation
or no EGR flow, while a small quantity of air indicates
deceleration, idle or full EGR situations.
The MAF sensor produces a frequency signal.
DTC P0102 will be set if the signal from the
MAF sensor does not match a predicted value
based on, engine coolant temperature, APP angle
and engine speed.
Engine Controls - 6.5L 6-2349
DTC P0102 will be set if the signal from the
MAF sensor is below the possible range of a
normally operating MAF sensor.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine speed is greater than 0 RPM.
• The ignition voltage is greater than 8.5 volts.
• The MAF frequency is less than 1280 Hz
(1.5 g/s).
• All diagnostic set conditions met for 2 seconds.
6-2350 Engine Controls ■ 6.5L
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the
diagnostic has been run and the fault condition
is no longer present.
• A history DTC P0102 will clear after
40 consecutive warm-up cycles have occurred
without a fault.
• DTC P0102 can be cleared by using the scan
tool Clear Info function.
Diagnostic Aids
Check for the following conditions:
• Poor connection at PCM. Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
• Damaged harness. Inspect the wiring harness
for damage. If the harness appears to be
OK, observe the scan tool while moving
connectors and wiring harnesses related to
the MAF sensor. A change in the display will
indicate the location of the fault.
• Plugged intake air duct or filter element. A
Wide-Open throttle acceleration from a stop
should cause the Mass Air Flow displayed on a
scan tool to increase.
Engine
If DTC P0102 cannot be duplicated, the information
included in the Fail Records data can be useful in
determining vehicle mileage since the DTC was
last set.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. This step verifies that the problem is present
at idle.
5. A voltage reading of less than 4 or over 6V at
the MAF sensor signal circuit indicates a fault
in the wiring or a poor connection.
6. Verifies that ignition feed voltage and a
good ground are available at the
MAF sensor.
13. This vehicle is equipped with a PCM which
utilizes an Electrically Erasable Programmable
Read Only Memory (EEPROM). When the PCM
is being replaced, the new PCM must be
programmed. Refer to PCM
Replacement/Programming.
Engine________________________________________________ Engine Controls - 6.5L 6-2351
DTC P0102 MAF Sensor Circuit Low Frequency
Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool to
save Freeze Frame and Failure Records for reference, as
the Scan tool loses data when using the Clear Info
1 function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Start the engine.
2. With the engine idling, monitor the MAF display on
2 1280 Hz
the scan tool.
Is the MAF display below the specified value? Go to Step 4 Go to Step 3
1. Turn the ignition ON leaving the engine OFF.
2. Review and record the scan tool Fail Records data.
3. Operate the vehicle within the Fail Records
3 conditions as noted. —
4. Using a scan tool, monitor the Specific DTC info for
DTC P0102. Refer to
Does scan tool indicate DTC P0102 failed this Ign? Go to Step 4 Diagnostic Aids
1. Check for the following conditions:
• Objects blocking the MAF sensor inlet.
• Large intake manifold leaks
• Large leaks at the EGR valve flange or tower
4 —
gasket.
• Large leaks downstream of the MAF sensor.
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 14 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the MAF sensor connector.
3. Turn the ignition ON leaving the engine OFF.
5 5V
4. Using a J 39200, measure the voltage between the
MAF signal circuit and ground.
Is the voltage near the specified value? Go to Step 6 Go to Step 9
Connect a test light between the MAF sensor ignition feed
6 and ground circuit at the MAF sensor harness connector. —
Is the test light ON? Go to Step 8 Go to Step 7
Connect a test light between MAF sensor ignition feed
7 circuit and battery ground. —
Is the test light ON? Go to Step 10 Go to Step 11
1. Check for a proper connection at the MAF sensor.
8 2. If a poor connection is found, repair as necessary. —
Was a poor connection found? Go to Step 14 Go to Step 12
1. Check the MAF signal circuit between the PCM and
the MAF sensor for an open, short to ground, short
to the MAF sensor ground circuit, or short to voltage.
9 —
2. If the MAF sensor signal circuit is open or shorted,
repair as necessary.
Was the MAF signal /circuit open or shorted? Go to Step 14 Go to Step 13
Locate and repair the open in the ground circuit to the
10 MAF sensor. — —
Is the action complete? Go to Step 14
6*2352 Engine Controls - 6.5L________________________________________________ Engine
DTC P0102 MAF Sensor Circuit Low Frequency (cont’d)
Step Action Value(s) Yes No
Locate and repair the open in the ignition feed circuit to
11 the MAF sensor. — —

Is the action complete? Go to Step 14

Replace the MAF sensor. Refer to MAF Sensor
12 Replacement. — —
Is the action complete? Go to Step 14
Replace the PCM.
Important: The new PCM must be programmed. Refer to
13 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 14
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
14 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
15 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________________ Engine Controls - 6.5L 6-2353
DTC P0103 MAF Sensor Circuit High Frequency

The Mass Air Flow (MAF) sensor measures the • The PCM performs this DTC diagnostic
amount of air entering the engine during a given continuously.
time. The PCM uses the mass air flow information to • The DTC P0102 diagnostic has ran and
monitor EGR flow rates. A large quantity of air passed.
entering the engine indicates an acceleration or high • The engine speed is greater than 0 RPM.
load situation, while a small quantity of air indicates
• The ignition voltage is greater than 8.5 volts.
deceleration or idle.
• The MAF frequency is greater than
The MAF sensor produces a frequency signal. 10496 Hz (342 g/s).
DTC P0101 will be set if the signal from the
• All of the diagnostic set conditions met for
MAF sensor does not match a predicted value based
2 seconds.
on, engine coolant temperature, throttle angle and
engine speed.
DTC P0103 will be set if the signal from the
MAF sensor is above the possible range of a
normally operating MAF sensor.
6-2354 Engine Controls - 6.5L
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the
diagnostic has been run and the fault condition
is no longer present.
• A history DTC P0103 will clear after 40
consecutive warm-up cycles have occurred
without a fault.
• DTC P0103 can be cleared by using the scan
tool Clear Info function.
Diagnostic Aids
Check for the following conditions:
• Poor connection at PCM Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
• Damaged harness Inspect the wiring harness
for damage. If the harness appears to be
OK, observe the scan tool while moving
connectors and wiring harnesses related to
the MAF sensor A change in the display will
indicate the location of the fault.
Engine
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step verifies that the problem is present
at idle.
4. A frequency reading with the MAF sensor
connector disconnected indicates an
Electro-Magnetic Interference (EMI) related fault
or a poor connection.
9. This vehicle is equipped with a PCM which
utilizes an Electrically Erasable Programmable
Read Only Memory (EEPROM). When the PCM
is being replaced, the new PCM must be
programmed. Refer to PCM
Replacement/Programming.

DTC P0103 MAF Sensor Circuit High Frequency

Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the Scan tool
to save Freeze Frame and Failure Records for reference,
as the Scan tool loses data when using the Clear Info
1 function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Start the engine.
2. With the engine idling, monitor the MAF display on
2 10496 Hz
the scan tool.
Is the MAF display above the specified value? Go to Step 4 Go to Step 3
1. Turn the ignition ON leaving the engine OFF.
2. Review and record the scan tool Fail Records data.
3. Operate the vehicle within the Fail Records
3 conditions as noted. —
4. Using a scan tool, monitor the Specific DTC info for
DTC P0103. Refer to
Does the scan tool indicate DTC P0103 Failed This Ign? Go to Step 4 Diagnostic Aids
Engine Engine Controls - 6.5L 6-2355
DTC P0103 MAF Sensor Circuit High Frequency (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the MAF sensor connector.
3. Turn the ignition ON, engine idling.
4 00 Hz
4. Using a scan tool, monitor the MAF display.
Does the scan tool indicate a MAF display at the
specified value? Go to Step 5 Go to Step 7
1. Check for a proper connection at the MAF sensor
harness terminals.
5 —
2. If a poor connection is found, replace the terminal(s).
Was a poor connection found? Go to Step 10 Go to Step 6
Replace the MAF sensor. Refer to MAF Sensor
6 Replacement. — —
Is the action complete? Go to Step 10
1. Check the MAF sensor harness for incorrect routing.
Verify the harness is not near aftermarket add-ons.
7 —
2. If incorrect routing is found, correct harness routing.
Was a problem found? Go to Step 10 Go to Step 8
1. Check the MAF sensor signal circuit terminal
connections at the PCM.
8 —
2. If a poor connection is found, repair as necessary.
Was a poor connection found? Go to Step 10 Go to Step 9
Replace the PCM.
Important: The new PCM must be programmed. Refer to
9 — —
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 to the
11 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2356 Engine Controls - 6.5L Engine

DTC P0112 IAT Sensor Circuit Low Voltage

1 Powertrain
IAT ECT Control
Sensor Sensor i Module (PCM)
i.__ _ Signal
_ _ _ _ _ _ _ _ _ _ _Signal
_ _ _ j
C4 C11 C1
A
TAN 472 YEL 410 A
joeonk

PCM
Cl =32 BRN
C2-24BRN
C3-32BLU

TAN 472 YEL 410

A A
Intake Air Engine Coolant
Temperature Temperature
(IAT) (ECT) Sensor
B Sensor B
BLK 452 BLK 452

Boost Pressure ►- BLK

Sensor 452
BLK 452

BLK 452
BLK
EGRControl Pressure/ ►-
BAROSensor 452
7V BLK 452
A BLK 452
CKPSensor "TPT5ensor
Cell 36

B12JLC2
\ “ s 7 n s " 1 Powertrain
around : Control A
[ _______1 Module (PCM) i s A

Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermister that controls signal voltage to the PCM.
When the air is cold, the sensor resistance is high,
therefore the PCM will see a high signal voltage. As
air warms, sensor resistance becomes less and
voltage drops.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine coolant temperature is less than
42.5‘ C (109*F).
• The Intake air temperature is greater than or
equal to 151* C (303 *F).
• All of the diagnostic set conditions met for
2 seconds.
185072
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine Engine Controls - 6.5L 6-2357
Conditions for Clearing the MIL/DTC Test Description
• The PCM will turn the MIL off after three Number(s) below refer to the step number(s) on the
consecutive trips without a fault condition. Diagnostic Table.
• A History DTC will clear when forty consecutive 2. This Step determines if P0112 is a hard failure
warm-up cycles that the diagnostic does not or an intermittent condition.
fail (coolant temperature has risen 5 ' C (40 * F)
3. This test will determine if the PCM can
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160 ’ F)) recognized an open sensor.
that same ignition cycle. 4. This step will determine if the problem is a
• Use of a Scan Tool short to ground or a malfunctioning PCM.

Diagnostic Aids
Check harness routing for a potential short to ground
in the signal circuit. Refer to Symptoms. The scan tool
displays intake air temperature in degrees centigrade.
A skewed sensor could result in poor driveability
complaints. Refer to Temperature vs Resistance.

DTC P0112 IAT Sensor Circuit Low Voltage

Step Action Value(s) Yea No
important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start the engine.
2 3. Monitor the IAT display on Scan Tool. 151* C (303-F)
Is the IAT display greater than or equal to the
specified value? Go to Step 3 Go to Step 5
1. Turn the engine OFF.
2. Turn the ignition ON leaving the engine OFF.
3 3. Disconnect the IAT sensor connector. -3 0 ‘ C (-22 *F)
Does the IAT display a temperature colder than or equal to
the specified value? Go to Step 7 Go to Step 4
1. Turn the ignition OFF.
4 2. Using the J 39200, measure the resistance across
Infinite
the IAT harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored, Go to the
5 refer to those table(s). —
Applicable Goto
Are any additional DTCs stored? DTC Table Diagnostic Aids
Repair the short to ground in the IAT signal circuit.
6 — —
Is the action complete? Go to Step 9
Replace the IAT sensor. Refer to IAT Sensor Replacement.
7 — —
Is the action complete? Go to Step 9
Replace the PCM.

8
Important: The new PCM must be programmed. Refer to
— —
PCM Replacement/Programming.
Is the action complete? Go to Step 9
6-2358 Engine Controls - 6.5L________________________________________________ Engine
DTC P0112 IAT Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
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
9 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 10 Go to Step 2
Does the Scan tool display any additional Go to the
10 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_________________________________
DTC P0113 IAT Sensor Circuit High Voltage
Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermister that controls signal voltage to the PCM.
When the air is cold, the sensor resistance is high,
therefore the PCM will see a high signal voltage. As
air warms, sensor resistance becomes less and
voltage drops.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine operation time is greater than
8 minutes.
• The intake air temperature is less than or equal
to -4 0 “C (-40 *F).
• All of the diagnostic set conditions met for
2 seconds.
Engine Controls - 6.5L 6-2359
PCM
Cl =32 BRN
G2=24 BRN
C3=32 BLU
185072
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2360 Engine Controls ■ 6.5L Engine

Conditions for Clearing the MIL/DTC Test Description

• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160 * F))
that same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
The scan tool displays intake air temperature in
degrees centigrade. Check harness routing for a
potential short to ground in the signal circuit. Refer
to Symptoms. A skewed sensor could result in poor
driveability complaints. Refer to Temperature vs
Resistance.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0113 is a hard failure
or an intermittent condition.
3. This step will determine if there is a wiring
problem or a malfunctioning PCM.
9. This step determines if there is a short to
voltage on the signal circuit. A short to voltage
increases current flow through the sensor which
’overwhelms* the sensor. This doesn’t allow the
sensor to pull-down the circuit to the correct
voltage and thus display the correct
temperature.
10. After repairing the short to voltage, check the
sensor for proper operation.

DTC P0113 IAT 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan Tool.
2. Start the engine.
2 3. Monitor the IAT display on scan tool. -30 *C (-2 2 ’ F)
Does the IAT display a temperature colder than or equal to
the specified value? Go to Step 3 Go to Step 5
1. Turn the engine OFF.
2. Turn the ignition ON.
3. Disconnect the IAT sensor connector.
3 151 *C (303*F)
4. Jumper the IAT harness terminals together.
Does the scan tool display an IAT temperature greater
than or equal to the specified value? Go to Step 6 Go to Step 4
Jumper the IAT sensor signal circuit to a known good
ground.
4 151-C (303*F)
Does the scan tool display an IAT temperature greater
than or equal to the specified value? Go to Step 7 Go to Step 8
The DTC is intermittent. If no other DTCs are stored, refer Go to the
5 to Diagnostic Aids. — Applicable Go to
Are than any other DTCs stored? DTC Table Diagnostic Aids
1. Inspect the sensor connector and PCM connector for
a proper connection.
6 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 9
1. Check the IAT sensor ground circuit for an open
between the IAT sensor and the PCM.
7 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 11
Engine________________________________________________ Engine Controls - 6.5L 6-2361
DTC P0113 IAT Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Check the IAT sensor signal circuit for an open
between the IAT sensor and the PCM.
8 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 11
With a J 39200 set to the mA scale, measure the current
9 at the IAT harness connector terminals. 50 mA
Is the current less than the specified value? Go to Step 12 Go to Step 10
Repair the short to voltage on the IAT signal circuit.
10 — —
Is the action complete? Go to Step 14
Inspect the PCM connectors for proper connections and
11 replace the terminals, if necessary. —
Was a problem found? Go to Step 14 Go to Step 13
Replace the IAT sensor. Refer to IAT Sensor Replacement
12 — —
Is the action complete? Go to Step 14
Replace the PCM.
Important: The new PCM must be programmed. Refer to
13 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 14
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
14 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
15 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2362 Engine Controls - 6.5L____________
DTC P0117 ECT Sensor Circuit Low Voltage
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor that controls signal voltage to the PCM.
When the engine is cold, the sensor resistance is
high, therefore the PCM will see high signal voltage.
As the engine warms, sensor resistance becomes
less and voltage drops. The voltage measured
across the thermister is interpreted as a temperature.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine coolant temperature is greater than
or equal to 151 *C (303 *F).
• All of the diagnostic set conditions met for
2 seconds.
Engine
PCM
C1=32BRN
C 2 -2 4 BRN
C 3 -3 2 BLU
185072
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine Engine Controls - 6.5L 6-2363
Conditions for Clearing the MILJDTC Test Description
• The PCM will turn the MIL off after three The numbers below refer to the step numbers on the
consecutive trips without a fault condition. diagnostic table.
• A History DTC will clear when forty consecutive 2. If the fault is still present, the engine coolant
warm-up cycles that the diagnostic does not voltage will greater than 151 *C (303 *F).
fail (coolant temperature has risen 5 * C (40' F)
3. This test simulates a DTC P0117. If the PCM
from start up coolant temperature and engine
coolant temperature exceeds 71 ‘ C (160*F)) recognizes the high signal voltage (low
that same ignition cycle. temperature) the PCM and the wiring are okay.
• Use of a Scan Tool 4. This step will determine if the problem is a
short to ground or a malfunctioning PCM.
Diagnostic Aids
Check the harness routing for a potential short to
ground. After the engine is started, the ECT
temperature should rise steadily to about 85 * C
(185’ F). Refer to Symptoms. A skewed sensor could
result in poor driveability complaints. Refer to
Temperature vs Resistance.

DTC P0117 ECT Sensor Circuit Low Voltage

Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool to
save the Freeze Frame and the Failure Records for
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine.
2 3. Monitor the Engine Coolant Temperature (ECT) 151 -C (303-F)
display on scan tool.
Does the scan tool display an ECT greater than the
specified value? Go to Step 3 Go to Step 5
1. Turn off the engine.
2. Turn the ignition ON leaving the engine OFF.
3 3. Disconnect the ECT sensor connector. -30-C (-22 *F)
Does the scan tool display an ECT a temperature colder
than or equal to the specified value? Go to Step 7 Go to Step 4
1. Turn the ignition OFF.

4 2. Using the J 39200, check the resistance across the

Infinite
ECT sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If the additional DTCs are Go to The
5 stored, refer to those tables first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Repair the short to the ground in the ECT signal circuit.
6 — —•
Is the action complete? Go to Step 9
Replace the ECT sensor. Refer to ECT Sensor
7 Replacement. — —
Is the replacement complete? Go to Step 9
Replace the PCM.
Important: If the PCM is malfunctioning, reprogram the
8 — —
PCM. Refer to PCM Replacement/Programming.
Is the replacement complete? Go to Step 9
6-2364 Engine Controls - 6 .5 L _______________________________________________ Engine
DTC P0117 ECT Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
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
9 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 10 Go to Step 2
Does the Scan tool display any additional Go to The
10 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine__________________________________
DTC P0118 ECT Sensor Circuit High Voltage
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor that controls signal voltage to the PCM.
When the engine is cold, the sensor resistance is
high, therefore the PCM will see high signal voltage.
As the engine warms, sensor resistance becomes
less and voltage drops. The voltage measured
across the thermistor is interpreted as a temperature.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine operation time is greater than
8 minutes.
• The engine coolant temperature is less than or
equal to -4 0 *C (-40 *F).
• All of the diagnostic set conditions met for
2 seconds.
Engine Controls - 6.5L 6-2365
PCM
C l = 3 2 BRN
C 2 = 2 4 BRN
C 3 = 3 2 B LU
185072
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2366 Engine Controls - 6.5L Engine

Conditions for Clearing the MIL/DTC Test Description

• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5*C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
Check harness routing for a potential short to
voltage. After engine is started, the ECT temperature
should rise steady to about 8 5 ‘ C (185*F). A skewed
sensor could result in poor driveability complaints.
Refer to Temperature vs Resistance.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0118 is a hard failure
or an intermittent condition.
3. This step will determine if there is a wiring
problem or a malfunctioning PCM.
9. This step determines if there is a short to
voltage on the signal circuit. A short to voltage
increases current flow through the sensor which
’overwhelms’ the sensor. This doesn’t allow the
sensor to pull-down the circuit to the correct
voltage and thus displaying the correct
temperature.
10. After repairing the short to voltage, check the
sensor for proper operation.

DTC P0118 ECT 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan Tool.
2. Start the engine.
2 3. Monitor the ECT display on scan tool. -30 X (-22 *F)
Does the ECT display a temperature colder than or equal
to the specified value? Go to Step 3 Go to Step 5
1. Turn the engine OFF.
2. Turn the ignition ON.
3. Disconnect the ECT sensor connector.
3 151 *C (303 *F)
4. Jumper the ECT harness terminals together.
Does the scan tool display an ECT temperature greater
than or equal to the specified value? Go to Step 6 Go to Step 4
Jumper the ECT sensor signal circuit to a known good
ground.
4 151 ‘ C (303 *F)
Does the scan tool display an ECT temperature greater
than or equal to the specified value? Go to Step 7 Go to Step 8
The DTC is intermittent. If no other DTCs are stored, refer Go to the
5 to Diagnostic Aids. — Applicable Go to
Are than any other DTCs stored? DTC Table Diagnostic Aids
1. Inspect the sensor connector for a proper
connection.
6 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 9
1. Check the ECT sensor ground circuit for an open
between the ECT sensor and the PCM.
7 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 11
Engine________________________________________________ Engine Controls - 6.5L 6-2367
DTC P0118 ECT Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Check the ECT sensor signal circuit for an open
between the ECT sensor and the PCM.
8 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 11
With a J 39200 set to the mA scale, measure the current
9 at the ECT harness connector terminals. 50 mA
Is the current less than the specified value? Go to Step 12 Go to Step 10
Repair the short to voltage on the ECT signal circuit.
10 — —
Is the action complete? Go to Step 14
Inspect the PCM connectors for proper connections and
11 replace the terminals, if necessary. —
Was a problem found? Go to Step 14 Go to Step 13
Replace the ECT sensor. Refer to ECT Sensor
12 Replacement — —
Is the action complete? Go to Step 14
Replace the PCM.
Important: The new PCM must be programmed. Refer to
13 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 14
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
14 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
15 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2368 Engine Controls - 6.5L______________ Engine

DTC P0121 APP Sensorl Circuit Performance

11 Powertrain
APP 3 APP 1 APP 2 1 Control
5 Volt 5 Volt 5 Volt
R e fe re n c e
5Vb"
R e fe re n c e
I Module /PCM1
L._______ _ ________ __ R_
e fe re n c e
____________ __ _ _ J
s --------
D3 D12 'C1 C2' C3

YEL/BLK 1275 WHT/BLK 1164 TAN 1274

4 4 4

PCM
C l = 3 2 BRN
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 = 2 4 BRN
C 3 = 3 2 BLU
E„ G. D,
4 4 * Accelerator
Pedal Position
(APP) Module

K' f J '' F' A' r C' ' B'

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

N
\ r ---------> ^----------^ r
t
---------------------■> r ----------------------- \
' ^---------^ /*

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

D4 .... PA C1 B2, C2 C5, .Cl A12 C2

n Powertrain
APP 3 Sensor APPt Sensor APP 2 Sensor
S ig n al G ro u n d S ignal G ro u n d S ignal G ro u n d 1 Control A
1 Module (PCM)
L ______________________________________________________J

185076

Circuit Description • The difference between the APP 1 sensor and

The Accelerator Pedal Position (APP) module the APP 3 sensor is greater than 0.50 volts
provides a voltage signal that changes relative to (PCM compares pre-scaled voltage (internal
accelerator pedal position. There are three sensors to PCM)).
located within the APP module that are scaled • There are no in range faults for the
differently. APP 2 sensor or the APP 3 sensor (PCM
checks for high and low voltage faults).
Conditions for Setting the DTC • All of the diagnostic set conditions met for
• The PCM performs this DTC diagnostic 2 seconds.
continuously.
• The ignition voltage is greater than 6.4 volts.
Action Taken When the DTC Sets
• The engine speed is greater than 300 RPM. • The Service Throttle Soon lamp will not
illuminate when one APP DTC sets. The PCM
• The difference between the APP 1 sensor and will only illuminate the Service Throttle Soon
the APP 2 sensor is greater than 0.23 volts lamp when multiple APP DTCs set.
(PCM compares pre-scaled voltage (internal
• The PCM records the operating conditions at
to PCM)).
the time the diagnostic fails. This information
stores in the Failure Records.
Engine
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• The use of a Scan tool
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulation
• Broken wire inside the insulation
A scan tool reads APP 1 position in volts. It should
read about 0.45 to 0.95 volt with throttle closed and
ignition ON or at idle. Voltage should increase at a
Engine Controls - 6.5L 6-2369
steady rate as throttle is moved toward Wide Open
Throttle (WOT). Also, 90% pedal travel is acceptable
for correct APP operation. Scan APP 1 sensor while
depressing accelerator pedal with engine stopped
and ignition ON. Display should vary from about
0.74 volt when throttle was closed to over about
3.7 volts when throttle is held at Wide Open Throttle
(WOT) position. The following chart will check
voltages on all APP circuits to see if they fall in
normal ranges. The PCM compares pre-scaled
voltages (these are voltages that the scan tool
cannot read). The scan tool reads only output
voltages.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. This step determines if there is a good 5 volt
reference.
5. This step will check for an open in the ground
circuit.

DTC P0121 APP Sensorl Circuit 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe APP voltages on 0.45-0.95 V
2 the scan tool. 4.0-4.5 V
Are APP voltages at specified values (values listed are 3.6-4.1 V
APP 1, APP 2, and APP 3 respectively)? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Turn the ignition ON leaving the engine OFF.
3. With J 39200 connected to ground, probe APP
4 sensor 5 volt reference circuits at APP harness 4.75 V
terminals G, D, and E.
Is the voltage greater than or equal to the specified value
on all circuits? Go to Step 5 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to B+, probe APP sensor
5 ground circuits at the APP sensor harness terminals —
A, B, and J.
Is Test light ON (all circuits)? Go to Step 9 Go to Step 8
6-2370 Engine Controls - 6.5L________________________________________________ Engine
DTC P0121 APP Sensorl Circuit Performance (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 11 Go to Step 7
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 11 Go to Step 10
1. Turn the ignition OFF.
2. Disconnect the PCM and check for an open sensor
8 ground circuit to the PCM. —
3. If problem is found, repair as necessary.
Was APP sensor ground circuit open? Go to Step 11 Go to Step 10
Replace the APP module. Refer to APP Module
9 Replacement. — —
Is the action complete? Go to Step 11
Replace the PCM.
Important: The new PCM must be programmed. Refer to —
10 —
PCM Replacement/Programming.
Is the action complete? Go to Step 11
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
11 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 12 Go to Step 2
Does the Scan tool display any additional Go to the
12 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2371

DTC P0122 APP Sensorl Circuit Low Voltage

” 1 Powertrain
APP 3 APP1 APP 2 I Control A
5 V o lt 5 Volt
5 Volt
5Vo" I Module (PCM)
R e fe re n c e
--------------
R e fe re n c e
—J
R e fe re n c e

D3' D12" C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274

4 4 4
4
PCM
C l = 3 2 BRN
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 -2 4 B R N
C 3 - 3 2 BLU
______ E, G. ____________ d
Accelerator
Pedal Position
(APP) Module

K' ' J' F' K C' ' B' ✓

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

fr ----------5 ' ---------- r ----------5 r ---------- -5 ^----------5 J

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

D4 . . . . P A C1 B2, P2 C5. kC1 A12, C2

APP 3 Sensor APP1 ‘1 Powertrain
Sensor APP2 Sensor
S ig n a l G ro u n d Signal 1 Control
G ro u n d Signal G ro u n d
I
L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _____________ _ ____ _____ J Module (PCM)

185076

Circuit Description Action Taken When the DTC Sets

The Accelerator Pedal Position (APP) module • The Service Throttle Soon lamp will not
provides a voltage signal that changes relative to illuminate when one APP DTC sets. The PCM
accelerator pedal position. There are three sensors will only illuminate the Service Throttle Soon
located within the APP module that are scaled lamp when multiple APP DTCs set.
differently. • The PCM records the operating conditions at
the time the diagnostic fails. This information
Conditions for Setting the DTC will store in the Failure Records.
• The PCM performs this DTC diagnostic
Conditions for Clearing the MIL/DTC
continuously.
• A History DTC will clear when forty consecutive
• The voltage on the APP 1 sensor is less than warm-up cycles that the diagnostic does not
0.25 volts. fail (coolant temperature has risen 5 * C (40 * F)
• All of the diagnostic set conditions met for from start up coolant temperature and engine
2 seconds. coolant temperature exceeds 71 *C (160‘ F))
that same ignition cycle.
• Use of a Scan tool
6-2372 Engine Controls - 6.5L
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
A scan tool reads APP 1 position in volts. Should
read about 0.45 to 0.95 volt with throttle closed and
ignition ON or at idle. Voltage should increase at a
steady rate as throttle is moved toward Wide Open
Throttle (WOT). Also, 90% pedal travel is acceptable
for correct APP operation. Scan APP sensor while
depressing accelerator pedal with engine stopped
Engine
and ignition ON. Display should vary from about
0.74 volt when throttle is closed to about 3.7 volts
when throttle is held at Wide Open Throttle (WOT)
position. A DTC P0122 will result if the signal or
reference circuit are open.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0122 is the result of a
hard failure or an intermittent condition.
4. This step checks the PCM and wiring.

DTC P0122 APP Sensorl Circuit Low 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 1 voltage
2 on the Scan Tool. 0.25 V
Is the APP 1 voltage less than or equal to the
specified value? Go to Step 4 Go to Step 3
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) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Jumper the APP 1 signal circuit and the 5 volt
reference circuit together at the APP sensor harness
4 connector.
4.75 V

3. Observe the APP 1 voltage on the Scan Tool.

Is the APP 1 voltage greater than the specified value? Go to Step 10 Go to Step 5
1. Connect a test light between B+ and the APP 1
sensor signal circuit at the APP sensor harness
5 connector. 4.75 V
2. Observe the APP 1 voltage on the Scan Tool.
Is the APP 1 voltage greater than the specified value? Go to Step 6 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 12 Go to Step 7
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace the terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
Engine________________________________________________ Engine Controls - 6.5L 6-2373
DTC P0122 APP Sensorl Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the APP 1 signal
circuit for an open, short to ground.
8 —
3. If the APP 1 sensor signal circuit is open or shorted
to ground, repair it as necessary.
Was the APP 1 signal circuit open or shorted to ground? Go to Step 13 Go to Step 9
Check the APP 1 sensor signal circuit for a proper
9 connection at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
Check for a proper electrical connection at the APP
10 —
module and repair if necessary. Was a problem found? Go to Step 13 Go to Step 11
Replace the APP module. Refer to APP Module
11 Replacement. — —
Is the action complete? Go to Step 13
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
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
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2374 Engine Controls - 6.5L Engine

DTC P0123 App Sensorl Circuit High Voltage

“ n Powertrain
APP 3 APP1 APP 2 I Control A
5 V o lt 5 Volt
5Volt
5 Volt
I Module (PCM)
, ---------
Reference Reference _ J
Reference
□
D3 D12 'C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274

4 4

PCM
C1 = 3 2 B R N
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 = 2 4 BRN
C 3 = 3 2 BLU
E G, s Di
Accelerator
Pedal Position
(APP) Module

K' ' J' F' ' A' C' ' B'

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

\v ---------; ?■---------- ^ r --------- ^----------^ ^---------^

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

__

.... PA C1
O |
CM I

w i!

D4, B2, A12.

r “ “
1

APP 3 Sensor APP1 Sensor APP2 Sensor ■* Powertrain

Signal G ro u n d Signal G ro u n d Signal G ro u n d * Control A
1 Module (PCM)
L ___________________________________________________________________________________________-I

185076

Circuit Description Action Taken When the DTC Sets

The Accelerator Pedal Position (APP) module
provides a voltage signal that changes relative to
accelerator pedal position. There are three sensors
located within the APP module that are scaled
differently.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The voltage on the APP 1 sensor is greater
than 4.75 volts.
• All of the diagnostic set conditions met for
2 seconds.
• The Service Throttle Soon lamp will not
illuminate when one APP DTC sets. The PCM
will only illuminate the Service Throttle Soon
lamp when multiple APP DTCs set.
• The PCM records the operating conditions at
the time the diagnostic fails. This information
will store in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• Use of a Scan tool
Engine
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
An intermittent may be caused by the following:
A scan tool reads APP 1 position in volts. Should
read about 0.45 to 0.95 volt with throttle closed and
ignition ON or at idle. Voltage should increase at a
steady rate as throttle is moved toward Wide Open
Throttle (WOT). Also, 90% pedal travel is acceptable
for correct 0 APP operation. Scan APP 1 sensor
while depressing accelerator pedal with engine
___________ Engine Controls - 6.5L 6-2375
stopped and ignition ON. Display should vary from
about 0.74 volt when throttle was closed to about
3.7 volt when throttle is held at Wide Open Throttle
(WOT) position. A P0123 will result if the ground
circuit is open or the signal circuit is shorted to
voltage.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if DTC P0123 is the result
of a hard failure or an intermittent condition.
3. This step checks the PCM and wiring.

DTC P0123 App Sensorl 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 1 display
2 4.75 V
on the scan tool.
Is the APP 1 above the specified value? Go to Step 4 Go to Step 3
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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
4 2. Observe the APP 1 display on the scan tool. 0.25 V
Is the APP 1 less than the specified value? Go to Step 5 Go to Step 6
Probe the APP 1 sensor ground circuit at the APP sensor
5 harness connector with a test light connected to B+. —
Is the test light ON? Go to Step 7 Go to Step 8
1. Check for a short to voltage on the APP 1 sensor
signal circuit.
6 2. If the APP 1 sensor signal circuit is shorted, repair it —
as necessary.
Was the APP 1 sensor signal circuit shorted? Go to Step 11 Go to Step 10
Check for proper electrical connections at the APP sensor
7 and replace the terminals if necessary. —
Did any terminals require replacement? Go to Step 11 Go to Step 9
1. Check for an open sensor ground circuit.
8 2. If a problem is found, repair it as necessary. —
Was the APP 1 sensor ground circuit open? Go to Step 11 Go to Step 10
Replace the APP module. Refer to APP Module
9 Replacement. — —
Is the action complete? Go to Step 11
Replace the PCM.
Important: The new PCM must be programmed. Refer to
10 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 11
6-2376 Engine Controls - 6.5L________________________________________________ Engine
DTC P0123 App Sensorl Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
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
11 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 12 Go to Step 2
Does the Scan tool display any additional Go to the
12 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine______________________________________ Engine Controls - 6.5L 6-2377

DTC P0126 Insufficient ECT for Stable Operation

PCM
C1 = 3 2 B R N
C 2 = 2 4 BRN
C 3 = 3 2 BLU

185072

Circuit Description
While the engine is warming, the PCM monitors the
ECT sensor to determine how long it takes the
engine to reach the coolant temperature required for
Closed Loop operation. DTC P0126 will set if the
PCM determines that the engine does not reach
Closed Loop temperature in a specified amount of
time. This test will not run if either the intake air or
engine coolant temperature is too low at start up.
The PCM will only run this DTC on a cold start and
only once per cold start.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic once
per ignition cycle until a pass or fail condition
exists.
• The engine operation time is greater than
600 seconds.
. The DTCs P0112, P0113, P0117 and P0118 are
not set.
• The engine coolant is less than 5 6 ‘ C (133‘ F).
• The intake air temperature is greater than
-7*C (20 T ).
• The fuel burned since start up is greater than
1,000,000 cu. mm.
• The total idle time since start up is less than
450 seconds.
• The engine operation time is greater than
300 seconds.
• The DTCs P0112, P0113, P0117 and P0118 are
not set.
• The engine coolant temperature is less than
5 6 'C (133-F).
• The intake air temperature is greater than
-7 ‘ C (20-F).
6-2378 Engine Controls - 6.5L
• The fuel burned since start up is greater than
468,120 cu. mm.
• The total idle time since start up is less than
225 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL OFF after three
consecutive drive trips that the diagnostic runs
and does not fail.
• A last test failed (Current DTC) will clear when
the ignition is cycled and the diagnostic runs
and does not fail.
• A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other emission related diagnostic.
• PCM battery voltage is interrupted.
• Using a Scan tool.
Diagnostic Aids
• Using Freeze Frame and/or Failure Records
data may aid in locating an intermittent
condition. If the DTC cannot be duplicated, the
information included in the Freeze Frame and/or
Failure Records data can be useful in
determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also
be used to determine how many ignition cycles
the diagnostic reported a pass and/or a fail.
Operate vehicle within the same freeze frame
conditions (RPM, load, vehicle speed,
temperature etc.) that were noted. This will
isolate when the DTC failed.
DTC P0126 Insufficient ECT for Stable Operation
Step Action
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for
reference, as the Scan tool loses data when using the
1 Clear Info function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Are any engine coolant temperature DTCs set?
2 —
Engine
• If other DTCs are set that share the same
ground and/or 5.0 volt reference circuit, check
for faulty connections and for faulty wiring.
• If the engine has been allowed to sit overnight,
the engine coolant temperature and intake air
temperature values should display within a few
degrees of each other.
• If the engine coolant temperature exceeds
60° C (140‘ F), this indicates that the engine is
capable of reaching the proper temperature, but
not necessarily in the correct amount of time.
This diagnostic table must be repeated on a
cold engine, engine coolant and intake air
temperature less than 50* C (122*F) and within
3 *C (5 * F) of each other, and the time required
to reach the temperature threshold must be
measured. When starting a cold engine,
measure the amount of time it takes the engine
to reach the specified temperature. The engine
should reach the specified temperature within 8
minutes. If the specified temperature is not
reached within 7 minutes, check the following:
• Coolant level.
• Thermostat operation.
• Cooling fan.
• Refer to Engine Cooling for additional
information.
Test Description
Number(s) below refer to step numbers on the
diagnostic table.
2. An ECT failure could cause a DTC P0126 to
set, so correct any ECT DTCs that are set.
6. If it is obvious that the engine is not reaching
full operating temperature, for example the
radiator hoses never gets very warm, or there
is a complaint of little or no heat from the
heater, this step could be skipped.
Value(s) Yes No
—
Go to
Powertrain OBD
Go to Step 2 System Check
Go to applicable
DTC table Go to Step 3
Engine________________________________________________ Engine Controls - 6.5L 6-2379
DTC P0126 Insufficient ECT for Stable Operation (cont’d)
Step Action Value(s) Yes No
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
Go to DTC P0117
3 3. Disconnect the ECT sensor. -3 5 ‘ C (-31 *F) ECT Sensor
Does the scan tool indicate the ECT sensor is at a Circuit Low
temperature colder than the specified value? Go to Step 4 Voltage
Using a jumper wire, jumper terminals at the ECT sensor Go to DTC P0118
harness connector together. ECT Sensor
4 150*C (302 *F)
Does the scan tool indicate the ECT is at a temperature Circuit High
greater than the specified value? Go to Step 5 Voltage
1. Reconnect the ECT sensor.
2. Start and idle the engine.
3. With the engine idling, observe the ECT sensor
display on the Engine 1 Data List of the scan tool.
Important: Allow time for the engine to warm up if it has
5 not already reached the specified temperature. 7 minutes 60 *C (140 *F)
is the maximum amount of time it should take to reach
this temperature from a cold start. Less time should be
System must be
necessary if the engine is already warm.
rechecked on a
Does the scan tool indicate the engine coolant temperature cold start. Refer
has reached the specified value? to Diagnostic Aids Go to Step 6
Using a DMM J 39200, measure the resistance of the
ECT sensor. Refer to Temperature vs Resistance.
6 —
Is the ECT resistance close to the value indicated in the
Temperature Vs Resistance Table? Go to Step 7 Go to Step 8
For an engine cooling system problem, check for the
following conditions:
• Thermostat operation
• Coolant level
7 — —
• Coolant to water ratio
• Cooling fan operation etc.
Refer to Engine Cooling.
Is the action complete? Go to Step 9
Replace the ECT sensor. Refer to ECT Sensor
8 Replacement. — —
Is the action complete? Go to Step 9
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
9 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 10 Go to Step 2
Does the Scan tool display any additional Go to the
10 undiagnosed DTCs? — applicable
DTC table System OK
6-2380 Engine Controls - 6.5L Engine

DTC P0182 Fuel Temperature Sensor CKT Low Voltage

n Powertrain
i Fuel
1Control
. 5 Volt T e m p e ra tu re
• R e fe re n c e B S ig n al I Module
J (PCM)
D14 C8 C1

GRY 474 YEL 1578

A
J O B D Ilk

PCM
C l = 32 BRN
C 2 = 2 4 BRN
C3=32B LU

GRY 474 YEL 1578

A E
5 Vo lt T
Optical/
R e fe re n c e B Fuel
Pum p CAM H ig h ? Temperature
Sensor R esolution Sensor f Sensor
S ig n a l S ig n a l G ro u n d I

/
B lr c ir d ir f i
BRN/WHT 633 CRN 1799
PNK/
BLK 632
PNK/BLK 632
-------- .------1>

PNK/BLK 632
> f >* ______ >f

BRN/WHT 633 ORN 1799 PNK/BLK 632

A4 >* ---------- ------------------
A24 kC2 D9 C1
• Pum p CAM H igh
.
Sensor .
Powertrain
Sensor R esolution G. ro u n d C o n tro l
I S ig n a l S ig n a l I Module ^
u ------------------------------------------------------ J {pCM) la A

185024

Circuit Description Action Taken When the DTC Sets

The fuel temperature sensor is a thermistor that • The PCM illuminates the Malfunction Indicator
controls signal voltage to the PCM. When the fuel is Lamp (MIL) on the second consecutive drive
cold, the sensor resistance is high, therefore the trip that the diagnostic runs and fails.
PCM will see high signal voltage. As fuel warms, • The PCM records the operating conditions at
sensor resistance becomes less and voltage drops.
the time the diagnostic fails. The first time the
The fuel temperature sensor is integrated with the
diagnostic fails, the Failure Records will store
optical sensor.
this information. If the diagnostic reports a
Conditions for Setting the DTC failure on the second consecutive drive trip, the
• The PCM performs this DTC diagnostic Freeze Frame records the operating conditions
continuously. at the time of failure and updates the Failure
Records.
• The fuel temperature is greater than or equal
to 102‘ C (215*F).
• All of the diagnostic set conditions met for
2 seconds.
Engine Engine Controls - 6.5L 6-2381

C onditions for C learing the M IL/DTC Test Description

• The PCM will turn the MIL off after three Number(s) below refer to the step number(s) on the
consecutive trips without a fault condition. Diagnostic Table.
• A History DTC will clear when forty consecutive 2. This step determines if DTC P0182 is a hard
warm-up cycles that the diagnostic does not failure or an intermittent condition.
fail (coolant temperature has risen 5 * C (40 * F) 3. This test will determine if signal circuit is
from start up coolant temperature and engine shorted to ground.
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
A scan tool reads fuel temperature in degrees
centigrade.
An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulaton
• Broken wire inside the insulation

DTC P0182 Fuel Tem perature Sensor CKT Low 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start the engine.
2 102’ C (215* F)
3. Monitor the Fuel Temp display on scan tool.
Is the Fuel Temp greater than the specified value? Go to Step 3 Go to Step 5
1. Turn the engine OFF.
2. Turn the ignition ON leaving the engine OFF.
3 3. Disconnect the Optical/Fuel Temperature sensor 17’ C ( 63*F)
connector.
Is the Fuel Temp less than or equal to the
specified value? Go to Step 7 Go to Step 4
1. Turn the ignition OFF.
4 2. Using the J 39200, measure the resistance across
Infinite
the Fuel Temperature sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored, Go to the
5 refer to the applicable DTC table(s) first. —
Applicable Go to
Are additional DTC(s) stored? DTC Table Diagnostic Aids
Repair the short to ground in the Fuel Temp signal circuit.
6 — —
Is the action complete? Go to Step 9
Replace the fuel injection pump. Refer to Fuel Injection
Pump Replacement
7 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 9
6-2382 Engine Controls - 6.5L________________________________________________ Engine
OTC P0182 Fuel Tem perature Sensor CKT Low Voltage (cont’d)
Step Action Value(s) Yes No
Replace the PCM.
Important: The new PCM must be programmed. Refer to
8 — —
PCM Reptacement/Programming.
Is the action complete? Go to Step 9
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
9 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 10 Go to Step 2
Does the Scan tool display any additional Go to the
10 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine____________________________________________ Engine Controls - 6.5L 6-2383
DTC P0183 Fuel Temperature Sensor CKT High Voltage

Powertrain
Fuel
5Volt Temperature • Control
I ReferenceB Signal I Module ^
L _ —_ —- J (PCM) la A
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ReferenceB Fuel
PumpCAM High < Temperature
Sensor Resolution Sensor [ Sensor
Signal Signal Ground I
✓
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BRN/WHT 633 CRN 1799
PNK/
BLK 632
PNK/BLK 632
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Sensor Resolution Ground Control
I Signal Signal I Module A
c ------------------------------------------------------J (PCM) ia A

185024

C ircuit Description A ction Taken W hen the DTC Sets

The fuel temperature sensor is a thermistor that
controls signal voltage to the PCM. When the fuel is
cold, the sensor resistance is high, therefore the
PCM will see high signal voltage. As fuel warms,
sensor resistance becomes less and voltage drops.
The fuel temperature sensor is integrated with the
optical sensor.
C onditions fo r S etting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine operation time is greater than
8 minutes.
• The fuel temperature is less than or equal to
18’ C (64*F).
• All of the diagnostic set conditions met for
2 seconds.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2384 Engine Controls ■ 6.5L Engine
Conditions for Clearing the MIL7DTC 4. This test will determine if signal circuit is
• The PCM will turn the MIL off after three open. There should be 5 volts at sensor
consecutive trips without a fault condition. connector if measured with J 39200. This will
determine if there is a wiring problem or a
• A History DTC will clear when forty consecutive
malfunctioning PCM.
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40 * F) 9. This step determines if there is a short to
from start up coolant temperature and engine voltage on the signal circuit. A short to voltage
coolant temperature exceeds 71 'C (16CTF)) increases current flow through the sensor which
that same ignition cycle. overwhelms the sensor. This doesn’t allow the
• Use of a Scan Tool senosr to pull-down the circuit to the correct
voltage and thus displaying the correct
Diagnostic Aids temperature.
A scan tool reads fuel temperature in degrees 10. After repairing the short to voltage, check the
centigrade. sensor for proper operation.
An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulaton
• Broken wire inside the insulation
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if DTC P0183 is a hard
failure or an intermittent condition.
3. This test simulates a DTC P0182. If the PCM
recognizes the low signal voltage (high temp)
the PCM and wiring are OK.

DTC P0183 Fuel Temperature Sensor CKT 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan Tool.
2. Start and idle the engine.
2 3. Monitor the Fuel Temp display on the Scan Tool. 18-C (64’ F)
Is the Fuel Temp less than or equal to the
specified value? Go to Step 3 Go to Step 5
1. Turn the engine OFF.
2. Turn the ignition ON.
3. Disconnect the Optical/Fuel Temperature sensor
connector.
3 105 X (221 *F)
4. Jumper the Fuel Temperature harness terminals
together.
Does the Scan Tool display fuel temperature greater than
the specified value? Go to Step 6 Go to Step 4
Jumper the Fuel Temperature sensor signal circuit to a
known good ground.
4 105-C (221 *F)
Does the Scan Tool display a Fuel Temp greater than the
specified value? Go to Step 7 Go to Step 8
Engine________________________________________________ Engine Controls - 6.5L 6-2385
DTC P0183 Fuel Temperature Sensor CKT High Voltage (cont’d)
Step Action Value(s) Yes No
DTC is intermittent. If no other DTC(s) are stored, refer to
Diagnostic Aids. If additional DTCs are stored, refer to Go to the
5 those table(s) first. —
Applicable Go to
Are any other DTCs stored? DTC Table Diagnostic Aids
1. Inspect the sensor connector for a proper
connection.
6 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 12
1. Check the Fuel Temperature sensor ground circuit
for an open between the Fuel Temp sensor and
the PCM.
7 —
2. If a problem is found, repair the problem as
necessary.
Was a problem found? Go to Step 14 Go to Step 11
1. Check the Fuel Sensor signal circuit for an open
between the Fuel Temp sensor and the PCM.
8 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 14 Go to Step 11
With a J 39200 set to the mA scale, measure the current
9 at the IAT harness connector terminals. 50 mA
Is the current less than the specified value? Go to Step 12 Go to Step 10
Repair the short to voltage on the IAT signal circuit.
10 — —
Is the action complete? Go to Step 14
Inspect the PCM connectors for proper connections and
11 replace the terminals, if necessary. —
Was a problem found? Go to Step 14 Go to Step 13
Replace the injection pump. Refer to Fuel Injection Pump
Replacement
12 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 14
Replace the PCM.
Important: The new PCM must be programmed. Refer to
13 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 14
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
14 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
15 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2386 Engine Controls - 6.5L
DTC P0215 Engine Shutoff Control Circuit
Circuit Description
The injection pump fuel supply line has a solenoid
controlled shutoff located in the injection pump.
When the solenoid is energized (key in the run
position), the valve is open and fuel is supplied to
the injection pump. By providing a ground path, the
PCM energizes the solenoid.
Conditions for Setting the DTC
• The PCM requested the ESO ON.
• The control circuit voltage at the PCM is
greater than 8 volts.
• All of the diagnostic set conditions met for
2 seconds.
or
Engine
185026
• The PCM requested the ESO OFF.
• The control circuit voltage at the PCM is less
than 8 volts.
• All of the diagnostic set conditions met for
2 seconds.
Action Taken When the DTC Sets
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
will store in the Failure Records.
Engine Engine Controls - 6.5L 6-2387
Conditions for Clearing the MIL/DTC Test Description
• A History DTC will clear when forty consecutive Number(s) below refer to the step number(s) on the
warm-up cycles that the diagnostic does not Diagnostic Table.
fail (coolant temperature has risen 5 ’ C (40’ F) 3. This step will check the ESO control circuit for
from start up coolant temperature and engine
an open.
coolant temperature exceeds 71 ’ C (160*F))
that same ignition cycle. 10. After repairing the circuit for a short to voltage,
• Use of a Scan tool check the solenoid for proper operation.

Diagnostic Aids
An open in the control circuit or the ignition feed
circuit will cause a P0215. Also a no start condition
will exist. The Scan Tool has the ability to turn the
engine shutoff solenoid ON and OFF. This can be
used as a quick operational check.

DTC P0215 Engine Shutoff Control Circuit

Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool to
save freeze frame and failure records for reference, as the
1 scan tool loses data when using the Clear Info function. — Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect the ESO harness electrical connector.
3. Ignition ON, engine OFF.
2 4. With a test light connected to chassis ground, probe —
the ESO ignition feed circuit at the engine harness
connector.
Is the test light ON? Go to Step 3 Go to Step 6
1. Turn the ignition OFF.
2. With a test light, jumper the ESO engine harness
3 terminals together. —

3. Turn the ignition ON leaving the engine OFF.

Is the test light ON? Go to Step 4 Go to Step 7
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to B+, probe the ESO
control circuit.
4 —
3. With the scan tool, command the ESO solenoid ON
and OFF.
Does the test light turn ON and OFF with each command? Go to Step 5 Go to Step 8
Check the ESO harness for a proper connection and
5 replace the terminals if necessary. —
Did any terminal require replacement? Go to Step 13 Go to Step 9
1. Check the ESO ignition feed circuit for.
• An open wire
6 • An open fuse — —
2. Repair the problem as necessary.
Is the action complete? Go to Step 13
6-2388 Engine Controls - 6.5L Engine
DTC P0215 Engine Shutoff Control Circuit (cont’d)
Step Action Value(s) Yes No
1. Check the ESO control circuit for the following
conditions:
• An open wire
7 • Proper connection at the PCM —
2. If an ESO control circuit problem was found, repair it
as necessary.
Was a repair performed? Go to Step 13 Go to Step 12
Repair the short to ground on the ESO control circuit.
8 — —
Is the action complete? Go to Step 13
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to ground, probe the
9 —
ESO control circuit at the ESO harness connector.
Is the test light ON? Go to Step 10 Go to Step 11
Repair the short to voltage on the ESO control circuit.
10 — —
Is the action complete? Go to Step 13
Replace the injection pump. Refer to Fuel Injection Pump
Replacement.
11 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 13
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
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
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2389

DTC P0216 Injection Timing Control Circuit

Ignition
S te p p e r
Timing
M otor
Stepper (ITS)
Coil
1 0 Coil
2
Motor
A
J Q B P IIL

PCM

\f \✓ \/ N✓ C l = 3 2 BRN

D A B c C 2 = 2 4 BRN
C3=32B LU

RED/BLK 1031 ORN/BLK 1032

TAN/BLK 1030 YEL/BLK 1033

>
* ............ ■? ..................5v ............. '

RED/BLK 1031 ORN/BLK 1032

TAN/BLK 1030 YEL/BLK 1033

A7 ....... Aft A9 .......... A10, kC2

, ITS ITS IT S ITS
1 Powertrain
1 Coil 1 Coil 1 C o il 2 coil 2 1 Control
I H igh L ow Low nigh I Module £
I _ _ \ (PCM)

185028

Circuit Description Action Taken When the DTC Sets

Timing of the combustion event is accomplished by
delivering a pulse of fuel into the combustion
chamber at a desired degree of cylinder travel. This
desired degree (desired timing), defines the current
position of the cylinder in relationship of Top Dead
Center. This test compares desired timing to
measured timing when certain conditions have been
met. To retard injection timing the PCM extends the
Stepper motor. To advance injection timing the PCM
retracts the Stepper motor. This is a type B DTC.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
. DTCs P0251, P0335 and P0370 not set.
• The Engine speed has not changed more than
56 RPM for 5 seconds.
• A 5 degree difference between Act. Inj. Time
and Des. Inj. Time
• All of the diagnostic set conditions met for
2 seconds.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear after forty consecutive
warm-up cycles when no failures are reported.
• The PCM battery voltage is interrupted.
• Use the scan tool in order to clear
the MIL/DTC.
6-2390 Engine Controls - 6.5L Engine

Diagnostic Aids 5. This step checks for an open or short in the

An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulation
• Broken wire inside the insulation
A hard start and possible poor performance condition
might exist. Act. Inj. Time will freeze at the point of
the fault. Its possible DTC P0216 will set if injection
timing is not set correctly. Refer to Injection Timing
Adjustment for correct procedure.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if DTC P0216 is a hard
failure or an intermittent.
4. This step checks for an open or short in the
injection timing coil circuit 1.
injection timing coil circuit 2.
6. The important thing in this step is that the PCM
is sending a varying voltage (voltage may vary
between 1 and 12 (usually you will see voltage
vary between 5 and 6 when engine is idling)),
this will indicate that the PCM is OK and that
there is a problem with the injection timing
Stepper motor. If there is a steady voltage
present on any circuit, this will indicate a
problem with the PCM or a circuit shorted to
voltage.

DTC P0216 Injection Timing 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Run the engine to operating temperature.
2. Using a Scan Tool, compare the injection timing at
idle and at 1500 RPM. 5*
2
Does the scan tool display a difference greater than or
equal to the specified value between Actual Inj Time and
Desired Inj Time at idle or at 2700 RPM? Go to Step 4 Go to Step 3
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) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the PCM.
4 3. Measure the resistance between coil 1 low and 10 - 60 G
coil 1 high at the PCM harness.
Is the resistance within the specified value? Go to Step 5 Go to Step 9
Measure the resistance between coil 2 low and
5 coil 2 high at the PCM harness. 10 - 60 Q
Is the resistance within the specified value? Go to Step 6 Go to Step 10
1. Reconnect the PCM.
2. Disconnect the Injection Timing Stepper motor.
3. Start and idle the engine.
6 4. Using the scan tool, command the Time Set ON. —
5. With a J 39200 connected to ground, check for a
varying voltage on all terminals at the injection timing
stepper motor electrical harness.
Does the voltage vary on all circuits? Go to Step 7 Go to Step 12
Engine________________________________________________ Engine Controls - 6.5L 6-2391
DTC P0216 Injection Timing Control Circuit (cont’d)
Step Action Value(s) Yes No
1. Disconnect the crankshaft position sensor.
2. Measure the resistance between the crankshaft
7 position sensor signal and the 5 volt reference circuit 950 -1050 Q
at the sensor pigtail.
Is the resistance within the specified value? Go to Step 8 Go to Step 13
1. Reconnect all the sensors.
2. Check for one of the following:
• Injection timing set correctly. Refer to Injection
Timing Adjustment.
8 • Sheared camshaft driven key. Refer to Engine —
Mechanical.
3. If a problem is found, repair the problem as
necessary.
Was a repair performed? Go to Step 17 Go to Step 15
1. Turn the ignition OFF.
2. Disconnect the Stepper motor and check for an open
or short in one of the following:
• Coil 1 low circuit
9 —
• Coil 1 high circuit
• If a problem is found, repair the problem as
necessary.
Was a repair performed? Go to Step 17 Go to Step 11
1. Turn the ignition OFF.
2. Disconnect the Stepper motor and check for an open
or short in one of the following:
• Coil 2 low circuit
10 —
• Coil 2 high circuit
• If a problem is found, repair the problem as
necessary.
Was a repair performed? Go to Step 17 Go to Step 11
Check for a proper electrical connection at the injection
11 timing stepper motor. —
Did any terminals require replacement? Go to Step 17 Go to Step 15
Check the non-varying circuit for a short to ground, short
12 to voltage, or a proper connection at the PCM. —
Was a repair performed? Go to Step 17 Go to Step 16
1. Check the crankshaft sensor pigtail for a short to
ground.
13 2. If the circuit is shorted to ground, repair the circuit as —
necessary.
Was a repair performed? Go to Step 17 Go to Step 14
Replace the crankshaft position sensor. Refer to
Crankshaft Position Sensor Replacement. After replacing
14 the sensor, the PCM must be programmed with a new — —
offset. Refer to TDC Offset Adjustment.
Is the action complete? Go to Step 17
Replace the injection pump. Refer to Fuel Injection Pump
Replacement.
15 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 17
6-2392 Engine Controls ■ 6.5L________________________________________________ Engine
DTC P0216 Injection Timing Control Circuit (cont’d)
Step Action Value(s) Yes No
Replace the PCM.
Important: The new PCM must be programmed. Refer to — —
16
PCM Replacement/Programming.
Is the action complete? Go to Step 17
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
17 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 18 Go to Step 2
Does the Scan tool display any additional Go to the
18 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________________ Engine Controls - 6.5L 6-2393

DTC P0219 Engine Overspeed Condition

| Hot In Run And Start l

A
iQ B O I I L

PC M
= 3 2 BRN
= 2 4 BRN
= 3 2 BLU

Engine Engine Fuel Fuel C lo s u re

■" Powertrain
C losu re
ShutOff ShutOff Injection Injection S ignal Ground 1Control
I Solenoid Solenoid Control Control
| Control Control
1 Module ^
\ (PCM) £

185026

Circuit Description Conditions for Clearing the MIL/DTC

The PCM has the ability to put the vehicle in a
ESO controlled idle if an engine overspeed condition
has been detected.
Conditions for Setting the DTC
An RPM drop with 5 ESO cycles.
Action Taken When the DTC Sets
• ESO controlled idle (the PCM will control RPM
by turning the ESO ON and OFF. RPM will
fluctuate from 800 to 1200 when DTC is set).
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
will store in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 "C (160” F))
that same ignition cycle.
• Use of a Scan tool.
Diagnostic Aids
This DTC will not set if an external fuel source is
causing an overspeed condition. A DTC P1216 will
set along with DTC P0219.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. The injection pump is being replaced in
this step.
6-2394 Engine Controls - 6.5L_______________________________________________ Engine
DTC P0219 Engine Overspeed Condition
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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the fuel injection pump. Refer to Fuel Injection
Pump Replacement.
2 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 3
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
3 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________ Engine Controls - 6.5L 6-2395

DTC P0220 APP Sensor2 Circuit

” Powertrain
APP3 APP1 APP2 I Control ^
5Volt 5Volt 5Volt
5Volt I Module (PCM)
Reference Reference Reference
_ j
f --------------
D3' D12" 'C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274

4 * 4 4
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 Cl =32 BRN
C2-24BRN
E„ G- k -- bJ Accelerator
Pedal Position
C3=32BLU

(APP) Module

K' ' J' F' K C' ' B' ✓

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

\ j . ---------> J-----------^ r --------- r ----------> * ---------^ J

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

____
O/

CD
CM

D4 . . . . “ L C2 C5. kC1 A12^ C2

\

APP3 Sensor APP1 Sensor APP2 Sensor 1 Powertrain

Signal Ground S ignal Ground Signal Ground 1 Control A
L ----------------------------------------------------------------------------------------- J 1 Module (PCM)

185076

Circuit Description Action Taken When the DTC Sets

The Accelerator Pedal Position (APP) module • The PCM will turn ON the Service Throttle
provides a voltage signal that changes relative to Soon lamp and limit power.
accelerator pedal position. There are three sensors • The PCM records the operating conditions at
located within the APP module that are scaled the time the diagnostic fails. This information
differently. will store in the Failure Records.
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
• The PCM performs this DTC diagnostic • A History DTC will clear when forty consecutive
continuously. warm-up cycles that the diagnostic does not
• The 5 reference voltage on the APP 2 sensor fail (coolant temperature has risen 5 ’ C (40' F)
is less than 4.8 volts. from start up coolant temperature and engine
• All of the diagnostic set conditions met for coolant temperature exceeds 71 'C (160'F))
2 seconds. that same ignition cycle.
• Use of a Scan tool
6-2396 Engine Controls - 6.5L Engine

Diagnostic Aids Test Description

The most likely cause of this DTC is loose Number(s) below refer to the step number(s) on the
connectors or terminals. All 5 volt reference circuits Diagnostic Table.
must be checked for proper reference voltage. Volt 2. This step will determine if there is a good
meter accuracy is important. voltage reference.

DTC P0220 APP Sensor2 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Disconnect the APP sensor electrical connector.
2. Turn the ignition ON leaving the engine OFF.
2 3. With J 39200 connected to ground, check all the 4.8 V
APP 5 volt reference circuits at the APP harness
connector.
Is the voltage less than the specified value? Go to Step 4 Go to Step 3
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) first. —
Applicable Go to
Are additional DTC(s) stored? DTC Table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for a short to ground.
4 —
3. If the 5 volt reference circuit is shorted to ground,
repair it as necessary.
Was the 5 volt reference circuit shorted to ground? Go to Step 6 Go to Step 5
Replace the PCM.
Important: The new PCM must be programmed. Refer to
5 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Does the Scan tool display any additional Go to the
7 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine___________________________________ Engine Controls - 6.5L 6-2397

DTC P0221 APP Sensor2 Circuit Performance

” “ n Powertrain
APP 3 APP 1 app I Control
2 £
5 Volt 5 Volt
R e fe re n c e R e fe re n c e I'S e n J M<*Me (PCM)
D3' D12 C1 C2' C3

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

josQiik
4 4 4
4
PCM
C l = 3 2 BRN
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 = 2A BR N
C 3 = 3 2 BLU
E, G. k D,
Accelerator
Pedal Position
(APP) Module

K' ' J' F' A' C' B' ✓

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

>
\ 5----------; v----------> ^--------- tr ------------------- n
>^---------^ *t

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

___ ^

D4j
CM

C1 B2, ,C1 A12. C2

W
N

APP 3 Sensor APP 1 Sensor APP 2 Sensor n Powertrain

S ig n a l G ro u n d Signal G ro u n d S ig n a l G ro u n d 1 Control £
L ------------------------------------------------------------------------------------------------------------------------------------------ ------------------------------------------------ --------------J
1 Module (PCM) M

185076

Circuit Description • No in range faults for APP 1 or APP 3 (PCM

The Accelerator Pedal Position (APP) module checks for high and low voltage faults).
provides a voltage signal that changes relative to • All of the diagnostic set conditions met for
accelerator position. There are three sensors located 2 seconds.
within the APP module that are scaled differently.
Action Taken When the DTC Sets
Conditions for Setting the DTC • The input from APP 2 sensor is ignored.
• The PCM performs this DTC diagnostic • This DTC will not turn on the Service Throttle
continuously. Soon lamp by itself.
• The ignition voltage is greater than 6.4 volts. • Throttle will operate normally as long as there
• Engine speed is greater than 300 RPM. is only one malfunction present. If there are two
• The difference between APP 2 and APP 1 is APP malfunctions present, the PCM will then
greater than 0.23 volts (PCM compares turn ON the Service Throttle Soon lamp and
pre-scaled voltage (internal to PCM)). limit power. If a third APP malfunction is
present, the Service Throttle Soon lamp will
• The difference between APP 2 and APP 3 is be ON and will only allow the engine to operate
greater than 0.50 volts (PCM compares at idle.
pre-scaled voltage (internal to PCM)).
6-2398 Engine Controls - 6.5L Engine

Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 'C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulation
• Broken wire inside the insulation
A scan tool reads APP 2 position in volts and should
read about 4.5 volts with throttle closed and ignition
ON or at idle. Voltage should decrease at a steady
rate as throttle is moved toward WOT. Also, 90%
pedal travel is acceptable for correct APP operation.
Scan APP 2 sensor while depressing accelerator
pedal with engine stopped and ignition ON. Display
should vary from about 4.5 volts when throttle was
closed to about 1.5 volts when throttle is held at
Wide Open Throttle (WOT) position.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. This step determines if there is a good 5 volt
reference.
5. This step will check for an open in the ground
circuit.

DTC P0221 APP Sensor2 Circuit 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe APP voltages on 0.45-0.95 V
2 the scan tool. 4.0-4.5 V
Are the APP voltages at the specified values (values are 3.6-4.0 V
listed as APP 1, APP 2, and APP 3 respectively)? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Turn the ignition ON leaving the engine OFF.
3. With a J 39200 connected to ground, probe APP
4 sensor 5 volt reference circuits at APP harness 4.75 V
terminals G, D, and E.
Is voltage greater than or equal to the specified value on
all circuits? Go to Step 5 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to B+, probe the APP
5 sensor ground circuits at the APP sensor harness —
terminals A, B, and J.
Is the test light ON (all circuits)? Go to Step 9 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 11 Go to Step 7
Engine Engine Controls - 6.5L 6-2399
DTC P0221 APP Sensor2 Circuit Performance (cont’d)
Step Action Value(s) Yes No
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 11 Go to Step 10
1. Turn the ignition OFF.
2. Disconnect the PCM and check for an open sensor
8 ground circuit to the PCM. —
3. If problem is found, repair as necessary.
Was APP sensor ground circuit open? Go to Step 11 Go to Step 10
Replace the APP module. Refer to APP Module
9 Replacement. — —
Is the action complete? Go to Step 11
Replace the PCM.
Important: The new PCM must be programmed. Refer to
10 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 11
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
11 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 12 Go to Step 2
Does the Scan tool display any additional Go to the
12 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2400 Engine Controls - 6.5L Engine

DTC P0222 APP Sensor2 Circuit Low Voltage

” Powertrain
APP 3 APP1 APP 2 I Control A
5 Volt 5 Volt 5
sVvonolt I Module (PCM)
R e fe re n c e R e fe re n c e R e fe re n c e
L ------------------------ --------------------------------------------- ------ _ _
"V. -------------------------------------- ------ ---- J
D3 D12TC1 C2 C3

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 io e m ik .

4 . j
4
PCM
C l = 3 2 BRN
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 - 2 4 BRN
C 3 = 3 2 BU J
E, . ______ G, D,
Accelerator
Pedal Position
(APP) Module

K' J' F' A' C' ' B'

/
DKGRN 1163 DKBLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

Nfr ---------^ ' ----------^ r ---------^ ' ----------; ---------^ J

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

□4, . ___PA C1 B2, C2 C5 ,C1 A12 kC2

"l Powertrain
APP3 APP1 APP2
Signal Ground Signal Ground Signal Ground
Sensor S e nsor Sensor
1 Control
I Module (PCM)
L ______________________________________________________________________________________________________________________________________J

185076

Circuit Description • The throttle will operate normally as long as

The Accelerator Pedal Position (APP) module there is only one sensor malfunction present. If
provides a voltage signal that changes relative to two different APP sensors have a malfunction,
accelerator pedal position. There are three sensors the Service Throttle Soon lamp will light and
located within the APP module that are scaled the PCM will limit power. If three APP sensors
differently. have a malfunction present, the Service Throttle
Soon lamp will light and the PCM will only
Conditions for Setting the DTC allow the engine to operate at idle.
• The PCM performs this DTC diagnostic
continuously. Conditions for Clearing the MIL7DTC
• The reference voltage on the APP 2 sensor is • A History DTC will clear when forty consecutive
less than 0.25 volts. warm-up cycles that the diagnostic does not
• All of the diagnostic set conditions met for fail (coolant temperature has risen 5 * C (40 ’ F)
2 seconds. from start up coolant temperature and engine
coolant temperature exceeds 71 mC (160‘ F))
Action Taken When the DTC Sets that same ignition cycle.
• The input from APP 2 sensor is ignored. • Use of a Scan tool
• This DTC will not turn on the Service Throttle
Soon lamp by itself.
Engine
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
A scan tool reads APP 2 position in volts and should
read about 4.5 volts with throttle closed and ignition
ON or at idle. Voltage should decrease at a steady
rate as throttle is moved toward WOT. Also, 90%
pedal travel is acceptable for correct APP operation.
Scan APP 2 sensor while depressing accelerator
___________ Engine Controls - 6.5L 6-2401
pedal with engine stopped and ignition ON. Display
should vary from about 4.5 volts when throttle was
closed to about 1.5 volts when throttle is held at
Wide Open Throttle (WOT) position.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0222 is the result of a
hard failure or an intermittent condition.
3. This step checks the PCM and wiring.

DTC P0222 APP Sensor2 C ircuit Low 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 2 voltage
2 on the Scan tool. 0.25 V
Is the APP 2 voltage less than or equal to the
specified value? Go to Step 4 Go to Step 3
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) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Use the J 39200 in order to probe the APP 2, 5 volt
4 5V
reference circuit at APP harness.
Is the APP 2 voltage greater than the specified value? Go to Step 5 Go to Step 6
Use the J 39200 in order to probe APP 2 sensor signal
5 circuit at the APP sensor harness. 5V
Is the APP 2 voltage greater than the specified value? Go to Step 10 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 13 Go to Step 7
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace the terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the APP 2 signal
circuit for an open, or a short to ground.
8 —
3. If the APP 2 sensor signal circuit is open or shorted
to ground, repair it as necessary.
Was the APP 2 signal circuit open or shorted to ground? Go to Step 13 Go to Step 9
Check the APP 2 sensor signal circuit for a proper
9 connection at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
6-2402 Engine Controls - 6.5L________________________________________________ Engine
DTC P0222 APP Sensor2 C ircuit Low Voltage (co n t’d)
Step Action Value(s) Yes No
Check for a proper electrical connection at the
10 APP sensor. —
Was a repair performed? Go to Step 13 Go to Step 11
Replace the APP module. Refer to APP Module
11 Replacement. — —
Is the action complete? Go to Step 13
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine____________________________________
DTC P0223 APP Sensor2 Circuit High Voltage
C ircu it D escription
The Accelerator Pedal Position (APP) module
provides a voltage signal that changes relative to
accelerator pedal position. There are three sensors
located within the APP module that are scaled
differently.
C onditions fo r Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The signal voltage on the APP 2 sensor is
greater than 4.8 volts.
• All of the diagnostic set conditions met for
2 seconds.
Engine Controls - 6.5L 6-2403
185076
Action Taken W hen the DTC Sets
• The input from APP 2 sensor is ignored.
• This DTC will not turn on the Service Throttle
Soon lamp by itself.
• The throttle will operate normally as long as
there is only one sensor malfunction present. If
two different APP sensors have a malfunction,
the Service Throttle Soon lamp will light and
the PCM will limit power. If three APP sensors
have a malfunction present, the Service Throttle
Soon lamp will light and the PCM will only
allow the engine to operate at idle.
6-2404 Engine Controls - 6.5L Engine

C onditions fo r C learing the MIL7DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 "C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
D iagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
A Scan tool reads APP 2 position in volts and
should read about 4.5 volts with throttle closed and
ignition ON or at idle. Voltage should decrease at a
steady rate as throttle Is moved toward WOT. Also,
90% pedal travel is acceptable for correct APP
operation. Scan APP 2 signal while depressing
accelerator pedal with engine stopped and ignition
ON. Display should vary from about 4.5 volts when
throttle was closed to about 1.5 volts when throttle is
held at Wide Open Throttle (WOT) position. Its
possible P1125 will set along with P0223 if the signal
circuit is open.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0223 is a hard failure
or an intermittent condition.
5. This step will check for an open in the ground
circuit.

DTC P0223 APP Sensor2 C ircuit 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 2 display
2 4.75 V
on the scan tool.
Is APP 2 greater than or equal to the specified value? Go to Step 4 Go to Step 3
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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor harness connector.
2. Probe the APP 2 sensor ground circuit at the APP
4 sensor harness connector with a test light connected —
to B+.
Is the test light ON? Go to Step 5 Go to Step 7
Use a fused jumper wire in order to jump the APP 2
signal circuit to the APP 2 ground circuit at the APP
5 harness connector. 0.25 V
Does the scan tool display the APP 2 voltage less than
the specified value. Go to Step 8 Go to Step 6
1. Check for an open on the APP 2 sensor signal
circuit.
6 2. If the APP 2 sensor signal circuit is open, repair it —
as necessary.
Was the APP 2 sensor signal circuit open? Go to Step 13 Go to Step 12
1. Check for an open sensor ground circuit.
7 2. If a problem is found, repair it as necessary. —
Was the APP 2 sensor ground circuit open? Go to Step 13 Go to Step 12
Engine________________________________________________ Engine Controls - 6.5L 6-2405
DTC P0223 APP Sensor2 C ircuit High Voltage (co n t’d)
Step Action Value(s) Yes No
1. Verify the ignition is ON with the engine OFF.
2. Verify the APP harness is still disconnected from the
APP module.
8 —
3. With a J 39200 connected to ground, check for
voltage on the APP 2 signal circuit.
Is voltage present on the circuit? Go to Step 9 Go to Step 10
Repair the short to voltage on the APP 2 signal circuit.
9 — —
Is the action complete? Go to Step 13
Check for a proper electrical connection at the
10 APP sensor. —
Was the repair performed? Go to Step 13 Go to Step 11
Replace the APP module. Refer to APP Module
11 Replacement. — —

Is the action complete? Go to Step 13

Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
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
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2406 Engine Controls - 6.5L Engine

DTC P0225 APP Sensor3 Circuit

1 Powertrain
APP3 APP1 APP2 1 Control A
5Volt 5Volt 5 Volt
Reference Reference Reference I Module (PCM)
5Volt
_ J
D3 D12 'C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

iOBDIIL
4 4 4
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C1=32 BRN
C2=24BRN
C3=32BLU
E, G, D.
Accelerator
Pedal Position
(APP) Module

K' ' J' F' A' C' ' B' ✓

DKGRN 1163 DKBLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

>sj.---------; r ---------- -> 5----------> J----------- ^ f.---------;

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

D4; v___PA Cl B2 B1 C2 C5 ( C1 A12. C2

APP3 Sensor APP1 Sensor APP2 Sensor '1 Powertrain
Signal G ro u n d Signal G ro u n d Signal G ro u n d 1 Control jk
1 Module (PCM) i a A
L_ ___ __________ ______ _—__ _ _ _ _ _
185076

C ircu it D escription C onditions fo r Clearing the M IL/DTC

The Accelerator Pedal Position (APP) module • A History DTC will clear when forty consecutive
provides a voltage signal that changes relative to warm-up cycles that the diagnostic does not
accelerator pedal position. There are three sensors fail (coolant temperature has risen 5 * C (40 * F)
located within the APP module that are scaled from start up coolant temperature and engine
differently. coolant temperature exceeds 71 'C (160*F) that
same ignition cycle.
C onditions fo r S etting the DTC
• Use of a Scan tool
• The PCM performs this DTC diagnostic
continuously. D iagnostic Aids
• The reference voltage on the APP 3 sensor is An intermittent may be caused by the following:
less than 4.8 volts. • Poor connections
• All of the diagnostic set conditions met for • Rubbed through wire insulation
2 seconds.
• Broken wire inside the insulation
A ction Taken W hen th e DTC Sets All 5 volt reference circuits must be checked for
• The PCM will turn ON the Service Throttle proper reference voltage. Voltmeter accuracy is
Soon lamp and limit power. important.
• Multiple DTCs will be present.
Engine Engine Controls ■ 6.5L 6-2407
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will check all 5 volt reference circuits.

DTC P0225 APP Sensor3 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Disconnect the APP sensor electrical connector.
2. Turn the ignition ON leaving the engine OFF.
2 3. With a J 39200 connected to ground, check all’the 4.8 V
APP 5 volt reference circuits at the APP harness
connector.
Is the voltage less than the specified value? Go to Step 5 Go to Step 3
Are any other APP DTCs set? Go to the
3 — Applicable
DTC Table 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
4 refer to the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for a short to ground.
5 —
3. If the 5 volt reference circuit is shorted to ground,
repair it as necessary.
Was the 5 volt reference circuit shorted to ground? Go to Step 7 Go to Step 6
Replace the PCM.
Important: The new PCM must be programmed. Refer to
6 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 7
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
7 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 8 Go to Step 2
Does the Scan tool display any additional Go to the
8 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2408 Engine Controls - 6.5L Engine

DTC P0226 APP Sensor3 Circuit Performance

— 1 Powertrain
APP3 APP1 APP2 • Control ^
5Volt 5Volt 5Volt
5Volt
Reference Reference Reference I Module (PCM)
f -----
D3 D12 'C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

> *
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 Cl =32 BRN
C2=24 BRN
C3=32 BLU
E, G. k D„
Accelerator
Pedal Position
(APP) Module

K' ' J' F' A' C' ' B' /

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

>
\ ' ---------^ 5----------- > J----------
' ----------; j.---------; /*

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

____
O/

oo
CM

D4j PA C2 C5, kC1 A12, C2

\

APP3 Sensor APP1 Sensor APP2 Sensor *' Powertrain

Signal G ro u n d Signal Ground Signal Ground 1 Control
I Module (PCM) A x A
_____ ___ _______ ___ _______ ___ ___ ___ ___ _______ ___ _____________________________________ ___ ___ ___ _ _ i

185076
Circuit Description • No in range faults for APP 1 or APP 2 (PCM
The Accelerator Pedal Position (APP) module checks for high and low voltage faults).
provides a voltage signal that changes relative to • All diagnostic conditions met for 2 seconds.
accelerator pedal position. There are three sensors
located within the APP module that are scaled
Action Taken When the DTC Sets
differently. • The input from APP 2 sensor is ignored.
• This DTC will not turn on the Service Throttle
Conditions for Setting the DTC Soon lamp by itself.
• The PCM performs this DTC diagnostic • Throttle will operate normally as long as there
continuously. is only one malfunction present. If there are two
• The ignition voltage is greater than 6.4 volts. APP malfunctions present, the PCM will then
• The engine speed is greater than 300 RPM. turn ON the Service Throttle Soon lamp and
• The difference between APP 3 and APP 1 is limit power. If a third APP malfunction is
present, the Service Throttle Soon lamp will be
greater than 0.23 volts (PCM compares
pre-scaled voltage (internal to PCM)). ON and will only allow the engine to operate
at idle.
• The difference between APP 3 and APP 2 is
greater than 0.50 volts (PCM compares
pre-scaled voltage (internal to PCM)).
Engine
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160' F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
An intermittent may be caused by the following:
• Poor connections
• Rubbed through wire insulation
• Broken wire inside the insulation
___________ Engine Controls - 6.5L 6-2409
A scan tool reads APP 3 position in volts. Should
read about 4.0 volts with throttle closed and ignition
ON or at idle. Voltage should decrease at a steady
rate as throttle is moved toward Wide Open Throttle
(WOT). Also, 90% pedal travel is acceptable for
correct APP operation. Scan APP 3 sensor while
depressing accelerator pedal with engine stopped
and ignition ON. Display should vary from about
4.0 volts when throttle was closed to about 2.0 volts
when throttle is held at Wide Open Throttle (WOT)
position.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if there is a good
reference voltage.

DTC P0226 APP Sensor3 Circuit 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP voltages 0.45-0.95 V
2 on the Scan tool. 4.0-4.5 V
Are the APP voltages at the specified values (values are 3.6-4.0 V
listed as APP 1, APP 2, and APP 3 respectively)? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Turn the ignition ON leaving the engine OFF.
3. With a J 39200 connected to ground, probe the
4 APP sensor 5 volt reference circuits at the 4.75 V
APP harness terminals G, D, and E.
Is the voltage greater than or equal to the specified value
on all circuits? Go to Step 5 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to B+, probe the
5 APP sensor ground circuits at the APP sensor —
harness terminals A, B, and J.
Is the test light ON (all circuits)? Go to Step 9 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 11 Go to Step 7
6-2410 Engine Controls ■ 6.5L Engine
DTC P0226 APP Sensor3 Circuit Performance (cont’d)
Step Action Value(s) Yes No
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 11 Go to Step 10
1. Turn the ignition OFF.
2. Disconnect the PCM and check for an open sensor
8 ground circuit to the PCM. —
3. If problem is found, repair as necessary.
Was APP sensor ground circuit open? Go to Step 11 Go to Step 10
Replace the APP module. Refer to APP Module
9 Replacement. — —
Is the action complete? Go to Step 11
Replace the PCM.
Important: The new PCM must be programmed. Refer to
10 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 11
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
11 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 12 Go to Step 2
Does the Scan tool display any additional Go to the
12 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine___________________________________ Engine Controls - 6.5L 6-2411
DTC P0227 APP Sensor3 Circuit Low Voltage

” n Powertrain
APP 3 APP1 APP 2 I Control A
Reference Reference Reference
5 Volt 5 V o lt 5 Volt
5Volt I Module (PCM1 in A
f
D3 D12 'C1 C2'

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

j 4 4
PCM
C l = 3 2 BRN
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 = 2 4 BRN
C 3 = 3 2 BLU
E, G. k D,
Accelerator
Pedal Position
(APP) Module

K' ' A' C' ' /

J" F' B'

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

>
\ f.---------^ j.---------- ^ 'r---------> Y---------- -v ^---------^ y

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

D4, P A C1 B2. C2 C5 ,C1 A12. C2

Sensor Sensor Sensor n Powertrain
Signal Ground Signal Ground Signal Ground
APP 3 APP1 APP 2
* Control
I
L ------------------------------------------------------------------------------------------J Module (PCM)

185076

Circuit Description • The throttle will operate normally as long as

The Accelerator Pedal Position (APP) module
provides a voltage signal that changes relative to
accelerator pedal position. There are three sensors
located within the APP module that are scaled
differently.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The signal voltage on the APP 3 sensor is less
than 0.25 volts.
• All diagnostic conditions met for 2 seconds.
Action Taken When the DTC Sets
• The input from APP 3 sensor is ignored.
• This DTC will not turn on the Service Throttle
Soon lamp by itself.
there is only one malfunction present. If two
different APP sensors have a malfunction, the
Service Throttle Soon lamp will light and the
PCM will limit power. If three APP sensors have
a malfunction present, the Service Throttle
Soon lamp will light and the PCM will only
allow the engine to operate at idle.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40" F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ’ C (160’ F) that
same ignition cycle.
• Use of a Scan tool
6-2412 Engine Controls - 6.5L Engine

Diagnostic Aids
There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
A scan tool reads APP 3 position in volts. Should
read about 4.0 volts with throttle closed and ignition
ON or at idle. Voltage should decrease at a steady
rate as throttle is moved toward Wide Open Throttle
(WOT). Also, 90% pedal travel is acceptable for
correct APP operation. Scan APP 3 sensor while
depressing accelerator pedal with engine stopped
and ignition ON. Display should vary from about
4.0 volts when throttle was closed to about 2.0 volts
when throttle is held at Wide Open Throttle (WOT)
position.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will determine if DTC P0227 is the
result of a hard failure or an intermittent
condition.
3. This step checks the PCM and wiring.

DTC P0227 APP Sensor3 Circuit Low 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 3 voltage
2 on the Scan tool. 0.25 V
Is the APP 3 voltage less than or equal to the
specified value? Go to Step 4 Go to Step 3
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) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor electrical connector.
2. Use the J 39200 in order to probe the APP 3, 5 volt
4 5V
reference circuit at the APP harness.
Is the voltage at the specified value? Go to Step 5 Go to Step 6
Use J 39200 in order to probe the APP 3 signal circuit at
5 the APP harness. 5V
Is the voltage at the specified value? Go to Step 10 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
6 3. If the 5 volt reference circuit is open or shorted to —
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? Go to Step 13 Go to Step 7
Check the 5 volt reference circuit for a proper connection
7 at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the APP 3 signal
circuit for an open, short to ground.
8 —
3. If the APP 3 sensor signal circuit is open or shorted
to ground, repair it as necessary.
Was the APP 3 signal circuit open or shorted to ground? Go to Step 13 Go to Step 9
Engine________________________________________________ Engine Controls - 6.5L 6-2413
DTC P0227 APP Sensor3 Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Check the APP 3 sensor signal circuit for a proper
9 connection at the PCM and replace terminal if necessary. —
Did the terminal require replacement? Go to Step 13 Go to Step 12
Check for a proper electrical connection at the
10 APP sensor. —
Was a repair performed? Go to Step 13 Go to Step 11
Replace the APP module. Refer to APP Module
11 Replacement. — —
Is the action complete? Go to Step 13
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2414 Engine Controls - 6.5L Engine

DTC P0228 APP Sensor3 Circuit High Voltage

"* Powertrain
APP 3 APP 1 APP 2 I Control
5 Volt 5 Volt 5 Volt
R e fe re n c e R e fe re n c e
5Volt
R e fe re n c e
I Module (PCM1 / bA
-------------------------_ — -------------------------— — — J
D3 f ---- D12 C1 C2 'C3

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

i o e o i ik

y y
j
PCM
C1 = 3 2 BR N
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C 2 = 2 4 BRN
C 3 = 3 2 BLU
E, G ,V D,
> /V y Accelerator
Pedal Position
(APP) Module

K' J' F' A' C' B' /

DKGRN 1163 DKBLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

V
\ ---------^ r ---------- > r ---------> r ---------- ^ ^---------^ /*

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

D4 . . . . D6 C1 B2 C2 C5 ^C1 A12y C2
APP 3 Sensor APP1 S e n so r APP 2 Sensor
n Powertrain
S ig n a l G ro u n d Signal G ro u n d S ig n al G ro u n d * Control A
1 Module (PCM)
_______________________________________________________ -I

185076

Circuit Description Action Taken When the DTC Sets

The Accelerator Pedal Position (APP) module • The input from APP 3 sensor is ignored.
provides a voltage signal that changes relative to • This DTC will not turn on the Service Throttle
accelerator pedal position. There are three sensors Soon lamp by itself.
located within the APP module that are scaled
• The throttle will operate normally as long as
differently.
there is only one malfunction present. If two
Conditions for Setting the DTC different APP sensors have a malfunction, the
Service Throttle Soon lamp will light and the
• The PCM performs this DTC diagnostic
PCM will limit power. If three APP sensors have
continuously.
a malfunction present, the Service Throttle
• The signal voltage on the APP 3 sensor is Soon lamp will light and the PCM will only
greater than 4.75 volts. allow the engine to operate at idle.
• All diagnostic conditions met for 2 seconds.
Engine
Conditions for Clearing the MIL7DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
___________ Engine Controls - 6.5L 6-2415
rate as throttle is moved toward Wide Open Throttle
(WOT). Also, 90% pedal travel is acceptable for
correct APP operation. Scan APP 3 sensor while
depressing accelerator pedal with engine stopped
and ignition ON. Display should vary from about
4.0 volts when throttle was closed to about 2.0 volts
when throttle is held at Wide Open Throttle (WOT)
position.

Diagnostic Aids Test Description

There are no driveability issues associated with the
APP module unless a DTC is present. The most
likely causes of this DTC are poor connections or
the sensor itself. The least likely is a PCM problem.
A scan tool reads APP 3 position in volts. Should
read about 4.0 volts with throttle closed and ignition
ON or at idle. Voltage should decrease at a steady
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0223 is a hard failure
or an intermittent condition.
5. This step will check for an open in the ground
circuit.

DTC P0228 APP Sensor3 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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. With the throttle closed, observe the APP 3 display
2 4.75 V
on the scan tool.
Is APP 3 greater than or equal to the specified value? Go to Step 4 Go to Step 3
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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the APP sensor harness connector.
2. Probe the APP 3 sensor ground circuit at the
4 APP sensor harness connector with a test light —
connected to B+.
Is the test light ON? Go to Step 5 Go to Step 7
Use a fused jumper wire in order to jump the APP 3
signal circuit to the APP 3 ground circuit at the
5 APP harness connector. 0.25 V
Does the scan tool display the APP 3 voltage less than
the specified value? Go to Step 8 Go to Step 6
1. Check for an open on the APP 3 sensor signal
circuit.
6 2. If the APP 3 sensor signal circuit is open, repair it —
as necessary.
Was the APP 3 sensor signal circuit open? Go to Step 13 Go to Step 12
1. Check for an open sensor ground circuit.
7 2. If a problem is found, repair it as necessary. —
Was the APP 3 sensor ground circuit open? Go to Step 13 Go to Step 12
6-2416 Engine Controls - 6.5L Engine
DTC P0228 APP Sensor3 Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Verify the ignition is ON with the engine OFF.
2. Verify the APP harness is still disconnected from the
APP module.
8 —
3. With a J 39200 connected to ground, check for
voltage on the APP 3 signal circuit.
Is voltage present on the circuit? Go to Step 9 Go to Step 10
Repair the short to voltage on the APP 3 signal circuit.
9 — —
Is the action complete? Go to Step 13
Check for a proper electrical connection at the
10 APP sensor. —
Was the repair performed? Go to Step 13 Go to Step 11
Replace the APP module. Refer to APP Module
11 Replacement. — —

Is the action complete? Go to Step 13

Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
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
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2417
DTC P0231 Fuel Pump Feedback Circuit Low Voltage
Refer to PCM, Fuel Pump, Lift Pump. Conditions for Clearing the MIL/DTC
Circuit Description • The PCM will turn the MIL off after three
consecutive trips without a fault condition.
The status of the lift pump is monitored by the PCM.
This signal is also used to store a DTC if the fuel • A History DTC will clear when forty consecutive
pump relay is defective or fuel pump voltage is lost warm-up cycles that the diagnostic does not
while the engine is running. There should be about fail (coolant temperature has risen 5 *C (40 * F)
12 volts on circuit 120 during glow plug cycle. from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160‘ F) that
Conditions for Setting the DTC same ignition cycle.
• The PCM performs this DTC diagnostic • Use of a Scan Tool
continuously.
• The fuel lift pump is commanded ON. Diagnostic Aids
• The difference between ignition voltage and fuel This DTC will not check the fuel pump operation.
pump voltage is geater than 4 volts.
• All diagnostic conditions met for 2 seconds. Test Description
Number(s) below refer to the step number(s) on the
Action Taken When the DTC Sets
Diagnostic Table.
• The PCM illuminates the Malfunction Indicator
3. This step checks the fuel lift pump circuit.
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.

DTC P0231 Fuel Pump Feedback Circuit Low 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Turn the ignition ON.
2 —
3. With the scan tool, command the fuel pump ON. Go to
Does the scan tool indicate the fuel pump is operating? Diagnostic Aids Go to Step 3
1. Turn the ignition OFF.
2. With a J 39200 connected to ground, backprobe the
fuel lift pump signal circuit at the PCM.
3 B+
3. Probe the fuel pump test terminal with a fused
jumper to B+.
Is the voltage at the specified value? Go to Step 8 Go to Step 4
1. Remove the fuel pump relay.
2. Verify the J 39200 is still connected.
4 3. From underneath the U/H relay center, probe the A3 B+
terminal with a fused jumper to B+.
Is the voltage at the specified value? Go to Step 5 Go to Step 6
6-2418 Engine Controls - 6.5L________________________________________________ Engine
DTC P0231 Fuel Pump Feedback Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Check for a proper connection at the fuel pump relay
center.
5 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 18 Go to Step 17
1. Check for an open or short to ground on the fuel
pump signal circuit.
6 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 18 Go to Step 7
1. Check for proper connections at the PCM and at the
relay center.
7 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 18 Go to Step 15
1. Remove the fuel pump relay.
2. Turn the ignition ON.
3. Connect a test light to ground. —
8
4. Probe the fuel pump relay harness connector
terminal B1.
Is the test light ON? Go to Step 10 Go to Step 9
Repair the open in the battery feed circuit to the fuel
9 pump relay. — —
Is the action complete? Go to Step 18
Connect a test light between terminal number B1 and
terminal number A1 of the fuel pump relay harness
10 connector. —

Is the test light ON? Go to Step 12 Go to Step 11

Repair the open fuel pump relay ground circuit.
11 — —
Is the action complete? Go to Step 18
1. Turn the ignition OFF.
2. Connect a test light between terminal number B3 of
the fuel pump relay harness connector and ground.
12 3. Monitor the test light. —
4. Turn the ignition ON.
Does the test light come ON during the glow plug cycle
and then go OFF after the glow plug cycle is complete? Go to Step 16 Go to Step 13
Check for an open or short to ground in the circuit from
the fuel pump relay harness connector terminal number B3
13 and PCM. —

Was a problem found? Go to Step 14 Go to Step 15

Repair the open or short to ground in the fuel pump relay
14 control circuit. — —
Is the action complete? Go to Step 18
Replace the PCM.
Important: The new PCM must be programmed. Refer to
15 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 18
Check for proper connections at the fuel pump relay
16 connector. —
Was a problem found? Go to Step 18 Go to Step 17
Engine________________________________________________ Engine Controls - 6.5L 6-2419
DTC P0231 Fuel Pump Feedback Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Replace the fuel pump relay. Refer to Fuel Pump Relay
17 Replacement. — —
Is the action complete? Go to Step 18
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
18 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 19 Go to Step 2
Does the Scan tool display any additional Go to the
19 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2420 Engine Controls ■ 6.5L Engine

DTC P0236 TC Boost System

I 5 V o lt
n Powertrain
ReferenceA 1 Control

PCM
C1=32 BRN
C2=24 BRN
C3=32 BLU

ECTand
IATSensors

EGRControl Pressure/ Sensor Boost 11 Powertrain

BARO Ground Sensor 1 Control >
Sensor Signal Signal 1 Module (PCM)

185023

Circuit Description • The Boost pressure is greater than, less

The PCM operates a solenoid to control boost. This
solenoid is normally open. By providing a ground
path the PCM energizes the solenoid which then
allows vacuum to pass to the wastegate valve.
During normal operation, the PCM compares its
wastegate duty cycle signal with the boost signal and
makes corrections in the duty cycle accordingly.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The engine speed is greater than 2400 RPM.
• The fuel rate is greater than 20 mm.
than, or equal to 20 kPa from desired (internal
to PCM).
• All diagnostic conditions met for 10 seconds,
or
• The engine speed is greater than 1800 but less
than 2400 RPM.
• The fuel rate is greater than 20 mm.
• All diagnostic conditions met for 10 seconds.
Action Taken When the DTC Sets
• A poor performance condition will exists.
• The PCM will reduce maximum fuel.
. The PCM will disable TCC.
Engine
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5°C (40’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160‘ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
A vacuum leak or a pinched vacuum line may cause
a DTC P0236. Check all vacuum lines and
components connected to the hoses for leaks or
sharp bends. Check vacuum source. A possible EGR
DTC will store if there is a problem with the vacuum
source. Also check for proper vacuum line routing.
Engine Controls - 6.5L 6-2421
The turbocharger wastegate actuator uses a pulse
width modulated vacuum solenoid that causes
vacuum to fluctuate under normal conditions. A
steady vacuum reading indicates a restricted or
plugged solenoid vent filter or solenoid vent orfice.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. This will check the wastegate solenoid and
filter. If the filter is plugged, the filter will not
allow the solenoid to vent and this will cause
an overboost condition.
5. This step checks the turbocharger wastegate
actuator for vacuum leaks. The actuator must
hold vacuum.
6. This step will check for vacuum leaks at
the lines.

DTC P0236 TC Boost System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is the DTC P1656 also set? Go to DTC P1656
2
Wastegate
—
Solenoid Control
Circuit Go to Step 3
1. Disconnect the vacuum line at the turbocharger
wastegate actuator.
2. Install a vacuum gage in place of the turbocharger
wastegate actuator.
3 15 in. Hg
3. Start the engine.
4. Observe the vacuum at idle.
Is the vacuum greater than or equal to the specified value
(vacuum will fluctuate)? Go to Step 4 Go to Step 6
1. Disconnect the wastegate solenoid electrical
connector with the engine still running.
4 2. With the vacuum gage still in place, observe the 1 in. Hg
vacuum at idle.
Is the vacuum greater than the specified value? Go to Step 10 Go to Step 5
1. Turn the engine OFF.
2. Connect a hand held vacuum pump to the
5 turbocharger wastegate actuator. —
3. Apply 5 in. Hg of vacuum.
Does the turbocharger wastegate actuator hold vacuum? Go to Step 7 Go to Step 12
1. Check all vacuum lines from the vacuum pump to
the turbocharger wastegate actuator for the following:
• Leaks
6 • Deformities —
• Pinches
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 9
6-2422 Engine Controls - 6.5L________________________________________________ Engine
DTC P0236 TC Boost System (cont’d)
Step Action Value(s) Yes No
1. Verify the engine if OFF.
2. Disconnect all vacuum lines to the wastegate
actuator.
3. Grip the wastegate actuator rod with a pair of pliers.
7 4. Attempt to move the wastegate actuator rod back —
and forth (refer to Engine Mechanical for further
testing).
Does the turbocharger wastegate actuator rod move
freely? Go to Step 8 Go to Step 12
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored, Go to the
8 refer to those table(s). —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check the vacuum pump for proper output (refer to Engine
9 Mechanical). — —
Is the action complete? Go to Step 13
Check for a plugged wastegate solenoid filter. Repair as
10 necessary. —
Is the wastegate solenoid filter plugged? Go to Step 13 Go to Step 11
Replace the wastegate solenoid. Refer to Wastegate
11 Solenoid Replacement. — —
Is the action complete? Go to Step 13
Replace the turbocharger wastegate actuator.
12 — —
Is the action complete? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________________________ Engine Controls - 6.5L 6-2423

DTC P0237 TC Boost Sensor Circuit Low Voltage

ri ...”
5 VOlt '1i Powertrain
^
1 ReferenceA Control
L ------------------ J Module (PCM)

GRY 416 PCM

V Cl =32BRN
C2-24BRN
GRY 416 C3=32 BLU

ECTand
IATSensors

GRY/BLK

C12iC1 B12JIC2 cm ci
EGAControl Pressure/ Sensor Boost " Powertrain
BARO Ground Sensor 1 Control A
Sensor Signal Signal J Module (PCM) l a A

Circuit Description
The PCM operates a solenoid to control boost. This
solenoid is normally open. By providing a ground
path the PCM energizes the solenoid which then
allows vacuum to pass to the wastegate valve.
During normal operation, the PCM compares its
wastegate duty cycle signal with the boost signal and
makes corrections in the duty cycle accordingly.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The Boost Pressure is less than 40 kPa.
• All diagnostic condition met for 2 seconds.
• All diagnostic conditions met for 10 seconds.
185023
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2424 Engine Controls - 6.5L
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 *C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F))
that same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
Very little boost can be attained by revving the
engine in neutral. If the Boost sensor signal circuit is
open or shorted to ground, Boost solenoid will show
a zero duty cycle.
An intermittent may be caused by the following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Engine
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will determine if DTC P0237 is the
result of a hard failure or an intermittent
condition.
3. This step simulates conditions for a DTC
P0237. If the PCM recognizes the change, the
PCM and signal circuit are OK.
9. In this step, components that share the 5 volt
reference can cause the reference voltage to
be shorted to ground. This can be checked by
disconnecting each component that shares the
5 volt reference one at a time, including the
PCM while checking for continuity on that circuit
to chassis ground.

DTC P0237 TC Boost Sensor Circuit Low 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) system Powertrain OBD
check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start the engine and let the engine idle.
2 3. Observe the Boost pressure display on the Scan tool 40 kPa
Does the scan tool display a Boost Pressure less than or
equal to the specified value? Go to Step 3 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the Boost sensor electrical connector.
3. Jumper the Boost sensor 5 volt reference to the
3 Boost sensor signal circuit at the harness. 202 kPa
4. Turn the ignition ON.
Does the scan tool display a Boost Pressure greater than
or equal to the specified value? Go to Step 6 Go to Step 4
1. Turn the ignition OFF.
2. The Boost sensor still disconnected.
3. Remove the jumper wire.
4 4. Probe the Boost sensor signal circuit at the harness 202 kPa
with a test light connected to B+.
5. Turn the ignition ON.
Does the scan tool display a Boost Pressure greater than
or equal to the specified value? Go to Step 8 Go to Step 7
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored, Go to the
5 refer to those table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Engine________________________________________________ Engine Controls - 6.5L 6-2425
DTC P0237 TC Boost Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Check for a proper connection at the Boost sensor.
6 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 13 Go to Step 10
1. Check for the following in Boost sensor signal circuit.
• For an open.
7 • For a short to ground. —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 11
1. Check for an open in the Boost sensor 5 volt
reference circuit.
8 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 9
1. Check for a short to ground in the Boost sensor
5 volt reference circuit.
9 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 12
Replace the Boost sensor. Refer to Boost Sensor
10 Replacement. — —
Is the action complete? Go to Step 13
1. Check the terminal connectors at the PCM for a
proper connections.
11 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 12
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2426 Engine Controls - 6.5L_________________ Engine

DTC P0238 TC Boost Sensor Circuit High Voltage

■ 5Volt Powertrain
ReferenceA 1 Control
J Module (PCM)
D13 C1

GRY 416

GRY 416 GRY 416 PCM

j Cl =32 BRN
C2-24BRN
GRY 416 C3=32BLU
CKPSensor GRY
416
GRY 416
C.
Exhaust Gas Boost
Recirculation Pressure
r< ^ (EGR) Control Pressure/ Sensor
Barometric (BARO) B' A
Sensor
| L56Only \ BLK 452

ECTand
IATSensors
BLK 452 LTGRN 432 BLK 452

BLK 452
GRY/BLK 433

BLK 452 BLK 452

CKPSensor TFTSensor
Cell 39
BLK 452 LTGRN 432

C12XC1 B12JIC2 C14JL.C1

EGRControl Pressure/ Sensor Boost " 11 Powertrain
BARO Ground Sensor 1 Control Jk
Sensor Signal Signal J Module (PCM) L A

1B 5023

Circuit Description Action Taken When the DTC Sets

The PCM operates a solenoid to control boost. This
solenoid is normally open. By providing a ground
path the PCM energizes the solenoid which then
allows vacuum to pass to the wastegate valve.
During normal operation, the PCM compares its
wastegate duty cycle signal with the boost signal and
makes corrections in the duty cycle accordingly.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• Engine Speed less than 3506 RPM.
• The Boost Pressure is greater than or equal
(202 kPa).
• All diagnostic set conditions met for 2 seconds.
• The PCM will limit boost pressure.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
. The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160'F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
Very little boost can be attained by revving the
engine in neutral.
An intermittent may be caused by the following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Engine Controls ■ 6.5L 6-2427
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. This step will determine if the PCM is
responding to a low signal voltage. This will
indicate that the PCM is OK.
9. If the scan display is still less than or equal to
9 kPa by disconnecting the PCM the short to
voltage is in the wiring.
10. If the voltmeter value stays the same by
disconnecting the PCM the short to battery
voltage is in the wiring.

DTC P0238 TC Boost 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start the engine and let the engine idle.
2 202 kPa
Does the scan tool display a Boost Pressure greater than
or equal to the specified value? Go to Step 3 Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the Boost sensor electrical connector.
3 3. Turn the ignition ON. 9 kPa
Does the Scan tool display a Boost Pressure less than or
equal to the specified value? Go to Step 5 Go to Step 9
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored, Go to the
4 refer to those table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition ON leaving the engine OFF
2. With a J 39200 connected to ground, probe the
5 5.2V
5 volt reference circuit at the boost sensor harness.
Is the voltage greater than the specified value? Go to Step 10 Go to Step 6
1. Verify the boost sensor is disconnected.
2. Jumper the Boost sensor ground circuit at the
6 —
harness with a test light connected to B+.
Is the test light ON? Go to Step 7 Go to Step 11
1. Check the Boost sensor for a restriction.
7 2. If a problem if found, repair as necessary. —
Was a repair performed? Go to Step 13 Go to Step 8
Replace the Boost sensor. Refer to Boost Sensor
8 Replacement. — —
__________ Is the action complete? Go to Step 13
6-2428 Engine Controls - 6.5L Engine
DTC P0238 TC Boost Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Check for a short to voltage in the Boost sensor
signal circuit.
9 —
2. If a problem is found, repair as necessary.
Was a repair performed? Go to Step 13 Go to Step 12
1. Check for a short to battery voltage in the Boost
sensor 5 volt reference circuit.
10 —
2. If a problem is found, repair as necessary.
Was a repair performed? Go to Step 13 Go to Step 12
Repair the Boost sensor ground circuit.
11 — —
Is the action complete? Go to Step 13
Replace the PCM.
Important: The new PCM must be programmed. Refer to
12 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine______________________________ Engine Controls - 6.5L 6-2429

DTC P0251 Injection Pump Cam System

"* Powertrain
Fuel
5Volt Temperature • Control
■ R e fe re n c e B Signal I Module £
J (PCM) l a A
D14 C8 Cl

GRY 474 YEL 1578

PCM
C1 = 32 BRN
C2=24 BRN
C3=32 BLU

GRY 474 YEL 1578

A E
5Volt Optical/
R e fe re n c e B Fuel
PumpCAM High Temperature
Sensor Resolution Sensor Sensor
Signal Ground
•>i____
/
B 1f t]r d ]r f ]
BRN/WHT 633 ORN 1799
PNK/
BLK 632
PNK/BLK 632
-------- -------1>

PNK/BLK 632
>' _______ > f

BRN/WHT 633 ORN 1799 PNK/BLK 632

A4 > A2 kC2 D9 / k Cl
• PumpCAM High Sensor 11 Powertrain
1 Sensor Resolution Ground 1 Control
Signal Signal 1 Module >
J (PCM) l a A

185024

Circuit Description Action Taken When the DTC Sets

The optical sensor provides a pump cam signal to
the PCM by counting pulses on the sensor disk
located in the injection pump. The pump cam is one
of the most important inputs by the PCM for fuel
control and timing. This test monitors the number of
crankshaft position pulses that have occurred since
the last cam pulse. The physical one to one
correspondence between the pump cam and the
crankshaft implies if more crank pulses are detected
than cam pulses, cam pulses have been missed.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The number of consecutive missing Cam pulse
are greater than or equal to 8.
• All diagnostic set conditions met for 2 seconds.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the first consecutive drive trip
that the diagnostic runs and fails.
• The Freeze Frame records the operating
conditions at the time of failure and updates the
Failure Records.
• The PCM will activate Back Up fuel.
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 'C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan Tool
6-2430 Engine Controls - 6.5L Engine

Diagnostic Aids Test Description

Intermittent DTCs (P0251, P0370 and P1216) may
be caused by air entering the fuel system when fuel
levels get below 1/8 of a tank while performing hard
acceleration or turning maneuvers. Its also possible
that a P0251, P0370 and P1216 will set if vehicle
has run out of fuel. Customer driving habits should
be checked to determine if vehicle has been
performing in these manners. If it has been
determine that the vehicle has been performing in
these conditions, bleed fuel system of all air and test
drive vehicle.
When PCM is in backup fuel, fast idle and poor
performance problems will exist.
An intermittent condition can be caused by the
following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. This step will determine if this is a hard or
intermittent DTC.
5. This step will determine if there is a 5 volt
reference.
7. This step will check to see if the sensor is
sending a signal back to the PCM.
11. The PCM supplies 5 volts on the signal circuit.
This step determines if that voltage is present,
not present, or too much voltage is present.
16. This step determines if the signal circuit is
shorted to 5V. A normal CAM signal circuit will
have 3-5mA. Any reading over 50mA indicates
a short to 5V.

DTC P0251 Injection Pump Cam System

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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is the DTC P0370 set also? Go to DTC P0370
2 — Timing Reference
High Resolution Go to Step 3
1. Start and idle the engine.
2. With the throttle closed, observe the CAM Ref
3 8
Missed display on the scan tool.
Does scan tool display the specified value? Go to Step 5 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
4 refer to the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the Optical/Fuel temperature sensor
electrical connector.
3. Turn the ignition ON leaving the engine OFF. 4.8-5.2V
5
4. Using a J 39200, measure the voltage between the
Optical sensor 5 volt reference circuit at the harness
connector and chassis ground.
Is the voltage within the specified value? Go to Step 6 Go to Step 8
Probe the sensor ground circuit with a test light connected
6 to B+ at the harness connector. —
Is the test light ON? Go to Step 7 Go to Step 9
Engine________________________________________________ Engine Controls - 6.5L 6-2431
DTC P0251 Injection Pump Cam System (cont’d)
Step Action Value(s) Yes No
1. Reconnect the Optical/Fuel temperature sensor
electrical connector.
2. Start and idle the engine.
60 Hz
7 3. With a scan tool, command 900 RPM.
(± 3 Hz)
4. With J 39200 on Hertz (Hz) scale, back probe the
Pump CAM signal circuit at the PCM.
Is the Hertz reading at the specified value? Go to Step 15 Go to Step 11
1. Turn the ignition OFF.
2. Disconnect the PCM and check the Optical sensor
5 volts reference circuit for an open, short to ground,
or short to the sensor ground circuit.
8 —
3. If the Optical sensor 5 volt reference circuit is open
or shorted to ground, repair it as necessary.
Was the Optical sensor 5 volt reference circuit open or
shorted to ground? Go to Step 21 Go to Step 10
1. Check for an open or a proper sensor ground
terminal connection at the PCM.
9 —
2. If a problem is found, repair as necessary.
Was a repair performed? Go to Step 21 Go to Step 20
Check the Optical/Fuel temperature 5 volt reference circuit
for a proper connection at the PCM and replace terminal if
10 necessary. —
Did the terminal require replacement? Go to Step 21 Go to Step 20
1. Turn the ignition ON leaving the engine OFF.
2. Disconnect the Optical/Fuel temperature sensor
electrical connector.
11 4.8-5.2V
3. With a J 39200 connected to ground, probe the CAM
signal circuit.
Is the voltage within the specified value? Go to Step 16 Go to Step 12
12 Is the voltage greater than the specified value? 4.8-5.2V Go to Step 13 Go to Step 14
Repair the short to battery/ignition voltage on the CAM
13 signal circuit. — —
Is the action complete? Go to Step 21
1. Turn the ignition OFF.
2. Check the Cam signal circuit for an open or short to
ground.
14 —
3. If the CAM signal circuit is open or shorted to
ground, repair the circuit as necessary.
Was the CAM signal circuit open or shorted to ground? Go to Step 21 Go to Step 15
Check for a proper connection at the PCM harness
15 terminal and replace the terminal if necessary. —
Did the terminal require replacement? Go to Step 21 Go to Step 20
With a DMM J 39200 set to the mA scale, measure the
current between the CAM signal circuit and the ground
16 circuit at the Optical/Fuel temperature sensor electrical 50mA
connector.
Is the current less than the specified value? Go to Step 18 Go to Step 17
Repair the short to reference voltage on the CAM signal
17 circuit. — —
Is the action complete? Go to Step 21
6-2432 Engine Controls - 6.5L________________________________________________ Engine
DTC P0251 Injection Pump Cam System (cont’d)
Step Action Value(s) Yes No
1. Check for a proper connection at the injection pump.
2. If a problem is found, repair the problem as —
18
necessary.
Was a problem found? Go to Step 21 Go to Step 19
Replace the injection pump. Refer to Fuel Injection Pump
Replacement.
19 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 21
Replace the PCM.
Important: The new PCM must be programmed. Refer to
20 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 21
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
21 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 22 Go to Step 2
Does the Scan tool display any additional Go to the
22 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0263 Cylinder 1 Balance System
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
Conditions for Setting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2433
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 ’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160°F) that
same ignition cycle.
• Use of a Scan tool
6-2434 Engine Controls - 6.5L
Diagnostic Aids
Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
_________________________________ Engine
If multiple cylinder balance DTCs are set and no
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0263 Cylinder 1 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
* Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0266 Cylinder 2 Balance System
CYL # 2 CYL # 4
CYL #1 CYL # 3
Circuit Description
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
Conditions for Setting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6*2435
CYL # 6 CYL # 8
CYL # 5 CYL # 7
29653
Action Taken When the DTC Sets
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160' F) that
same ignition cycle.
• Use of a Scan tool
6-2436 Engine Controls - 6.5L___________ _________________________________ Engine

Diagnostic Aids If multiple cylinder balance DTCs are set and no

Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0266 Cylinder 2 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC tabie(s) first. —
Applicable Go to Diagnostic
Are any additional DTCs stored? DTC Table Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? , Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional undiagnosed Go to the
6 DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0269 Cylinder 3 Balance System
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
Conditions for Clearing the MIUDTC
Conditions for Setting the DTC
• Engine at idle greater than a total of 90
seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2437
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (4 0 ' F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
6-2438 Engine Controls ■ 6.5L _________________________________ Engine

Diagnostic Aids If multiple cylinder balance DTCs are set and no

Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0269 Cylinder 3 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0272 Cylinder 4 Balance System
CYL # 2 CYL # 4
CYL #1 CYL # 3
Circuit Description
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
Conditions for Setting the DTC
• Engine at idle greater than a total of 90
seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2439
CYL # 6 CYL # 8
CYL # 5 CYL # 7
29653
Action Taken When the DTC Sets
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 ’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
6-2440 Engine Controls - 6.5L
Diagnostic Aids
Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
_________________________________ Engine
If multiple cylinder balance DTCs are set and no
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0272 Cylinder 4 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________ Engine Controls - 6.5L 6-2441
DTC P0275 Cylinder 5 Balance System

CYL # 2 CYL # 4 CYL # 6 CYL # 8

-l
—
-

V ------------ ------------------------

CYL #1 CYL # 3 CYL # 5 CYL # 7

29653

Circuit Description Action Taken When the DTC Sets

The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
Conditions for Clearing the MIL/DTC
Conditions for Setting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40 ’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
6-2442 Engine Controls - 6.5L___________
D iagnostic Aids
Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
_____________________________ Engine
If multiple cylinder balance DTCs are set and no
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0275 C ylinder 5 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0278 Cylinder 6 Balance System
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
C onditions fo r C learing the MIL7DTC
C onditions fo r S etting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2443
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5*C (40'F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ’ C (160 * F) that
same ignition cycle.
• Use of a Scan tool
6-2444 Engine Controls ■ 6.5L___________ _________________________________ Engine

D iagnostic Aids If multiple cylinder balance DTCs are set and no

Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0278 C ylinder 6 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0281 Cylinder 7 Balance System
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
C onditions fo r C learing the M IL/DTC
C onditions fo r Setting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2445
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
6-2446 Engine Controls - 6.5L___________
D iagnostic Aids
Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
_________________________________ Engine
If multiple cylinder balance DTCs are set and no
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0281 C ylinder 7 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________
DTC P0284 Cylinder 8 Balance System
CYL # 2 CYL # 4
CYL #1 CYL # 3
C ircuit D escription
The PCM has the ability to increase and decrease
the amount of fuel to each cylinder to provide
smooth idle operation. If the PCM decides that the
fuel reduction amount to a specific cylinder exceeds
define limits, this DTC will set. This DTC only
monitors fuel reduction.
C onditions fo r S etting the DTC
• Engine at idle greater than a total of
90 seconds.
• All engine misfire DTCs ran and passed.
• Engine coolant at normal temperatures.
• Cylinder fault must be constant.
• Amount of fuel reduction for a specific cylinder
exceeds limits (internal to PCM).
• Conditions met for 2 seconds.
Engine Controls - 6.5L 6-2447
CYL # 6 CYL # 8
CYL # 5 CYL # 7
29653
Action Taken W hen th e DTC Sets
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
C onditions fo r C learing the M IU D TC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ’ C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
6-2448 Engine Controls - 6.5L___________
D iagnostic Aids
Injector balance test on scan tool should be used to
confirm fault cylinder problems. Scan tool will cutout
specific cylinder requested. It is possible that if a
cylinder balance fault has been detected and engine
has been running for a long time, the PCM will try to
increase or decrease fuel in other cylinders to
compensate for a rough idle which can cause
multiple cylinder balance DTCs to set. The scan tool
snap shot mode can be used to properly identify the
suspected cylinder. The most likely cause of cylinder
balance DTCs are malfunctioning nozzles.
_________________________________ Engine
If multiple cylinder balance DTCs are set and no
problem is found, check for the following:
• Pinched or restricted fuel feed lines between
fuel tank and fuel injection pump
• Restricted fuel filter
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will properly identify a suspected
cylinder by looking for a RPM drop (if RPM
drops, cylinder is contributing, if not cylinder is
not contributing).

DTC P0284 C ylinder 8 Balance System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Scan tool connected.
2. Start and idle engine.
3. Engine at operating temperature.
2 4. Make sure all DTCs are cleared. —
5. Using the scan tool, cutout (Inj. Balance) the
suspected cylinder.
Is there an RPM drop in the suspected cylinder? 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 the applicable DTC table(s) first. —.
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for the following basic engine mechanical or fuel
delivery problems in that cylinder.
• Injection nozzle malfunctioning (refer to Injection
4 — —
Nozzle(s) Diagnosis)
• Intake manifold restriction.
Was a repair performed? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine__________________________
DTC P0300 Engine Misfire Detected
C ircuit D escription
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel.
C onditions fo r S etting the DTC
• Engine coolant temperature greater than
5 6 ‘ C (132’ F).
• Engine idling for a total of 90 seconds.
Engine Controls - 6.5L 6-2449
• Fuel adjustment is greater than the calibrated
value (internal to PCM).
• Multiple engine misfires detected.
Action Taken W hen the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
6-2450 Engine Controls ■ 6.5L Engine
C onditions fo r Clearing the M IL/DTC After the repair has been performed, it may take
• The PCM will turn off the MIL after three approximately 30 seconds for the vehicle to return to
consecutive trips with out a fault condition a stable idle.
• A History DTC will clear after 40 consecutive Test Description
warm up if no failures are reported by this or
any other emissions related diagnostic. The number(s) below refer to the step number(s) on
the Diagnostic Table.
• PCM battery voltage is interrupted.
• Use of a scan tool. 2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
D iagnostic Aids likely cause of failure.
The scan tool can be used to control the suspected
cylinder (Inj. Balance Test).
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression in more than one cylinder.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzles stuck closed.

DTC P0300 Engine M isfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
Engine________________________________________________ Engine Controls ■ 6.5L 6-2451
DTC P0300 Engine M isfire D etected (cont’d)
Step Action Value(s) Yes No
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating temperature.
3. Select DTC, Specific, then enter the DTC number
which was set.
6 —
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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2452 Engine Controls - 6.5L
DTC P0301 Cylinder 1 Misfire Detected
C ircuit D escription
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
C onditions fo r S etting th e DTC
• Engine coolant temperature greater than
5 6 *C (132‘ F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken W hen the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
C onditions fo r C learing the MIL7DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
D iagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2453
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0301 C ylinder 1 M isfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action compbte? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2454 Engine Controls - 6.5L_______
DTC P0302 Cylinder 2 Misfire Detected
C ircuit D escription
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
C onditions fo r Setting th e DTC
• Engine coolant temperature greater than
56 *C (132 * F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken W hen the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
C onditions fo r C learing the M IL/DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
D iagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2455
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0302 C ylinder 2 M isfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2456 Engine Controls - 6.5L
DTC P0303 Cylinder 3 Misfire Detected
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
Conditions for Setting the DTC
• Engine coolant temperature greater than
5 6 *C (132‘ F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIL7DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls ■ 6.5L 6-2457
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0303 Cylinder 3 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2458 Engine Controls - 6.5L
DTC P0304 Cylinder 4 Misfire Detected
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reiuctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
Conditions for Setting the DTC
• Engine coolant temperature greater than
56 ’ C (132 * F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2459
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0304 Cylinder 4 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2460 Engine Controls - 6.5L_______
DTC P0305 Cylinder 5 Misfire Detected
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM -will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
Conditions for Setting the DTC
• Engine coolant temperature greater than
5 6 ’ C (132' F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2461
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0305 Cylinder 5 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2462 Engine Controls - 6.5L_______
DTC P0306 Cylinder 6 Misfire Detected
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
Conditions for Setting the DTC
• Engine coolant temperature greater than
5 6 'C (132*F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2463
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0306 Cylinder 6 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —

Is action complete? Go to Step 6

1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2464 Engine Controls - 6.5L_______
DTC P0307 Cylinder 7 Misfire Detected
CYL # 2 CYL # 4
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
CYL #6 CYL #8
29653
Conditions for Setting the DTC
• Engine coolant temperature greater than
56 °C (132 ° F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIUDTC
• The PCM will turn off the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2465
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0307 Cylinder 7 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2466 Engine Controls - 6.5L_______
DTC P0308 Cylinder 8 Misfire Detected
Circuit Description
The PCM times the intervals between each pulse of
the crankshaft position sensor and compares each
time interval with the other 8 to determine when an
excessive change in crankshaft speed has occurred.
This pulse is generated from a 4X reluctor wheel
located on the front of the crankshaft. If the
crankshaft speed is less than an expected amount,
the PCM will increase the amount of fuel needed to
correct the misfire. If the amount of fuel exceeds the
calibrated value, the PCM will interpret this as a
misfire and set the DTC. The misfire diagnostic is
used only to identify a week cylinder needing
additional fuel. This diagnostic will only run once per
ignition cycle.
Engine
Conditions for Setting the DTC
• Engine coolant temperature greater than
56 °C (132 ‘ F).
• Engine idling for a total of 90 seconds.
• The amount of fuel added is greater than the
calibrated value (internal to PCM).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn oft the MIL after three
consecutive trips with out a fault condition
• A History DTC will clear after 40 consecutive
warm up if no failures are reported by this or
any other emissions related diagnostic.
• PCM battery voltage is interrupted.
• Use of a scan tool.
Diagnostic Aids
The most likely cause for this DTC is the following:
• a mechanical failure causing low cylinder
compression.
• a fuel leak at the high pressure fuel injection
lines or injection nozzles.
• a fuel injection nozzle stuck closed.
Engine Controls - 6.5L 6-2467
If an injection nozzle is suspected, it can be
transferred to another cylinder to determine if the
DTC follows the nozzle.
After the repair has been performed, it may take
approximately 30 seconds for the vehicle to return to
a stable idle.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. This step will help identify a suspected cylinder.
4. This step will identify an area with the mostly
likely cause of failure.

DTC P0308 Cylinder 8 Misfire Detected

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Start the engine and allow the engine to idle at
normal operating temperature.
2 —
3. Use the scan tool in order to cut out the suspected
cylinder (Inj. Balance).
Is there an RPM drop in the suspected cylinder? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to diagnostic aids. If any additional DTCs were — Applicable Go to
stored, refer to the applicable DTC table(s) first. DTC Table Diagnostic Aids
Check for basic engine mechanical or fuel delivery
problems in that cylinder.
• Low compression or valve train problems.
4 —
• Injection nozzle stuck closed or restricted high
pressure fuel injection lines.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the fuel injection pump. Refer to Fuel Injection
5 Pump Replacement. — —
Is action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 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 7 Go to Step 2
Go to the
7 Does the Scan tool display any additional — Applicable
undiagnosed DTCs? DTC Table System OK
6-2468 Engine Controls - 6.5L
DTC P0335 Crankshaft Position (CKP) Sensor CKT
r ——
5 V o lt
R e fe re n c e A
L __ __ __ __ __ __ _ _
Circuit Description
The crankshaft position sensor is a Hall-effect type
sensor that monitors crankshaft position and speed.
There are four teeth 90 degrees apart on the front of
the crankshaft sprocket that induce a pulse in the
sensor which is transmitted to the PCM. There is a
physical one to one correspondence between the
pump cam and crankshaft.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The number of consecutive missing Crank
pulses are greater than or equal to 8.
• All diagnostic set conditions met for 2 seconds.
Engine
— -i Powertrain
Control
PCM
C1 = 3 2 B R N
C 2 = 2 4 BRN
C 3 = 3 2 BLU
185025
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the first consecutive drive trip
that the diagnostic runs and fails.
• The Freeze Frame records the operating
conditions at the time of failure and updates the
Failure Records.
• The PCM will activate Back Up fuel.
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan Tool
Engine Engine Controls - 6.5L 6-2469
Diagnostic Aids Test Description
When PCM is in backup fuel, long crank times, fast Number(s) below refer to the step number(s) on the
idle and poor performance conditions will exist. Diagnostic Table.
Check for good connection at crankshaft position 2. This step will determine if DTC P0335 is the
sensor and at PCM. Many intermittent problems are result of a hard failure or an intermittent
caused by poor electrical connections or wiring. condition.
When attempting to diagnose an intermittent
4. This step checks the 5 volt reference circuit
problem, always begin by trying to reproduce the
(the 5 volt reference may vary slightly).
conditions under which the failure occurs. This
usually involves raising the engine to a higher 5. This step checks the ground circuit.
temperature or operating it near RPM that the
problem occurs. Since heat and vibration are often
the cause of intermittent, this may bring out the
failure.

DTC P0335 Crankshaft Position (CKP) Sensor CKT

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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Start and idle the engine.
2. Observe the Crank Ref. Missed display on the
2 8
scan tool.
Does the scan tool display the specified value? Go to Step 4 Go to Step 3
The DTC is intermittent. If no additional DTCs are stored, Go to the
3 refer to the Applicable DTC Table(s) first. — Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the CKP sensor electrical connector.
3. Turn the ignition ON leaving the engine OFF.
4 4.8-5.2V
4. With a DMM J 39200, measure the voltage between
the CKP 5 volt reference circuit and chassis ground.
Is the voltage within the specified range? Go to Step 5 Go to Step 8
Probe the sensor ground circuit with a test light connected
5 to B+. —
Is the test light ON? Go to Step 6 Go to Step 9
1. Reconnect the CKP sensor.
2. Back probe the CKP signal circuit at the PCM with a
6 DMM J 39200 connected to ground. 4.2-4.5V
3. Crank the engine.
Is the voltage within the specified value? Go to Step 14 Go to Step 7
7 Is the voltage greater than the specified value? 4.2-4.5V Go to Step 12 Go to Step 11
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the CKP 5 volt
reference circuit for an open, short to ground, or
8 short to the sensor ground circuit. —
3. If the CKP 5 volt reference circuit is open or shorted
to ground, repair it as necessary.
Was a repair performed? Go to Step 17 Go to Step 10
6-2470 Engine Controls - 6.5L________________________________________________ Engine
DTC P0335 Crankshaft Position (CKP) Sensor CKT (cont’d)
Step Action Value(s) Yes No
1. Check for an open or a proper sensor ground
terminal connection at the PCM.
9 2. If a problem is found, repair the problem as —
necessary.
Was a repair performed? Go to Step 17 Go to Step 16
Check the CKP 5 volt reference circuit for a proper
connection at the PCM and replace the terminal if
10 necessary. —
Did the terminal require replacement? Go to Step 17 Go to Step 16
1. Turn the ignition OFF.
2. Disconnect the PCM and check the CKP signal
circuit for an open, short to ground, or short to the
sensor ground circuit.
11 3. Check the terminal connections at the CKP sensor —
for damage or a poor connection.
4. If a problem is found, repair the problem as
necessary.
Was a repair performed? Go to Step 17 Go to Step 15
1. Disconnect the CKP sensor pigtail connector.
2. Turn the ignition ON leaving the engine OFF.
12 3. With the J 39200 connected to ground, probe the —
CKP signal circuit at the engine harness connector.
Is there voltage present on the CKP sensor signal circuit? Go to Step 13 Go to Step 14
Repair the short to voltage on the CKP sensor signal
13 circuit. — —
Is the action complete? Go to Step 17
Check the CKP signal circuit for a proper connection at
14 the PCM and replace the terminal if necessary. —
Did the terminal require replacement? Go to Step 17 Go to Step 16
Replace the Crankshaft position sensor. Refer to
Crankshaft Position Sensor Replacement. After replacing
15 the sensor, the PCM must be programmed with a new — —
TDC Offset. Refer to TDC Offset Adjustment.
Is the action complete? Go to Step 17
Replace the PCM.
Important: The new PCM must be programmed. Refer to
16 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 17
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
17 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 18 Go to Step 2
Does the Scan tool display any additional Go to the
18 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine____________________________________ Engine Controls - 6.5L 6-2471
DTC P0370 Timing Reference High Resolution

n Powertrain
Fuel
5Volt Temperature • Control
ReferenceB Signal I Module A
J (PCM) l a A
D14' C8 C1

GRY 474 YEL 1578

PCM
Cl =32BRN
C2=24 BRN
C3=32 BLU

GRY 474 YEL 1578

A E
5Volt
ReferenceB J/T Optical/
Fuel
Temperature
PumpCAM High <
Sensor Resolution Sensor f Sensor
Signal Signal Ground J

T C1r d i[ FT
633 ORN 1799
PNK/
BLK 632
PNK/BLK 632
---------------o

PNK/BLK 632
_____ >t >f

633 ORN 1799 PNK/BLK

A4 A A2 C2
-------- --- --------------/
D9 A Cl
• PumpCAM High Sensor Powertrain
1 Sensor Resolution Ground 1 Control
I Signal Signal 1 Module A
J (PCM) i a A
185024

C ircuit Description Action Taken W hen the DTC Sets

The optical sensor provides a high resolution signal
to the PCM by counting pulses on the sensor disk
located in the injection pump. The high resolution is
one of the most important inputs by the PCM for fuel
control and timing. This test monitors the number of
high resolution pulses which have been missed (not
detected).lts based on a comparison between the
number of pulses that were detected since the last
pump cam pulse and the number of the pulses that
should have occurred. There are approximately
64 high resolution pulses for every Cam pulse.
C onditions fo r Setting the DTC
A number of High Resolution pulses missing (internal
to PCM (64 to 1 ratio) per every 8 cam reference
pulses.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the first consecutive drive trip
that the diagnostic runs and fails.
• The Freeze Frame records the operating
conditions at the time of failure and updates the
Failure Records.
• The PCM will activate Back Up fuel.
C onditions fo r C learing the M IL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160” F) that
same ignition cycle.
• The PCM battery voltage interrupted.
• Use a Scan Tool in order to clear MIL/DTC.
6-2472 Engine Controls - 6.5L Engine

D iagnostic Aids 4. This step determines if the problem is currently

Intermittent DTCs (P0251, P0370 and P1216) may
be caused by air entering the fuel system when fuel
levels get below 1/8 of a tank while performing hard
acceleration or turning maneuvers. Its also possible
that a P0251, P0370 and P1216 will set if vehicle
has run out of fuel. Customer driving habits should
be checked to determine if vehicle has been
performing in these manners. If it has been
determine that the vehicle has been performing in
these conditions, bleed fuel system of all air and test
drive vehicle.
When PCM is in backup fuel, fast idle and poor
performance problems will exist. If P0251 is also
stored, the snap shot mode on the scan tool should
be used to properly identify fault. DTCs P0335,
P1216, and P1217 may set along with this DTC.
The least likely cause of failure is the PCM.
Test D escription
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will determine if the 5 volt reference
is present.
3. This step checks the ground circuit.
active by the scan tool displaying Last Test
Failed. Do not proceed any further with this
table if the scan tool does not display the term
Last Test Failed. Duplicating the conditions in
Freeze Frame and Failure Records can help
create an active fault.
5. This step determines if a High Res signal is
being sent to the PCM. Refer to the RPM vs
Hertz table to compare the Hertz readings at
different RPMs. Using Freeze Frame and
Failure Records will help identify the RPM the
problem occurs.
9. The PCM supplies 5 volts on the signal circuit.
This step determines if that voltage is present,
not present, or too much voltage is present..
13. This step determines if the signal circuit is
shorted to 5V. A normal high res signal circuit
will have 3-5mA. Any reading over 50mA
indicates a short to 5V.

DTC P0370 Tim ing Reference High Resolution

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
reference, as the scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect the Optical/Fuel temperature sensor
electrical connector.
3. Turn the ignition ON leaving the engine OFF.
2 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
Engine________________________________________________ Engine Controls - 6.5L 6-2473
DTC P0370 Tim ing Reference High Resolution (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
Records).
5 —
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,
or short to the sensor ground circuit.
6 —
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 3. With a DMM J 39200 connected to ground, probe 4.8-5.2V
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 50mA
connector.
Is the current less than the specified value? Go to Step 15 Go to Step 14
6-2474 Engine Controls ■ 6.5L________________________________________________ Engine
DTC P0370 Tim ing Reference High Resolution (cont’d)
Step Action Value(s) Yes No
Repair the short to reference voltage on the high
14 resolution signal circuit. — —
Is the action complete? Go to Step 19
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
Engine
DTC P0380 Glow Plug Circuit Performance
Refer to PCM, Glow Plugs, Underhood Fuse-Relay
Center
C ircuit Description
The glow plug system is used to assist in providing
the heat required to begin combustion during cold
engine temperatures. The glow plugs are heated
before and during cranking, as well as initial engine
operation. The PCM controls the glow plug ON times
by monitoring coolant temperatures and glow plug
voltage.
C onditions for S etting the DTC
• The PCM has commanded glow plugs ON and
the glow plug signal voltage is less than
4.0 volts,
or
• The PCM has commanded glow plugs OFF and
the glow plug signal voltage is greater than
4.0 volts,
or
• When the PCM has commanded glow plugs
ON and there is more than a 2 volt difference
between glow plug voltage and ignition voltage.
Action Taken W hen the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
DTC P0380 G low Plug C ircuit Perform ance
Step Action
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for
reference, as the Scan tool loses data when using the
1 Clear Info function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
3. Use the Scan Tool in order to command the glow
plugs ON.
2 —
4. Observe the Glow Plug System on the Scan Tool
display.
Does the Scan Tool display the Glow Plug System as
enabled?
Engine Controls - 6.5L 6-2475
C onditions fo r C learing the M IU D TC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 'C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160’ F) that
same ignition cycle.
• Use of a Scan Tool
D iagnostic Aids
If glow plug relay is stuck in the ON position, check
for proper operation of glow plugs, refer to Glow
Plug System Check. When glow plugs are
commanded ON by the Scan tool, an internal PCM
timer protects the glow plugs from damage by
cycling them ON for 3 seconds and the OFF for
12 seconds.
The glow plug output feed wire nut and battery feed
wire nut at the relay should be checked for proper
torque (5 N-m 44 lb in) and for corrosion.
An intermittent may be caused by the following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Test Description
The number(s) below refer to the Step number(s) on
the Diagnostic Table.
2. This Step will determine if P0380 is a hard
failure.
3. This Step will determine if the PCM is
requesting the glow plug system is ON.
8. This Step will determine if the glow plug relay
has been activated and the output voltage has
been seen by the PCM.
Value(s) Yes No
—
Go to
Powertrain OBD
Go to Step 2 System Check
Go to Step 3 Go to Step 8
6-2476 Engine Controls - 6.5L________________________________________________ Engine
DTC P0380 G low Plug C ircuit Perform ance (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition ON with the engine OFF.
2. Use the Scan Tool in order to command the glow
plugs ON.
3 B+
3. Observe the Glow Plugs display on the Scan Tool.
Does the Scan Tool display the Glow Plugs at the
specified value? Go to Step 4 Go to Step 6
Does the Scan Tool display Glow Plug voltage present all
4 —
the time? Go to Step 16 Go to Step 5
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids If any additional DTCs were Go to the
5 stored, refer to those table(s). —
Applicable Go to
Were there any additional DTCs stored? DTC Table Diagnostic Aids
1. Disconnect the glow plug relay connector.
2. Turn the ignition ON with the engine OFF.
6 3. With the test light connected to ground, probe the —
glow plug relay harness ignition feed circuit.
Is the test light ON? Go to Step 7 Go to Step 10
1. Turn the ignition ON with the engine OFF.
2. Connect the test light between the glow plug harness
7 —
ignition feed circuit and the harness ground circuit.
Is the test light ON? Go to Step 8 Go to Step 11
1. Turn the ignition ON with the engine OFF.
2. Verify that the glow plug harness is still
disconnected.
3. With a J 39200 connected to ground, probe the glow
8 plug relay control circuit at the glow plug harness B+
connector.
4. Use a Scan Tool in order to command the glow
plugs ON.
Is the voltage at the specified value? Go to Step 9 Go to Step 12
1. Reconnect the glow plug relay.
2. Turn the ignition ON with the engine OFF.
3. With a test light connected to ground, probe the glow
plug side of the relay.
9 —
4. Use a Scan Tool in order to command the glow
plugs ON.
Is the test light ON when the Scan Tool commands the
glow plugs ON? Go to Step 14 Go to Step 18
Repair an open or a short to ground in glow plug relay
10 ignition feed circuit. — —
Is the action complete? Go to Step 20
Repair any open or poor connections in the glow plug
11 relay ground circuit. — —
Is the action complete? Go to Step 20
1. Check the glow plug relay control circuit for an open
or short to ground.
12 2. If the glow plug relay control circuit is open or —
shorted to ground, repair as necessary.
Was a problem found? Go to Step 20 Go to Step 13
Engine________________________________________________ Engine Controls - 6.5L 6-2477
DTC P0380 G low Plug C ircuit Perform ance (co n t’d)
Step Action Value(s) Yes No
Check the glow plug relay control circuit for a proper
connection at the PCM and replace the terminal if
13 necessary. —
Was a problem found? Go to Step 20 Go to Step 19
1. Check the glow plug relay signal control circuit for an
open or short to ground.
14 2. If the glow plug relay signal circuit is open or shorted —
to ground, repair as necessary.
Was a problem found? Go to Step 20 Go to Step 15
Check the glow plug relay signal circuit for a proper
connection at the PCM and replace the terminal if
15 necessary. —

Was a problem found? Go to Step 20 Go to Step 19

1. Disconnect the glow plug relay connector.
2. Turn the ignition ON leaving the ignition OFF.
16 3. Probe the glow plug relay control circuit with a test —
light connected to ground.
Is the test light ON all the time? Go to Step 17 Go to Step 18
Repair the short to voltage on the glow plug relay control
17 circuit. — —
Is the action complete? Go to Step 20
Replace the glow plug relay. Refer to Glow Plug Relay
18 Replacement. — —
Is the action complete? Go to Step 20
Replace the PCM.

19 Important: The new PCM must be programmed. Refer to — —

PCM Replacement/Programming.
Is the action complete? Go to Step 20
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
20 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 21 Go to Sfep 2
Does the Scan tool display any additional Go to the
21 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2478 Engine Controls - 6.5L
DTC P0400 EGR System
Refer to Emission Hose Routing Diagram.
Circuit Description
The PCM operates a PWM solenoid to control the
EGR valve. This solenoid is normally open. By
providing a ground path the PCM energizes the
solenoid which then allows vacuum to pass to the
EGR valve. During normal operation, the PCM
compares its desired MAF signal with the measured
MAF signal and makes corrections in the duty cycle
accordingly.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• Baro greater than 75 kPa.
• The DTCs P0405, P0406, P0102 and P0103
are not set.
• Lowest achieved EGR pressure at full EGR is
less than look up table value (internal to PCM)
Engine
• MAF value is greater than or equal to
0.1484 g/cyl.
• All diagnostic set conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 ’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ‘ C (160'F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
The most likley cause of failure is a restricted
vacuum line from the EGR valve to the vacuum tee
(including the vacuum tee).
To run the diagnostic test the engine must be at the
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.
___________ Engine Controls - 6.5L 6-2479
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step checks for the correct amount of
vacuum at the EGR valve.
3. At zero vacuum and at 15 in. Hg, there should
be a difference greater than 0.10 g/cyl. If the
difference is not greater than 0.10 g/cyl the
EGR valve is malfunctioning.

DTC P0400 EGR System

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Install a vacuum gage in place of the EGR valve.
2. Start and idle the engine in Park.
3. Using the scan tool, command the EGR solenoid to
2 15 in. Hg
100% duty cycle.
4. 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. Monitor Cylinder Air display on scan tool.
3 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
6-2480 Engine Controls - 6.5L________________________________________________ Engine
DTC P0400 EGR System (cont’d)
Step Action Value(s) Yes No
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
Engine________________________________
DTC P0401 EGR System Flow Insufficient
The PCM operates a PWM solenoid to control the
EGR valve. This solenoid is normally open. By
providing a ground path the PCM energizes the
solenoid which then allows vacuum to pass to the
EGR valve. During normal operation, the PCM
compares its desired MAF signal with the measured
MAF signal and makes corrections in the duty cycle
accordingly.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• Baro greater than 75 kPa.
. The DTCs P0405, P0406, P0102 and P0103
are not set.
• Two of three EGR test must fail (internal
to PCM).
• All diagnostic set conditions met for 2 seconds.
Engine Controls - 6.5L 6-2481
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2482 Engine Controls - 6.5L
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40'F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
The most likley cause of failure is a condition
causing low back pressure.
To run the diagnostic test the engine must be at the
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.
Engine
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step checks for a low back pressure
problem.

DTC P0401 EGR System Flow Insufficient

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are there any other EGR DTCs set? Go to the
2 — Applicable
DTC Table Go to Step 3
Check for the following conditions:
• Plugged EGR ports.
3 • Exhaust system leaks. — —
• Exhaust system modifications.
Has a repair been performed? Go to Step 4
Important: After repairs, the EGR ALM cells must be reset
4 (under special functions in scan tool). — —
Are EGR ALM cells reset? Go to Step 5
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
5 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________
DTC P0402 EGR Flow Excessive
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air
entering the engine indicates an acceleration, high
load situation or no EGR flow, while a small quantity
of air indicates deceleration, idle or full EGR
situations.
The PCM will monitor MAF and EGR pressures at
different ranges to determine correct EGR flow rates.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• Baro greater than 75 kPa.
. The DTCs P0405, P0406, P0102 and P0103
are not set.
Engine Controls - 6.5L 6-2483
• Five ALM Cells that are less than 0.5.
• All diagnostic set conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2484 Engine Controls - 6.5L Engine

Conditions for Clearing the MILJDTC The Adaptive Learn Matrix (ALM) is used to adjust
• The PCM will turn the MIL off after three the EGR vacuum control based on Mass Air Flow
consecutive trips without a fault condition. (MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
• A History DTC will clear when forty consecutive other engine system variations. The ALM is made up
warm-up cycles that the diagnostic does not of sixteen cells (numbered from zero to fifteen) in
fail (coolant temperature has risen 5 ’ C (40'F) which each cell covers a range of engine speed
from start up coolant temperature and engine (RPM) and load (mm3).
coolant temperature exceeds 71 "C (160'F) that
same ignition cycle. Test Description
• Use of a Scan tool Number(s) below refer to the step number(s) on the
Diagnostic Table.
Diagnostic Aids
3. If the EGR valve is at fault, excessive black
The most likley cause of failure is a mechanical smoke will be present.
problem in the EGR value not allowing it to close.
To run the diagnostic test the engine must be at the
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.

DTC P0402 EGR Flow Excessive

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are there any other EGR DTCs set? Go to the
2 — Applicable
DTC Table Go to Step 3
1. Repair one of the following conditions:
• Malfunctioning EGR valve (valve not remaining
closed).
3 • Restriction in exhaust system (high back — —
pressure).
2. Repair the problem as necessary.
Is the action complete? Go to Step 4
Important: After repairs, the EGR ALM cells must be reset
4 (under special function in scan tool). — —
Are the EGR ALM cells reset? Go to Step 5
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 —
which was set.
4. Operate vehicle until scan tool indicates the
diagnostic Ran.
Does the Scan Tool indicate the diagnostic Passed? Go to Step 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine____________________________
DTC P0404 EGR System Performance
Circuit Description
The PCM operates a solenoid to control the EGR
valve. This solenoid is normally open. By providing a
ground path the PCM energizes the solenoid which
then allows vacuum to pass to the EGR vlave.
During normal operation, the PCM compares its
desired EGR signal with the EGR pressure signal
and makes corrections in the duty cycle accordingly.
If there is a difference in the PCM command and
what is at the EGR valve sensed by the EGR control
pressure/BARO sensor, the PCM makes minor
adjustments to correct.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
. The DTCs P0405, P0406, P0102 and P0103
are not set.
• The EGR Vent Solenoid ON.
Engine Controls - 6.5L 6-2485
• The difference between ambient air pressure
and EGR pressure is less than 15 kPa.
• All diagnostic set conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2486 Engine Controls - 6.5L
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40' F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ‘ C (160’ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
A vacuum leak or a pinched vacuum will cause a
DTC P0404. Check all vacuum lines and
components connected to the hoses for leaks or
sharp bends or deformities. Check vacuum source to
EGR solenoid assembly. Also check for small leak in
EGR valve, and proper vacuum line routing.
Engine
To run the diagnostic test the engine must be at
operating temperature, vehicle in drive at idle for
approximately 1 minute, the with vehicle in park hold
engine rpm steady between 1500 and 2100 rpm for
30 seconds. If the diagnostic test fails to run, vehicle
must be driven.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. This step checks vacuum to the EGR valve
control pressure/BARO sensor.

DTC P0404 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Install vacuum gage in place of EGR control
pressure/BARO.
2. Start and idle engine (engine at operating
temperature).
2 15 in. Hg
3. Using the scan tool, command the EGR solenoid to
100% duty cycle.
4. At idle, observe the vacuum.
Is the vacuum greater than the specified value? Go to Step 4 Go to Step 3
Repair restriction between EGR control pressure/BARO
3 sensor and vacuum tee (including vacuum tee). — —
Is action complete? Go to Step 5
Replace the EGR Control Pressure/BARO sensor. Refer to
4 EGR Control Pressure Sensor Replacement. — —
Is the action complete? Go to Step 5
Important: After Repairs, the EGR ALM cells must be
5 reset (under special functions in scan tool). — —
Are EGR ALM cells reset? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 —
which was set.
4. Operate the vehicle until Scan tool indicates the
diagnostic Ran.
Does the Scan Tool indicate the diagnostic Passed? Go to Step 7 Go to Step 2
Does the Scan tool display any additional Go to the
7 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine__________________________________ Engine Controls - 6.5L 6-2487

DTC P0405 EGR Sensor Circuit Low Voltage

. 5 Volt
Powertrain
Reference A * Control
L _ _ _ _ _ _
J Module (PCM)
D13 C1
A
GRY 416

GRY 416 GRY 416 PCM

4 Cl = 32 BRN
C2 = 24BRN
GRY 416 C3=32 BLU
CKP Sensor -4-
GRY
416
GRY 416
B CJL
Exhaust Gas Boost
Recirculation Pressure
(EGR) Control Pressure/
Barometric (BARO)
r Sensor
A
Sensor
| L56 Only | BLK 452

ECTand
(AT Sensors
BLK 452 LTGRN 432 BLK 452
-----------y

BLK 452
GRY/BLK 433

BLKj452 BLK 452

CKP Sensor TFT Sensor

Cell 39

BLK 452 LTGRN 432

-<
5

o
CM

C12JvC1
CM

C14JLC1
EGR Control Pressure/ Sensor Boost " ■" Powertrain
BARO Ground Sensor 1 Control A
Sensor Signal Signal * Module (PCM) ifa A

Refer to Emission Hose Routing Diagram.
Circuit Description
An EGR Control Pressure/Baro sensor is used to
monitor the amount of vacuum in the EGR circuit. It
senses the actual vacuum in the EGR vacuum line
and sends a signal back to the PCM. This signal is
used to control EGR duty cycle calculated by
the PCM.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The EGR Control Pressure signal is less than
0.24 volts (15 kPa).
• All diagnostic set conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
6-2488 Engine Controls - 6.5L
Conditions for Clearing the MIL7DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160’ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
With the ignition ON and the engine stopped, the
EGR pressure is equal to atmospheric pressure with
the signal voltage being high.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
Engine
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if P0405 is a hard failure
or an intermittent condition.
3. Jumpering the 5 volt reference circuit to the
signal circuit will determine if the sensor is at
fault, or if there is a problem with the PCM or
wiring.
4. The scan tool may not display 5 volts. The
important thing is that the PCM recognized the
voltage as more than 4 volts, indicating that the
PCM and the signal circuit are OK.

DTC P0405 EGR Sensor Circuit Low 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) system Powertrain OBD
check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start the engine and let the engine idle.
2 3. Observe the EGR Sensor display on the scan tool. 0.24 V
Does the scan tool display EGR Sensor less than or equal
to the specified value? Go to Step 3 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the EGR Control Pressure/Baro sensor
electrical connector.
3. Jumper the sensor 5 volt reference circuit to the
3 4.0 V
sensor signal circuit at the harness connector.
4. Turn the ignition ON leaving the engine OFF
Does the scan tool display the EGR Sensor voltage
greater than the specified value? Go to Step 6 Go to Step 4
1. Turn the ignition OFF.
2. Remove the jumper wire.
3. Probe the sensor signal circuit at the harness
4 connector with a test light connected to B+ 4.0 V
4. Turn the ignition ON leaving the engine OFF.
Does the scan tool display the EGR Sensor voltage
greater than the specified value? Go to Step 9 Go to Step 7
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to the
5 to those table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for a proper connection at the EGR Control
6 pressure/BARO sensor. —
Was a problem found? Go to Step 12 Go to Step 11
Engine________________________________________________ Engine Control's - 6.5L 6-2489
DTC P0405 EGR Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Check for an open EGR Control pressure/BARO sensor
7 signal circuit. —
Was a problem found? Go to Step 12 Go to Step 8
Check the EGR Control pressure/BARO sensor signal
8 circuit for a short to ground. —
Was a problem found? Go to Step 12 Go to Step 13
Check for an open in the EGR Control pressure/BARO
9 sensor 5 volt reference circuit. —
Was a problem found? Go to Step 12 Go to Step 10
Check for a short to ground in the EGR Control
10 pressure/BARO sensor 5 volt reference circuit. —

Was a problem found? Go to Step 12 Go to Step 13

Replace the EGR Control pressure/BARO sensor. Refer to
11 EGR Control Pressure Sensor Replacement. — —
Is the action complete? Go to Step 14
Repair the circuit as necessary.
12 — —
Is the action complete? Go to Step 14
Replace the PCM.
Important: The new PCM must be programmed. Refer to
13 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 14
Important: After Repairs, the EGR ALM cells must be
14 reset (under special functions in scan tool). — —
Are EGR ALM cells reset? Go to Step 14
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
15 which was set. —
4. 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 16 Go to Step 2
Does the Scan tool display any additional Go to the
16 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2490 Engine Controls - 6.5L_____________ Engine

DTC P0406 EGR Sensor Circuit High Voltage

5Volt Powertrain
ReferenceA • Control
J Module (PCM)
D13 C1

GRY 416

GRY 416 GRY 416 PCM

J C1=32 BRN
C2=24 BRN
GRY 416 C3=32 BLU
CKPSensor GRY
416
GRY 416

r<*4
C.
Exhaust Gas Boost
Recirculation Pressure
(EGR) Control Pressure/ Sensor
Barometric (BARO) A'
Sensor
(L56Only | BLK 452

ECTand
IATSensors
BLK 452 LTGRN 432 BLK 452

BLK 452
GRY/BLK 433

BLK 452 BLK 452

CKPSensor TFTCensor
Cell 39
BLK 452 LTGRN 432

C12JX1 B12JLC2 cmci

EGRControl Pressure/ Sensor Boost ■ •• Powertrain
BARO Ground Sensor 1 Control A
Sensor Signal Signal J Module (PCM) i a A

Refer to Emission Hose Routing Diagram.
Circuit Description
A EGR Control Pressure/Baro sensor is used to
monitor the amount of vacuum in the EGR circuit. It
senses the actual vacuum in the EGR vacuum line
and sends a signal back to the PCM. This signal is
used to control EGR duty cycle calculated by the
PCM. This is a type B DTC.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The EGR Control Pressure signal is greater
than 3.96 volts (85 kPa).
• All diagnostic set conditions met for 2 seconds.
185023
Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine
Conditions for Clearing the MIL7DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 °C (160’ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
With the ignition ON and the engine stopped, the
manifold pressure is equal to atmospheric pressure
with the signal voltage being high. This information is
used by the PCM as an indicator of vehicle altitude.
If DTC P0406 is intermittent, refer to Symptoms.
To run the diagnostic test the engine must be at the
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.
Engine Controls - 6.5L 6-2491
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will check for EGR Vent Solenoid
DTC.
3. This step determines if DTC P0406 is a hard
failure or an intermittent condition.
4. This step simulates conditions for a
DTC P0405. If the PCM recognizes the change,
the PCM and the signal circuit are OK.

DTC P0406 EGR 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is the DTC P1653 also set? Go to DTC P1653
EGR Vent
2 —
Solenoid Control
Circuit Go to Step 3
1. Connect a scan tool.
2. Start the engine and let the engine idle.
3 Does the scan tool display the EGR Control 4.0 V
pressure/BARO sensor voltage greater than the
specified value? Go to Step 4 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the EGR Control Pressure/BARO sensor
electrical connector.
4 1.0 V
3. Turn the ignition ON.
Does the scan tool display a EGR Control pressure/BARO
sensor voltage less than the specified value? Go to Step 6 Go to Step 10
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to the
5 to those table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Turn the ignition ON leaving the engine OFF.
2. With a J 39200 connected to ground, probe the
6 5 volt reference circuit at the EGR Control 5.2V
Pressure/BARO Sensor harness connector.
Is the voltage greater than the specified value? Go to Step 11 Go to Step 7
6-2492 Engine Controis - 6.5L Engine
DTC P0406 EGR Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
Probe the EGR Control Pressure/BARO sensor ground
7 circuit with a test light to B+. —
Is the test light ON? Go to Step 8 Go to Step 12
Check the EGR vacuum source for a restriction.
8 —
Was a problem found? Go to Step 13 Go to Step 9
Replace the EGR Control Pressure/BARO sensor. Refer to
9 EGR Control Pressure Sensor Replacement. — —
Is the action complete? Go to Step 15
Check for a short to voltage in the sensor signal circuit.
10 —
Was a problem found? Go to Step 13 Go to Step 14
1. Check for a short to voltage in the 5 volt reference
circuit.
11 —
2. If a problem is found, repair as necessary.
Was a repair performed? Go to Step 15 Go to Step 14
Repair the open in the sensor ground circuit.
12 — —
Is the action complete? Go to Step 15
Repair as necessary.
13 — —
Is the action complete? Go to Step 15
Replace the PCM.
Important: The new PCM must be programmed. Refer to
14 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 15
Important: After Repairs, the EGR ALM cells must be
15 reset (under special functions in scan tool). — —
Are the EGR ALM cells reset? Go to Step 16
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
16 which was set. —
4. 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 17 Go to Step 2
Does the Scan tool display any additional Go to the
17 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2493

DTC P0501 Vehicle Speed Sensor Circuit

Refer to PCM, VSS Buffer, VSS, EBCM.
Circuit Description
The speed sensor circuit consists of a magnetic
induction type sensor, a vehicle speed sensor buffer
module and wiring. Gear teeth pressed on the output
shaft induce an alternating current in the sensor.
This signal is transmitted to the buffer. The buffer
compensates for various axle ratios and converts the
signal into a square wave for use by the
speedometer, cruise control, antilock brake and PCM.
The buffer sends two different signals to the PCM.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
• The vehicle speed greater than 20 mph.
• The four wheel low not selected.
• The VSS buffer calculated speed is less than
half the transmission calculated speed.
• All of the diagnostic set conditions met for
2 seconds.
or
• The PCM performs this DTC diagnostic
continuously.
• The VSS buffer calculated speed is greater
than transmission calculated speed by 20 mph.
• All of the diagnostic set conditions met for
2 seconds.
Action Taken When the DTC Sets
• The PCM disallows all cruise control inputs.
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles during which the diagnostic
does not fail (coolant temperature has risen
5 * C (40 * F) from the start up coolant
temperature and the engine coolant
temperature exceeds 71 *C (160’ F) during that
same ignition cycle.
• Use of a Scan tool.
Diagnostic Aids
Check connections at VSS buffer and PCM. Refer to
4L80E Diagnostic Trouble Codes in Transmission if
DTC P0722 or DTC P0723 is also set.
Test Description
Number(s) below refer to number(s) on the
Diagnostic Table.
3. This tests for B+ at VSS buffer.
4. This tests for proper ground path for vehicle
speed sensor signal buffer.

DTC P0501 Vehicle Speed Sensor 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a scan tool.
2. Raise the drive wheels.
2 3. Start the engine.
—

4. Place the transmission in any drive range.

With the drive wheels rotating, does the vehicle speed
increase with drive wheel speed increase? Go to Step 7 Go to Step 3
1. Place the transmission in Park.
3 2. Back probe the VSS buffer module ignition feed
—
circuit with a test light connected to ground.
Is the test light ON? Go to Step 4 Go to Step 8
Back probe the VSS buffer module ignition feed circuit to
4 the ground circuit with a test light. —

Is the test light ON? Go to Step 5 Go to Step 9

6-2494 Engine Controls - 6.5L________________________________________________ Engine
DTC P0501 Vehicle Speed Sensor Circuit (cont’d)
Step Action Value(s) Yes No
1. Back probe the VSS buffer module at the VSS input
circuit (C7) to the other VSS input circuit (C12) with
a J 39200 on the AC scale.
5 2. Place the transmission in any drive range with the —
drive wheels rotating.
Does the voltage increase on the J 39200 with drive wheel
increase? Go to Step 6 Go to Step 10
Does the scan tool display a trans output speed (MPH)
6 —
increase with drive wheel increase? Go to Step 13 Go to Step 12
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to the
7 to those table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Repair the open in the ignition feed circuit.
8 — —
Is the action complete? Go to Step 18
Repair the open in the ground circuit.
9 — —
Is the action complete? Go to Step 18
Check the complete VSS input circuit for an open or short
10 to ground. —
Was a repair performed? Go to Step 18 Go to Step 11
1. Check for a proper connection at the VSS sensor.
2. If a problem is found, repair the problem as
11 —
necessary.
Was a problem found? Go to Step 18 Go to Step 15
1. Back probe the VSS buffer module at the VSS
output circuit (C15) with a J 39200 connected to
ground.
12 —
2. Place the transmission in any drive range with the
drive wheels rotating.
Is there voltage present? Go to Step 13 Go to Step 16
Check the VSS output circuit for an open or short to
13 ground. —
Was a repair performed? Go to Step 18 Go to Step 14
Check VSS output circuit for a proper connections at
14 the PCM. —
Was a repair performed? Go to Step 18 Go to Step 17
Replace the Vehicle Speed Sensor.
15 — —
Is the action complete? Go to Step 18
Replace the VSS Buffer module. Refer to Vehicle Speed
16 Signal Buffer Replacement. — —
Is the action complete? Go to Step 18
Replace the PCM.
Important: The new PCM must be programmed. Refer to
17 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 18
Engine________________________________________________ Engine Controls ■ 6.5L 6-2495
DTC P0501 Vehicle Speed Sensor Circuit (cont’d)
Step Action Value(s) Yes No
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
18 which was set. —
4. 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 19 Go to Step 2
Does the Scan tool display any additional Go to the
19 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2496 Engine Controls - 6.5L Engine

DTC P0567 Cruise Resume Circuit

|H o t In Run And S ta rt]

"• IP
i Pow er

i Distribution CRUISE ! Fuse

C e ll 10 Fuse 6 , Block
i 10A
i
L.

BRN 41
PCM
Cl = 32 BRN
C2 = 24 BRN
BRN 41 C3 = 32 BLU

Cruise
Control
j O n /O fl J' Set/Coast
7 Resum e/
A c c e le ra te
Switch

GRY 397 GRY/BLK 87

DK BLU 84
A12> A14 A15 C266
>

GRY 397 GRY/BLK 87

DK BLU 84

GRY 397 GRY/BLK 87

DK BLU 84

A11 B11 C2 D10 Cl

I C ru ise S e t/C o a s t Resum e/

1 Powertrain
. O n /O ff Request A c c e le ra te ! Control
Request S ig n al R e quest
i Module A
1 S ig n a l Signal
i (PCM)

185074

Circuit Description • The PCM performs this DTC diagnostic

The cruise Resume/Accel switch is an input to the continuously.
fuel control portion of the PCM. These inputs allow • The Cruise Control ON/OFF switch in the ON
the PCM to control and hold a requested speed. position.
Cruise Resume/Accel switch sends ignition voltage to • Resume switch ON for longer than
the PCM when the switch is closed (ON). 25.5 seconds.
• All of the diagnostic set conditions met for
Conditions for Setting the DTC
2 seconds.
• The PCM performs this DTC diagnostic
continuously. Action Taken When the DTC Sets
• The Cruise Control ON/OFF switch in the OFF • The PCM disallows all cruise control inputs.
position. • TCC shift schedules may be affected.
• Ignition voltage on Resume request signal • The PCM will not illuminate the Malfunction
circuit. Indicator Lamp (MIL).
• All of the diagnostic set conditions met for • The PCM records the operating conditions at
2 seconds. the time the diagnostic fails. This information
or stores in the Failure Records.
Engine Engine Controls - 6.5L 6-2497
Conditions for Clearing the MIUDTC Diagnostic Aids
• A History DTC will clear when forty consecutive Check for a resume/accel switch stuck in the engage
warm-up cycles that the diagnostic does not position or the signal circuit is shorted to voltage.
fail (coolant temperature has risen 5 *C (40 ‘ F)
from start up coolant temperature and engine
Test Description
coolant temperature exceeds 71 ’ C (160‘ F) that Number(s) below refer to the step number(s) on the
same ignition cycle. Diagnostic Table.
• Use of a Scan tool 2. This step determines if the signal circuit is
shorted to voltage.
3. This step determines if the PCM or switch is
at fault.

DTC P0567 Cruise Resume 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
2 —
3. Turn the Cruise switch OFF.
Does the scan tool display Resume Switch ON? Go to Step 3 Go to Step 4
1. Turn the ignition ON leaving the engine OFF.
2. Disconnect the PCM connector containing the
Resume switch signal circuit.
3 3. Probe the Resume switch signal circuit at the —
PCM harness with a test light connected to chassis
ground.
Is the test light ON? Go to Step 5 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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. The Resume switch signal circuit is shorted to
voltage or stuck in the ON position.
5 — —
2. Repair the problem as necessary.
Is the action complete? Go to Step 8.
Replace the PCM.
Important: The new PCM must be programmed. Refer to
6 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 7
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
7 which was set. —
4. 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 8 Go to Step 2
Does the Scan tool display any additional Go to the
8 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2498 Engine Controls - 6.5L Engine

DTC P0568 Cruise Set Circuit

|H o t In R un A n d S ta rt!

I Pow er
IP
. io n
D istribution *M 8 ^ c r u is e Fuse
1 C ell 10
N7T s r «Biock

BRN 41
PCM
C l = 3 2 BRN
C 2 = 2 4 BR N
BRN 41 C 3 = 3 2 BLU

Cruise
Control
/ i
O n /O fl
/ \
S e t/C o a s t
?
Resum e/
A c celerate
Switch

GRY 397 GRY/BLK 87

DK BLU 84
A12 A14 ' ___ _ A15
_ >,C266
\

GRY 397 GRY/BLK 87

DK BLU 84
>
N✓ \ r -- --- -vsf

GRY 397 GRY/BLK 87

DK BLU 84

A11/k. __
___ - B11
_ -Ak
- >
C2 D10 A/k Cl

C ruise S e t/C o a s t Resum e/

n Powertrain
O n /O ff Request A c c e le ra te ! Control
R e quest
R e q u est Signal
i Module A
S ig n a l Signal
I (PCM)

185074

Circuit Description • The PCM performs this DTC diagnostic

The cruise Set/Coast switch is an input to the fuel continuously.
control portion of the PCM. These inputs allow the • The Cruise Control ON/OFF switch in the
PCM to control and hold a requested speed. Cruise ON position.
Set/Coast switch sends a ignition voltage signal to • Set/Coast request switch ON for longer than
the PCM when the Set/Coast switch is ON. 25.5 seconds.
• All of the diagnostic set conditions met for
Conditions for Setting the DTC
2 seconds.
• The PCM performs this DTC diagnostic
continuously. Action Taken When the DTC Sets
• The Cruise Control ON/OFF switch in the • The PCM disallows all cruise control inputs.
OFF position. • TCC shift schedules may be affected.
• Ignition voltage on Set/Coast request signal • The PCM will not illuminate the Malfunction
circuit. Indicator Lamp (MIL).
• All of the diagnostic set conditions met for • The PCM records the operating conditions at
2 seconds. the time the diagnostic fails. This information
or stores in the Failure Records.
Engine Engine Controls ■ 6.5L 6-2499
C onditions fo r C learing the M IL/DTC Test Description
• A History DTC will clear when forty consecutive Number(s) below refer to the step number(s) on the
warm-up cycles that the diagnostic does not Diagnostic Table.
fail (coolant temperature has risen 5 ' C (40' F) 2. This step determines if the signal circuit is
from start up coolant temperature and engine shorted to voltage.
coolant temperature exceeds 71 'C (160’ F) that 3. This step determines if the PCM or switch is
same ignition cycle. at fault.
• Use of a Scan tool

D iagnostic Aids
If the Set/Coast switch is stuck in the ON position or
the driver is holding the Set/Coast switch ON for
longer than 25.5 seconds, DTC P0568 will set.
DTC P0568 only checks the signal circuit for a short
to voltage.

DTC P0568 Cruise Set C ircuit

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
2 —
3. Turn the Cruise switch OFF.
Does the scan tool display the Set switch ON? Go to Step 3 Go to Step 4
1. Turn the ignition ON leaving the engine OFF.
2. Disconnect the PCM connector containing the Set
switch signal circuit.
3 3. Probe the Set switch signal circuit at the —
PCM harness with a test light connected to
chassis ground.
Is the test light ON? Go to Step 5 Go to Step 6
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 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. The Set switch signal circuit is shorted to voltage or
stuck in the ON position.
5 — —
2. Repair the problem as necessary.
Is the action complete? Go to Step 8
Replace the PCM.
Important: The new PCM must be programmed. Refer to
6 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 7
6-2500 Engine Controls - 6.5L________________________________________________ Engine
DTC P0568 Cruise S et C ircuit (cont’d)
Step Action Value(s) Yes No
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
7 which was set. —
4. 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 8 Go to Step 2
Does the Scan tool display any additional Go to the
8 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine______________________________ Engine Controls - 6.5L 6-2501

D T C P0571 C ru is e B ra ke S w itc h C irc u it

|Hot At All Times| |Hot InRunj

PCM
C1 = 3 2 B R N
C 2 = 2 4 BR N
C 3 = 3 2 BLU

r ——— — 1 Powertrain
| Stoplamp Brake B ra k e /C P P
1Control
. Switch Switch Switch
1 Input Input Input 1Module £
J (PCM) ia A

185078

C ircuit D escription • The PCM will not illuminate the Malfunction

The TCC normally closed brake switch supplies a B+
signal on the Brake Switch Input circuit to the PCM.
The circuit is opened when the brakes are applied.
The stop lamp/cruise control normally open brake
switch supplies a B+ signal on the Stoplamp Switch
Input circuit to the PCM when the brake is applied.
C onditions fo r S etting th e DTC
• Brake switches disagree for 10 consecutive
minutes.
or
• TCC and cruise control brake switches are not
toggling open and closed, during 6 brake
applications on the same ignition cycle.
A ction Taken W hen the DTC Sets
• The PCM disallows all cruise control inputs.
• TCC shift schedules may be affected.
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
C onditions fo r C learing the M IL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5*C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
D iagnostic A ids
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).
6-2502 Engine Controls - 6.5L Engine

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This test simulates brake switch closed or
brakes OFF.
3. This test checks the feed circuit.

DTC P0571 C ruise Brake Sw itch C ircuit

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
2 3. Apply the brakes. —
Does the scan tool display the Cruise Brake switch Closed
and then Open when the brake is released? Go to Step 3 Go to Step 4
Apply the brakes again.
3 Does the scan tool display the Brake switch Open and —
then Closed when the brake is released? Go to Step 8 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. Verify the Stop lamp switch is disconnected.
4 3. With a test light connected to ground, probe the —
normally open feed circuit (terminal B).
Is the test light ON? Go to Step 5 Go to Step 9
1. Disconnect the stop lamp switch.
2. Jumper the normally open (terminal A) feed circuit
and the normally open signal circuits (terminal B)
5 —
together.
Does the scan tool display the Cruise Brake switch
Closed? Go to Step 6 Go to Step 10
1. Turn the ignition ON leaving the engine-OFF.
2. Verify the Stop lamp switch is disconnected.
6 3. With a test light connected to ground, probe the —
normally closed feed circuit (terminal F).
Is the test light ON? Go to Step 7 Go to Step 12
1. Verify the Stop top lamp switch is disconnected.
2. Jumper the normally closed (terminal F) feed circuit
and the normally closed signal circuits (terminal E)
7 —
together.
Does the scan tool display the Cruise Brake switch
Closed? Go to Step 6 Go to Step 14
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
8 refer to the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check the normally open feed circuit (terminal B) for and
9 open or short to ground. — —
Is the action complete? Go to Step 17
Engine Engine Controls - 6.5L 6-2503
DTC P0571 Cruise Brake Sw itch C ircuit (cont’d)
Step Action Value(s) Yes No
Check the normally open Cruise Brake switch signal circuit
10 for and open or short to ground. —
Was a repair performed? Go to Step 17 Go to Step 11
Check the normally open Cruise Brake switch signal circuit
11 for a proper connection at PCM? —
Was a repair performed? Go to Step 17 Go to Step 16
Check the normally closed feed circuit (terminal F) for and
12 open or short to ground. — —
Is the action complete? Go to Step 17
Check the normally closed Brake switch signal circuit for
13 and open or short to ground. —
Was a repair performed? Go to Step 17 Go to Step 14
Check the normally closed Brake switch signal circuit for a
14 proper connection at PCM? —
Was a repair performed? Go to Step 17 Go to Step 16
Replace the stop lamp switch.
15 — —
Is the action complete? Go to Step 17
Replace the PCM.
Important: The new PCM must be programmed. Refer to
16 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 17
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
17 which was set. —
4. 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 18 Go to Step 2
Does the Scan tool display any additional Go to the
18 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2504 Engine Controls - 6.5L Engine

DTC P0601 PCM M em ory

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the PCM
Important: The new PCM must be programmed. Refer to
2 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 3
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
3 which was set. —
4. 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2505

DTC P0602 PCM N ot Program m ed

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Weis the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the PCM.
Important: The new PCM must be programmed. Refer to
2 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 3
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
3 which was set. —
4. 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2506 Engine Controls ■ 6.5L Engine

DTC P0604 C ontrol M odule Random Access Mem ory

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the PCM.
Important: The new PCM must be programmed. Refer to
2 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 3
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
3 which was set. —
4. 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2507

DTC P0606 PCM Internal Com m unication Interrupted

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is DTC P0370 set? Go to DTC P0370
2 — Timing Reference
High Resolution Go to Step 3
Replace the PCM.
Important: The new PCM must be programmed. Refer to
3 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 4
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
4 which was set. —
4. 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 5 Go to Step 2
Does the Scan tool display any additional Go to the
5 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2508 Engine Controls - 6.5L Engine

DTC P1125 APP System

""
Powertrain
APP 3 APP1 APP 2 1 Control A
5 Volt 5 V o lt 5 Volt
5Volt
eference I Module {PCM)
_ _ __________ __ R_eference
L ________Reference _ ------------ --J R
D3 D12 'C1 C2' C3

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 A

JOBOIIk.
4 - 4

PCM

YEL/BLK 1275 WHT/BLK 1164 TAN 1274 Cl =32 BRN

C2 = 24 BRN
BLU
J J
C 3=32
E G dJ
J j 4 Accelerator
Pedal Position
(APP) Module

K' ' J' F' K C' ' B'

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

>
V ^----------5 ' ---------- ^ r ---------^ r ---------- > 'r ---------> t

DKGRN 1163 DK BLU 1161 LT BLU 1162

GRY 1273 BRN 1271 PPL 1272

o•

CO
CM

D4 PA B1
_ J^
C2 C5J,C1 A12^ C2
\

APP 3 Sensor APP1 Sensor APP2 Sensor n Powertrain

Signal Ground Signal Ground Signal Ground 1 Control £
1 Module (PCM)
L ________________ __ _______ ________ _______ __ _______________________ J

185076

C ircuit D escription C onditions fo r C learing th e M IL/DTC

The Accelerator Pedal Position (APP) module
provides a voltage signal that changes relative to
accelerator pedal position. There are three sensors
located within the APP module that are scaled
differently.
C onditions fo r S etting th e DTC
PCM has* recognized an intermittent APP fault and
there are no other current APP faults stored.
A ction Taken W hen the DTC Sets
• Vehicle will operate at limited power.
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
D iagnostic Aids
A DTC P1125 will set along with multiple APP DTCs.
All other DTCs should be diagnosis first.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if DTC P1125 is a hard
failure or an intermittent condition.
Engine Engine Controls - 6.5L 6-2509
DTC P1125 APP System
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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Disconnect the APP sensor electrical connector.
2. Ignition ON, engine OFF.
2 3. With J 39200 connected to ground, check all APP 4.8 V
5 volt reference circuits at APP harness.
Is voltage less than specified value? Go to Step 4 Go to Step 3
DTC is intermittent. If no additional DTCs are stored, refer
to Diagnostic Aids. If additional DTCs were stored refer to Go to the
3 the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
circuit for a short to ground.
4 —
3. If the 5 volt reference circuit is shorted to ground,
repair it as necessary.
Was the 5 volt reference circuit shorted to ground? Go to Step 6 Go to Step 5
Replace the PCM.
Important: The new PCM must be programmed. Refer to
5 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 which was set. —

4. 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 7 Go to Step 2
Does the Scan tool display any additional Go to the
7 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2510 Engine Controls - 6.5L
DTC P1191 Intake Air Duct Leak
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air
entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates
deceleration or idle.
The PCM has the ability to determine a intake leak
by using the Mass Air Flow (MAF) sensor and the
EGR Control Pressure / BARO sensor.
Conditions for Setting the DTC
• The PCM performs this DTC diagnostic
continuously.
. The DTCs P0405, P0406, P0102 and P0103
are not set.
• Baro greater than 75 kPa.
Engine
• All EGR tests have been completed (internal
to PCM).
• Intake leak greater than calibarteted value
(internal to PCM)
• All of the diagnostic set conditions met for
2 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine Engine Controls - 6.5L 6-2511
Conditions for Clearing the MIL/DTC Test Description
• The PCM will turn the MIL off after three Number(s) below refer to the step number(s) on the
consecutive trips without a fault condition. Diagnostic Table.
• A History DTC will clear when forty consecutive 3. A lagre leak in the intake system will set MAF
warm-up cycles that the diagnostic does not sensor DTC. All intake ducts should be
fail (coolant temperature has risen 5 ' C (40 * F) checked after the MAF sensor.
from start up coolant temperature and engine
coolant temperature exceeds 71 "C (160*F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
The most likely cause of failure is a leaky intake
duct after the MAF sensor.
To run the diagnostic test the engine must be at
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.

DTC P1191 Intake Air Duct Leak

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are there any EGR DTCs set? Go to the
2 — applicable
DTC Table Go to Step 3
Check for the following conditions:
• Air inlet duct leaks (after the MAF sensor).
3 — —
• All intake manifold gasket in place.
Has a repair been performed? Go to Step 4
Important: After repairs, the EGR ALM cells must be reset
4 (under special functions in scan tool). — —
Are EGR ALM cells reset? Go to Step 5
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
5 which was set. —
4. 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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2512 Engine Controls - 6.5L_________
DTC P1214 Injection Pump Timing Offset
1 5Volt
Reference A
__ _ _ _ _ _ J Module A
Circuit Description
The PCM has the ability to dtermine the amount of
offset needed to bring the engine to top dead center.
This is used by the PCM to determine proper
injection time.
Conditions for Setting the DTC
The TDC offset is greater than 2.46 degrees
or
The TDC Offset is less than -2.46 degrees.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Engine
1Powertrain
!Control
PCM
Cl =32BRN
C2=24 BRN
C3=32 BLU
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Conditions for Clearing the MIL7DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ‘ C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160'F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
The PCM will only run the diagnostic test when a
time set procedure has been activated. It is highly
unlikely that the vehicle will be brought in with this
DTC set. Refer to TDC Offset Adjustment.
Engine________________________________________________ Engine Controls - 6.5L 6-2513
DTC PI 214 injection Pump Timing Offset
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
reference, as the Scan tool loses data when using the
1 Clear Info function. —

Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are there any other DTCs set? Go to the
2 — Applicable
DTC Table Go to Step 3
Clear all codes and reset injection timing until TDC Offset
is between specified values. Refer to TDC Offset
3 Adjustment. -0.25 to -0.75
Is timing within specified value? Go to Step 6 Go to Step 4
Check the crankshaft position sensor for the following.
• Proper installation.
4 —
• Loose or broken sensor mounting tab.
Was a repair performed? Go to Step 6 Go to Step 5
Replace the Injection Pump. Refer to Fuel Injection Pump
Replacement.
5 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 6
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
6 which was set. —
4. 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 7 Go to Step 2
Does the Scan tool display any additional Go to the
7 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2514 Engine Controls - 6.5L____________________
DTC P1216 Fuel Solenoid Response Time Too Short
Circuit Description
The injection pump delivers fuel to individual
cylinders by opening and closing a solenoid control
fuel valve. The PCM monitors the amount of time it
takes for the fuel solenoid valve to physically close
after commanded to close. Closure time out of range
is seen as a fault. This response time is measured
in milliseconds.
Conditions for Setting the DTC
• The battery voltage is greater than 12 volts and
less than 15 volts.
• The engine coolant temperature is greater than
50 *C (122 * F).
• The ENGINE SPEED is greater than
1350 RPM.
• The requested fuel rate is greater than 0.0 mm
• The Inj. Pump Closure Time less than .75 ms.
Engine
185026
Action Taken When the DTC Sets
• The Malfunction Indicator Lamp (MIL) will not
illuminate.
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIL/DTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5*C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
Engine
Diagnostic Aids
Intermittent DTCs (P0251, P0370 and P1216) may
be caused by air entering the fuel system when fuel
levels get below 1/8 of a tank while performing hard
acceleration or turning maneuvers. Its also possible
that a P0251, P0370 and P1216 will set if vehicle
has run out of fuel. Customer driving habits should
be checked to determine if vehicle has been
performing in these manners. If it has been
determine that the vehicle has been performing in
these conditions, bleed fuel system of all air and test
drive vehicle.
When PCM is in backup fuel, fast idle and poor
performance problems will exist. If P0251 is also
stored, the snap shot mode on the scan tool should
be used to properly identify fault. DTCs P0335,
P1216, and P1217 may set along with this DTC.
___________ Engine Controls - 6.5L 6-2515
If DTC P1216 is set with any other DTCs, diagnose
them first. If the vehicle is running close to the DTC
setting closure time, vehicle should be checked
during cold start ups and during hot conditions.
An intermittent can be caused by the following:
• Poor connections
• Rubbed through wire insulation
• Broken wire inside the insulation
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step will determine if the ground circuit is
open which causes the vehicle not to start.
3. This step will determine if the signal circuit is
open or an injection pump (fuel solenoid) is
at fault.

DTC P1216 Fuel Solenoid Response Time Too Short

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is DTC P0219 set? Go to DTC P0219
Engine
2 —
Overspeed
Condition Go to Step 3
3 Will the engine start? — Go to Step 4 Go to Step 7
1. Verify the engine is at operating temperature.
2. Observe the Inj. Pump Closure Time on the
4 scan tool. 0.75 ms
Is the scan tool display less than or equal to the
specified value? Go to Step 5 Go to Step 6
1. Maintain the engine running.
5 2. Again, observe Inj. Pump Closure Time on scan tool.
0.1 ms
Is the Inj. Pump Closure Time display less than or equal
to the specified value? Go to Step 8 Go to Step 10
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
6 . refer to those applicable DTC table(s) first. — —
Applicable
Are any additional DTCs stored? DTC Table
1. Check the Closure ground circuit for an open.
7 2. If the Closure ground circuit is open, repair as
—
necessary.
Was a repair performed? Go to Step 12 Go to Step 10
1. Check the Closure signal circuit for an open or short
to ground and check connections at the driver.
8 2. If a problem is found, repair the problem as —
necessary.
Was a repair performed? Go to Step 12 Go to Step 9
Check the Closure signal circuit for a proper connection at
9 the PCM and replace the terminal if necessary. —
Did the terminal require replacement? Go to Step 12 Go to Step 11
6-2516 Engine Controls - 6.5L Engine
DTC P1216 Fuel Solenoid Response Time Too Short (cont’d)
Replace the Injection pump. Refer to Fuel Injection Pump
Replacement
10 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment
Is the action complete? Go to Step 12
Replace the PCM.
Important: The new PCM must be programmed. Refer to
11 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 12
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
12 which was set. —

4. 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 13 Go to Step 2
Does the Scan tool display any additional Go to the
13 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2517

DTC P1217 Fuel Solenoid Response Time Too Long

|_HotJn_Rijn^ndStartJ

PCM
Cl =32BRN
C2=24BRN
C3=32BLU

. Engine Engine Fuel Fuel Closure Closure Powertrain

1 Shut Off Shut Off Injection Injection Signal Ground 1Control
I Solenoid Solenoid Control Control 1Module ^
| Control Control
\ (PCM)

Circuit Description
The injection pump delivers fuel to individual
cylinders by opening and closing a solenoid control
fuel valve. The PCM monitors the amount of time it
takes for the fuel solenoid valve to physically close
after commanded to close. Closure time out of range
is seen as a fault. This response time is measured
in milli seconds.
Conditions for Setting the DTC
• The battery voltage greater than 12 volts and
less than 15 volts.
• The engine coolant temperature is greater than
5 0 'C (122’ F).
• The ENGINE SPEED greater than 1350 RPM.
• The requested fuel rate is greater than 0.0 mm
• The Closure Time is greater than 2.5 ms.
185026
Action Taken When the DTC Sets
• The Malfunction Indicator Lamp (MIL) will not
illuminate.
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
Conditions for Clearing the MIUDTC
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40 ‘ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160*F) that
same ignition cycle.
• Use of a Scan tool
6-2518 Engine Controls - 6.5L Engine
Diagnostic Aids Test Description
A weak (mechanical failure) fuel solenoid will result Number(s) below refer to the step number(s) on the
in a DTC P1217. If DTC P1217 is set with any other Diagnostic Table.
DTCs, diagnose them first. If the vehicle is running 3. This step determines if DTC 1217 is a hard
close to the DTC setting closure time, vehicle should failure or an intermittent.
be checked during cold start ups and during hot 6. This step will determine if the solenoid is at
conditions. fault, or if there is a problem with the PCM or
Poor performance and starting conditions will exist. wiring.
Fuel contamination could also cause this DTC.

DTC P1217 Fuel Solenoid Response Time Too Long

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Is DTC P0370 set? Go to DTC P0370
2 — Timing Reference
High Resolution Go to Step 3
1. Start and idle the engine.
2. Observe the Inj. Pump Closure Time display on the
3 2.4 ms
scan tool.
Is the scan tool display greater than the specified value? Go to Step 4 Go to Step 5
1. Turn all accessories ON (includes aftermarket
add-ons).
2. Maintain the engine idling.
4 3. Verify all post glow plug cycles are completed
12 - 15V
4. With a J 39200 connected to ground, measure the
voltage at the FUEL SOL fuse (fuel solenoid driver
ignition feed circuit) in the U/H relay center.
Is the voltage between specified value? Go to Step 7 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
5 refer to those DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Repair the fuel solenoid driver ignition feed circuit
connections or aftermarket add-ons.
6 Notice: Refer to Add-On Electrical Operated Equipment to — —
Battery Notice.
Was a repair performed? Go to Step 8
Important: Before replacing the Injection pump, check for
fuel system contamination. Refer to Contamination Testing.
Replace the Injection pump. Refer to Fuel Injection Pump
7 Replacement. — —
Important: The new injection pump must be timed. Refer
to Injection Timing Adjustment.
Is the action complete? Go to Step 8
Engine________________________________________________ Engine Controls ■ 6.5L 6-2519
DTC P1217 Fuel Solenoid Response Time Too Long (cont’d)
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
8 which was set. —
4. 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 9 Go to Step 2
Does the Scan tool display any additional Go to the
9 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2520 Engine Controls - 6.5L Engine

DTC P1218 Injection Pump Calibration Circuit

^HotJn_Run^nd_Startj|

PCM
=32BRN
=24 BRN
=32 BLU

. Engine Engine ■» Powertrain

Fuel Fuel Closure Closure
1 ShutOff ShutOff Injection Injection Signal Ground 1 Control
I Solenoid Solenoid Control Control 1 Module ^
| Control Control
\ (PCM) ia A

Circuit Description
The PCM uses a calibrated resistor mounted
internally in the injection pump to determine fuel
rates. The resistor value is stored in the PCM
memory. If the PCM memory has been disturbed or
the PCM has been replaced, the PCM will relearn
the resistor value on the next ignition cycle.
Conditions for Setting the DTC
• The PCM currently does not have a valid
resistor valve.
• The PCM is unable to read a resistor value.
185026
Action Taken When the DTC Sets
• The PCM will default to lowest fuel table.
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store
this information. If the diagnostic reports a
failure on the second consecutive drive trip, the
Freeze Frame records the operating conditions
at the time of failure and updates the Failure
Records.
Engine
Conditions for Clearing the MILVDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 *C (40' F)
from start up coolant temperature and engine
coolant temperature exceeds 71 “C (160‘ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
Intermittent DTCs (P0251, P0370 and P1216) may
be caused by air entering the fuel system when fuel
levels get below 1/8 of a tank while performing hard
acceleration or turning maneuvers. Its also possible
that a P0251, P0370 and P1216 will set if vehicle
has run out of fuel. Customer driving habits should
___________ Engine Controis - 6.5L 6-2521
be checked to determine if vehicle has been
performing in these manners. If it has been
determine that the vehicle has been performing in
these conditions, bleed fuel system of all air and test
drive vehicle.
Check connection at fuel injector driver. Clear DTC,
and cycle ignition. If DTC clears, treat condition as
an intermittent.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. This step will determine if there is a problem
with the connection at the fuel solenoid driver
or malfunctioning injection pump. This DTC will
only clear DTC Status when a Time Set
procedure has been activated (injection timing
does not have to be adjusted).

DTC P1218 Injection Pump Calibration 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are than any other DTCs set? Refer to
2 — Applicable
DTC Table Go to Step 3
1. Check the connection at the Fuel Solenoid Driver.
2. Clear the DTC, and cycle the ignition.
3. Start and idle the engine.
3 4. Activate the Time set procedure (the diagnostic will —
only run when a Time Set procedure is performed).
5. Exit out of the Time set procedure and Select DTC,
Specific, then enter the DTC number.
Does the Scan Tool indicate that the diagnostic Passed? Go to Step 5 Go to Step 4
Replace the Injection pump. Refer to Fuel Injection Pump
Replacement.
4 Important: The new injection pump must be timed. Refer — —
to Injection Timing Adjustment.
Is the action complete? Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
5 refer to those table(s). —
Applicable Go to
Are any additional DTC(s) stored? DTC Table Diagnostic Aids
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2522 Engine Controls - 6.5L
DTC P1406 EGR Valve Position
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air
entering the engine indicates an acceleration, high
load situation or no EGR flow, while a small quantity
of air indicates deceleration, idle or full EGR
situations.
The PCM will monitor MAF and EGR pressures
at different ranges to determine correct EGR
flow rates.
Engine
. DTCs P0405, P0406, P0102 and P0103
not set.
• All MAF and EGR Control Pressure test
complete (internal to PCM).
• EGR in Closed Loop.
• IAT greater than or equal to 2 0 ’ C (68 *F) and
less than or equal to 95 ’ C (203 * F).
• ALM cells not changed for greater than
2 seconds.
• Fuel rate between 10 and 25 mm3.
• Engine RPM between 1500 and 2100.
• Engine speed stable.
• Above conditions persist for at least 3 seconds.
Engine
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ' C (40 * F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ’ C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
A vacuum leak will cause a DTC P1406. Carefully
check all vacuum lines and components connected
to the hoses for leaks or deformities. Check vacuum
___________ Engine Controls - 6.5L 6-2523
source to EGR solenoid assembly. Also check for
small leak in EGR valve, and proper vacuum line
routing. Vacuum line ends can be trimmed to ensure
a tight fit if length permits.
To run the diagnostic test the engine must be at the
operating temperature, vehicle in drive at idle for
approximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and 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.

DTC P1406 EGR Valve Position

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Are there any other EGR DTCs set? Go To The
2 — Applicable
DTC Table Go to Step 3
Repair one of the following conditions:
• Restriction in the vacuum line from the EGR valve to
3 the vacuum tee (including the vacuum tee). — —
• A malfunctioning EGR valve (EGR valve stuck open).
Is the action complete? Go to Step 4
Important: After the Repairs, the EGR ALM cells must be
4 reset (under special functions in scan tool). — —
Are the EGR ALM cells reset? Go to Step 5
1. Using the Scan tool, clear the DTCs.
.2. Start engine and idle at normal operating temperature.
3. Select DTC, Specific, then enter the DTC number
which was set.
5 —
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 6 Go to Step 2
Does the Scan tool display any additional Go to the
6 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2524 Engine Controls - 6.5L_______
DTC P1409 EGR Vacuum System Leak
Refer to Emission Hose Routing Diagram.
Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The PCM uses the mass air flow information to
monitor EGR flow rates. A large quantity of air
entering the engine indicates an acceleration, high
load situation or no EGR flow, while a small quantity
of air indicates deceleration, idle or full EGR
situations.
The PCM will monitor MAF and EGR pressures at
different ranges to determine correct EGR flow rates.
Conditions for Setting the DTC
. DTCs P0405, P0406, P0102 and P0103
not set.
• All MAF and EGR Control Pressure tests
complete (internal to PCM).
Engine
• Engine at operating temperature.
• IAT greater than or equal to 2 0 'C (68 *F) and
less than or equal to 95 * C (203' F).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Engine
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after
three consecutive trips without a fault
condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ” C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160°F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
A vacuum leak will cause a DTC P1409. Carefully
check all vacuum lines and components connected
to the hoses for leaks or deformities. Check vacuum
source to EGR solenoid assembly. Also check for
small leak in EGR valve, and proper vacuum line
routing, refer to the Emission Hose Routing Diagram.
Vacuum line ends can be trimmed to ensure a tight
fit if length permits.
Engine Controls - 6.5L 6-2525
To run the diagnostic test the engine must be at
operating temperature, vehicle in drive at idle for
aproximately 1 minute, then with the vehicle in park
hold engine rpm steady between 1500 and 2100 rpm
for 30 seconds. If the diagnostic test fails to run,
vehicle must be driven.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. This step checks for a vacuum source to the
EGR valve.
4. This step checks for a malfunctioning EGR vent
solenoid.
5. This step checks for a good vacuum source.

DTC P1409 EGR Vacuum System Leak

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Install a vacuum gage in place of the EGR valve.
2. Start the engine.
3. Using the scan tool, command the EGR solenoid to
2 15 in. Hg
100% duty cycle.
4. At idle, observe the vacuum.
Is the vacuum greater than the specified value? Go to Step 4 Go to Step 3
1. Disconnect the vacuum feed to the EGR vent
solenoid.
2. Install the vacuum gage on the vacuum feed.
3 3. Start the engine. 15 in. Hg
4. Place the vehicle in drive.
5. Observe the vacuum gage at idle.
Is the vacuum greater than or equal to the specified value? Go to Step 7 Go to Step 5
1. Turn the ignition OFF.
2. Install a vacuum pump on the EGR valve.
4 —
3. Pump the vacuum pump up to 15 in. Hg of vacuum.
Does the EGR valve hold vacuum? Go to Step 6 Go to Step 11
1. Disconnect the vacuum feed to the EGR solenoid.
2. Install the vacuum gage on the vacuum feed.
3. Start the engine.
5 15 in. Hg
4. Place the vehicle in drive.
5. Observe the vacuum gage at idle.
Is the vacuum greater than or equal to the specified value? Go to Step 10 Go to Step 8
6-2526 Engine Controls - 6.5L________________________________________________ Engine
DTC P1409 EGR Vacuum System Leak (cont’d)
Step Action Value(s) Yes No
DTC is intermittent. If no additional DTCs are stored, refer
to Diagnostic Aids. If additional DTCs were stored refer to Go to the
6 those table(s). —
Applicable Go to
Are any additional DTC(s) stored? DTC Table Diagnostic Aids
Repair one of the following:
• Leaking, restricted or deformed vacuum hoses from
the EGR vent solenoid to the EGR valve and the
7 — —
EGR pressure control/BARO sensor.
• A malfunctioning EGR vent solenoid.
Is the action complete? Go to Step 12
1. Check for a leaking or deformed vacuum hose to the
vacuum pump.
8 —
2. Repair as necessary.
Was a problem found? Go to Step 12 Go to Step 9
Replace the vacuum pump.
9 — —
Is the action complete? Go to Step 12
Repair one of the following:
• Leaking, restricted or deformed vacuum hoses
between the EGR solenoid and the EGR vent
10 — —
solenoid.
• Malfunctioning EGR solenoid.
Is action complete? Go to Step 12
Replace the EGR valve. Refer to EGR Valve Replacement.
11 — —
Is the action complete? Go to Step 12
Important: After the Repairs, the EGR ALM cells must be
12 reset (under special functions in scan tool). — —
Are the EGR ALM cells reset? Go to Step 13
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
13 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 14 Go to Step 2
Does the Scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine Engine Controls - 6.5L 6-2527

DTC P1621 EEPROM Write

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the PCM.
Important: The new PCM must be programmed. Refer to
2 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 3
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
3 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
6-2528 Engine Controls - 6.5L_____________
DTC P1626 VTD Controller Serial Data Circuit
Circuit Description
The Passlock Module receives the code from the hall
effect sensor in the steering column and compares it
to the code the Passlock module learned at the first
power up at the factory. If this code matches the
code stored in the Passlock module, the Passlock
module will send a fuel continue message to the
PCM (The PCM enables fuel injection temporarily
until the fuel continue/disable decision is made.). If
the Passlock module does not send a code or if the
PCM doesn’t receive it, the vehicle will not start
(start and stall). If the Passlock module and PCM
loose communication with each other while the
engine is running the Passlock module will
Fail-Enable and allow the driver to restart the
vehicle on future ignition cycles until communications
between the Passlock module and PCM are
restored. If the battery is disconnected during this
period, the vehicle will loose its Fail-Enable status
and will no longer start until communications has
been reestablished. If the Passlock module and PCM
loose communications with each other while the
engine is not running, the Passlock system will
disable fuel until communications is restored to
prevent vehicle theft. In both cases DTC P1626 will
be set. The PCM will not disable fuel injection once
it has been enabled within a given ignition cycle to
prevent stalling as a result of Passlock system faults.
Engine
Conditions for Setting the DTC
• The vehicle Theft Deterrent (VTD) system is
enabled.
• The fuel enable decision point has been
reached.
• The system has Fail-Enabled due to a loss of
communications while the engine is running.
OR
• No password (code) message is received by
the PCM from the Passlock control module prior
to the VTD Fuel Decision Point.
Action Taken When the DTC Sets
• The vehicle will not start.
• The Malfunction Indicator Lamp (MIL) will not
illuminate.
Conditions for Clearing the DTC
• A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other emission related failure.
• PCM battery voltage is interrupted.
• Using a scan tool.
Engine Engine Controls - 6.5L 6-2529
Diagnostic Aids
The most likely cause of DTC P1626 is a loss of
serial data communication to the Passlock module.
Check for loss of power to the Passlock module or
for other causes of communication loss. Use the
Class 2 Circuit Check in the scan tool to determine if
the Passlock module is active (Class 2 Message
Monitor on the scan tool). Refer to Vehicle Theft
Deterrent system (VTD System Check for further
diagnosis.

DTC P1626 VTD Controller Serial Data Circuit

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool
Capture Info to record freeze frame and failure records for
reference, as data will be lost when clear Info function is
1 — Go to Vehicle
used.
Theft Deterrent Go to
Was the Powertrain On-Board Diagnostic (OBD) System (VTD) System Powertrain OBD
Check performed? diagnosis System Check
6-2530 Engine Controls ■ 6.5L Engine

DTC P1627 A/D 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Replace the PCM.
Important: The new PCM must be programmed. Refer to
2 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 3
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
3 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 4 Go to Step 2
Does the Scan tool display any additional Go to the
4 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_____________________________________ Engine Controls - 6.5L 6-2531

DTC P1630 Theft Deterrent PCM in Learn Mode

This diagnostic test checks for the Enable Password
Learning Flag indicating the PCM is in learn
password mode. This mode allows the PCM to learn
the password from the Passlock module at assembly
or when being serviced. The password needs to be
learned whenever the PCM or the Passlock module
is replaced.
Conditions for Setting the DTC
When the Enable Learning Flag, is set.
Action Taken When the DTC Sets
The Malfunction Indicator Lamp (MIL) will not
illuminate.
• A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other emission related failure.
• PCM battery voltage is interrupted.
• Using a scan tool.
Diagnostic Aids
The PCM in learn mode is a DTC for the vehicle at
the assembly plant, dealership and outside garage
personnel as an indication that the learn mode is
enabled. This means the PCM is now ready to learn
a new password. Refer to Vehicle Theft Deterrent
system for further diagnosis.

DTC P1630 Theft Deterrent PCM in Learn Mode

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool
Capture Info to record freeze frame and failure records
for reference, as data will be lost when clear Info function
1 — Go to Vehicle
is used.
Theft Deterrent Go to
Was the Powertrain On-Board Diagnostic (OBD) System (VTD) System Powertrain OBD
Check performed? diagnosis System Check
6-2532 Engine Controls - 6.5L Engine

DTC P1631 Theft Deterrent Password Incorrect

■[ Powertrain ip
Control Fuse
Block
Module A ▼
PCM PCM Serial Data . (PCM)
Ground Ground (ClassII)
FuseBlock ORN 840
D7 D6 C3 C8YC3
Details
Cell 11___
PPL 1807
PCM
Electronic
■Serial Datai 1 32BRN
TAN/ BLK/WHT 451 Ground i (Classii) | Brake
■24BRN
Distribution ►- - n ■32BLJ
WHT 551 i i Control A
Cell 14__
J Module
G C1 (EBCM)

r— 1EVO
PPL 1807
BLK/WHT^ BLK/WHT
451 451 Passlock
Module
BLK/WHT ORN 840
Ground 1807
Distribution
fol|, 14__

Ground
Distribution PPL 1807
Cell 14
BLK 150 E91
r“" Active Transfer
BLK/WHT 451
PPL 1807 l_ _ JCase (ATC)
BLK 150 BLK 150 Control Module
4. 2. 16 Data Link
Connector (DLC)

192130

Circuit Description Diagnostic Aids

This test checks for mismatched (incorrect)
passwords between the Passlock module and PCM.
Whenever the Passlock module or PCM are
replaced, a theft learn procedure must be followed in
order for the new password to be learned.
Conditions for Setting the DTC
• An incorrect fuel continue password has been
received from the Passlock module.
t limit can exceed this limit, without interfering
Action Taken When the DTC Sets
• TheVTD system is enabled.
• The vehicle will not start.
• The Malfunction Indicator Lamp (MIL) will not
illuminate.
Conditions for Clearing the DTC
• A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other emission related failure.
• PCM battery voltage is interrupted.
• Using a scan tool.
Refer to Vehicle Theft Deterrent system for further
diagnosis.
Test Description
Number(s) below refer to the step number(s) on the
diagnostic table.
3. The 10 minute and 30 second time criteria, are
a minimum required amount of time. The time
with the Auto Learn Procedure. A scan tool can
be used (VTD Auto Learn Timer equals
Inactive) to determine when the 10 minutes has
expired.
4. The security lamp will remain ON until
10 minute timer is complete. Depending on the
component replaced, the lamp may remain
ON steady or flash.
8. If DTC P1631 is set, indicates that the
procedure was not followed correctly. The
Re-learn procedure will have to be
re-performed.
Engine________________________________________________ Engine Controls - 6.5L 6-2533
DTC P1631 Theft Deterrent Password incorrect
Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool
Capture Info to record freeze frame and failure records
for reference, as data will be lost when clear Info function
1 is used. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Important: Before proceeding with this table, check for
any Vehicle Theft Deterrent (VTD) DTCs being set (except
2 if you were sent here from PCM replacement). If VTD —
DTCs are set, refer to the appropriate DTC.
Is a T-50/T-60 available? Go to Step 5 Go to Step 3
3 Is a Tech 2 available? — Go to Step 6 Go to Step 4
Important: While the PCM is in the Auto Learn Procedure,
battery voltage must be maintained at all times. This
procedure must be followed exactly as indicated or the
procedure will have to be repeated from the beginning.
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Attempt to start vehicle (vehicle will start and stall),
after the engine has stalled leave the ignition ON
for 10 minutes (security light will remain on for
10 minutes and then go out).
2. After the Security lamp turns OFF, turn the ignition
off for 30 seconds.
4 —
3. Again, attempt to start vehicle (vehicle will start and
stall), after the engine has stalled leave the ignition
ON for 10 minutes (security light will remain on for
10 minutes and then go out).
4. After the Security lamp turns OFF, turn the ignition
off for 30 seconds.
5. Again, attempt to start vehicle (vehicle will start
and stall), after the engine has stalled leave the
ignition ON for 10 minutes (security light will
remain on for 10 minutes and then go out) or until
DTC P1630 sets.
6. Turn the ignition off for 30 seconds.
7. Turn the ignition on and wait 30 seconds.
8. Attempt to start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
6-2534 Engine Controls - 6.5L________________________________________________ Engine
DTC P1631 Theft Deterrent Password Incorrect (cont’d)
Step Action Value(s) Yes No
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Using Techline terminal, enter the Service
Programming System (SPS).
2. Select terminal to vehicle programming.
3. Select Done and follow instructions on Vehicle
Set-up screen
4. Select Vehicle Theft Re-learn.
5 —
5. Follow the instructions on the remaining screens.
• The PCM and the Passlock control module will be
prepared for a re-leam.
• A security timer will be on for approximately
10 minutes or until DTC P1630 sets. It is
important that during the 10 minute-wait, the user
keep the terminal connected to the vehicle.
• When the PCM and the Passlock control module
are prepared to re-learn, turn the ignition OFF for
30 seconds and then start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
Engine________________________________________________ Engine Controls ■ 6.5L 6-2535
DTC P1631 Theft Deterrent Password Incorrect (cont’d)
Step Action Value(s) Yes No
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Using a scan tool enter the Service Programming
System (SPS).
2. After entering the vehicle information, choose the
Request Info soft key on the scan tool.
3. Select Done and follow instructions on Vehicle
Set-up screen
4. Disconnect the scan tool from the vehicle and
connect to the Techline terminal.
5. At the Techline terminal select Service Programming
System (SPS) and select terminal to scan tool
programming method. Select Done.
6. Follow the instructions on the remaining screens.
7. Select Vehicle Theft Re-leam.
6 8. Select Program at the summary screen. The terminal —
will download information to the scan tool.
9. Return the scan tool to the vehicle and connect to
Diagnostic Link Connector (DLC).
10. Select Service Programming from the scan tool main
menu. Answer the prompts regarding the model year
and vehicle type. Press the Theft Re-leam soft key
on the scan tool.
11. Follow the instructions on the remaining screens.
• The PCM and the Passlock control module will be
prepared for re-leam.
• A security timer will be on for approximately
10 minutes or until DTC P1630 sets. It is
important that during the 10 minute-wait, the user
keep the terminal connected to the vehicle.
• When the PCM and the Passlock control module
are prepared to re-leam, turn the ignition OFF for
30 seconds and then start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
Important: Before Clearing DTCs, monitor all DTC status
parameters and note any additional DTCs.
1. Clear PCM DTCs.
7 —
2. Turn the ignition off for 30 seconds.
3. Attempt to start the engine.
Does the engine start and operate normally? System OK Go to Step 8
Go to Applicable
8 —
Are DTCs P1626, P1630 or P1631 set? DTC table Go to Step 2
6-2536 Engine Controls - 6.5L Engine

DTC P1635 5 Volt Reference Low

Powertrain
5Volt Control
ReferenceA
_ _ _ _ _ _ _ _ J Module A

A
J 0 6 0 Ilk

PCM
Cl =32 BRN
C2=24 BRN
C3=32 BLU

185025

Circuit Description Conditions for Clearing the MIL/DTC

The PCM provides a 5 volt supply for use in
powering up sensors. This test monitors the voltage
present at terminals BRD13 (shared by Boost,
EGR Control Pressure/BARO and Crankshaft
Position sensors) and BRD14 (Optical/Fuel
temperature sensor (Cam/HI.Res).
Conditions for Setting the DTC
5 volt reference is less than 1 volt.
Action Taken When the DTC Sets
• The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM records the operating conditions at
the time the diagnostic fails. This information
stores in the Failure Records.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40’ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ’ C (160‘ F) that
same ignition cycle.
• Use of a Scan tool
Diagnostic Aids
During the time the failure is present, the setting of
additional DTCs that share a 5 volt reference may
also set.
Engine Engine Controls - 6.5L 6-2537
Test Description 4. Checks to determine if there is a
Number(s) below refer to the step number(s) on the short-to-ground in the reference circuit or a
short-to-ground in the PCM.
Diagnostic Table.
7. This step determines if the short is being
2. Checks to confirm that a DTC is still present.
caused by one of the sensors on the engine or
3. Checks to determine if there is a 5 volt the short is in the wiring harness.
reference from the PCM.

DTC P1635 5 Volt Reference Low

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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Install a Scan Tool.
2 2. Crank engine for 15 seconds or until start up. —
Does the DTC reset? Go to Step 3 Go to Step 5
1. Turn the ignition ON leaving the engine OFF.
2. Disconnect the Boost sensor.
3 3. With J 39200 DMM, probe the 5 volt reference circuit 4.0 V
at the harness connector.
Is the voltage less than the specified value? Go to Step 4 Go to Step 6
1. Disconnect the PCM connector with the Boost sensor
5 volt reference circuit.
4 2. With a test light connected to B+, probe the 5 volt —
reference circuit at the PCM harness.
Is the test light ON? Go to Step 7 Go to Step 10
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
5 refer to those table(s). —
Applicable Go to
Are any additional DTCs stored? DTC table Diagnostic Aids
Replace the Boost sensor. Refer to Boost Sensor
6 Replacement. — —
Is the action complete? Go to Step 11
With the test light still probing the Boost sensor 5 volt
reference circuit at the PCM, disconnect each sensor, one
at a time, that shares the 5 volt reference with the Boost
7 sensor. —
Does the test light turn OFF when one of the sensors are
disconnected? Go to Step 8 Go to Step 9
Replace the sensor that caused the test light to turn OFF.
8 — —
Is the action complete? Go to Step 11
Repair the short to ground in 5 volt reference circuit.
9 — —
Is the action complete? Go to Step 11
Replace the PCM.
Important: The new PCM must be programmed. Refer to
10 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 11
6-2538 Engine Controls - 6.5L________________________________________________ Engine
DTC P1635 5 Volt Reference Low (cont’d)
Step Action Value(s) Yes No
1. Using the Scan tool, clear the DTCs.
2. Start engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
11 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 12 Go to Step 2
Does the Scan tool display any additional Go to the
12 undiagnosed DTCs? — Applicable
DTC table System OK
Engine______________________ Engine Controls - 6.5L 6-2539

D TC P1641 M IL C o n tro l C irc u it

| Hot In Run And Start]

“*IP
I Power "4"
Distribution GAGES
Fuse 4
^use
I Cell 10 1Block
I 10 A I

PNK 39
Fuse Block
Details PCM
Cell 11 Cl = 32 BRN
PNK 39 C2 = 24 BRN
C 3=32 BLU
22 a
r ■* Instrument A
I Instrument 4 f "~T Malfunction
[ Cluster
Cluster A SERVICE A . Indicator
Cell 81 m THROTTLE ( I ) Lamp (MIL)
I Y SOON (SERVICE i
L
X Lamp
I f
ENGINE SOON) i
21' 23'
WHT/BLK 176 BRN/WHT 419
> /
Ak A k

WHT/BLK 176 BRN/WHT 419

Dll ________ P14 C3

r - — — — — — — —
1 Service Throttle MIL ■*Powertrain
Soon Lamp Control 1 Control
1 Control 1 Module (PCM) i a A
L _ _ _

185027
C ircuit Description C onditions fo r C learing the M IL/DTC
A dash light is illuminated by the PCM if diagnostics • A History DTC will clear when forty consecutive
have detected certain errors related to the engine warm-up cycles that the diagnostic does not
performance or engine sensor status. When the fail (coolant temperature has risen 5 ’ C (40 * F)
PCM is commanding the MIL ON, the voltage from start up coolant temperature and engine
potential of the circuit will be low (near 0 volts). coolant temperature exceeds 71 *C (160‘ F) that
When the PCM is commanding the MIL OFF, the same ignition cycle.
voltage potential of the circuit will be high (near • Use of a Scan tool
battery volts). The primary function of the PCM is D iagnostic A ids
to supply the ground for the MIL circuit.
A malfunctioning bulb, the control circuit shorted to
C onditions fo r S etting th e DTC ground or battery voltage, will cause a P1641 to set.
An intermittent can be caused by the following:
• MIL requested ON.
• Poor connections
• Voltage on MIL control circuit high (near
battery volts). • Rubbed through wire insulation
or • Broken wire inside the insulation
• MIL requested OFF. Test Description
• Voltage on MIL control circuit low (near 0 volts). Number(s) below refer to the step number(s) on the
Diagnostic Table.
A ction Taken W hen th e DTC Sets 2. Be sure that both the ON and the OFF states
• The PCM will not illuminate the Malfunction are commanded. Repeat the commands as
Indicator Lamp (MIL). many times as necessary.
• The PCM records the operating conditions at 9. If no trouble is found in the control circuit or the
connection at the PCM, the PCM maybe
the time the diagnostic fails. This information
malfunctioning, however, this is an extremely
stores in the Failure Records.
unlikely failure.
6-2540 Engine Controls - 6.5L Engine
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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
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
Engine
DTC P1643 Wait to Start Lamp Control Circuit
Refer to Glow Plug Controls.
Circuit Description
A dash light (Wait To Start) is illuminated by the
PCM when the glow plugs are commanded ON.
When the PCM is commanding the Wait To Start
lamp ON, the voltage potential of the circuit will be
low (near 0 volts). When the PCM is commanding
the Wait To Start lamp OFF, the voltage potential of
the circuit will be high (near battery volts). The
primary function of the PCM is to supply the ground
for the Wait To Start lamp circuit.
Engine Controls ■ 6.5L 6-2541
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 * C (40 “ F)
from start up coolant temperature and engine
coolant temperature exceeds 71 'C (160’ F) that
same ignition cycle.
• Use of a Scan tool

Conditions for Setting the DTC Diagnostic Aids

• Wait To Start lamp requested ON.
• Voltage on Wait To Start lamp circuit high (near
battery volts).
or
• Wait To Start lamp requested OFF.
• Voltage on Wait To Start lamp control circuit low
(near 0 volts).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
A faulty bulb or the control circuit shorted to ground
will cause a P1643 to set.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Repeat the command as many times
as necessary (when glow plugs are
commanded ON by the scan tool, an internal
PCM timer protects the glow plugs from
damage by cycling them ON for 3 seconds and
OFF for 12 seconds. After the 12 seconds has
elapsed, the glow plugs can be commanded
ON again).
9. If no trouble is found in the control circuit or the
connection at the PCM, the PCM maybe
malfunctioning, however, this is an extremely
unlikely failure.

DTC P1643 Wait to Start Lamp 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
2. Using a scan tool, command the Glow Plug
2 —
system ON.
Does the lamp turn ON? 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 additional DTC(s) stored? DTC table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the Wait
4 To Start lamp control circuit. —
3. Turn the ignition ON leaving the engine OFF.
Is the lamp OFF? Go to Step 5 Go to Step 7
6-2542 Engine Controls - 6.5L Engine
DTC P1643 Wait to Start Lamp Control Circuit (cont’d)
Step Action Value(s) Yes No
With a fused jumper wire connected to ground, probe the
Wait To Start lamp control circuit in the PCM harness
5 connector. —
Is the lamp ON? Go to Step 6 Go to Step 8
Check the connections at PCM.
6 —
Was a repair performed? Go to Step 10 Go to Step 9
The Wait To Start control circuit is shorted to ground,
7 repair as necessary. — —
Is the action complete? Go to Step 10
Check the Wait To Start circuit for the following.
• Open ignition feed to the bulb
8 • malfunctioning bulb — —
• Control circuit open or shorted to B+
Was a repair performed? Go to Step 10
Replace the PCM.
Important: The new PCM must be programmed. Refer to
9 — —
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 to the
11 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine____________________________________
DTC P1653 EGR Vent Solenoid Control Circuit
The EGR flow is controlled by the vacuum actuated
EGR valve. The EGR vent solenoid purges to
atmosphere the vacuum level at the EGR valve
actuator as commanded by the PCM. This is done
when the EGR flow is desired to turn off quickly.
When the PCM is commanding the EGR vent ON,
the voltage potential of the circuit will be low (near
0 volts). When the PCM is commanding the EGR
vent OFF, the voltage potential of the circuit will be
high (near battery volts). The primary function of the
PCM in this circuit is to supply the ground for the
EGR vent solenoid.
Conditions for Setting the DTC
• PCM requested EGR vent ON.
• Voltage on EGR vent control circuit high (near
battery volts).•
• Conditions met for 2 seconds.
or
Engine Controls - 6.5L 6-2543
• Voltage on EGR vent control circuit low (near
0 volts).
• Conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
6-2544 Engine Controls - 6.5L
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ‘ C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 ‘ C (160‘ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
The scan tool has a 5 second ON time abort. The
EGR vent solenoid can be commanded ON for as
many times as needed, in 5 second intervals. Its
possible other EGR DTCs may set along with DTC
P1653. This diagnostic can be checked at key up.
A quick operational check can be made by
commanding the EGR vent solenoid ON and OFF
with the scan tool while monitoring Actual EGR.
Actual EGR will display BARO (approximately) when
EGR solenoid is OFF.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
Engine
pressure increases over the life of the vehicle or
other engine system variations. The ALM is made
up of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
An intermittent may be caused by the following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Be sure that both the ON and OFF states are
commanded. Repeat the commands as many
times as necessary.
3. This check can detect a partially shorted coil
which would cause excessive current flow.
Leaving the circuit energized for 2 minutes
allows the coil to warm up. When warm, the
coil may open (Amps drop to zero, or short
(Amp draw greater than 0.75 A).
7. Listen for an audible click when the solenoid
operates.

DTC P1653 EGR Vent Solenoid 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Disconnect the EGR vent solenoid
2. Turn the ignition ON leaving the engine OFF.
3. Connect a DMM J 39200 J between the EGR vent
2 solenoid control circuit and the ignition feed circuit at B+
the harness connector.
4. Using a scan tool, command the solenoid ON.
Is voltage at the specified value? Go to Step 3 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the EGR
vent solenoid control circuit.
3. Turn the ignition ON leaving the engine OFF.
3 4. Using a DMM J 39200 on the 10 Amp scale, 0.75 A
measure the current from the solenoid control circuit
in the PCM harness connector to ground for
2 minutes.
Is the current draw less then the specified value, but
not zero? Go to Step 8 Go to Step 4
Engine Engine Controls - 6.5L 6-2545
DTC P1653 EGR Vent Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored
4 refer to the applicable DTC table(s) first. —
Go to Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
1. Verify the EGR vent solenoid still disconnected.
2. Turn the ignition ON leaving the engine OFF.
5 3. Connect a DMM J 39200 between the EGR vent B+
ignition feed circuit at the harness connector and
chassis ground.
Is the voltage at the specified value? Go to Step 9 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to ground, probe the
6 ignition feed circuit at the EGR vent solenoid harness —
connector.
Is the test light ON? Go to Step 7 Go to Step 12
1. Turn the ignition OFF.
2. Reconnect the solenoid.
3. Disconnect the PCM harness containing the solenoid
control circuit.
7 4. Turn the ignition ON. —
5. With a fused jumper wire connected to ground, probe
the solenoid control circuit in the PCM harness
connector.
Does the solenoid operate? Go to Step 11 Go to Step 10
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
8 refer to the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for a proper connection at the EGR vent solenoid
9 and replace terminals as necessary. —
Did the terminal require replacement? Go to Step 15 Go to Step 13
Repair the EGR vent solenoid control circuit.
10 — —
Is the action complete? Go to Step 15
Check for a proper connection at the PCM EGR vent
11 control circuit. —
Was a problem found? Go to Step 15 Go to Step 14
Repair the open in the ignition feed circuit.
12 — —
Is the action complete? Go to Step 15
Replace the EGR vent solenoid. Refer to EGR Vent
13 Solenoid Replacement. — —
Is the action complete? Go to Step 15
Replace the PCM.
Important: The new PCM must be programmed. Refer to
14 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 15
6-2546 Engine Controls ■ 6.5L________________________________________________ Engine
DTC P1653 EGR Vent Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
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
15 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 16 Go to Step 2
Does the Scan tool display any additional Go to the
16 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine__________________________________________ Engine Controls - 6.5L 6-2547

DTC P1654 Service Throttle Soon Lamp Control CKT

| Hot In Run And Start]

..Asr I81
r ---------- I_ T --------IP
| Power
Distribution H8 X GAGES 1Fl
Fuse
> Cell 10 Block
I

PNK 39
Fuse Block
Details PCM
Cell 11 Cl =32 BRN
PNK 39 C2=24 BRN
22 X
C3=32 BLU
Instrument A
I Instrument 4 - J ■ ■—f Malfunction
I Cluster SERVICE Indicator | Cluster
Cell 81 (T ) THROTTLE (JJ Lamp (MIL)
I 'y so o n (SERVICE l
I T LamP l ENGINE SOON) j
l
21' /
23'
WHT/BLK 176 BRN/WHT 419
*
A k /Ak

WHT/BLK 176 BRN/WHT 419

D U . c. - _ _________ PJ1 C3
r --------------------
> Service Throttle "* Powertrain
Soon Lamp Control 1 Control ^
I Control ■Module(PCM)
k______ _ __ ___ _ _ j

185027
Circuit Description Conditions for Clearing the MIL/DTC
A dash light is illuminated by the PCM if the • The PCM will turn the MIL off after three
diagnostics has detected certain errors related to the consecutive trips without a fault condition.
Accelerator Pedal Position (APP) sensor. When the
• A History DTC will clear when forty consecutive
PCM is commanding the Service Throttle Soon Lamp
warm-up cycles that the diagnostic does not
ON, the voltage potential of the circuit will be low
(near 0 volts). When the PCM is commanding the fail (coolant temperature has risen 5 * C (40 * F)
Service Throttle Soon Lamp OFF, the voltage from start up coolant temperature and engine
potential of the circuit will be high (near battery coolant temperature exceeds 71 *C (160*F) that
volts). The primary function of the PCM in this circuit same ignition cycle.
is to supply the ground for the Service Throttle Soon • Use of a Scan Tool
Lamp.
Diagnostic Aids
Conditions for Setting the DTC
A malfunctioning bulb or the control circuit shorted to
• Service Throttle Soon lamp requested ON. ground will cause a P1654 to set.
• Voltage on the Service Throttle Soon control
circuit high (near battery volts). Test Description
or Number(s) below refer to the step number(s) on the
• Service Throttle Soon lamp requested OFF. Diagnostic Table.
• Voltage on the Service Throttle Soon control 2. Be sure that both the ON and the OFF states
circuit low (near 0 volts). are commanded. Repeat the commands as
many times as necessary.
Action Taken When the DTC Sets
9. If no trouble is found in the control circuit or the
• The PCM will not illuminate the Malfunction connections at the PCM, the PCM maybe
Indicator Lamp (MIL). malfunctioning, however, this is an extremely
• The PCM records the operating conditions at unlikely failure.
the time the diagnostic fails. This information
stores in the Failure Records.
6-2548 Engine Controls - 6.5L________________________________________________ Engine
DTC P1654 Service Throttle Soon Lamp Control CKT
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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition ON leaving the engine OFF.
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
With a fused jumper wire connected to ground, probe the
5 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 Service Throttle Soon lamp control circuit is shorted to
7 ground, repair as necessary. — —
Is the action complete? Go to Step 10
1. Check the Service Throttle Soon circuit for the
following:
• Open ignition feed to the bulb.
8 • Malfunctioning bulb. — —
• Control circuit open or shorted to B+.
2. Repair the problem as necessary.
Is the repair complete? Go to Step 10
Replace the PCM.
Important: The new PCM must be programmed. Refer to
9 — —
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 to the
11 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________________
DTC P1655 EGR Solenoid Control Circuit
Circuit Description
The EGR flow is controlled by the vacuum actuated
EGR valve. The EGR pulse width modulated solenoid
meters the vacuum level at the EGR valve actuator as
commanded by the PCM. When the PCM is
commanding the EGR solenoid ON, the voltage
potential of the circuit will be low (near 0 volts). When
the PCM is commanding the EGR solenoid OFF, the
voltage potential of the circuit will be high (near battery
volts). The primary function of the PCM in this circuit is
to supply the ground for the EGR solenoid.
Conditions for Setting the DTC
• PCM requested EGR solenoid ON.
• Voltage on EGR solenoid control circuit high
(near battery volts).
• 2 consecutive faults detected.
• Conditions met for 2 seconds.
or
Engine Controls - 6.5L 6-2549
• PCM requested EGR solenoid OFF.
• Voltage on EGR solenoid control circuit low
(near 0 volts).
• 2 consecutive faults detected.
• Conditions met for 2 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
6-2550 Engine Controls - 6.5L
Conditions for Clearing the MIL/DTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5*C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160‘ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
The scan tool has a 5 second ON time abort. The
EGR solenoid can be commanded ON for as many
times as needed, in 5 second intervals. Its possible
other EGR DTCs may set along with DTC P1655.
This diagnostic can be checked at key up. A quick
operational check can be made by commanding the
EGR solenoid ON and OFF with the scan tool while
monitoring Actual EGR. Actual EGR will display Baro
(approximately) when EGR solenoid is OFF. Full
EGR will be achieved when EGR solenoid is
commanded ON with the scan tool.
The Adaptive Learn Matrix (ALM) is used to adjust
the EGR vacuum control based on Mass Air Flow
(MAF). The ALM may change as a result of back
pressure increases over the life of the vehicle or
Engine
other engine system variations. The ALM is made up
of sixteen cells (numbered from zero to fifteen) in
which each cell covers a range of engine speed
(RPM) and load (mm3).
An intermittent may be caused by the following:
• Poor connections.
• Rubbed through wire insulation.
• Broken wire inside the insulation.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Be sure that both the ON and OFF states are
commanded. Repeat the commands as many
times as necessary. This Step will determine if
this DTC is a current or intermittent.
3. This check can detect a partially shorted coil
which would cause excessive current flow.
Leaving the circuit energized for 2 minutes
allows the coil to warm up. When warm, the
coil may open (amps drop to zero), or short
(amp draw greater than 0.75A).
7. Listen for an audible click when the solenoid
operates. This step checks the ignition feed
circuit for an open.

DTC P1655 EGR Solenoid 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
reference, as the Scan tool loses data when using the
1 Clear Info function. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect a Scan tool.
2. Start and idle the engine.
2 3. With the scan tool, command the EGR solenoid ON —
and OFF.
Does the Actual EGR respond to the scan tool
commands? Go to Step 3 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the EGR
solenoid control circuit.
3. Turn the ignition ON leaving the engine OFF.
3 4. Using a DMM J 39200 on 10 Amp scale, measure 0.75 A
current from the solenoid control circuit in the PCM
harness connector to ground for 2 minutes.
Is the current draw less than the specified value, but
not zero? Go to Step 8 Go to Step 4
1. Turn the ignition OFF.
2. Verify the PCM connector is still disconnected.
3. Disconnect the EGR solenoid.
4 4. Using a DMM, J 39200 measure the resistance from —
the solenoid control circuit in the PCM harness
connector to ground.
Does the DMM display infinite resistance? Go to Step 13 Go to Step 10
Engine Engine Controls - 6.5L 6-2551
DTC P1655 EGR Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
1. Disconnect the EGR solenoid
2. Turn the ignition ON leaving the engine OFF.
3. Connect a test light between the EGR solenoid
control circuit and the ignition feed circuit at the
5 —
harness connector.
4. Using a scan tool, command the solenoid ON
and OFF.
Does the test light turn ON and OFF with each command? Go to Step 9 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to ground, probe the
6 ignition feed circuit at the EGR solenoid harness —
connector.
Is the test light ON? Go to Step 7 Go to Step 12
1. Turn the ignition OFF.
2. Reconnect the solenoid.
3. Disconnect the PCM harness containing the solenoid
control circuit.
7 4. Turn the ignition ON leaving the engine OFF. —
5. With a fused jumper wire connected to ground, probe
the solenoid control circuit in the PCM harness
connector.
Does the solenoid operate? Go to Step 11 Go to Step 10
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
8 refer the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for a proper connection at the EGR solenoid and
9 replace any terminals as necessary. —
Did the terminal require replacement? Go to Step 15 Go to Step 13
Repair the EGR solenoid control circuit.
10 — —
Is the action complete? Go to Step 15
Check for a proper connection at the PCM EGR control
11 circuit. —
Was a problem found? Go to Step 15 Go to Step 14
Repair the open in the ignition feed circuit.
12 — —
Is the action complete? Go to Step 15
Replace the EGR solenoid. Refer to EGR Solenoid
13 Replacement. — —
Is the action complete? Go to Step 15
Replace the PCM.
Important: The new PCM must be programmed. Refer to
14 — —
PCM Replacement/Programming.
Is the action complete? Go to Step 15
6-2552 Engine Controls - 6.5L________________________________________________ Engine
DTC P1655 EGR Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
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
15 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
16 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine___________________________________
DTC P1656 Wastegate Solenoid Control Circuit
The turbocharger wastegate is a vacuum actuated
valve used to control the exhaust gas heat sent to
the turbo. The wastegate pulse width modulated
solenoid meters the vacuum level at the wastegate
valve actuator as commanded by the PCM. When
the PCM is commanding the Wastegate solenoid
ON, the voltage potential of the circuit will be low
(near 0 volts). When the PCM is commanding the
wastegate solenoid OFF, the voltage potential of the
circuit will be high (near battery volts). The primary
function of the PCM in this circuit is to supply the
ground for the wastegate solenoid.
Engine Controls - 6.5L 6-2553
• PCM requested Wastegate solenoid ON.
• Voltage on Wastegate solenoid control circuit
high (near battery volts).
• 2 consecutive faults detected.
• Conditions met for 2 seconds.
• PCM requested Wastegate solenoid OFF.
• Voltage on Wastegate solenoid control circuit
low (near 0 volts).
• 2 consecutive faults detected.
• Conditions met for 2 seconds.
6-2554 Engine Controls - 6.5L
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip the diagnostic runs and fails.
• The PCM records the operating conditions at
the time the diagnostic fails. The first time the
diagnostic fails, the Failure Records store this
information. If the diagnostic reports a failure on
the second consecutive drive trip, the Freeze
Frame records the operating conditions at the
time of failure and updates the Failure Records.
Conditions for Clearing the MIUDTC
• The PCM will turn the MIL off after three
consecutive trips without a fault condition.
• A History DTC will clear when forty consecutive
warm-up cycles that the diagnostic does not
fail (coolant temperature has risen 5 ’ C (40*F)
from start up coolant temperature and engine
coolant temperature exceeds 71 *C (160‘ F) that
same ignition cycle.
• Use of a Scan Tool
Diagnostic Aids
This diagnostic will set when control circuit does not
follow the PCM command (when the solenoid is
requested ON voltage will drop, when the solenoid is
DTC P1656 Wastegate Solenoid Control Circuit
Step Action
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for
reference, as the Scan tool loses data when using the
1 Clear Info function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect a Scan tool.
2. Turn the ignition ON leaving the engine OFF.
2 3. With a scan tool, command the wastegate solenoid
ON and OFF and listen for an audible click.
Does the solenoid turn ON and OFF (audible click) with
each command?
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the
wastegate solenoid control circuit.
3. Turn the ignition ON leaving the engine OFF.
3 4. Using a DMM J 39200 on 10 Amp scale, measure
current from the solenoid control circuit in the PCM
harness connector to ground for 2 minutes.
Is the current draw less than the specified value, but
not zero?
Engine
OFF ignition voltage will be present). The scan tool
has a 5 second ON time abort. The wastegate
solenoid can be commanded ON for as many times
as needed, in 5 second intervals. Its possible
DTC P0236 may set along with DTC P1656. This
diagnostic can be checked during key up. The
engine will not respond to scan tool commands at
idle (engine unable to achieve boost pressures
greater than BARO at idle) or at any engine speed
greater than idle (PCM control abort to prevent
engine damage).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Be sure that both the ON and OFF states are
commanded. Repeat the commands as many
times as necessary.
3. This check can detect a partially shorted coil
which would cause excessive current flow.
Leaving the circuit energized for 2 minutes
allows the coil to warm up. When warm, the
coil may open (amps drop to zero), or short
(amp draw greater than 0.75A).
14. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
malfunctioning. However, this is an extremely
unlikely failure.
Value(s) Yes No
—
Go to
Powertrain OBD
Go to Step 2 System Check
—
Go to Step 3 Go to Step 5
0.75 A
Go to Step 8 Go to Step 4
Engine Engine Controls ■ 6.5L 6-2555
DTC P1656 Wastegate Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Verify the PCM connector is still disconnected.
3. Disconnect the wastegate solenoid.
4 4. Using a DMM J 39200, measure the resistance from —
the solenoid control circuit in the PCM harness
connector to ground.
Does the DMM display infinite resistance? Go to Step 13 Go to Step 10
1. Disconnect the wastegate solenoid
2. Turn the ignition ON leaving the engine OFF.
3. Connect a test light between the terminals at the
5 harness connector. —
4. Using a scan tool, command the solenoid ON
and OFF.
Does the test light turn ON and OFF with each command? Go to Step 9 Go to Step 6
1. Turn the ignition ON leaving the engine OFF.
2. With a test light connected to ground, probe the
6 ignition feed circuit at the wastegate solenoid —
harness connector.
Is the test light ON? Go to Step 7 Go to Step 12
1. Turn the ignition OFF.
2. Reconnect the solenoid.
3. Disconnect the PCM harness containing the solenoid
control circuit.
7 4. Turn the ignition ON leaving the engine OFF. —
5. With a fused jumper wire connected to ground, probe
the solenoid control circuit in the PCM harness
connector.
Does the solenoid operate (audible click)? Go to Step 11 Go to Step 10
the DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
8 refer to the applicable DTC table(s) first. —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check for a proper connection at the wastegate solenoid
9 and replace any terminals as necessary. —
Did any terminals require replacement? Go to Step 15 Go to Step 13
Repair the wastegate solenoid control circuit.
10 — —
Is the action complete? Go to Step 15
Check for a proper connection at the PCM wastegate
11 solenoid control circuit. —
Was a problem found? Go to Step 15 Go to Step 14
Repair the open in the ignition feed circuit.
12 — —
Is the action complete? Go to Step 15
Replace the wastegate solenoid. Refer to Wastegate
13 Solenoid Replacement. — —
Is the action complete? Go to Step 15
Replace the PCM.
Important: The new PCM must be programmed.
14 — —
Refer to PCM Replacement/Programming.
Is the action complete? Go to Step 15
6-2556 Engine Controls - 6.5L________________________________________________ Engine
DTC P1656 Wastegate Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
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
15 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 15 Go to Step 2
Does the Scan tool display any additional Go to the
16 undiagnosed DTCs? — Applicable
DTC Table System OK
Engine_______________________________________ Engine Controls - 6.5L 6-2557

DTC U1026 Loss of ATC Class 2 Communication

n Powertrain ip

Control Fus e
B lock
| Module A T
PC M PCM Serial D a ta , (PCM)
G ro und G ro u n d (C lass II)
ORN 840
D7 D6YC3 C8YC3 F u s e B lock
D etails
C ell 11
A
JO B O IIk

PPL 1807
PCM
= 3 2 BRN
T s e ria l Data"! Electronic
TAN/ BLK/WHT 451 G ro und i (C lass to | Brake
= 2 4 BRN
= 3 2 BLU
WHT 551 Distribution
i i Control A
Cell 14
L “ ~ “ - J Module
G C1 (EBCM)
PPL 1807
BLK/WHT BLK/WHT
— <4
r — “I EVO
451 451 Passlock
Module
BLK/WHT ORN 840
G ro und 1807
Distribution
Cell 14

G ro u n d
D istribution PPL 1807
C ell14
E9 k
BLK 150
BLK/WHT 451 r “ ” nActive T ransfer
Case (ATC)
BLK 150 BLK 150 PPL 1807
Control Module
4. 2. 16 Data Link
Connector (DLC)

192130

Circuit Description Diagnostic Aids

The PCM monitors the serial data (class II) circuit for This DTC will not set unless the PCM and
communications from the Automatic Transfer Case ATC controllers have already establish
(ATC) controller. If the ATC controller is not communications first. This DTC will only diagnosis
communicating with the PCM this DTC will set. an open or intermittent connection from the
Conditions for Setting the DTC ATC controller to the splice.
No serial data (class II) from ATC controller to
Test Description
the PCM.
The number(s) below refer to the step number(s) on
Action Taken When the DTC Sets the Diagnostic Table.
This DTC will not illuminate the MIL. 1. In this step, the Powertrain OBD System Check
Conditions for Clearing the MIL/DTC is being performed.
• A History DTC will clear after 40 consecutive
warm up cycles with no failures of any
non-emissions related diagnostic test.
• PCM battery voltage is interrupted.
• Use of a scan tool.

DTC U1026 Loss of ATC Class 2 Communication

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the Scan Tool
Capture Info to record Freeze Frame and Failure Records
for reference, as data will be lost when Clear Info function
1 is used. —
Go to ATC Go to
Was the Powertrain On-Board Diagnostic (OBD) System Controller Powertrain OBD
Check performed? Diagnosis System Check
6-2558 Engine Controls - 6.5L Engine

DTC U1192 Loss of VTD (Passlock)/EVO Communication

Circuit Description Diagnostic Aids

The PCM monitors the serial data (class II) circuit for
communications from the Passlock/EVO controller. If
the Passlock/EVO controller is not communicating
with the PCM this DTC will set.
Conditions for Setting the DTC
No serial data (class II) from Passlock/EVO controller
to the PCM.
Action Taken When the DTC Sets
This DTC will not illuminate the MIL.
Conditions for Clearing the MIL/DTC
• A History DTC will clear after 40 consecutive
warm up cycles with no failures of any
non-emissions related diagnostic test.
• PCM battery voltage is interrupted.
• Use of a scan tool.
This DTC will not set unless the PCM and
ATC controllers have already establish
communications first. This DTC will only diagnosis an
open or intermittent connection from the
Passlock/EVO controller to the splice.
The PCM enables fuel (scan tool display PCM in
VTD Fail Enable YES) on this and future ignition
cycles only if the failure occurred when the engine
was running.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
1. In this step, the Powertrain OBD System Check
is being performed.

DTC U1192 Loss of VTD (Passlock)/EVO Communication

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the Scan Tool
Capture Info to record Freeze Frame and Failure Records
for reference, as data will be lost when Clear Info function
1 — Go to
is used. Passlock/EVO Go to
Was the Powertrain On-Board Diagnostic (OBD) System Controller Powertrain OBD
Check performed? Diagnosis System Check
Engine Engine Controls - 6.5L 6-2559

Symptoms
Checks Action
Before Using This Section Before using this section, you should have performed the On-Board Diagnostic
System Check and determined that:
1. The Control Module and the MIL (Malfunction Indicator Lamp) are operating
correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but
without an MIL.
Several of the following symptom procedures call for a careful visual and physical
check. The visual and physical checks are very important. The checks can lead to
correcting a problem without further checks which may save valuable time.
Visual and Physical Checks • Check the Control Module grounds for being clean, tight and in their proper
location.
• Check the vacuum hoses for splits, kinks and proper connections, as shown
on the Vehicle Emission Control Information label.
• Thoroughly check the mounting areas of the intake manifold sealing surfaces
for any type of leak or restriction.
• Check the wiring for the following items:
- Proper connections
- Pinches
- Cuts
• The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the scan tool
readings do not indicate the problems, then proceed in a logical order, easiest
to check or most likely to cause first. In order to determine if a specific vehicle
is using a particular system or component, refer to the Engine Schematic and
Routing Diagrams for an application.
Symptom Verify the customer complaint.
Locate the correct symptom table. Check the items indicated under that symptom
from the following symptom tables:
• Intermittent Condition
• Hard Start
• Surges/Chuggles
• Lack of Power, Sluggishness, or Sponginess
• Fuel Knock/Combustion Noise
• Hesitation, Sag, Stumble
• Cuts Out, Misses
• Poor Fuel Economy
• Excessive Smoke
6-2560 Engine Controls - 6.5L Engine
Intermittent Condition
Checks Action
Definition: The problem may or may not turn the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (PTC).
Preliminary Checks • Refer to Symptoms.
• The fault must be present to locate the problem. If a fault is intermittent, the
use of DTC Tables may result in the replacement of good parts.
Electrical Connections or Wiring Poor electrical connections or wiring can cause most intermittent problems. Perform
a careful check of the suspected circuit for the following:
• Check for poor mating of the connector halves, or terminals not fully seated in
the connector body (backed-out).
• Check for improperly formed or damaged terminals. Carefully reform or
replace all the connector terminals in the problem circuit to ensure the proper
contact tension.
• Check for poor terminal to wire connections. This requires removing the
terminal from the connector body to check.
Road Test If a visual/physical check does not locate the cause of the problem, drive the
vehicle with a J 39200 connected to a suspected circuit or use a scan tool. An
abnormal voltage or scan reading, when the problem occurs, indicates the problem
may be in that circuit.
Intermittent Malfunction Indicator The following can cause an intermittent MIL and no DTCs:
Lamp (MIL) • Electrical system interference caused by a malfunctioning relay, PCM driven
solenoid or switch. They can cause a sharp electrical surge. Normally, the
problem will occur when the malfunctioning component is operating.
• The improper installation of electrical devices; such as lights, 2-way radios,
electric motors, etc.
• The Malfunction Indicator Lamp (MIL) circuit intermittently shorted to ground.
• Poor PCM grounds.
Loss of DTC Memory Check for loss of DTC memory by disconnecting the Engine Coolant Temperature
(ECT) sensor and idling the engine until the MIL turns ON. An Engine Coolant
Temperature (ECT) DTC should store and remain in memory when turning OFF the
ignition for at least 10 seconds. If not, the PCM is malfunctioning.
Additional Checks Check for an open diode across the A/C compressor clutch and for other
open diodes.

Hard S ta rt
Checks Action
Definition: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but
immediately dies.___________________________________________________ _____ __________________ ______
Preliminary Checks • Refer to Symptoms.
• Make sure the driver is using the correct starting procedure.
Sensor Checks • 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.
Fuel System Checks • Check the Supply to injection pump. Refer to Fuel Supply System Check.
• Check for air in the fuel system.
• Check the fuel return from the injection pump.
• Check for engine shut-off solenoid operation.
• Check the fuel injection nozzles.
• Check the fuel tank cap vent.
• Check for an internal injection pump problem.
Engine
Checks
Electrical System Checks
Air Intake System Checks
Exhaust System Check
Engine Mechanical Checks
Additional Checks
Engine Controls - 6.5L 6-2561
Hard Start (cont’d)
Action
• Check glow plug operation. Refer to Glow Plug System Check.
• Check for slow cranking speed.
• Check the air cleaner and air intake ducts for a restriction.
• Check for a restriction in turbo charger inlet duct.
• Check for a restriction in the intake manifold.
Check the exhaust system for possible restriction. Refer to Restricted Exhaust
System Check.
Check the engine for the following:
• Improper valve timing
• Bent pushrods
• Worn rocker arms
• Low compression
• Broken or weak valve springs
• Worn camshaft lobes
• Check for no crank signal.
• Check the Service Bulletins for control module software updates.

Surges/Chuggles
Checks 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 reading of VSS matches the
vehicle speedometer. This excludes vehicles with electronic transmissions
where some variation between VSS and the speedometer is normal. Refer to
DTC P0501 Diagnostic Aids.
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.
6-2562 Engine Controls - 6.5L Engine
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 or
clean. 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 leakage 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 Component Locations.
• Check the torque Converter Clutch (TCC) operation.
• Check the A/C operation. Refer to AJC Request Circuit Diagnosis.
• Check the generator output voltage. Repair if less than 9 or more than
16 volts.

Fuel Knock/C om bustion Noise

Checks Action
Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with the throttle opening.____________________________________________________ ______________________ _
Preliminary Checks • Refer to Symptoms.
• Make sure the vehicle has an actual problem.
• Check the fuel quality. Refer to Specific Gravity Testing
Cooling System Checks • Check for obvious overheating problems. Refer to the appropriate service
manual.
• Check for a low engine coolant level.
• Check for a loose water pump belt.
• Check for any restricted air flow through the radiator, or restricted coolant flow.
• Check for a malfunctioning or incorrect thermostat.
• Check for a correct coolant solution. The solution should be a 50/50 mix of
anti-freeze and water.
Engine _____________________________ Engine Controls - 6.5L 6-2563
Fuel Knock/Combustion Noise (cont’d)
Checks Action
Sensor Check Check the Engine Coolant Temperature (ECT) sensor by using 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.
Fuel System Checks • Check for air leaks in the fuel supply to the injection pump. Refer to Fuel
Supply System Check.
• Check the injection pump static timing. Refer to Injection Timing Adjustment.
• Check the injection nozzles. Refer to Injection Nozzle(s) Diagnosis.
Engine Mechanical Checks • Check for incorrect basic engine parts such as cam, heads, pistons, etc.
• Check for any excessive oil entering combustion chamber.
Additional Checks Check the Service Bulletins for control module software updates.

Hesitation, Sag, Stumble

Checks Action
Definition: The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur
at any vehicle speed. The condition is usually most severe when trying to make the vehicle move, as from a stop sign.
The condition may cause the engine to stall if it is severe enough.
Preliminary Check Refer to Symptoms.
Fuel System Checks • Check the fuel pressure. Refer to Fuel Supply System Check.
• Check for water contamination in the fuel. Refer to Contamination Testing.
• Perform the Injector Balance Test.
• Check for low fuel pressure after a cold start or during moderate or full throttle
acceleration. If fuel pressure drops below specification, there is possibly a
malfunctioning fuel pump or a restriction in the fuel system.
Additional Checks • Check the Service Bulletins for control module software updates.
• Check the generator output voltage.

Cuts Out, Misses

Checks Action
Definition: A steady or jerking that follows the engine speed, usually more pronounced as the engine load increases which
is not normally felt above 1500 RPM or 48 km/h (30 mph). The exhaust has a steady spitting sound at idle, low speed, or
hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Check Refer to Symptoms.
Engine Mechanical Checks • Perform a cylinder compression check. Refer to Engine Mechanical.
• Check the engine for the following:
- Improper valve timing
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes
- Broken or weak valve springs Refer to Engine Mechanical.
• Check the intake and exhaust manifold passages for casting flash. Refer to
Engine Mechanical.
Fuel System Checks • Check the fuel system for a plugged fuel filter, low fuel pressure, air in the
fuel system, etc. Refer to Fuel Supply System Check.
• Check for water contamination in the fuel. Refer to Contamination Testing.
6-2564 Engine Controls - 6.5L Engine

Poor Fuel Economy

Checks Action
Definition: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, the economy is
noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test._______________
Preliminary Checks • Refer to Symptoms.
• Check air cleaner filter for dirt or being plugged.
• Visually (physically) check: Vacuum hoses for splits, kinks, and proper
connections.
• Perform Powertrain On-Board Diagnostic System Check.
• Check the driving habits of the owner.
• Is the A/C ON full time (Defroster mode ON)?
• Are the tires at the correct pressure?
• Are excessively heavy loads being carried?
• Is the acceleration too much, too often?
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
. Suggest to the driver to read the Important Facts on Fuel Economy in the
Owner Manual.
Fuel System Checks • Check the fuel type and quality. Refer to Specific Gravity Testing.
• Check the fuel pressure. Refer to Fuel Supply System Check.
Cooling System Checks • Check the engine coolant level.
• Check the engine thermostat for always being open or for the wrong
heat range.
Additional Checks • Check the transmission shift pattern.
. Check the Torque Converter Clutch (TCC) operation. When the TCC is
commanded ON, a scan tool should indicate an RPM drop.
• Check the Service Bulletins for control module software updates.
• Check for dragging brakes.

Excessive Sm oke
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.
Engine
Restricted Exhaust System Check
Diagnostic Aids
Proper diagnosis for a restricted exhaust system is
essential before any components are replaced. The
following procedure may be used for diagnosis:
1. Inspect the entire exhaust system for a
collapsed pipe, heat distress, or a possible
internal muffler failure.
2. If there are no obvious reasons for the
excessive backpressure, the catalytic converter
is suspected to be restricted and should be
replaced using current recommended
procedures. Refer to Engine Exhaust.
___________ Engine Controis - 6.5L 6-2565
A/C Request Circuit Diagnosis
Refer to A/C Controls.
C ircuit Description
Turning ON the air conditioning supplies ignition
voltage to the A/C compressor clutch and to the
PCM to increase and maintain idle speed.
The PCM does not control the A/C compressor
clutch. Therefore, if the A/C system does not
function, refer to A/C Systems of the appropriate
service manual for diagnosis of the system.
6-2566 Engine Controls - 6.5L Engine

Cruise Control Diagnosis

{H o t In Run And S ta rt!

■ Pow er ^ — |
IP
. D istribution M 8 A Ccruise
R U IS E . Fuse
1
I
C e ll 10 r Fuse 6
N 7 i 10 A
i Block

BRN 41
PCM
C l = 3 2 BRN
C 2 = 2 4 BRN
BRN 41 C 3 = 3 2 BLU

Cruise
Control
/ On/Oft Set/Coast
7 Resume/
Accelerate
Switch

GRY 397 GRY/BLK 87

DK BLU 84
A12 > A14 A15„ C266

GRY 397 GRY/BLK 87

DK BLU 84

GRY 397 GRY/BLK 87

DK BLU 84

A11 B11 C2 D10 Cl

I Cruise S e t/C o a s t Renjme/ ’ Powertrain

. On/Ofl R equest Accelerate ■ Control
Request S ig n a l Request Module A
1 Signal
Slgna' | (PCM)

185074
C ircuit Description Other conditions that will not allow the cruise control
The Cruise control multi function lever is wired to engage that do not pertain to the cruise system.
directly 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 • The vehicle is in 4 wheel drive low.
be disengaged at anytime time by applying the
• Any DTC that puts the vehicle in Back Up Fuel
brakes. This input is sent to the PCM by the Cruise
Mode (Back Up Fuel Mode affects the fuel
Control Brake Switch.
control portion of the PCM). Refer to the
D iagnostic Aids appropriate DTC.
If the cruise is inoperative, and no Cruise Control or • More than one Accelerator Pedal Position
Brake Switch DTC(s) are stored, check for the (APP) DTC is set.
following conditions:
• A malfunctioning Cruise multi function switch/ Test Description
wiring harness (opens or malfunctioning 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
position. Cruise Control Switch.
Engine Engine Controls - 6.5L 6-2567
Cruise Control Diagnosis
Step Action Value(s) Yes No
Go to
1 Was the Powertrain On-Board Diagnostic (OBD) System — Powertrain OBD
Check performed? Go to Step 2 System Check
Go to the
2 — Applicable
Are DTCs P0501, P0567, P0568, or P0571 set? 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 cycling the Cruise Control Resume/Accelerate
6 —
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.
2. With the ignition still in the Run position, cycle the —
7
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.
2. With the ignition still in the Run position, cycle the
9 —
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
6-2568 Engine Controls - 6.5L Engine
Cruise Control Diagnosis (cont’d)
Step Action 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.
2. With the ignition still in the Run position, cycle the
11 —
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? Go to 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 Go 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
16 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.
2. If a problem is found, repair the problem as
19 —
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
Engine
Fuel Tank Leak Check
The diagnosis of fuel odor may be a condition of
leaking fuel tank, filler neck or filler cap. A defective
filler cap, a plugged or pinched vent pipe can cause
a collapsed fuel tank. Loose mounting straps or
foreign material in tank may be the cause of a rattle
at the fuel tank.
Leak Check Procedure
Caution: Place a d ry chem ical (Class B) fire
extinguisher near the area before perform ing a
Fuel Tank Leak Check. Before rem oving the fuel
tank fo r a suspected leak, make sure that the
fuel pipes o r the tubes are not leaking onto the
tank. Once removed, make sure that the fuel is
not leaking around the fuel sender O-ring. Failure
to follow these precautions may result in
personal injury.
1. This check requires the fuel sender and the
o-ring to be installed.
2. Disconnect the battery cables.
3. Drain the fuel tank (refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank (refer to Fuel Tank
Replacement).
5. Cap the fuel feed tube and the fuel return tube
on the fuel sender.
6. Connect a piece of hose to the filler tube nipple
and plug the opposite end.
7. Submerge the tank in water or apply a soap
solution to the outside of the tank.
8. Apply 35 kPa (5 psi) of air pressure to the vent
hose of the fuel tank (a leak will show up as
bubbles).
Contamination Testing
Fungi and other microorganisms can survive and
multiply in diesel fuel if water is present. The fungi
can be present in any part of the fuel handling
system. These fungi grow into long strings and will
form into large globules. The growths appear slimy
and are usually black, green, or brown. The fungi
may grow anywhere in the fuel but are most plentiful
where diesel fuel and water meet. As the fuel is
agitated (when service station tanks are being filled),
fungi are distributed throughout the tank and may be
pumped into a vehicle.
Fungi use the fuel as their main energy supply and
need only trace amounts of water and minerals. As
they grow and multiply, they change fuel into water,
sludge, acids, and products of metabolism. The most
common symptom is fuel filter plugging; however,
various metal components (fuel tank, pipes, and
injection pump) can corrode.
Caution: A void physical contact with the biocides
in order to avoid personal injury.
If fungi have caused fuel system contamination, use
a diesel fuel biocide to sterilize the fuel system. Do
not exceed the dosage recommended on the label.
Discontinue the use of a biocide when towing a
___________ Engine Controls - 6.5L 6-2569
trailer. It is permissible to have biocide in the fuel
when starting to tow, but do not add any biocide
while towing.
Steam cleaning may be necessary if most of the
fungus growth cannot be removed with biocides.
The presence of water or gasoline in diesel fuel may
also cause injection pump and nozzle damage.
This procedure checks for the presence of water and
gasoline in diesel fuel that may cause injection pump
and nozzle damage.
Remove the fuel filter element and inspect it.
• If water, gasoline or fungi/bacteria are not
present, end the inspection.
• If water or fungi/bacteria are present, Go to
Cleaning Water from the Fuel System.
• If gasoline is present, Go to Cleaning Gasoline
from the Fuel System.
Cleaning Water from the Fuel System
1. Disconnect the batteries.
2. Drain the fuel tank.
3. Remove the fuel tank (Refer to Fuel Tank
Replacement).
4. Remove the fuel sender unit (Refer to Fuel
Sender Assembly Replacement).
5. Inspect the fuel tank and the fuel sender for
rust, fungi or bacteria.
6. Clean the inside of the fuel tank and the fuel
sender with hot water.
7. Use compressed air in order to dry the fuel
tank and the fuel sender.
8. Disconnect the ends of the following lines:
• The lift pump suction line
• The lift pump feed line
• The fuel filter outlet line
• The fuel filter drain line
• The fuel return line
9. Inspect each of the pipes.
10. Replace any rusted pipes.
11. Clean the inside of the fuel filter housing.
12. Dry the fuel filter housing with compressed air.
13. Dry the inside of each line with low pressure air.
14. Remove the FUEL SOL fuse from the fuse panel.
15. Install a new fuel filter element.
16. Install the fuel sender and the fuel tank (add
clean diesel fuel to 1/4 full).
17. Reconnect the following lines:
• The lift pump suction (both ends) lines.
• The lift pump feed (both ends) lines.
• The fuel filter drain line.
• The fuel return (at the injection pump) line.
18. Connect the fuel filter outlet and the fuel return
line at the fuel sender to the hoses that flow to
the metal containers.
19. Connect the batteries.
6-2570 Engine Controls - 6.5L
20. Use the scan tool in order to command the lift
pump ON.
21. Operate the lift pump until clean fuel flows from
the fuel filter outlet into a metal container.
22. Connect the hose from the fuel filter outlet to
the injection pump inlet.
23. Open each injection line at its nozzle end and
crank the engine until clean fuel flows from it.
• Use two wrenches when loosening the
injection line fittings.
• Allow a maximum of 15 seconds cranking
time, followed by 1 minute of cranking motor
cooling time.
24. Tighten each injection line fitting at its nozzle.
Use two wrenches when tightening the injection
line fittings.
25. Install the FUEL SOL fuse in the fuse panel.
26. Start and run the engine for 1 minute while the
fuel flows from the fuel return line into a metal
container.
27. Stop the engine.
28. Connect the fuel return hose to the fuel sender.
29. Clean any fuel spillage from the engine.
30. Fill the fuel tank and add a biocide, if needed.
Cleaning Gasoline from the Fuel System
1. Drain the fuel tank.
2. Fill the fuel tank.
3. Remove the FUEL SOL fuse from the
fuse panel.
4. Remove the fuel filter outlet and connect it to a
hose that flows to a metal container.
5. Use a scan tool and command the lift pump
ON until clean fuel flows from the fuel filter
outlet into a metal container.
6. Connect the hose from the fuel filter outlet to
the injection pump inlet.
7. Install the FUEL SOL fuse into the fuse panel.
8. Attempt to start and run the engine for
15 minutes (If engine does not start, purge the
injection system).
9. Stop the engine.
10. Clean any fuel spillage from the engine.
11. Clear the engine of any DTCs.
Fuel Quality Diagnosis
Fuel quality may cause driveability problems such as
hesitation, lack of power, stall, no start, etc.
For best results, use Number 2-D diesel fuel
year-round (above and below freezing conditions) as
oil companies blend Number 2-D fuel to address
climate differences. Number 1-D diesel fuel may be
used in very cold temperatures (when it stays below
-1 8 ’ C (O'F); however; it will produce a power and
fuel economy loss. The use of Number 1-D fuel in
warm or hot climates may result in stalling, poor
starting when the engine is hot and may damage the
fuel injection system.
Engine
Specific Gravity Testing
The fuel quality hydrometer provides a general
indication of fuel quality and should not be
considered scientifically accurate.
Fuel Oil Specific Gravity Requirements
Number Number
2-Diesel 1-Diesel Tool
API Gravity 30 - 39 39 - 44 J 38641 B
1. Drain the fuel filter housing by following the
steps below:
1.1. Stop the engine.
1.2. Place a container under the water drain
valve exit hose at the left front side of
the engine.
1.3. Open the drain valve.
1.4. Use a scan tool and command the fuel
lift pump ON.
1.5. Fill a 1 liter (0.946 quart) container with a
sample of fuel.
1.6. Close the drain valve.
2. Obtain a fuel quality hydrometer (J 38641-B).
3. Fill the hydrometer with the fuel sample by
doing the following:
3.1. Squeeze the hydrometer bulb.
3.2. Submerse the hydrometer tip into the
sample.
3.3. Release the bulb, allowing fuel to enter
the glass tube until it completely floats
the glass bulb inside the tube.
3.4. Gently spin the hydrometer to relieve the
surface tension of the fuel sample. Read
the scale on the glass bulb at the point
where the top of the fuel sample
contacts it. By reading this value, it will
give a approximate fuel oil specific
gravity. Refer to tool instructions on how
to determine API Gravity.
4. Refer to Fuel Oil Specific Gravity Requirements
table. If the correct fuel is being used in the
conditions listed in Fuel Quality, and meets
number 1-Diesel or number 2-Diesel fuel oil
specific gravity requirements, fuel is OK. If not,
the fuel should be replaced.
Fuel Sender Diagnosis
The fuel sender should be checked for return
restrictions. For diagnosis of the pickup tube, refer to
Fuel Return System Diagnosis.
Fuel Strainer
The strainer is self cleaning and normally requires no
maintenance. Fuel stoppage at this point indicates
that the fuel tank contains an abnormal amount of
sediment or water and should be thoroughly cleaned.
Engine
Fuel Supply System Check
If the fuel supply system is not delivering enough
fuel, or air is being drawn into the fuel injection
system, driveability could be greatly effected or a
Cranks But Will Not Run symptom could exist. If
another diagnosis indicates, or if the fuel supply
system is suspected of not delivering enough fuel or
drawing air, the following systems should be
checked.
• Air leaks or restrictions on the suction side of
the fuel pump will seriously affect pump output.
• Restriction in the fuel return system.
• Make certain that there is sufficient fuel in
the tank.
• Check for leaks at all of the fuel connections
from the fuel tank to the injection pump.
• Tighten any loose connections.
• With the engine running, check all of the hoses
and the lines for flattening or kinks that would
restrict the flow of fuel.
Fuel Lift Pump Flow Check
1. Remove the FUEL SOL fuse.
2. Disconnect the pipe at the lift pump outlet fitting.
3. Install a hose at the lift pump outlet fitting and
place a 1 liter (0.946 quart) container at the
hose in order to collect fuel.
4. Crank the engine and measure the amount
of fuel.
• If more than 0.24 liter (1/2 pint) in
15 seconds, refer to Fuel Lift Pump
Pressure Check.
• If less than 0.24 liter (1/2 pint) in 15 seconds,
refer to Fuel Lift Pump Suction Line Check.
Fuel Lift Pump Suction Line Check
1. Remove the fuel tank cap and repeat the Lift
Pump Flow Check.
• If the flow is more than 0.24 liter (1/2 pint)
in 15 seconds, replace the defective fuel
tank cap.
• If the flow is less than 0.24 liter (V2 pint) in
15 seconds, go to the next step.
2. Separate the lift pump suction line from the fuel
sender.
3. Connect the suction line to a source of clean
fuel by using an additional hose.
4. Repeat the Lift Pump Flow Check.
• If the flow is more than 0.24 liter (1/2 pint)
in 15 seconds, go to Fuel System Air
Leak Check.
• If the flow is less than 0.24 liter (1/2 pint) in
15 seconds, Go to Step 5.
Engine Controls - 6.5L 6-2571
5. Check the lift pump suction line for restriction.
• If restriction exists, repair it and recheck lift
pump flow.
• If no restriction exists, replace the lift pump
and recheck the lift pump flow. Refer to Fuel
Pump Relay Circuit Diagnosis.
6. Attach the lift pump suction line to the fuel
sender.
Fuel Lift Pump Pressure Check
1. Install a tee adapter at the injection pump.
2. Connect a pressure gauge with the dial
indication of 0-103 kPa (0 to 15 psi) to the tee
adapter.
3. Start the engine and measure the fuel pressure.
• If the fuel pressure is a least 4 psi (27 kPa)
continue to step 4.
• If the pressure is less than 4 psi, refer to
Fuel Pump Relay Circuit Diagnosis before
replacing the lift pump.
4. Remove the pressure gauge and the tee
adapter.
5. Connect the inlet pipe.
6. Clean any fuel spillage
7. Operate the engine and check for any fuel leaks.
Fuel System Air Leak Check
1. Install a transparent hose between the filter
outlet and the injection pump inlet.
2. Start and idle the engine, observing the fuel for
air bubbles.
• If air bubbles are not present, stop the
engine and Go to Step 7.
• If air bubbles are present, stop the engine
and Go to Step 3.
3. Check the lift pump suction line for air leakage.
• Disconnect the fuel pipe from the fuel
sender.
• Plug the fuel pipe.
• Disconnect the fuel pipe from the lift pump.
• Install a hand held vacuum pump with
a gauge.
• Apply the vacuum to the fuel pipe and
observe the gauge reading.
- If the vacuum does not drop, connect the
fuel pipe and Go to Step 4.
- If the vacuum drops, repair the air leak in
the suction line and install the suction line
pipe and the hose.
4. Check the fuel sender for air leakage.
• Remove the fuel tank.
• Remove the fuel sender from the fuel tank.
• Remove the strainer and plug the bottom
end of the pickup tube.
6-2572 Engine Controls - 6.5L
• Apply a vacuum to the upper end of the
pickup tube.
• Observe the gauge reading.
- If the vacuum does not drop (fuel inlet
side of sender is OK), install the fuel
sender and the fuel tank.
- If the vacuum drops, replace the fuel
sender, install the fuel tank, connect the
fuel pipe and Go to Step 5.
5. Start and run the engine.
6. Observe the fuel for air bubbles.
• If air bubbles are present, stop the engine
and recheck Steps 3 and 4.
• If air bubbles are not present, stop the
engine and Go to Step 7.
7. Remove the transparent hose and connect the
hose of the filter outlet to the injection pump
inlet fitting.
8. Disconnect the return hose at the injection pump.
9. Install a transparent hose between the injection
pump and the hose of the return line.
10. Start and run the engine.
11. Observe the fuel for air bubbles.
Important: It is normal to see small amounts of
bubbles during snap acceleration.
• If air bubbles are present, replace the
injection pump. Refer to Fuel Injection Pump
Replacement.
• If air bubbles are not present, Go to Step 12.
Engine
12. Stop the engine.
13. Remove the transparent hose and attach the
fuel return hose at the injection pump.
14. Clean any fuel spillage.
15. Run the engine to check for fuel leakage.
Fuel Lift Pump Electrical Circuit
When the key is first turned ON without the engine
running, the control module turns the fuel lift pump
relay ON during glow plug cycle. This builds up fuel
pressure quickly. If the engine is not started after the
glow plug cycle, the control module shuts the fuel lift
pump OFF and waits for engine rpm. As soon as the
engine is cranked, the control module turns the relay
ON and runs the fuel lift pump.
As a backup system to the fuel lift pump relay, the fuel
lift pump is also turned ON by an oil pressure switch.
When engine oil pressure reaches about 28 kPa (4 psi)
through cranking, the oil pressure switch will close to
complete the circuit to the fuel pump.
For the location of the fuel pump relay, refer to
Engine Controls Component Location. For diagnosis
of the lift pump electrical circuit, refer to Fuel Pump
Relay Circuit Diagnosis.
Fuel Manager/Filter Diagnosis
Diagnosis of the fuel filter can be found in the
Contamination Testing. For diagnosis of the Water in
Fuel lamp circuit, refer to the Water-in-Fuei Lamp
Circuit Diagnosis.
Diagnosis of the fuel heater can be found in the Fuel
Heater Functional Diagnosis.
Engine________________________ Engine Controls - 6.5L 6-2573

Fuel Heater Functional Diagnosis

PCM
Cl =32 BRN
C2-24BRN
C3-32BLU

Circuit Description
The fuel manager/filter assembly consists of the fuel
heater, the water in fuel sensor and a filter. The filter
contains the ’coalescer’ (the device that combines
small droplets of water into larger ones) and the
filter/separator.
A fuel lift pump delivers diesel fuel from the tank to
the fuel filter. As fuel enters the filter, it passes first
though the fuel heater. The heater contains a
thermostatic switch. The switch opens or closes to
turn the heater OFF or ON, depending on the
temperature of the fuel.
The fuel then passes through the filter. Next the fuel
flows through the water coalescer. Here the droplets
of water in the fuel combine into larger drops, the
drops fall to the water reservoir in the filter. When
fuel flows from the fuel manager/filter assembly to
the injection pump, the fuel is clean and free
of water.
185075
The solid state water in fuel sensor supplies voltage
to a probe. When the probe touches water, the
module closes a switch. This completes a circuit to
ground to light the ‘Water In Fuel’ lamp.
A time delay circuit in the water in fuel module
grounds the lamp briefly to test the bulb each time
the system is turned ON.
The fuel heater is operated by a built-in thermostatic
switch. The thermostatic switch completes the circuit
for the fuel heater element when it senses a
temperature below 8*C (46*F).
Test Description
2. This step checks for a fuel heater that is
stuck ON.
3. This steps checks for a thermostatic switch that
completes the circuit.
6-2574 Engine Controls - 6.5L________________________________________________ Engine
Fuel Heater Functional Diagnosis
Step Action Value(s) Yes No
Go to
Water-In-Fuel
—
Lamp Circuit
1 Is the Water In Fuel lamp operating properly? 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 Go to Step 1
Engine Engine Controis - 6.5L 6-2575

Water-in-Fuel Lamp Circuit Diagnosis

Underhood
Fuse-Relay
Center

PCM
Cl =32 BRN
C2=24 BRN
C3°32BLU

Circuit Description
The fuel manager/filter assembly consists of the fuel
heater, the water in fuel sensor and a filter. The filter
contains the coalescer (the device that combines
small droplets of water into larger ones) and the
filter/separator.
A fuel lift pump delivers diesel fuel from the tank to
the fuel filter. As fuel enters the filter, it passes first
though the fuel heater. The heater contains a
thermostatic switch. The switch opens or closes to
turn the heater OFF or ON, depending on the
temperature of the fuel.
The fuel then passes through the filter. Next the fuel
flows through the water coalescer. Here the droplets
of water in the fuel combine into larger drops, the
drops fall to the water reservoir in the filter. When
fuel flows from the fuel manager/filter assembly to
the injection pump, the fuel is clean and free
of water.
185075
The solid state water in fuel sensor supplies voltage
to a probe. When the probe touches water, the
module closes a switch. This completes a circuit to
ground to light the ’Water In Fuel’ lamp.
A time delay circuit in the water in fuel module
grounds the lamp briefly to test the bulb each time
the system is turned ON.
The fuel heater is operated by a built-in thermostatic
switch. When the switch is closed, battery voltage is
supplied to the heater.
Test Description
2. This step will determine if the ignition feed
circuit is open.
3. This step will determine if the ground circuit
is OK.
4. This step will determine if the fuse, bulb, and
wiring are OK.
6-2576 Engine Controls - 6.5L________________________________________________ Engine
Water-in-Fuel Lamp Circuit Diagnosis
Step Action Value(s) Yes No
Turn the ignition ON leaving the engine OFF.
1 —
Does the Water In Fuel light come ON briefly? Go to Step 5 Go to Step 2
1. Disconnect the Water In Fuel sensor.
2. With a test light connected to ground, probe
2 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 the test light, jumper the harness terminals A and C
3 with the ignition still ON. —
Is the test light ON? Go to Step 4 Go to Step 8
With the test light connected to ground, probe terminal B
4 of the harness connector. —
Is the test light ON? Go to Step 11 Go to Step 10
Operate the vehicle under which the system was noted.
5 —
Does the system operate properly? System OK Go to Step 1
1. Check the ignition feed circuit for an open.
2. If a problem is found, repair the problem as
6 —
necessary.
Was a problem found? 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.
Was a problem found? 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.
Was a problem found? 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.
Was a problem found? Go to Step 12 Go to Step 11
Repair the open in the lamp circuit.
10 — —
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
Engine
Fuel Injection System Diagnosis
Always begin diagnosis of the electronic fuel injection
system with the On-Board Diagnostic (OBD) System
Check before proceeding to any other diagnostics.
This will reduce diagnosis time and prevent
unnecessary replacement of parts. The On-Board
Diagnostic (OBD) System Check will give direction to
further diagnostics, such as Engine Cranks But Will
Not Run or a DTC Table. Diagnosis of electronic fuel
injection pump, including the fuel injection solenoid,
fuel solenoid driver, injection timing stepper motor
and engine shutoff solenoid also starts with the
On-Board Diagnostic (OBD) System Check.
If a driveability symptom exists, refer to the particular
symptom in the Driveability Symptoms.
Damage to the injection lines including kinking that
causes restrictions or leakage could effect driveability
or cause a DTC to set.
Fuel Pipes and Hoses
The diagnosis of fuel odor may be a condition of a
leaking fuel feed, or return pipe or hose. Fuel pipes
that are pinched, plugged, or miss-routed may cause
restricted fuel delivery.
Injection Nozzle(s) Diagnosis
If an injection nozzle is not properly delivering fuel
into the pre-combustion chamber of a cylinder,
driveability could be greatly effected, or a DTC could
be set. If other diagnosis indicates, or if the injection
nozzles are suspected of not properly delivering fuel,
they should be tested. Typically, a nozzle failure can
been detected by using the injector balance test.
Nozzle testing is comprised of the following checks:
• Injector Balance test (performed with scan tool).
• Nozzle opening pressure (see Important
statement).
• Leakage (see Important statement).
Injector Balance Test
An injector balance test is performed with the scan
tool. This test will properly identify a stuck closed or
noisy injector nozzle. Typically, a nozzle failure will
fall into this criteria.
1. Install a scan tool.
2. Start and idle the engine.
3. Perform the injector balance test on each
cylinder (balance test refer to a specific
cylinder).
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.
Engine Controls - 6.5L 6-2577
Nozzle Opening Pressure Test
Caution: Do not place your hands or arms near
the tip o f the nozzle when testing the nozzles.
The high pressure atom ized fuel spray from a
nozzle has sufficient penetrating pow er to
puncture flesh and destroy tissue. This may
result in blood poisoning. Always enclose the
nozzle tip in a receptacle, preferably transparent,
in order to contain the spray.
Im portant: Injector Nozzle Opening Pressure and
Leakage tests should only be performed on vehicles
with high mileage, engines that have been over
heated or on vehicles that pull heavy loads. False or
inaccurate readings can occur if the following tests
are not performed to the above criteria.
Im portant: Each test should be considered
independent of the others (for example, when
checking opening pressure, do not check for
leakage). If all of the following tests are satisfied, the
nozzle assembly can be reused. If any one of the
tests is not satisfied, the complete nozzle assembly
must be replaced. When performing the injection
nozzle tests, refer to the instructions provided with
the nozzle tester J 29075-B.
• Position a nozzle tester on a workbench.
• Install one nozzle on the tester fitting.
• Place a container under the nozzle that will
deflect the nozzle spray absorb the test fluid.
• Install two clear plastic hoses (1 in. long) over
the leak-off fittings.
• Close the shutoff valve at the pressure gauge.
• Operate the lever of the nozzle tester
repeatedly and briskly to fill and flush the
nozzle with test oil.
1. Open the shutoff valve at the pressure gage
one-quarter turn.
2. Depress the tester lever slowly. Note at what
pressure the needle of the pressure gage
stopped. The maximum observed pressure is
the opening pressure. Some nozzles may pop
while other nozzles may drip down (this is not
leakage).
3. The opening pressure should not fall below the
lower limit of 105 bar (1500 psi) for naturally
aspirated engines and 117 bar (1700 psi) for
turbo-charged engines for used nozzles.
4. Replace nozzles which fall below the
lower limit.
Nozzle Leak Test
Caution: When testing nozzles, do not place your
hands o r arms near the tip o f the nozzle. The
high pressure atom ized fuel spray from a nozzle
has sufficient penetrating pow er to puncture flesh
and destroy tissue and may result in blood
poisoning. The nozzle tip should always be
enclosed in a receptacle, preferably transparent,
to contain the spray.
6-2578 Engine Controls - 6.5L
Im portant: Injector Nozzle Opening Pressure and
Leakage tests should only be performed on nozzles
with high mileage, engines that have been over
heated or on vehicles that pull heavy loads. False or
inaccurate readings can occur if the following test
are not performed to the above criteria.
1. Open the shutoff valve at the pressure gage
(1 turn).
2. Blow dry the nozzle tip.
3. Depress the lever of the manual test stand
slowly until the gage reads a pressure of
95 bar (1400 psi). Observe the nozzle tip. A
drop may 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 falls
during the 10 seconds.
Fuel Return System Diagnosis
Any restriction in the fuel return system could greatly
effect driveability. If other diagnosis indicates or the
fuel return system is suspected of being restricted, it
should be tested.
1. Disconnect the hose of the fuel return line at
the fuel sender.
2. Disconnect the hose of the fuel return line at
the injection pump, and connect a vacuum
pump with gauge to the hose.
3. Apply vacuum to the return line and observe
the gage reading.
• If vacuum does not build and hold, Go to
Step 4.
• If vacuum builds and holds, repair the return
line restriction.
4. Connect the fuel return line at the injection
pump and fuel sender.
5. Clean any fuel spillage.
6. Run the engine to check for fuel leakage.
Glow Plug System Check
Step Action
Important: Before clearing DTCs use the scan tool
Capture Info to record freeze frame and failure records
for reference, as data will be lost when Clear Info function
1 is used.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Is DTC:
. P0117
2 . P0118
. P0380
stored as history or current codes?
Engine
Glow Plug System Check
Refer to Glow Plug Controls.
Circuit Description
The glow plug system is used to assist in providing
the heat required to begin combustion during engine
starting at cold ambient temperatures. The glow
plugs are heated before and during cranking, as well
as during the engine operation. The PCM controls
the glow plug ON times by monitoring coolant
temperatures and glow plug voltage. This system
check will check the glow plugs and the glow plug
feed circuit coming from the relay.
Diagnostic Aids
If the glow plug relay is stuck in the ON position,
check for proper operation of glow plugs. When glow
plugs are commanded ON by the scan tool, an
internal PCM timer protects the glow plugs from
damage by cycling them ON for 3 seconds and then
OFF for 12 seconds. Most glow plug system failures
are covered by DTC P0380. If no DTCs are stored,
vehicle is hard to start and white smoke is present
during cranking or after the vehicle is started. The
most likely cause of failure is the glow plugs.
Test Description
Number(s) below refer to the number(s) on the
diagnostic table.
1. This step will make sure OBD system check is
performed.
2. This step will make sure there are no other
DTCs stored that will affect the operation of the
glow plug system.
3. This step will check each glow plug for
an open.
4. This step will check each glow plug feed circuit
for an open.
Value(s) Yes No
—
Go to
Powertrain OBD
Go to Step 2 System Check
—
Go to the
Applicable
DTC Table Go to Step 3
Engine________________________________________________ Engine Controls - 6.5L 6-2579
Glow Plug System Check (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect ail the glow plugs.
3 3. With a test light connected to B+, probe the spade —
terminal on each glow plug.
Do all glow plugs turn test light ON? Go to Step 4 Go to Step 9
1. Turn the ignition ON leaving the engine OFF.
2. Verify the glow plugs are still disconnected.
3. With a test light, jumper each glow plug connector
4 —
terminal to ground.
4. With a scan tool, command the glow plugs ON.
Does each circuit turn the test light ON? Go to Step 5 Go to Step 10
Does the test light stay ON all the time for each glow
5 plug terminal (even when the glow plugs aren’t —
commanded ON)? Go to Step 6 Go to Step 11
1. Disconnect the glow plug output (gray) cable from
the glow plug relay.
6 2. Probe each glow plug terminal with a test light —
connected to ground.
Is the test light ON for all terminals? Go to Step 7 Go to Step 8
Repair the short to voltage on the glow plug output circuit
7 or the short to voltage on the glow plug signal circuit. — —
Is the action complete? Go to Step 11
Replace the glow plug relay. Refer to Glow Plug Relay
8 Replacement. — —
Is the action complete? Go to Step 11
Replace all glow plugs that do not turn ON the test light.
9 Refer to Glow Plug(s) Replacement. — —
Is action complete? Go to Step 11
Repair open in each circuit that does not turn ON the
10 test light? — —
Is action complete? Go to Step 11
Operate vehicle within the conditions under which system
11 was noted. —
Does system operate properly? System OK Go to Step 1
6-2580 Engine Controls - 6.5L
CDR Valve Test
The purpose of the CDR valve is to maintain 0 to
4 inches of water vacuum in the crankcase at all
engine speeds, assuming that piston/ring combustion
blow by is not excessive (less than 4 cfm). Too little
vacuum will tend to force oil leaks.
The CDR valve is checked with a water manometer.
The U-tube manometer indicates pressure or vacuum
by the difference in the height of the two columns
of fluid.
If the crankcase vacuum is too high (greater than
4 in. water), dirt or dust can more likely be pulled
into the crankcase cavity (pulled through front/rear
crankcase seal, etc...) and contaminate the oil. If the
crankcase pressure is positive, engine oil leaks are
more likely to occur around engine seals and
gaskets.
1. Connect one end of the manometer to the
engine oil dipstick hole. The other end of the
manometer is vented to atmosphere.
2. Unplug rubber vent tube from turbo inlet elbow.
3. Run engine through no-load speed range (gear
selector in park) and observe manometer
readings. If manometer reading is +4 in. water
or less positive pressure, reconnect CDR
system and proceed to Step 4. If manometer
reading is higher than +4 in. water positive
pressure.
Engine
4. Install air cleaner.
5. Start engine and observe manometer reading.
It should read zero to one inch (0 in. -1 in.) of
water (vacuum) at idle to approximately
3 -4 inches of water (vacuum) at 2000 RPM.
Add the amount that the manometer column
travels up, to the amount that the column
travels down to obtain total water pressure
(vacuum). An example of a manometer reading
is as follows: One-half inch above zero plus
one-half inch below zero equals one inch
vacuum reading (1/2 in. +1/2 in. =1 in.).
Air Cleaner Diagnosis
A restricted or leaking air intake system could cause
loss of power and engine damage.
• Inspect the air cleaner filter for damage or
excessive dirt accumulation. Replace if
necessary.
• Inspect the air inlet elbow and CDR tube for
damage or cracks. Replace if necessary.
Refer to Maintenance and Lubrication of the
appropriate service manual for change intervals.
Operation of the vehicle in dusty areas will
necessitate more frequent replacement.
Engine Engine Controls - 6.5L 6-2581

Repair Instructions
PCM Replacement/Programming
Service of the PCM should normally consist of
replacement of the PCM.
If the diagnostic procedures calls for replacing the
PCM, peform the following procedures in the
following order:
1. Programming the PCM
2. Passlock Learn Procedure
3. Programming the TDC Offset

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Remove the negative battery cables.
2. Remove the PCM from the passenger 26961
compartment.
3. Remove the connectors from the PCM.
Important: To prevent possible electrostatic
discharge to the PCM, do not touch the
component leads, and do not remove the
integrated circuit from the carrier.
4. Remove the PCM mounting hardware.
Installation Procedure
1. Install the PCM mounting hardware.
2. Install the connectors to the PCM.
3. Install the PCM in the passenger compartment
behind glove box.
4. Install the negative battery cables.
The MIL, antilock and brake lamps will continue
to be enabled until the PCM is programmed.
Once the programming is complete, the lamps
will turn OFF and normal operation will occur.
5. Refer to PCM Programming.

26961
6-2582 Engine Controls - 6.5L Engine
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 programed, operate
the vehicle until the coolant temperature is
greater than 77 *C (170*F). This will allow the
TDC Offset to be programed (refer to
Programming the TDC Offset).
5. Check the Data list for a TDC Offset.
6. If the PCM fails to reprogram, do the following:
• Check all the PCM connections.
• Check the Techline terminal/equipment for
the latest software version.
• Try again to reprogram the PCM. If it fails
again, replace the PCM. Refer to PCM
replacement.

Programming the TDC Offset

The PCM will automatically activate the TDC Offset
program when the engine coolant is greater than
7 7 ‘ C (170‘ F). If the PCM is not programmed with a
TDC Offset, a DTC P1214 will set.
Engine
Password Learn Procedure
Passlock Learn Procedure Using a
T50/T60/T20+
Important: Performing the following procedures will
cause a DTC P1630 to set when they are
completed. This is the intended functionality. Once
P1630 is set, turn the ignition OFF for 30 seconds,
then turn the ignition ON and P1630 will clear. If
P1630 does not clear, go to DTC P1630 Theft
Deterrent PCM in Learn Mode.
1. Using the T50/T60/T20+, enter the Service
Programming System (SPS).
2. Select Terminal to Vehicle Programming.
3. Select Done and follow instructions on Vehicle
Set-up screen.
4. Select Vehicle Theft Re-learn.
5. Follow the instructions on the remaining
screens.
• The PCM and the Passlock control module
will prepare for a re-leam.
• A security timer will be ON for approximately
10 minutes or until DTC P1630 sets.
• When the PCM and the Passlock control
module are prepared to re-learn, turn the
ignition OFF for 30 seconds and then start
the engine.
Passlock Learn Procedure Using a Tech 2
Scan Tool
Important: Performing the following procedures will
cause a DTC P1630 to set when they are
completed. This is the intended functionality. Once it
is set, turn the ignition OFF for 30 seconds, then
turn the ignition ON and P1630 will clear. If P1630
does not clear, go to DTC P1630 Theft Deterrent
PCM in Learn Mode.
1. Using a Tech 2 enter the Service Programming
System (SPS).
2. After entering the vehicle information, choose
the Request Info soft key on the Tech 2.
3. Select Done and follow the instructions on the
Vehicle Set-up screen.
4. Disconnect the Tech 2 from the vehicle and
connect the Tech 2 to a Techline terminal.
5. At the Techline terminal, select Service
Programming System (SPS), select the Terminal
to Scan Tool Programming method and then
select Done.
6. Follow the instructions on the remaining
screens.
7. Select Vehicle Theft Re-learn.
8. Select Program at the summary screen. The
terminal will download the information to the
Tech 2.
Engine Controls - 6.5L 6-2583
9. Return the Tech 2 to the vehicle and
connect the Tech 2 to the Diagnostic Link
Connector (DLC).
10. Select Service Programming from the Tech 2
main menu. Answer the prompts regarding the
model year and vehicle type. Press the Theft
Re-learn soft key on the Tech 2.
11. Follow the instructions on the remaining
screens.
• The PCM and the Passlock control module
will prepare for re-learn.
• A security timer will be on for approximately
10 minutes or until DTC P1630 sets.
• When the PCM and the Passlock control
module are prepared to re-learn, turn the
ignition OFF for 30 seconds and then start
the engine.
Passlock Learn Procedure w/o Tech 2 Scan
Tool or Techline Terminal
Important: While the PCM is in the Auto Learn
Procedure, maintain the battery voltage at all times.
Follow the procedure exactly as indicated or the
procedure will have to be repeated from the
beginning.
Important: Performing the following procedures will
cause a DTC P1630 to set when they are
completed. This is the intended functionality. Once it
is set, turn the ignition OFF for 30 seconds, then
turn the ignition ON and P1630 will clear. If P1630
does not clear, go to DTC P1630 Theft Deterrent
PCM in Learn Mode.
1. Attempt to start the vehicle (the vehicle will
start and stall), after the engine has stalled,
leave the ignition ON for 10 minutes (the
security light will remain ON for 10 minutes and
then go OFF).
2. After the Security lamp turns OFF, turn the
ignition OFF for 30 seconds.
3. Again, attempt to start the vehicle (the vehicle
will start and stall), after the engine has stalled,
leave the ignition ON for 10 minutes (the
security light will remain ON for 10 minutes and
then go OFF).
4. After the Security lamp turns OFF, turn the
ignition OFF for 30 seconds.
5. Again, attempt to start the vehicle (the vehicle
will start and stall), after the engine has stalled,
leave the ignition ON for 10 minutes (the
security light will remain ON for 10 minutes and
then go OFF) or until DTC P1630 sets.
6. Turn the ignition OFF for 30 seconds.
7. Turn the ignition ON and wait 30 seconds.
8. Attempt to start the engine.
6-2584 Engine Controls ■ 6.5L Engine

ECT Sensor Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Remove the negative battery cables.
2. Drain the cooling system below the level of
the sensor.
3. Remove the electrical connector releasing
locking tab.

26963
4. Remove the sensor.

Installation Procedure
1. Install the sensor into the engine.

26943
Engine Engine Controls - 6.5L 6-2585
2. Install the electrical connector.
3. Refill the coolant system.
4. Install the negative battery cables.

MAF Sensor Replacement

Removal Procedure
1. Loosen the turbocharger inlet duct clamp at the
intake duct.
2. Disconnect the MAF sensor electrical connector.

3. Unfasten the air cleaner cover clips.

55465
6-2586 Engine Controls - 6.5L Engine
4. Remove the air filter, MAF sensor, and intake
duct assembly from the air cleaner box..

& t 5. Remove the air filter from the MAF sensor by

pulling them apart.

63699
6. Loosen the intake duct clamp and remove the
intake duct from the MAF sensor.
7. Remove the air filter adapter from MAF sensor.

Installation Procedure
1. Install the air filter adapter to the MAF sensor.
2. Install the intake duct to the MAF sensor.
3. Tighten the intake duct clamp.
4. Install the air filter onto the air filter adapter.

63696
Engine Engine Controls - 6.5L 6-2587
5. Install the air filter, MAF sensor, and intake duct
assembly into the air cleaner box.

6. Fasten the air cleaner cover clips.

7. Install the turbocharger inlet duct onto the

intake duct.
8. Tighten the clamp.

55474
6-2588 Engine Controls - 6.5L _______________________________ Engine
9. Connect the MAF sensor electrical connector.

63702
IAT Sensor Replacement
Removal Procedure
Caution: Disconnect the negative battery cable
under the follow ing circum stances:
• When installing an electrical unit.
• When a tool o r equipm ent could easily come
into contact with “live ” exposed electrical
terminals.
Failure to disconnect the negative battery
term inal may result in personal in ju ry o r damage
to the vehicle's components. Turn OFF the
vehicle ignition, unless Instructed otherwise.
1. Remove the negative battery cables.
2. Remove the electrical connector.

3. Remove the IAT sensor.

73425
Engine Engine Controls - 6.5L 6-2589
Installation Procedure
1. Install the IAT sensor.

2. Install the electrical connector.

3. Install the negative battery cables.

APP Module Replacement

Rem oval Procedure
1. Remove the negative battery cables.
2. Remove the electrical connector.

72269
6-2590 Engine Controls - 6.5L Engine
3. Remove the mounting bolts.

4. Remove the APP module.

Installation Procedure
1. Install the APP module.

72271
Engine Engine Controls - 6.5L 6-2591
2. Install the mounting bolts.
Tighten
Tighten the mounting bolts to 1 N-m (10 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

3. Install the electrical connector.

4. Install the negative battery cables.

Fuel Filter Element Replacement

Removal Procedure
1. Remove the fuel tank filler cap.
2. Remove the upper intake cover.

55489
6-2592 Engine Controls - 6.5L Engine
3. Open the air bleed valve on top of the fuel
manager/filter to release any pressure in the
fuel supply system.

4. Remove the element nut by turning it in a

counterclockwise direction, if the nut is unable
to turn by hand, a strap wrench (oil filter type)
may be used to break loose the element nut.

55503
5. Remove the filter by lifting the straight up and
out of the filter assembly. It is not necessary to
drain fuel from the filter assembly to change the
filter element since the fuel will remain in the
filter assembly’s cavity.

55505
Engine________________________________________________ Engine Controls - 6.5L 6-2593
Installation Procedure
Important: Make sure the mating surface between
the element 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.

55507
2. Push the element, in a downwards direction
until the mating surfaces make contact.
3. Install the element nut.
Tighten
Tighten the element nut securely by hand.
Notice: Refer to Fastener Notice in Cautions
and Notices.
4. Bleed air from fuel manager/filter. Refer to Fuel
Feed and Fuel Return Pipe Purge Procedure.

55505
5. Install the upper intake manifold cover.
6. Install fuel tank filler cap.

55489
 t
6-2594 Engine Controls - 6.5L Engine

f Uo i
Fuel Manager/Filter Replacement
Rem oval Procedure
1. Remove the fuel tank filler cap.

SL4\ *i
2. Remove the upper intake manifold cover.

SS 55489
3. Open the air bleed valve on top of the fuel

L i^ manager/filter to release any pressure in the

fuel supply system.

'4 \ 55498
4. Remove the mounting bolts which attach the
fuel manager/filter to the intake manifold.

55513
Engine Engine Controls - 6.5L 6-2595
5. Remove the wiring harnesses and fuel hoses.
6. Remove the fuel manager/filter by lifting
straight up.

55514
Installation Procedure
1. Install the fuel hoses and wiring harnesses.
2. Position the fuel manager/filter to the intake
manifold.

55514

55514
6-2596 Engine Controls - 6.5L _______________________________ Engine
4. Install the fuel manager/filter mounting bolts.
Notice: Refer to Fastener Notice in Cautions
and Notices.
Tighten
Tighten the mounting bolts to 25 N-m (18 lb ft).
5. Bleed air from fuel manager/filter. Refer to Fuel
Feed and Fuel Return Pipe Purge Procedure.

6. Install the upper intake manifold cover.

7. Install the fuel tank filler cap.

55489
Fuel Manager/Filter Water Draining
Procedure
1. Turn OFF the engine and apply the parking
brake.
2. Place a suitable container under the filter drain
hose.
3. Open the the filter drain valve.
4. Start the engine and allow it to idle for one
minute or until clear fuel is observed. A scan
tool can also be used to turn the fuel pump on.
5. Close the filter drain valve (3) and stop the
engine.
6. Dispose of the drained mixture in a proper
manner.
7. If the Water In Fuel lamp comes on again,
repeat procedure until all of the water is
removed.
27616
Engine________________________________________________ Engine Controls - 6.5L 6-2597

Water-in-Fuel Sensor Replacement

Rem oval Procedure
1. Remove the upper intake manifold cover.

55489
2. Open the air bleed valve on top of the fuel
manager/filter to release any pressure in the
fuel supply system.

55503
3. Remove the mounting bolts that connect the
fuel manager/filter to the intake manifold.

55513
6-2598 Engine Controls - 6.5L Engine
4. Remove the wiring harnesses and the fuel
hoses.
5. Remove the fuel manager/filter by lifting
straight up.

55514
6. Remove the sensor mounting screws.

55496
7. Remove the sensor.

55517
Engine________________________________ Engine Controls - 6.5L 6-2599
Installation Procedure
1. Install the new water in fuel sensor and a new
water in fuel sensor seal.

2. Instal the sensor mounting screws.

Tighten
Tighten the mounting screws to
2 N.m (13 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

55496
3. Position the fuel manager/filter to the intake
manifold.
Notice: Use the correct fastener in the correct
location. Replacement fasteners must be the
correct part number for that application.
Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or
sealant are identified in the service procedure.
Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces
unless specified. These coatings affect fastener
torque and joint clamping force and may
damage the fastener. Use the correct tightening
sequence and specifications when installing
fasteners in order to avoid damage to parts and
systems.

55514
6-2600 Engine Controls - 6.5L _______________________________ Engine
4. Install the wiring harnesses and fuel hoses.

5. Install the mounting bolts that connect the fuel

manager/filter to the intake manifold.
Tighten
Tighten the mounting bolts to 25 N-m (18 lb. ft.).
6. Bleed the air from fuel manager/filter if
necessary (Refer to Fuel Feed and Fuel Return
Pipe Purge Procedure.

55513
7. Install the upper intake manifold cover.

55489
Engine____________________________ Engine Controls - 6.5L 6-2601

Fuel Heater Replacement

Rem oval Procedure
1. Remove the upper intake manifold cover.

2. Open the air bleed valve on top of the fuel

manager/filter to release any pressure in the
fuel supply system.

3. Remove the mounting bolts that connect the

fuel manager/filter to the intake manifold.

55513
6-2602 Engine Controls - 6.5L Engine
4. Remove the wiring harnesses and fuel hoses.
5. Remove the fuel manager/filter by lifting
straight up.

55514
Remove the fuel heater threaded nut by using
hand pressure or a strap wrench.
Remove the fuel heater from the filter housing.
Clean the fuel heater to housing sealing
surfaces.

55494
Installation Procedure
1. Install the cap seal (8) into filter housing.
2. Install the fuel heater (10).
3. Install the cap nut (9).
Tighten
Tighten the cap nut securely by hand.
N otice: Refer to Fastener Notice in Cautions
and Notices.
4. Install the fuel manager/filter (Refer to Fuel
Manager/FHter Replacement
5. Bleed the air from fuel manager/filter (Refer to
Fuel Feed and Fuel Return Pipe Purge
Procedure.

27617
Engine Engine Controls - 6.5L 6-2603

Fuel Tank Draining Procedure

Caution: Gasoline or gasoline vapors are highly
flammable. A fire could occur if an ignition
source is present. Never drain or store gasoline
or diesel fuel in an open container, due to the
p o ssib ility o f fire o r explosion. Have a dry
chem ical (Class B) fire extinguisher nearby.
To drain the fuel tank is to remove as much fuel as
possible before servicing the fuel tank.
1. Disconnect the negative battery cables.
2. Use a hand operated pump device to drain as
much fuel as possible through the filler neck.
3. Remove the fuel and reinstall the filler cap.

Fuel Tank Replacement (Suburban)

Rem oval Procedure
Caution: Disconnect the negative battery cable
under the follow ing circum stances:
• When installing an electrical unit.
• When a tool o r equipm ent could easily come
into contact with "liv e " exposed electrical
terminals.
Failure to disconnect the negative battery
term inal m ay result in personal in ju ry o r damage
to the vehicle's components. Turn OFF the
vehicle ignition, unless instructed otherwise.
1. Disconnect the negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle. 18322
4. Remove the fuel tank off-road shield, if
equipped.
5. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18442
6-2604 Engine Controls - 6.5L Engine
Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

7. Lower the fuel tank shield.

8. Lower the fuel tank. Disconnect the fuel feed

and vapor hoses. Disconnect the electrical
connections at the sender.

1S321
Engine Engine Controls - 6.5L 6-2605
9. Remove the fuel sender assembly and seal
ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

17407

18321
6-2606 Engine Controls - 6.5L Engine
4. Reinstall the fuel tank filler neck to the tank.
Tighten the clamp.

Notice: Tighten the strap nuts by steps, alternating

between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
5. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).

6. Install the fuel tank off-road shield, if equipped.

7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.

18322
Engine________________________________________________ Engine Controls - 6.5L 6-2607

Fuel Tank Replacement (Tahoe/Yukon)

Removal Procedure
Caution: Disconnect the negative battery cable
under the follow ing circum stances:
• When installing an electrical unit.
• When a tool or equipm ent could easily come
into contact with "liv e ” exposed electrical
terminals.
Failure to disconnect the negative battery
term inal m ay result in personal in ju ry o r damage
to the vehicle’s components. Turn OFF the
vehicle ignition, unless instructed otherwise.
1. Remove negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle.
4. Remove the fuel tank off-road shield, if
equipped.
5. Loosen the filler neck hose clamp at the
fuel tank.
6. Disconnect the fuel tank filler neck from the
fuel tank.

7. Support the fuel tank and remove the tank

straps and insulator strips, if equipped.

18329
6-2608 Engine Controls - 6.5L Engine
8. Lower the fuel tank shield.

9. Lower the fuel tank. Disconnect the fuel feed

and vapor hoses.
10. Disconnect the electrical connections at the
sender.

11. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407
Engine________________________________________________ Engine Controls - 6.5L 6-2609
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

17407

4. Reinstall the fuel tank filler neck to the tank.

Tighten the clamp.

18442
6-2610 Engine Controls - 6.5L Engine
Notice: Tighten the strap nuts by steps, alternating
between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
5. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).

6. Install the fuel tank off-road shield, if equipped.

7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the
ON position.
9.4. Check for fuel leaks.

Fuel Tank Replacement (Pickup Side Tank)

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Remove negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle.
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18442
Engine Engine Controls - 6.5L 6-2611
5. Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

6. Remove the frame mounted bracket.

7. Lower the fuel tank shield.

18408
6-2612 Engine Controls - 6.5L Engine
8. Lower the fuel tank.

9. Disconnect the fuel hoses and lines. Disconnect

the electrical connections at the sender.

10. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407
Engine________________________________________________ Engine Controls - 6.5L 6-2613
Installation Procedure
1. Install the new seal ring.
2. Use tool J 39765 in order to reinstall the
sender.

17407
3. Raise the tank slightly and reconnect the fuel
hoses, the lines, and the electrical connections
at the sender.

4. Raise the tank fully.

18409
6-2614 Engine Controls - 6.5L ________________ _______________ Engine
5. Install the fuel tank shield.

6. Reinstall the fuel tank filler neck on to the tank.

7. Tighten the clamp.

8. Install the frame mounted bracket.

18406
Engine Engine Controls - 6.5L 6-2615
9. Install the fuel tank brackets with the insulator
strips in place.
Notice: Tighten the strap nuts by steps,
alternating between the four nuts, until the
specified torque is reached. A failure to tighten
the strap nuts as specified will cause the
bottom of the tank to flex upward. This will
result in the fuel gauge indicating that there
is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
10. Tighten the strap nuts.
Tighten
Tighten the strap nuts to 45 N.m (33 lb ft).
11. Replenish the fuel in the tank.
12. Reinstall the fuel tank filler cap.
13. 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.
14. Check for leaks.
14.1. Turn ON the ignition switch for
2 seconds.
14.2. Turn OFF the ignition switch for
10 seconds.
14.3. Again, turn the ignition switch to the
ON position.
14.4. Check for fuel leaks.
Fuel Tank Replacement
(Cab and Chassis Side Tank)
Rem oval Procedure
1. Disconnect negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle.
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18440
6-2616 Engine Controls - 6.5L _______________________________ Engine
5. Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

6. Lower the fuel tank shield.

7. Lower the fuel tank.

18420
Engine Engine Controls - 6.5L 6-2617
8. Disconnect the fuel hoses and lines. Disconnect
the electrical connections at the sender.

9. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407
Installation Procedure
1. Install the new seal ring.
2. Use tool J 39765 in order to reinstall the
sender.

17407
6-2618 Engine Controls - 6.5L Engine
3. Raise the tank slightly and reconnect the fuel
hoses, the lines, and the electrical connections
at the sender.

4. Raise the tank fully.

5. Install the fuel tank shield.

18419
Engine________________________________________________ Engine Controls - 6.5L 6-2619
6. Reinstall the fuel tank filler neck to the tank.
7. Tighten the clamp.

8. Install the fuel tank brackets with the insulator

strips in place.
Notice: Tighten the strap nuts by steps,
alternating between the four nuts, until the
specified torque is reached. A failure to tighten
the strap nuts as specified will cause the
bottom of the tank to flex upward. This will
result in the fuel gauge indicating that there
is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
9. Tighten the strap nuts.
Tighten
Tighten the strap nuts to 45N-m (33 lb ft).
10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
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.
6-2620 Engine Controls - 6.5L Engine

Fuel Tank Replacement

(Cab and Chassis Rear Tank)
Rem oval Procedure
1. Disconnect the negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle.
4. Remove the fuel tank off-road shield, if
equipped.

5. Loosen the filler neck hose clamp at the fuel

tank and disconnect the fuel tank filler neck
from the fuel tank.

18440

18424
Engine Engine Controls - 6.5L 6-2621
7. Lower the fuel tank. Disconnect the fuel hoses
and lines. Disconnect the electrical connections
at the sender.

8. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407

Installation Procedure
1. Install the new seal ring.
2. Use tool J 39765 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.

17407
6-2622 Engine Controls - 6.5L Engine
4. Raise the tank fully.

5. Reinstall the fuel tank filler neck to the tank.

6. Tighten the clamp.

18440
7. Install the fuel tank brackets with the insulator
strips in place.
Notice: Tighten the strap nuts by steps,
alternating between the four nuts, until the
specified torque is reached. A failure to tighten
the strap nuts as specified will cause the
bottom of the tank to flex upward. This will
result in the fuel gauge indicating that there
is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
8. Tighten the strap nuts.
Tighten
Tighten the strap nuts to 45N.m (33 lb ft).

18424
Engine Engine Controls ■ 6.5L 6-2623
9. Install the fuel tank off-road shield, if equipped.
10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
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.

Fuel Tank Replacement

(Extended Cab Side Tank)
Removal Procedure
Caution: Refer to Battery Disconnect Caution In
Cautions and Notices.
1. Disconnect negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
3. Raise the vehicle.
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

5. Support the fuel tank and remove the tank

straps and insulator strips, if equipped.

18413
6-2624 Engine Controls - 6.5L Engine
6. Lower the fuel tank shield.

18414
7. Lower the fuel tank.

8. Disconnect the fuel hoses and lines. Disconnect

the electrical connections at the sender.

19204
Engine Engine Controls - 6.5L 6-2625
9. Remove the fuel sender assembly and seal
ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

17407
Installation Procedure
1. Install the new seal ring.
2. Use tool J 39765 in order to reinstall the
sender.

17407
3. Raise the tank slightly and reconnect the fuel
hoses, the lines, and the electrical connections
at the sender.

19204
6-2626 Engine Controls - 6.5L Engine
4. Raise the tank fully.

5. Install the fuel tank shield.

6. Reinstall the fuel tank filler neck to the tank.

7. Tighten the clamp.

16442
Engine Engine Controls - 6.5L 6-2627
8. install the fuel tank brackets with insulator strips
in place.
Notice: Tighten the strap nuts by steps,
alternating between the four nuts, until the
specified torque is reached. A failure to tighten
the strap nuts as specified will cause the
bottom of the tank to flex upward. This will
result in the fuel gauge indicating that there
is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice in Cautions
and Notices.
9. Tighten the strap nuts.
Tighten
Tighten the strap nuts to 45N.m (33 lb ft).
10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
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.
Fuel Sender Assembly Replacement
Removal Procedure
1. Remove the fuel tank filler cap.
2. Disconnect the negative battery cable(s).
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices..
3. Raise the vehicle on a hoist.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Remove the sender unit by turning the cam
lock counterclockwise using the tool J36608.

17406
6-2628 Engine Controls ■ 6.5L________________________________________________ Engine
Important: Do not damage the rubber insulator or
the strainer.
6. Remove the sending unit by pulling up.
7. Inspect the attaching hose for signs of
deterioration.
8. Inspect the strainer.

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.

4. Install the cam lock assembly.

5. Turn the cam lock clockwise in order to lock it.
6. Install the fuel tank. Refer to Fuel Tank
Installation.
7. Connect the negative battery cable.
8. Check the system for leaks.
8.1. Turn ON the ignition switch for
2 seconds. The scan tool can be used to
activate the fuel pump to check for fuel
system leaks.
8.2. Turn OFF the ignition switch for
10 seconds.
8.3. Again, turn the ignition switch to the ON
position.
8.4. Check for fuel leaks.

17406
Engine Engine Controls - 6.5L 6-2629

Fuel Sender Assembly Service

If the in-tank filter requires service, refer to Fuel
Sender Assembly Replacement
Fuel Lift Pump Replacement
Rem oval Procedure
Caution: To reduce the ris k o f fire and personal
in ju ry that may result from a fuel leak, always
replace O-rlng seals exposed during component
services.
1. Remove negative battery cable(s).
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Loosen filler cap(s) to relieve tank pressure.
3. Release the fuel pump electrical connector.

4. Clean both fuel line connections and

surrounding areas at fuel pump before
disconnecting to avoid possible contamination of
the fuel system.
5. Remove both fuel lines from fuel pump by
loosening the fuel line fittings.

19670
6. Remove fuel pump hold down bracket nut.
7. Slide fuel pump out of bracket.

19671
6-2630 Engine Controls - 6.5L Engine
Installation Procedure
1. Position the new pump in the pump bracket.

19671
2. Install both fuel lines on the fuel pump.
Tighten
Use a backup wrench in order to prevent the
pump from turning. Tighten the fuel line fittings
to 30 N.m (22 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

19670
3. Connect the fuel pump electrical harness
connector.
4. Connect the negative battery cables.
5. Tighten the fuel tank filler cap(s).
6. Bleed the air from the system.
7. Start the engine and check for leaks.
Engine
Fuel Hose/Pipes Assembly Replacement
Materials
Fuel Lines - These are welded steel tubes, meeting
GM Specifications 124-M, or its equivalent. Do not
use copper or aluminum tubing to replace steel
tubing. Those materials do not have satisfactory
durability to withstand normal vehicle vibration.
Coupled hose - These are not to be repaired and
are replaced only as an assembly.
Uncoupled Hose - Use only reinforced furl resistant
hose, made of Fluoroelastomer material. Do not use
a hose within 4 inches (100 mm) of any part of the
exhaust system, or within 10 inches (254 mm) of the
catalytic converter. The hose inside diameter must
match the outside diameter of the steel tubing.
Clamps - These are stainless steel, screw bank-type
clamps, #2494772, or equivalent.
Fuel Pipe Repair
1. Cut a piece of fuel hose 4 inches (100 mm)
longer than the section of pipe to be removed.
If more than 6 inches (152 mm) is to be
removed, use a combination of steel pipe and
hose. The hose length should not be more than
10 inches total.
2. Cut a section of the pipe to be replaced with
a tube cutter. Use the first step of a double
flaring tool to form a bead on the ends of the
pipe and, also, on the new section of pipe,
if used.
3. Slide the hose clamps onto the pipe and push
the hose 2 inches (51 mm) onto each portion of
the fuel pipe. Tighten a clamp on each side of
the repair.
4. Secure the fuel line to the frame.
Fuel System Cleaning
Removal Procedure
1. Remove the negative battery cable(s).
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the fuel from the tank. Refer to Fuel
Tank Draining Procedure.
3. Remove the fuel tank.
4. Remove the fuel sender. Refer to Fuel Sender
Assembly Replacement
5. Clean the fuel tank.
Important: The fuel tank should be replaced if
the tank is rusted internally.
6. Remove the fuel strainer or replace if
necessary. Refer to Fuel Sender Assembly
Service.
7. Remove the fuel feed hose at the fuel
lift pump.
___________ Engine Controls - 6.5L 6-2631
8. Remove the fuel return line at the injection
pump.
• Use low air pressure to blow out the lines
toward the rear of the vehicle.
• Replace the pipes if they are rusted
internally.
9. Remove the FUEL SOL from the fuse panel.
10. Remove the fuel filter. Refer to Fuel Filter
Element Replacement.
Installation Procedure
1. Install the fuel sender. Refer to Fuel Sender
Assembly Replacement.
2. Install the fuel tank.
3. Install the fuel feed pipes at the fuel lift pump.
4. Install clean diesel fuel into the tank until it
is 1/4 full.
5. Install the fuel tank cap.
6. Install the negative battery cables.
7. Crank the engine for 15 seconds with one
minute cooling periods until the clean fuel is
pumped out.
Important: Use a suitable container to catch
the fuel.
8. Install a new fuel filter. Refer to Fuel Filter
Element Replacement.
9. Install a hose from the return line at the fuel
injection pump to a closed metal container with
a capacity of at least 8 liters (2 gallons).
10. Crank the engine for 15 seconds with one
minute cooling periods until clean fuel appears
at the return line.
11. Install the FUEL SOL fuse in the fuse panel.
• Crack open each injection line at the nozzle.
Use two wrenches to prevent nozzle
damage.
• Crank the engine for 15 seconds with one
minute cooling periods until clean fuel
appears from each nozzle.
Tighten
Tighten the injection line to nozzle fitting to
25 N-m (18 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
Important: Use two wrenches to prevent
nozzle damage.
• Start the engine and allow it to idle for
15 minutes.
Important: Make sure the fuel return line is
in the metal container and that the container
does not overflow.
• Remove the hose from the metal container.
12. Install the fuel return line to the injection pump.
13. Check for leaks.
14. Clear any engine DTCs.
6-2632 Engine Controls - 6.5L Engine
Gasoline in Fuel System
Engine Will Run or Start
1. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
2. Fill the fuel tank with diesel fuel.
3. Run the engine for 15 minutes.
Engine Will Not Run
1. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
2. Fill the fuel tank with diesel fuel.
3. Disconnect the engine shutoff solenoid
connector.
4. Remove the fuel hose between the fuel
manager/filter and the injection pump.
5. Connect a hose to the fuel manager/filter outlet
and run it to a closed metal container.
6. Crank the engine for 15 seconds with one
minute cooling periods to purge the gasoline
from the system.
7. Install the fuel hose between the fuel filter and
the injection pump.
8. Connect the engine shutoff solenoid connector.
9. Start the engine,
important: Check for leaks.
10. Run the engine for 15 minutes.
11. Clear the engine DTCs.
Fuel Feed and Fuel Return Pipe Purge
Procedure
Caution: The water/diesel fuel m ixture is
flammable. The water/diesel fuel m ixture could be
h o t In order to help avoid personal in ju ry and
property damage, do not touch the fuel coming
from the drain hose. Also do not expose the fuel
to open flames or sparks.
Be sure you do not o ve rfill the container. Heat
(such as from the engine ) can cause the fuel to
expand. If the container is too full, fuel could be
forced out o f the container. This could lead to
the risk o f personal in ju ry and vehicle damage.
1. Open the air bleed valve on top of the fuel
manager/filter.
2. Connect a hose to the air bleed valve located
on top of the fuel manager/filter and place the
other end of the hose into a suitable container.
55498
3. Remove the FUEL SOL (U/H relay center) fuse.
4. Crank the engine in 10 to 15 second intervals
until clear fuel is observed at the air bleed hose
(wait for one minute between cranking intervals
to cool down starter motor).
5. Close the air bleed valve.
6. Install the FUEL SOL fuse.
7. Start the engine and allow to run for 5 minutes
at idle.
8. Check for fuel leaks.
9. Clear all engine DTCs.
Engine Engine Controls - 6.5L 6-2633

Fuel Injection Pump Replacement

Rem oval Procedure
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the intake manifold. Refer to Intake
Manifold Removal.
3. Remove the injection lines. Refer to Injection
Line(s) Replacement.
4. Remove the fuel inlet line from the
injection pump.
5. Remove all necessary harness connectors and
hoses from the injection pump.
6. Remove the fuel return line at the top of the
injection pump.
7. Remove the oil fill tube.
8. Remove the grommet for oil filler tube.
9. Rotate the engine to gain access to the
bolts (1) that hold the driven gear to the
injection pump. Access is gained through
the oil filler neck hole.
10. Remove the driven gear bolts.
Important: Never engage the starter motor to
rotate the engine when the injection pump is
removed as severe engine damage will occur.
With the injection pump removed the pump
driven gear could jam in the front housing by
engaging the starter motor, resulting in a
sheared crankshaft or camshaft gear key and
possible valve train damage. Always bar the
engine over by hand to avoid internal engine
damage.
11. Remove the injection pump flange nuts. Use
wrench J 41069.

193160
6-2634 Engine Controls - 6.5L Engine

193162
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.

3. Install the injection pump making sure the

locating stud is positioned within the
slotted/elongated hole (3) in the driven gear.

27613
Engine Engine Controls - 6.5L 6-2635
4. Install the injection pump flange nuts.
Tighten
Tighten nuts to 40 N.m (30 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

193160
Important: All the driven gear bolts should not be
torqued until all the bolts are installed. This will allow
for the proper alignment of all the bolt holes.
5. Install the driven gear bolts (1).
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
6. Install the grommet for oil filler tube.
7. Install the oil filler tube.
8. Install the fuel feed line at the injection pump.
9. Install the fuel return line to the top of the
injection pump.
10. Install all necessary harness and connectors.
11. Install the injection lines. Refer to the tags on
lines. Refer to Injection Line(s) Replacement
12. Install the intake manifold. Refer to Intake
Manifold Installation.
13. Install the negative battery cables.
14. Adjust the injection timing. Refer to Injection
Timing Adjustment
6-2636 Engine Controls - 6.5L
Injection Timing Adjustment
This procedure should be used after an injection
pump installation or when injection timing needs to
be checked or adjusted. A scan tool must be used
to check or adjust injection timing. A static timing
mark can be used as a reference. If a static timing
mark is not present on the injection pump mounting
flange, one can be scribed to further assist in how
far the injection pump needs to be rotated.
Injection Pump Timing Specification
All injection pump timing averages 3.5 degrees.
Important: There will be no change in engine
performance or vehicle driveability if injection timing
is advanced during the Time Set procedure. Injection
timing must be set to Injection Timing Specifications.
If injection timing is not set correctly, a possible
DTC P0216 may set (see DTC P0216, Conditions for
setting the DTC).
1. Start the engine.
2. Run the engine to operating temperature.
3. Install a scan tool.
4. Use a scan tool to activate Time Set (if Time
Set has been activated correctly, Des. Inj. Time
on scan tool will read 0.0 degrees).
Important: The Act. Inj. Time value on the
scan tool will fluctuate. The Average reading
should be 3.5 degrees.
5. Act. Inj. Time (scan tool display) should be
approximately 3.5 degrees. If not, continue to
step 6.
Important: If engine stalls during Time Set
activation, slightly (1 mm equals 2 degrees)
rotate the injection pump toward the driver side
of the vehicle, tighten flange nuts and repeat
Time Set.
6. If the injection timing needs to be adjusted,
continue. If not, adjustment is complete.
Important: Move the A/C compressor to the
side to improve access to the injection pump
lower mounting bolts.
7. Turn the engine OFF and loosen the injection
pump flange nuts using J 41089.
8. Slightly rotate the injection pump using J 29872.
9. Set Act. Inj. Time to 3.5 degrees.
Important: It is normal for the Act. Inj. Time
value on the scan tool to fluctuate. The
average fluctuation of Act. Inj. Time should be
3.5 degrees.
10. Continue to repeat the procedure until average
fluctuation of Act. Inj. time is 3.5 degrees.
• If the Act. Inj Time is above 3.5 degrees
SLIGHTLY (1 mm equals 2 degrees)
ROTATE INJECTION PUMP TOWARDS THE
PASSENGER SIDE OF VEHICLE.
• If the Act. Inj time is below 3.5 degrees,
SLIGHTLY (1 mm equals 2 degrees)
ROTATE INJECTION PUMP TOWARD
DRIVERS SIDE OF VEHICLE.
Engine
TDC Offset Adjustment
This procedure should only be used when a DTC
has directed you to or one of the following repairs
has been performed:
• A DTC 1214 is set.
• The engine has been replaced
• The front engine cover has been replaced.
• The PCM and the Injection pump have been
replaced.
The PCM has the ability to perform a TDC Offset
learn when one is not present or has been cleared.
This procedure allows the PCM to be updated with
the correct TDC offset for the vehicle.
Important: The TDC Offset specification is only to
be used after the Clear and Learn procedure has
been performed.
TDC Offset Specification
All TDC Offsets are within -0.25 to -0.75.
Clearing and Learning TDC Offset
1. One of the above repairs has been performed.
If not, do not continue. Refer to On Vehicle
Service for repair that was performed.
2. Install the scan tool.
3. Start the engine.
4. Operate the vehicle until the engine coolant
temperature is greater than 7 7 'C (170*F).
5. Clear all DTCs.
6. Turn the Ignition ON with the engine OFF.
7. Hold the accelerator pedal in the wide open
throttle position for a minimum of 45 seconds
(this step prepares the PCM to activate the
offset learn.(internal).
8. Turn the ignition OFF for 30 seconds. In this
step, the PCM is being powered down.
9. Start the engine.
• Verify in the scan tool that ECT is greater
than 77 *C (170‘ F). If not, operate vehicle
until desired ECT is achieved (vehicle can be
driven or throttle can be depressed until
correct coolant temperature is achieved).
• As soon as ECT is greater than 77 *C
(170 * F) and the engine speed is below
1500 RPMs, the PCM automatically learns a
new offset.
10. A new offset will over write the previous one.
The TDC Offset should be between -0.25 and
-0.75. If the TDC Offset is within the specififed
value, the procedure is complete, If not,
continue to the next step (adjusting the
injection pump).
11. Turn the engine OFF.
12. Loosen injection pump flange nuts
using J 41089.
13. Slightly (1 mm equals 2 degrees) rotate the
injection pump (use tool J 29872 to rotate
injection pump) and tighten injection pump
flange nuts.
Engine
Rotate pump toward driver side; a positive (+)
number, rotate toward passenger side (1 mm
equals 2 degrees) in order to achieve a
negative (-) number.
14. Repeat steps 3 through 11 until correct TDC
Offset has been achieved. Its possible that the
injection pump may be adjusted multiple times
until the specified value is achieved.
Important: If you are unable to set the correct
TDC Offset, check the following:
• Check to see if coolant temperature is
greater than 77 *C (170‘ F).
• Check all PCM and injection timing
stepper motor connections.
• Check the Techline terminal/equipment for
the latest software version.
• Check for proper base installation of the
injection pump (injection pump ESO
solenoid should be approximately straight
up and down).
• If all checks have been performed, the
injection pump may be malfunctioning,
however, this is an extremely unlikely failure.
Injection Line(s) Replacement
Removal Procedure
Important: Clean all the line fittings that will be
loosened or removed.
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the intake manifold. Refer to Intake
Manifold Removal.
Important: Before any further service work is to
be done, cover the intake ports with J 29664-1.
___________ Engine Controls - 6.5L 6-2637
3. Remove the injection line clips at the loom
brackets.
4. Remove the injection lines at the nozzles.
• Cap the lines and the nozzles
immediately.
• Do not bend the injection lines.
5. Remove the injection lines at the pump. Refer
to Fuel System Description.
• Cap the lines and the pump fittings
immediately.
• Tag the lines for installation.
Installation Procedure
1. Install the injection lines at the pump. Refer to
Fuel System Description.
• Uncap the lines and pump fittings.
• Refer to the tags for the correct installation.
• Install the injection lines at the nozzles.
2. Uncap the lines and the nozzles.
Tighten
Tighten the fittings to 25 N.m (20 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Install the injection line clips at the loom
brackets.
4. Remove the J 29664-1.
5. Install the intake manifold. Refer to Intake
Manifold Removal.
6. Install the negative battery cables.
6-2638 Engine Controls - 6.5L Engine

Injection Nozzle(s) Replacement

Removal Procedure
Important: When removing an injection nozzle, use
J 29873. Remove the nozzle using the 30 mm hex
portion. Failure to do so will result in damage to the
injection nozzle.
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
2. Remove the fuel line clip.
3. Remove the fuel return hoses (1) from the
nozzle (2).
4. Remove the fuel injection line.
5. Cap the nozzle and the lines.
6. Remove the injection nozzle (2) using J 29873.

27624
Installation Procedure
Important: When installing an injection nozzle, use
J 29873. 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).
2. Tighten the nozzle.
Tighten
Tighten the nozzle to 70 N.m (50 lb. ft.).
Notice: Refer to Fastener Notice in Cautions
and Notices.
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.

Fuel Pump Relay Replacement

Removal Procedure
1. Remove the protective cover (under hood
electrical center).
2. Remove the relay.

Installation Procedure
1. Install the relay.
2. Install the protective cover (under hood
electrical center).
Engine Engine Controls - 6.5L 6-2639

Engine Oil Pressure Sensor/Switch

Replacement
Removal Procedure
1. Remove the Fuel Filter/Manger. Refer to Fuel
Manager/Filter Replacement
2. Disconnect the electrical connector.
3. Remove the switch (1).

Installation Procedure
1. Install the Fuel Filter/Manger. Refer to Fuel
Manager/Filter Replacement
2. Install the switch (1).
3. Reconnect the electrical connector.
4. Bleed the fuel system. Refer to Fuel Feed and
Fuel Return Pipe Purge Procedure.

Crankshaft Position Sensor Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution In
Cautions and Notices.
1. Remove the negative battery cables.
2. Remove the sensor electrical connector.
3. Remove power steering pump. Refer to Power
Steering Pump Removal.

72319
6-2640 Engine Controls - 6.5L Engine
4. Remove the sensor mounting bolt.

5. Remove the sensor from engine.

Important: Care must be taken when handling
the sensor. Damage to the sensor will affect
proper operation of the injection timing control
system.
6. Inspect the sensor O-ring for wear, cracks or
leakage and replace if necessary.

Installation Procedure
1. Lube the new O-ring with engine oil.
2. Install the sensor in engine.

72321
Engine Engine Controls - 6.5L 6-2641
3. Install the sensor mounting bolt.
Tighten
Tighten the mounting bolt to 25 N-m (17 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

4. Install the sensor electrical connector.

5. Install the negative battery cables.
Important: A new TDC Offset must be learned
after replacing a crankshaft position sensor.
Refer to TDC Offset Adjustment

Glow Plug Relay Replacement

Rem oval Procedure
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the upper intake manifold cover by
loosening the four mounting bolts

55489
6-2642 Engine Controls - 6.5L Engine
3. Release the wiring harness connector at the
glow plug relay.
4. Remove the glow plug wiring harness nuts and
harness.

5. Remove the relay mounting nuts.

6. Remove the glow plug relay by lifting it off the

the mounting studs.

26782
Engine______________________ Engine Controls ■ 6.5L 6-2643

Installation Procedure
1. Install the glow plug relay on the
mounting studs.

2. Install the glow plug relay mounting nuts.

Tighten
Tighten the nuts to 42 N-m (31 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

3. Install the wiring harness connector to the relay.

4. Install the glow plug wiring harness and nuts.
Tighten
Tighten the nuts to 5 N-m (44 lb in).

26780
6-2644 Engine Controls - 6.5L Engine
5. Install the upper intake manifold cover.
6. Install the negative battery cables.

55469
Glow Plug(s) Replacement
Removal Procedure
Left Side of Vehicle
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
In Cautions and Notices.
2. Remove the glow plug lead wires using
J 39083 glow plug connector remover and
installer.
3. Use one of the following two methods to
remove glow plugs with blistered or swollen
heater coil sheaths.
Notice: Serious engine damage will occur if the
damaged glow plug is not retrieved from the cylinder.
Method I
3.1. Remove the injector nozzle from the failed glow
plug cylinder.
3.2. Place a shop towel in the precup chamber in
order to capture the glow plug tip when it
breaks off from the glow plug shell upon
removal (this will keep the tip from dropping
into the cylinder).
3.3. Use a pair of needle nose pliers (or other
griping device) in order to grasp the tip and
remove it from the precup chamber.
3.4. Remove the shop towel and reinstall the
injector nozzle.
Method II
If the glow plug tip has already broken off the glow
plug and it is not retrievable from the precup
chamber, remove the cylinder head so that the tip
can be retrieved from the piston cylinder. Refer to
cylinder head removal.
Engine Engine Controls - 6.5L 6-2645
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 J 39083 to disconnect the glow plug
wires.
8. Use one of the following two methods to
remove glow plugs with blistered or swollen
heater coil sheaths.
Notice: Serious engine damage will occur if the
damaged glow plug is not retrieved from the cylinder.
Method I
8.1. Remove the injector nozzle from the failed glow
plug cylinder.
8.2. Place a shop towel in the precup chamber in
order to capture the glow plug tip when it
breaks off from the glow plug shell upon
removal (this will keep the tip from dropping
into the cylinder).
8.3. Use a pair of needle nose pliers (or other
griping device) in order to grasp the tip and
remove it from the precup chamber.
8.4. Remove the shop towel and reinstall the
injector nozzle.
Method II
If the glow plug tip has already broken off the glow
plug and it is not retrievable from the precup
chamber, remove the cylinder head so that the tip
can be retrieved from the piston cylinder. Refer to
cylinder head removal.
Remove the glow plugs from cylinders 2, 4, and 6.
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.
For easier access to glow plugs on cylinders 6
and 8, it may be necessary to remove the
exhaust down pipe from turbocharger.
6-2646 Engine Controls - 6.5L Engine
Installation Procedure
Right Side of Vehicle
1. Install the glow plug into cylinder 8.
Tighten
Tighten the glow plugs to 17 N.m (13 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
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.
Left Side of Vehicle
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. Install the negative battery cables.

64994
Engine______________________________ Engine Controls - 6.5L 6-2647

EGR Valve Replacement

Removal Procedure
1. Remove the upper intake manifold cover by
loosening the four mounting bolts.

2. Remove the vacuum hose from the

EGR valve (2).
3. Remove the EGR valve mounting bolts (1).
4. Remove the EGR valve (2) and the gasket (3).

Installation Procedure
1. Install the EGR valve (2) and gasket (3).
2. Install EGR valve mounting bolts (1).
Tighten
Tighten bolts to 25 N-m (18 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Install the EGR valve vacuum hose.

25113
6-2648 Engine Controls - 6.5L Engine
4. Install the upper intake manifold cover.
5. Install negative battery cables.
6. 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.
7. Reset ALM cells using scan tool (under special
functions in scan tool).

55489
EGR Solenoid Replacement
Removal Procedure
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect Caution
In Cautions and Notices.
2. Remove the electrical connector from the
solenoid.
3. Remove the vacuum hoses.
4. Remove EGR Solenoid mounting bolt (2).
5. Remove the EGR solenoid (1).

Installation Procedure
1. Install the EGR solenoid (1).
2. Install mounting bolt (2).
Tighten
Tighten mounting bolt to 6.0 N-m (53 lb in).
Notice: Refer to Fastener Notice in General
Information.
3. Install the vacuum hoses.
4. Install the electrical connector to the solenoid.
5. Install the negative battery cable(s).

25300
Engine Engine Controls - 6.5L 6-2649

EGR Vent Solenoid Replacement

Removal Procedure
1. Remove the negative battery cables.
Caution: Refer to Battery Disconnect
Caution.
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).

Installation Procedure
1. Install the EGR vent solenoid (1).
2. Install EGR Vent Solenoid mounting bolt (2).
Tighten
Tighten mounting bolt to 6.0 N.m (53 lb in).
Notice: Refer to Fastener Notice.
3. Install the vacuum hoses.
4. Install the electrical connector to the solenoid.
5. Install the negative battery cables.

EGR Solenoid Filter Replacement

Removal Procedure
1. Remove the filter retainer clip (2).
2. Remove the solenoid filter (1).

25479
6-2650 Engine Controls - 6.5L Engine
Installation Procedure
1. Install the solenoid filter (1).
2. Install the filter retainer clip (2).

EGR Control Pressure Sensor

Replacement
Removal Procedure
1. Remove negative battery cables.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the vacuum harness assembly.
3. Remove the electrical connector.
4. Remove the mounting bolts.
5. Remove the sensor.

Installation Procedure
1. Install the mounting bolts with the sensor.
Tighten
Tighten the mounting bolts to 3.5 N-m (27 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the electrical connector.
3. Install the vacuum harness.
4. Install the negative battery cables.

26954
Engine________________________________________________ Engine Controls - 6.5L 6-2651

Vehicle Speed Signal Buffer Replacement

The VSS buffer module (1) is mounted in the
instrument panel. Go to Engine Electrical.

38008
Boost Sensor Replacement
Removal Procedure
1. Remove negative battery cables.
Caution: Refer to Battery Disconnect Caution
In Cautions and Notices.
2. Remove the electrical connector.
3. Remove the mounting bolts.
4. Remove the sensor.

26957
Installation Procedure
1. Install the port gasket on sensor.
2. Install the sensor.
3. Install the mounting bolts.
Tighten
Tighten the mounting bolts to 3.5 N.m (27 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
4. Install the electrical connector.
5. Install the negative battery cables.

26957
6-2652 Engine Controls - 6.5L Engine

Wastegate Solenoid Replacement

Removal Procedure
1. Remove negative battery cables.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the electrical connector from the
solenoid.
3. Remove the vacuum hoses.
4. Remove the solenoid mounting bolt
5. Remove the wastegate solenoid.

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.

CDR Valve and Hoses Replacement

Removal Procedure
The crankcase depression regulator valve (1) is
replaced as an assembly. Replace the hoses (3),
pipes (3) and grommet (4) as required, if the
inspection indicates any cracks or decay.
Refer to the appropriate service information for diesel
crankcase ventilation system maintenance
requirements.

25616
Engine Engine Controls - 6.5L 6-2653
1. Remove the clamp (2) at the CDR valve (1).
2. Remove the hose (3) from the CDR valve (1).
3. Remove the CDR valve by pulling straight up.

Installation Procedure
1. Install the CDR valve (1) into the valve cover.
2. Install the hose (3).
3. Install the clamp (2).
Tighten
Tighten the clamp to 1.7 N.m (15 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

A ir Cleaner Element Replacement

Removal Procedure
1. Loosen the clamp and separate the air cleaner
inlet elbow from the turbocharger inlet elbow.

55474
6-2654 Engine Controls - 6.5L________________________________________________ Engine
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 cleaner filter with air inlet elbow

t attached.
5. Separate the air inlet elbow from the filter by
pulling apart.
• Inspect the CDR hose for cracks or binds.
• Inspect the air cleaner cover seals for
damage.
• Inspect the air cleaner filter for damage or
excessive dirt accumulation.
• A high capacity air filter can be used if
necessary (AC type A 1306C).

63699
Engine Engine Controls - 6.5L 6-2655
Installation Procedure
1. Install the air inlet elbow on the filter by
pushing together (filter by pushing on
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).

4. Install the air cleaner cover into the housing

and clip into place.

5. Install the air cleaner inlet elbow into the

turbocharger inlet elbow.
6. Tighten the elbow clamp.
Tighten
Tighten the elbow clamp to 5 N.m (45 lb in).

55474
6-2656 Engine Controls - 6.5L Engine
Air Cleaner Assembly Replacement
Removal Procedure
1. Loosen the clamp and separate the air cleaner
inlet elbow from the turbocharger inlet elbow

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.

5. Remove the air cleaner assembly

mounting bolts.
6. Remove the air cleaner assembly.
• Inspect the air cleaner filter for damage or
excessive dirt accumulation. Replace if
necessary.
• Inspect the air inlet elbows and the
CDR hose for damage or cracks, replace if
necessary.

55483
Engine________________________________ Engine Controls - 6.5L 6-2657
Installation Procedure
1. Install the air cleaner assembly.
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.

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).

6. Install the air cleaner inlet elbow to the

turbocharger inlet elbow and tighten the clamp.
Tighten
Tighten the inlet elbow clamp to
5 N.m (45 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

55474
6-2658 Engine Controls - 6.5L___________
Description and Operation
Powertrain Control Module Description
The PCM processes the various input information.
The PCM sends the necessary electrical responses
to the control fuel delivery, spark timing, and other
emission control systems.
The input information has an interrelation to more
than one output. One failed input can affect more
than one system’s operation.
On-Board Diagnostic System Check
The On-Board Diagnostic (OBD) System Check is an
organized approach to identify a problem caused by
an electronic engine control system malfunction. The
OBD must be the starting point for any driveability
complaint diagnosis. The OBD directs the technician
to the next logical step in diagnosing the complaint.
Use the Engine Scan Tool Data Definitions list for a
comparison after fulfilling the following items:
• Completes the OBD System Check
• The on-board diagnostics are functioning
properly
• Displays no diagnostic trouble codes
The Engine Scan Tool Definitions are an average of
display values recorded from normal operating
vehicles. The Definitions intend to represent what a
normal functioning system should display.
Important: Do not use a scan tool that displays
faulty data. Report the problem to the manufacturer.
Using a malfunctioning scan tool can result in
misdiagnosis and unnecessary parts replacement.
Use only the parameters listed in the Engine Scan
Tool Definitions for diagnosis. When a scan tool
reads other parameters, General Motors
recommends not using the values for use in
diagnosis.
For more description on the values and the use of
the scan tool to diagnose the PCM inputs, refer to
the applicable diagnostic file.
When all the values are within the ranged illustrated
in the Engine Scan Tool Data Definitions, refer to
Driveability Symptoms.
Control Module Communications
The control module system has a computer,
Powertrain Control Module (PCM) to control fuel
delivery, timing, and some emission control systems.
The control module system, monitors a number of
engine and vehicle functions and controls the
following operations:
• Fuel control.
• Fuel injection timing.
• Exhaust gas recirculation.
• Transmission shift and shift quality functions.
• Specific transmission control diagnostics are
covered in Transmissions.
Engine
The diesel Powertrain Control Module (PCM), located
in the passenger compartment, is the control center
of the control module system. The Powertrain
Control Module used on the electronic fuel injected
6.5L diesel is referred to as a PCM.
The PCM constantly looks at the information from
various sensors, and controls the systems that affect
vehicle performance. The PCM performs the
diagnostic function of the system. It can recognize
operational problems, alert the driver through the MIL
(Service Engine Soon), and store one or more DTCs
which identify the problem areas to aid the
technician in making repairs. See the specific
diagnosis procedure for more information.
The PCM processes the various input information
and sends the necessary electrical responses to
control fuel delivery, timing and other emission
control systems. The input information has an
interrelation to more than one output, therefore, if the
one input failed it could effect more than one
systems operation.
Aftermarket (Add-On) Electrical And Vacuum
Equipment
Installed any equipment on a vehicle after leaving
the factory that connects to the electrical or vacuum
systems of the vehicle defines Aftermarket (Add-On)
Electrical and Vacuum Equipment. The vehicle
design makes no allowances for this type of
equipment.
Notice: Do not attach add-on vacuum operated
equipment to this vehicle. The use of add-on vacuum
equipment may result in damage to vehicle
components or systems.
Notice: Connect any add-on electrically operated
equipment to the vehicle’s electrical system at the
battery (power and ground) in order to prevent
damage to the vehicle.
The Add-On electrical equipment, even when
installed to these strict guidelines, may still cause the
Powertrain system to malfunction. This may also
include any equipment which is not connected to the
electrical system of the vehicle such as portable
telephones and radios. Therefore, the first step in
diagnosing any Powertrain problem is to eliminate all
of the Aftermarket electrical equipment from the
vehicle. After this is done, if the problem still exists,
diagnose the problem in the normal manner.
Engine Controls Information
The driveability and emissions information describes
the function and operation of the control module.
The emphasis is placed on the diagnosis and repair
of problems related to the system.
Engine Components, Wiring Diagrams, and
Diagnostic Tables (DTCs):
• The Component Locations
• The Wiring Diagrams
• The Control Module Terminal End View and
Terminal Definitions
• The On-Board Diagnostic (OBD) System Check
. The Diagnostic Trouble Code Tables (DTCs)
Engine_________________________________
The Component System includes the following items:
• The Component and circuit description
• The On-vehicle service for each subsystem
• The Functional checks with the Diagnostic
Tables
• How To Use Electrical Systems Diagnostic
Information
The DTCs also contain the diagnostic support
information containing the circuit diagrams, the circuit
or the system information, and helpful diagnostic
information.
Wiring Harness Service
The control module harness electrically connects the
control module to the various solenoids, switches,
and sensors in the vehicle engine room and
passenger compartment.
Replace the wire harnesses with the proper part
number replacement. When splicing signal wires into
a harness, use the wiring that has high temperature
insulation.
Consider the low amperage and voltage levels
utilized in the Powertrain control systems. Make the
best possible bond at all splices. Use rosin-core
solder in these areas.
Molded-on connectors require complete replacement
of the connector. Splice a new connector into the
harness. Replacement connectors and terminals are
listed in Group 8.965 in the Standard Parts Catalog.
For wiring repair, refer to Wiring Repairs.
Connectors and Terminals
In order to prevent shorting between opposite
terminals, use care when probing a connector and
when replacing terminals. Damage to the
components could result.
Always use jumper wires between connectors for
circuit checking.
Never probe through the Weather-Pack seals.
Use the tachometer adapter J 35812, or the
equivalent, which provides a convenient connection
to the tachometer lead. The connector test adapter
kit J 35616, or the equivalent, contains an
assortment of flexible connectors used in order to
probe the terminals during the diagnosis. The fuse
remover and the test tool BT-8616, or the equivalent,
is used for removing a fuse and to adapt the fuse
holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight
because oxidation or terminal misalignment are
hidden by the connectors. Merely wiggling a
connector on a sensor or in the wiring harness may
temporarily correct the open circuit. Oxidized or loose
connections may cause intermittent problems.
Be certain the type of connector and terminal before
making any connector or terminal repair.
Weather-Pack and Corn-Pack III terminals look
similar, but are serviced differently.
___________ Engine Controls - 6.5L 6-2659
Serial Data Communications
Class II Serial Data
U.S. Federal regulations require that all automobile
manufacturers establish a common communications
system. This vehicle utilizes the Class II
communications system. Each bit of information can
have one of two lengths: long or short. This allows
the vehicle wiring to be reduced by the transmission
and reception of the multiple signals over a single
wire. The messages which are carried on Class II
data streams are also prioritized. In other words, if
two messages attempt to establish communications
on the data line at the same time, only the message
with the higher priority will continue. The device with
the lower priority message must wait. The most
significant result of this regulation is that the
regulation provides the scan tool manufacturers with
the capability of accessing the data from any make
or model vehicle sold in the United States.
The Diagnostic Executive
The Diagnostic Executive is a unique segment of the
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the
protocol for recording and displaying their results. The
main responsibilities of the Diagnostic Executive are:
• Monitoring the Diagnostic Test Enabling
Conditions
• Requesting the Malfunction Indicator Light (MIL)
• Illuminating the MIL.
• Recording Pending, Current, and History DTCs
• Storing and Erasing Freeze Frame Data
• Monitoring and Recording Test Status
information
On-Board Diagnostic Tests
A diagnostic test is a series of steps which has a
beginning and an end. The result of which is a pass
or fail reported to the Diagnostic Executive. When a
diagnostic test reports a pass result, the Diagnostic
Executive records the following data:
• The diagnostic test has completed since the
last ignition cycle
• The diagnostic test has passed during the
current ignition cycle
• The fault identified by the diagnostic test is not
currently active
When a diagnostic test reports a fail result, the
Diagnostic Executive records the following data:
• The diagnostic test has completed since the
last ignition
• The fault identified by the diagnostic test is
currently active
• The fault has been active during this
ignition cycle
• The operating conditions at the time of the
failure
6-2660 Engine Controls - 6.5L
Trip
The ability for a diagnostic test to run depends
largely upon whether or not a Trip has been
completed. A Trip for a particular diagnostic is
defined as a key ON and key OFF cycle in which all
the enabling criteria for a given diagnostics as been
met allowing the diagnostic to run vehicle operation,
followed by an engine OFF period of duration and
driving mode such that any particular diagnostic test
has had sufficient time to complete at least once.
The requirements for trips vary as they may involve
items of an unrelated nature; driving style, length of
trip, ambient temperature, etc. Some diagnostic tests
run only once per trip (e.g. catalyst monitor) while
others run continuously (e.g. misfire and fuel system
monitors). If the proper enabling conditions are not
met during that ignition cycle, the tests may not be
complete or the test may not have run.
Warm-Up Cycle
A Warm-up cycle consists of an engine start-up and
vehicle operation such that the coolant temperature
has risen greater than 40 *F from the start-up
temperature and reached a minimum engine coolant
temperature of 160‘ F. If this condition is not met
during the ignition cycle, the diagnostic may not run.
Diagnostic Information
The diagnostic Tables and the functional checks are
designed in order to locate a poor circuit or a
malfunctioning component through a process of
logical decisions. The Tables are prepared with the
assumption that the vehicle functioned correctly at
the time of assembly and that there are no multiple
faults present.
There is a continuous self-diagnosis on certain
control functions. This diagnostic capability is
complemented by the diagnostic procedures which
are contained in this manual. The language of
communicating the source of the malfunction is a
system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code will set and the Malfunction
Indicator Lamp (MIL) will illuminate on some
applications.
Malfunction Indicator Lamp (MIL)
The MIL (Malfunction Indicator Lamp) is on the
instrument panel. The MIL has the following
functions;
• The MIL informs the driver that a fault that
affects the emission levels of the vehicle has
occurred. The owner should take the vehicle in
for service as soon as possible.
• As a bulb and system check, the MIL
(Malfunction Indicator Lamp) comes ON with
the key ON and the engine not running. When
the engine is started, the MIL turns OFF if no
DTCs are set.
Engine
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.
Intermittent Malfunction Indicator Lamp
In the case of an intermittent fault, the MIL
(Malfunction Indicator Lamp) may illuminate and then
after 3 trips turn OFF. However, the corresponding
diagnostic trouble code will store in the memory.
When unexpected diagnostic trouble codes appear,
check for an intermittent malfunction.
Data Link Connector (DLC)
The provision for communicating with the control
module is a Data Link Connector (DLC). The DLC is
usually located under the instrument panel. The DLC
is used in order to connect to a scan tool. Some
common uses of the scan tool are listed below:
• Identifying stored Diagnostic Trouble Codes
(DTCs)
• Clearing the DTCs
• Performing the output control tests
• Reading the serial data
Reprogramming (Flashing) The Control
Module
Some vehicles allow the reprogramming of the
control module without removal from the vehicle. This
provides a flexible and a cost-effective method of
making changes in software and calibrations.
Refer to the latest Techline information on
reprogramming or flashing procedures.
Verifying Vehicle Repair
Verification of the vehicle repair will be more
comprehensive for vehicles with OBD II system
diagnostics. Following a repair, the technician should
perform the following steps:
1. Review the fail records and the Freeze Fame
data for the DTC which was diagnosed. Record
the fail records or Freeze Fame data. The
Freeze Frame data will only store for an A or B
type diagnostic and only if the MIL has
illuminated.
2. Clear the DTCs.
3. Operate the vehicle within the conditions noted
in the fail records or the Freeze Frame data.
4. Monitor the DTC status information for the
specific DTC which has been diagnosed until
the diagnostic test associated with that DTC
runs.
Following these steps are very important in verifying
repairs on the OBD II systems. Failure to follow
these steps could result in an unnecessary repair.
Engine
Reading Diagnostic Trouble Codes
Use a diagnostic scan tool in order to read the
diagnostic trouble codes. Failure to follow this step
could result in unnecessary repairs.
DTC Modes
The OBD II vehicles have three options available in
the scan tool DTC mode in order to display the
enhanced information available. A description of the
new modes, the DTC Info and the Specific DTC,
follows. After selecting the DTC, the following menu
appears:
. The DTC Info
• The Specific DTC
• The Freeze Frame
• The Fail Records
• The Clear Info
The following is a brief description of each of the
sub menus in the DTC Info and the Specific DTC.
The order in which they appear here is alphabetical
and not necessarily the way they will appear on the
scan tool.
DTC Info Mode
Use the DTC Info mode in order to search for a
specific type of stored DTC information. There are
seven choices. The electronic service information
may instruct the technician to test for DTCs in a
certain manner. Always follow the published service
procedures.
In order to get a complete description of any status,
press the Enter key before pressing the desired
F-key. For example, pressing enter, then an F key
will display a definition of the abbreviated scan tool
status.
DTC Status
This selection displays any DTCs that have not run
during the current ignition cycle or have reported a
test failure during this ignition up to a maximum of
33 DTCs. The DTC tests which run and pass
removes that DTC number from the scan tool
screen.
Fail This Ign. (Fail This Ignition)
This selection displays all of the DTCs that have
failed during the present ignition cycle.
History
This selection displays only the DTCs that are stored
to the history memory of the control module. The
history memory will not display the Type B DTCs
that have not requested the MIL. The history
memory will display all of the type A and B DTCs
that have the MIL and have failed within the last 40
warm-up cycles. In addition, the history memory will
display all of the type C DTCs that have failed within
the last 40 warm-up cycles.
Engine Controls - 6.5L 6-2661
Last Test Fail
This selection displays only the DTCs which have
failed during the last time that the test ran. The last
test may have ran during a previous ignition cycle if
the a type A or B DTC is displayed. For type C
DTCs, the last failure must have occurred during the
current 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.
Not Run SCC (Not Run Since Code Clear)
This option displays up to 33 DTCs that have not
run since the DTCs were last cleared. Since any
displayed DTCs have not run, their condition
(passing or failing) is unknown.
Test Fail SCC (Test Failed Since Code Clear)
This selection displays all of the active and history
DTCs that have reported a test failure since the last
time the DTCs were cleared. The DTCs that last
failed over 40 warm-up cycles (before this option is
selected) will not be displayed.
Specific DTC Mode
This mode is used in order to check the status of
the individual diagnostic tests by the DTC number.
This selection can be accessed if a DTC has passed
or failed. Many OBD II DTC mode descriptions are
possible because of the extensive amount of
information that the Diagnostic Executive monitors
regarding each test. Some of the many possible
descriptions follow with a brief explanation.
This selection only allows the entry of the DTC
numbers that are supported by the vehicle that is
being tested. If an attempt is made to enter the DTC
numbers for tests which the diagnostic executive
does not recognize, the requested information will
not be displayed correctly and the scan tool may
display an error message. The same applies to using
the DTC trigger option in the Snapshot mode. If an
invalid DTC is entered, the scan tool will not trigger.
Failed Last Test
For type A and B DTCs, this message will display
during the subsequent ignition cycles until the test
passes or the DTCs are cleared. For type C DTCs,
this message clears whenever the ignition is cycled.
Failed Since Clear
This message displayed indicates that the diagnostic
test failed at least once within the last 40 warm-up
cycles since the last time the control module cleared
the DTCs.
6-2662 Engine Controls - 6.5L___________
Failed This Ign. (Failed This Ignition)
This message displayed indicates that the diagnostic
test has failed at least once during the current
ignition cycle. This message will clear when the
DTCs are cleared or the ignition is cycled.
History DTC
This message displayed indicates that the DTC has
stored to memory as a valid fault. A DTC displayed
as a History fault does not necessarily mean that the
fault is no longer present. The history description
means that all of the conditions necessary for
reporting a fault have met.
Engine
Prior to repairing a vehicle, use the status
information in order to evaluate the state of the
diagnostic test and to help identify an intermittent
problem. The technician can conclude that although
the MIL is illuminated, the fault condition that caused
the code to set is not present. An intermittent
condition must be the cause.
Information Sensors/Switches Description
Engine Coolant Temperature (ECT) Sensor

MIL Requested
This message displayed indicates that the DTC is
currently causing the MIL to turn ON. Remember
that only type A and B DTCs can request the MIL.
The MIL request cannot determine if the DTC fault
conditions are currently being experienced. This is
because the diagnostic executive requires up to
3 trips during which the diagnostic test passes to
turn OFF the MIL.

Not Run Since Cl (Not Run Since Cleared)

This message displayed indicates that the selected
diagnostic test has not run since the last time the
DTCs were cleared. Therefore, the diagnostic test
status (passing or failing) is unknown. After the
DTCs are cleared, this message continues to be
displayed until the diagnostic test runs.
Not Run This Ign. (Not Run This Ignition)
This message displayed indicates that the selected
diagnostic test has not run this ignition cycle.
Test Ran and Passed
This message displayed indicates that the selected
diagnostic test has the following items:
• Passed the last test
• Ran and passed during this ignition cycle
• Ran and passed since the DTCs were last
cleared
• This test has not failed since the DTCs were
last cleared.
Whenever the indicated status of the vehicle is Test
Ran and Passed after a repair verification, the
vehicle is ready to be released to the customer.
If the indicated status of the vehicle is Failed This
Ign after a repair verification, then the repair is
incomplete. A further diagnosis is required.
13578
Legend
(1) ECT Electrical Connector
(2) Connector Tab
(3) Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
Low coolant temperature produces a high resistance
(100,000 ohms at -40’ C/-40‘ F) while high
temperature causes low resistance (70 ohms at
130 * C/266 * F).
The PCM supplies a 5 volt signal through the
thermistor in the Engine Coolant Temperature (ECT)
sensor and then the PCM and measures the voltage
to determine temperature. The voltage will be high
when the engine is cold, and low when the engine is
hot. By measuring the voltage, the PCM knows the
engine coolant temperature. Engine coolant
temperature affects fuel control and the glow plug
system.
Engine
Intake Air Temperature (IAT) Sensor
Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Electrical Harness Connector
The Intake Air Temperature (IAT) sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the intake manifold.
Low temperature produces a high resistance
(100,000 ohms at -4 0 *C /-4 0 *F ) while high
temperature causes low resistance (70 ohms at
130 ’ C/266 * F).
The PCM supplies a 5 volt signal through a resistor
in the sensor and the PCM then measures the
voltage. The voltage will be high when the intake air
is cold, and low when the air is hot. By measuring
the voltage, the control module knows the intake air
temperature.
The PCM uses the IAT signal to control fuel.
___________ Engine Controls - 6.5L 6-2663
Mass Air Flow (MAF) Sensor
13487
The Mass Air Flow (MAF) sensor measures the
amount of air which passes through it. The PCM
uses this information to determine the operating
condition of the engine, to control EGR operation. A
large quantity of air indicates acceleration. A small
quantity of air indicates deceleration or idle.
The scan tool reads the MAF value and displays it in
Grams per Cylinder, Grams per Second (gm/s), and
Hertz (Hz). Values should change rather quickly on
acceleration, but values should remain fairly stable at
any given RPM. When the PCM detects a
malfunction in the MAF sensor circuit, the following
DTCs will set:
• DTC P0101 system performance.
• DTC P0102 frequency low.
• DTC P0103 frequency high.
6-2664 Engine Controis - 6.5L
Optical/Fuel Temperature Sensor
The optical sensor has a 5V reference that powers
the optics. The PCM supplies 5V to the optical
sensor through the High Res signal circuit and
Pump CAM signal circuit. The optical sensor then
generates a High Resolution Signal and a Pump
Cam signal and sends these signals back to
the PCM.
Accelerator Pedal Position (APP) Module
27618
The APP module contains three potentiometers (a
device for measuring an unknown voltage or
potential difference by comparison to a standard
voltage). Each of the APP sensors send a varying
voltage to the PCM. By monitoring the output voltage
from the Accelerator Pedal Position (APP) module,
the PCM can determine fuel delivery based on the
accelerator pedal position (driver demand).
Engine
High Resolution Signal (256X)
The high resolution signal is an optical device which
generates 64 equally spaced pulses per cylinder
combustion stroke from the slotted disc mounted on
the injection pump timing cam ring. The pulses are
counted by the PCM and used to measure the
angular pump displacement. Fuel is metered by
using the angular indication and timing is measured
by counting the angular pulses between the pump
cam signal and the crankshaft position sensor signal.
Injection Pump Cam Signal (4X)
The Pump Cam signal is an optical device which
generates one pulse per cylinder combustion stroke
from a slotted disc mounted on the injection pump
timing cam ring. The pulse is used to located the
start of injection event for each cylinder (i.e. timing)
with the respect to the crankshaft position sensor.
The number one cylinder is identified with a wider
pulse (larger slot in disc). The PCM uses this
information to adjust idle fuel, timing, trigger real time
events and is used in the diagnostics of crankshaft
position sensor and the high resolution circuit.
Fuel Temperature Sensor
The fuel temperature sensor is a thermistor (a
resistor which changes value based on temperature)
mounted in the injection pump.
The fuel temperature sensor is part of the optical/fuel
temperature sensor. The resulting voltage is
monitored by the PCM which uses this signal to
minimize fueling error due to injection pump
efficiency changes due to very hot fuel.
The fuel temperature sensor receives 5V from the
PCM through the Fuel Temperature signal circuit.
The fuel temperature sensor has a thermistor (a
resistor that changes based on temperature) that
causes a voltage drop across the circuit. The PCM
then interprets the amount of voltage on the circuit
to determine fuel temperature.
Engine
Crankshaft Position (CKP) Sensor (4X)
The crankshaft position sensor is a hall effect type of
a device which generates one pulse per cylinder
combustion stroke from a four tooth reluctor wheel
attached to the engine crankshaft. The pulse is used
to locate the cylinder reference event (top dead
center) for each cylinder. The PCM uses this
information to adjust timing, trigger real time events
and is used in the injection pump cam signal
diagnostic.
EGR Control Pressure/BARO Sensor
Legend
(1) Electrical Connector
(2) Manifold Absolute Pressure (MAP) Sensor
On vehicles equipped with EGR, the EGR control
pressure sensor, mounted on the left side of the
cowl, is used to monitor the amount of vacuum
applied to the EGR valve. It senses the actual
vacuum in the EGR vacuum line and sends a signal
back to the PCM. The signal is compared to the
desired EGR calculated by the PCM. If there is a
difference in the PCM command and what is at the
EGR valve sensed by the EGR control
pressure/BARO sensor, on vehicles not equipped
with EGR the Boost sensors is used to measure
BARO. This sensor reads barometric pressure
(BARO) under certain conditions, which allows the
PCM to automatically adjust for different altitudes.
Boost (BARO) Sensor
The boost sensor measures the changes in the
intake manifold pressure. The boost sensor converts
engine load and speed changes, then converts the
change in readings to voltage output.
The PCM sends a 5 volt reference signal to the
boost sensor. As the manifold pressure changes, the
electrical resistance of the boost sensor also
changes. By monitoring the sensor output voltage,
the PCM detects the boost pressure. A high
Engine Controls - 6.5L 6-2665
pressure (high voltage) requires more fuel. A lower
pressure (low voltage) required less fuel. The control
module uses the boost pressure signal to control fuel
delivery.
The Boost sensor also is used for BARO readings
only on vehicle not equipped with EGR. This sensor
reads barometric pressure (BARO) under certain
conditions, which allows the PCM to automatically
adjust for different altitudes.
Vehicle Speed Sensor (VSS)
The VSS is attached to the output shaft housing.
This device contains a permanent magnet
surrounded by a coil of wire producing a magnetic
field which is interrupted by rotor teeth pressed on
an output shaft. As the rotor interrupts the magnetic
field an AC voltage is generated in the circuit.
Vehicle Speed Signal (VSS) Buffer Module
The VSS buffer module (1) is an electronic device.
The VSS buffer module process inputs from the
vehicle speed sensor and outputs various signals.
The VSS buffer module outputs a 4000 pulse per
mile signal. This signal is used by the PCM to
determine vehicle speed. The PCM uses vehicle
speed signal input for cruise control and fuel cutoff.
The VSS buffer module is matched to the vehicle
based on transmission, final drive ratio and tire size.
The VSS buffer module is located behind the
instrument panel.
Fuel Solenoid Driver
The fuel injector driver receives an inject command
signal from the PCM and provides a current
regulated output to the fuel solenoid that controls
injection. It also returns an fuel solenoid closure time
signal back to the PCM to inform it when the fuel
solenoid has actually seated.
6-2666 Engine Controls - 6.5L
Brake Switch
The TCC normally closed brake switch supplies a
B+ signal into the PCM. The signal voltage is
opened when the brakes are applied.
The cruise control normally open brake switch
supplies a B+ signal to the PCM when the brake is
applied. These signals are used by the PCM to
control transmission and cruise control functions. The
brake switches are part of the stoplamp switch.
Glow Plug System
The glow plug system is used to assist in providing
the heat required to begin combustion during engine
starting at cold ambient temperatures.
The glow plug relay switches power to the glow
plugs and is commanded on and off by the PCM.
The glow plugs are heated before and during
cranking, as well as initial engine operation. The
PCM monitors the glow plug relay output voltage
which indicates if the relay is following the
PCM commands.
Cruise Control System
The cruise control switches are part of the
multifunction turn signal lever. These switches enable
the driver to control the cruise on/off, set/coast and
resume/accel signals. These signals are inputs to the
fuel control portion of the PCM and allow the PCM
to maintain a desired vehicle speed under normal
driving conditions.
Engine
A/C Signal
This signal indicated that the A/C compressor clutch
is engaged. The PCM uses this signal to adjust the
idle speed.
APP Module Description
The accelerator control system is an electronically
controlled throttle type with an accelerator pedal
attached to an accelerator pedal position module.
This module sends signals to the powertrain control
module which controls the fuel injection pump.
Fuel System Description
The fuel injection system has a PCM controlled fuel
injection pump mounted on top of the engine under
the intake manifold. The pump is driven by the
camshaft through two gears, one attached to the
front of the camshaft and the other attached to the
end of the pump shaft. These gears are the same
size and have the same number of teeth; therefore,
the injection pump shaft turns at the same speed as
the camshaft.
Engine____________________ Engine Controls - 6.5L 6-2667

Electronic Fuel Injection Pump

54847

Legend
(1) Fuel Solenoid Driver
(2) Optical/Fuel Temperature Sensor
(3) Fuel Inlet
(4) Engine Shutoff Solenoid
(5) Two Stage Housing Pressure Regulator
(6) Injector Timing Stepper Motor
(7) Fuel Solenoid

The injection pump is a high pressure rotary type

that is controlled by the PCM. The injection pump
meters, pressurizes, and distributes fuel to the eight
injector nozzles by way of eight high pressure lines.
An outlet port in the injection pump allows the fuel to
enter the fuel return system and then travel back to
the fuel tank.
6-2668 Engine Controls ■ 6.5L Engine
Injection Nozzles Injection Lines

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

The injection lines connect the high pressure

discharge fittings on the head of the injection pump
to the injection nozzles. The injection lines are
pre-bent for correct routing and connect to the
injection pump head as shown in the figure above.
The injection lines are equal in length and interior
volume.

(1) Inlet
(2) Return
(3) Pressure Spring
(4) Nozzle Nut
(5) Needle Valve
(6) Pintle
Each cylinder has an identical fuel injection nozzle
mounted in the pre-combustion chamber. As the
pressure wave of injection reaches a nozzle, the
needle valve is lifted against spring force and fuel
exits into the pre-combustion chamber of the cylinder
as a highly atomized spray. A small amount of fuel
travels between the needle valve and pintle nozzle,
providing lubrication. Two passages inside the upper
half of the nozzle body allow fuel that has lubricated
the needle valve to exit into the fuel return system.
Fuel Metering
The fuel metering is accomplished by the fuel
solenoid driver by using the signals from the PCM in
order to control the fuel injection solenoid.
Injection Timing
The injection timing stepper motor advances or
retards the injection timing by the signals that are
received from the PCM.
Engine Shutoff Solenoid
When not activated by the PCM, the engine shutoff
solenoid blocks the fuel flow from entering the
transfer pump inside of the injection pump and stops
the engine operation.
Engine_________________ Engine Controls - 6.5L 6-2669
Accelerator Control System

The accelerator control system is an electronically

controlled throttle type with an accelerator pedal
attached to an accelerator pedal position module (2).
This module sends the signals to the PCM which
then controls the fuel injection pump.
6-2670 Engine Controls - 6.5L________________________________________________ Engine

Fuel Supply Component Description

Legend
(1) Fuel Gauge (5) Fuel Lift Pump
(2) Fuel Filter/Manager (6) Fuel Sender
(3) Fuel Injection Pump (7) Fuel Tank
(4) Injector

The fuel supply is stored in the fuel tank. Fuel is
drawn from the fuel tank by the fuel lift pump. Fuel
is then pumped through the fuel manager/filter. The
fuel manager/filter is located on the intake manifold.
The fuel is then transferred to the injection pump.
Unused fuel is returned to the fuel tank by a
separate line.
Fuel Tank
The fuel tank is held in place by two metal straps
and a cross strap attached to the underbody.
Fuel Tank Filler Neck
The fuel tank filler neck is positioned at the left rear
quarter panel of the vehicle.
Fuel Filler Cap
The fuel tank filler neck is equipped with a
threaded-type cap. The threaded part of the cap
requires several turns counterclockwise to remove. A
built-in torque-limiting device prevents over
tightening. To install, turn the cap clockwise until a
clicking noise is heard. This signals that the correct
torque has been reached and the cap is fully seated.
Fuel Sender
The fuel sender is located inside the fuel tank and is
attached to the top of the fuel tank.
The fuel sender has a float, wire float arm, and a
rheostat. Fuel level is sensed by the position of the
float and float arm which operate the 90 ohm
rheostat. As the float position changes, the amount
of current passing through the rheostat varies, thus
changing the gage reading on the instrument panel.
Engine______
Fuel Lift Pump
Legend
(1) Inlet Port
(2) Pressure Spring
(3) Primary Winding
(4) Secondary Winding
(5) Piston and Valve Assembly
The electric fuel lift pump mounts on the inside of
the left frame rail, and is used to deliver fuel at a
low pressure (at least 3 psi or 21 kPa) at the rate of
0.24 liter (V2 pint) in 15 seconds (15 GPH). The lift
pump is controlled by the PCM.
Fuel Lift Pump Electrical Circuit
When the key is in turned ON, the PCM energizes
the fuel pump relay which sends voltage to the lift
pump. The lift pump remains during the glow plug
cycle. If the engine is not started immediately after
the glow plug cycle, the PCM shuts the fuel lift pump
OFF and waits until engine RPM is greater than zero
and then turns the relay back ON. As a backup
system to the fuel pump relay, the fuel lift pump can
also be turned ON by the fuel pump/oil pressure
switch. When the engine oil pressure reaches
28 kPa (4 psi), and the fuel pump relay does not
complete the circuit, the fuel pump/oil pressure
switch will close and complete the circuit to run the
fuel lift pump.
Engine Controls - 6.5L 6-2671
27783
(6) Inlet Valve
(7) Outlet Valve
(8) Cylinder
(9) Teflon Ring
Fuel Manager/Filter
The fuel manager/filter is an in-line type filter which
combines several different functions. It acts as a fuel
filter, water separator, water detector, water drain,
and a fuel heater.
The fuel manager/filter mounts on the rear of the
intake manifold. The filter housing has an inlet fitting
connecting to the pipe/hose from the lift pump and
an outlet fitting connecting to the fuel injection pump
with a hose. A third fitting connects through a hose
to a drain valve mounted on the water
crossover/thermostat housing.
The fuel manager/filter has a replaceable element. The
element has an air vent valve on its top surface that is
used during lift pump diagnosis and filter element
replacement procedure. The fuel manager/filter also
has a water in fuel sensor and a fuel heater.
Fuel Filter Element
The fuel filter element separates particles larger
than 10 microns (0.00039 in) from fuel moving
through it under lift pump pressure. Filter action is
very critical to the operation of internal parts of the
fuel injection pump.
6-2672 Engine Controls ■ 6.5L___________
Water In Fuel Sensor
The design of the fuel manager/filter includes an
area that allows water droplets (as small as one
micron) to separate from the fuel and collect in a
lower portion of the housing. The water in fuel
sensor will detect a certain amount of water in the
fuel inside the filter housing and then turn the Water
in Fuel lamp ON in the instrument cluster.
When the ignition switch is first turned to the run
position, the Water in Fuel lamp will come ON for
2 to 5 seconds. This action provides a bulb check.
Fuel Heater
The fuel heater operates when the temperature of
fuel at the inlet of the filter housing is cold enough
to possibly cause waxing that could restrict flow to
the injection pump. A control circuit inside the fuel
heater completes the circuit for the heater element
when it senses a temperature below 8 * C (46 * F).
Fuel Pipes and Hoses
The fuel feed and return pipes and hoses extend
from the fuel sender to the fuel manager/filter. They
are secured with clamps and are routed along the
frame side member.
Fuel Pipe O-Rings
Some fuel feed pipes have threaded connections
that are sealed with replaceable O-ring seals. These
O-ring seals are made of special material, and
should only be serviced with the correct service part.
Glow Plug System Description
Legend
(1) Glow Plug
(2) Fuel Injector
(3) Cylinder Head
(4) Pre-Combustion Chamber
(5) Heated Sheath
Engine
In the diesel engine, air alone is compressed in the
cylinder; then, after the air has been compressed, a
charge of fuel is sprayed into the cylinder and
ignition occurs, due to the heat of compression.
Eight glow plugs are used as an aid to.starting.
Control of the Glow Plugs has been accomplished by
moving the logic for controlling the heat of the plugs
to the PCM. The new logic can incorporate the
higher accuracy of digital processing compared to
the previous analog controller. Additionally, logic
involving engine speed and estimates of engine
combustion can be added to the traditional time and
temperature data used in the previous controller.
This capability yields more optimum heat times for
the glow plugs, thus pre-glow times can be kept to a
minimum for short wait to crank times and maximum
glow plug durability.
A normal functioning system operates as follows:
• Key ON, engine not running and at room
temperature.
• Glow plugs ON for a short period of time
(approximate on times may range from 1 to
16 seconds).
• If the engine is cranked during or after the
above sequence, its possible the glow plugs will
cycle ON/OFF after the engine control switch is
returned from the crank position, whether the
engine starts or not. The engine does not have
to be running to terminate the glow plug
cycling.
The glow plug initial ON times may range from 1 to
16 seconds and cycling ON/OFF times vary also with
system voltage and/or temperature. Lower
temperature causes longer duration of cycling.
The PCM provides glow plug operation after starting
a cold engine. This after glow operation is initiated
when the ignition switch is returned to Run, from the
Start position. This function helps clean up excessive
white smoke and/or poor idle quality after starting.
Glow Plugs
These are 6-volt heaters (operated at 12 volts) that
turn ON, when the ignition switch is turned to the
run position, prior to starting the engine. They remain
pulsing a short time after starting, then are
turned OFF.
A Wait to Start lamp on the instrument panel,
provides information on engine starting conditions.
The Wait to Start lamp will not come ON during post
glows.
Glow Plug Relay
The glow plug relay is mounted at the rear of the left
cylinder head. It is a solid state device which
operates the glow plugs.
The PCM uses a ignition voltage signal to control
the solid state circuitry of the glow plug relay.
Engine
EGR System Description
The EGR system lowers the formation of nitrogen
oxides by reducing combustion temperature. This is
done by introducing exhaust gases into the cylinders
through an EGR valve. The PCM, in the control
module system, controls the amount of EGR to meet
emission control requirements and maintains good
driveability through a EGR pulse width modulated
solenoid and a EGR vent solenoid, which regulates
the vacuum to the EGR valve. One main sensor
input to the PCM is used to calculate the amount
of EGR.
The EGR valve, installed on the intake manifold,
introduces the exhaust gases to the incoming fresh
air at the engine crossover.
A vacuum pump is required to provide a vacuum
source to operate the EGR system.
Engine Controls - 6.5L 6-2673
engine speed (RPM) and load (mm3). A normal
functioning EGR system ALM cells should display a
value between 115 and 140 (the scaling of these
cells are 0 to 256).
Resetting the ALM cells will allow the EGR system
to quickly return to a normal function (reset ALM
cells will display 128). If the ALM cells are not reset,
the vehicle may experience black smoke and poor
driveability complaints until the system is able to
adjust (approximately 5 to 10 miles) or a DTC P0401
may set.
Crankcase Ventilation System Description

EGR Solenoid
The EGR solenoid assembly is mounted at the top,
left rear of the engine. The PCM controls the time
the EGR solenoid to regulate the vacuum to the
EGR valve. This regulates the amount of EGR. The
PCM calculates the amount of EGR based on engine
speed and accelerator pedal position. The PCM is
programmed to vary the ON and OFF time of the
EGR solenoid, based on these two inputs. To
monitor the PCM control of EGR, an EGR control
pressure/BARO sensor is used to measure the
amount of absolute pressure in the EGR vacuum
line. If a minor variation in calculated EGR and
actual EGR as monitored by the EGR control
pressure/BARO sensor, the PCM makes a correction. 26779
If the variation exceeds an amount in excess of what Legend
the PCM can correct for, an error is detected by the
PCM and the system will go into default. (1) Crankcase Vapors to Induction System
(3) Blowby Leakage At Valves and Pistons
When the PCM recognizes the operating range for
no EGR, the EGR vent solenoid operates to allow (4) Crankcase Vapors
rapid venting of vacuum to the EGR valve.
The crankcase ventilation system used on diesel
Adaptive Learn Matrix (ALM) engines is designed to maintain a slightly negative
(vacuum) crankcase pressure across the speed
The Adaptive Learn Matrix (ALM) is a matrix of cells
range. The system consists of a Crankcase
arranged by RPM and engine load. ALM is used to
Depression Regulator (CDR) valve, located on the
adjust EGR vacuum control based on Mass Air Flow
right valve cover and the attaching vent hose/pipes
(MAF). The ALM cells may change as a result of
to the engine inlet system. The CDR valve is used
back pressure increases over the life of the engine
only to regulate crankcase pressure between 0’ and
or other engine system variations. Too much EGR
4’ water depression over the engine speed range.
will cause ALM cells to go high, not enough EGR
The CDR valve is Not an oil separator or a
will cause the ALM cells to go low as shown below:
crankcase effluent flow regulator. Hence, the
• If backpressure is excessive (too much EGR), CDR valve Does Not prevent oil droplets/mist from
the ALM cells will be high (above 128). This will entering the intake system, nor does it effect engine
cause the PCM to reduce vacuum to the EGR oil consumption.
valve. This in turn will reduce the amount of
The intake manifold vacuum acts against a spring
EGR going into the engine.
loaded diaphragm to control the flow of crankcase
• If the EGR is not opening completely (not gases. Higher intake vacuum (or high intake
enough EGR), ALM cells will be low (below restriction, e.g. plugged air filter) levels pull the
128). This will cause the PCM to increase the diaphragm closer to the top of the outlet tube. This
amount of EGR entering the engine. reduces the vacuum level from getting too high in
As the engine operating conditions change, the PCM the crankcase. As the intake vacuum decreases, the
will switch from cell to cell to determine what factor spring pushes the diaphragm away from the top of
to use. ALM is made up of sixteen cells numbered the outlet tube to prevent the crankcase pressure
zero to fifteen in which each cell covers a range of from going positive.
6-2674 Engine Controls - 6.5L Engine

Air Intake System Description

The air intake system is used to direct cool air from
the exterior of the engine compartment to the intake
manifold. An air cleaner is incorporated into the
system to keep dirt from entering the engine. Some
applications also have a PCM controlled turbocharger
to increase power, improve driveability and reduce
emissions. Refer to the appropriate service manual
for more information on the turbocharger.

Air Cleaner Restriction Indicator

Legend
(1) Reset Button
(2) Window

The air cleaner restriction indicator is located on the

intake duct between the air cleaner assembly and
the Mass Air Flow (MAF) sensor.
If the area inside of the clear section is green, no air
filter service is required. If the area inside the clear
section is orange and Change Air Filter appears,
replace the air filter.
Engine________________________ Engine Controls - 6.5L 6-2675

Special Tools and Equipment

J 23738-A
Vacuum Pump

5386

J 35689-A
Metri-Pack Terminal
Remover

5395

J 33095
Control Module Connector
Terminal Remover

5397

J 34616-A/BT-8637
Connector Test Adapter Kit

13552

Diesel Fuel Quality Tester

39385
6-2676 Engine Controls - 6.5L Engine
Engine Engine Controls - 7.4L 6-2677

Engine Controls - 7.4L

Specifications

Temperature vs Resistance
•C *F OHMS
Temperature vs Resistance Values (Approximate)
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700

Fastener Tightening Specifications

Application N-m Lb Ft Lb In
EGR Valve Attaching Bolts 25.0 18 —
Vacuum Module Attaching Bolts 10.0 — 88
Coolant Hose Nipple 17.0 13 —
Power Brake Fitting 13.0 — 115
Throttle Cable Bracket Bolts 25.0 18 —
Upper Manifold Bolts 10.0 —- 90
Upper Manifold Nuts 10.0 — 90
Rear Fuel Line Bracket Retaining Bolts 6.0 — 53
EGR Tube Retaining Bolt 25.0 18 —
Idle Air Control Attaching Scews 3.0 — 26
Fuel Pipe Retaining Nuts 3.0 — 27
Fuel Pipe Nuts 30.0 22 —
Pressure Regulator Screw 9.5 — 84
Air Inlet Duct Retaining Nut 2.0 — 18
6-2678 Engine Controls ■ 7.4L________________________________________________ Engine
Fastener Tightening Specifications (cont’d)
Application N-m Lb Ft Lb In
Throttle Position Screws 2.0 — 18
Intake Plenum Bolts 25.0 18 —
Throttle body Attaching Nuts 25.0 18 —
Fuel Rail Attaching Bolts: Front Stud 25.0 18 —
Fuel Rail Attaching Bolts: Center Bolts 10.0 8 —

Fuel Rail Attaching Bolts: Rear Bolts 10.0 8 —

Engine Fuel Pipe Nuts 17.0 13 —
Pressure Regulator Attaching Screws 8.5 — 6
Throttle Posititon Sensor Screws 2.0 — 18
Idle Air Control Valve Screws 3.0 — 27
EGR Attaching Bolts 24.0 17 —

Engine Scan Tool Data List Do not use a scan tool that displays faulty data.
Report the problem to the manufacturer. The use of
Use the scan tool data listed in this table for
a faulty scan tool can result in misdiagnosis and
comparison after the On-Board Diagnostic system
unnecessary parts replacement.
check and finding the on-board diagnostics function
properly with no diagnostic codes displayed. Use only the parameters listed in the tables for
diagnosis. If a scan tool reads other parameters, the
The Typical Scan Tool Data Values are an average
values are not recommended by General Motors for
of display values recorded from normally operating
use in diagnosis. For more description on the values
vehicles. The Typical Scan Tool Data Values are
and the use of the scan tool diagnosis the VCM
intended to represent what a normally functioning
inputs, refer to the applicable diagnosis. If all
system would display. The values you get may vary
values are within the range illustrated, refer to
due to a low battery charge or other reasons. But
Driveability Symptoms.
they should be very close.
Scan Tool Data Display

Engine Data 1
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Engine Speed RPM 650 RPM
Desired Idle Speed RPM 600 RPM
IAC Position Counts 60 Counts
Desired IAC Position Counts 60 Counts
TP Sensor Volts 0.47 Volts
TP Angle % 0%
Start Up ECT Degrees Varies
ECT Degrees 93 *C (200-F)
ECT Sensor Volts 2.00 volts
MAP Volts .71 Volts
MAP kPa 36 kPa
BARO Volts 1.94 Volts
BARO kPa 99 kPa
Startup IAT Degrees Varies
IAT Degrees 45-C (113* F)
Engine Engine Controls - 7.4L 6-2679
Engine Data 1 (cont’d)
Engine at Operating Temp/Engine idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
IAT Sensor Volts 1.1 Volts
MAF g/s 7.05 g/s
MAF Frequency Hz 2540 Hz
2% idle
Engine Load %
9-13%@2500 RPM
Long Term FT Bank 1 Counts 127 Counts
Long Term FT Bank 1 % 0%
Long Term FT Bank 2 Counts 127 Counts
Long Term FT Bank 2 % 0%
Short Term FT Bank 1 Counts 127 Counts
Short Term FT Bank 1 % 0%
Short Term FT Bank 2 Counts 127 Counts
Short Term FT Bank 2 % 0%
Engine Speed RPM 650 RPM
Fuel Trim Cell Cell Cell 17
Fuel Trim Enable Yes/No Yes
EVAP Canister Purge ON/OFF ON
EVAP Duty Cycle % 17%
EGR Duty Cycle % 0%
Actual EGR Position % 0%
Desired EGR Position % 0%
EGR Sensor Volts 0.64 Volts
Vehicle Speed Kph, Mph 0 Kph
Ref. Pulse Occured Yes/No Yes
Valid Ref. Pulse Occured Yes/No Yes
Knock Sensor Volts 2.6 Volts
KS Activity Counts 0
Spark Degrees 21'
Knock Retard Degrees 0*- 2 ’
CMP Retard Degrees 0*- 2*
Spark Control Advance/Retard Advance
Loop Status Open Loop/Closed Loop Closed Loop
Pre H02S Ready/Not Ready Ready
Post H02S Ready/Not Ready Ready
Rich/Lean Bank 1 Rich/Lean Rich/Lean
Rich/Lean Bank 2 Rich/Lean Rich/Lean
Ignition 1 Volts 13.5 Volts
Air Fuel Ratio Ratio 14.7:1
Engine Run Time Min/Sec Varies
6-2680 Engine Controls - 7.4L Engine
Engine Data 2
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutrai/Accessories OFF
Scan Position Units Displayed Typical Data Value
Engine Speed RPM 600 RPM
Desired Idle Speed RPM 650 RPM
IAC Position Counts 18 Counts
Desired IAC Counts 18 Counts
TP Sensor Volts 0.47 Volts
TP Angle % 0%
Start Up ECT Degrees Varies
ECT Degrees 93 *C (200-F)
ECT Sensor Volts 2.00 Volts
Start Up IAT Degrees Varies
IAT Degrees Varies
MAP Volts 1.46 Volts
MAP Kpa 38 kPa
BARO Volts 4.76 Volts
BARO Kpa 101 kPa
Engine Load % 19%
MAF g/S 4.6 g/s
MAF Frequency Hz 2285 Hz
Power Enrichment Active/lnactive Active/lnactive
Inj. Pwm. Ave B1 ms 4.5 ms
Inj. Pwm. Ave B2 ms 4.5 ms
EVAP Duty Cycle % 0%
EVAP Canister Purge ON/OFF Off
EVAP Vent Solenoid Open/Closed Open
EGR Duty Cycle % 0%
Actual EGR Position % 0%
Desired EGR Position % 0%
Rich/Lean Bank 1 Rich/Lean Rich/Lean
Rich/Lean Bank 2 Rich/Lean Lean
Closed Loop Since Restart Yes/No Yes
Fuel Trim Enable Yes/No Yes
VTD Fuel Disable Active/lnactive Inactive
VTD Auto Learn Timer Active/lnactive Inactive
VCM in VTD Fail Enable Yes/No Yes
VTD Fuel Disable Until Ign. Off Yes/No No
Ignition 1 Volts 13.5 Volts
Ignition 1 On Yes/No Yes
Ignition 1 Low Yes/No No
Ignition 1 High Yes/No No
A/C Request Yes/No No
A/C Relay ON/OFF Off
A/C Evaporator Sw. Open/Closed Closed
A/C Sec. High Pres. Sw. Open/Closed Closed
Auto Recirculation Mode ON/OFF Off
Engine Engine Controls - 7.4L 6-2681
Engine Data 2 (cont’d)
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Fuel Level % Varies
4WD Enable/Disable Disable
4WD Low Enable/Disable Disable
Brake Sw Applied/Released Released
TR Switch Park/Neutral Park/Neutral
A/B/C Range Switch (ON/OFF)/(ON/OFF)/(ON/OFF) ON/OFF/On
Clutch Switch ON/OFF OFF

Vehicle Speed Kph/Mph

0 Kph
1-2 Solenoid ON/OFF ON
2-3 Solenoid ON/OFF Off
TCC Enable Yes/No No
TCC Duty Cycle % 0%
Cruise Enable Disable
Decel Fuel Mode Active/lnactive Inactive
Engine Run Time Min/Sec Varies

H02S Data
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Engine Speed RPM 650 RPM
Desired Idle Speed RPM 650 RPM
IAC Position Counts 18 Counts
Desired IAC Position Counts 18 Counts
TP Sensor Volts 0.47 Volts
TP Angle % 0%
Start up ECT Degrees Varies
ECT Degrees 93‘ C (200-F)
ECT Sensor Volts 2.00 Volts
Loop Status Open Loop/Closed Loop Closed Loop
Pre H02S Not Ready/Ready Ready
Post H02S Not Ready/Ready Ready
Rich/Lean Bank 1 Rich/Lean Varies
Rich/Lean Bank 2 Rich/Lean Varies
H02S Bank 1 Sensor 1 mV Varies
H02S Bank 1 Sensor 2 mV Varies
H02S Bank 2 Sensor 1 mV Varies
H02S Bank 2 Sensor 2 mV Varies
H02S Bank 1 Sensor 3 mV Varies
H02S XCounts Bank 1 Counts Varies
H02S XCounts Bank 2 Counts Varies
Closed Loop Since Restart Yes/No Yes
Air Fuel Ratio Ratio 14.7:1
MAP Volts 0.71 Volts
6-2682 Engine Controls ■ 7.4L Engine
H02S Data (cont’d)
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
MAP Kpa 36 kPa
MAF g/s 7.05 g/s
MAF Frequency Hz 2540 Hz
Vehicle Speed Kph/Mph 0 Mph
2% idle
Engine Load %
11%@2500 RPM
Long Term FT Bank 1 Counts 127 Counts
Long Term FT Bank 1 % 0%
Long Term FT Bank 2 Counts 127 Counts
Long Term FT Bank 2 % 0%
Short Term FT Bank 1 Counts 127 Counts
Short Term FT Bank 1 % 0%
Short Term FT Bank 2 Counts 127 Counts
Short Term FT Bank 2 % 0%
Fuel Trim Cell Cell # Cell 17
Fuel Trim Enable ON/OFF OFF
Injector PWM Average Bank 1 ms 3.6 ms
Injector PWM Average Bank 2 ms 3.6 ms
EVAP Canister Purge ON/OFF ON
EVAP Duty Cycle % 17%
EGR Duty Cycle % 0%
Actual EGR Position % 0%
Desired EGR Position % 0%
AIR Pump On/Off Off
Brake Switch Applied/Released Released
Milage Since DTC Clear Km/Mi Varies
DTC Set this IGN Yes/No No
Engine Run Time Min/Sec Varies

Misfire Data
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Engine Speed RPM 650 RPM
Misfire Current Cyl. #1 Counts 0
Misfire Current Cyl. #2 Counts 0
Misfire Current Cyl. #3 Counts 0
Misfire Current Cyl. #4 Counts 0
Misfire Current Cyl. #5 Counts 0
Misfire Current Cyl. #6 Counts 0
Misfire Current Cyl. #7 Counts 0
Misfire Current Cyl. #8 Counts 0
Engine Speed RPM 650 RPM
Misfire History Cyl. #1 Counts 0
Misfire History Cyl. #2 Counts 0
Engine Engine Controls - 7.4L 6-2683
Misfire Data (cont’d)
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Misfire History Cyl. #3 Counts 0
Misfire History Cyl. #4 Counts 0
Misfire History Cyl. #5 Counts 0
Misfire History Cyl. #6 Counts 0
Misfire History Cyl. #7 Counts 0
Misfire History Cyl. #8 Counts 0
Inj. Pwm. Ave. BNK 1 ms 3.6 ms
Inj. Pwm. Ave. BNK 2 ms 3.6 ms
Total Misfire Failures Counts Varies
Total Misfire Passes Since First Failure Counts 0
Cycles of Misfire Data Counts Varies
Total Misfire Current Count Counts Varies
Spark Degrees 21'
TP Angle % 0%
ECT C/F 93‘ C (200’ F)
Map Volts 1.31 Volts
Map Kpa 35 kPa
2% idle
Engine Load %
11%@2500 RPM
MAF g/S 4.6 g/s
Brake Sw. Applied/ Released Released
A/C Request Yes/No Yes
A/C Relay ON/OFF OFF
Loop Status Open Loop/Closed Loop Closed Loop
Vehicle Speed Kph/Mph Mph
Clutch Switch Manual Trans. Only ON/OFF OFF
TCC Enable Yes/No No
TCC Duty Cycle % 0%
Engine Run Time Min/Sec Varies

Enhanced EVAP
Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessories OFF
Scan Position Units Displayed Typical Data Value
Engine Speed RPM 650 RPM
Desired Engine Speed RPM 650 RPM
TP Sensor Volts 0.47 Volts
TP Angle % 0%
ECT C/F 93'C (200*F)
IAT C/F 1.1 Volts
MAP Volts 0.71 volts
MAP Kpa 36 kPa
BARO Volts 1.94 Volts
BARO Kpa 99 kPa
MAF g/s 7.05 g/s
6-2684 Engine Controls - 7.4L Engine

Enhanced EVAP (cont’d)

Engine at Operating Temp/Engine Idling in Closed Loop/Closed Throttle/Park or Neutral/Accessorles OFF
Scan Position Units Displayed Typical Data Value
EVAP Canister Purge ON/OFF OFF
EVAP Duty Cycle % 0%
EVAP Vent Sol. Open/Closed Open
Fuel Tank Pressure In H20 Varies
Excess Vacuum Test Pass/Not R/F Pass
Weak Vacuum Test Pass/Not R/F Pass
Small Leak Test Pass/Not R/F Pass
Purge Leak Test Pass/Not R/F Pass
Fuel Level % Varies
Fuel Level Sensor Volts Varies
Rich/Lean Bank 1 Rich/Lean Rich/Lean
Rich/Lean Bank 2 Rich/Lean Rich/Lean
Loop Status Open Loop/Closed Loop Closed Loop
2% idle
Engine Load %
11%@2500 RPM
Fuel Trim Cell Cell # Cell 17
Knock Adjust Factor Counter 0*
Engine Run Time Min/Sec Varies

Engine Scan Tool Data Definitions Start Up ECT - Range -4 0 -2 1 5 #C (-40°-419’F):

Engine Data 1
Engine Speed - Range (0-16384 RPM): The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Desired idle Speed - Range (0-3187 RPM): The
VCM commands the desired IAC. The VCM
compensates for various engine loads in order to
maintain the desired idle speed.
IAC Position - Range (0-255) Counts: The scan
tool displays in counts the Idle Air Control (IAC)
pintle position commanded from the VCM. The
greater the number of counts, the greater the
command idle speed (air passages opened) is. The
idle air control should respond fairly quickly to
changes in the engine load in order to maintain the
desired idle RPM.
Desired IAC Position - Range (0-255) Counts: The
desired IAC indicates the desired IAC position.
Throttle Position (TP) Sensor - Range
(0.0-5.0 Volts): The VCM uses the Throttle Position
in order to determine the amount of throttle
demanded by the operator of the vehicle. The TP
sensor reads between 0.36-0.96 volts at idle to
above 4.0 volts at Wide Open Throttle (WOT).
TP Angle - Range (0-100%): The VCM computes
the TP Angle from the TP signal voltage input. The
TP Angle should read 0% at idle. AT 0%, the TP
voltage will read below 0.90 volts. The TP Angle
should read 100% at Wide Open Throttle.
When the engine is started, the VCM records the
engine coolant temperature. The VCM uses the
recorded temperature in order to calculate the time
to a Closed Loop.
ECT - Range ^O ’^ I S ’C (-40S-4 1 9 T ): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
ECT Sensor - Range (0.0-5.0 Volts): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
Engine
Manifold Absolute Pressure (MAP) Sensor -
Range (0.0-5.0 Volts): The MAP sensor produces a
low signal voltage when the manifold pressure is low.
A low manifold pressure means a high vacuum. The
MAP sensor produces a high signal voltage when
the manifold pressure is high. A high manifold
pressure means a low vacuum. With the ignition ON
and the engine stopped, the manifold pressure
equals the atmospheric pressure causing the signal
voltage to be high. The VCM uses this information
as an indication of the vehicle’s altitude. This
information is referred to as the BARO. Comparison
of this BARO reading with a known good vehicle
with the same sensor is a good way to check
accuracy of a suspect sensor. The readings should
read the same +0.4 volt.
Manifold Absolute Pressure (MAP) - Range
(10 kPa-104 kPa): The Manifold Absolute Pressure
(MAP) sensor measures the change in the intake
manifold pressure from the engine load and the
speed changes. As the intake manifold pressure
increases, the air density in the intake manifold also
increases. Additional fuel is required.
Barometric Pressure (BARO) - Range
(0.0-5.0 Volts): The BARO represents a
measurement of the barometric air pressure. This
measurement is determined by using the Manifold
Air Pressure (MAP) sensor in order to determine the
manifold vacuum. Since the barometric air pressure
depends on the altitude, the measurement may vary
from 100 kPa (sea level) to 60 kPa (14,000 ft.).
Barometric Pressure (BARO) Sensor - Range
(0-62 kPa): The VCM determines the displayed
BARO reading from the MAP sensor at the ignition
ON and the engine OFF and the WOT conditions.
The BARO reading displayed represents the
barometric pressure. The VCM uses the displayed
BARO readings in order to compensate for the
altitude differences.
Startup IAT - Range (-40-151 °C): The VCM
converts the resistance of the Intake Air Temperature
(IAT) sensor to degrees. The VCM uses the intake
air temperature in order to adjust the fuel delivery
and the spark timing according to the incoming
air density.
IAT Sensor - Range (-40*-151°C): The VCM
converts the resistance of the Intake Air Temperature
(IAT) sensor to degrees. The VCM uses the intake
air temperature in order to adjust the fuel delivery
and the spark timing according to the incoming
air density.
Intake Air Temperature (IAT) Sensor -
(0.0-5.0 Volts): The VCM converts the resistance of
the Intake Air Temperature (IAT) sensor to degrees.
The VCM uses the intake air temperature in order to
adjust the fuel delivery and the spark timing
according to the incoming air density.
MAF - Range (0-512 g/s): The VCM converts the
Mass Air Flow sensor input signal into grams per
second. The MAF indicates the amount of air
entering the engine.
Engine Controls - 7.4L 6-2685
MAF Frequency (Hertz): The VCM converts the
Mass Air Flow sensor input signal into grams per
second or hertz. The MAF indicates the amount of
air entering the engine.
Engine Load - Range (0-100%): The VCM
determines the engine load based upon the engine
speed and MAF sensor readings. Engine Load
increases with any increase in RPM and/or airflow.
Long Term Fuel Trim (FT) Bn 1 - Range
(0-255 Counts): The Long Term Fuel Trim (FT) is
derived from the short term fuel trim value. The VCM
uses the Long Term Fuel Trim for the long-term
correction of the fuel delivery. A value of 128 counts
(0% indicates that the fuel delivery requires no
compensation to maintain a 14.7:1 air to fuel ratio. A
value below 128 counts means that the fuel system
is too rich and the fuel delivery is being reduced,
decreased injector pulse width. A value above
128 counts indicates that a lean condition exists. The
VCM compensates by adding fuel, increased injector
pulse width.
Long Term Fuel Trim (FT) Bn 1 - Percentage of
Compensation Required: The Long Term Fuel Trim
(FT) is derived from the short term fuel trim value.
The VCM uses the Long Term Fuel Trim for the
long-term correction of the fuel delivery. A value of
128 counts (0% indicates that the fuel delivery
requires no compensation to maintain a 14.7:1 air to
fuel ratio. A value below 128 counts means that the
fuel system is too rich and the fuel delivery is being
reduced, decreased injector pulse width. A value
above 128 counts indicates that a lean condition
exists. The VCM compensates by adding fuel,
increased injector pulse width.
Long Term Fuel Trim (FT) Bn 2 - Range
(0-255 Counts): The Long Term Fuel Trim (FT) is
derived from the short term fuel trim value. The VCM
uses the Long Term Fuel Trim for the long-term
correction of the fuel delivery. A value of 128 counts
(0% indicates that the fuel delivery requires no
compensation to maintain a 14.7:1 air to fuel ratio. A
value below 128 counts means that the fuel system
is too rich and the fuel delivery is being reduced,
decreased injector pulse width. A value above
128 counts indicates that a lean condition exists. The
VCM compensates by adding fuel, increased injector
pulse width.
Long Term Fuel Trim (FT) Bn 2 - Percentage of
Compensation Required: The Long Term Fuel Trim
(FT) is derived from the short term fuel trim value.
The VCM uses the Long Term Fuel Trim for the
long-term correction of the fuel delivery. A value of
128 counts (0% indicates that the fuel delivery
requires no compensation to maintain a 14.7:1 air to
fuel ratio. A value below 128 counts means that the
fuel system is too rich and the fuel delivery is being
reduced, decreased injector pulse width. A value
above 128 counts indicates that a lean condition
exists. The VCM compensates by adding fuel,
increased injector pulse width.
6-2686 Engine Controls - 7.4L
Short Term Fuel Trim (FT) Bn 1 - Range
(0-255 Counts): The short term fuel trim was
formerly the fuel integrator. The short term fuel trim
represents a short-term correction to the fuel delivery
by the VCM in response to the amount of time the
H02S voltage spends above or below the 450 mV
threshold. A H02S voltage reading below 450 mV
indicates a lean air to fuel mixture. If the H02S
voltage has mainly been below 450 mV threshold,
the short term fuel trim increases in order to tell the
VCM to add fuel. If the H02S voltage stays mainly
above the threshold, the VCM reduces the fuel
delivery in order to compensate for the indicated
rich condition.
Short Term Fuel Trim (FT) Bn 1 - Percentage of
Compensation Required: The short term fuel trim
was formerly the fuel integrator. The short term fuel
trim represents a short-term correction to the fuel
delivery by the VCM in response to the amount of
time the H02S voltage spends above or below the
450 mV threshold. A H02S voltage reading below
450 mV indicates a lean air to fuel mixture. If the
H02S voltage has mainly been below 450 mV
threshold, the short term fuel trim increases in order
to tell the VCM to add fuel. If the H02S voltage
stays mainly above the threshold, the VCM reduces
the fuel delivery in order to compensate for the
indicated rich condition.
Short Term Fuel Trim (FT) Bn 2 - Range
(0-255 Counts): The short term fuel trim was
formerly the fuel integrator. The short term fuel trim
represents a short-term correction to the fuel delivery
by the VCM in response to the amount of time the
H02S voltage spends above or below the 450 mV
threshold. A H02S voltage reading below 450 mV
indicates a lean air to fuel mixture. If the H02S
voltage has mainly been below 450 mV threshold,
the short term fuel trim increases in order to tell the
VCM to add fuel. If the H02S voltage stays mainly
above the threshold, the VCM reduces the fuel
delivery in order to compensate for the indicated
rich condition.
Short Term Fuel Trim (FT) Bn 2 - Percentage of
Compensation Required: The short term fuel trim
was formerly the fuel integrator. The short term fuel
trim represents a short-term correction to the fuel
delivery by the VCM in response to the amount of
time the H02S voltage spends above or below the
450 mV threshold. A H02S voltage reading below
450 mV indicates a lean air to fuel mixture. If the
H02S voltage has mainly been below 450 mV
threshold, the short term fuel trim increases in order
to tell the VCM to add fuel. If the H02S voltage
stays mainly above the threshold, the VCM reduces
the fuel delivery in order to compensate for the
indicated rich condition.
Engine Speed - Range 0-16384 RPM: The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Engine
Fuel Trim Cell - Range (0-22) Cell: The Fuel Trim
Cell is dependent upon the engine speed and the
MAP sensor readings. A plot of the RPM vs the
MAP sensor readings. A plot of the RPM vs the
MAP is broken into 22 cells. The Fuel Trim Cell
indicates which cell is currently active.
Fuel Trim Enable - Range (ON/OFF): The Fuel Trim
Enable indicates the state of the fuel trim
(Enable/Disabled) that the VCM is commanding. Fuel
trim will be disabled when the vehicle is not in
closed loop, malfunction codes related to fuel trim
are set, large ammounts of purge vapor are injested
by the engine, or additional diagnostics that
temporarily affect fuel trim operation are active.
EVAP Canister Purge - OFF/ON: The EVAP
Canister Purge pulls a small vacuum on the entire
evaporative emission system. The scan tool displays
if the EVAP Canister Purge Solenoid Valve is
currently OFF or ON. When the scan tool displays
ON, the small vacuum is being applied.
EVAP Duty Cycle - Range (0-100% ): The scan tool
indicates the EVAP duty cycle that the VCM is
commanding. The EVAP duty cycle is a pulse
modulated signal whch is translated into a direct
percentage of the maximum commandable state.
EGR Duty Cycle - (0%-100%): The EGR Duty
Cycle determines a percentage of time the valve is
being opened and closed.
Actual EGR Position - Range (0-100% ): The
Actual EGR Position indicates the actual EGR
position in a percentage.
Desired EGR Position - Range (0-199.9% ): The
Desired EGR Position indicates the desired EGR
position in a percentage.
EGR Sensor - Range (0.00-5.00 Volts): The EGR
Sensor indicates the actual EGR position in voltage.
Vehicle Speed - km/h - Range (0-255): The MPH -
km/h indicates in MPH and in km/h how fast the
drive wheels are turning.
Ref. Pulse Occured - Range (Yea/No): The scan
tool will indicate a Yes for up to 1 second after a
reference pulse has been detected by the CKP.
Valid Ref. Pulse Occured - Range (Yes/No): The
scan tool will indicate a Yes after 2 or more
reference pulses have been detected by the CKP.
Knock (KS) Sensor - Range (0.0-5.0 Volts): The
scan tool indicates the current knock sensor voltage.
Knock (KS) Sensor Activity - Range
(0-255 Counts): The Knock Sensor Activity indicates
the amount of spark knock the VCM detects.
Spark - Range (-96 Degrees to -255 Degrees): The
Spark Advance is a display of the spark advance
calculation which the VCM is programming into the
ignition system. The VCM computes the desired
spark advance using data such as the engine
temperature, the RPM, the load, the vehicle speed,
and the operating mode.
Knock Retard - Range (0.0-90 Degrees): The KS
Retard indicates the amount of spark advance is the
VCM removes in order to diminish spark knock.
Engine
CMP Retard -Range (0.0-90 Degrees): The CAM
Retard indicates the difference between the CMP
sensor and the CKP sensor relationship.
Spark Control - Range (Advance/Retard): The
Spark Control indicates whether the VCM is
advancing or retarding spark.
Loop Status - Range (Open/Close): The Loop
Status indicates that the VCM is controlling fuel
delivery according to H02S input. During open loop,
the VCM ignores the H02S input and bases fuel
delivery upon TP, engine coolant, and MAF
sensor input.
Pre H02S (Not Ready/Ready): The scan tool will
display the current state of the H02S system.
Post H02S (Not Ready/Ready): The scan tool will
display the current state of the H02S system.
Rich/Lean Bn 1 - (Rich/Lean): The Rich/Lean Bn 1
indicates the condition of the exhaust gases in
bank 1.
Rich/Lean Bn 2 - (Rich/Lean): The Rich/Lean Bn 2
indicates the condition of the exhaust gases in
bank 2.
Ignition 1 - Range (0.0-25.5 Volts): The Ignition 1
indicates the voltage of the ignition input to
the VCM.
Air Fuel Ratio - Range (0.0:1-25.5:1): The scan
tool indicates the VCM calculated air to fuel ratio.
The typical air to fuel ratio is 14.7:1.
Engine Run Time - Range (0:00:00-18:12:15)
Hours: Minutes: Seconds: The Engine Run Time is
a measure of how long the engine has run during
this ignition cycle. When the engine stops running,
the timer resets to zero.
Engine Data 2
Engine Speed - Range (0-16384 RPM): The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Desire Idle Speed - Range (0-3187 RPM): The
VCM commands the desired IAC. The VCM
compensates for various engine loads in order to
maintain the desired idle speed.
IAC Position - Range (0-255 Counts): The scan
tool displays in counts the Idle Air Control (IAC)
pintle position commanded from the VCM. The
greater the number of counts, the greater the
command idle speed (air passages opened) is. The
idle air control should respond fairly quickly to
changes in the engine load in order to maintain the
desired idle RPM.
Desired IAC - Range (0-255 Counts): The desired
IAC indicates the desired IAC position.
Throttle Position (TP) Sensor - Range
(0.0-5.0 Volts): The VCM uses the Throttle Position
in order to determine the amount of throttle
demanded by the operator of the vehicle. The TP
sensor reads between 0.36-0.96 volts at idle to
above 4.0 volts at Wide Open Throttle (WOT).
Engine Controls - 7.4L 6-2687
TP Angle - Range (0-100%): The VCM computes
the TP Angle from the TP signal voltage input. The
TP Angle should read 0% at idle. AT 0%, the TP
voltage will read below 0.90 volts. The TP Angle
should read 100% at Wide Open Throttle.
Start Up ECT - Range -4 0 -2 1 5*C (-40°-h419°F):
When the engine is started, the VCM records the
engine coolant temperature. The VCM uses the
recorded temperature in order to calculate the time
to a Closed Loop.
ECT - Range -4 0 -2 1 5#C (-40°-419*F): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
ECT Sensor - Range (0.0-5.0 Volts): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
Engine Coolant Level Low - Range (Yes/No): The
Engine Coolant Level Low indicates whether or not a
Low engine coolant condition is present. If the
internal float is not suspended in coolant, a Yes
condition will be reported.
Engine Oil Level Low - Range (Yes/No): The
Engine Oil Level Low indicates wheter or not a low
Oil condition Is present.
Startup IAT - Range (-40*-151#C): The VCM
converts the resistance of the Intake Air Temperature
(IAT) sensor to degrees. The VCM uses the intake
air temperature in order to adjust the fuel delivery
and the spark timing according to the incoming
air density.
IAT Sensor - Range (-40-151 °C): The VCM
converts the resistance of the Intake Air Temperature
(IAT) sensor to degrees. The VCM uses the intake
air temperature in order to adjust the fuel delivery
and the spark timing according to the incoming
air density.
6-2688 Engine Controls - 7.4L
Manifold Absolute Pressure (MAP) Sensor -
Range (0.0-5.0 Volts): The MAP sensor produces a
low signal voltage when the manifold pressure is low.
A low manifold pressure means a high vacuum. The
MAP sensor produces a high signal voltage when
the manifold pressure is high. A high manifold
pressure means a low vacuum. With the ignition ON
and the engine stopped, the manifold pressure
equals the atmospheric pressure causing the signal
voltage to be high. The VCM uses this information
as an indication of the vehicle’s altitude. This
information is referred to as the BARO. Comparison
of this BARO reading with a known good vehicle
with the same sensor is a good way to check
accuracy of a suspect sensor. The readings should
read the same +0.4 volt.
Manifold Absolute Pressure (MAP) - Range
(10 kPa-104 kPa): The Manifold Absolute Pressure
(MAP) sensor measures the change in the intake
manifold pressure from the engine load and the
speed changes. As the intake manifold pressure
increases, the air density in the intake manifold also
increases. Additional fuel is required.
Barometric Pressure (BARO) - Range
(0.0-5.0 Volts): The BARO represents a
measurement of the barometric air pressure. This
measurement is determined by using the Manifold
Air Pressure (MAP) sensor in order to determine the
manifold vacuum. Since the barometric air pressure
depends on the altitude, the measurement may vary
from 100 kPa (sea level) to 60 kPa (14,000 ft.).
Barometric Pressure (BARO) Sensor - Range
(0 kPa-62 kPa): The VCM determines the displayed
BARO reading from the MAP sensor at the ignition
ON and the engine OFF and the WOT conditions.
The BARO reading displayed represents the
barometric pressure. The VCM uses the displayed
BARO readings in order to compensate for the
altitude differences.
Engine Load - Range (0-100%): The VCM
determines the engine load based upon the engine
speed and MAF sensor readings. Engine Load
increases with any increase in RPM and/or airflow.
MAF - Range 0-512 g/s: The VCM converts the
Mass Air Flow sensor input signal into grams per
second. The MAF indicates the amount of air
entering the engine.
MAF Frequency (Hertz): The VCM converts the
Mass Air Flow sensor input signal into grams per
second or hertz. The MAF indicates the amount of
air entering the engine.
Power Enrichment - Range (Yes/No): The Power
Enrichment indicates if the Power Enrichment mode
is active.
Inj. PWM Avg. Bank 1 - Range (0-499 ms): The
Inj. Avg. Bank 1 indicates the injector on time that
the VCM is commanding.
Inj. PWM Avg. Bank 2 - Range (0-499 ms): The
Inj. Avg. Bank 2 indicates the injector on time that
the VCM is commanding.
Engine
EVAP Duty Cycle - Range (0-100% ): The scan tool
indicates the EVAP duty cycle that the VCM is
commanding. The EVAP duty cycle is a pulse
modulated signal whch is translated into a direct
percentage of the maximum commandable state.
EVAP Canister Purge ■ OFF/ON: The EVAP
Canister Purge pulls a small vacuum on the entire
evaporative emission system. The scan tool displays
if the EVAP Canister Purge Solenoid Valve is
currently OFF or ON. When the scan tool displays
ON, the small vacuum is being applied.
EVAP Vent Solenoid - (Closed/Open): The scan
tool will show the staus of the EVAP Vent Solenoid.
EGR Duty Cycle - (0%-100%): The EGR Duty
Cycle determines a percentage of time the valve is
being opened and closed.
Actual EGR Position - Range (0-100%): The
Actual EGR Position indicates the actual EGR
position in a percentage.
Desired EGR Position - Range (0-199.9%): The
Desired EGR Position indicates the desired EGR
position in a percentage.
Rich/Lean Bn 1 - (Rich/Lean): The Rich/Lean Bn 1
indicates the condition of the exhaust gases in bank 1.
Rich/Lean Bn 2 - (Rich/Lean): The Rich/Lean Bn 2
indicates the condition of the exhaust gases in bank 2.
Closed Loop Since Restart - Range (Yes/No): The
Closed Loop Since Restart indicates whether or not
the vehicle has been in a closed loop state.
Fuel Trim Enable ■ Range (ON/OFF): The Fuel Trim
Enable indicates the state of the fuel trim
(Enable/Disabled) that the VCM is commanding. Fuel
trim will be disabled when the vehicle is not in
closed loop, malfunction codes related to fuel trim
are set, large ammounts of purge vapor are injested
by the engine, or additional diagnostics that
temporarily affect fuel trim operation are active.
Ignition 1 - Range (0.0-25.5 Volts): The Ignition 1
indicates the voltage of the ignition input to
the VCM.
Ignition 1 On - Range (Yes/No): The Ignition 1 On
indicates the presence of a valid ignition 1 signal.
The normal ignition 1 voltage is approximately
13.8 volts, but may vary between 11 and 16 volts.
The VCM monitors the ignition 1 voltage to
compensate for low voltage operation of the injectors
and to increase dwel time of the ignition timing
signal to the distributor.
Ignition 1 Low - Range (Yes/No): The scan tool
indicates whether a low ignition voltage has beed
detected. A low ignition 1 voltage may degrade
ignition timing and injector operation. The normal
ignition 1 voltage is approximately 13.8 volts, but
may vary between 11 and 16 volts.
Ignition 1 High - Range (Yes/No): The scan tool
indicates whether a high ignition voltage has beed
detected. An excessively high ignition 1 voltage
could damage hardware. The normal ignition 1
voltage is approximately 13.8 volts, but may vary
between 11 and 16 volts.
Engine
A/C Request - Range (Yes/No): The scan tool
indicates the state of the A/C request input circuit.
The VCM uses the A/C request signal in order to
determine whether A/C compressor operation has
been requested.
A/C Relay - Range (Yes/No): The scan tool
indicates whether the A/C relay control curcuit has
been commanded ON.
A/C Evaporator Switch - Range (Open/Closed):
The A/C Evaporator Switch is used to indicate to the
VCM if the A/C clutch should be enabled or
disabled. The switch is opened when the compressor
is between aproximately 22-45.5 psi.
A/C Sec. High Pres. Switch - Range
(Open/Closed): The switch notifies the VCM when
the compressor pressure limit is approached. The
swich closes at a high pressure value which is
calibrated for specific platforms. The VCM monitors
the sec. high pressure switch at least every 100 ms.
Auto Recirculation - Range (ON/OFF): The Auto
Recirculation mode will be commanded ON when an
A/C high pressure is detected, vehicle speed falls
below a calibrated speed, and the engine is ON. The
VCM monitors the auto recirculation switch at least
every 100 ms.
Fuel Level - Range (0-100% ): The scan tool
indicates the current percentage of fuel tank
occupancy. The float position changes the value of a
variable resistor who’s voltage the VCM converts to
the displayed percentage.
4WD - Range (Enable/Disable): The scan tool
indicates the state of the transfer case.
4WO Low - Range (Enable/Disable): The scan tool
displays the state of the 4WD Low gear.
Brake Switch - Range (Open/Closed): The Brake
Switch indicates the status of the brake switch.
TR Switch: The Trans. Range indicates the current
drive gear.
A/B/C Range - Range (ON/OFF): The A/B/C Range
indicates the current state of the transmission
range switch.
Clutch Switch - Range (ON/OFF): The scan tool
indicates the current clutch switch state. When
the clutch pedal is depressed the cruise control
is disabled.
Vehicle Speed- km/h - Range (0-255): The MPH -
km/h indicates in MPH and in km/h how fast the
drive wheels are turning.
1 - 2 Solenoid - Range (ON/OFF): The scan tool
indicates whether the automatic transmission’s shift
solenoid is active.
2 - 3 Solenoid - Range (ON/OFF): The scan tool
indicates whether the automatic transmission’s shift
solenoid is active.
3 - 2 Downshift Solenoid - Range (ON/OFF): The
scan tool indicates whether the automatic
transmission’s shift solenoid is active.
TCC Enable - Range (Yes/No): The scan tool
indicates whether or not the VCM commanded the
TCC enable solenoid to an active state.
Engine Controls - 7.4L 6-2689
TCC Duty Cycle - Range (0-100% ): The scan tool
indicates the ammount that the VCM commands the
TCC ON. The TCC solenoid is pulse modulated to
provide a determined ammount of pressure, which is
translated into a percentage of the supply pressure.
An open solenoid circuit would cause the duty cycle
to be fixed at maximum.
Cruise Enable - Range (Yes/No): The Cruise
Mode indicates if the driver has requested the
cruise control.
Decel Fuel Cutoff - Range (Yes/No): The scan tool
indicates whether the vehicle is in fuel cutoff mode.
Milage Since DTC Clear - Range (Km/Mi): The
scan tool indicates the total distance the vehicle has
traveled since the DTCs were cleared.
DTC Set this Ignition - Range (Yes/No): The scan
tool indicates wheter or not any DTC has set during
the current ignition cycle.
Powertrain DTC Set - Range (Yes/No): The scan
tool indicates whether a Powertrain DTC has set.
Engine Run Time - Range (0:00:00-18:12:15)
Hours: Minutes: Seconds: The Engine Run Time is
a measure of how long the engine has run during
this ignition cycle. When the engine stops running,
the timer resets to zero.
H02S Data
Engine Speed - Range (0-16384 RPM): The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Desired Idle Speed - Range (0-3187 RPM): The
VCM commands the desired IAC. The VCM
compensates for various engine loads in order to
maintain the desired idle speed.
IAC Position - Range (0-255) Counts: The scan
tool displays in counts the Idle Air Control (IAC)
pintle position commanded from the VCM. The
greater the number of counts, the greater the
command idle speed (air passages opened) is. The
idle air control should respond fairly quickly to
changes in the engine load in order to maintain the
desired idle RPM.
Desired IAC Position - Range (0-255) Counts: The
desired IAC indicates the desired IAC position.
Throttle Position (TP) Sensor - Range
(0.0-5.0 Volts): The VCM uses the Throttle Position
in order to determine the amount of throttle
demanded by the operator of the vehicle. The TP
sensor reads between 0.36-0.96 volts at idle to
above 4.0 volts at Wide Open Throttle (WOT).
TP Angle - Range (0-100%): The VCM computes
the TP Angle from the TP signal voltage input. The
TP Angle should read 0% at idle. AT 0%, the TP
voltage will read below 0.90 volts. The TP Angle
should read 100% at Wide Open Throttle.
6-2690 Engine Controls - 7.4L
Start Up ECT - Range -4 0 -2 1 5'C (-40°-419* F):
When the engine is started, the VCM records the
engine coolant temperature. The VCM uses the
recorded temperature in order to calculate the time
to a Closed Loop.
ECT - Range -40-215°C (-40*-419T): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
ECT Sensor - Range (0.0-5.0 Volts): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
Loop Status - Range (Open Loop/Closed Loop):
The scan tool indicates whether the vehicle is in an
open or closed loop state. The VCM uses H02S
information for determining fuel delivery during
closed loop.
Pre H02S (Not Ready/Ready): The scan tool will
display the current state of the H02S system.
Post H02S (Not Ready/Ready): The scan tool will
display the current state of the H02S system.
Rich/Lean Bn 1 - (Rich/Lean): The Rich/Lean Bn 1
indicates the condition of the exhaust gases in bank 1.
Rich/Lean Bn 2 - (Rich/Lean): The Rich/Lean Bn 2
indicates the condition of the exhaust gases in bank 2.
H02S BN 1 Sen. 1 - Range (0-1107 mV): The
H02S BN 1 Sen. 1 indicates the activity of the
H02S (Bank 1 Sensor 1).
H02S BN 2 Sen. 1 - Range (0-1107 mV): The
H02S BN 2 Sen. 1 indicates the activity of the
H02S (Bank 2 Sensor 1).
H02S BN 1 Sen. 3 - Range (0-1107 mV): The
H02S BN 1 Sen. 3 indicates the activity of the
H02S (Bank 1 Sensor 3).
H02S Xcounts Bn 1 - Range (0-255): The H02S
Xcounts Bn 1 indicates the number of times that the
H02S (Bank 1 Sensor 1) crosses a threshold.
H02S Xcounts Bn 2 - Range (0-255): The H02S
Xcounts Bn indicates the number of times that the
H02S (Bank 2 Sensor 1) crosses a threshold.
Engine
Closed Loop Since Restart - Range (Yes/No): The
Closed Loop Since Restart indicates whether or not
the vehicle has been in a closed loop state.
Air Fuel Ratio - Range (0.0:1-25.5:1): The scan
tool indicates the VCM calculated air to fuel ratio.
The typical air to fuel ratio is 14.7:1.
Manifold Absolute Pressure (MAP) Sensor -
Range (0.0-5.0 Volts): The MAP sensor produces a
low signal voltage when the manifold pressure is low.
A low manifold pressure means a high vacuum. The
MAP sensor produces a high signal voltage when
the manifold pressure is high. A high manifold
pressure means a low vacuum. With the ignition ON
and the engine stopped, the manifold pressure
equals the atmospheric pressure causing the signal
voltage to be high. The VCM uses this information
as an indication of the vehicle’s altitude. This
information is referred to as the BARO. Comparison
of this BARO reading with a known good vehicle
with the same sensor is a good way to check
accuracy of a suspect sensor. The readings should
read the same +0.4 volt.
Manifold Absolute Pressure (MAP) - Range
(10 kPa-104 kPa): The Manifold Absolute Pressure
(MAP) sensor measures the change in the intake
manifold pressure from the engine load and the
speed changes. As the intake manifold pressure
increases, the air density in the intake manifold also
increases. Additional fuel is required.
MAF - Range 0-512 g/s: The VCM converts the
Mass Air Flow sensor input signal into grams per
second. The MAF indicates the amount of air
entering the engine.
MAF Frequency (Hertz): The VCM converts the
Mass Air Flow sensor input signal into grams per
second or hertz. The MAF indicates the amount of
air entering the engine.
Vehicle Speed- km/h - Range (0-255): The MPH -
km/h indicates in MPH and in km/h how fast the
drive wheels are turning.
Engine Load - Range (0-100%): The VCM
determines the engine load based upon the engine
speed and MAF sensor readings. Engine Load
increases with any increase in RPM and/or airflow.
Long Term Fuel Trim (FT) Bn 1 - Percentage of
Compensation Required: The Long Term Fuel Trim
(FT) is derived from the short term fuel trim value.
The VCM uses the Long Term Fuel Trim for the
long-term correction of the fuel delivery. A value of
128 counts (0% indicates that the fuel delivery
requires no compensation to maintain a 14.7:1 air to
fuel ratio. A value below 128 counts means that the
fuel system is too rich and the fuel delivery is being
reduced, decreased injector pulse width. A value
above 128 counts indicates that a lean condition
exists. The VCM compensates by adding fuel,
increased injector pulse width.
Engine
Long Term Fuel Trim (FT) Bn 1 - Range
(0-255 Counts): The Long Term Fuel Trim (FT) is
derived from the short term fuel trim value. The VCM
uses the Long Term Fuel Trim for the long-term
correction of the fuel delivery. A value of 128 counts
(0% indicates that the fuel delivery requires no
compensation to maintain a 14.7:1 air to fuel ratio. A
value below 128 counts means that the fuel system
is too rich and the fuel delivery is being reduced,
decreased injector pulse width. A value above
128 counts indicates that a lean condition exists. The
VCM compensates by adding fuel, increased injector
pulse width.
Long Term Fuel Trim (FT) Bn 2 - Percentage of
Compensation Required: The Long Term Fuel Trim
(FT) is derived from the short term fuel trim value.
The VCM uses the Long Term Fuel Trim for the
long-term correction of the fuel delivery. A value of
128 counts (0% indicates that the fuel delivery
requires no compensation to maintain a 14.7:1 air to
fuel ratio. A value below 128 counts means that the
fuel system is too rich and the fuel delivery is being
reduced, decreased injector pulse width. A value
above 128 counts indicates that a lean condition
exists. The VCM compensates by adding fuel,
increased injector pulse width.
Long Term Fuel Trim (FT) Bn 2 - Range
(0-255 Counts): The Long Term Fuel Trim (FT) is
derived from the short term fuel trim value. The VCM
uses the Long Term Fuel Trim for the long-term
correction of the fuel delivery. A value of 128 counts
(0% indicates that the fuel delivery requires no
compensation to maintain a 14.7:1 air to fuel ratio. A
value below 128 counts means that the fuel system
is too rich and the fuel delivery is being reduced,
decreased injector pulse width. A value above
128 counts indicates that a lean condition exists. The
VCM compensates by adding fuel, increased injector
pulse width.
Short Term Fuel Trim (FT) Bn 1 - Percentage of
Compensation Required: The short term fuel trim
was formerly the fuel integrator. The short term fuel
trim represents a short-term correction to the fuel
delivery by the VCM in response to the amount of
time the H02S voltage spends above or below the
450 mV threshold. A H02S voltage reading below
450 mV indicates a lean air to fuel mixture. If the
H02S voltage has mainly been below 450 mV
threshold, the short term fuel trim increases in order
to tell the VCM to add fuel. If the H02S voltage
stays mainly above the threshold, the VCM reduces
the fuel delivery in order to compensate for the
indicated rich condition.
Short Term Fuel Trim (FT) Bn 1 - Range
(0-255 Counts): The short term fuel trim was
formerly the fuel integrator. The short term fuel trim
represents a short-term correction to the fuel delivery
by the VCM in response to the amount of time the
H02S voltage spends above or below the 450 mV
threshold. A H02S voltage reading below 450 mV
indicates a lean air to fuel mixture. If the H02S
Engine Controls - 7.4L 6-2691
voltage has mainly been below 450 mV threshold,
the short term fuel trim increases in order to tell the
VCM to add fuel. If the H02S voltage stays mainly
above the threshold, the VCM reduces the fuel
delivery in order to compensate for the indicated
rich condition.
Short Term Fuel Trim (FT) Bn 2 - Percentage of
Compensation Required: The short term fuel trim
was formerly the fuel integrator. The short term fuel
trim represents a short-term correction to the fuel
delivery by the VCM in response to the amount of
time the H02S voltage spends above or below the
450 mV threshold. A H02S voltage reading below
450 mV indicates a lean air to fuel mixture. If the
H02S voltage has mainly been below 450 mV
threshold, the short term fuel trim increases in order
to tell the VCM to add fuel. If the H02S voltage
stays mainly above the threshold, the VCM reduces
the fuel delivery in order to compensate for the
indicated rich condition.
Short Term Fuel Trim (FT) Bn 2 - Range
(0-255 Counts): The short term fuel trim was
formerly the fuel integrator. The short term fuel trim
represents a short-term correction to the fuel delivery
by the VCM in response to the amount of time the
H02S voltage spends above or below the 450 mV
threshold. A H02S voltage reading below 450 mV
indicates a lean air to fuel mixture. If the H02S
voltage has mainly been below 450 mV threshold,
the short term fuel trim increases in order to tell the
VCM to add fuel. If the H02S voltage stays mainly
above the threshold, the VCM reduces the fuel
delivery in order to compensate for the indicated
rich condition.
Fuel Trim Cell - Range (0-22) Cell: The Fuel Trim
Cell is dependent upon the engine speed and the
MAP sensor readings. A plot of the RPM vs the
MAP sensor readings. A plot of the RPM vs the
MAP is broken into 22 cells. The Fuel Trim Cell
indicates which cell is currently active.
Fuel Trim Enable - Range (ON/OFF): The Fuel Trim
Enable indicates the state of the fuel trim
(Enable/Disabled) that the VCM is commanding. Fuel
trim will be disabled when the vehicle is not in
closed loop, malfunction codes related to fuel trim
are set, large ammounts of purge vapor are injested
by the engine, or additional diagnostics that
temporarily affect fuel trim operation are active.
Inj. PWM Avg. Bank 1 - Range (0-499 ms): The
Inj. Avg. Bank 1 indicates the injector oh time that
the VCM is commanding.
Inj. PWM Avg. Bank 2 - Range (0-499 ms): The
Inj. Avg. Bank 2 indicates the injector on time that
the VCM is commanding.
EVAP Canister Purge - OFF/ON: The EVAP
Canister Purge pulls a small vacuum on the entire
evaporative emission system. The scan tool displays
if the EVAP Canister Purge Solenoid Valve is
currently OFF or ON. When the scan tool displays
ON, the small vacuum is being applied.
6-2692 Engine Controls - 7.4L
EVAP Duty Cycle - Range (0-100% ): The scan tool
indicates the EVAP duty cycle that the VCM is
commanding. The EVAP duty cycle is a pulse
modulated signal whch is translated into a direct
percentage of the maximum commandable state.
EGR Duty Cycle - (0%-100%): The EGR Duty
Cycle determines a percentage of time the valve is
being opened and closed.
Actual EGR Position - Range (0-100%): The
Actual EGR Position indicates the actual EGR
position in a percentage.
Desired EGR Position - Range (0-199.9%): The
Desired EGR Position indicates the desired EGR
position in a percentage.
Brake Switch - Range (Open/Closed): The Brake
Switch indicates the status of the brake switch.
Milage Since DTC Clear - Range (Km/Mi): The
scan tool indicates the total distance the vehicle has
traveled since the DTCs were cleared.
Powertrain DTC Set - Range (Yes/No): The scan
tool indicates whether a Powertrain DTC has set.
DTC Set this Ignition - Range (Yes/No): The scan
tool indicates wheter or not any DTC has set during
the current ignition cycle.
Engine Run Time - Range (0:00:00-18:12:15)
Hours: Minutes: Seconds: The Engine Run Time is
a measure of how long the engine has run during
this ignition cycle. When the engine stops running,
the timer resets to zero.
Misfire Data
Engine Speed - Range 0-16384 RPM: The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Misfire Current Cyl. #1: The scan tool will display
the number of current cylinder misfires.
Misfire Current Cyl. #2: The scan tool will display
the number of current cylinder misfires.
Misfire Current Cyl. #3: The scan tool will display
the number of current cylinder misfires.
Misfire Current Cyl. #4: The scan tool will display
the number of current cylinder misfires.
Misfire Current Cyl. #5: The scan tool will display
the number of current cylinder misfires.
Misfire Current Cyl. #6: The scan tool will display
the number of current cylinder misfires.
Cycles of Misfire Data - Range (0-100): Displays
which engine cycle of the 100 engine cycle test the
VCM is collecting data for.
Engine
Total Misfire Current Count - Range (0-255): The
Total Misfire Current Count indicates the total number
of cylinder firing events that the VCM detected as
being misfires during the last 200 crankshaft revolution
sample period. Misfire is diagnosed using crankshaft
speed variations in relation with engine speed and
load data.
Engine Speed - Range 0-16384 RPM: The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Misfire History Cyl. #1: The scan tool will display
the number of history cylinder misfires.
Misfire History Cyl. #2: The scan tool will display
the number of history cylinder misfires.
Misfire History Cyl. #3: The scan tool will display
the number of history cylinder misfires.
Misfire History Cyl. #4: The scan tool will display
the number of history cylinder misfires.
Misfire History Cyl. #5: The scan tool will display
the number of history cylinder misfires.
Misfire History Cyl. #6: The scan tool will display
the number of history cylinder misfires.
Inj. PWM Avg. Bank 1 - Range (0-499 ms): The
Inj. Avg. Bank 1 indicates the injector on time that
the VCM is commanding.
Inj. PWM Avg. Bank 2 - Range (0-499 ms): The
Inj. Avg. Bank 2 indicates the injector on time that
the VCM is commanding.
Total Misfire Failures - Range (0-255): The Total
Misfire Failures indicates the total number of cylinder
firing events that the VCM determined as misfires
during the last 200 crankshaft revolution sample.
Total Misfire Passes Since First Failure - Range
(0-65,535): The Total Misfire Passes Since First Fail
indicates the total number of cylinder firing events
that the VCM detected as being good since the
first fail.
TP Angle - Range (0-100%): The VCM computes
the TP Angle from the TP signal voltage input. The
TP Angle should read 0% at idle. AT 0%, the TP
voltage will read below 0.90 volts. The TP Angle
should read 100% at Wide Open Throttle.
ECT - Range -4 0 -2 1 5 #C (-40*-419T): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the
engine temperature information to the VCM. The
VCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes the internal
resistance as the temperature changes. When the
sensor is cold meaning the internal resistance is
high, the VCM monitors a high voltage signal. The
VCM interprets the high voltage signal as a cold
engine. As the sensor warms meaning the internal
resistance decreases, the voltage signal decreases.
The VCM interprets the lower resistance as a
warm engine.
Engine
Manifold Absolute Pressure (MAP) Sensor -
Range (0.0-5.0 Volts): The MAP sensor produces a
low signal voltage when the manifold pressure is low.
A low manifold pressure means a high vacuum. The
MAP sensor produces a high signal voltage when the
manifold pressure is high. A high manifold pressure
means a low vacuum. With the ignition ON and the
engine stopped, the manifold pressure equals the
atmospheric pressure causing the signal voltage to be
high. The VCM uses this information as an indication
of the vehicle’s altitude. This information is referred to
as the BARO. Comparison of this BARO reading with
a known good vehicle with the same sensor is a good
way to check accuracy of a suspect sensor. The
readings should read the same +0.4 volt.
Manifold Absolute Pressure (MAP) - Range
(10 kPa-104 kPa): The Manifold Absolute Pressure
(MAP) sensor measures the change in the intake
manifold pressure from the engine load and the
speed changes. As the intake manifold pressure
increases, the air density in the intake manifold also
increases. Additional fuel is required.
Engine Load - Range (0-100%): The VCM
determines the engine load based upon the engine
speed and MAF sensor readings. Engine Load
increases with any increase in RPM and/or airflow.
MAF - Range (0-512 g/s): The VCM converts the
Mass Air Flow sensor input signal into grams per
second. The MAF indicates the amount of air
entering the engine.
Brake Switch - Range (Open/Closed): The Brake
Switch indicates the status of the brake switch.
A/C Request - Range (Yes/No): The scan tool
indicates the state of the A/C request input circuit.
The VCM uses the A/C request signal in order to
determine whether A/C compressor operation has
been requested.
A/C Relay - Range (Yes/No): The scan tool
indicates whether the A/C relay control curcuit has
been commanded ON.
KS Active Counter - Range (0-255): The KS Active
Counter indicates the number of knock occurances
that occur within one-eigth of a second.
Spark - Range (-96 Degrees to -255 Degrees): The
Spark Advance is a display of the spark advance
calculation which the VCM is programming into the
ignition system. The VCM computes the desired
spark advance using data such as the engine
temperature, the RPM, the load, the vehicle speed,
and the operating mode.
Loop Status - Range (Open Loop/Closed Loop):
The scan tool indicates whether the vehicle is in an
open or closed loop state. The VCM uses H02S
information for determining fuel delivery during
closed loop.
Vehicle Speed- km/h - Range (0-255): The MPH -
km/h indicates in MPH and in km/h how fast the
drive wheels are turning.
Clutch Switch - Range (ON/OFF): The scan tool
indicates the current clutch switch state. When the
clutch pedal is depressed the cruise control
is disabled.
Engine Controls ■ 7.4L 6-2693
TCC Enable - Range (Yes/No): The scan tool
indicates whether or not the VCM commanded the
TCC enable solenoid to an active state.
TCC Duty Cycle - Range (0-100% ): The scan tool
indicates the ammount that the VCM commands the
TCC ON. The TCC solenoid is pulse modulated to
provide a determined ammount of pressure, which is
translated into a percentage of the supply pressure.
An open solenoid circuit would cause the duty cycle
to be fixed at maximum.
DTC Set this Ignition - Range (Yes/No): The scan
tool indicates wheter or not any DTC has set during
the current ignition cycle.
Powertrain DTC Set - Range (Yes/No): The scan
tool indicates whether a Powertrain DTC has set.
Decel Fuel Cutoff - Range (Yes/No): The scan tool
indicates whether the vehicle is in fuel cutoff mode.
Engine Run Time - Range (0:00:00-18:12:15)
Hours: Minutes: Seconds: The Engine Run Time is
a measure of how long the engine has run during
this ignition cycle. When the engine stops running,
the timer resets to zero.
EVAP Data
Engine Speed - Range 0-16384 RPM: The VCM
computes the Engine Speed from the fuel control
reference input. The speed should remain close to
the desired idle under the various engines loads with
the engine idling.
Desired Idle Speed - Range (0-3187 RPM): The
VCM commands the desired IAC. The VCM
compensates for various engine loads in order to
maintain the desired idle speed.
Throttle Position (TP) Sensor - Range
(0.0-5.0 volts): The VCM uses the Throttle Position
in order to determine the amount of throttle
demanded by the operator of the vehicle. The TP
sensor reads between 0.36-0.96 volts at idle to
above 4.0 volts at Wide Open Throttle (WOT).
TP Angle - Range (0-100%): The VCM computes
the TP Angle from the TP signal voltage input. The
TP Angle should read 0% at idle. AT 0%, the TP
voltage will read below 0.90 volts. The TP Angle
should read 100% at Wide Open Throttle.
ECT - Range -4 0 -2 1 5*C (-40*-419T): The Engine
Coolant Temperature (ECT) sensor is mounted in the
intake the intake manifold. The ECT sends the engine
temperature information to the VCM. The VCM
supplies 5 volts to the ECT sensor circuit. The sensor
is a thermistor which changes the internal resistance
as the temperature changes. When the sensor is cold
meaning the internal resistance is high, the VCM
monitors a high voltage signal. The VCM interprets the
high voltage signal as a cold engine. As the sensor
warms meaning the internal resistance decreases, the
voltage signal decreases. The VCM interprets the
lower resistance as a warm engine.
IAT - Range (-40*-151’ C): The VCM converts the
resistance of the Intake Air Temperature (IAT) sensor
to degrees. The VCM uses the intake air temperature
in order to adjust the fuel delivery and the spark timing
according to the incoming air density.
6-2694 Engine Controls - 7.4L
Manifold Absolute Pressure (MAP) Sensor -
Range (0.0-5.0 volts): The MAP sensor produces a
low signal voltage when the manifold pressure is low.
A low manifold pressure means a high vacuum. The
MAP sensor produces a high signal voltage when
the manifold pressure is high. A high manifold
pressure means a low vacuum. With the ignition ON
and the engine stopped, the manifold pressure
equals the atmospheric pressure causing the signal
voltage to be high. The VCM uses this information
as an indication of the vehicle’s altitude. This
information is referred to as the BARO. Comparison
of this BARO reading with a known good vehicle
with the same sensor is a good way to check
accuracy of a suspect sensor. The readings should
read the same +0.4 volt.
Manifold Absolute Pressure (MAP) - Range
(10 kPa-104 kPa): The Manifold Absolute Pressure
(MAP) sensor measures the change in the intake
manifold pressure from the engine load and the
speed changes. As the intake manifold pressure
increases, the air density in the intake manifold also
increases. Additional fuel is required.
Barometric Pressure (BARO) - Range
(0.0-5.0 Volts): The BARO represents a
measurement of the barometric air pressure. This
measurement is determined by using the Manifold
Air Pressure (MAP) sensor in order to determine the
manifold vacuum. Since the barometric air pressure
depends on the altitude, the measurement may vary
from 100 kPa (sea level) to 60 kPa (14,000 ft.).
Barometric Pressure (BARO) Sensor - Range
(0 kPa-62 kPa): The VCM determines the displayed
BARO reading from the MAP sensor at the ignition
ON and the engine OFF and the WOT conditions.
The BARO reading displayed represents the
barometric pressure. The VCM uses the displayed
BARO readings in order to compensate for the
altitude differences.
MAF - Range (0-512 g/s): The VCM converts the
Mass Air Flow sensor input signal into grams per
second. The MAF indicates the amount of air
entering the engine.
EVAP Canister Purge - (ON/OFF): The EVAP
Canister Purge pulls a small vacuum on the entire
evaporative emission system. The scan tool displays
if the EVAP Canister Purge Solenoid Valve is
currently OFF or ON. When the scan tool displays
ON, the small vacuum is being applied.
EVAP Duty Cycle - Range (0-100% ): The scan tool
indicates the EVAP duty cycle that the VCM is
commanding. The EVAP duty cycle is a pulse
modulated signal whch is translated into a direct
percentage of the maximum commandable state.
EVAP Vent Solenoid - (Closed/Open): The scan
tool will show the staus of the EVAP Vent Solenoid.
Fuel Tank Pressure - (-20-7 in. H20): The scan
tool indicates the current fuel tank pressure that is
converted by the VCM using the fuel tank pressure
sensor signal voltage. As pressure decreases a
greater vacuum is created.
Engine
Excess Vacuum Test - (Pass/Not R/F): The Excess
Vacuum Test will fail if the fuel tank vacuum builds at
an excessive rate during normal EVAP canister
purge. A restricted vent valve or vent valve hoses
will cause improper venting.
Weak Vacuum Test - (Pass/Not R/F): The Weak
Vacuum Test only runs if the Loaded Canister Test
does not pass. Insufficient vacuum buildup during
normal purge operation with the vent valve closed
will cause this test to fail.
Small Leak Test - (Pass/Not R/F): The Small Leak
Test runs immediately after the Weak Vacuum Test.
The EVAP system is closed and the fuel tank
vacuum is monitored by the VCM. A high loss of
vacuum rate will cause this test to fail. This test may
run up to three times before reporting a failure.
Purge Leak Test - (Pass/Not R/F): The Purge Leak
Test runs only after a cold start occured during the
current ignition and the Weak Vacuum Test did not
fail. The VCM commands both the purge and vent
valves closed. If a vacuum builds, then the restricted
or inoperative vent valve will cause this test to fail.
Fuel Level - Range (0-100% ): The scan tool
indicates the current percentage of fuel tank
occupancy. The float position changes the value of a
variable resistor who’s voltage the VCM converts to
the displayed percentage.
Fuel Level Sensor - (0.0-2.9 Volts): The scan tool
will display the voltage coming from the Fuel Level
Sensor which will vary from .39 volts to 2.9 volts.
Rich/Lean Bn 1 - (Rich/Lean): The Rich/Lean Bn 1
indicates the condition of the exhaust gases in bank 1.
Rich/Lean Bn 2 - (Rich/Lean): The Rich/Lean Bn 2
indicates the condition of the exhaust gases in bank 2.
Loop Status - Range (Open Loop/Closed Loop):
The scan tool indicates whether the vehicle is in an
open or closed loop state. The VCM uses H02S
information for determining fuel delivery during
closed loop.
Engine Load - Range (0-100%): The VCM
determines the engine load based upon the engine
speed and MAF sensor readings. Engine Load
increases with any increase in RPM and/or airflow.
Fuel Trim Cell - Range (0-22) Cell: The Fuel Trim
Cell is dependent upon the engine speed and the
MAP sensor readings. A plot of the RPM vs the
MAP sensor readings. A plot of the RPM vs the
MAP is broken into 22 cells. The Fuel Trim Cell
indicates which cell is currently active.
Knock Adjust Factor - Range (-90-90°): The knock
sensor is a piezoelectric device which detects
vibration due to spark knock. The VCM converts the
knock sensor signal according to calibrated values;
thus allowing the engine to operate at optimum spark
advance with out knock to improve drivability and
fuel economy.
Engine Run Time - Range (0:00:00-18:12:15)
Hours: Minutes: Seconds: The Engine Run Time is
a measure of how long the engine has run during
this ignition cycle. When the engine stops running,
the timer resets to zero.
Engine
DTC List
This information refers to domestic and Export
calibration packages. Export vehicles may have
differences in DTC types that will affect Malfunction
Indicator Lamp (MIL) operation. Certain DTCs have
been changed from type A to type C or, in some
cases, type X. When a type A diagnostic fails, a
DTC is set immediately and the Malfunction Indicator
Lamp (MIL) is illuminated. When a type B DTC
diagnostic fails, the Malfunction Indicator Lamp (MIL)
will illuminate if the fault is present after two
consecutive drive trips. A type C DTC will set after
one failure and be stored in history but will not
illuminate the Malfunction Indicator Lamp (MIL). Type
X DTCs have been turned off (the diagnostic does
not run, no codes are stored, and the Malfunction
Indicator Lamp (MIL) will not illuminate.
_______________ Engine Controls - 7.4L 6-2695
If a system is malfunctioning and the associated
DTC has been disabled (Type X), it may be
beneficial to use the diagnostic table as a guide to
aid in diagnosis. Many of the DTC tables include a
functional check of the system that may pinpoint a
problem. However, it is important to remember that
the DTC tables are specifically designed for use only
when a DTC is set. Therefore, a thorough
understanding of the normal operation of the system
being diagnosed is necessary and use of the tables
for this purpose is at the discretion of the technician.
Important: For Automatic Transmission DTC types,
refer to Transmission.

Diagnostic Trouble Code (DTC) Type Table

7.4L L29
7.4L (J), HD,
L29 (J) P30 7.4L Export,
7.4L L29 (J) (without L29 (J), Leaded
DTC Description (with/AIR) AIR) HD,OBD1 Fuel
P0101 Mass Air Flow (MAF) System Performance A A C C
P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency A A A A
P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency A A A A
Manifold Absolute Pressure (MAP) Sensor Circuit
P0107 A A A A
Low Voltage
Manifold Absolute Pressure (MAP) Sensor Circuit
P0108 A A A A
High Voltage
Intake Air Temperature (IAT) Sensor Circuit
P0112 A A A A
Low Voltage
Intake Air Temperature (IAT) Sensor Circuit
P0113 A A A A
High Voltage
P0117 Engine Coolant Temperature (ECT) Sensor Low Voltage A A A A
Engine Coolant Temperature (ECT) Sensor
P0118 A A A A
High Voltage
P0121 Throttle Position (TP) Sensor Performance B B C C
P0122 Throttle Position (TP) Sensor Circuit Low Voltage A A A A
P0123 Throttle Position (TP) Sensor Circuit High Voltage A A A A
Engine Coolant Temperature (ECT) Excessive Time To
P0125 B B C X
Closed Loop
Heated Oxygen Sensor (H02S) Circuit Low Voltage
P0131 A A A X
Bank 1 Sensor 1
Heated Oxygen Sensor (H02S) Circuit High Voltage
P0132 A A A X
Bank 1 Sensor 1
Heated Oxygen Sensor (H02S) Slow Response Bank 1
P0133 B B C X
Sensor 1
Heated Oxygen Sensor (H02S) Circuit Insufficient
P0134 A A A X
Activity Bank 1 Sensor 1
Heated Oxygen Sensor (H02S) Heater Circuit Bank 1
P0135 B B C X
Sensor 1
Heated Oxygen Sensor (H02S) Circuit Low Voltage
P0137 B B C X
Bank 1 Sensor 2
6-2696 Engine Controls - 7.4L Engine
Diagnostic Trouble Code (DTC) Type Table (cont’d)

(J),
7.4L L29
HD,
7.4L L29 P30 7.4L Export,
7.4L L29 (J) (J) (without L29 (J), Leaded
DTC Description (with/AIR) AIR) HD,OBD1 Fuel
Heated Oxygen Sensor (H02S) Circuit High Voltage
P0138 B B C X
Bank 1 Sensor 2
Heated Oxygen Sensor (H02S) Circuit Insufficient
P0140 B B C X
Activity Bank 1 Sensor 2

P0141
Heated Oxygen Sensor (H02S) Heater Circuit Bank 1
Sensor 2
B B c X

Heated Oxygen Sensor (H02S) Circuit Low Voltage

P0151 A A A X
Bank 2 Sensor 1
Heated Oxygen Sensor (H02S) Circuit High Voltage
P0152 A A A X
Bank 2 Sensor 1
Heated Oxygen Sensor (H02S) Slow Response Bank 2
P0153 B B C X
Sensor 1
Heated Oxygen Sensor (H02S) Circuit Insufficient
P0154 A A A X
Activity Bank 2 Sensor 1
Heated Oxygen Sensor (H02S) Heater Circuit Bank 2
P0155 B B C X
Sensor 1
Heated Oxygen Sensor (H02S) Circuit Low Voltage
P0157 B B B X
Bank 2 Sensor 2
Heated Oxygen Sensor (H02S) Circuit High Voltage
P0158 B B B X
Bank 2 Sensor 2
Heated Oxygen Sensor (H02S) Circuit Insufficient
P0160 B B B X
Activity Bank 2 Sensor 2
Heated Oxygen Sensor (H02S) Heater Circuit Bank 2
P0161 B B C X
Sensor 2
P0171 Fuel Trim System Lean Bank 1 B B B X
P0172 Fuel Trim System Rich Bank 1 B B B X
P0174 Fuel Trim System Lean Bank 2 B B B X
P0175 Fuel Trim System Rich Bank 2 B B B X
P0300 Engine Misfire Detected B B X X
P0325 Knock Sensor (KS) Module Circuit B B C C
P0327 Knock Sensor (KS) Noise Channel Low Voltage B B C C
P0336 Crankshaft Position (CKP) Sensor Circuit Performance A A A A
Crankshaft Position (CKP) Sensor Circuit
P0337 B B C C
Low Frequency
Crankshaft Position (CKP) Sensor Circuit
P0338 C C C C
High Frequency
P0339 Crankshaft Position (CKP) Sensor Circuit Intermittent B B C C
P0340 Camshaft Position (CMP) Sensor Circuit B B C C
P0341 Camshaft Position (CMP) Circuit Performance B B C C
Exhaust Gas Recirculation (EGR) System
P0401 A A A A
Flow Insufficient
Exhaust Gas Recirculation (EGR) Valve Open
P0404 B B B B
Pintle Position
Exhaust Gas Recirculation (EGR) Pintle Position Circuit
P0405 B B B B
Low Volage
P0410 AIR System B X X X
Engine Engine Controls - 7.4L 6-2697
D iagnostic Trouble Code (D TC ) Type Table (cont’d)

(J),
7.4L L29
HD,
7.4L L29 P30 7.4L Export,
7.4L L29 (J) (J) (without L29 (J), Leaded
DTC Description (with/AIR) AIR) HD,OBD1 Fuel
Three-Way Catalytic Converter (TWC) System Low
P0420 A A X X
Efficiency Bank 1
Three-Way Catalytic Converter (TWC) System Low
P0430 A A X X
Efficiency Bank 2
P0440 Evaporative Emissions (EVAP) System A A X X
Evaporative Emissions (EVAP) Control System Small
P0442 A A X X
Leak Detected
P0446 Evaporative Emissions (EVAP) Vent Valve Performance A A X X
Evaporative Emissions (EVAP) Pressure Sensor Circuit
P0452 B B X X
Low Voltage
Evaporative Emissions (EVAP) Pressure Sensor Circuit B B X X
P0453
High Voltage
P0461 Fuel Level Sensor Circuit Performance C C C C
P0462 Fuel Level Sensor Circuit Low Voltage C C c C
P0463 Fuel Level Sensor Circuit High Voltage C C c C
P0500 Vehicle Speed Sensor (VSS) Circuit A A A A
P0506 Idle Control System Low RPM B B B B
P0507 Idle Control System High RPM B B B B
P0601 Vehicle Control Module (VCM) Memory A A A A
P0602 Vehicle Control Module (VCM) Not Programmed C C C C
P0603 Vehicle Control Module (VCM) Memory Reset A A A A
Vehicle Control Module (VCM) Random Access
P0604 A A A A
Memory (RAM)
Vehicle Control Module (VCM) Read Only
P0605 A A A A
Memory (ROM)
P0704 Clutch Switch Circuit (M/T) B B B B
Manifold Absolute Pressure (MAP) Sensor Circuit
P1106 C C C C
Intermittent High Voltage
Manifold Absolute Pressure (MAP) Sensor Circuit
P1107 C C C C
Intermittent Low Voltage
Intake Air Temperature (IAT) Sensor Circuit Intermittent
P1111 C C C C
High Voltage
Intake Air Temperature (IAT) Sensor Circuit Intermittent
P1112 C C C C
Low Voltage
Engine Coolant Temperature (ECT) Sensor Circuit
P1114 C C C C
Intermittent Low Voltage
Engine Coolant Temperature (ECT) Sensor Circuit
P1115 C C C C
Intermittent High Voltage
Throttle Position (TP) Sensor Circuit Intermittent
P1121 C C C C
High Voltage
Throttle Position (TP) Sensor Circuit Intermittent
P1122 C C C C
Low Voltage
Heated Oxygen Sensor (H02S) Insufficient Switching
P1133 B B C X
Bank 1 Sensor 1
Heated Oxygen Sensor (H02S) Transition Time Ratio
P1134 B B C X
Bank 1 Sensor 1
6-2698 Engine Controls - 7.4L________________________________________________ Engine
Diagnostic Trouble Code (DTC) Type Table (cont’d)
7.4L L29
(J), h d ,
7.4L L29 P30 7.4L Export,
7.4L L29 (J) (J) (without L29 (J), Leaded
DTC Description (with/AIR) AIR) HD,OBD1 Fuel
Heated Oxygen Sensor (H02S) Insufficient Switching
P1153 B B C X
Bank 2 Sensor 1
Heated Oxygen Sensor (H02S) Transition Time Ratio
P1154 B B C X
Bank 2 Sensor 1
Crankshaft Position (CKP)/Camshaft
P1345 A A A A
Position (CMP) Correlation
P1351 Ignition Control (IC) Circuit High Voltage A A A A
P1361 Ignition Control (IC) Circuit Low Voltage A A A A
P1336 Crankshaft Position (CKP) System Variation Not learned X C C C
Electronic Brake Control Module (EBCM) DTC Rough
P1380 C C X X
Road Data Unusable
Misfire Detected - No Electronic Brake Control Module
P1381 C C X X
(EBCM)/Vehicle Contol Module (VCM) Serial Data
Exhaust Gas Recirculation (EGR) Valve Closed
P1404 B B B B
Pintle Position
Evaporative Emissions (EVAP) System Flow
P1441
During Non-Purge
B B ’ x X

P1508 Idle Air Control (IAC) System Low RPM B B ; b B

P1509 Idle Air Control (IAC) System High RPM B B i B B
P1621 Vehicle Control Module (VCM) EEPROM Performance C C C C
Loss of Serial Communication with Vehicle
P1626
Theft Deterrent (VTD)
C C c C

Theft Deterrent Vehicle Control Module (VCM) in

P1630
Learn Mode
C C c C

P1631 Theft Deterrent Password Incorrect C C c C

GM SPO Group Numbers

Application GM SPO Group Number
Vehicle Control Module (VCM) 3.670
KS Calibration Prom 3.760
Engine Coolant Temperature (ECT) Sensor 3.862
Intake Air Temperature (IAT) Sensor 3.862
Manifold.Absolute Pressure (MAP) Sensor 3.862
Mass Air Flow (MAF) Sensor 3.862
Heated Oxygen Sensor 3.862
Throttle Position (TP) Sensor 3.862
Vehicle Speed (VSS) Sensor 3.862
Crankshaft Position (CKP) Sensor 2.383
Throttle Body Assembly 3.335
Engine Fuel Pipes 3.163
Upper Manifold Assembly 3.265
Fuel Meter Body Assembly 3.734
Fuel Injectors 3.300
Fuel Pressure Regulator Assembly 3.330
Engine________________________________________________ Engine Controls - 7.4L 6-2699
GM SPO Group Numbers (cont’d)
Application GM SPO Group Number
Linear Exhaust Gas Recirculation (EGR) Valve 3.670
Fuel Pump Relay 3.900
Fuel Pump Oil Pressure Switch 1.800
Intake Manifold Plenum 3.265
Fuel Rail Assembly 3.330
Fuel Tanks 3.001
Fuel Tank Shields 3.015
Fuel Tank Straps 3.022
Filler Tube 3.003
Fuel Sender 3.107
Balance Fuel Pump 3.900
Inline Fuel Filter 3.890
Spin On Cartridge Fuel Filter 3.890
Fuel Hoses Pipes Assemblys 3.120-3.163
Accelerator Pedall 3.451
Accelerator Control Cable 3.430
Evap Canister 3.130
Evap Purge Solenoid 3.140
Evap Vacuum Switch 3.140
Knock Sensors 2.383
Drive Belt for AIR 1.006
AIR Pump 3.660
AIR Valve 3.670
AIR Output Hose 3.280
AIR Pipes 3.675
Crankcase Pipes 1.762
Crankcase Hoses 1.762
Crankcase Vent Valve 1.745
Air Filter 3.410
Air Cleaner Assembly 3.402
Aif Cleaner Duct Resonator Assembly 3.417
6-2700 Engine Controls - 7.4L Engine

Schematic and Routing Diagrams

Emission Hose Routing Diagram

Legend
(1) Crankcase Vent
(2) Fuel Pressure Regulator Valve
(3) EVAP Canister Purge Solenoid Valve
(4) Positive Crankcase Ventilation Valve
(5) To Fuel Tank
(6) EVAP Canister Vent
(7) EVAP Canister Purge Hose
(8) Manifold Absolute Pressure (MAP) Sensor
(9) Throttle Body

Engine Controls Schematic References

Service Category type Number
Reference on Schematic • Service Category
ABS Controls - EBCM 5 - Brakes
Cruise Control - Cell 34 8A - Electrical
Engine Controls - Sensors, EGR Valve, MAP Sensor 6E - Engine Controls
Fuel Pump Balance Relay 8A -Electrical
Fuse Block Details - Cell 11 8A - Electrical
Ground Distribution - Cell 14 8A - Electrical
Instrument Cluster - Cell 81 8A - Electrical
Power Distribution - Cell 10 8A - Electrical
Transfer Case - Four Wheel Drive (4WD) 7 - Transmission
Transmission Controls - TFT Sensor 7 - Transmission
Engine________________________________________________ Engine Controls - 7.4L 6-2701
Engine Controls Schematic Icons
Icon Icon Definition
Refer to Electrostatic Discharge (ESD) Sensitive Devices in Section 8A-3 Symbols

19384
Refer to On-Board Diagnostics II (OBD II) Circuits in Section 8A-5 Repair Procedures

A
JO BD ~iTk
19385
6-2702 Engine Controls - 7.4L ________________________________________________ Engine
185775
Engine Controls Schematics (PWR} GND, and DLC)
Engine________________________________________________ Engine Controls ■ 7.4L 6-2703
185788
Engine Controls Schematics (Engine Sensors)
 6-2704
Engine Controls Schematics (Engine Sensors)

Engine Controls - 7.4L ________________________________________________ Engine

I I (VCM) A
* ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------^

185796
 Engine________________________________________________ Engine Controls - 7.4L
Engine Controls Schematics (Fuel Controls)
I Hot Ai Atl Times]

’ Underhood
ecmb ! Fuse-Relay
( Center
i
440
1 ORN 1440 0
dA
[■ T ■* Fuel Pump/
0.8 ORN 440
0
j&L
| / 1Oil Pressure
Switch 0.8 RED ** Underhood
CY Fuse-Relay
1 GRY 120 Center VCM
S100< Fuel Pump Cl -BLU
Prime Connector C2 -R E D
1 GRY 120 C3 -C LR
B Cl 03 C4 -B LK
C5 -B LK
1 GRY 120
|W /Q Dual Tanks| | W/Dual Tanks | 1 GRY

1 GRY FuelPump
1 GRY 120 S318<
1 GRY 120
120 Balance Relay
Cell 81
B
B
’ Fuel Pump ’ Fuel Pump 0.5 DK GRN/WHT 465

i®
I
k — _j
1And Sender
I
S
k_
J And Sender 0.5 BLK/WHT 451

A A

1 BLK/ 150 1 BLK/WHT Ground

WHT S319< Distribution
CeB14

Ground
0.8 BLK 150 D is trib u tio n
a *"
1AC4 21AC3
1 BLK/WHT • Fuel "^ ■ •V e h ic le
1 Pump Feed 1Control
I Relay 1Module (VCM)
HG104 ■ Control
4 G404

6-2705
— ' A

185792
 6-2706
Engine Controls Schematics (Fuel Injector Controls)
|Hot In Run And Start!

Engine Controls - 7.4L______________________________________________

0
0
A

I Fuel Fuel Fuel Fuel Fuel Fuel Fuel Fuel

Vehicle
I Injector # 1 Injector # 3 Injector # 5 Injector # 7 Injector # 2 Injector # 4 Injector # 6 Injector # 8 Control
. Driver Driver Driver Driver Driver Driver Driver Driver Module
(VCM)

Engine
185795
 Engine________________________________________________ Engine Controls - 7.4L
Engine Controls Schematics (EVAP and EGR Controls)
| Hot In Run And Start]

A/C
Compressor
Low
Pressure
Cutout
Switch

1 BLK/
WHT

6-2707
185797
 6-2708
Engine Controls Schematics (H02S Sensors)
|Hot In Run And Start!
''Underhood
'Fuse-Relay

Engine Controls - 7.4L________________________________________________ Engine

'Center

0.8 PNK
539 D: ‘C107
0.8 PNK 539
S148
n Vehicle
' Control
Bank # 2 Bank # 2 Bank # 2 Bank # 2 Bank #1 VCM
H02S # 2 H02S # 2 H02S #1 H02S #1 H02S # 2 SSL-!!.,'
H02S # 2 Module C1-BLU
High Low Low High Low High (VCM) C2 = RED
C3 = CLR
A
22 " 2fT 20 Cl C4-BLK
C5-BLK
0.8 0.8 N f
PPL7 1668 TAN/ 1669 0.8
WHT WHT 1671 PPL 1670
B :t Am
C107 . . . F i : Cl 07
0.8 0.8
PPL/ 1668 TAN/ 1669 0.8 0.8 0.8
WHT WHT TAN 1671 PPL 1670 PNK 539
kw
B :‘ A- B *i D$

_____ _________

Heated Oxygen Heated Oxygen RH Heated Oxygen Heated Oxygen C: : C107

Sensor (H02S) „ Sensor (H02S) Sensor (H02S) Sensor (H02S)
Bank 1 Sensor 0.8 BLK Bank 2 Sensor S149 Bank 2 Sensor Bank 1 Sensor 0.8 BLK 150

0.8
BLK

Electronic r “ "* S162

Brake1 ' 1 BLK 150 Ground
Distribution
Control I I Ceil 14
Module LB7 i , S147
ABS BTC3 3 BLK 150
Controls T 5 BLK
150
IG105

185810
 Engine________________________________________________ Engine Controls - 7.4L
Engine Controls Schematics (4WD, IAC and Upshift Controls)

I Power 1 ,P
r —n
Axle 1 1
r "* Transfer w
. Distribution
1Cel10
I
I
k _ _ _ _ _
H8 L Gauges

_J
Fuse 4
10 A

. - - • j
Fuse
'B lo c k
| DIOCK
I
Axle
|
Case
Relay1
85
1
k _ j
e ''
1
[

B '
] Case
k — j1Switch
1
El
0.8 BLK/WHT 1695
0.8 PNK 39 1 BLK/WHT 1695

S213 <►-----
Fuse Biock
Details
►
S314 0
Cell 14
0.35 PNK 39
22
0.8
GRY/BLK 1694
A
VCM
Cl -BLU
C2 -R E D
C3 = CLR
C4 -B LK
Selectable]

(
Automatic C5 = BLK
4WD I 4WD

Idle Air
Control (IAC)
Valve

1 BLK/WHT 1695

B C120
Four Wheel
Drive
Transfer Case
0.8 BLK/WHT 1695
S111<i ----------------- '
0.8 BLK/WHT 1695 0.5 GRY/BLK 1694
»P101 &P101
19 _______________23-A C4
Fuel IAC IAC IAC IAC 4WD Low 4WD Front n Vehicle
Level Coil B Coil B Coil A Col A Indicator Wheel Lock Control
Output High Low Low High Signal Feed Module
(VCM)
a
-------------------------------------------------------- -----------------------------------------------------------------------------------—--------------------------------- J

6-2709
185790
 6-2710
Engine Controls Schematics (VSS and Cruise Controls)

' — "JEVO/ r-- i T— ] HVAC Recirculation

1 i Transfer r — 1 Radio VCM
i vss I Passiock 1 1Case i i ▲ i I Control i | Door Cl -BLU
»input | Control 1 1 Control i i i i Module i i Motor C2 -R E D

Engine Controls - 7.4L ________________________________________________ Engine

L - _
jjg-y- J Module D8Y J k ——j C3 =CLR
Module 16YC2 '‘4YC3 6V C4-B LK
C5 -B LK
0.5
1614 DK GRN 1614
FSC230 Vehicle Speed
0.5 DK 0.5 Sensor (VSS)
GRN/
DK GRN 1614
WHT S212
0.5 LT GRN/BLK

MVTwMWDl |m/Tw/4Wd| 2WD

m m

Vehicle Speed
Sensor (VSS)
Adapter w
Y
D>
D *f*

1614

i
Instrument Vehicle *■Electronic
Cluster Speed
1Brake
Input Vehicle
Speed
'Control
„ 14' Input ' Module
0.35
J (EBCM)
DKGRN 389 Cl
P$C200
•*"1 Convenience
C9> JCenter
P101 i_ j
0.35
0.5 WHT 1827
1614 DKGRN 389 0.5 LT GRN/BLK
0.5 LT B5tC100
BLU/BLK 0.5 DKGRN 389
3 7 _____ A ,C 4 1 5 ....
Cruise Vehicle Air Vehicle Vehicle VSS VSS i Vehicle
Engaged Speed Inlet Speed Speed Low High ' Control
Input Output Motor Output Output I Module (VCM)
Feed
1 *

185801
 Engine________________________________________________ Engine Controls - 7.4L
Engine Controls Schematics (Transmission Controls)

■] Vehicle
Control
Transmission Transmission Transmission TFT | Module (VCM)
Range A Range B Range C Sensor
Input Input Input Signal i $
23'r 22 — ,V 'C 3 27YC2

0.5 PNK 1224 0.5 RED 1226

0

0.5 DK BLU 1225 0.5 YEL/BLK 1227

0
N L Cl 22
*■ ** Automatic
VCM
0.5 BRN 1227 Cl -BLU
Transmission C2 -R E D
A$ C3 -C LR
Automatic Pressure
Control Solenoid C4 =BLK
Transmission
(PC SOL) Valve C5 -B LK
Fluid Pressure
(TFP) Manual
Valve Position
Switch

Transmission
Fluid
Automatic
Temperature Transmission
(TFT) Input Shaft
Sensor
Speed (AT ISS)
0.5 LT BLU 1229 0.5 PPL 1228 Sensor
B!
0.5 GRY 452

M D C ' Cl 22
0.5 BLK 470
Sensors
Engine --------< »S106
Controls
0.5 LT BLU/WHT 1229 0.5 DK BLU/WHT 1231
0.5 0.5
0.5 BLK 470 RED/BLK 1228 RED/BLK 1230
19 > 16 6 7 _______ 8 .C3
Sensor PC SOL PC SOL ATT ISS a?tiss ! vehicle
Ground Valve Low Valve High Sensor Sensor • Control
High
^ I Module (VCM)
' A

6-2711
— ■*

185802
6-2712 Engine Controls - 7.4L ________________________________________________ Engine
185804
Engine Controls Schematics (A/C Controls)
 Engine________________________________________________ Engine Controls - 7.4L
Engine Controls Schematics (Secondary Air Injection Controls)
iHot In Run And Start |

s
ioamtk
VCM
C1 = BLU
C2 -R E D
C3 -C LR
C4 = BLK
C5 -BLK

■j Vehicle
[ Control
Module
i (VCM)
J >

6-2713
185806
6-2714 Engine Controls - 7.4L Engine

Component Locator

Engine Controls Components

Name Location Locator View Connector End View
At the front of the A/C compressor, at the
A/C Compressor Clutch 201-14 —
LF of the engine
In the underhood fuse-relay center, at the
A/C Compressor
LR of the engine compartment, on 201-6 —
Clutch Relay
the fender
On the top RH of the A/C accumulator, at
A/C Compressor
the RH of the engine compartment, on 201-17 —
Cycling Switch
the bulkhead
A/C Compressor High On the rear of the A/C compressor, at the
201-10 —
Pressure Cutout Switch LF of engine
A/C Compressor Low At the top of the A/C compressor, in the
201-10 —
Pressure Cutout Switch high pressure refrigerant line
Air Injection Reaction
At the lower RF of the engine 201-9 —
(A.I.R.) Pump
Automatic Transfer Case
Under the LH of the IP, near the
Control Module, 201-34 202-23
convenience center
Connector C1
Automatic Transmission
Input Shaft Speed At the LF of the transmission 201-25 —
(A/T ISS) Sensor
Auxiliary Cooling
At the LR of the engine compartment 201-4 202-60
Fan Relay
Camshaft (CMP)
In the distributor 201-12 —
Position Sensor
Clutch Pedal Position
At the top of the clutch pedal 201-41 202-61
(CPP) Switch
Convenience Center Under the LH of the IP, on the bulkhead 201-33 —
Crankshaft Position At the lower RF of the engine block, near
201-11 —
(CKP) Sensor the crankshaft
Cruise Control At the LR of the engine compartment, on
201-31 202-29
Module (CCM) the bulkhead
Under the LH of the IP, at the LH of the
Data Link
steering column, mounted at the bottom of 201-43 202-30
Connector (DLC)
the knee bolster
At the top of the engine, at the
Distributor — —
rear bulkhead
Electronic Brake Control Near the brake master cylinder, at the
201-6 —
Module (EBCM) LF wheelhousing
Electronic Variable
Orifice (EVO)/Passlock Under the center of the IP 201-40 202-31
Control Module
Engine Coolant
At the top RH of the engine, near the
Temperature (ECT) 201-14 —
thermostat housing
Sensor
Evaporative (EVAP)
Emissions Canister At the top RH of the engine, toward
201-11 —
Purge Solenoid the rear
Vacuum Switch
Evaporative (EVAP)
Emissions Canister At the top RH of the engine 201-11 —
Purge Solenoid Valve
Engine________________________________________________ Engine Controls - 7.4L 6-2715
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
Evaporative (EVAP) At the LF of the EBCM, near the brake
201-11 202-49
Emissions Canister Vent master cylinder, at the LF wheelhousing
Exhaust Gas
At the top LH center of the engine, above
Recirculation 201-20 202-66
the valve cover
(EGR) Valve
Front Axle Actuator At the RF of the front drive axle 201-19 202-62
Fuel Injectors In the intake manifold 201-19 202-32
Fuel Pump and Sender In the fuel tank 201-73 —

Fuel Pump Oil Pressure At the rear and top center of the engine,
201-12 202-63
Switch and Sender behind the distributor
Fuel Pump In the IP harness, approximately 20 cm into
— —
Prime Connector the underhood fuse- relay center breakout
In the underhood fuse-relay center, at
Fuel Pump Relay the LR of the engine compartment, on 201-6 —
the fender
Fuel Tank
In the fuel tank 201-73 202-64
Pressure Sensor
Heated Oxygen In the exhaust pipe, in the front and back
201-15 202-64
Sensors (H02S) of the catalytic converters
Part of heater controls, in the center of the
HVAC Control Module 201-53 202-35
IP, under the radio
Idle Air Control
Attached to the RR of the throttle body 201-10 202-65
(IAC) Valve
Ignition Coil At the RR of the engine 201-18 —
Ignition Control
At the RR of the engine 201-11 202-64
Module (ICM)
Under the LH end of the IP, above the
Instrument Cluster 201-32 202-38
steering column
Intake Air Temperature
In the air intake duct 201-17 —
(IAT) Sensor
At the LH of the IP, near the LF door
IP Fuse Block 201-32 —
jamb switch
At the LR of the engine mount, on
Knock Sensor (KS) 201-18 —
the engine
Manifold Absolute At the top RH center of the intake
201-11 —
Pressure (MAP) Sensor manifold, near the fuel injectors
Mass Air Flow At the air intake duct, near the air filter, at
201-13 —
(MAF) Sensor the RH of the engine
Radio In the center of the IP 201-35 202-43, 44
Recirculation Door Motor Under the IP, on the HVAC plenum 201-50 202-69
Stoplamp Switch At the top of the brake pedal 201-44 202-70
Throttle Position
On the side of the throttle body 201-10 —
(TP) Sensor
Transfer Case Control Under the IP, on the steering column
201-38 202-46
Module (TCCM) support bracket
At the RR of the engine compartment, near
Transfer Case Relay 201-23 202-70
the center of the bulkhead
Transfer Case Switch At the top LH of the transfer case 201-24, 25, 27, 28 —
Underhood Fuse- At the LR of the engine compartment, on
201-5 —
Relay Center the fender
6-2716 Engine Controls ■ 7.4L________________________________________________ Engine
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
Vehicle Control
In the engine compartment, near the EBCM 201-37 —
Module (VCM)
Vehicle Speed
At the LR of the transfer case 201-23 —
Sensor (VSS)
The engine harness to the IP harness, at
C100 the LR of the engine compartment, at 201-4 202-0
the bulkhead
The engine harness to the fuel pump
motor, at the LR of the engine
C103 201-4 202-2
comaprtment, near the underhood
fuse-relay center
The engine harness to the fuel injectors, at
C105 201-18 202-3
the rear of the intake manifold
The engine harness to the heated oxygen
C107 sensors (H02S) harness, at the LF of 201-25 202-49
the transmission
The engine harness to the front axle
C120 actuator, at the rear of the engine, near 201-27 202-50
the transmission
C122 On the LH of the transmission 201-23 202-6
The engine harness, approximately 18 cm
C130 201-6 202-50
from the VCM breakout
Behind the RH of the IP, near the blower
C200 201-37 202-10
motor, in the foam wrap
C227 At the convenience center 201-44 202-70
Behind the RH of the IP, above the HVAC
C230 201-27 202-54
evaporator housing
The engine harness, approximately 8 cm
D104 201-16 —
from the A/C compressor clutch connector
At the RF of the engine, near the
G103 201-14 —
thermostat housing
G104 At the RH top center of the cylinder head 201-16 —

G105 At the RF of the engine block 201-13 —

Behind the LH of the IP, below the IP fuse
G200 201-32 —
block, on the tie bar
Inside the LH frame rail,near the
G404 201-73 —
rear crossmember
At the LR of the engine compartment, at
P100 201-4 —
the bulkhead
At the RR of the engine compartment, at
P101 201-7 —
the bulkhead
The engine harness, approximately 23 cm
S100 from the EBCM breakout, toward the — —
taillamp harness
The engine harness, approximately 15 cm
S101 (A/T) — —
from the EBCM breakout
The engine harness, approximately 12 cm
S101 (M/T) — —
from the EBCM breakout
The engine harness, approximately 34 cm
S103 (A/T) from the fuel injector breakout, toward the — —
taillamp harness breakout
Engine________________________________________________ Engine Controls - 7.4L 6-2717
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
The engine harness, approximately 12 cm
S103 (MfT) — —
from the EGR valve breakout
The engine harness, approximately 30 cm
S104 — —
from the fuel injectors breakout
The engine harness, approximately 7 cm
S106 from the EGR valve breakout, toward the , — —
fuel injectors breakout
The engine harness, approximately 18 cm
S107 from the EBCM breakout, toward the — —
taillamp harness breakout
The engine harness, approximately 13 cm
S108 from the ignition coil breakout, toward the — —

starter solenoid
The engine harness, approximately 7 cm
S111 — —
from the EBCM breakout
The engine harness, approximately 11 cm
S145 — —
into the EGR valve breakout
The engine harness, approximately 22 cm
S146 — —
from the EBCM breakout
The engine harness, approximately 5 cm
S147 — —
from the EGR valve breakout
The heated oxygen sensor (H02S)
harness, approximately 7 cm from the RH
S148 (w/Leaded Fuel) — —
bank heated oxygen sensor (H02S)
breakout, toward the engine harness
Approximately 19 cm into the heated
S148 (w/o Leaded Fuel) — —
oxygen sensor (H02S) harness
The heated oxygen sensor (H02S)
harness, approximately 7 cm from the RH
S149 (w/Leaded Fuel) bank heated oxygen sensor (H02S) — —

breakout, toward the LH bank

oxygen sensor
Approximately 25 cm into the heated
S149 (w/o Leaded Fuel) — —
oxygen sensor (H02S) harness
The engine harness, approximately 13 cm
S150 — —
from the EBCM breakout
The engine harness, approximately 7 cm
S151 — —
from the EBCM breakout
The engine harness, approximately 7 cm
S152 — —
from the EBCM breakout
The IP harness, approximately 13 cm from
S153 — —
P100, toward the CCM
The engine harness, approximately 40 cm
from the LH heated oxygen sensor (H02S)
S162 (A/T) — —
breakout, toward the starter
solenoid breakout
The engine harness, approximately 15 cm
from the RH heated oxygen sensor (H02S)
S162 (M/T) — —
breakout, toward the starter solenoid
breakout
The IP harness, approximately 10 cm from
S204 — —
the steering column harness breakout
6-2718 Engine Controls - 7.4L________________________________________________ Engine
Engine Controls Components (cont’d)
Name Location Locator View Connector End View
The IP harness, approximately 8 cm from
S212 the inflatable restraint IP module — —
switch breakout
The IP harness, approximately 4 cm from
S213 — —
the steering column harness breakout
The IP harness, approximately 12 cm from
S215 the instrument cluster breakout, toward the — —
radio connectors breakout
The IP harness, approximately 40 cm from
S221 — —
the instrument cluster breakout
The IP harness, approximately 20 cm
S222 from the inflatable restraint IP module — —
switch breakout
The engine harness, approximately 18 cm
S231 (A/T) — —
from the EGR valve breakout
The engine harness, approximately 7 cm
S231 (M/T) — —
from the EGR valve breakout
The engine harness, approximately 4 cm
S232 — —
into the EGR valve breakout
The IP harness, approximately 7 cm
S268 from the inflatable restraint IP module — —
switch breakout
The IP harness, approximately 4 cm from
S272 — —
the auxiliary power center breakout
The IP harness, approximately 5 cm from
S280 — —
the DLC breakout
The IP harness, approximately 24 cm from
S298 the instrument cluster breakout, toward the — —
radio breakout
The selectable 4WD harness,
approximately 5 cm from the transfer
S314 — —
case relay breakout, toward the front
axle actuator
The taillamp extension harness,
approximately 10 cm from the fuel pump
S318 — —
balance module breakout, toward the
engine harness
The taillamp extension harness,
approximately 7 cm from the fuel pump and
S319 — —
sender breakout, toward the fuel pump
balance module breakout
The taillamp extension harness,
S430 approximately 6 cm from the fuel pump — —
harness breakout, toward C409
Engine Engine Controls - 7.4L 6-2719
Engine Controls Component Views
Underhood Fuse/Relay Center

1 2 \

209017
Legend
(1) AUX B (18) ABS (60 amp)
(2) AUX A (19) Ignition E (20 amp)
(3) AUX B (30 amp) (20) ECM 1 (20 amp)
(4) Lighting (50 amp) (21) Engine 1 (20 amp)
(5) AUX A (30 amp) (22) Blower (50 amp)
(6) Battery (50 amp) (23) Fuel Sol.-Diesel (10 amp)
(7) Spare (10 amp) (24) Stop/Hazzard (30 amp)
(8) Fuse Puller (25) Glow Plug (10 amp)
(9) Spare (20 amp) (26) Diode 1
(10) Spare (30 amp) (27) Diode 2
(11) Ignition A (40 amp) (28) Horn relay
(12) ECM B (20 amp) (29) Fuel pump relay
(13) Horn (20 amp) (30) A/C relay
(14) Air conditioning (10 amp) (31) A.I.R. relay
(15) Ignition B (50 amp) (32) Starter relay
(16) Rear defog (30 amp) (33) Brake lamp relay
(17) Aux fan (30 amp)
6-2720 Engine Controls - 7.4L Engine
Fuel Balance Module and Fuel Balance Pump (dual tanks only)

209617
Legend
(1) Fuel balance pump module
(2) Fuel balance pump

Vehicle Speed Sensor (4WD)

209620
Legend
(1) Vehicle Speed Sensor (VSS)
(2) Transfer case
Engine Engine Controls - 7.4L 6-2721
Vehicle Speed Sensor (2WD)

209622
Legend
(1) Vehicle Speed Sensor (VSS)

Fuel Tank Pressure Sensor and Fuel Tank Sender Assembly (rear tank)

209630
Legend
(1) Fuel Tank Sender Assembly
(2) Fuel Tank Pressure Sensor
6-2722 Engine Controls - 7.4L Engine
Fuel Tank Pressure Sensor and Fuel Tank Sender Assembly (side tank)

209633
Legend
(1) Fuel Tank Pressure Sensor
(2) Fuel Tank Sender Assembly
Engine________________________________________________ Engine Controls - 7.4L 6-2723
Idle Air Control, Manifold Absolute Pressure,Engine Coolant Temperature,Throttle
Position Sensors

214402

Legend
(1) Idle Air Control (IAC) valve motor.
(2) Engine Coolant Temperature (ECT) Sensor.
(3) Manifold Absolute Pressure (MAP) Sensor.
(4) Crankshaft Position (CKP) Sensor.
(5) Throttle Position (TP) Sensor.
6-2724 Engine Controls - 7.4L___________________________________ Engine
Coil Driver,Camshaft Position Sensor,Knock Sensor

214403
Legend
(1) Coil Driver
(2) Camshaft Position Sensor
(3) Knock Sensor
(4) Fuel Pump/Engine Oil Pressure Switch
Engine Engine Controls - 7.4L 6-2725
Intake Air Temperature,Mass Air Flow Sensors

Legend
(1) Intake Air Temperature (IAT) Sensor.
(2) Mass Air Flow (MAF) Sensor.
6-2726 Engine Controls - 7.4L________________________________ Engine
Canister Purge, Linear EGR, Knock Sensor

Legend
(1) Canister Purge Valve Solenoid.
(2) Canister Purge Valve Diag, Switch.
(3) Linear Exhaust Gas Recirculation (EGR)
Valve.
(4) Knock Sensor.
Engine Engine Controls - 7.4L 6-2727
EVAP C anister, EVAP Vent Valve

Legend
(1) Evap Canister Vent Valve.
(2) Evap Canister.
6-2728 Engine Controls - 7.4L Engine
VCM, Auxiliary Electric Cooling Fan, Underhood Electrical Center

214407
Legend
(1) Auxiliary Electric Cooling Fan Relay.
(2) Vehicle Control Module (VCM).
Engine Engine Controls - 7.4L 6-2729
Heated Oxygen Sensors

Legend
(1) H02S Bank 2 Sensor 2
(2) H02S Bank 1 Sensor 2
(3) H02S Bank 1 Sensor 1
(4) H02S Bank 2 Sensor 1
6-2730 Engine Controls - 7.4L Engine

VCM Connector End Views

Blue C1 32 Pin Connector End View

v ■
----- TE 1----- 1_______ i----- 1 3T--------■ ^ )

218792
Connector Part • 12129025
Information • Blue C1 32 Pin Connector
Pin Wire Color Circuit No. Function
1 — — Not Used
2 — — Not Used
3 BRN/WHT 633 1X CMP Signal
4 — — Not Used
5 — — Not Used
6 — — Not Used
7 TAN 1667 H02S Low Bank 2 Sensor 1
8 — 632 CMP Low
9 PPL 30 Fuel Gage
10 — — Not Used
11 — — Not Used
12 — — Not Used
13 — — Not Used
14 BRN 436 AIR Relay Control (California Only)
15 YEL/BLK 1827 VSS
16 — — Not Used
17 — — Not Used
18 PPL/WHT 1589 Dual Tank Fuel Module
19 PPL/WHT 1665 H02S High Bank 1 Sensor 1
20 PPL 1670 H02S High Bank 1 Sensor 2
21 PPL 1666 H02S High Bank 2 Sensor 1
22 PPL/WHT 1668 H02S High Bank 2 Sensor 2
23 — — Not Used
24 TAN 1671 H02S Low Bank 1 Sensor 2
25 TAN/WHT 1653 H02S Low Bank 1 Sensor 1
26 TAN/WHT 1669 H02S Low Bank 2 Sensor 2
27 — — Not Used
28 PPL 574 CKP Low
29 LT.GRN/BLK 822 VSS Low
30 PPL/WHT 821 VSS Signal
31 Yel 573 4X CKP Signal
32 — — Not Used
Engine ____________________________ Engine Controls - 7.4L 6-2731
Red C2 32 Pin Connector End View

J ------------- 1

■
J
---------------1_________________ i---------------

218792
Connector Part • 12129025
Information • Red C2 32 Pin Connector
Pin Wire Color Circuit No. Function
1 — — Not Used
2 WHT 1310 Canister Vent Solenoid
3 — — Not Used
4 YEL/BLK 1223 2-3 Shift Solenoid
5 — — Not Used
6 LT/GRN 1222 1-2 Shift Solenoid
7 BRN 418 PWM TCC Solenoid
8 BLK 1744 Injector # 1 Control
9 DK/BLU/WHT 878 Injector # 8 Control
10 BRN 1456 EGR Pintle Position
11 LT/GRN/BLK 1745 Injector # 2 Control
12 RED/BLK 877 Injector # 7 Control
13 LT/GRN/WHT 1749 IAC B High
14 LT/BLU/WHT 1747 IAC A High
15 BLK/WHT 845 Injector # 5 Control
16 YEL/BLK 846 Injector # 6 Control
17 — — Not Used
18 — — Not Used
19 DK/BLU 496 KS Signal
20 — — Not Used
21. LT/GRN 432 MAP Signal
22 TAN 472 IAT Signal
23 YEL 410 ECT Signal
24 DK/BLU 417 TP Signal
25 DK/GRN 890 Fuel Tank Vacuum Sensor
26 — — Not Used
27 YEL/BLK 1227 TFT Signal (Automatic Transmission only)
28 YEL 492 MAF Signal
29 LT/GRN/BLK 444 IAC High
30 LT/BLU/BLK 1748 IAC Low
31 LT/BLU/BLK 844 Injector #4 control
32 PNK/BLK 1746 Injector #3 control
6-2732 Engine Controls - 7.4L_____________________________ Engine
Clear C3 32 Pin Connector End View

'-S ----- TS-1 ------1

______ i----- ------------ '- s
218792

Connector Part • 12129025

Information • Clear C3 32 Pin Connector
Pin Wire Color Circuit No. Function
1 DK/GRNWHT 459 A/C Relay
DK/GRNWHT
2 428 Purge Canister Solenoid

3 — — Not Used
4 BLK 452 ECT/TP Sensor Ground
5 — — Not Used
6 RED/BLK 1228 PCS High
7 DK/BLU/WHT 1231 Input Speed Sensor Low
8 RED/BLK 1230 Input Speed Sensor High
9 WHT 423 IC Control
10 — — Not Used
11 RED 1226 Range Signal C

12 GRY 416
TP Sensor 5V Reference
13 PPL/WHT 1589 Fuel Level Module (Single Tank)
14 DK/BLU 604 A/C Recirculation
15 — — Not Used
16 LT/BLU/WHT 1229 PCS Low (Automatic Transmission Only)
17 BLK/WHT 451 System Ground
18 BLK/WHT 451 System Ground
19 BLK 470 IAT/MAP/EGR Sensor Ground
20 — — Not Used
21 ORN 440 Battery feed
22 DK/BLU 1225 Range Signal B
23 PNK 1224 Range Signal A
24 — — Not Used
25 DK/GRN/WHT 762 A/C Request Signal
26 — . — Not Used
27 GRY 474 EGR/MAP 5V Reference
28 — — Not Used
29 — — Not Used
30 DK/GRN 603 A/C Compressor Cycling Switch
31 — — Not Used
32 — — Not Used
Engine _____________________________ Engine Controls - 7.4L 6-2733
Black C4 24 Pin Connector End View

1 O © ® ® 0 0 ® © ( D ® © © )

^ L j— J \p

218795

Connector Part • 12129225

Information • Black C4 32 Pin Connector
Pin Wire Color Circuit No. Function
1 DK/GRN/WHT 465 Fuel Pump Relay Control
2 — — Not Used
3 DK/GRN/WHT 817 VSS Output Signal (TCCM.Radio.Cruise)
4 DK/GRN 389 VSS Output Signal (speedo)
5 BRN/WHT 419 MIL Control
6 — — Not Used
7 DK/GRN 1614 Inlet Air Actuator
8 — — Not Used
9 DK/BLU 473 Auxiliary Electric Cooling Fan
10 PPL 420 Brake Signal
11 PPL 1807 Class 2 Serial Data
12 BLK 900 Dual Fuel Module Return
13 BRN 441 Ignition Feed
14 — — Not Used
15 — — Not Used
16 RED 1676 EGR Valve Feed
17 — — Not Used
18 PNK 439 Ignition Feed
19 BLK/WHT 1695 4WD Engaged Signal
20 WHT 257 EGR Valve Control
21 — — Not Used
22 — — Not Used
23 GRY/BLK 1694 Transfer Case High Low Switch
24 LT/BLU/BLK 396 Cruise Engaged Signal
6-2734 Engine Controls - 7.4L Engine

Engine Controls Connector End Views EGR Valve Connector

(Connector End Views)
Camshaft Position (CMP) Sensor Connector /

ED
:DC

m 1)
D8
:\A_

i i

68773

• 12186057
Connector Part
68730 Information • ASM 5F M/P 150.2 P2S
(BLACK)
• 12110293
Connector Part Circuit
• ASM 3F M/P 150 SLD Wire Color
Information Pin No. Function
(BLACK)
A RED 1676 EEGR Solenoid Feed
Circuit
Wire Color B BLK 470 S>ensor Return
Pin No. Function
A PNK/BLK 632 CMP Sensor Return EGR Solenoid
C BRN 1456 p
’osition Signal
B BRN/WHT 633 CMP Sensor Signal
D GRY 474 E Volt Reference
Fuse Output - Ignition 1 -
C PNK 439 E WHT 257 EEGR Solenoid Output
Type III Fuse

Crankshaft Position (CKP) Sensor Connector Engine Coolant Temperature (ECT)

Sensor Connector

62453
62471
Connector Part • 12059595
Information • 12162194
• ASM 3F M/P 150 (BLACK) Connector Part
Information • ASM 2F M/P 150.2 P2S
Circuit
Wire Color (BLACK)
Pin No. Function
Circuit
Fuse Output - Ignition 1 - Wire Color
A PNK 439 Pin No. Function
Type III Fuse
A BLK 452 Sensor Return
B PPL 574 CKP Sensor Return
Coolant Temperature
C YEL 573 CKP Sensor Signal B YEL 410
Sensor Signal
Engine_______________________ Engine Controls - 7.4L 6-2735
Fuel Pump And Sender Connector Manifold Absolute Presssure (MAP)
Sensor Connector

68760

• 12160482 68740
Connector Part
• ASM 4F M/P 150 SLD Connector Part • 12129946
Information
(BLACK) Information • ASM 3F M/P 150 (GRAY)
Circuit Circuit
Wire Color Wire Color
Pin No. Function Pin No. Function
A WHT 1589 Fuel Level Signal To VCM A BLK 470 MAP Sensor Return
B GRY 120 Fuel Pump Motor Feed B LT GRN 432 MAP Sensor Signal
C BLK 150 Ground C GRY 474 5 Volt Reference
D BLK 470 Sensor Return
Secondary Air Injection Reaction Pump
Intake Air Take (IAT) Sensor Connector Clutch Connector

68719 35437

• 12162198 • 12052644
Connector Part Connector Part
• ASM 2F M/P 150.2 P2S Information • ASM 2F M/P 150 (LIGHT
Information
(MEDIUM GRAY) GRAY)
Circuit Circuit
Wire Color Wire Color
Pin No. Function Pin No. Function
A TAN 472 IAT Sensor Signal A RED 78 A.I.R. Pump Feed
B BLK 470 IAT Sensor Return B BLK 150 Ground
6-2736 Engine Controls - 7.4L Engine
Throttle Position Sensor Connector

/ B| A \
\ c

62485

• 12078090
Connector Part
Information • ASM 3F M/P 150 P2S
(BLACK)
Circuit
Wire Color
Pin No. Function
A GRY 416 5 Volt Reference
B BLK 452 Sensor Return
C DK BLU 417 TP Sensor Signal
Engine
Diagnostic Information and
Procedures
Powertrain OBD System Check
(OBD System Check)
Refer to Power, Ground, MIL and DLC.
Circuit Description
The On-Board Diagnostic (OBD) System Check is an
organized approach to identifying a problem created
by a control module system malfunction. The OBD is
the starting point for any driveability concern
diagnosis. The OBD directs the service technician to
the next logical step in diagnosing the concern.
Perform this check ONLY if there is a driveability
complaint or if you have been sent to this
system check from another section in the
service information.
Understanding the table properly reduces the
diagnostic time. Proper use of the OBD helps
prevent the unnecessary replacement of good parts.
Diagnostic Aids
im portant: Do not clear the DTCs unless directed
by a diagnostic procedure. Clearing the DTCs will
also clear valuable Freeze Frame and Failure
Records data.
Inspect all related wiring and connections including
the connections at the VCM. These may cause an
intermittent malfunction.
Check any circuitry that is suspected of causing an
intermittent problem for the following conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections
• Physical damage to the wiring harness
• Corrosion
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
1. This step will check for power and grounds to
the DLC.
2. When the ignition switch is initially turned to the
ON (Run) position, the Malfunction Indicator
Lamp (MIL) will flash and then remain ON. This
is the normal operation of the MIL.
Engine Controls - 7.4L 6-2737
3. Monitor the actively communicating modules
with the scan tool’s Diagnostic Circuit Check
function. An active module is a module that is
successfully communicating on the Class II
Serial Data line with the scan tool. An inactive
module is a module that previously established
communication with the scan tool, but currently
is not communicating. If a module is not listed
at all, then the module never successfully
established communications with the scan tool;
refer to Electrical Diagnosis for any unlisted
modules.
4. If a serial data circuit malfunction occurs, a
module will log Class II (Lost Communication)
DTCs for the modules which it normally
monitors.
7. This step will check for DTCs associated with
the Vehicle Theft Deterrent (VTD) which will
prevent the vehicle from starting.
8. Whenever multiple DTCs are stored, refer to
the following DTCs in this order: VCM error
DTCs (P0601, P0602, P0604, and P0605),
System voltage DTCs (Refer to Transmission,
Component level DTCs (DTCs that indicate a
malfunctioning part), and System Level DTCs
(DTCs that indicate a system fault).
9. Checking the sensors for proper operation
during warm up can be a crucial step in
correctly diagnosing any driveability concern.
Careful observation of these sensors during the
engine warm up may reveal a slow responding
sensor or a sensor that malfunctions only within
a small portion of its range. After the engine is
at the normal operating temperature, a
comparison of the actual control system data
with the typical values is a quick way to
determine if any parameter is not within limits.
Keep in mind that a base engine problem (i.e.
advanced cam timing) may substantially alter
sensor values. Check the Engine Coolant
Temperature (ECT) sensor’s initial coolant
temperature while looking for a rise in ECT
temperature as the engine warms up.
10. A driveability complaint may not be present if
you were sent to this system check from
another section in the service information
(i.e. the System Check for: EBCM, ATCCM).
6-2738 Engine Controls - 7.4L________________________________________________ Engine
Powertrain OBD System Check (OBD System Check)
Step Action Value(s) Yes No
Important: Check for applicable service bulletins before
proceeding with this diagnostic.
Perform this test only if there is a driveability complaint or
if you have been sent to this table from another section in
the service information.
Important: Do not turn the ignition OFF when performing
1 —
this diagnostic. Do Not clear DTCs unless instructed by
this diagnostic.
1. Connect the scan tool to the Data Link
Connector (DLC).
Go to Data Link
2. Turn ON the ignition leaving the engine OFF Connector
Does the scan tool power up? Go to Step 2 Diagnosis
Is the MIL ON? Go to Malfunction
2 — Indicator Lamp
Go to Step 3 Circuit Check
1. Use the scan tool to select the Diagnostic
System Check.
3 2. Monitor the Serial Data Class II messages. —
Go to Data Link
Are all the modules connected to the Serial Data Class II Connector
circuit communicating? Go to Step 4 Diagnosis
Check for any Class II (U type) DTCs using a scan tool. Go to applicable
4 —
Are there any Class II (U type) DTCs? DTC table Go to Step 5
Command the MIL OFF with the scan tool. Go to Malfunction
5 Does the MIL turn OFF? — Indicator Lamp
Go to Step 6 Circuit Check
Start the engine.
6 —
Does the engine start and continue to run? Go to Step 8 Go to Step 7
Is DTC P1626 or P1631 stored? Go to Go to Engine
7 — the applicable Cranks but Does
DTC table Not Run
Check the VCM DTCs using the scan tool. Go to
8 Were any last test failed, history, or MIL request — the applicable
DTCs set? DTC table Go to Step 9
1. Turn ON the ignition leaving the engine OFF.
2. Check the ECT values using a scan tool.
3. Start the engine.
4. While the engine is reaching normal operating
temperature, check the ECT values using a
scan tool.
9 —
5. Allow the engine to reach normal
operating temperature.
6. Compare the scan tool sensor values with the typical
values shown in the Engine Scan Tool Data List.
Refer to Engine Scan Tool Data List. Go to
Are the displayed values within typical ranges? Go to Step 10 Diagnostic Aids
10 Is there a driveability complaint? — Go to Symptoms System OK
Engine
Malfunction Indicator Lamp Circuit Check
Refer to Power, Ground, MIL and DLC.
Circuit Description
When the ignition switch is initally turned to the run
position, the Malfunction Indicator Lamp (MIL) flashes
and then remains On. When the engine is running
and no Diagnostic Trouble Codes (DTCs) are stored,
the Vehicle Control Module (VCM) turns Off the MIL.
The ignition switch supplies battery voltage directly to
the MIL telltale. The VCM controls the MIL by
providing a ground path through the MIL control
circuit in order to turn On the MIL.
Diagnostic Aids
An open gauge fuse will cause the entire IP cluster
to be inoperative.
Check for any circuitry that is suspected of causing
an intermittent complaint for the following conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections
• Physical damage to the wiring harness
Test Description
Number(s) below refer to step number(s) on the
Diagnostic Table.
1. The Powertrain OBD System Check prompts
the technician to complete some basic checks
and store the freeze frame and failure records
data with the scan tool if applicable. This
creates an electronic copy of the data taken
when the fault occurred. The information is then
stored in the scan tool for later reference.
Engine Controls - 7.4L 6-2739
4. A MIL that responds correctly to the scan tool
commands indicates that the fault is not present
at this time or that the condition that caused
the No MIL condition has been corrected.
5. The MIL should be OFF. This step checks for a
short to ground in the MIL control circuit by
removing the VCM from the circuit.
7. This step checks for the MIL control circuit for a
short to B+.
9. The power and ground circuits for the VCM
and MIL control are OK. The VCM is
probably faulty.
10. VCM grounds will only cause a problem if all of
the grounds are not making a good connection.
If a VCM ground problem is suspected, the
most probable place to check is where all the
grounds meet, at the engine block.
12. If the fuse is open, check for a short to voltage
on the circuit between the VCM and the
MIL bulb.
15. For MIL bulb replacement procedures, refer to
Electrical Diagnosis.
17. For IP replacement procedures, refer to
Electrical Diagnosis.
19. The scan tool can communicate with the VCM;
therefore, the serial data circuit is OK. If the
VCM connections are OK, the VCM is
probably faulty.
20. Locate and repair any shorts that may have
caused the fuse to open before replacing
the fuse.

Malfunction Indicator Lamp Circuit Check

Step Action Value(s) Yes No
Important; Before clearing any DTCs, use the scan tool
Capture Info function to store the Freeze Frame and the
Failure Records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn OFF the ignition for 15 seconds.
2 2. Turn ON the ignition leaving the engine OFF. —
Is the MIL ON? Go to Step 3 Go to Step 6
1. Install a scan tool.
Go to
2. Turn ON the ignition leaving the engine OFF.
3 — Data Link
3. Attempt to establish communications with the VCM. Connector
Does the scan tool communicate with the VCM? Go to Step 4 Diagnosis
Command the MIL OFF and ON using a scan tool.
4 —
Does the MIL turn OFF and ON when commanded? Go to Step 23 Go to Step 5
6-2740 Engine Controls - 7.4L________________________________________________ Engine
Malfunction Indicator Lamp Circuit Check (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Disconnect the VCM BLK connector.
5 —
3. Turn ON the ignition leaving the engine OFF.
Is the MIL OFF? Go to Step 19 Go to Step 18
Inspect the fuses for the MIL, the Battery Positive Voltage,
6 and the Ignition Positive Voltage circuits for an open. —
Are the fuses OK? Go to Step 7 Go to Step 20
1. Turn OFF the ignition.
2. Disconnect the VCM CLR and BLK connectors.
3. Turn ON the ignition leaving the engine OFF.
7 —
4. Probe the MIL control circuit with a fused jumper
connected to ground.
Is the MIL ON? Go to Step 8 Go to Step 12
1. Turn ON the ignition leaving the engine OFF.
2. Probe the VCM Battery Positive Voltage, and Ignition
8 Positive Voltage circuits harness connectors with a —
test light connected to ground.
Does the test light illuminate on each circuit? Go to Step 9 Go to Step 22
Probe the VCM ground circuits at the harness with a test
9 light connected to B+. —

Is the test light ON? Go to Step 19 Go to Step 10

Check for faulty VCM ground connections at the engine Go to Powertrain
block. If a problem is found, refer to Wiring Repairs in OBD System
10 Electrical Diagnosis. —
Check (OBD
Was a problem found and repaired? System Check) Go to Step 11
Repair the open in the VCM ground circuit(s). Go to Powertrain
Is the action complete? OBD System
11 — —
Check (OBD
System Check)
12 Did the fuse in the fused jumper open? — Go to Step 21 Go to Step 13
Check for an open in the MIL control circuit. If a problem Go to Powertrain
is found, refer to Wiring Repairs in Electrical Diagnosis. OBD System
13 —
Was a problem found and repaired? Check (OBD
System Check) Go to Step 14
Check the Instrument Panel (IP) cluster connections. If a Go to Powertrain
problem is found, refer to Wiring Repairs in OBD System
14 Electrical Diagnosis. —
Check (OBD
Was a problem found and repaired? System Check) Go to Step 15
Check for an open MIL lamp. If a problem is found, refer Go to Powertrain
to Wiring Repairs in Electrical Diagnosis. OBD System
15 —
Was a problem found and repaired? Check (OBD
System Check) Go to Step 16
Check for an open to the MIL circuit from the Gauge fuse. Go to Powertrain
If a problem is found, refer to Wiring Repairs in OBD System
16 Electrical Diagnosis. —
Check (OBD
Was a problem found, and repaired? System Check) Go to Step 17
Replace the Instrument panel (IP) cluster. Go to Powertrain
Is the action complete? OBD System
17 —
Check (OBD
System Check)
Engine________________________________________________ Engine Controls - 7.4L 6-2741
Malfunction Indicator Lamp Circuit Check (cont’d)
Step Action Value(s) Yes No
Repair the short to ground in the MIL control circuit. Go to Powertrain
Is the action complete? OBD System
18 — —
Check (OBD
System Check)
Check for a faulty VCM connection. If a problem was Go to Powertrain
found, repair the VCM connection. Refer to Wiring Repairs OBD System
19 in Electrical Diagnosis. —
Check (OBD
Was a faulty connection found and repaired? System Check) Go to Step 24
1. Check for a short to ground in the circuit of the fuse Go to Powertrain
that was open and repair if necessary.
20 — OBD System —
2. Replace the faulty fuse. Check (OBD
Is the action complete? System Check)
Repair the short to voltage in the MIL control circuit Go to Powertrain
between the VCM and the MIL lamp. OBD System
21 — —
Is the action complete? Check (OBD
System Check)
Repair the open in the VCM circuit that did not illuminate Go to Powertrain
the test light. OBD System
22 — —
Is the action complete? Check (OBD
System Check)
The problem is intermittent. Refer to Diagnostic Aids. Go to Powertrain
Is the action complete? OBD System
23 — —
Check (OBD
System Check)
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.

24 3. Perform the VTD Password Learn Procedure. Refer

— —
to Password Learn Procedure.
Go to Powertrain
4. Perform the Crankshaft Variation Learn Procedure. OBD System
Refer to CKP System Variation Learn Procedure. Check (OBD
Is the action complete? System Check)
6-2742 Engine Controls - 7.4L Engine

Data Link Connector Diagnosis 4. Monitor the actively communicating modules

with the scan tool’s Diagnostic Circuit Check
Refer to Power, Ground, MIL and DLC.
function. An active module is a module that is
Circuit Description successfully communicating on the Class II
Serial Data line with the scan tool. An inactive
The Class II Serial Data circuit to the DLC allows
module is a module which had previously
bi-directional communication between the VCM and
established communication with the scan tool,
the scan tool. This is accomplished through pin 2 of
but currently is not communicating. If a module
the DLC. If communication between the scan tool
is not listed at all, then the module never
and the VCM cannot be established, the procedure
successfully established communications with
in the DLC Diagnosis table should be used to
the scan tool; refer to Electrical Diagnosis^or
diagnose the condition.
any unlisted modules.
Diagnostic Aids 5. If a serial data circuit malfunction occurs, a
Check for the following items: module will log Class II (Lost communication)
DTCs for the modules which it normally
• For the VCM to establish communication with
monitors.
the scan tool, system voltage must be between
9.0 and 16.0 volts. If the system voltage is not 7. This step isolates the VCM by disconnecting all
within this range, refer to Charging System the other components on the Class II Serial
for diagnosis. Data circuit. If VCM Class II Serial Data exists
after disconnecting all other components on the
• Ensure that the correct application^ (model year,
Class 2 Serial Data circuit, refer to Electrical
truckline, VIN code) has been selected on the
Diagnosis for the shared components on the
scan tool.
Class II Serial Data circuit. After making repairs,
• An intermittent may be caused by a poor it is necessary to clear DTCs from the modules
connection, rubbed through wire insulation, or a that can communicate. Clearing DTCs will avoid
broken wire inside the insulation. Check for a future misdiagnosis.
poor connections or a damaged harness.
11. This step determines if voltage is not available
Inspect the VCM harness and the connectors
at the DLC due to an open battery feed fuse. If
for improper mating, broken locks, improperly
the fuse is open, determine if the open was
formed or damaged terminals, poor terminal to
due to a short in the battery feed circuit before
wire connection, and damaged harness.
replacing the fuse.
Test Description
2. This step determines if the scan tool is
operating correctly.

Data Link Connector Diagnosis

Step Action Value(s) Yes No
Was the On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
Install the scan tool on a known good vehicle.
2 —
Does the scan tool display the VCM data? Go to Step 3 Go to Step 17
1. Return to the original vehicle.
2. Install the scan tool.
3 —
3. Turn ON the ignition leaving the engine OFF.
Does the scan tool power up? Go to Step 4 Go to Step 8
Monitor the Class II messages with a scan tool.
4 Are all the modules on the Serial Data —
circuit communicating? Go to Step 5 Go to Step 6
Check for Class II DTCs with the scan tool. Go to
5 Are any Class II DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Is the VCM communicating? Go to Electrical
6 —
Diagnosis Go to Step 7
Engine Engine Controls - 7.4L 6-2743
Data Link Connector Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Disconnect the components sharing the Serial Data
7 circuit leaving the VCM connected. —
3. Turn ON the ignition leaving the engine OFF. Go to Electrical
Does the scan tool display VCM data? Diagnosis Go to Step 12
Probe the battery feed circuit (DLC pin 16) with a test light
8 connected to ground. —
Is the test light ON? Go to Step 9 Go to Step 11
Probe the ground circuit (DLC pin 4) with a test light
9 connected to B+. —
Is the test light ON? Go to Step 10 Go to Step 15
Probe the ground circuit (DLC pin 5) with a test light
10 connected to B+. —
Is the test light ON? Go to Step 17 Go to Step 15
Inspect the fuse in the fuse block.
11 —
Is the fuse open? Go to Step 13 Go to Step 14
Check for an open or poor connection in the Class II
12 Serial Data circuit. —
Was a problem found? Go to Step 16 Go to Step 18
1. Check for a short to ground in the battery feed
circuit and repair if necessary. Refer to Wiring
13 Repairs in Electrical Diagnosis. — —
2. Replace the open fuse.
Is the action complete? Go to Step 20
Repair the open in the battery feed circuit. Refer to Wiring
14 Repairs in Electrical Diagnosis. — —

Is the action complete? Go to Step 20

Repair the open in the DLC ground circuit. Refer to Wiring
15 Repairs in Electrical Diagnosis. — —

Is the action complete? Go to Step 20

Repair the open or poor connection in the Class II
Serial Data circuit. Refer to Wiring Repairs in
16 Electrical Diagnosis. — —
Is the action complete? Go to Step 20
1. The scan tool or cables are faulty.
17 2. Refer to the scan tool manual for repair information. — —
Is the action complete? Go to Step 20
Check for a poor connection of the Class II Serial Data
18 circuit at the VCM and DLC harness connectors. —
Was a repair necessary? Go to Step 20 Go to Step 19
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
19 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 20
Display the Capture Info and the Review Capture Info Go to
20 functions with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
6-2744 Engine Controls - 7.4L Engine

Engine Cranks but Does Not Run

jl-lot In Run And Start!

Power 1 Underhood
Distribution ecm i , Fuse-Relay
1 Cell 10
Fuse , Center Instrument1"
J8 20 A
Cluster1 Tachometer .
_ Input
____ _ j *
PNK 439
Fuse Block
A ' WHT 1216"
Details VCM
Cell 11 = BLU
-R E D
PNK 439 -CLEAR
-BLK

PNK 439
Fuse Block
Details WHT 121
Cell 11

PNK 439 PNK 439

WHT/BLK 1847
Crankshaft Ignition Ignition Tachometer
Position Positive Signal
Control Voltage
(CKP) Module Ignition
Sensor (ICM) Timing
Signal Ground Ignition
Coil
B C'
C
YEL 573 BLK/WHT 451
WHT 423
PPL 574
Coil Wire
31 28 C1 9. >C3
Distributor
' Vehicle
I 4xCKP
. Sensor
CKP
Sensor
ic
Control J
Control
j Signal Ground Module A
l. __ _____ ___ ___ ___ ___ — — ___ — — — — — — — — — J(VCM)
----------------------- i
I --------------
Ground
Distribution
BLK/WHT 451 I----- l l . .
Cell 14 Spark Plugs

33671

Circuit Description The VCM has integrated IC circuits that are fault
This table assumes that the battery condition and protected; therefore, if a circuit has failed, the
the engine cranking speed are OK, as well as integrated IC may not be damaged. If that is the
having adequate fuel in the tank. case, the IC will keep the circuit open until the fault
in the circuit has been corrected.
Diagnostic Aids When the fault has been corrected, reinstall the VCM
If no trouble is found in the fuel pump circuit or the and check the circuit. Replace the VCM only if the
ignition system and the cause of an Engine Cranks circuit is still inoperative.
But Will Not Run has not been found, check for the
following conditions: Test Description
• Fouled spark plugs The numbers below refer to the step numbers on the
diagnostic tables.
• An EGR valve stuck open
2. If the signal is over 2.5 volts, the engine may
• L o w fu e lp re ssu re .R e fe rto F i/e /S ysfe m
be in the clear flood mode which will cause
Diagnosis.
starting problems.
• Water or foreign material in the fuel system
3. If the engine coolant sensor is below - 3 0 ‘ C,
• A grounded Ignition Control (IC) signal the VCM provides fuel for this extremely cold
circuit may cause a No Start or a Start then temperature which will severely flood
Stall condition the engine.
• Basic engine problem
Engine
5. Use the injector test lamp J 34730-350 in order
to test the injector circuit. A blinking lamp
indicates that the VCM is controlling
the injector.
Engine Controls - 7.4L 6-2745
6. Voltage at the spark plug is checked using the
spark plug tester tool J 26792. No spark
indicates a basic ignition problem.
7. This test will determines if there is fuel pressure
at the fuel injection unit and holding steady.

Engine Cranks but Does Not Run

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Install the scan tool.
2. Monitor the TP sensor on the scan tool. Go to DTC P0123
2 2.5V
With the throttle closed is the TP sensor over the TP Sensor Circuit
specified value? High Voltage Go to Step 3
Monitor the ECT sensor on the scan tool. Go to DTC P0118
Is the ECT sensor below the specified value? ECT Sensor
3 -30’ C
Circuit High
Voltage (98) Go to Step 4
1. Turn off the ignition for 10 seconds.
Go to Fuel
4 2. Turn ON the ignition. — Pump Relay
Does the fuel pump operate for 2 seconds? Go to Step 5 Circuit Diagnosis
1. Disconnect the injector connector at the
intake manifold.
2. Connect a test lamp to a ground.
5 —
3. Probe the injector ignition feed circuit.
4. Ignition ON engine OFF.
Does the test lamp illuminate? Go to Step 6 Go to Step 8
1. Disconnect one spark plug wire.
2. Install the spark tester J 26792.
6 — Go to
3. Crank the engine. Enhanced Ignition
Is the spark present? Go to Step 7 System Diagnosis
1. Reconnect the one spark plug wire.
2. Turn off the ignition.
380-420 kPa
7 3. Connect the fuel pressure guage J 34730-1A.
(55-61 psi)
4. Ignition ON engine OFF Go to Fuel Go to Fuel
Is the fuel pressure within the specified range? Injector Coil Test System Diagnosis
Repair the injector ignition feed circuit. Refer to Wiring
8 — —
Repairs in Engine Electrical. Go to Step 9
1. Using the scan tool, select the DTC and the
Clear Info.
9 —
2. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 9 Go to Step 2
1. Allow the engine to idle until normal operating
temperature is reached.
10 — Go to
2. Select the DTC and the Failed This Ign. The Applicable
Are any DTCs displayed? DTC Table Go to Step T\
Using the scan tool, select the Capture info and the Go to
11 Review info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2746 Engine Controls - 7.4L Engine

Fuel Pump Relay Circuit Diagnosis
Refer to Fuel Pump Controls.
Circuit Description
When the ignition switch is turned ON, the VCM
turns the in-tank fuel pump ON. The in-tank fuel
pump remains ON as long as the engine is cranking
or running and the VCM is receiving the distributor
reference pulses. If there are no reference pulses,
the VCM shuts the fuel pump OFF within 2 seconds
after the ignition is ON or the engine stops.
Should the fuel pump relay or the 12 volt relay drive
from the VCM fail, the fuel pump receives a supply
current through the oil pressure switch backup
circuit. The fuel pump test terminal is located in the
drivers side of the engine compartment. When the
engine is stopped, applying the battery voltage to the
test terminal can turn on the fuel pump.
Diagnostic Aids
An inoperative fuel pump relay can result in long
cranking times. The time necessary for the oil
pressure to reach the pressure required in order to
close the oil pressure switch and supply the
necessary current for the fuel pump causes the
extended crank period. If the fuel pump relay circuit
checks out OK, refer to Fuel System Diagnosis.
Excessive fuel may also cause long cranking times
which is accompanied by the following conditions:
• A start that is not as fast as normal
• A puff of black smoke at the tailpipe
An improperly connected or faulty EVAP canister
control valve can cause this problem. Disconnect the
EVAP purge hose from the EVAP canister control
valve in order to diagnose. Refer to EVAP Control
System Diagnosis.
One or more leaking poppet nozzles may also
extend the cranking time. Perform the Poppet Nozzle
Test, in the Injector Balance Test Table. Refer to
Fuel Injector Balance Test.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step checks for the correct operation of
the fuel pump.
3. This step checks the operation of the fuel
pump by supplying 12 volts to the fuel pump
control circuit.
5. This step checks the battery feed circuit to the
fuel pump relay.
10. This step checks for the proper operation of the
fuel pump relay.

Fuel Pump Relay Circuit Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Turn off the ignition for 10 seconds.
Go to Engine
2 2. Turn ON the ignition. — Cranks but Does
Does the fuel pump operate for 2 seconds? Not Run Go to Step 3
Apply a 12 volt fused jumper to the fuel pump
3 test terminal. —
Does the fuel pump operate? Go to Step 4 Go to Step 12
1. Remove the 12 volt jumper from the test terminal.
2. Turn OFF the ignition for 10 seconds.
4 —
3. Turn ON the ignition.
Does the fuel pump operate for 2 seconds and then stop? Go to Step 25 Go to Step 5
1. Turn OFF the ignition.
2. Disconnect the Fuel Pump Relay.
3. Turn ON the ignition while leaving the engine OFF.
5 4. Command the fuel pump ON while probing the fuel —
pump relay control circuit at the fuel pump relay
harness connector with a test light to ground.
Is the test light ON? Go to Step 6 Go to Step 14
Connect a test light between the fuel pump relay battery
6 feed circuit harness connector and a ground. —
Is the test light ON? Go to Step 7 Go to Step 15
Engine________________________________________________ Engine Controls - 7.4L 6-2747
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Connect a test light between the fuel pump relay
terminal and a ground.
7 2. Turn OFF the ignition for 10 seconds. —
3. Turn ON the ignition.
Is the test light ON for 2 seconds and then OFF? Go to Step 8 Go to Step 16
Check for a faulty connection at the fuel pump relay
8 control connector terminal. —
Was a problem found? Go to Step 11 Go to Step 9
Replace the fuel pump relay. Refer to Fuel Pump
9 Relay Replacement. — —
Is the action complete? Go to Step 10
1. Start the engine and idle until the engine reaches
the normal operating temperature.
2. The oil pressure should be within the normal
10 operating range. —
3. Disconnect the fuel pump relay.
Does the engine continue to run? Go to Step 11 Go to Step 17
1. Reinstall the fuel pump relay.
2. Turn OFF the ignition.
11 3. Probe the fuel pump test connector with a test light —
connected to the ground.
Is the test light ON? Go to Step 18 Go to Step 25
1. Disconnect the chassis fuel pump harness connector
at the fuel tank.
2. Connect a 12 volt fused jumper to the fuel pump
12 test terminal. —
3. Probe the fuel pump feed circuit with a test light
connected to a ground.
Is the test light ON? Go to Step 13 Go to Step 20
With a test light to a ground to the fuel pump ground
circuit (tank side), probe the fuel pump feed circuit
13 (engine side). —
Is the test light ON? Go to Step 19 Go to Step 21
Repair the open in the battery feed circuit to the fuel pump
relay harness connector terminal. Refer to Wiring Repairs
14 in Engine Electrical. — —
Is the action complete? Go to Step 25
Repair the open in the fuel pump relay ground circuit.
15 Refer to Wiring Repairs in Engine Electrical. — —
Is the action compete? Go to Step 25
1. Check for a faulty connection at the VCM connector
pump relay control circuit.
■ 2. Check for an open or short to ground in the harness
16 between the fuel pump relay connector terminal and —
the fuel pump relay control connector terminal and
the fuel pump relay control circuit.
Was a problem found? Go to Step 22 Go to Step 24
Check the fuel pump oil pressure switch harness connector
17 terminals for a faulty connection. —
Was a problem found? Go to Step 22 Go to Step 18
6-2748 Engine Controls - 7.4L___________________ _____________________________Engine
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
Replace the fuel pump oil pressure switch. Refer to Fuel
18 Pump and Engine Oil PRESS Switch Replacement. — —

is the action complete? Go to Step 25

Replace the fuel pump.
• Refer to Fuel Tank Replacement (Suburban) for
the Suburban.
. Refer to Fuel Tank Replacement (2DR Utility) for
the Tahoe/Yukon.
• Refer to Fuel Tank Replacement (Pick-up - Side
Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended Cab -
19 Side Tank) for the Extended Cab. — —
• Refer to Fuel Tank Replacement (4DR Utility) for
the 4DR Utility.
• Refer to Fuel Tank Replacement (Cab and Chassis -
Side Tank) for the Cab and Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and Chassis -
Rear Tank) for the Cab and Chassis with a rear
tank only.
Is the action complete? Go to Step 25
Repair the open between the fuel pump teat terminal and
the fuel pump feed circuit at the fuel pump harness
20 connector. Refer to Wiring Repairs in Engine Electrical. — —

Is the action complete? Go to Step 25

Repair the open in the fuel pump harness ground circuit.
21 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 25
Repair the circuit as necessary. Refer to Wiring Repairs in
22 Engine Electrical. — —

Is the action complete? Go to Step 25

Repair the connection as necessary. Refer to Wiring
23 Repairs in Engine Electrical. — —
Is the action complete? Go to Step 25
1. Replace the VCM. Refer to VCM
Replacement/Programming
2. Program the VCM.
24 — —
3. Perform the VTD Password Leam Procedure. Refer
to Password Leam Procedure.
Is the action complete? Go to Step 25
1. Using the scan tool, select the DTC and the
Clear Info.
25 —
2. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 26 Go to Step 2
1. Allow the engine to idle until the engine reaches the
normal operating temperature. Go to
26 —
2. Select the DTC Failed This Ign. the applicable
Are any DTCs displayed? DTC table Go to Step 27
Use the scan tool in order to display the Capture Info and Go to
27 the Review Capture Info function. — the applicable
Are any DTCs displayed that have not been diagnosed? DTC table System OK
Engine_______________
Fuel System Diagnosis
Circuit Description
When you turn ON the ignition switch, the Vehicle
Control Module (VCM) turns ON the in-tank fuel
pump. The pump remains ON as long as the engine
is cranking or running and the VCM is receiving
reference pulses. If there are no reference pulses,
the VCM shuts the fuel pump OFF within 2 seconds
after you turn the ON the ignition or if the
engine stops.
An electric fuel pump pumps the fuel through an
in-line filter to the SFI unit. The pump is attached to
the fuel level meter assembly inside of the fuel tank.
The pump is designed in order to provide fuel at a
pressure above the regulated pressure needed by
the injectors. The pressure regulator keeps the fuel
available to the injector at a regulated pressure.
Unused fuel is returned to the fuel tank by a
separate line.
Diagnostic Aids
Tools Required
• J 34730-E Fuel Pressure Gauge.
• J 34730-1A Fuel Pressure Gauge with
J 34730-250 Fuel Pressure Adapter Kit.
. J 42873-1 3/8 Fuel Feed Pipe Shutoff Valve
and the J 42873-2 5/16 Fuel Return Pipe
Shutoff Valve.
Engine Controls - 7.4L 6-2749
34976
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Wrap a shop towel around the fuel pressure
connection to absorb any small amount of fuel
leakage that may occur when installing the fuel
pressure gauge. Turn ON the ignition, the fuel
pressure should be 385-430 kPa (56-62 psi).
This pressure is controlled by a spring pressure
within the regulator assembly.
4. The fuel pressure that continues to fall is
caused by one of the following items:
• The in-tank modular fuel sender is not
holding pressure.
• The fuel pressure regulator valve is leaking.
• An SFI injector is leaking.
• Fuel line is leaking.
6-2750 Engine Controls - 7.4L
15. If the fuel pressure is less than 385 kPa
(56 psi), it falls into the following 3 areas:
• The pressure is regulated but less than
385 kPa (56 psi).The amount of fuel reaching
the injector is sufficient, but the pressure is
too low. The system will run lean, hard
starting cold, no start, overall poor
performance, and may set a DTC. Refer to
Engine Cranks but Does Not Run
• A restricted flow causing pressure drop —
Normally, a vehicle with a fuel pressure of
less than 300 kPa (44 psi) at idle is
inoperable. However, if the pressure drop
occurs only while driving, the engine will
normally surge then stop running as the
pressure begins to drop rapidly. This is most
likely caused by a restricted fuel line or
plugged filter.
• A leaking or contaminated pressure regulator
valve or seat interface may not allow the
regulated pressure to be achieved.
Engine
Notice: Do not allow the fuel pressure to exceed
517 kPa (75 psi). Excessive pressure may damage
the fuel pressure regulator.
21. Restricting the fuel return line allows the fuel
pressure to build above regulated pressure.
With the battery voltage applied to the fuel
pump test terminal, the pressure should rise
above 430 kPa (62 psi), as the valve in the
return line is partially closed.
26. When the engine is idling, the manifold
pressure is low (high vacuum) and is applied to
the fuel pressure regulator diaphragm. This will
offset the spring and result in a lower fuel
pressure. This idle pressure will vary somewhat
depending on the barometric pressure; however,
the pressure at idle should be less indicating
the pressure regulator control.

Fuel System Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Turn OFF the ignition for 10 seconds with the
A/C OFF.
2. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk
of fire and personal injury. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge
is complete.
3. Install the fuel pressure gauge J 34730-1A or SFI -
2 the equivalent. 385-430 kPa
(56-62 psi)
4. Turn ON the ignition leaving the engine OFF.
5. The fuel pump should operate for 2 seconds.
6. Bleed the air out of the fuel pressure gauge into an
approved gasoline container.
7. Turn OFF the ignition for 10 seconds.
8. Turn ON the ignition leaving the engine OFF.
9. Monitor the fuel pressure with the fuel pump running.
It should measure within the specified value.
Important: The ignition may have to be cycled ON more
than once in order to obtain the maximum fuel pressure.
Is the fuel pressure within the specified value? Go to Step 3 Go to step 8
Engine Engine Controls - 7.4L 6-2751
Fuel System Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition for 10 seconds with the
A/C OFF.
2. Turn ON the ignition leaving the engine OFF. The
fuel pump should operate for 2 seconds. SFI -
3 3. Monitor the fuel pressure after the pump stops 385-430 kPa
running. The pressure may vary a few pounds then (56-62 psi)
the pressure should stabilize and hold steady.
Does the fuel pressure hold steady within the
specified value? Go to Step 5 Go to Step 4
1. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
Caution: Place a dry chemical (Class B) fire
extinguisher near work area before attempting
any On-Vehicle Service.
Caution: Provide proper ventilation when working
with fuel in enclosed areas where fuel vapors can
collect The lack of adequate ventilation may
result in personal injury.
2. Disconnect the fuel filter.
3. Drain any remaining fuel from the fuel pipes into an
approved gasoline container.
4. Install the J 42873-1 3/8 Fuel Feed Pipe Shutoff
Valve in the place of the fuel filter. SFI -
4 5. Open the valve on the fuel pipe shut-off adapter. 385-430 kPa
6. Turn OFF the ignition for 10 seconds with the (56-62 psi)
A/C OFF.
7. Turn ON the ignition leaving the engine OFF.
8. Check for any leaks at the fuel shut-off
adapter fittings.
9. Start the engine and let idle for 30 seconds.
10. Turn OFF the ignition for 10 seconds with the
A/C OFF.
11. Turn ON the ignition leaving the engine OFF.
12. Wait for the fuel pressure to build.
13. Close the valve in the fuel feed pipe shut-off. The
pressure should remain constant.
Does the fuel pressure remain constant within the
specified value? Go to Step 12 Go to Step 6
Is the fuel pressure suspected of dropping-off during
5 —
acceleration, cruise, or hard cornering? Go to Step 27 Go to Step 26
Inspect the fuel feed line between the shut-off adapter and
6 the engine fuel pipes. —
Was a problem found? Go to Step 25 Go to Step 7
6-2752 Engine Controls - 7.4L Engine
Fuel System Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Open the valve in the fuel feed pipe shut-off adapter.
2. Releive the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
Caution: Place a dry chemical (Class B) fire
extinguisher near work area before attempting any
On-Vehicle Service.
Caution: Provide proper ventilation when working with
fuel in enclosed areas where fuel vapors can collect
The lack of adequate ventilation may result in
personal injury.
3. Disconnect the fuel return pipe union located near
the fuel filter.
4. Drain any remaining fuel from the fuel pipes into an
approved gasoline container.
5. Install the J 42873-2 5/16 Fuel Return Pipe Shutoff
7 Valve in the place of the fuel return pipe union. —
6. Open the valve in the fuel return pipe
shut-off adapter.
7. Turn OFF the ignition for 10 seconds with the
A/C OFF.
8. Turn ON the ignition leaving the engine OFF.
9. Check for any leaks at the fuel shut-off
adapter fittings.
10. Start the engine and let idle for 30 seconds.
11. Turn OFF the ignition for 10 seconds with the
A/C OFF.
12. Turn ON the ignition leaving the engine OFF.
13. Wait for the fuel pressure to build.
14. Close the valve in the shut-off adapter that is
connected to the fuel return pipe.
Does the fuel pressure remain constant? Go to Step 22 Go to Step 29
1. Turn OFF the ignition for 10 seconds with the
A/C OFF.
2. Turn ON the ignition leaving the engine OFF. The
fuel pump should operate for 2 seconds and then
8 turn off. —
3. Monitor the fuel pressure after fuel pump
stops running.
Is the fuel pressure present? Go to Step 13 Go to Step 9
1. Turn OFF the ignition.
2. Connect a 10 amp fused jumper wire from B+ to the
9 fuel pump test terminal. — Go to Fuel
3. Listen for the fuel pump running. Pump Relay
Does the fuel pump run? Go to Step 10 Circuit Diagnosis
Check for the following conditions:
• Plugged in-line fuel filter
10 • Plugged fuel pump strainer —
• Restricted fuel line
Was a problem found? Go to Step 11 Go to Step 12
Repair or replace as necessary.
11 — —
Is the action complete? Go to Step 30
Engine Engine Controls - 7.4L 6-2753
Fuel System Diagnosis (cont’d)
Step Action Value(s) Yes No
Replace the modular fuel sender. Refer to Fuel Pump
12 Replacement (Main). — —

Is the action complete? Go to Step 30

1. Turn OFF the ignition for 10 seconds with the
A/C OFF.
2. Turn ON the ignition leaving the engine OFF. The SFI - 430 kPa
13 fuel pump should operate for 2 seconds. (62 psi)
3. Monitor the fuel pressure.
Is the fuel pressure above the specified value? Go to Step 14 Go to Step 15
1. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
Caution: Place a dry chemical (Class B) fire
extinguisher near work area before attempting
any On-Vehicle Service.
Caution: Provide proper ventilation when working
with fuel in enclosed areas where fuel vapors can
collect The lack of adequate ventilation may SFI -
14 result in personal injury. 385-430 kPa
(56-62 psi)
2. Disconnect the engine compartment fuel return line
3. Attach a flex hose to the fuel return line.
4. Insert the other end into an approved
gasoline container.
5. Monitor the fuel pressure within 2 seconds after the
ignition is turned ON.
Is the fuel pressure within the specified value? Go to Step 16 Go to Step 17
1. Turn OFF the ignition for 10 seconds with the
A/C OFF.
2. Turn ON the ignition leaving the engine OFF. The SFI - 385 kPa
15 fuel pump should operate for 2 seconds. (56 psi)
3. Monitor the fuel pressure.
Is the fuel pressure below the specified value Go to Step 19 Go to Step 30
Locate and correct the restriction in the fuel return line.
16 —
Is the action complete? Go to Step 30 Go to Step 17
Visually and physically inspect the engine fuel return outlet
17 pipe (where the fuel line was disconnected) for restriction. —
Was a restriction found? Go to Step 18 Go to Step 22
Replace the engine fuel pipes. Refer to Fuel Hose/Pipes
18 Replacement (Engine Compartment). — —
Is the action complete? Go to Step 30
Perform the following items:
• Check for a restricted fuel line.
19 —
• Check for a restricted in-line fuel filter
Was a problem found? Go to Step 20 Go to Step 21
Repair or replace as necessary the following items:
• The restricted fuel line
20 — —
• The restricted fuel line filter
Is the action complete? Go to Step 30
6-2754 Engine Controls - 7.4L Engine
Fuel System Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
Caution: Place a dry chemical (Class B) fire
extinguisher near work area before attempting
any On-Vehicle Service.
Caution: Provide proper ventilation when working
with fuel in enclosed areas where fuel vapors can
collect. The lack of adequate ventilation may
result in personal injury.
2. Disconnect the fuel return pipe union located near
the fuel filter.
3. Drain any remaining fuel from the fuel pipes into an
approved gasoline container.
4. Install the J 42873-2 5/16 Fuel Return Pipe Shutoff
Valve in the place of the fuel return pipe union.
SFI - 430 kPa
21 5. Open the valve on the fuel return pipe
(62 psi)
shut-off adapter.
6. Turn OFF the ignition for 10 seconds with the
A/C OFF.
7. Turn ON the ignition leaving the engine OFF.
8. Bleed the air out of the fuel pressure gauge into an
approved gasoline container.
9. Connect a 10 amp fused jumper wire from B+ to the
fuel pump test terminal.
Notice: Do not allow the fuel pressure to exceed
517 kPa (75 psi). Excessive pressure may damage
the fuel pressure regulator.
10. Slowly close the valve on the fuel return pipe shut-off
adapter. The pressure should rise above the
specified value.
Does the fuel pressure rise above the specified value? Go to Step 22 Go to Step 23
Replace the fuel pressure regulator. Refer to Fuel Pressure
22 Regulator Replacement (SFI). — —
Is the action complete? Go to Step 30
Perform the following items:
• Check for low fuel pump voltage due to high
resistance connections
• Check for high fuel pump voltage due to internal
pump binding
23 —
• Check for a poor fuel pump ground
• Check for a partially restricted fuel pump strainer
• Check for an incorrect fuel pump
• Check for a faulty fuel pump
Was a problem found? Go to Step 24 Go to Step 12
Repair or replace as necessary.
24 — —
Is the action complete? Go to Step 30
Replace the fuel feed line.
25 — —
Is the action complete? Go to Step 30
Engine Engine Controls - 7.4L 6-2755
Fuel System Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Start the engine.
2. Idle until the engine reaches the normal
operating temperature.
3. Open the throttle quickly. SFI -
26 385-430 kPa
4. Monitor the fuel pressure. (56-62 psi)
5. The fuel pressure should approach the top of the
specified range. Go to Driveability
Does the fuel pressure rise quickly? Symptoms Go to Step 27
Visually and physically inspect the following items for
a restriction:
1. The in-line fuel filter.
2. The fuel feed pipe.
3. The fuel pump strainer must not be damaged
27 or mispositioned. —
4. The fuel pump flex pipe for leaks.
5. Verify the fuel pump is the correct fuel pump for
this vehicle.
6. The fuel pump electrical wiring for high resistance.
Was a problem found in any of these areas? Go to Step 28 Go to Step 12
Repair the problem as necessary.
28 — —
Is the action complete? Go to Step 30
Locate and replace any leaking injector(s). Go to
29 Is the action complete? — Fuel Injector
Go to Step 30 Balance Test
Use the scan tool in order to display the Capture
Information and the Review Capture Information function. Go to
30 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
6-2756 Engine Controls - 7.4L
Fuel Metering System
The fuel pump relay is mounted in the underhood
electrical center located in the engine compartment.
For diagnosis of the fuel pump relay circuit, refer to
Fuel Pump Relay Circuit Diagnosis.The fuel pump
and engine oil pressure indicator switch is mounted
in the engine block near the distributor. For diagnosis
of the fuel pump circuit, refer to Fuel Pump Relay
Circuit Diagnosis. Some failures of this system will
result in an Engine Cranks But Will Not Run
symptom. This table determines if the problem is
caused by the ignition system, VCM, or fuel
pump circuit.
This includes the fuel injector poppet assembly, fuel
pressure regulator, fuel pump and fuel pump relay.
The fuel system wiring schematic diagram is covered
in Fuel Pump Circuit Diagnosis.
If a problem occurs in the fuel metering system, it
usually results in either a rich or lean exhaust
condition. This condition is sensed by the H02S.
This condition causes the VCM to change the fuel
calculation (injector pulse width). The change made
to the fuel calculation is indicated by a change in the
short and long term fuel trim values which can be
monitored by a scan tool. A momentary change to
the fuel calculation is indicated by the short term fuel
trim value, while a prolonged change is indicated by
the long term fuel trim value. Average fuel trim
values will measure around 128. The averages may
vary slightly from engine to engine.
Im portant: When using a scan too! to observe fuel
trim values, remember that if the system is in
control, no action is required unless a driveability
symptom is present.
Listed below are examples of lean and rich H02S
signals with the system in control and out of control.
• A momentary lean H02S signal (system is in
control) will appear on the scan tool as the
following items:
- Short term fuel trim value above 128
(adding fuel).
- Long term fuel trim value around 128.
• A prolonged lean H02S signal (system is in
control) will appear on the scan tool as the
following items:
- Short term fuel trim value around 128.
- Long term fuel trim value above 128
(added fuel).
• A prolonged lean H02S signal (system is out of
control) will appear on the scan tool as the
following items:
- Short term fuel trim value well above 128
(adding fuel).
- Long term fuel trim value well above 128
(added fuel).
Engine
If both fuel trim values are fixed well above 128, see
DTC P0131 for items which can cause a lean
system. Refer to DTC P0131 H02S Circuit Low
Voltage Bankl Sensorl.
• A momentary rich H02S signal (system is in
control) will appear on the scan tool as the
following items:
- Short term fuel trim value less than 128
(reducing fuel).
- Long term fuel trim value around 128.
• A prolonged rich H02S signal (system is in
control) will appear on the scan tool as the
following items:
- Short term fuel trim value around 128.
- Long term fuel trim value less than 128
(reduced fuel).
• A prolonged rich H02S signal (system is out of
control) will appear on the scan tool as the
following items:
- Short term fuel trim value much less than
128 (reducing fuel).
- Long term fuel trim value much less than
128 (reduced fuel).
If the fuel trim values are fixed well below 128, see
DTC P0132 for items which can cause the system to
run rich. Refer to DTC P0132 H02S Circuit High
Voltage B ankl Sensorl.
If a driveability symptom exists, refer to the particular
symptom in Symptoms, for additional items to check.
Fuel Control
Fuel delivery is controlled by the control
module system.
The diagnosis of fuel control starts with Engine
Cranks But Will Not Run. This table will test the fuel
system to determine if there is a problem. Refer to
Engine Cranks but Does Not Run.
Fuel Injector
Testing of the fuel injector circuit is located in the
Fuel Injector Circuit Diagnosis Table.
A fuel injector which does not open may cause a
no-start condition. An injector which is stuck partially
open could cause loss of pressure after sitting,
resulting in extended crank times on some engines.
Also, dieseling could occur because some fuel
could be delivered to the engine after the key is
turned OFF.
Pressure Regulator
If the pressure regulator supplies pressure which is
too low, poor performance could result. If the
pressure is too high, exhaust odor may result.
Engine
Idle Air Control (IAC)
The diagnosis of Idle Air Control (IAC) can be found
in Idle Air Control System Diagnosis.
If the IAC valve is disconnected or connected when
the engine is running, the idle RPM may be wrong.
The IAC valve may be reset by turning the ignition
switch ON for 10 seconds, OFF for 5 seconds.
The IAC valve affects the idle characteristics of the
engine as well as throttle follow-up to compensation
for sudden throttle closing. If it is open fully too
much air will be allowed in the manifold and idle
speed will be high. If it is stuck closed, too little air
will be allowed in the manifold, and idle speed will
be too low. If it is stuck part way open, the idle
may be rough, and will not respond to engine
load changes.
Fuel Pump Circuit
The relay has a terminal to test the fuel pump
operation which is a separate terminal located near
the fusible link cluster. By applying voltage at this
terminal, it can be determined if the fuel pump will
operate. This terminal will also prime the fuel line to
the fuel injection unit.
For diagnosis of the Fuel Pump Circuit refer to Fuel
Pump Relay Circuit Diagnosis.
An inoperative fuel pump will cause a no start
condition. A fuel pump which does not provide
enough pressure can result in poor performance.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold.
The fuel pump oil pressure switch will turn ON the
fuel pump as soon as oil pressure reaches
about 28 kPa (4 psi).
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
Low coolant temperature produces a high resistance
(100,000 ohms at -40*C/-40*F) while high
temperature causes low resistance (70 ohms
at 130 *C/266 * F).
The VCM supplies a 5V signal to the engine coolant
temperature sensor through a resistor in the VCM
and measures the voltage. The voltage will be high
when the engine is cold, and low when the engine is
hot. By measuring the voltage, the VCM calculates
the engine coolant temperature. Engine coolant
temperature affects most systems the VCM controls.
The scan tool displays engine coolant temperature in
degrees. After engine start-up, the temperature
should rise steadily to about 90 *C (194*F) then
stabilize when thermostat opens. If the engine has
not been run for several hours (overnight), the
engine coolant temperature and intake air
temperature displays should be close to each other.
A fault in the engine coolant sensor circuit should
set DTC P0117 or DTC P0118.
Engine Controls - 7.4L 6-2757
Intake Air Temperature (IAT) Sensor
The Intake Air Temperature (IAT) sensor is a
thermistor which changes value based on the
temperature of air entering the engine. Low
temperature produces a high resistance
(100,000 ohms at -40 *C/-40 * F), while high
temperature causes low resistance (70 ohms at
130’ C/266 *F). The VCM supplies a 5V signal to the
sensor through a resistor in the VCM and measures
the voltage. The voltage will be high when the
incoming air is cold, and low when the air is hot. By
measuring the voltage, the VCM calculates the
incoming air temperature.
The IAT sensor signal is used to adjust spark timing
according to incoming air density.
The scan tool displays temperature of the air
entering the engine, which should read close to
ambient air temperature when engine is cold, and
rise as underhood temperature increases. If the
engine has not been run for several hours
(overnight) the IAT sensor temperature and engine
coolant temperature should read close to each other.
A failure in the IAT sensor circuit should set
DTC P0112 or DTC P0113.
Manifold Absolute Pressure (MAP) Sensor
DTC P0107 or DTC P0108 indicates a failure in the
MAP sensor circuit, which may effect fuel metering.
Heated Oxygen Sensor (H02S 1)
The exhaust Heated Oxygen Sensor (H02S 1) is
mounted in the exhaust manifold where it can
monitor the oxygen content of the exhaust
gas stream.
The oxygen content in the exhaust reacts with the
sensor to produce voltage output. This voltage
should constantly fluctuate from approximately
100 mV (high oxygen content - lean mixture) to
900 mV (low oxygen content - rich mixture). The
heated oxygen sensor voltage can be monitored with
a Scan tool.
By monitoring the voltage output of the heated
oxygen sensor, the VCM calculates what fuel mixture
command to give to the injector (lean mixture-low
H02S 1 voltage=rich command, rich mixture-high
H02S 1 voltage=lean command).
The heated oxygen sensor circuit, if open, should set
a DTC P0134 and the Scan tool will display a
constant voltage between 350-550 mV. A constant
voltage below 250 mV in the sensor circuit should
set DTC P0131, while a constant voltage above
750 mV in the circuit should set DTC P0132.
DTC P0131 and DTC P0132 could also be set as a
result of fuel system problems.
6-2758 Engine Controls - 7.4L
H02S 2 (Catalyst Monitor)
In order to control emissions of Hydrocarbons (HC),
Carbon Monoxide (CO) and Oxides of Nitrogen
(NOx), a three-way catalytic converter is used. The
catalyst within the converter promotes a chemical
reaction which oxidizes the HC and CO present in
the exhaust gas, converting them into harmless
water vapor and carbon dioxide. The catalyst also
reduces NOx, converting it to nitrogen. The VCM has
the capability to monitor this process using H02S 2.
H02S 2, located in the exhaust stream past the
three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst; this in turn indicates the catalyst
[prime ]s ability to convert exhaust emissions
effectively. A problem with the H02S 2 electrical
circuits should set DTC P0137, P0138 or P0140,
depending on the specific condition. If the catalyst is
functioning correctly, the H02S 2 signal will be far
less active than that produced by H02S 1. If a
problem exists which causes the VCM to detect
excessive H02S 2 activity outside of an acceptable
range for an extended period of time, the VCM will
set DTC P0420, indicating that the three-way
catalytic converter[prime ]s oxygen storage capacity
is below a threshold considered acceptable.
Throttle Position Sensor
The Throttle Position (TP) sensor is a potentiometer
connected to the throttle shaft on the throttle body.
By monitoring the voltage on the signal line, the
VCM calculates throttle position. As the throttle valve
angle is changed (accelerator pedal moved), the TP
sensor signal also changes.
At a closed throttle position, the output of the TP
sensor is low. As the throttle valve opens, the output
increases so that at Wide Open Throttle (WOT), the
output voltage should be above 4V.
The VCM calculates fuel delivery based on throttle
valve angle (driver demand). A broken or loose TP
sensor may cause intermittent bursts of fuel from an
injector and unstable idle because the VCM thinks
the throttle is moving. A problem in the TP sensor
5V reference or signal circuits should set either a
DTC P0122 or DTC P0123. A problem with the TP
sensor ground circuit may set DTCs P0123 and
P0117. Once a DTC is set, the VCM will use an
artificial default value based on mass air flow for TP
sensor and some vehicle performance will return. A
high idle may result when either DTC P0122 or
DTC P0123 is set.
TP Sensor Output
This check should be performed when TP sensor
attaching parts have been replaced. A scan tool can
be used to read the TP signai output voltage.
1. Connect digital voltmeter J 39200 from TP
sensor connector terminal B (BLK wire) to
terminal C (DK Blue wire). Jumpers for terminal
access can be made using terminals 1214836
and 12014837.
Engine
2. With ignition ON, engine stopped, the TP signal
voltage should be less than 1.25V if more than
1.25V verify free throttle movement. If still more
than 1.25V, replace TP sensor.
3. Remove the voltmeter and jumpers, reconnect
the TP sensor connector to the sensor.
Idle Speed
When there is a problem with the idle refer to Idle
Air Control System Diagnosis.
• System too lean (High air/fuel ratio) - Idle
speed may be too high or too low. Engine
speed may vary up and down, disconnecting
the IAC valve has no effect.
• System too rich (Low air/fuel ratio) - Idle speed
too low. Scan counts usually above 80. System
obviously rich and may exhibit black exhaust
smoke. Scan tool and/or voltmeter will read a
Heated Oxygen Sensor (H02S) signal fixed
above 800 mV (.8V).
4X Crankshaft Position Sensor
The scan tool scan tool displays crankshaft position
sensor data as engine speed (RPM). An error in the
crankshaft position sensor circuit should set a
DTC P0336, P0337, P0338, or a P0339. The
crankshaft position sensor provides a signal through
the ignition control module which the VCM uses as
reference to calculate RPM and crankshaft position.
Camshaft Position Sensor
The scan tool scan tool will display camshaft position
sensor data as a 0 and 1 as the sensor pulses, the
scan data will switch from 0 to 1. All camshaft
position sensor data should be checked at idle. An
error in the camshaft position sensor circuit should
set a DTC P0340. The camshaft position sensor
sends a signal to the VCM which uses it as a sync
pulse to trigger the injectors in proper sequence.
Cam Signal
The VCM uses this signal to determine the position
of the #1 piston during its power stroke. This signal
is used by the VCM to calculate fuel injection
mode of operation. A loss of this signal will set
DTC P0340.
If the cam signal is lost while the engine is running,
the fuel injection system will shift to a calculated fuel
injection mode based on the last fuel injection pulse,
and the engine will continue to run. The engine can
be restarted and will run in the calculated mode as
long as the fault is present.
Engine_____________________________________ Engine Controls - 7.4L 6-2759
DTC P0101 Mass Air Flow System Performance
|hcXIn RunAndStart]
r ------ .
■*Underhood
I Power
ion K7 Jk ENG1
Distribution 1Fuse-Relay
I Cell 10
lbC F use15
20A
JCenter

FuseBlock PNK 539

Details
CeH11 \ VCM
\
H I Cl =BLU
C2=RED
C3=CLEAR
PNK 539 PNK 539 C4=BLK
CA ▼
Mass Air flow Ignition EVAPCanister
Positive PurgeValve
(MAF) Sensor Voltage MAF
Sensor
Ground Signal
B
BLK/WHT 451

YEL 492

28 C2
Ground r “ Vehicle
Distribution
Cell 14 1 Sensor 1 Control
I signal | Module A
BLK/WHT 451 l ---------- j (VCM)

190379
Circuit Description • The system Voltage is between 10-17 volts.
The Mass Air Flow (MAF) sensor measures the • The Canister Purge Duty Cycle is less
amount of air entering the engine during a given than 99.6%.
time. The VCM uses the mass air flow information • The change in throttle position is less
for the fuel delivery calculations. A large quantity of than 3.9%.
air entering the engine indicates an acceleration or
• The EGR duty cycle is no more than 89.9%.
high load situation. A small quantity of air indicates a
deceleration or an idle situation. • The EGR Pintle Position is no more
than 89.9%.
The MAF sensor produces a frequency signal which
can be monitored by using a scan tool. The • The MAP is no more than 90 kPa.
frequency varies within a range of around 5 to 7 g/s • The throttle position is no more than 89.8%.
at idle to approximately 125 g/s at the maximum • The above conditions met for greater than
engine load. 2 seconds.
Conditions for Setting the DTC Action Taken When the DTC Sets
The following conditions will set the DTC: • The VCM illuminates the Malfunction Indicator
• The engine is running. Lamp (MIL) the first time the fault is detected.
• No TP sensor DTCs. • The VCM calculates an airflow value based on
• No MAP sensor DTCs. the idle air control (IAC) valve position, the
throttle position, the engine speed, and the
. No EVAP DTCs.
barometric pressure.
• EGR DTC P0401 not active. • The VCM will store the conditions which were
• MAF DTCs P0102 or P0103 not active. present when the DTC set as Freeze Frame
and the Fail Records data.
6-2760 Engine Controls - 7.4L
Conditions for Clearing the MIUDTC
. The VCM turns the MIL OFF after 3
consecutive drive trips when the test has Run
and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 7 0 ‘ C
(160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Check for the following conditions:
• A skewed or stuck TP sensor. A faulty TP
sensor or TP sensor circuit can cause the VCM
to incorrectly calculate the predicted mass air
flow value. Observe the Throttle Angle with the
throttle closed. If the Throttle Angle reading is
not 0%, check for the following conditions:
- The throttle plate sticking or excessive
deposits on the throttle plate or the
throttle bore
- The TP sensor signal circuit shorted
to voltage
- A Poor connection or high resistance in the
TP sensor ground circuit.
If none of the above conditions are noted
and the Throttle Angle reading at closed
throttle is not 0%, replace the TP sensor.
• Inspect harness connectors for the
following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connection
• A misrouted harness. Inspect the MAF sensor
harness in order to ensure that it is not routed
too close to high voltage wires such as spark
plug leads.
DTC P0101 Mass Air Flow System Performance
Step Action
Important: Before clearing the DTCs, record Freeze
Frame and the Failure Records for reference with a scan
tool. This data will be lost when the Clear DTC
1 Information function is used.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Start the engine.
2. With the engine idling, monitor the MAF reading on
2 2 g/s
the scan tool.
Is the MAF reading below the specified value?
Engine
• A damaged harness. Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the scan tool while moving the
connectors and the wiring harnesses related to
the MAF sensor. A change in the display
indicates the location of the fault.
• A plugged intake air duct or dirty air filter
element. A wide open throttle acceleration from
a stop should cause the Mass Air Flow
displayed on a scan tool to increase from about
4-7 gm/s at idle to 100 gm/s or greater at the
time of the 1-2 shift. If not, check for
a restriction.
• Skewed MAP sensor. A skewed MAP sensor
can cause the BARO reading to be incorrectly
calculated. In order to check the MAP sensor,
compare the BARO reading on the vehicle
being diagnosed to the BARO reading on a
normally operating vehicle. If a large difference
is noted (over 8 kPa), replace the MAP sensor.
Refer to MAP Sensor Replacement.
Test Description
The numbers below refer to step numbers on the
diagnostic table.
2. This step verifies that the problem is present
at idle.
6. A voltage reading of less than 4 or over 6 volts
at the MAF sensor signal circuit indicates a
fault in the wiring or a poor connection
7. This step verifies that the ignition feed voltage
and a good ground are available at the
MAF sensor.
11. This step determines if the fuse is open. If the
fuse is open, locate and repair the short to
ground in the Ignition Positive Voltage circuit.
Refer to Fuse Block Details in Section 8A.
15. This vehicle is equipped with a VCM. The VCM
utilizes an Electrically Erasable Programmable
Read Only Memory (EEPROM). When the VCM
is being replaced, reprogram the VCM. Refer to
VCM Replacement/Programming VCM
Replacement/Programming.
Value(s) Yes No
Go to Powertrain
—
OBD System
Check (OBD
Go to Step 2 System Check)
Go to Step 4 Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2761
DTC P0101 Mass Air Flow System Performance (cont’d)
Step Action Value(s) Yes No
1. Turn ON the ignition leaving the engine OFF.
2. Review the scan tool Failure Records data.
3. Record the scan tool Failure Records data.
4. Operate vehicle within the Failure Records
3 conditions as noted. —

5. Monitor the Specific DTC information for DTC P0102

with a scan tool.
Does the scan tool indicate DTC P0102 Failed Go to
This Ignition? Go to Step 4 Diagnostic Aids
Inspect the MAF Ignition Positive Voltage Fuse.
4 —
Is the fuse open? Go to Sep 11 Go to Step 5
1. Check for the following conditions:
• Objects blocking the MAF sensor inlet screen
• Vacuum leaks in the:
- Intake manifold
- Throttle body
- EGR valve flange and pipes
5 - MAP sensor seal —
- EVAP canister purge valve seal
- Fuel meter body seal
• The crankcase ventilation valve for being faulty,
missing or incorrectly installed.
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 16 Go to Step 6
1. Turn OFF the ignition.
2. Disconnect the MAF sensor connector.
3. Turn ON the ignition leaving the engine OFF.
6 5.0 V
4. Measure the voltage between the MAF signal circuit
and battery ground with a J 39200 DMM.
Is the voltage near the specified value? Go to Step 7 Go to Step 10
Connect a test lamp between the MAF sensor
ignition feed and ground circuits at the MAF sensor
7 harness connector. —
Is the test lamp ON? Go to Step 9 Go to Step 8
Connect a test lamp between the MAF sensor ignition
8 feed circuit and the battery ground. —
Is the test lamp ON? Go to Step 12 Go to Step 13
Check for a poor connection at the MAF sensor.
If a poor connection is found, repair the circuit as
9 —
necessary. Refer to Wiring Repairs in Electrical Diagnosis.
Was a poor connection found? Go to Step 16 Go to Step 14
1. Check the MAF signal circuit between the VCM and
the MAF sensor for an open, short to ground, short
to the MAF ground circuit, or short to voltage.
10 2. If the MAF signal circuit is open or shorted, repair it —
as necessary. Refer to Wiring Repairs in
Electrical Diagnosis.
Was the MAF signal circuit open or shorted? Go to Step 16 Go to Step 15
6-2762 Engine Controls - 7.4L________________________________________________ Engine
DTC P0101 Mass Air Flow System Performance (cont’d)
Step Action Value(s) Yes No
1. Check for a short to ground in the MAF Ignition
Positive Voltage circuit. Repair as necessary.
11 — —
2. Replace the open fuse.
Is the action complete? Go to Step 16
1. Locate the open in the ground circuit to the
MAF sensor.
2. Repair the open in the ground circuit to the
12 — —
MAF sensor. Refer to Wiring Repairs in
Electrical Diagnosis.
Is the action complete? Go to Step 16
1. Locate the open in the ignition feed circuit to the
MAF sensor.
2. Repair the open in the ignition feed circuit to the
13 — —
MAF sensor. Refer to Wiring Repairs in
Electrical Diagnosis.
Is the action complete? Go to Step 16
Replace the MAF sensor. Refer to MAF
14 Sensor Replacement. — —
Is the action complete? Go to Step 16
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
15 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 16
1. Select the DTC and the Clear DTC Information
functions with a scan tool.
2. Start the Engine.
3. Allow the engine to Idle until the normal operating
temperature is reached.
16 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 17 Go to Step 2
Display the Capture Info and the Review Capture Info
functions with a scan tool. Go to
17 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC tables System OK
Engine________________________________________________ Engine Controls - 7.4L 6-2763

DTC P0102 MAF Sensor Circuit Low Frequency (P0102 MAF Low)

|H o l In Run A n d S tart]

Pow er
nUnderhood
Distribution ENG 1 'Fuse-Relay
C e ll 10 Fuse 15 'Center
20 A
L

F us e B lock PNK 539

D etails
C ell 11 VCM
C1 = B LU
C 2 = RED
C 3 = CLEAR
PNK 539 PNK 539 C 4 = BLK

CA ▼
EV AP C a nis ter
Mass Air flow Ignition P u rg e V a lve
(MAF) Sensor P o sitive
V o lta g e
MAF
S e n so r
G ro u n d Signal

B
BLK/WHT 451

YEL 492

1 28 C2
G ro u n d
D istribution l MAF , * ",
C ell H ' Sensor ' C o n tro l
I S ig n a l | M o d u le A
BLK/WHT 451 u -----------------j (V C M )

190379

Circuit Description • Above conditions present for greater than

The Mass Air Flow (MAF) sensor measures the 2 seconds.
amount of air entering the engine during a given • This DTC sets if the signal from the MAF senor
time. The VCM uses the Mass Air Flow information measures below the possible range of a
for fuel delivery calculations. A large quantity of air normally operating MAF sensor.
entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates Action Taken When the DTC Sets
deceleration or idle. • The VCM illuminates the Malfunction Indicator
The MAF sensor produces a frequency signal which Lamp (MIL) the first time the fault is detected.
can be monitored with a scan tool. The frequency • The VCM calculates an airflow value based on
varies within a range of around 5 to 7 g/s at idle to the Idle Air Control (IAC) valve position, throttle
near 125 g/s at maximum engine load. position, engine speed and barometric pressure.
• The VCM stores the conditions which were
Conditions for Setting the DTC
present when the DTC set as Freeze Frame
Power Up Test and the Fail Records data.
• The engine is OFF.
Conditions for Clearing the MIL7DTC
• The ignition is ON for 2 seconds.
• The VCM turns the MIL OFF after 3
• MAF sensor is no more than 60Hz. consecutive drive trips when the test has Run
Low Frequency Test and Passed and not Failed.
• The engine speed is greater than or equal to • A history DTC will clear if no fault conditions
300 RPM. have been detected for 40 warm-up cycles
• Engine run time is greater than 0.2 seconds. (coolant temperature has risen 22 *C (40 *F)
• System voltage is greater than 10 volts. from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
• Throttle Position is less than 89.8%. (160 * F) during the same ignition cycle).
• MAF signal frequency is no more than 300Hz.. • Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
6-2764 Engine Controls - 7.4L
Diagnostic Aids
Check for the following conditions:
• A poor connection at the VCM. Inspect harness
connectors for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connection
• A misrouted harness. Inspect the MAF sensor
harness in order to ensure that it is not routed
too close to high voltage wires such as spark
plug leads.
• A damaged harness. Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the scan tool while moving the
connectors and the wiring harnesses related to
the MAF sensor. A change in the display
indicates the location of the fault.
• A plugged intake air duct or filter element. A
wide open throttle acceleration from a stop
should cause the Mass Air Flow displayed on a
scan tool to increase from about 4-7 g/s at idle
to 100 g/s or greater at the time of the 1-2
shift. If not, check for a restriction.
Engine
Test Description
The numbers below refer to step numbers on the
diagnostic table.
2. This step verifies that the problem is present
at idle.
6. A voltage reading of less than 4 or over 6 volts
at the MAF sensor signal circuit indicates a
fault in the wiring or a poor connection
7. This step verifies that the ignition feed voltage
and a good ground are available at the
MAF sensor.
11. This step determines if the fuse is open. If the
fuse is open, locate and repair the short to
ground in the Ignition Positive Voltage circuit.
Refer to Fuse Block Details in Section 8A.
15. This vehicle is equipped with a VCM. The VCM
utilizes an Electricity Erasable Programmable
Read Only Memory (EEPROM). When the VCM
is being replaced, reprogram the VCM. Refer to
VCM Replacement/Programming.

DTC P0102 MAF Sensor Circuit Low Frequency (P0102 MAF Low)
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function. OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Start the engine.
2. With the engine idling, monitor the MAF reading on
2 2 g/s
the scan tool.
Is the MAF reading below the specified value? Go to Step 4 Go to Step 3
1. Turn ON the ignition leaving the engine OFF.
2. Review the scan tool Failure Records data.
3. Record the scan tool Failure Records data.
4. Operate vehicle within the Failure Records
3 conditions as noted. —
5. Using a scan tool, monitor the Specific DTC
information for DTC P0102.
Does the scan tool indicate DTC P0102 failed Go to
this ignition? Go to Step 4 Diagnostic Aids
Inspect the MAF Ignition Positive Voltage Fuse.
4 —
Is the fuse open? Go to Step 11 Go to Step 5
Engine________________________________________________ Engine Controls - 7.4L 6-2765
DTC P0102 MAF Sensor Circuit Low Frequency (P0102 MAF Low) (cont’d)
Step Action Value(s) Yes No
1. Check for the following conditions:
• Objects blocking the MAF sensor inlet screen.
• Crankcase ventilation valve faulty, missing, or
incorrectly installed.
• Vacuum leaks in the:
• Throttle body
5 —
• EGR valve flange and pipes
• MAP sensor seal
• EVAP canister purge valve seal
• Fuel meter body seal
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 16 Go to Step 6
1. Turn OFF the ignition.
2. Disconnect the MAF sensor connector.
3. Turn ON the ignition leaving the engine OFF.
6 5.0 V
4. Using a DVM, measure the voltage between the
MAF signal circuit and battery ground.
Is the voltage near the specified value? Go to Step 7 Go to Step 10
Connect a test lamp between the MAF sensor
ignition feed and ground circuits at the MAF sensor
7 harness connector. —

Is the test lamp ON? Go to Step 9 Go to Step 8

Connect a test lamp between the MAF sensor ignition
8 feed circuit and the battery ground. —
Is the test lamp ON? Go to Step 12 Go to Step 13
Check for a poor connection at the MAF sensor.
If a poor connection is found, replace faulty terminals.
9 —
Refer to Wiring Repairs in Engine Electrical.
Was a poor connection found? Go to Step 16 Go to Step 14
1. Check the MAF signal circuit between the VCM and
the MAF sensor for an open, short to ground, short
to the MAF ground circuit, or short to voltage.
10 2. If the MAF signal circuit is open or shorted, repair —
it as necessary. Refer to Wiring Repairs in
Engine Electrical.
Was the MAF signal circuit open or shorted? Go to Step 16 Go to Step 15
1. Check for a short to ground in the MAF Ignition
Positive Voltage circuit. Repair as necessary.
11 — —
2. Replace the open fuse.
Is the action complete? Go to Step 16
1. Locate the open in the ground circuit to the
MAF sensor.
12 2. Repair the open in the ground circuit to the MAF — —
sensor. Refer to Wiring Repairs in Engine Electrical.
Is the action complete? Go to Step 16
1. Locate the open in the ignition feed circuit to the
MAF sensor.
2. Repair the open in the ignition feed circuit to the —
13 —
MAF sensor. Refer to Wiring Repairs in
Engine Electrical.
Is the action complete? Go to Step 16
6-2766 Engine Controls - 7.4L Engine
DTC P0102 MAF Sensor Circuit Low Frequency (P0102 MAF Low) (cont’d)
Step Action Value(s) Yes No
Replace the MAF sensor. Refer to MAF
14 Sensor Replacement — —
Is the action complete? Go to Step 16
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
15 to Password Learn Procedure.
— —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 16
1. Use the scan tool in order to select the DTC and
the Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to Idle until the normal operating
temperature is reached.
16 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 17 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions.
17 —
Are there any DTCs displayed that have not Go to Applicable
been diagnosed? DTC Tables System OK
Engine________________________________________________ Engine Controls - 7.4L 6-2767

DTC P0103 MAF Sensor Circuit High Frequency (MAF Sensor High)
|Hot In Run And Start!
r ------ . ■*Underhood
I Power
Distribution
ion K7 L ENG 1 'Fuse-Relay
I Cell 10 JCenter
lbC Fuse
20 A
15

Fuse Block PNK 539

Details ■>
Cell 11 \ VCM
\
Cl = BLU
C2 = RED
C3-CLEAR
PNK 539 PNK 539 C4-BLK

CA t
EVAP Canister
Mass Air flow Ignition Purge Valve
(MAF) Sensor Positive
Voltage MAF
Sensor
Ground Signal

B
BLK/WHT 451

YEL 492

28 C2
Ground
Distribution
P "k.7p “ ^ Vehicle
Cell 14 1 Sensor 1 Control
I signal | Module A
BLK/WHT 451 u ---------- j (VCM)

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine during a given
time. The VCM uses the Mass Air Flow information
for the fuel delivery calculations. A large quantity of
air entering the engine indicates an acceleration or a
high load situation, while a small quantity of air
indicates a deceleration or a idle situation.
The MAF sensor produces a frequency signal which
a scan tool can monitor. The frequency varies within
a range of around 5 to 7 g/s at idle to near 125 g/s
at maximum engine load.
Conditions for Setting the DTC
Power Up Test
• The engine is off.
• The ignition is ON for 2 seconds.
• The MAF is greater than or equal to 12000 Hz.
High Frequency Test
• The engine speed is greater than or equal to
300 RPM.
• Engine Run Time is at least 2.0 second.
• System voltage is at least 10 volts.
• Throttle Position is less than 89.8%.
• The MAF sensor is at least 11000 Hz.
• The signal from the MAF sensor is above
the possible range of a normally operating
MAF sensor.
190379
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) the first time the fault is detected.
• The VCM calculates an airflow value based on
the Idle Air Control (IAC) valve position, throttle
position, engine speed and barometric pressure.
• The VCM stores the conditions which were
present when the DTC set as Freeze Frame
and the Fail Records data.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test has Run
and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160' F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
6-2768 Engine Controls - 7.4L
Diagnostic Aids
Check for the following conditions:
• Poor connection at VCM Inspect harness
connectors for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connection
• A misrouted harness. Inspect the MAF sensor
harness in order to ensure that it is not routed
too close to the high voltage wires such as
spark plug leads.
Engine
• A damaged harness. Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the scan tool while moving connectors
and wiring harnesses related to the MAF
sensor. A change in the display will indicate the
location of the fault.
Test Description
The numbers below refer to the step numbers on the
diagnostic table:
2. This step verifies that the problem is present
at idle.
4. A frequency reading with the MAF sensor
connector disconnected indicates an
Electromagnetic Interference (EMI) related fault
or a poor connection.

DTC P0103 MAF Sensor Circuit High Frequency (MAF Sensor High)
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Start the engine.
2. With the engine idling, monitor the MAF reading on
2 20 g/s
the scan tool.
Is the MAF reading above the specified value? Go to Step 4 Go to Step 3
1. Turn ON the ignition leaving the engine OFF.
2. Review the scan tool Failure Records data.
3. Record the scan tool Failure Records data.
4. Operate the vehicle within the Failure Records
3 conditions as noted. —
5. Using a scan tool, monitor the Specific DTC
information for DTC P0103.
Does the scan tool indicate DTC P0103 Failed Go to
This Ignition? Go to Step 4 Diagnostic Aids
1. Turn OFF the ignition.
2. Disconnect the MAF sensor connector.
4 3. Turn ON the ignition allowing the engine to idle. 0.0 g/s
4. Monitor the MAF on the scan tool.
Is the MAF reading at the specified value? Go to Step 5 Go to Step 7
1. Check for a poor connection at the MAF sensor
harness terminals.
2. If a poor connection is found, repair the circuit
5 —
as necessary. Refer to Wiring Repairs in
Engine Electrical.
Was a poor connection found? Go to Step 10 Go to Step 6
Replace the MAF sensor. Refer to MAF
6 Sensor Replacement — —
Is the action complete? Go to Step 10
Engine________________________________________________ Engine Controls - 7.4L 6-2769
DTC P0103 MAF Sensor Circuit High Frequency (MAF Sensor High) (cont’d)
Step Action Value(s) Yes No
1. Perform the following MAF sensor harness checks
for incorrect routing near:
• Secondary ignition wires or coils.
• Other high voltage components (solenoids,
7 —
relays, motors).
2. If an incorrect routing is found, correct the
harness routing.
Was a problem found? Go to Step 10 Go to Step 8
1. Check the MAF signal circuit terminal connections at
the VCM.
8 2. If a poor connection is found, repair as necessary. —
Refer to Wiring Repairs in Engine Electrical.
Was a poor connection found? Go to Step 10 Go to Step 9
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
9 — —
to Password Leam Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
1. Use the scan tool in order to select DTC and the
Clear DTC Information function.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
10 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 11 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function.
11 —
Are there any DTCs displayed that have not Go to Applicable
been diagnosed? DTC Table System OK
6-2770 Engine Controls - 7.4L
DTC P0107 MAP Sensor Circuit Low Voltage
Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in the intake manifold pressure
(vacuum). A 5 volt reference is applied to the sensor
on the 5 volt reference circuit. A variable resistor
moves in relation to the manifold pressure and a
voltage signal is sent back to the VCM on the MAP
signal circuit. This voltage signal varies from
1.0-1.5 volts at closed throttle to 4.0-4.5 volts at wide
open throttle (low vacuum). The VCM utilizes the MAP
signal and throttle position in order to determine the
correct amount of fuel delivered to the engine.
Conditions for Setting the DTC
• No TP sensor DTCs.
• The engine is running.
• Throttle Position is greater than or equal to 0%
when engine speed is less than or equal to
800 RPM.
• Throttle Position greater than or equal to12.5
when engine speed is greater than 800 RPM.
• The MAP voltage is less than 0.25 Volts.
Action Taken When the DTC Sets
The VCM turns ON the MIL when DTC P0107 is
reported and 1 failure has occurred. The VCM
substitutes a calculated value for the MAP
sensor value so an acceptable driving condition
is maintained.
Engine
VCM
Cl =BLU
C2=RED
C3=CLEAR
C4=BLK
IAT and Fuel Tank
Pressure Sensors
and EGR Valve
190358
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
An intermittent open in the MAP sensor signal circuit
or the 5 volt reference circuit will result in a
DTC P1107.
With the ignition ON and the engine OFF, the
manifold pressure is equal to the atmospheric
pressure with the signal voltage high. The VCM
uses this information as an indication of the altitude
of the vehicle.
Comparison of this reading with a known good
vehicle using the same sensor is a good way to
check the accuracy of a suspect sensor. Readings
should be the same ±0.4 volt.
Refer to Intermittent Condition.
Engine
Important: The electrical connector must remain
securely fastened.
Important: After removing the MAP sensor from the
intake manifold, replace the MAP Sensor to intake
manifold seal.
Remove the MAP sensor. Twist the sensor by hand
(only) in order to check for intermittent connections.
Output changes greater than 0.1 volt indicates a bad
connector or connection. If OK, replace sensor.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if DTC P0107 is the result
of a hard failure or an intermittent condition.
Engine Controls - 7.4L 6-2771
3. By jumping the 5 volt reference to the signal
circuit, this step determines if the sensor is at
fault, or if there is a problem with the VCM or
wiring.
4. The scan tool may not display 5 volts. The
important thing is that the VCM recognized the
voltage as more than 4 volts, indicating that the
VCM and MAP signal circuit are OK.
10. The VCM terminals GR 12 and GR 27 are
spliced together inside the VCM. When
checking the 5 volt reference for a short to
ground, both the 5 volt reference circuits and all
the components on the 5 volt reference circuits
must also be checked.

DTC P0107 MAP Sensor Circuit Low Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install the scan tool.
2. Start the engine.
2 3. idle the engine until the operating temperature 0.25 V
is reached.
Does the scan tool display a MAP sensor voltage less
than the specified value? Go to Step 3 Go to Step 5
1. Turn OFF the ignition.
2. Disconnect the MAP sensor electrical connector.
3. Connect a jumper wire between the MAP sensor
5 volt reference circuit and the MAP sensor
3 4.7 V
signal circuit.
4. Turn ON the ignition.
Does the scan tool display a MAP sensor voltage greater
then the specified value? Go to Step 6 Go to Step 4
1. Turn OFF the ignition.
2. Remove the jumper wire.
3. Probe terminal B of the MAP sensor harness with a
4 test lamp to B+. 4.7 V
4. Turn ON the ignition.
Does the scan tool display a MAP sensor voltage greater
the specified value? Go to Step 9 Go to Step 7

The DTC is intermittent. Go to

5 — The Applicable Go to
Are any additional DTCs stored? DTC Table. Diagnostic Aids
Check for a faulty connection at the MAP sensor.
6 —
Was a problem found? Go to Step 12 Go to Step 11
Check for an open MAP sensor signal circuit.
7 —
Was a problem found? Go to Step 12 Go to Step 8
Check the MAP sensor signal circuit for a short to ground.
8 —
Was a problem found? Go to Step 12 Go to Step 13
6-2772 Engine Controls - 7.4L________________________________________________ Engine
DTC P0107 MAP Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Check for an open in the MAP sensor 5 volt
9 reference circuit. —
Was a problem found? Go to Step 12 Go to Step 10
Check for a short to ground in the MAP sensor 5 volt
10 reference circuit. —

Was a problem found? Go to Step 12 Go to Step 13

Replace the MAP sensor. Refer to MAP
11 Sensor Replacement. — —
Is the action complete? Go to Step 14
Repair the circuit as necessary. Refer to Wiring Repairs in
12 Electrical Diagnosis. — —
Is the action complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Use the scan tool in order to Select DTC and the
Clear DTC Information function.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
14 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 15 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
15 —
Are there any DTCs displayed that have not The Applicable
been diagnosed? DTC Table System OK
Engine___________________________________
DTC P0108 MAP Sensor Circuit High Voltage
Vehicle
Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in the intake manifold pressure
(vacuum). A 5 volt reference is applied to the sensor
on the 5 volt reference circuit. A variable resistor
moves in relation to the manifold pressure and a
voltage signal is sent back to the VCM on the MAP
signal circuit. This voltage signal varies from
1.0-1.5 volts at closed throttle to 4.0-4.5 volts at wide
open throttle (low vacuum). The VCM utilizes the MAP
signal and throttle position in order to determine the
correct amount of fuel delivered to the engine.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensor DTCs are set
• Throttle Position i less than or equal to .4%
when engine speed is less than or equal
to 1200 RPM.
• Or the Throttle Position is less than or equal
to19.9% when engine speed is greater
than 1200 RPM.
• MAP is greater than or equal to 4.34 V.
(222 counts).
Engine Controls - 7.4L 6-2773
A
io B P iik
VCM
Cl =BLU
C2=RED
C3=CLEAR
C4=BLK
IATandFuel Tank
-4 PressureSensors
and EGRValve
190358
Action Taken When the DTC Sets
The VCM tuijis ON the MIL when DTC P0108 is
reported ana 1 failure has occurred. The VCM
substitutes a calculated value for the MAP
sensor value so an acceptable driving condition
is maintained.
Conditions for Clearing the MIUDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ' C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
6-2774 Engine Controls - 7.4L
Diagnostic Aids
An intermittent ground in the MAP signal or the
5 volt reference circuit results in a DTC P1106.
With the ignition ON and the engine OFF, the
manifold pressure is equal to atmospheric pressure
with the signal voltage high. The VCM uses this
information as an indication of the vehicle’s altitude.
Comparison of this reading with a known good
vehicle using the same sensor is a good way to
check accuracy of a suspect sensor. Readings
should be the same ±0.4 volts.
Refer to Intermittent Condition.
Important: The electrical connector must remain
securely fastened.
Important: After removing the MAP sensor from the
intake manifold, replace the MAP Sensor to intake
manifold seal.
Engine
Remove the MAP sensor. Twist sensor by hand
(only) to check for intermittent connections. Output
changes greater than 0.1 volts indicates a bad
connector or connection. If OK, replace sensor.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
Important: Be sure to use the same diagnostic
equipment for all measurements.
5. This step checks for a short to voltage on the
5 V reference circuit.
7. This step checks the integrity of the MAP
sensor ground circuit.
11. The VCM terminals GRY 12 and GRY 27 are
spliced together inside the VCM. When
checking the 5 volt reference for a short to
ground, both the 5 volt reference circuits and all
of the components on the 5 volt reference
circuits must also be checked.

DTC P0108 MAP Sensor Circuit High Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. If the engine idle is unstable, incorrect or if the
manifold vacuum at idle is less than the specified
value, correct the fault before using this table. Refer
to Engine Symptoms. 15 in Hg
2 2. Connect the scan tool. 4.0 V
3. Engine at idle.
Does the scan tool display a MAP sensor voltage greater
than the specified value? Go to Step 3 Go to Step 4
1. Turn OFF the ignition.
2. Disconnect the MAP sensor electrical connector.
3 3. Turn ON the ignition. 1.0 V
Does the scan tool display a voltage less than the
specified value? Go to Step 5 Go to Step 10
The DTC is intermittent. Go to
4 Are any additional DTCs stored? — The Applicable Go to
DTC Tables Diagnostic Aids
With a DVM connected to ground, probe the 5 V reference
5 circuit at the MAP sensor harness connector. 5.2 V
Is the voltage greater than the specified value? Go to Step 11 Go to Step 6
6 Are DTCs P0113, P116, and P1111 set? — Go to Step 16 Go to Step 7
Probe the MAP sensor ground circuit (at the MAP sensor
7 connector) with a test light to B+. —
Is the test light ON? Go to Step 8 Go to Step 15
Check the MAP sensor vacuum source for a restriction.
8 —
Was a problem found? Go to Step 17 Go to Step 9
Engine________________________________________________ Engine Controls - 7.4L 6-2775
DTC P0108 MAP Sensor Circuit High Voltage (cont’d)
Step Action Vaiue(s) Yes No
Replace the MAP sensor. Refer to MAP
9 Sensor Replacement. — —
Is the replacement complete? Go to step 21
Check for a short to the voltage in the MAP sensor
10 signal circuit. —

Was a problem found? Go to Step 17 Go to Step 20

1. Turn the ignition OFF.
2. Disconnect the GRY VCM connector.
3. Turn the ignition ON.
11 4. With a DVM connected to ground, measure the 0V
voltage on the 5 V reference circuit at the VCM
harness connector.
Is the voltage greater than the specified value? Go to Step 12 Go to Step 14
1. Disconnect the EGR valve electrical connector.
12 2. Measure the voltage on the 5 V reference circuit. 0V
Is the voltage greater than the specified value? Go to Step 13 Go to Step 18
Repair the short to voltage on the 5 V reference circuit.
13 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 21
With a DVM connected to ground, measure the voltage on
14 the VCM connector terminal GRY 12. 5.2 V
Is the voltage greater than the specified value? Go to Step 19 Go to Step 20
Repair the MAP sensor ground circuit. Refer to Wiring
15 Repairs in Engine Electrical. — —
Is the action complete? Go to Step 21
Rapair the Sensor Ground Circuit between the VCM and
16 the splice. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 21
Repair as necessary.
17 — —
Is the action complete? Go to Step 21
Replace the EGR valve. Refer to EGR
18 Valve Replacement. — —
Is the action complete? Go to Step 21
Repair the short to voltage on the 5 V reference
circuit terminal GRY 12. Refer to Wiring Repairs in
19 Engine Electrical. — —

Is the action complete? Go to Step 21

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
20 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 21
6-2776 Engine Controls - 7.4L________________________________________________ Engine
DTC P0108 MAP Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select the DTC and the
Clear DTC Information function.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
21 4. Select the DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 22 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
22 —
Are there any DTCs displayed that have not The Applicable
been diagnosed? DTC Table System OK
Engine_________________________________
DTC P0112 IAT Sensor Circuit Low Voltage
MAPandFuel Tank
PressureSensors ►--------
a n d E G R V a lve
Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermistor located in the fresh air duct to the throttle
body in order to monitor the temperature of the air
entering the throttle body. The VCM applies 5 volts
to the sensor on the 5 volt reference circuit. When
the air is cool, the resistance in the sensor measures
high and the VCM senses a high voltage signal. If
the air is warm, the sensor resistance measures low
and the VCM senses a low voltage signal.
Conditions for Setting the DTC
The following conditions will set the DTC:
. No VSS DTCs.
• Vehicle speed is greater than or equal
to 2 mph.
• Engine run time is greater than 100 seconds.
• IAT circuit voltage less than 0.82 V.
Action Taken When the DTC Sets
The VCM turns ON the MIL when DTC P0112 is
reported and 1 failure has occurred.
Conditions for Clearing the MIUDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 'C (160'F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine Controls - 7.4L 6-2777
: IAT ” 1 Vehicle
Sensor Control A
l _ !L9ni! _ j Module (VCM) la A
22TC2
TAN 472
A
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK
190377
Diagnostic Aids
A scan tool indicates the temperature of the ambient
air entering the throttle body. The air temperature
should read very close to the temperature of the
outside air. The air temperature should rise gradually
as the engine warms up and the underhood
temperature increases. If DTC P1112 is set, the
problem is intermittent. Check for a short to ground
in the IAT sensor signal circuit. This may be
accomplished by moving the VCM harness at various
locations and monitoring the IAT temperature or the
IAT voltage on the scan tool. If the voltage varies,
look for a short to ground in the area of the harness
that caused the variance. Also, a sensor may
become skewed or mis-scaled. The Temperature vs.
Resistance Value Table will help to detect a skewed
sensor. Refer to Temperature vs Resistance.
Test Description
The numbers below refer to the numbers on the
diagnostic table.
Important: Use the same diagnostic test equipment
for all the measurements.
2. If the IAT sensor circuit voltage measure less
than 0.82 volts, the conditions for the DTC are
still present and the problem is not intermittent.
3. This test bypasses the IAT sensor and confirms
that the IAT signal circuit and the sensor ground
circuit to the VCM are sound. Opening the
signal circuit provides a high voltage input to
the VCM. The VCM should recognize this high
voltage and indicate a low IAT temperature.
4. This test determines if the IAT sensor signal
circuit is shorted to the sensor ground.
6-2778 Engine Controls - 7.4L________________________________________________ Engine
DTC P0112 IAT Sensor Circuit Low Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 0.82 V
3. Monitor the IAT sensor voltage.
Is the IAT sensor voltage less than the specified value? Go to Step 3 Go to Step 5
1. Turn OFF the engine.
2. Turn ON the ignition.
3 4.0 V
3. Disconnect the IAT sensor connector.
Is the IAT sensor voltage greater than the specified value? Go to Step 7 Go to Step 4
1. Turn OFF the ignition.
2. Using the J 39200, measure the resistance across oo
4
the IAT sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. Go to
5 Are any additional DTCs stored? — The Applicable Go to
DTC Tables Diagnostic Aids
Repair the short to the ground in the IAT signal circuit.
6 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 9
Replace the IAT sensor. Refer to IAT Sensor Replacement
7 — —
Is the action complete? Go to Step 9
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
8 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Leam Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 9
1. Use the scan tool in order to select DTC and Clear
DTC Information function.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
9 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 10 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
10 —
Are there any DTCs displayed that have not The Applicable
been diagnosed? DTC Table System OK
Engine_________________________________
DTC P0113 IAT Sensor Circuit High Voltage
MAPandFuel Tank
PressureSensors ►----
and EGRValve
Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermistor located in the fresh air duct to the throttle
body in order to monitor the temperature of the air
entering the throttle body. The VCM applies 5 volts
to the sensor on the 5 volt reference circuit. When
the air is cool, the resistance in the sensor measures
high and the VCM senses a high voltage signal. If
the air is warm, the sensor resistance measures low
and the VCM senses a low voltage signal.
Conditions for Setting the DTC
The following items will set the DTC:
• No ECT sensor DTCs.
• No VS sensor DTCs.
• No MAF sensor DTCs.
• The vehicle speed less than 2 mph.
• The MAF is less than 250 grams per second.
• The engine coolant temperature greater
than 84.7'C .
• The engine run time is greater than
100 seconds.
• The IAT voltage is greater than 4.90 volts.
Action Taken When the DTC Sets
The VCM turns the MIL ON when P0113 is reported
and 1 failure has occurred.
Engine Controls - 7.4L 6-2779
I IAT I Vehicle
Sensor Control A
l _ !L9ni! _ j Module (VCM) ia A
22TC2
TAN 472
A
VCM
Cl =BLU
C2=RED
C3=CLEAR
C4=BLK
190377
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ' C (160* F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
A scan tool indicates the temperature of the ambient
air which is entering the throttle body. The air
temperature should read very close to the
temperature of the outside air. The air temperature
should rise gradually as the engine warms up and
the underhood temperature increases. If DTC P1111
is set, the problem is intermittent. Check for an open
in the IAT sensor circuit. This may be accomplished
by moving the VCM harness at various locations and
monitoring IAT temperature or IAT voltage on the
scan tool. If the voltage varies, look for an open in
the area of the harness that caused the variance
Also, a sensor may become skewed or mis-scaled.
The Temperature vs. Resistance Value Table will
help in order to detect a skewed sensor. Refer to
Temperature vs Resistance.
6-2780 Engine Controls - 7.4L Engine
Test Description 3. This test will bypass the IAT sensor and will
The numbers below refer to the step numbers on the confirm that the IAT signal circuit and the
diagnostic table. sensor ground circuit to the VCM are sound.
Grounding the signal circuit will provide a low
Important: Use the same diagnostic test equipment voltage input to the VCM. The VCM should
for all the measurements. recognize this low voltage and indicate a high
2. If the IAT sensor circuit voltage measures IAT temperature.
greater than 4.90 volts, the conditions for the 4. This test determines if the IAT sensor signal
DTC are still present, and the problem is circuit is okay. If the scan tool does not indicate
not intermittent. a high temperature, the IAT signal circuit
is open.

DTC P0113 IAT Sensor Circuit High Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 4.90 V
3. Monitor the IAT sensor voltage.
Is the IAT sensor voltage greater than the specified value? Go to Step 3 Go to Step 6
1. Turn OFF the engine.
2. Turn ON the ignition switch.
3. Disconnect the IAT sensor connector.
3 0.82 V
4. Jumper the IAT harness terminals together.
Does the scan tool display an IAT sensor voltage less than
the specified value? Go to Step 5 Go to Step 4
Jumper the IAT sensor signal circuit to a known
good ground.
4 0.82 V
Does the scan tool display an IAT sensor voltage less than
the specified value? Go to Step 8 Go to Step 9
Use a DVM J 39200 in order to check the voltage between
5 the IAT sensor signal circuit and a known ground. 5.20 V
Is the voltage greater than the specified value? Go to Step 10 Go to Step 7
The DTC is intermittent. Go to
6 Are any additional DTCs stored? — The Applicable Go to
DTC Table Diagnostic Aids
Inspect the sensor connector and the VCM connector for
7 the proper connection. —
Was a problem found? Go to Step 11 Go to Step 12
Check the IAT sensor ground circuit for an open between
8 the IAT sensor and the VCM. —
Was a problem found? Go to Step 11 Go to Step 13
Check the sensor signal circuit for an open between the
9 IAT sensor and the VCM. —
Was a problem found? Go to Step 11 Go to Step 13
Repair the short to voltage in the IAT sensor signal circuit.
10 Refer to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Engine________________________________________________ Engine Controls - 7.4L 6-2781
DTC P0113 IAT Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
Replace the IAT sensor. Refer to IAT Sensor Replacement.
12 — —
Is the action complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
14 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 15 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
15 —
Are there any DTCs displayed that have not The Applicable
been diagnosed? DTC Table System OK
6-2782 Engine Controls - 7.4L Engine
DTC P0117 ECT Sensor Circuit Low Voltage
r "J Vehicle
I ECT
• Sensor Control
^ Signal J Module (VCM)
23TC2
YEL 410

Engine Coolant
Temperature VCM
(ECT) Sensor Cl =BLU
C2=RED
A C3=CLEAR
C4-BLK
BLK 452
BLK
TPSensor ► ----- 1>
452
BLK 452
4. ,C3
Sensor ■J Vehicle
Ground Control A
J Module (VCM)
33179
Circuit Description Diagnostic Aids
The Engine Coolant Temperature (ECT) sensor is a After starting the engine, the temperature should rise
thermistor which controls the signal voltage to the steadily to about 90 *C (194*F) then stabilize when
VCM. The VCM applies a voltage on a 5 volt the thermostat opens. A poor connection or an open
reference circuit to the sensor. When the engine in the 5 volt reference circuit or the sensor ground
coolant is cold, the sensor’s internal resistance is circuit results in a DTC P0117.
high resulting in a high voltage ECT Sensor Signal. Use the Temperature vs. Resistance Value Table to
As the engine coolant temperature increases, the test the coolant sensor at various temperature levels
sensor’s internal resistance and ECT Sensor in order to evaluate the possibility of a skewed
Signal decrease. (mis-scaled) sensor. A skewed sensor could result in
Conditions for Setting the DTC poor driveability concerns. Refer to Temperature
vs Resistance.
The following conditions will set the DTC:
• The engine run time is greater than 5 seconds. Test Description
• ECT signal voltage is less than 0.78 V. The numbers below refer to the step numbers on the
diagnostic table.
Action Taken When the DTC Sets 2. If the fault is still present, the engine coolant
The VCM turns the MIL ON when P0117 is reported voltage will measure less than 0.25 volts.
and 1 failure has occurred. 3. This test simulates a DTC P0118. If the VCM
Conditions for Clearing the MIL/DTC recognizes the high signal voltage and the scan
tool display reads 40 volts or more, the VCM
• The VCM turns the MIL OFF after and the wiring are okay.
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 * F)
from the startup coolant temperature
and the engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine Engine Controls - 7.4L 6-2783
DTC P0117 ECT Sensor Circuit Low Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
3. Monitor the Engine Coolant Temperature (ECT) 0.25V
2
sensor voltage. (0.78V for 7.4L)
Does the scan tool display an ECT sensor voltage less
than the specified value? Go to Step 3 Go to Step 5
1. Turn OFF the engine.
2. Turn ON the ignition.
3 3. Disconnect the ECT sensor connector. 4.0V
Does the scan tool display an ECT sensor voltage greater
than the specified value? Go to Step 7 Go to Step 4
1. Turn OFF the ignition.
2. Using the DVM J 39200, check the resistance across oo
4
the ECT sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. Go to
5 Are any additional DTCs set? — The Applicable Go to
DTC Table Diagnostic Aids
Repair the short to the ground in the ECT signal circuit.
6 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 9
Replace the ECT sensor. Refer to ECT
7 Sensor Replacement. — —
Is the action complete? Go to Step 9
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
8 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 9
6-2784 Engine Controls - 7.4L________________________________________________ Engine
DTC P0117 ECT Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select DTC and the
Clear DTC Information function.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
9 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 10 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
10 —
Are there any DTCs displayed that have not been The Applicable
diagnosed? DTC Table System OK
Engine______________________________________
DTC P0118 ECT Sensor Circuit High Voltage (98)
YEL 410
Engine Coolant
Temperature
(ECT) Sensor
A C3=CLEAR
BLK 452
TPSensor ► BLK
----- 1»
452
BLK 452
4, .C3
Sensor
Ground
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor which controls the signal voltage to the
VCM. The VCM applies a voltage on a 5 volt
reference circuit to the sensor. When the engine
coolant is cold, the sensor’s internal resistance is
high resulting in a high voltage ECT Sensor Signal.
As the engine coolant temperature increases, the
sensor’s internal resistance and ECT Sensor
Signal decrease.
Conditions for Setting the DTC
• The engine run time is greater than 5 seconds
• The ECT signal voltage indicates an ECT
voltage above 4.90 volts
Action Taken When the DTC Sets
The VCM turns ON the MIL when this DTC is
reported and 1 failure has occurred.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine Controls - 7.4L 6-2785
VCM
Cl =BLU
C2=RED
04-BLK
1 Vehicle
Control ^
Module (VCM)
33179
Diagnostic Aids
Check the harness routing for a potential short to
ground in the 5 volt reference circuit. After starting
the engine, the temperature should rise steadily to
about 9 0 ‘ C (194*F), then stabilize when the
thermostat opens.
Use the Temperature vs Resistance Value table in
order to test the coolant sensor at various
temperature levels in order to evaluate the possibility
of a skewed (mis-scaled) sensor. A skewed sensor
could result in poor driveability complaints. Refer to
Temperature vs Resistance.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the fault is present, the engine coolant
temperature voltage measures greater
than 4.90 volts.
3. This test simulates the conditions for a
DTC P0117. If the VCM recognizes the
grounded circuit (low voltage) and displays a
low voltage message, the VCM and the wiring
are okay.
4. This test checks for an open or grounded signal
sensor circuit. Also being checked are the ECT
sensor ground circuit and the VCM.
5. This test checks for a short to voltage on the
ECT signal circuit.
12. After repairing a short to voltage, it is
necessary to recheck the operation of the
ECT sensor.
6-2786 Engine Controls - 7.4L________________________________________________ Engine
DTC P0118 ECT Sensor Circuit High Voltage (98)
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 3. Monitor the ECT sensor voltage. 4.90 V
Does the scan tool display an ECT sensor voltage greater
than the specified value? Go to Step 3 Go to Step 6
1. Turn OFF the engine.
2. Disconnect the ECT sensor connector.
3. Jumper the ECT sensor harness terminals together.
3 0.82 V
4. Turn ON the ignition.
Does the scan tool display an ECT sensor voltage less
than the specified value? Go to Step 5 Go to Step 4
Jumper the ECT sensor signal circuit to a known
good ground.
4 0.82 V
Does the scan tool display an ECT sensor voltage less
than the specified value? Go to Step 8 Go to Step 9
Use a DVM J 39200 in order to check the voltage between
5 the ECT sensor signal circuit and a known ground. 5.20 V
Is the voltage greater than the specified value? Go to Step 10 Go to Step 7
The DTC is intermittent. Go to
6 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Inspect the ECT sensor connector and the VCM connector
7 for a proper connection. —
Was a problem found? Go to Step 11 Go to Step 13
Check the ECT sensor ground circuit for an open between
8 the ECT sensor and the VCM. —
Was a problem found? Go to Step 11 Go to Step 14
Check the ECT sensor signal circuit for an open between
9 the ECT sensor and the VCM. —
Was a problem found? Go to Step 11 Go to Step 14
Repair the short to voltage in the ECT sensor signal
10 circuit. Refer to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 12
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 15
1. Reconnect the ECT sensor harness.
2. Start the Engine.
12 3. Monitor the ECT sensor voltage. 4.90 V
Does the scan tool display an ECT sensor voltage less
than the specified value? Go to Step 15 Go to Step 13
Replace the ECT sensor. Refer to ECT
13 Sensor Replacement. — —
Is the action complete? Go to Step 15
Engine________________________________________________ Engine Controls - 7.4L 6-2787
DTC P0118 ECT Sensor Circuit High Voltage (98) (cont’d)
Step Action Value(s) Yes No
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
14 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 15
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
4. Select the DTC and the Specific DTC functions.
15 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions
for setting this DTC as specified in the
supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 16 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info. Go to
16 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
6-2788 Engine Controls - 7.4L Engine

DTC P0121 TP Sensor Performance

r ** Vehicle
I 5Volt I Control A
Reference A
L -> Module (VCM) l a A
12 C3
GRY 416
A
T “ 1Throttle
S Position (TP) ECTSensor
Sensor VCM
C1=BLU
B BLK 452 C2=RED
C3=CLEAR
BLK 452 04=BLK
DKBLU 417
BLK 452
24 JIC2 4, .C3
r 1 Vehicle
TP Sensor
I Sensor Ground 1Control Jk
I Signal J Module (VCM)
L

33237

Circuit Description Diagnostic Aids

The Throttle Position (TP) sensor provides a voltage
signal that changes relative to the throttle opening.
The TP sensor signal voltage varies from about
0.6 volts at idle to about 4.8 volts at Wide Open
Throttle (WOT).
The TP sensor signal is one of the most important
inputs used by the VCM for fuel control and for most
of the VCM control inputs.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No MAP DTCs are active.
• Engine is running
• BARO not defaulted.
• Change In TP is less than 2.0%
• MAP is greater than 60 kPa.
Action Taken When the DTC Sets
The VCM turns ON the MIL after 2 consecutive
driving cycles with the fault active. The TP sensor
reads 0% if the vehicle speed is less than 2 mph.
The TP sensor reads 10% if the vehicle speed is
greater than 2 mp/h. The scan tool will show a
defaulted value.
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 * F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
The scan tool displays the throttle position in volts. It
should display 0.20 volts to 0.90 volts with the
throttle closed and ignition ON or at idle. The voltage
should increase at a steady rate as the throttle is
moved toward Wide Open Throttle (WOT). Also, the
scan tool displays the throttle angle %. 0 % = closed
throttle. 100 % = WOT.
Check the condition of the connector and sensor
terminals for moisture or corrosion, and clean or
replace as necessary. If corrosion is found, check
the condition of the connector seal and repair or
replace as necessary. If DTC P0121 is intermittent,
refer to Intermittent Condition.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The TP sensor has an auto zeroing feature. If
the voltage reading is within the range of about
0.2 to 0.9 volt, the VCM uses that value as a
closed throttle. If the reading is out of the auto
zero range at the closed throttle, check for a
binding throttle or a damaged linkage. If the
throttle and the linkage are okay, continue with
the diagnosis.
4. With the TP sensor disconnected, the TP
sensor voltage should go low if the VCM and
the wiring are okay.
Engine________________________________________________ Engine Controls - 7.4L 6-2789
DTC P0121 TP Sensor Perform ance
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Turn ON the ignition.
2 3. Turn off the engine. 2%
Does the scan tool display the TP sensor percentage
above the specified value? Go to Step 4 Go to Step 3
1. Depress the throttle while watching the throttle
position go through the specified range.
0%-99.6%
3 2. Release the throttle.
2%
Does the scan tool display the TP sensor percentage
above the specified value? Go to Step 4 Go to Step 5
Disconnect the TP sensor electrical connector.
4 Does the scan tool display the TP sensor at the 0.00V
specified value? Go to Step 6 Go to Step 9
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored Go to
5 refer to those tables first. —
The Applicable
Are any additional DTCs set? DTC Table Go to Step 6
Check for a faulty connections at the TP sensor.
6 —
Was a problem found? Go to Step 7 Go to Step 8
Repair the circuit as necessary. Refer to Wiring Repairs in
7 Engine Electrical. — —
Is the action complete? Go to Step 10
Replace the TP sensor. Refer to TP Sensor Replacement.
8 — —
Is the action complete? Go to Step 10
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
9 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
10 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 11 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
11 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2790 Engine Controls - 7.4L___________ Engine
D T C P 0122 T P S e n s o r C irc u it L o w V o ltag e

r 1 Vehicle
I 5 Volt
Reference A
I Control
L -* Module (VCM) i a A
12 C3
GRY 416
AJL
Throttle
Position (TP) ECTSensor
Sensor ▼ VCM
Cl = BLU
C B' BLK 452 C2 = RED
C3 = CLEAR
BLK 452 0 4 - BLK

DK BLU 417
BLK 452
24 XC2 4. .C3
TP Sensor "l Vehicle
I Sensor Ground 1Control A
I Signal 'Module (VCM)

C ircuit Description
The Throttle Position (TP) sensor provides a voltage
signal which changes relative to the throttle
blade angle.
The TP sensor signal voltage varies from about
0.5 volts at idle to about 4.5 volts at Wide Open
Throttle (WOT). The TP sensor signal is one of the
most important inputs used by the VCM for
controlling the fuel and for most of the VCM
control outputs.
Each time the voltage drops below 1.25 volts and
stops, the VCM assumes this value as 0 throttle
angle. The measures the percent throttle from this
point on.
C onditions fo r Setting the DTC
Engine running.
TP sensor signal voltage is less than .15 volts
(8 counts).
A ction Taken W hen the DTC Sets
Important: The scan tool will not indicate a
default value.
The VCM sets the DTC P0122. The VCM turns
ON the MIL when P0122 is reported, and 1 failure
has occurred.
C onditions fo r Clearing the M IL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 ° F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160’ F during that same ignition cycle) or
the scan tool clearing feature has been used.
33237
Diagnostic Aids
The scan tool reads throttle position in volts. The TP
should read about 0.45 to 0.85 volts with the throttle
closed and the ignition ON or at idle. The voltage
should increase at a steady rate as the throttle is
moved toward Wide Open Throttle (WOT).
An open or short to ground in the 5 volt reference
circuit or the TP sensor signal circuit results in a
DTC P0122.
Refer to the Intermittent Condition.
Scan the TP sensor signal while depressing the
accelerator pedal with the engine stopped and the
ignition ON. The display should vary from below
1.25 volts (1250 mV) when throttle was closed, to
over 4.5 volts (4500 mV) when throttle is held at the
Wide Open Throttle (WOT) position.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the TP signal measures less than 0.15 volt,
then the fault exists.
3. If the VCM recognizes the high signal voltage,
the VCM and the wiring are okay.
4. This test simulates a high signal voltage
in order to check for an open in the TP
signal circuit.
6. This step checks the 5 volt reference circuit for
an open, short to ground, a poor connection, or
a faulty VCM.
7. The VCM terminals GR 12 and GR 27 are
spliced together inside the VCM. When
checking the 5 volt reference for a short to
ground, both the 5 volt reference circuits and all
the components on the 5 volt reference circuits
must also be checked.
Engine Engine Controls - 7.4L 6-2791
DTC P0122 TP Sensor Circuit Low Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Close the throttle.
2 0.15V
Does the scan tool display a throttle position signal less
than the specified value? Go to Step 3 Go to Step 5
1. Disconnect the TP sensor.
2. Jumper the TP sensor signal circuit and the TP
3 sensor 5 volt reference circuit together. 4.0V
Does the scan tool display a throttle position signal greater
than the specified value? Go to Step 12 Go to Step 4
Probe the TP sensor signal circuit with a test lamp
connected to B+.
4 4.0V
Does the scan tool display a throttle position signal over
the specified value? Go to Step 6 Go to Step 8
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
5 refer to those tables. — —
The Applicable
Are any additional DTCs set? DTC Table
Check for an open in the 5 volt reference circuit.
6 —
Was a problem found? Go to Step 11 Go to Step 7
Check the 5 volt reference for a short to ground.
7 —
Was a problem found? Go to Step 11 Go to Sltep 10
Check the TP sensor signal circuit for an open.
8 —
Was a problem found? Go to Step 11 Go to Step 9
Check the TP sensor signal circuit for a short to
9 the ground. —
Was a problem found Go to Step 11 Go to Step 10
Check for a poor connection at the VCM.
10 —
Was a problem found? Go to Step 11 Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Engine Electrical. — —
Is the repair complete? Go to Step 14
Replace the faulty TP sensor. Refer to TP
12 Sensor Replacement. — —
Is the replacement complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
6-2792 Engine Controls - 7.4L________________________________________________ Engine
DTC P0122 TP Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
14 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed. DTC Table System OK
Engine_________________________________ Engine Controls - 7.4L 6-2793
DTC P0123 TP Sensor Circuit High Voltage

^ Vehicle
| 5Volt
L
ReferenceA • Control
______________________ J
Module (VCM)
12 C3
GRY 416
A
Throttle
A
iO B O I I k

Position (TP) ECT Sensor

Sensor ▼ VCM
=BLU
B' BLK 452 =RED
=CLEAR
BLK 452 =BLK
DK BLU 417
BLK 452
24 a C2 4, .C3
r ----------- Sensor 11Vehicle
I TP
Sensor Ground 'Control >
I Signal
L _ _ _ _ ______________________________ ____ j 'Module(VCM)

Circuit Description
The Throttle Position (TP) sensor provides a voltage
signal which changes relative to the throttle blade
angle. The signal voltage varies from about 0.5 volt
at idle to about 4.0 volts at Wide Open
Throttle (WOT).
The VCM uses the TP signal, one of the most
important inputs, for fuel control and for most of the
VCM control outputs.
Each time the voltage drops below 1.25 volts and
stops, the VCM assumes this value as the 0 throttle
angle, and the VCM measures the percent throttle
from this point on.
Conditions for Setting the DTC
The engine is running.
TP sensor signal voltage is greater than 4.9 volts
(249 counts).
Action Taken When the DTC Sets
Important: The scan tool will not indicate
default values.
When the P0123 is reported and 1 failure has
occurred, the VCM sets the DTC P0123, and the
VCM turns ON the MIL.
Conditions for Clearing the MIL7DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 *F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160‘ F during that same ignition cycle) or
the scan tool clearing feature has been used.
33237
Diagnostic Aids
The scan tool reads the throttle position in volts. The
scan tool should read about 0.45 to 0.85 volt with
the throttle closed and the ignition switch turned ON
or at idle. The voltage should increase at a steady
rate as the throttle is moved toward the Wide Open
Throttle (WOT).
Also, some scan tools will read the throttle angle.
0% = closed throttle. 100% = WOT.
Scan the TP sensor while depressing the accelerator
pedal with the engine turned off and the ignition
turned on. The display should vary from below the
1.25 volts (1250 mV) when the throttle was closed to
over 4.5 volts (4500 mV) when the throttle is held at
WOT position.
This DTC will result if the TP ground circuit is open
or the TP signal circuit is shorted to the voltage.
Refer to the Intermittent Condition.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. If the TP signal measures greater than
4.8 volts, then the fault exists.
3. With the TP sensor disconnected and if the
VCM and the wiring are okay, the TP signal
should go low.
4. Probing the TP ground circuit with a test lamp
checks the 5.0 volt return circuit. This step
isolated a faulty sensor, the VCM or an open
TP ground circuit.
6-2794 Engine Controls - 7.4L________________________________________________ Engine
DTC P0123 TP Sensor Circuit High Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Turn the ignition ON, engine OFF.
2 4.8V
Does the scan tool display a TP sensor signal greater than
the specified value? Go to Step 3 Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the TP sensor electrical connector.
3 3. Turn the ignition ON. 0.2V
Does the scan tool display a TP sensor signal less than
the specified value? Go to Step 5 Go to Step 8
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
4 refer to those tables first. — —
The Applicable
Are any additional DTCs stored? DTC Table
With a DVM connected to ground, probe the 5V reference
5 circuit (at the TP sensor electrical connector). 5.2V
Is the voltage greater than the specified value? Go to Step 9 Go to Step 6
Probe the TP sensor ground circuit ( at the TP sensor
6 connector) with a test light connected to B+. —
Is the test lamp on? Go to Step 7 Go to Step 13
Replace the TP sensor. Refer to TP Sensor Replacement.
7 — —
Is the action complete? Go to Step 18
Check for a short to voltage in the TP sensor
8 signal circuit. —
Was a problem found Go to Step 14 Go to Step 17
1. Turn the ignition OFF.
2. Disconnect the VCM gray connector.
3. Turn the ignition ON.
9 5.2V
4. With a DVM connected to ground, measure the 5V
reference circuit at the VCM harness connector.
Is the voltage greater than the specified value? Go to Step 12 Go to Step 10
With a DVM connected to ground, measure the voltage on
10 the VCM connector terminal GR27. 5.2V
Is the voltage greater than the specified value? Go to Step 11 Go to Step 17
1. Disconnect the EGR valve electrical connector.
2. Measure the voltage on the 5V reference circuit (at
11 5.2V
the VCM harness connector GR27).
Is the voltage greater than the specified value? Go to Step 16 Go to Step 15
Repair the short to voltage on the 5V reference circuit.
12 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 18
Check the sensor ground circuit for an open.
13 —
Was a problem found? Go to Step 14 Go to Step 17
Repair as necessary. Refer to Wiring Repairs in
14 Engine Electrical. — —
Is the action complete? Go to Step 18
Engine________________________________________________ Engine Controls - 7.4L 6-2795
DTC P0123 TP Sensor Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
Replace the EGR valve. Refer to EGR
15 Valve Replacement. — —
Is the action complete? Go to Step 18
Repair the short to voltage on the 5V reference circuit
16 (terminal GR27). — —
Is the action complete? Go to Step 18
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
17 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 18
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
18 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 19 Go to Step 2
Using the scan tool, select the Capture Info and Go to
19 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed DTC Table System OK
6-2796 Engine Controls - 7.4L________________
DTC P0125 ECT Excessive Time to Closed Loop
ECT
Sensor
Signal
Engine Coolant
Temperature
(ECT) Sensor
A C3=CLEAR
BLK 452
TPSensor ► BLK
452
BLK 452
4, .C3
Sensor
Ground
Circuit Description
While the engine is warming, the VCM monitors the
ECT sensor in order to determine how long the
engine takes to reach the coolant temperature that is
required for closed loop operation.
A DTC sets if the VCM determines that the engine
did not reach a closed loop temperature in a
specified amount of time. This diagnostic will not run
if either the intake air or the engine coolant
temperature measure below a predetermined
temperature. The VCM will only run this DTC on a
cold start and only once per cold start.
Conditions for Setting the DTC
The following conditions will set the DTC:
• Engine running.
• IAT is greater than -7 * C.
• ECT is greater than -9 * C.
• The vehicle speed greater than 1 mph
• A start-up ECT less than or equal to 40 * C
Closed Loop Test
• For a vehicle saturated between -7 * C (20 * F)
and 10 *C (5 0 *F) accumulated air flow since
start is greater than 5500 grams and
accumulated idle time is less than 225 seconds.
• For a vehicle saturated greater than 10 * C
(50 * F) accumulated air flow since start is
greater than 5000 grams and accumulated idle
time is less than 180 seconds.
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive
driving cycles with the fault active.
Engine
Vehicle
Control
Module (VCM)
VCM
C1=BLU
C2=RED
C4=BLK
Vehicle
Control A
Module (VCM) l u &
33179
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 * F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
When a DTC P0125 sets, a skewed ECT sensor or
the engine thermostat that does not operate correctly
is indicated.
A poor connection, a rubbed through wire insulation,
or a wire broken inside of the insulation may cause
an intermittent.
Check for the following conditions:
• A poor connection or a damaged harness.
Inspect the VCM harness connector for the
following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connection and
- A damaged harness
• The intermittent test: If the connections and the
harness check OK, monitor a digital voltmeter
connected between the VCM terminals while
moving the related connectors and the wiring
harness. If the failure is induced, the voltage
reading changes. This may help in order to
isolate the location of the malfunction.
Engine Engine Controls - 7.4L 6-2797
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
3. This test checks the engine warm-up rate.
5. This test checks the coolant sensor reading on
the scan tool and the actual coolant
temperature.

DTC P0125 ECT Excessive Time to Closed Loop

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during Go to Powertrain
1 the Clear DTC Information function. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Allow the engine to cool completely.
2. Install the scan tool.
2 3. Turn ON the ignition.
— Go to DTC P0117
4. Compare the IAT to the ECT. The values should ECT Sensor
be close. Circuit Low
Are they close? Go to Step 3 Voltage
1. Start the engine.
2. Run the engine while the monitoring the ECT on the
3 scan tool. 35’ C (95‘ F)
Does the ECT value rise steadily to above the specified Go to
value within 9 minutes? Diagnostic Aids Go to Step 4
Check the cooling system coolant level. Go to Engine
4 —
Was a problem found? Cooling System Go to Step 5
Compare the ECT display on the scan tool to the actual
5 coolant temperature. The values should be close. — Go to Engine
Are they close? Cooling System Go to Step 6
ReplacetheECTsensor.R efertoECTSensor
6 Replacement. — —
Is the replacement complete? Go to Step 7
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
7 4. Select the DTC and the Specific.
—
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 8 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
8 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2798 Engine Controls - 7.4L Engine

DTC P0131 H02S Circuit Low Voltage Bankl Sensori

|Hot InRunAndStart]

VCM
Cl =BLU
C2-RED
C3=CLEAR
C4-BLK

Ground
Distribution
Cell 14

Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of about 0.45 volt
(450 mV) between the H02S Signal and H02S Low
circuits. The Heated Oxygen Sensor varies the
voltage within the range of about 1.0 volt (1000 mV)
if the exhaust is rich, down to about 0.10 volt
(100 mV) if the exhaust is lean.
The sensor is like an open circuit and produces no
voltage when it is below 360 *C (600 *F). The
DTC P0131, P0132, an open signal circuit, or a cold
sensor causes Open Loop operation. The
DTC P0131 determines if the H02S sensor or the
signal circuit is shorted to low by checking for a lean
condition during a steady throttle and power
enrichment (PE).
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensor DTCs
. No EVAP DTCs
• No IAT sensor DTCs
• No MAP sensor DTCs
• No ECT sensor DTCs
200042
• No MAF sensor DTCs
• No active Misfire DTCs
• No intrusive test in progress
• No device controls active
• The system voltage measures greater than or
equal to 9.0 volts.
Test Enable Lean Test
• Closed Loop.
• Closed Loop low MAP not active.
• Air to fuel ratio is at least 14.5 but less
than 14.8
• The TP is greater than 10% but less than 99%
• The above met for 5 seconds
Test Enable PE Lean Test
• A Closed Loop
• The Power Enrichment mode active
• The high speed fuel cutoff not active
• Time elapsed since test enable is greater than
or equal to 1 seconds.
• Time elapse since test enable is at least
1 second
• The H02S Bank 1 Sensor 1 voltage measures
less than 0.598 volts (598 mV)
Engine
Action Taken When the DTC Sets
A current DTC P0131 set causes the system to
operate in an Open Loop. With a DTC P0131 set,
the MIL (Malfunction Indicator Lamp) turns ON at the
first test failure.
Conditions for Clearing the MIL7DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ' C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 'C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repair refer to Wiring Repairs in
Electrical Diagnosis.
Using the scan tool, observe the L.T. fuel trim values
at the different RPM and the air flow conditions. The
scan tool also displays the fuel trim cells, so the L.T.
fuel trim values can be checked in each of the cells
in order to determine when the DTC may have set.
If the conditions for this DTC exist, the L.T. fuel trim
values measure around 158 or greater.
Check for the following conditions:
• Display the H02S voltage with a scan tool. If
the voltage is less than 0.086 V (86 mV) and
increases to about 0.450 V (450 mV) after the
H02S is disconnected, then the H02S is
internally shorted and should be replaced.
DTC P0131 H02S Circuit Low Voltage Bankl Sensorl
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 —
the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral.
4. Apply the parking brake.
2
5. Increase the engine speed to the specified value.
Does the scan tool data display indicate the H02S
(Bank 1, Sensor 1) voltage fixed less than the
specified value?
Engine Controls - 7.4L 6-2799
• A sensor pigtail may be mispositioned and
contacting the exhaust system.
• An intermittent short to ground in the signal
circuit between the VCM connector and H02S.
• A poor VCM to the engine block ground.
• Lean injectors: Perform the Injector
Balance Test.
• Fuel Contamination: Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the injectors. The water causes
a lean exhaust and can also set this DTC.
• Fuel pressure: If the pressure is too low, the
system will be lean. In order to confirm, monitor
a fuel pressure while driving the vehicle at
various speeds and loads.
• Exhaust leaks: If there is an exhaust leak, the
engine may pull the outside air into the
exhaust, and past the sensor.
• Vacuum or the Crankcase leaks can cause a
lean condition or a possibly a high idle.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Running the engine at 1200 RPM keeps the
oxygen sensor hot in order to ensure the
oxygen sensor remains active and can indicate
the exhaust oxygen content accurately.
3. Opening the H02S Signal circuit should result
in a displayed voltage between the 350 and
550 mV. If the display is fixed below 350 mV,
the fault is a short to the ground in the H02S
Signal circuit or a faulty VCM.
Value(s) Yes No
Go to Powertrain
OBD System
Check (OBD
Go to Step 2 System Check)
1200 RPM
0.086 V (86 mV)
Go to Step 3 Go to Step 4
6-2800 Engine Controls - 7.4L________________________________________________ Engine
DTC P0131 H02S Circuit Low Voltage Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Disconnect the H02S (Bank 1, Sensor 1).
3. Use the J 346-A/BT-8637 Connector Test Adapter Kit
in order to connect the H02S (Bank 1, Sensor 1) 0.35-0.55 V
3
Low circuit to ground. (350-550 mV)
4. Turn ON the ignition leaving the engine OFF.
Does the scan tool data display the H02S (Bank 1,
Sensor 1) voltage within the specified range? Go to Step 7 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Check for a short to the ground in the H02S (Bank 1,
5 Sensor 1) signal circuit. —
Was a problem found? Go to Step 6 Go to Step 9
Repair the circuit as necessary. Refer to Wiring Repairs in
6 Electrical Diagnosis. — —
Is the action complete? Go to Step 10
Refer to Diagnostic Aids. If a problem is found, then repair
7 as necessary. —
Was a problem found? Go to Step 10 Go to Step 8
Replace the H02S (Bank 1, Sensor 1). Refer to
8 H02S Replacement. — —
Is the action complete? Go to Step 10
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
9 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
Allow the engine to idle until the normal operating
temperature is reached.
10 Select the DTC and the Specific DTC functions. —
3. Enter the DTC number which was set.
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 11 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
11 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
Engine___________________________________________ Engine Controls - 7.4L 6-2801
DTC P0132 H 02S Circuit High Voltage Bankl Sensorl
|Hot InRunAndStart|

VCW
Cl =BLU
C2=RED
C3«CLEAR
C4-BLK

Ground
Distribution
Cell 14

Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of about 0.45 volt
(450 mV) between the H02S Signal and H02S Low
circuits. The Heated Oxygen Sensor varies the
voltage within the range of about 1.0 volt (1000 mV)
if the exhaust is rich, down to about 0.10 volt
(100 mV) if the exhaust is lean. This is a
type A DTC.
The sensor is like an open circuit and produces no
voltage when it is below 360 * C (600 * F). The
DTC P0131, P0132, an open signal circuit, or a cold
sensor causes Open Loop operation. The
DTC P0131 determines if the H02S sensor or the
signal circuit is shorted to low by checking for a lean
condition during a steady throttle and power
enrichment (PE).
Conditions for Setting the DTC
• No TP sensor DTCs
. No EVAP DTCs
• No IAT sensor DTCs
• No MAP sensor DTCs
• No ECT sensor DTCs
• No MAF sensor DTCs
200042
• No intrusive test in progress
• No device controls active
• The system voltage measures at least 9.0 volts
Test Enable (Rich Test)
• Closed Loop
• Air to fuel ratio is at least 14.5 but less
than 14.8
• The TP is greater than 0% but less than 50%
• The above must be met for 5 seconds
• H02S (Bank 1, Sensorl) DTCs not active since
code clear
• The H02S (Bank 1, Bank 1) voltage measures
greater than 0.976 volts (976 mV)
Test Enable (DFCO Rich Test)
• Decel Fuel cutoff mode is active
• Closed Loop
• The time elapsed is at least 2 seconds
• H02S (Bank 1, Sensor 1) DTCs not active
since code clear
• The H02S (Bank 1, Sensor 1) voltage
measures greater than 0.468 volts (486 mV)
Action Taken When the DTC Sets
A current DTC P0132 causes the system to operate
in the Open Loop. With a current DTC P0132 set,
the MIL turns ON after 1 test failure.
6-2802 Engine Controls - 7.4L
Conditions for Clearing the MIUDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 'C (40°F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ’ C (160'F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Check the following items:
• The fuel pressure: If the pressure is too high,
the system will run rich. The VCM can
compensate for some increase; however, if the
pressure gets too high, the DTC P0132 may
set. Refer to Fuel System Diagnosis.
• A rich injector. Perform an Injector Balance
test. Refer to Fuel Injector Balance Test.
• Fuel contaminated oil
• EVAP canister purge: Check for a fuel
saturation. If full of fuel, check the canister
control and hoses. Refer to Fuel System
Cleaning (Fuel Tank).
• Leaking fuel pressure regulator diaphragm by
checking the vacuum line to the regulator
for fuel.
Engine
• The TP sensor: An intermittent TP sensor
output causes the system to run rich due to a
false indication of the throttle moving.
• False rich indication due to silicon
contamination of the heated oxygen sensor. A
DTC P0132 accompanied by a lean driveability
conditions and a powdery white deposit on the
sensor indicates a false rich indication.
• Faulty H02S (Bank 1, Sensor 1): the H02S
(Bank 1, Sensor 1) is internally shorted, the
H02S (Bank 1, Sensor 1) voltage displayed on
a scan tool will be over 1.0 volt (1000 mV). Try
disconnecting the H02S (Bank 1, Sensor 1), if
the displayed voltage goes from over 1000 mV
to around 450 mV, replace the H02S (Bank 1,
Sensor 1).
Never solder the H02S wires. For proper wire
and connector repair, refer to Wiring Repairs in
Engine Electrical.
Test Description
The number below refers to the step number on the
diagnostic table.
2. This test determines if the conditions exist in
order to set the DTC P0132.
3. If the H02S (Bank 1, Sensor 1) is internally
shorted, the H02S (Bank 1, Sensor 1) voltage
displayed on a scan tool will be over 1.0 volt
(1000 mV).

DTC P0132 H02S Circuit High Voltage Bankl Sensorl

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 Information function is used. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral. 1200 RPM
2 4. Apply the parking brake.
7.4L - 0.950 V
5. Increase the engine speed to the specified value. (950 mV)
Does the scan tool data display indicate the H02S
(Bank 1, Sensor 1) voltage fixed above the
specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S (Bank 1, Sensor 1).
2. Turn the Ignition ON while leaving the the
3 engine OFF. 0.40 V (400 mV)
Does the scan tool data display indicate the H02S
(Bank 1, Sensor 1) voltage near the specified value? Go to Step 6 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs set? — the applicable Go to
DTC table Diagnostic Aids
Engine________________________________________________ Engine Controls - 7.4L 6-2803
DTC P0132 H02S Circuit High Voltage Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
1. Check for a short to voltage in the H02S (Bank 1,
Sensor 1) Signal circuit.
5 2. If a problem is found, repair the circuit as necessary. —
Refer to Wiring Repairs in Electrical Diagnosis.
Was the H02S (Bank 1, Sensor 1) Signal circuit shorted? Go to Step 8 Go to Step 7
Replace the Ho2S (Bank 1, Sensor 1). Refer to
6 H02S Replacement. — —

Is the action complete? Go to Step 8

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
7 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 8
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
8 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 9 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
9 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
6-2804 Engine Controls - 7.4L Engine

DTC P0133 H 02S Slow Response Bankl Sensorl

|Hot InRunAndStart]

A
JO B O IIk.

VCM
Cl =BLU
C2-RED
C3=CLEAR
C4=BLK

Ground
Distribution
Cell 14

Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of approximately
0.45 volt (450 mV) between the H02S High and the
H02S Low circuits. The Heated Oxygen Sensor
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
The VCM monitors the H02S activity for
100 seconds after the Closed Loop. During the
monitor period, the VCM counts the number of times
the H02S switches from rich to lead and from lean
to rich and adds the amount of time the sensor took
to complete all the switches. With this information,
the VCM determines an average time. If the average
time to switch is too slow, a DTC P0133 sets.
When the H02S temperature measures below 360*
(600 * F), the sensor will not produce any voltage.
The sensor will behave like an open circuit. This will
result in an Open Loop operation.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time. This allows the sensor to
remain active during a long extended idle. The
DTC P0133 determines if the H02S is functioning
properly by checking the response time of
the sensor.
200042
Conditions for Setting the DTC
• No TP sensor DTCs.
. No EVAP DTCs.
• No IAT sensor DTCs.
• No MAP sensor DTCs.
• No ECT sensor DTCs.
• No MAF sensor DTCs.
• No intrusive test in progress.
• No device controls are active
• The system voltage measures at least 9.0 volts.
• The H02S (Bank 1, Sensor 1) average
transition time from lean to rich is excessive.
• The H02S (Bank 1, Sensor 1) average
transition time from rich to lean is excessive.
Response Test Enable
• Closed loop low MAP not active.
• Closed loop.
• The DTCs P0131, P0132, P0134 and P0135
are not present.
• The ECT is greater than 5 7 ' C.
• The engine run time is greater than
75 seconds.
• The MAF is at least 15 grams per second but
less than 55 grams per second.
Engine
• Engine speed isgreater than or equal to
1100 RPM but less than 3000 RPM.
• The EVAP canister purge duty cycle is greater
than or equal to 0%.
• The above condition is present for greater than
than 2 seconds.
• The (Bank 1, Sensor 1) voltage remains
between 0.300 volt and 0.600 volt.
Action Taken When DTC Sets
The VCM turns the MIL ON after the second
test failure.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ’ C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
___________ Engine Controls - 7.4L 6-2805
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and
proper connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The number below refers to the step number on the
diagnostic table.
4. This step checks for physical damage to the
engine components and the converter.

DTC P0133 H02S Slow Response Bankl Sensorl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Are any other H02S DTCs stored? Go to
2 — the applicable
DTC table Go to Step 3
Important: The change in voltage can only occur if the
vehicle has sat for more than 30 minutes. If there is hot
exhaust, then the voltage could increase.
1. Turn the ignition ON while leaving the engine OFF. 0.150 V
3
2. Use the scan tool to monitor the H02S (Bank 1, (150 mV)
Sensor 1) voltage.
Is the displayed voltage gradually decreasing to the
specified value? Go to Step 8 Go to Step 4
1. Disconnect the H02S (Bank 1, Sensor 1)
electrical connector.
2. With a test lamp connected to an engine ground,
4 —
probe terminal D of the connector (engine
harness side).
Is the test lamp ON? Go to Step 5 Go to Step 6
6-2806 Engine Controls - 7.4L________________________________________________ Engine
DTC P0133 H02S Slow Response Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
Connect a test lamp between the terminals C and D of the
5 H02S (Bank 1, Sensor 1) connector (engine harness side). —
Is the test lamp ON? Go to Step 15 Go to Step 10
Check for an open H02S (Bank 1, Sensor 1) fuse.
6 —
Was the H02S fuse open? Go to Step 11 Go to Step 7
Check the connections at the H02S (Bank 1, Sensor 1).
7 —
Was a problem found? Go to Step 13 Go to Step 12
1. Remove the H02S (Bank 1, Sensor 1).
8 2. Inspect the sensor for contamination. —
Is the sensor contaminated? Go to Step 14 Go to Step 9
The DTC is intermittent. Go to
9 Are any‘additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Repair the open in the H02S (Bank 1, Sensor 1) ground
10 circuit. Refer to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 16
1. Repair the short to ground in the H02S (Bank 1,
Sensor 1) ignition feed circuit. Refer to Wiring
11 Repairs in Electrical Diagnosis. —
2. Replace the H02S fuse,
is the action complete? Go to Step 16 Go to Step 2
Repair the open in the H02S (Bank 1, Sensor 1) ignition
12 feed circuit. Refer to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 16
Repair as necessary.
13 — —
Is the action complete? Go to Step 16
Repair the source of the H02S
14 (Bank 1, Sensor 1) contamination. — —
Is the action complete? Go to Step 15
Replace the H02S 1. Refer to H02S Replacement.
15 — —
Is the action complete? Go to Step 16
1. Use the scan tool in order to select the DTC and the Go to Step 2
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
16 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 17
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
17
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
Engine Engine Controls - 7.4L 6-2807

DTC P0134 H 02S Insufficient Activity Bankl Sensorl

|Hot In Run And Start!

A
J 0 6 0 Ilk

VCM
Cl =BLU
C2=RED
C3=CLEAR
C4= BLK

Ground
Distribution
Cell 14

Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of about 0.45 volt
between the H02S High and the H02S Low circuits.
The Heated Oxygen Sensor (H02S) varies the
voltage from approximately 1.0 volt (1000 mV)
during rich conditions to 0.10 volt (100 mV) during
lean conditions.
The sensor is like an open circuit and produces no
voltage when it is below 360 * C (600 * F). An open
oxygen sensor circuit or a cold oxygen sensor
causes an Open Loop operation.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time and remain active during
a long extended idle.
The DTC P0134 determines if the H02S at the
H02S circuit has developed an open.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensor DTCs.
. No EVAP DTCs.
200042
• No IAT sensor DTCs.
• No MAP sensor DTCs.
• No ECT sensor DTCs.
• No MAF sensor DTCs.
• No intrusive test in progress.
• No device controls active.
• The system voltage is greater than or equal
to 9.0 volts.
• The engine run time is greater than 2 minutes.
• The H02S sensor is greater than 0.350 Volts
but less than 0.550 Volts.
H02 Sensor Temperature Test
• Engine Running.
• Not in DFCO.
• ECT greater than or equal to 80 * C.
• Air flow greater than or equa 15 g/sec.
H02S Sensor Open Test Enable
• The DTC P0135 (H02S Bank 1, Sensor 1
heater) is not set.
Action Taken When the DTC Sets
With a current DTC set, the system operates in
open loop and the MIL (Malfunction indicator lamp)
turns ON.
6-2808 Engine Controls - 7.4L
Conditions for Clearing the MIUDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40'F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 'C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Electrical Diagnosis.
A intermittent may be caused by a poor connection,
a rubbed through wire insulation, or a broken wire
inside the insulation.
Check for the following conditions:
• A poor connection or a damaged harness:
Inspect the harness connectors for the
following conditions:
- Backed out terminals
- Improperly formed or damaged terminals
- Poor terminal to wire connection
- Damaged harness
DTC P0134 H02S Insufficient Activity Bankl Sensorl
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect the scan tool.
2. Allow the engine to idle until the normal operating
temperature is reached.
2 1200 RPM
3. Run the engine above the specified value
for 2 minutes.
Does the scan tool indicate a Closed Loop?
1. Disconnect the H02S (Bank 1, Sensor 1) connector.
2. Use the J 346-A/BT-8637 Connector Test Adaptor Kit
in order to connect the H02S (Bank 1, Sensor 1)
3 Signal and Low circuits to ground.
3. Turn ON the ignition while leaving the engine OFF.
Does the scan tool data display indicate a H02S voltage
less than the specified value?
Engine
• A malfunctioning H02S heater or heater circuit:
With the ignition ON and the engine OFF, the
H02S voltage displayed on a scan tool should
gradually drop to below 0.150 volt, indicating
that the heater works properly. If not,
disconnect the H02S and connect a test lamp
between the terminals C and D. If the test lamp
does not light, repair the open in the H02S
ground circuit or the H02S ignition feed circuit.
If the test lamp lights, replace the H02S.
• The Intermittent test: Use a scan tool in order
to monitor this H02S signal voltage. Move the
related connectors and the wiring harness with
a warm engine running at part throttle in Closed
Loop. If the failure is induced, the H02S signal
voltage reading changes from its normal
fluctuating voltage (above 600 mV and below
300 mV) to a fixed value around 450 mV.
This may help to isolate the location of
the malfunction.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the conditions for setting the DTC P0134
exist, the system will not go into a
Closed Loop.
4. This test checks the continuity of the H02S 1
signal circuit.
Value(s) Yes No
Go to Powertrain
—
OBD System
Check (OBD
Go to Step 2 System Check)
Go to Step 5 Go to Step 3
0.2V (200 mV)
Go to Step 4 Go to Step 6
Engine________________________________________________ Engine Controls - 7.4L 6-2809
DTC P0134 H02S Insufficient Activity Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Remove the jumpers.
4 3. Use the J 39200 in order to check the voltage —
between the H02S (Bank 1, Sensor 1) Low circuit
and B+.
Is the voltage near the specified value? Go to Step 7 Go to Step 9
DTC is intermittent. Go to
5 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Check for an open in the H02S (Bank 1, Sensor 1)
6 signal circuit. —

Was a problem found? Go to Step 11 Go to Step 8

Check for a faulty H02S (Bank 1, Sensor 1) connection.
7 —
Was a problem found? Go to Step 11 Go to Step 10
Check for a poor connection at the VCM.
8 —
Was a problem found? Go to Step 11 Go to Step 12
Repair the open H02S (Bank 1, Sensor 1) ground circuit.
9 Refer to Wiring Repairs in Electrical Diagnosis. — —

Is the action complete. Go to Step 13

Replace the H02S (Bank 1, Sensor 1). Refer to
10 H02S Replacement. — —
Is the action complete? Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
13 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 14 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
14 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
6-2810 Engine Controls - 7.4L_______________
DTC P0135 H02S Heater Circuit Bankl Sensorl
Circuit Description
Im portant: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of approximately
0.45 volt (450 mV) between the H02S High and
H02S Low circuits. The Heated Oxygen Sensor
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
When the H02S temperature measures below
360 * C (600 * F) the sensor will not produce any
voltage and will behave like an open circuit. This will
result in an Open Loop operation.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time. The sensor will remain
active during a long extended idle. The DTC P0135
determines if the H02S is functioning properly by
checking the response time of the sensor.
Conditions for Setting the DTC
• The system voltage is greater than 9.0 volts but
less than 17.0 volts, ( if voltage remains outside
this window for 4 consecutive seconds, the test
is void for this cold start.)
• The MAF is less than 45 grams per second.
Engine
iHot InRunAndStart!
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j 0 6 0 nk
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK
Ground
Distribution
Cell 14
200042
• The engine run time is greater than 2 seconds.
• The ECT sensor is less than 32 * C.
• The IAT is less than 32 * C.
• The difference between the ECT and IAT is less
than or equal to 8*C.
• The elapsed time to obtain the ±0.150 volts
from the H02S bias voltage (0.300-0.600 volts)
is greater than the calculated value.
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive
test failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 *C (4 0 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ' C (160 ‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine_________________________________
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Engine Electrical.
• Check for a poor connection or a
damaged harness.
• Inspect the harness for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection
- A damaged harness
10. This step checks for an open H02S signal or
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. The H02S should be allowed to cool before
performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the
H02S signal will remain near the 450mv
bias voltage.
Engine Controls - 7.4L 6-2811
4. This step determines if the ignition feed circuit
to the H02S is not open or shorted. The test
light should be connected to a known good
chassis ground, in case the H02S low or H02S
heater ground circuit is faulty.
5. This step checks the H02S heater
ground circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a hot
H02S heater element will measure a much
higher resistance than a H02S heater element
at room temperature). It is important to allow
the H02S to cool before measuring the H02S
heater element resistance.
low circuit which can cause the H02S heater to
appear not to be operating correctly. It is
important to check these circuits before
replacing the sensor.

DTC P0135 H02S Heater Circuit Bankl Sensorl

Step Action Value(s) Yes No
important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Go to the
Failure records for reference. This data will be lost during
1 — Powertrain OBD
the Clear DTC Information function.
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
Important: If engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Install the scan tool.
0.150V
2 2. Turn ON the ignition leaving the engine OFF.
(150 mV)
3. Moniter the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by Go to
the specified value? Diagnostic Aids Go to Step 3
Inspect the fuse for the H02S ignition feed.
3 . —
Is the fuse open? Go to Step 12 Go to Step 4
1. Turn OFF the ignition switch.
2. Disconnect the H02S electrical connector.
3. Use a test light connected to a known good ground
4 (Do not use H02S heater ground or H02S low) in —
order to probe the ignition feed circuit at the H02S
electrical connector (VCM harness side).
Is the test light ON? Go to Step 5 Go to Step 7
Use a test light in order to connect the H02S ignition feed
5 and the H02S heater ground. —
Is the test light ON? Go to Step 6 Go to Step 8
6-2812 Engine Controls - 7.4L________________________________________________ Engine
DTC P0135 H02S Heater Circuit Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
1. Allow the H02S to cool for at least 10 minutes.
2. Use the J 39200 digital voltmeter (DVM) in order to
6 measure the resistance between the H02S ignition 3-10 ohms
feed and H02S heater ground at the H02S pigtail.
Is the H02S heater resistance within the specified values? Go to Step 9 Go to Step 11
Repair the open in the H02S ignition feed circuit. Refer to
7 Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Repair the open in the H02S heater ground circuit. Refer
8 to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
1. Check for a poor connection at the H02S
harness terminals.
9 2. If a poor connection is found, replace the terminals. —

Refer to Wiring Repairs in Electrical Diagnosis.

Was a poor connection found? Go to Step 14 Go to Step 10
1. Turn OFF the ignition switch.
2. Disconnect the VCM.
10 3. Use the J 39200 digital voltmeter (DVM) in order to 5 ohms
check the resistance of the H02S signal and H02S
low circuit.
Is the H02S resistance above the specified value? Go to Step 13 Go to Step 11
Replace the H02S. Refer to H02S Replacement
11 — —
Is the action complete? Go to Step 14
1. Check for a short to ground in the battery feed
circuit and repair if necessary. Refer to Wiring
12 Repairs in Electrical Diagnosis. — —

2. Replace the open fuse.

Is action complete? Go to Step 14
Repair the open or poor connection in the H02S signal
or H02S low circuit. Refer to Wiring Repairs in
13 Electrical Diagnosis.
— —

Is the action complete? Go to Step 14

Important: If the engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Turn ON the ignition leaving the engine OFF.
2. Use the scan tool in order to select the DTC and the 0.150V
14
Clear DTC Information functions. 150mV
3. Monitor the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by
the specified value? Go to Step 15 Go to Step 3
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
15 —
Are there any DTCs displayed that have not the Applicable
been diagnosed? DTC Table System OK
Engine Engine Controls - 7.4L 6-2813

DTC P0137 H02S Circuit Low Voltage Bankl Sensor2

Circuit Description remain active during a long extended idle. The

The VCM supplies a voltage of approximately DTC P0137 determines if the H02S or circuit is
0.45 volt (450 mV) between the H02S High and shorted low by checking for a lean condition during a
H02S Low circuits. steady throttle and power enrichment (PE).

Important: If the voltage is measured with a Conditions for Setting the DTC
10 megaohm digital voltmeter, the voltage may read The following conditions will set the DTC:
as low as 0.32 volt. The Heated Oxygen Sensor • No TP sensor DTCs.
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt . No EVAP DTCs.
(100 mV) during lean conditions. • No IAT sensor DTCs.
When the H02S temperature measures below • No MAP sensor DTCs.
360‘ C (600 *F) the sensor will not produce any • No ECT sensor DTCs.
voltage. The sensor will behave like an open circuit. • No MAF sensor DTCs.
This will result in an open loop operation.
• No active Misfire DTCs.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active • No intrusive test in progress.
in a shorter period of time. The sensor will also • No device controls active.
• The system voltage is greater than or equal
to 9.0 volts.
6-2814 Engine Controls - 7.4L
Test Enable Lean Test
• Closed Loop Low MAP not active.
• Closed Loop.
• Air to fuel ratio is greater than or equal to 14.5
but less than or equal to 14.8.
• The TP is greater than 3.5% but less
than 99%.
• The above met for 5 seconds
• Related H02S DTCs not active since
code clear
Test Enable PE Lean Test
• A Closed Loop.
• The Power Enrichment mode active.
• The high speed fuel cutoff not active.
• Related H02S DTCs not active.
• Time elapse since test enable is greater than or
equal to 2 second.
Action Taken When the DTC Sets
The VCM turns on the MIL (Malfunction Indicator
Lamp) after 2 consecutive failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 * C (160 * F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
important: Never solder the H02S wires. For proper
wire and connector repair refer to Wiring Repairs in
Electrical Diagnosis.
Engine
Using the scan tool, observe the L.T. fuel trim values
at the different RPM and the air flow conditions. The
scan tool also displays the fuel trim cells, so the L.T.
fuel trim values can be checked in each of the cells
in order to determine when the DTC may have set.
If the conditions for this DTC exist, the L.T. fuel trim
values measure around 158 or greater.
Check for the following conditions:
• A sensor pigtail may be mispositioned and
contacting the exhaust manifold.
• An intermittent ground in wire between the
connector and the sensor.
• A poor VCM ground.
• Lean injectors: Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test
• Fuel Contamination: Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the injectors. The water causes
a lean exhaust and can also set this DTC.
• Fuel pressure: If the pressure is too low, the
system will be lean. In order to confirm, monitor
a fuel pressure while driving the vehicle at
various speeds and loads. Refer to Fuel
System Diagnosis.
• Exhaust leaks: If there is an exhaust leak, the
engine may pull the outside air into the
exhaust, and past the sensor.
. Vacuum or the Crankcase leaks can cause a
lean condition or a possibly a high idle.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Running the engine at 1200 RPM keeps the
H02S temperature hot in order to ensure the
H02S remains active. Running the engine at
1200 RPM can indicate the exhaust oxygen
content accurately.
3. Opening the H02S circuit should result in a
displayed voltage between 350 and 550 mV. If
the display is still fixed below the 350 mV, the
fault is a short to a ground in the H02S high
signal circuit or a faulty VCM.
Engine Engine Controls - 7.4L 6-2815
DTC P0137 H02S Circuit Low Voltage Bankl Sensor2
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral. 1200 RPM
2 4. Apply the parking brake. 0.017 V
5. Increase the engine speed to the specified value. (17 mV)
Does the scan tool data display indicate a H02S voltage
fixed less than the specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S.
2. Jumper the H02S Low circuit to a ground.
0.35-0.55 V
3 3. Turn ON the ignition while leaving the engine OFF. (350-550 mV)
Does the scan tool data display indicate the H02S voltage
that is within the specified range. Go to Step 7 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Check for a short to ground in the H02S Signal circuit.
5 —
Was a problem found? Go to Step 6 Go to Step 9
Repair the circuit as necessary. Refer to Wiring Repairs in
6 Electrical Diagnosis. — —
Is the action complete? Go to Step 10
Refer to Diagnostic Aids.
7 —
Was a problem found and repaired? Go to Step 10 Go to Step 8
Replace the H02S. Refer to H02S Replacement.
8 — —
Is the action complete? Go to Step 10
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
9 to Password Learn Procedure.
— —

4. Perform the Crankshaft Variation Learn Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
6-2816 Engine Controls - 7.4L Engine
DTC P0137 H02S Circuit Low Voltage Bankl Sensor2 (cont’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
10 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan toot indicate that this diagnostic ran
and passed? Go to Step 11 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
11 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
Engine___________________________________________ Engine Controls - 7.4L 6-2817

DTC P0138 H 02S Circuit High Voltage Bankl Sensor2

Circuit Description remain active during a long extended idle. The

The VCM supplies a voltage of about 0.45 volt DTC P0138 determines if the H02S or circuit is
shorted low by checking for a lean condition during a
(450 mV) between the H02S High and H02S Low
steady throttle and power enrichment (PE).
circuits.
Important: If the voltage is measured with a
Conditions for Setting the DTC
10 megaohm digital voltmeter, the voltage may read The following conditions will set the DTC:
as low as 0.32 volt. The Heated Oxygen Sensor • No TP sensor DTCs.
(H02S) varies the voltage from approximately . No EVAP DTCs.
1.0 volt (1000 mV) during rich conditions to 0.10 volt
• No IAT sensor DTCs.
(100 mV) during lean conditions.
• No MAP sensor DTCs.
When the H02S temperature measures below • No ECT sensor DTCs.
360' C (600 * F) the sensor will not produce any
• No MAF sensor DTCs.
voltage. The sensor will behave like an open circuit.
This will result in an open loop operation. • No active Misfire DTCs.
The H02S heater provides for a faster sensor • No intrusive test in progress.
warm-up which allows the sensor to become active • No device controls active.
in a shorter period of time. The sensor will also • The system voltage measures greater than or
equal to 9.0 volts.
6-2818 Engine Controls - 7.4L___________
Test Enable Rich Test
• A Closed Loop.
• Air to fuel ratio is greater than or equal to 14.5
but less than or equal to 14.8.
• The TP is greater than 0% but less than 50%.
• The above must meet for 5 seconds.
Test Enable DFCO Rich Test
• Decel Fuel cutoff mode is active.
• A Closed Loop
• The time elapsed is at least 2 seconds.
Action Taken When the DTC Sets
The VCM turns on the MIL (Malfunction Indicator
Lamp) after 2 consecutive failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 'C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ‘ C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connector repair refer to Wiring Repairs in
Electrical Diagnosis.
Check the following items:
• The fuel pressure: If the pressure is too high,
the system will run rich. The VCM can
compensate for some increase; however, if the
pressure gets too high, the DTC P0138 may
set. Refer to Fuel System Diagnosis.
Engine
• A rich injector. Perform an Injector Balance test.
Refer to Fuel Injector Balance Test.
• A leaking injector. Refer to Fuel
System Diagnosis.
• Fuel contaminated oil
• EVAP canister purge: Check for a fuel
saturation. If full of fuel, check the canister
control and hoses. Refer to EVAP Control
System Diagnosis.
• Leaking fuel pressure regulator diaphragm by
checking the vacuum line to the regulator
for fuel.
• The TP sensor: An intermittent TP sensor
output causes the system to run rich due to a
false indication of the throttle moving.
• False rich indication due to silicon
contamination of the heated oxygen sensor. A
DTC P0138 accompanied by a lean driveability
conditions and a powdery white deposit on the
sensor indicates a false rich indication.
• Faulty H02S: the H02S is internally shorted,
the H02S voltage displayed on a scan tool will
be over 1.0 volt (1000 mV). Try disconnecting
the H02S, if the displayed voltage goes from
over 1000 mV to around 450 mV, replace
the H02S.
Test Description
The number below refers to the step number on the
diagnostic table.
2. This step determines if the conditions exist in
order to set the DTC P0152.
3. If the H02S is internally shorted, the H02S
voltage displayed on a scan tool will be over
1.0 volt (1000 mV).
Engine________________________________________________ Engine Controls - 7.4L 6-2819
DTC P0138 H02S Circuit High Voltage Bankl Sensor2
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral. 1200 RPM
2 4. Apply the parking brake. 0.976 V
5. Increase the engine speed to the specified value. (976 mV
Does the scan tool data display indicate H02S voltage
fixed above the specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S.
2. Turn ON the ignition while leaving the engine OFF.
3 400 mV
Does the scan tool data display indicate the H02S voltage
near the specified value? Go to Step 6 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs set? — the applicable Go to
DTC table Diagnostic Aids
1. Check for a short to voltage in the H02S
Signal circuit.
5 2. If a problem is found, repair the circuit as necessary. —
Refer to Wiring Repairs in Electrical Diagnosis.
Was the H02S Signal circuit shorted? Go to Step 8 Go to Step 7
Replace the H02S. Refer to H02S Replacement
6 — —
Is the action complete? Go to Step 8
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
7 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 8
1. Use the scan tool in order to select the DTC and the
Clear DTC Information function.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
8 4. Select the DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
' 6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 9 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
9 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
6-2820 Engine Controls - 7.4L Engine

DTC P0140 H 02S Insufficient Activity Bankl Sensor2

Circuit Description Conditions for Setting the DTC

Important: If the voltage is measured with a The following conditions will set the DTC:
10 megohm digital voltmeter, the voltage may read • No TP sensor DTCs.
as low as 0.32 volt. . No EVAP DTCs.
The VCM supplies a voltage of about 0.45 volt • No IAT sensor DTCs.
(450 mV) between the H02S High and the H02S • No MAP sensor DTCs.
Low circuits.
• No ECT sensor DTCs.
The Heated Oxygen Sensor (H02S) varies the
voltage from approximately 1.0 volt (1000 mV) • No MAF sensor DTCs.
during rich conditions to 0.10 volt (100 mV) during • No active misfire DTCs.
lean conditions. The sensor is like an open circuit • No intrusive test in progress.
and produces no voltage when it is below
• No device controls active.
360 *C (600 *F).
• The system voltage measures is greater than or
The H02S heater provides for a faster sensor
equal to 9.0 volts.
warm-up which allows the sensor to become active
in a shorter period of time and remain active during • The engine run time is greater than or equal
a long extended idle. The DTC P0140 determines if to 2 minutes.
the H02S or the H02S circuit has developed
an open.
Engine
H02 Sensor Temperature Test
• Engine Running.
• Not in DFCO.
• ECT is greater than or equal to 80 * C.
• Air Flow is greater than or equal to 15 g/s.
H02S Sensor Open Test Enable
• H 0 2 Sensor Temperature Test = True.
• The DTC P0141 (H 02S heater) not set.
• Closed Loop.
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive
test failures.
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 *F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160 * F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
Important: Never solder the H 02S wires. For proper
wire and connection repairs, refer to W iring Repairs
in Electrical Diagnosis.
A intermittent may be caused by a poor connection,
a rubbed through wire insulation, or a broken wire
inside the insulation.
DTC P0140 H02S Insufficient Activity Bankl Sensor2
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 —
the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect the scan tool.
2. Allow the engine to idle until normal operating
temperature is reached.
2 1200 RPM
3. Run the engine above the specified value
for 2 minutes.
Does the scan tool indicate a Closed Loop?
1. Disconnect the H02S connector.
2. Use the J 346-A/BT-8637 Connector Test Adaptor Kit
in order to connect the H02S Signal and Low
3 circuits to ground.
3. Turn ON the ignition while leaving the engine OFF.
Does the scan tool data display indicate a H02S voltage
less than the specified value?
Engine Controls - 7.4L 6-2821
Check for the following conditions:
• A poor connection or a damaged harness:
Inspect the harness connectors for the
following conditions:
- Backed out terminals
- Improperly formed or damaged terminals
- Poor terminal to wire connection
- Damaged harness
• A malfunctioning H 02S heater or heater circuit:
With the ignition ON and the engine OFF, the
H 02S voltage displayed on a scan tool should
gradually drop to below 0.150 volt, indicating
that the heater works properly. If not,
disconnect the H 02S and connect a test lamp
between the terminals C and D. If the test lamp
does not light, repair the open in the H 02S
ground circuit or the H 02S ignition feed circuit.
If the test lamp lights, replace the H02S.
• The Intermittent test: Use a scan tool in order
to monitor this H 02S signal voltage. Move the
related connectors and the wiring harness with
a warm engine running at part throttle in Closed
Loop. If the failure is induced, the H 02S signal
voltage reading changes from its normal
fluctuating voltage (above 600 mV and below
300 mV) to a fixed value around 450 mV.
This may help to isolate the location of
the malfunction.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the conditions for setting this DTC exist, the
system will not go into a Closed Loop.
3. This test checks the continuity of the H 02S
signal circuit.
Value(s) Yes No
Go to Powertrain
OBD System
Check (OBD
Go to Step 2 System Check)
Go to Step 5 Go to Step 3
0.2 V (200 mV)
Go to Step 4 Go to Step 6
6-2822 Engine Controls - 7.4L Engine
DTC P0140 H02S Insufficient Activity Bankl Sensor2 (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Remove the jumpers.
4 3. Use the DVM J 39200 in order to check the voltage 12.0V
between the H02S Low circuit and B+.
Is the voltage near the specified value? Go to Step 7 Go to Step 9
This DTC is intermittent. Go to
5 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Check for an open in the H02S signal circuit.
6 —
Was a problem found? Go to Step 11 Go to Step 8
Check for a faulty H02S connection.
7 —
Was a problem found? Go to Step 11 Go to Step 10
Check for a poor connection at the VCM.
8 —
Was a problem found? Go to Step 11 Go to Step 12
Repair the open H02S ground circuit. Refer to Wiring
9 Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 13
Replace the H02S. Refer to H02S Replacement.
10 — —
Is the action complete? Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until normal operating
temperature is reached.
13 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 14 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
14 —
Are there any DTCs displayed that have not the applicable
been diagnosed? DTC table System OK
Engine_____________________________________
DTC P0141 H 02S Heater Circuit Bankl Sensor2
Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of approximately
0.45 volt (450 mV) between the H02S High and
H02S Low circuits. The Heated Oxygen Sensor
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
When the H02S temperature measures below
360 * C (600' F) the sensor will not produce any
voltage and will behave like an open circuit. This will
result in an Open Loop operation.
Engine Controls - 7.4L 6-2823
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time. The sensor will remain
active during a long extended idle. The DTC P0135
determines if the H02S is functioning properly by
checking the response time of the sensor.
Conditions for Setting the DTC
• The system voltage is greater than 9.0 volts but
less than 17.0 volts.
• The MAF is less than 45 grams per second.
• The engine run time is greater than 2 seconds.
• The ECT sensor is less than 32 * C.
• The IAT is less than 32 * C.
• The difference between the ECT and IAT is no
more than 8 * C.
6-2824 Engine Controls - 7.4L
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive
test failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160’ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Engine Electrical.
• Check for a poor connection or a
damaged harness.
• Inspect the harness for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection
- A damaged harness
Engine
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. The H 02S should be allowed to cool before
performing this test. If the H 02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the
H 02S signal will remain near the 450mv
bias voltage.
4. This step determines if the ignition feed circuit
to the H 02S is not open or shorted. The test
light should be connected to a known good
chassis ground, in case the H 02S low or H02S
heater ground circuit is faulty.
5. This step checks the H 02S heater
ground circuit.
6. This step checks for an open or shorted H 02S
heater element. The heater element resistance
will vary according to H 02S temperature (a hot
H 02S heater element will measure a much
higher resistance than a H 02S heater element
at room temperature). It is important to allow
the H 02S to cool before measuring the H 02S
heater element resistance.
10. This step checks for an open H 02S signal or
low circuit which can cause the H 02S heater to
appear not to be operating correctly. It is
important to check these circuits before
replacing the sensor.

DTC P0141 H 0 2 S Heater C ircuit B ankl Sensor2

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Go to the
Failure records for reference. This data will be lost during Powertrain OBD
1 the Clear DTC Information function. —
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
Important: If engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Install the scan tool.
0.150V
2 2. Turn ON the ignition leaving the engine OFF.
(150 mV)
3. Moniter the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by Go to
the specified value? Diagnostic Aids Go to Step 3
Inspect the fuse for the H02S ignition feed.
3 —
Is the fuse open? Go to Step 12 Go to Step 4
Engine Engine Controls - 7.4L 6-2825
DTC P0141 H02S Heater Circuit Bankl Sensor2 (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition switch.
2. Disconnect the H02S electrical connector.
3. Use a test light connected to a known good ground
4 (Do not use H02S heater ground or H02S low) in —
order to probe the ignition feed circuit at the H02S
electrical connector (VCM harness side).
Is the test light ON? Go to Step 5 Go to Step 7
Use a test light in order to connect the H02S ignition feed
5 and the H02S heater ground. —
Is the test light ON? Go to Step 6 Go to Step 8
1. Allow the H02S to cool for at least 10 minutes.
2. Use the J 39200 digital voltmeter (DVM) in order to
6 measure the resistance between the H02S ignition 3-10 ohms
feed and H02S heater ground at the H02S pigtail.
Is the H02S heater resistance within the specified values? Go to Step 9 Go to Step 11
Repair the open in the H02S ignition feed circuit. Refer to
7 Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Repair the open in the H02S heater ground circuit. Refer
8 to Wiring Repairs in Electrical Diagnosis. — —

Is the action complete? Go to Step 14

1. Check for a poor connection at the H02S
harness terminals.
9 2. If a poor connection is found, replace the terminals. —
Refer to Wiring Repairs in Electrical Diagnosis.
Was a poor connection found? Go to Step 14 Go to Step 10
1. Turn OFF the ignition switch.
2. Disconnect the VCM.
10 3. Use the J 39200 digital voltmeter (DVM) in order to 5 ohms
check the resistance of the H02S signal and H02S
low circuit.
Is the H02S resistance above the specified value? Go to Step 13 Go to Step 11
Replace the H02S. Refer to H02S Replacement
11 — —
Is the action complete? Go to Step 14
1. Check for a short to ground in the battery feed
circuit and repair if necessary. Refer to Wiring
12 Repairs in Electrical Diagnosis. — —
2. Replace the open fuse.
Is action complete? Go to Step 14
Repair the open or poor connection in the H02S signal
or H02S low circuit. Refer to Wiring Repairs in
13 Electrical Diagnosis. — —

Is the action complete? Go to Step 14

6-2826 Engine Controls - 7.4L Engine
DTC P0141 H02S Heater Circuit Bankl Sensor2 (cont’d)
Step Action Value(s) Yes No
Important: If the engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Turn ON the ignition leaving the engine OFF.
2. Use the scan tool in order to select the DTC and the 0.150V
14
Clear DTC Information functions. 150mV
3. Monitor the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by
the specified value? Go to Step 15 Go to Step 3
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
15 —
Are there any DTCs displayed that have not the Applicable
been diagnosed? DTC Table System OK
Engine___________________________________________ Engine Controls ■ 7.4L 6-2827

DTC P0151 H02S Circuit Low Voltage Bank2 Sensori

|Hot In RunAndStart|

N
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK

200113

Circuit Description • No MAF sensor DTCs

Important: If the voltage is measured with a • No intrusive test in progress
10 Megaohm Digital Voltmeter, the voltage may read • No device controls active
as low as 0.32 volt (320 mV). • The system voltage measures at least 9.0 volts
The VCM supplies a voltage of about 0.45 volt
(450 mV) between the H02S Signal and H02S Low
Test Enable Lean Test
circuits. The Heated Oxygen Sensor varies the • Closed Loop
voltage within the range of about 1.0 volt (1000 mV) • Closed Loop low MAP not active
if the exhaust is rich, down to about 0.10 volt • Air to fuel ratio is at least 14.5 but less
(100 mV) if the exhaust is lean. -This is a than 14.8
type A DTC.
• The TP is greater than 10% but less than 99%
The sensor is like an open circuit and produces no
voltage when it is below 360 *C (600 *F). The • The above met for 5 seconds
DTC P0131, P0132, an open signal circuit, or a cold • Related H02 sensor DTCs not active since
sensor causes Open Loop operation. The code clear
DTC P0131 determines if the H02S sensor or the • The H02S (Bank 2, Sensor 1) voltage is less
signal circuit is shorted to low by checking for a lean than 0.086 volts (86 mV)
condition during a steady throttle and power
enrichmeht (PE). Test Enable PE Lean Test
• A Closed Loop
Conditions for Setting the DTC
• The Power Enrichment mode active
The following conditions will set the DTC:
• The high speed fuel cutoff not active
• No TP sensor DTCs
• Time elapse since test enable is at least
. No EVAP DTCs
1 second
• No IAT sensor DTCs • Related H02 sensor DTCs not active since
• No MAP sensor DTCs code clear
• No ECT sensor DTCs • The H02S (Bank 2, Sensor 1) voltage is less
than 0.598 volts (598 mV)
6-2828 Engine Controls - 7.4L
Action Taken When The DTC Sets
A current DTC P0151 causes the system to operate
in open loop. With the DTC P0151 set, the MIL
(Malfunction Indicator Lamp) turns ON at the first
test failure.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ‘ C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repair refer to Wiring Repairs in
Electrical Diagnosis.
Using the scan tool, observe the L.T. fuel trim values
at the different RPM and the air flow conditions. The
scan tool also displays the fuel trim cells, so the L.T.
fuel trim values can be checked in each of the cells
in order to determine when the DTC may have set.
If the conditions for this DTC exist, the L.T. fuel trim
values measure around 158 or greater.
Check for the following conditions:
• Display the H02S voltage with a scan tool. If
the voltage is less than 0.086 V (86 mV) and
increases to about 0.450 V (450 mV) after the
H02S is disconnected, then the H02S is
internally shorted and should be replaced.
DTC P0151 H02S Circuit Low Voltage Bank2 Sensorl
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 Go to Powertrain
the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral.
4. Apply the parking brake.
2
5. Increase the engine speed to the specified value.
Does the scan tool data display indicate the H02S
(Bank 2, Sensor 1) sensor voltage fixed less than the
specified value?
Engine
• A sensor pigtail may be mispositioned and
contacting the exhaust system.
• An intermittent short to ground in the signal
circuit between the VCM connector and H02S.
• A poor VCM to the engine block ground.
• Lean injectors: Perform the Injector
Balance Test.
• Fuel Contamination: Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the injectors. The water causes
a lean exhaust and can also set this DTC.
• Fuel pressure: If the pressure is too low, the
system will be lean. In order to confirm, monitor
a fuel pressure while driving the vehicle at
various speeds and loads.
• Exhaust leaks: If there is an exhaust leak, the
engine may pull the outside air into the
exhaust, and past the sensor.
• Vacuum or the Crankcase leaks can cause a
lean condition or a possibly a high idle.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Running the engine at 1200 RPM keeps the
oxygen sensor hot in order to ensure the
oxygen sensor remains active and can indicate
the exhaust oxygen accurately.
3. Opening the H02S Signal circuit should result
in displayed voltage between 350 and 550 mV.
If the display is fixed below 350 mV, the fault is
a short to ground in the H02S Signal circuit or
a faulty VCM.
Value(s) Yes No
—
OBD System
Check (OBD
Go to Step 2 System Check)
1200 RPM
0.086 (86 mV
Go to Step 3 Go to Step 4
Engine________________________________________________ Engine Controls - 7.4L 6-2829
DTC P0151 H02S Circuit Low Voltage Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Disconnect the H02S (Bank 2, Sensor 1).
3. Use the J 346-A/BT-8637 Connector Test Adaptor Kit
to connect the H02S (Bank 2, Sensor 1) Low circuit 0.35-0.55 V
3
to ground. (350-550 mV)
4. Turn ON the ignition while leaving the engine OFF.
Does the scan tool data display indicate H02S (Bank 2,
Sensor 1) voltage within the specified range? Go to Step 7 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Check for a short to ground in the H02S (Bank 2,
5 Sensor 1) Signal circuit. —
Was a problem found? Go to Step 6 Go to Step 9
Repair the circuit as necessary. Refer to Wiring Repairs in
6 Electrical Diagnosis. — —
Is the action complete? Go to Step 10
Refer to the Diagnostic Aids. If a problem is found, then
7 repair as necessary. —
Was a problem found? Go to Step 10 Go to Step 8
Replace the H02S (Bank 2, Sensor 1). Refer to
8 H02S Replacement. — —

Is the action complete? Go to Step 10

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
9 to Password Leam Procedure.
— —

4. Perform the Crankshaft Variation Leam Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
10 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran
and passed? Go to Step 11 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
11 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
6-2830 Engine Controls - 7.4L_____________________ Engine
DTC P0152 H 02S Circuit High Voltage Bank2 Sensorl
|Hot In Run And Start|

VCM
C1 = BLU
C2 = RED
C3 = CLEAR
C4 = BLK

200113

Circuit Description • No device controls active.

Important: If measured with a megaohm digital
voltmeter, this may read as low as 0.32 volt.
The VCM supplies a voltage of about 0.45 volt
(450 mV) between the H02S signal and the H02S
Low circuits. The Heated Oxygen Sensor (H02S)
varies the voltage from approximately 1.0 volt
(1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
The sensor acts like an open circuit and produces
no voltage when the temperature is below 360 * C
(600 * F). The DTC P0151, P0152 or an open sensor
circuit or the cold sensor causes the open loop
operation. The DTC P0152 determines if the H02S
sensor or the circuit is shorted to high by checking
for a rich condition during a steady throttle.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensor DTCs.
. No EVAP DTCs.
• No IAT sensor DTCs.
• No MAP sensor DTCs.
• No ECT sensor DTCs.
• No MAF sensor DTCs.
• No active Misfire DTCs.
• No intrusive test in progress.
• The system voltage is greater than or equal to
9.0 volts.
Test Enable Rich Test
• A Closed Loop.
• Air to fuel ratio is greater than or equal to 14.5
but less than or equal to 14.8.
• The TP is greater than 0% but less than 50%.
• The above must meet for 5 seconds.
• The H02S (Bank 2, Sensor 1) voltage is
greater than 950 mV.
Test Enable DFCO Rich Test
• Decel Fuel cutoff mode is active.
• A Closed Loop.
• The time elapsed is at least 2 seconds.
• The H02S (Bank 2, Sensor 1) voltage is
greater than 468 mV.
Action Taken When The DTC Sets
A current DTC P0151 causes the system to operate
in open loop. With the DTC P0151 set, the MIL
(Malfunction Indicator Lamp) turns ON at the first
test failure.
Engine
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after 3
consecutive drive trips when the test has Run
and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 *C
(160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Check the following items
• Fuel pressure. System will go rich if pressure is
too high. The VCM can compensate for some
increase. However, if it gets too high, DTC
P0158 may be set. Refer to Fuel System
Diagnosis.
• Rich injector. Perform the Fuel Injector
Balance Test
• Check for fuel contaminated oil.
• EVAP canister purge. Check for fuel saturation.
If full of fuel, check canister control and hoses.
Refer to EVAP Control System Diagnosis.
Engine Controls ■ 7.4L 6-2831
• Check for leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for fuel.
• TP sensor. An intermittent TP sensor output will
cause the system to go rich due to a false
indication of the throttle moving.
• False rich indication due to silicon
contamination of the H02S. This will be
indicated by DTC P0158 accompanied by lean
driveability conditions and a powdery white
deposit on the sensor.
• Faulty H02S (Bank 2 Sensor 2). If H02S (Bank
2 Sensor 2) is internally shorted the H02S
(Bank 2 Sensor 2) voltage displayed on a scan
tool will be over 1 V. Try disconnecting the
H02S (Bank 2 Sensor 2); if the displayed
voltage goes from over 1000 mV to around
450 mV, replace H02S (Bank 2 Sensor 2).
• Never solder the H02S wires.
Test Description
The number below refers to the step number on the
diagnostic table.
2. This step determines if the conditions exist in
order to set the DTC P0152.
3. If the H02S is internally shorted, the H02S
voltage displayed on a scan tool will be over
1.0 volt (1000 mV).

DTC P0152 H02S Circuit High Voltage Bank2 Sensorl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Run the engine at the normal operating temperature.
3. Place the vehicle in park or neutral. 1200 RPM
2 4. Apply the parking brake. 0.976 V
5. Increase the engine speed to the specified value. (976 mV
Does the scan tool data display indicate H02S voltage
fixed above the specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S.
2. Turn ON the ignition while leaving the engine OFF.
3 400 mV
Does the scan tool data display indicate the H02S voltage
near the specified value? Go to Step 6 Go to Step 5
The DTC is intermittent. Go to
4 Are any additional DTCs set? — the applicable Go to
DTC table Diagnostic Aids
1. Check for a short to voltage in the H02S Signal
circuit.
5 2. If a problem is found, repair the circuit as necessary. —
Refer to Wiring Repairs in Electrical Diagnosis.
Was the H02S Signal circuit shorted? Go to Step 8 Go to Step 7
6-2832 Engine Controls - 7.4L________________________________________________ Engine
DTC P0152 H02S Circuit High Voltage Bank2 Sensor! (cont’d)
Step Action Value(s) Yes No
Replace the H02S. Refer to H02S Replacement.
6 — —
Is the action complete? Go to Step 8
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
7 to Password Learn Procedure.
— —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 8
1. Use the scan tool in order to select the DTC and the
Clear DTC Information function.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
8 4. Select the DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 9 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
9 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine_______________________________________ Engine Controls - 7.4L 6-2833

DTC P0153 H02S Slow Response Bank2 Sensorl

| Hot In Run And Start |

VCM
Cl = BLU
C2 = RED
C3 = CLEAR
C4 = BLK

200113

Circuit Description Conditions for Setting the DTC

Important: If a 10 megaohm digital voltmeter The following conditions will set the DTC:
measures this voltage, the voltage may read as low • No TP sensor DTCs.
as 0.32 volt. The Heated Oxygen Sensor (H02S) . No EVAP DTCs.
varies the voltage within a range of about 1.0 volt
(1000mV) if the exhaust is rich to as low as 0.1 volt • No IAT sensor DTCs.
(100 mV) if the exhaust is lean. • No MAP sensor DTCs.
The VCM supplies a voltage of approximately • No ECT sensor DTCs.
0.45 volt (450 mV) between the H02S High and the • No MAF sensor DTCs.
H02S Low circuits. • No Misfire DTCs active.
The VCM monitors the Heated Oxygen Sensor • No intrusive test in progress.
(H02S) activity for 100 seconds after the Closed
• No device controls active.
Loop. During the monitor period, the VCM counts the
number of times that the H02S switches from rich to • System voltage is greater than or equal to
lean and from lean to rich, and adds the amount of 9.0 volts.
time the sensor took to complete all switches. With • The H02S average transition time from lean to
this information, the VCM determines an average rich is greater than 125 millisec.
time. If the average time to switch is too slow, a • The H02S average transition time from rich to
DTC P0153 sets. lean is greater than 125 millisec.
When the H02S temperature is below 360 *C
(600 * F), the sensor will not produce any voltage. Response Test Enable
The sensor will behave like an open circuit. This will . DTCs P0131, P0132, P0134, and P0135 are
result in an Open Loop operation. not active.
The H02S heater provides for a faster sensor • A Closed Loop.
warm-up which allows the sensor to become active • The ECT is greater than 57 * C.
in a shorter period of time and remain active during
a long extended idle. The DTC P0153 determines if • The engine run time is greater than
the H02S is functioning properly by checking its 75 seconds.
response time.
6-2834 Engine Controls - 7.4L
• The MAF is at least 15 grams per seconds but
no more than 55 grams per second.
• Engine speed is greater than or equal to
1100 RPM but less than or equal to 3000 RPM.
• The EVAP canister purge duty cycle is greater
than or equal to 0%.
• The above conditions are present for greater
than 2 seconds.
Action Taken When DTC Sets
The VCM turns the MIL ON after the second test
failure.
Conditions for Clearing the MIL7DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 7 0 ’ C
(160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and proper
connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The number below refers to the step number on the
diagnostic table.
4. This step checks the ignition feed to the H02S.

DTC P0153 H02S Slow Response Bank2 Sensorl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Are any other H02S DTCs stored? Go to
2 — the applicable
DTC table Go to Step 3
Important: The change in voltage can only occur if the
vehicle has sat for more than 30 minutes. If there is hot
exhaust, then the voltage could increase.
3 1. Turn the ignition ON while leaving the engine OFF. 0.150 (150 mV)
2. Use the scan tool to monitor the H02S voltage.
Is the displayed voltage gradually decreasing to the
specified value? Go to Step 8 Go to Step 4
1. Disconnect the H02S electrical connector.
2. With a test lamp connected to an engine ground,
4 probe terminal D of the connector (engine —
harness side).
Is the test lamp ON? Go to Step 5 Go to Step 6
Connect a test lamp between the terminals C and D of the
5 H02S connector (engine harness side). —
Is the test lamp ON? Go to Step 15 Go to Step 10
Engine________________________________________________ Engine Controis - 7.4L 6-2835
DTC P0153 H02S Slow Response Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
Check for an open H02S fuse.
6 —
Was the H02S fuse open? Go to Step 11 Go to Step 7
Check the connections at the H02S.
7 —
Was a problem found? Go to Step 13 Go to Step 12
1. Remove the H02S.
8 2. Inspect the sensor for contamination. —
Is the sensor contaminated? Go to Step 14 Go to Step 9
The DTC is intermittent. Go to
9 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Repair the open in the H02S ground ciruit. Refer to Wiring
10 Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 16
1. Repair the short to ground in the H02S ignition feed
circuit. Refer to Wiring Repairs in Electrical
11 Diagnosis. — —
2. Replace the H02S fuse.
Is the action complete? Go to Step 16
Repair the open in the H02S ignition feed circuit. Refer to
12 Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 16
Repair as necessary.
13 — —
Is the action complete? Go to Step 16
Repair the source of the H02S contamination.
14 — —
Is the action complete? Go to Step 15
Replace the H02S. Refer to H02S Replacement.
15 — —
Is the action complete? Go to Step 16
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to Idle until the normal operating
temperature is reached.
16 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 17 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
17 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
6-2836 Engine Controls - 7.4L____________________ Engine

DTC P0154 H 02S Insufficient Activity Bank2 Sensorl

| Hot In Run And Start |

VCM
Cl = BLU
C2 «* RED
C3 = CLEAR
C4 = BLK

200113

Circuit Description • No ECT sensor DTCs.

Im portant: If the voltage is measured with a . No MAF DTCs.
10 megohm digital voltmeter, the voltage may read • No Misfire CTDs active.
as low as 0.32 volt. • No intrusive test in progress.
The VCM supplies a voltage of about 0.45 volt • No device controls active.
between the H02S High and the H02S Low circuits. • System Voltage is greater than or equal to
The Heated Oxygen Sensor (H02S) varies the 9 volts.
voltage from approximately 1.0 volt (1000 mV) during • The engine run time isgreater than or equal to
rich conditions to 0.10 volt (100 mV) during lean 2 minutes.
conditions. The H02S is like an open circuit and
produces no voltage when it is below 360 *C H 02 Sensor Temperature Test
(600 *F). • Engine Running.
The H02S heater provides for a faster sensor • Not in DFCO.
warm-up which allows the sensor to become active • ECT is greater than or equal to 80 * C.
in a shorter period of time and remain active during • Air Flow is greater than or equal to 15 g/sec.
a long extended idle. The DTC P0154 determines if
H 02 Sensor Open Test Enable
the H02S or the H02S circuit has developed
an open. • H02 Sensor Temperature Test = true
• DTC P0147 is not active.
Conditions for Setting the DTC
• A Closed Loop.
The following conditions will set the DTC.
• The H02S (Bank 2 Sensor 1) voltage is greater
• No TP sensor DTCs. than 350 mV, but less than 550 mV.
. No EVAP DTCs.
• No IAT sensor DTCs.
Action Taken When the DTC Sets
. No MAP DTCs. The VCM turns the MIL ON after 2 consecutive test
failures.
Engine
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 4 0 ’ F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160"F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Electrical Diagnosis.
A intermittent may be caused by a poor connection,
a rubbed through wire insulation, or a broken wire
inside the insulation.
Check for the following conditions:
• A poor connection or a damaged harness:
Inspect the harness connectors for the following
conditions:
- Backed out terminals
- Improperly formed or damaged terminals
- Poor terminal to wire connection
- Damaged harness
Engine Controls - 7.4L 6-2837
• A malfunctioning H02S heater or heater circuit:
With the ignition ON and the engine OFF, the
H02S voltage displayed on a scan tool should
gradually drop to below 0.150 volt, indicating
that the heater works properly. If not,
disconnect the H02S and connect a test lamp
between the terminals C and D. If the test lamp
does not light, repair the open in the H02S
ground circuit or the H02S ignition feed circuit.
If the test lamp lights, replace the H02S.
• The Intermittent test: Use a scan tool in order
to monitor this H02S signal voltage. Move the
related connectors and the wiring harness with
a warm engine running at part throttle in Closed
Loop. If the failure is induced, the H02S signal
voltage reading changes from its normal
fluctuating voltage (above 600 mV and below
300 mV) to a fixed value around 450 mV. This
may help to isolate the location of the
malfunction.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the conditions for setting this DTC exist, the
system will not go into a Closed Loop.
3. This test checks the continuity of the H02S
signal circuit.

DTC P0154 H02S Insufficient Activity Bank2 Sensorl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during Go to Powertrain
1 the Clear DTC Information function. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Allow the engine to idle until normal operating
temperature is reached.
2 1200 RPM
3. Run the engine above the specified value for
2 minutes.
Does the scan tool indicate a Closed Loop? Go to Step 5 Go to Step 3
1. Disconnect the H02S connector.
2. Use the J 346-A/BT-8637 Connector Test Adaptor Kit
in order to connect the H02S Signal and Low
3 circuits to iround. 0.2 V (200 mV)
3. Turn ON the ignition while leaving the engine OFF.
Does the scan tool data display indicate a H02S voltage
less than the specified value? Go to Step 4 Go to Step 6
1. Turn OFF the ignition.
2. Remove the jumpers.
4 3. Use the DVM J 39200 in order to check the voltage 12.0V
between the H02S Low circuit and B+.
Is the voltage near the specified value? Go to Step 7 Go to Step 9
This DTC is intermittent. Go to
5 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
6-2838 Engine Controls - 7.4L________________________________________________ Engine
DTC P0154 H02S Insufficient Activity Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
Check for an open in the H02S signal circuit.
6 —
Was a problem found? Go to Step 11 Go to Step 8
Check for a faulty H02S connection.
7 —
Was a problem found? Go to Step 11 Go to Step 10
Check for a poor connection at the VCM.
8 —
Was a problem found? Go to Step 11 Go to Step 12
Repair the open H02S ground circuit. Refer to Wiring
9 Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 13
Replace the H02S. Refer to H02S Replacement.
10 — —
Is the action complete? Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until normal operating
temperature is reached.
13 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
14 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine_____________________________________
DTC P0155 H 02S Heater Circuit Bank2 Sensorl
|Hot In RunAndStart1
Circuit Description
Im portant: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of approximately
0.45 volt (450 mV) between the H02S High and
H02S Low circuits. The Heated Oxygen Sensor
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
When the H02S temperature measures below
360 * C (600 * F) the sensor will not produce any
voltage and will behave like an open circuit. This will
result in an Open Loop operation.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time. The sensor will remain
active during a long extended idle. The DTC P0135
determines if the H02S is functioning properly by
checking the response time of the sensor.
Conditions for Setting the DTC
The following conditions will set the DTC:
• The System Voltage is greater than 9 volts but
less than 17 volts, (if voltage remains outside
this window for 4 consecutive seconds, the test
is void for this cold start)
• The MAF is less than 45 grams per second.
Engine Controls - 7.4L 6-2839
VCM
Cl = BLU
C2 = RED
C3 = CLEAR
C4 = BLK
200113
• The Engine run time is greater than 2 seconds.
• The Engine Coolant Temperature (ECT) is less
than 32 *C (90 *F).
• The Intake Air Temperature (IAT) is less than
32 *C (90 *F).
• The difference between the ECT sensor and the
IAT sensor is less than or equal to 8 ‘ C (47’ F).
• The time for the H02S (Bank 2, Sensor 1)
in order to obtain ±150 mV from 450 mV is
too great.
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive test
failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 'C (40°F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 “ C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
6-2840 Engine Controls - 7.4L
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Engine Electrical.
• Check for a poor connection or a damaged
harness.
• Inspect the harness for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection
- A damaged harness
10. This step checks for an open H02S signal or
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. The H02S should be allowed to cool before
performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the
H02S signal will remain near the 450mv bias
voltage.
Engine
4. This step determines if the ignition feed circuit
to the H02S is not open or shorted. The test
light should be connected to a known good
chassis ground, in case the H02S low or H02S
heater ground circuit is faulty.
5. This step checks the H02S heater ground
circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a hot
H02S heater element will measure a much
higher resistance than a H02S heater element
at room temperature). It is important to allow
the H02S to cool before measuring the H02S
heater element resistance.
low circuit which can cause the H02S heater to
appear not to be operating correctly. It is
important to check these circuits before
replacing the sensor.

DTC P0155 H02S Heater Circuit Bank2 Sensorl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Go to the
Failure records for reference. This data will be lost during
1 — Powertrain OBD
the Clear DTC Information function.
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
important: If engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Install the scan tool.
0.150V
2 2. Turn ON the ignition leaving the engine OFF.
(150 mV)
3. Moniter the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by Go to
the specified value? Diagnostic Aids Go to Step 3
Inspect the fuse for the H02S ignition feed.
3 —
Is the fuse open? Go to Step 12 Go to Step 4
1. Turn OFF the ignition switch.
2. Disconnect the H02S electrical connector.
3. Use a test light connected to a known good ground
4 (Do not use H02S heater ground or H02S low) in —
order to probe the ignition feed circuit at the H02S
electrical connector (VCM harness side).
Is the test light ON? Go to Step 5 Go to Step 7
Use a test light in order to connect the H02S ignition feed
5 and the H02S heater ground. —
Is the test light ON? Go to Step 6 Go to Step 8
Engine________________________________________________ Engine Controls ■ 7.4L 6-2841
DTC P0155 H02S Heater Circuit Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
1. Allow the H02S to cool for at least 10 minutes.
2. Use the J 39200 digital voltmeter (DVM) in order to
6 measure the resistance between the H02S ignition 3-10 ohms
feed and H02S heater ground at the H02S pigtail.
Is the H02S heater resistance within the specified values? Go to Step 9 Go to Step 11
Repair the open in the H02S ignition feed circuit. Refer to
7 Wiring Repairs in Electrical Diagnosis. — —

Is the action complete? Go to Step 14

Repair the open in the H02S heater ground circuit. Refer
8 to Wiring Repairs in Electrical Diagnosis. — • —
Is the action complete? Go to Step 14
1. Check for a poor connection at the H02S harness
terminals.
9 2. If a poor connection is found, replace the terminals. —

Refer to Wiring Repairs in Electrical Diagnosis.

Was a poor connection found? Go to Step 14 Go to Step 10
1. Turn OFF the ignition switch.
2. Disconnect the VCM.
10 3. Use the J 39200 digital voltmeter (DVM) in order to 5 ohms
check the resistance of the H02S signal and H02S
low circuit.
Is the H02S resistance above the specified value? Go to Step 13 Go to Step 11
Replace the H02S. Refer to H02S Replacement
11 — —
Is the action complete? Go to Step 14
1. Check for a short to ground in the battery feed
circuit and repair if necessary. Refer to Wiring
12 Repairs in Electrical Diagnosis. — —
2. Replace the open fuse.
Is action complete? Go to Step 14
Repair the open or poor connection in the H02S signal or
H02S low circuit. Refer to Wiring Repairs in Electrical
13 Diagnosis. — —

Is the action complete? Go to Step 14

Important: If the engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Turn ON the ignition leaving the engine OFF.
2. Use the scan tool in order to select the DTC and the 0.150V
14
Clear DTC Information functions. 150mV
3. Monitor the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by
the specified value? Go to Step 15 Go to Step 3
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
15 —
Are there any DTCs displayed that have not been the Applicable
diagnosed? DTC Table System OK
6-2842 Engine Controls ■ 7.4L_____________________ Engine
DTC P0157 H 02S Circuit Low Voltage Bank2 Sensor2
iHotJn^RLjn^AndStffll]

VCM
Cl = BLU
C2 = RED
C3 = CLEAR
C4 = BLK

33430

Circuit Description Conditions for Setting the DTC

The VCM supplies a voltage of about 0.45V The following criteria must be met to enable the H02
(450 mV) between the H02S High and the H02S Lean Test
Low circuits. (If measured with a 10 megohm digital • No TP sensor DTCs.
voltmeter, this may read as low as 0.32V). The
. No EVAP DTCs.
H02S (Bank 2 Sensor 2) varies the voltage within a
range of about 1.0V (1000 mV) if the exhaust is • No IAT sensor DTCs.
rich, down to about 0.10V (100 mV) if the exhaust • No MAP sensor DTCs.
is lean. • No ECT sensor DTCs.
The sensor is like an open circuit and produces no • No MAF sensor DTCs.
voltage when it is below about 360’ C (600 ’ F).
DTC P0151, P0152 or an open sensor circuit or cold • No Misfire DTCs active.
sensor causes Open Loop operation. DTC P0157 • No intrusive test in progress.
determines if the H02S sensor or circuit is shorted • No device controls active.
to low by checking for a lean condition during steady
• System voltage is greater than or equal to 9 V.
throttle and power enrichment (PE).
Engine
Test Enable Lean Test
• Closed Loop low MAP not active
• Closed Loop
• Air/fuel ratio is greater than or equal to 14.5 but
less than or equal to 14.8
• TP is greater than 5% but less than 99%
• Above met for 5 seconds
• The H02 Sensor (Bank 2 sensor 2) voltage is
less than 17 mV.
Test Enable PE Lean Test
• Closed Loop
• Power Enrichment mode active
• High speed fuel cutoff not active
• Time elapsed since test enable is greater than
or equal to 2 seconds.
• The H02 Sensor (Bank 2 sensor 2) voltage is
less than 399 mV.
Action Taken When the DTC Sets
A current DTC P0157 set will cause the system to
operate in Open Loop. With DTC P0157 set, the MIL
(Malfunction Indicator Lamp) will be turned ON the
first test failure.
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 4 0 ‘ F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
Using the scan tool, observe the L.T. fuel trim values
at different RPM and air flow conditions. The scan
tool also displays the fuel trim cells, so the L.T. fuel
trim values can be checked in each of the cells to
determine when DTC P0157 may have been set. If
the conditions for DTC P0157 exist, the L.T. fuel trim
values will be around 158 or greater.
Engine Controls - 7.4L 6-2843
Check for the following:
• H02S wire - Sensor pigtail may be
mispositioned and contacting the exhaust
manifold
• Intermittent ground in the wire between the
connector and the sensor
• Poor VCM to engine block ground
• Lean injector(s). Perform the Fuel Injector
Balance Test
• Fuel contamination. Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the injectors. The water causes
a lean exhaust and can set a DTC P0151
• Fuel pressure. System will be lean if pressure
is too low. It may be necessary to monitor fuel
pressure while driving the vehicle at various
road speeds and/or loads to confirm. Refer to
Fuel System Diagnosis.
• Exhaust leaks. If there is an exhaust leak, the
engine can cause outside air to be pulled into
the exhaust and past the sensor.
• Vacuum or crankcase leaks can cause a lean
condition and/or possibly a high idle.
• If the above are OK, it is a faulty H02S.
• Never solder the H02S wires.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Running the engine at 1200 RPM keeps the
H02S hot to ensure the H02S remains active
and can indicate the exhaust oxygen content
accurately.
3. Opening the H02S sensor circuit should result
in a displayed voltage between 350 and
550 mV. If the display is still fixed below
350 mV, the fault is a short to ground in the
H02S (Bank 2 Sensor 2) high signal circuit or
a faulty VCM.
6-2844 Engine Controls - 7.4L________________________________________________ Engine
DTC P0157 H02S Circuit Low Voltage Bank2 Sensor2
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Go to the
Failure records for reference. This data will be lost during
1 — Powertrain OBD
the Clear DTC Information function.
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
1. Connect the scan tool.
2. Engine at normal operating temperature.
3. Vehicle in Park or Neutral.
1200 RPM
2 4. Apply the parking brake.
0.017V (17 mV)
5. Increase the engine speed to the specified value.
Does the scan tool data display indicate H02S (Bank 2
Sensor 2) voltage fixed less than the specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S (Bank 2 Sensor 2).
2. Jumper the H02S (Bank 2 Sensor 2) Low circuit
(VCM side) to ground. 0.35 - 0.55V
3 (350 mV -
3. Turn the ignition ON, engine OFF. 550 mV)
Does the scan tool data display indicate H02S (Bank 2
Sensor 2) voltage within the specified range? Go to Step 7 Go to Step 5
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to
4 to those Table(s). —
the Applicable
Are any additional DTCs stored? DTC Table Go to Step 5
Check for a short to ground in the H02S (Bank 2
5 Sensor 2) signal circuit. —
Was a problem found? Go to Step 6 Go to Step 8
Repair the circuit as necessary.
6 — —
Is the action complete? Go to Step 9
7 Refer to Diagnostic Aids. — — —
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
8 to Password Learn Procedure.
— —

4. Perform the Crankshaft Variation Leam Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 9
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
9 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 10 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
10 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
Engine___________________________________________ Engine Controls - 7.4L 6-2845

DTC P0158 H02S Circuit High Voltage Bank2 Sensor2

[Hbtjn^Run^AndStjrt]

VCM
Cl = BLU
C 2-R E D
C3-CLEAR
C4-BLK

33430
Circuit Description • No IAT sensor DTCs.
The VCM supplies a voltage of about 0.45V • No MAP sensor DTCs.
(450 mV) between the H02S High and the H02S • No ECT sensor DTCs.
Low circuits. (If measured with a 10 megohm digital • No MAF sensor DTCs.
voltmeter, this may read as low as 0.32V.) The
H02S varies the voltage within a range of between • No Misfire DTCs active.
about 1.0V (1000 mV) if the exhaust is rich, to about • No intrusive test in progress.
0.10V (100 mV) if the exhaust is lean. • No device controls active.
The sensor is like an open circuit and produces no • System voltage is greater than or equal to 9 V.
voltage when it is below about 360 * C (600 ’ F).
DTC P0158, P0158 or an open sensor circuit or cold Test Enable Rich Test
sensor causes Open Loop operation. P0152 • Closed Loop.
determines if the H02S or circuit is shorted to high
• Air/fuel ratio is is greater than or equal to 14.5
by checking for a rich condition during steady
but less than or equal to 14.8.
throttle.
• TP is greater than 5% but less than 99%.
Conditions for Setting the DTC • Above met for 5 seconds.
• No TP sensor DTCs. • The H 02 Sensor voltage is greater than
. No EVAP DTCs. 976 mV.
6-2846 Engine Controls - 7.4L
Test Enable Decel Fuel Cut Off (DFCO)
Rich Test
• Decel Fuel cutoff mode active.
• Closed Loop.
• Time elapsed is greater than or equal
to 2 seconds.
• The H02 Sensor voltage is greater than
468 mV.
Action Taken When the DTC Sets
A current DTC P0158 will cause the system to
operate in Open Loop. With a current DTC P0158
set, the MIL (Malfunction Indicator Lamp) will be
illuminated after 1 test failure.
Conditions for Clearing the MIL/DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 * F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
Check the following items
• Fuel pressure. System will go rich if pressure is
too high. The VCM can compensate for some
increase. However, if it gets too high,
DTC P0158 may be set. Refer to Fuel System
Diagnosis.
• Rich injector. Perform the Fuel Injector
Balance Test.
Engine
• Check for fuel contaminated oil.
• EVAP canister purge. Check for fuel saturation.
If full of fuel, check canister control and hoses.
Refer to EVAP Control System Diagnosis.
• Check for leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for fuel.
• TP sensor. An intermittent TP sensor output will
cause the system to go rich due to a false
indication of the throttle moving.
• False rich indication due to silicon
contamination of the H02S. This will be
indicated by DTC P0158 accompanied by lean
driveability conditions and a powdery white
deposit on the sensor.
• Faulty H02S (Bank 2 Sensor 2). If H02S
(Bank 2 Sensor 2) is internally shorted the
H02S (Bank 2 Sensor 2) voltage displayed on
a scan tool will be over 1 V. Try disconnecting
the H02S (Bank 2 Sensor 2); if the displayed
voltage goes from over 1000 mV to around
450 mV, replace H02S (Bank 2 Sensor 2).
• Never solder the H02S wires.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
1. Determines if conditions necessary to set
DTC P0158 exist.

DTC P0158 H02S Circuit High Voltage Bank2 Sensor2

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Go to the
Failure records for reference. This data will be lost during
1 — Powertrain OBD
the Clear DTC Information function.
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
1. Connect the scan tool.
2. Engine at normal operating temperature.
3. Vehicle in Park or Neutral. 1200 RPM
2 4. Apply the parking brake. 0.976V
5. Increase the engine speed to the specified value. (976 mV)
Does the scan tool data display indicate H02S (Bank 2
Sensor 1) voltage fixed above the specified value? Go to Step 3 Go to Step 4
1. Disconnect the H02S (Bank 2 Sensor 2).
2. Jumper the H02S (Bank 2 Sensor 2) Low circuit
(VCM side) and the H02S (Bank 2 Sensor 2) HI
3 circuit to ground. 0.20V (200 mV)
3. Turn the ignition ON, engine OFF.
Does the scan tool data display indicate H02S (Bank 2
Sensor 2) voltage is below the specified value? Go to Step 5 Go to Step 6
Engine________________________________________________ Engine Controls - 7.4L 6-2847
DTC P0158 H02S Circuit High Voltage Bank2 Sensor2 (cont’d)
Step Action Value(s) Yes No
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to
4 —
to those Table(s). the Applicable
Are any additional DTCs stored? DTC Table Go to Step 5
5 Refer to Diagnostic Aids. — — —
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
6 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 7
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
7 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 8 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
8 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
6-2848 Engine Controls - 7.4L____________________ Engine
DTC P0160 H02S Insufficient Activity Bank2 Sensor2
|Hot In R un A nd Start]

VCM
Cl =BLU
C2=RED
C3=CLEAR
04=BLK

33430

Circuit Description Conditions for Setting the DTC

The VCM supplies a voltage of about 0.45 V • No TP sensor DTCs.
(450 mV) between the H02S High and the H02S . No EVAP DTCs.
Low circuits. (If measured with a 10 megohm digital
• No IAT sensor DTCs.
voltmeter, this may read as low as 0.32 V.) The
Heated Oxygen Sensor H02S (Bank 2 Sensor 2) • No MAP sensor DTCs.
varies the voltage within a range of about 1 V if the • No ECT sensor DTCs.
exhaust is rich, down through about 0.10 V if • No MAF sensor DTCs.
exhaust is lean.
• No Misfire DTCs active.
The sensor is like an open circuit and produces no
voltage when it is below 360’ C (600 ’ F). • No intrusive test in progress.
The H02S heater provides for faster sensor • No device controls active.
warm-up which allows the sensor to become active • System voltage is greater than or equal to 9 V.
in a shorter period of time and remain active during • Engine run time is greater than or equal to
long extended idle. DTC P0160 determines if the 120 seconds.
H02S or the H02S circuit has developed an open.
Engine
H02 Sensor Temperature Test
• Engine running.
• Not in DFCO.
• ECT is greater than or equal to 80 * C.
• Air Flow greater than or equal to 15 g/sec.
Open Test Enable
• H02 Sensor temperature test = true.
• DTC P0155 not active.
• Closed Loop.
Action Taken When the DTC Sets
With a current DTC set, the VCM will turn ON the
MIL (Malfunction Indicator Lamp).
Conditions for Clearing the MIL7DTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 4 0 ‘ F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation, or a wire broken
inside the insulation.
Check for the following:
• Poor connection or damaged harness - Inspect
harness connectors for backed out terminals,
improper mating, broken locks, improperly
formed or damaged terminals, poor terminal to
wire connection, and damaged harness.
DTC P0160 H02S insufficient Activity Bank2 Sensor2
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Connect the scan tool.
2. Engine at normal operating temperature.
2 3. Run the engine above the specified value for two
minutes.
Does the scan tool indicate Closed Loop?
1. Disconnect the H02S (Bank 2 Sensor 2) electrical
connector.
2. Jumper the H02S (Bank 2 Sensor 2) harness High
3 and Lo circuits (VCM side) to ground.
3. Turn the ignition ON, engine OFF.
Does the scan tool data display indicate H02S (Bank 2
Sensor 2) voltage less than the specified value?
Engine Controls - 7.4L 6-2849
• Faulty H02S (Bank 2 Sensor 2) heater or
heater circuit - With the ignition ON, engine
OFF, the H02S (Bank 2 Sensor 2) voltage
displayed on a scan tool should gradually drop
to below .300 V, indicating that the heater is
working properly. If not, disconnect the H02S
(Bank 2 Sensor 2) and connect a test light
between terminals C and D. If the test light
does not light, repair the open in the affected
circuit. If the test light lights, replace H02S
(Bank 2 Sensor 2).
• Intermittent test - With a scan tool, monitor
H02S (Bank 2 Sensor 2) signal voltage while
moving related connectors and wiring harness,
with a warm engine running at part throttle in
Closed Loop. If the failure is induced, the
H02S (Bank 2 Sensor 2) signal voltage reading
will change from its normal fluctuating voltage
(above 600 mV and below 300 mV) to a fixed
value around 450 mV. This may help to isolate
the location of the malfunction.
• Never solder the H02S wires. For proper wire
and connector repair, refer to Wiring Repairs in
Engine Electrical.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. If the conditions for setting DTC P0160 exist,
the system will not go into Closed Loop.
3. This will determine if the sensor or the wiring is
the cause of DTC P0160.
Value(s) Yes No
Go to the
Powertrain OBD
—
System Check
(OBD System
Go to Step 2 Check)
1200 RPM
Go to Step 5 Go to Step 3
0.2V
(200 mV)
Go to Step 7 Go to Step 4
6-2850 Engine Controls - 7.4L________________________________________________ Engine
DTC P0160 H02S insufficient Activity Bank2 Sensor2 (cont’d)
Step Action Vaiue(s) Yes No
1. Remove the jumpers and reconnect H02S (Bank 2
Sensor 2).
2. Turn the ignition OFF.
4 3. Disconnect the VCM blue connector. —
4. Probe the H02S (Bank 2 Sensor 2) Low circuit with
a test light to B+.
Is the test light ON? Go to Step 6 Go to Step 9
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs are stored refer Go to
5 to those Table(s). —
the Applicable
Are any additional DTCs stored? DTC Table Go to Step 6
Check for an open in the H02S (Bank 2 Sensor 2) High
6 circuit. —
Was a problem found? Go to Step 11 Go to Step 8
Check for a faulty H02S (Bank 2 Sensor 2) connection.
7 —
Was a problem found? Go to Step 11 Go to Step 10
Check for a poor connection at the VCM.
8 —
Was a problem found? Go to Step 11 Go to Step 12
Repair the open H02S (Bank 2 Sensor 2) Low circuit.
9 — —
Is the action complete? Go to Step 13
Replace the H02S (Bank 2 Sensor 2). Refer to H02S
10 Replacement. — —

Is the action complete? Go to Step 13

Repair the circuit as necessary.
11 — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
13 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 14 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
14 Are any DTCs displayed that have not been diagnosed? — the Applicable
DTC Table System OK
Engine_____________________________________
DTC P0161 H02S Heater Circuit Bank2 Sensor2
[HotJ^Run^ndSU^]
Circuit Description
Important: If the voltage is measured with a
10 Megaohm Digital Voltmeter, the voltage may read
as low as 0.32 volt (320 mV).
The VCM supplies a voltage of approximately
0.45 volt (450 mV) between the H02S High and
H02S Low circuits. The Heated Oxygen Sensor
(H02S) varies the voltage from approximately
1.0 volt (1000 mV) during rich conditions to 0.10 volt
(100 mV) during lean conditions.
When the H02S temperature measures below
360 * C (600 * F) the sensor will not produce any
voltage and will behave like an open circuit. This will
result in an Open Loop operation.
The H02S heater provides for a faster sensor
warm-up which allows the sensor to become active
in a shorter period of time. The sensor will remain
Engine Controls - 7.4L 6-2851
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK
33430
active during a long extended idle. The DTC P0135
determines if the H02S is functioning properly by
checking the response time of the sensor.
Conditions for Setting the DTC
• System Voltage is greater than 9 V but less
than 17 V, (if voltage remains outside this
window for more than 4 consecutive seconds,
the test is void this cold start)
• MAF is less than 27 grams per second
• Engine run time is greater than 2 seconds
• Engine Coolant Temperature (ECT) is less than
32 *C (90 ’ F)
• Intake Air Temperature (IAT) is less than
32 *C (90 * F)
• The difference between the ECT sensor and the
IAC sensor is no more than 8* C
6-2852 Engine Controls - 7.4L
Action Taken When the DTC Sets
The VCM turns the MIL ON after 2 consecutive test
failures.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Important: Never solder the H02S wires. For proper
wire and connection repairs, refer to Wiring Repairs
in Engine Electrical.
• Check for a poor connection or a damaged
harness.
• Inspect the harness for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection
- A damaged harness
DTC P0161 H02S Heater Circuit Bank2 Sensor2
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 —
the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Important: If engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Install the scan tool.
2 2. Turn ON the ignition leaving the engine OFF.
3. Moniter the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by
the specified value?
Engine
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
2. The H02S should be allowed to cool before
performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the
H02S signal will remain near the 450mv bias
voltage.
4. This step determines if the ignition feed circuit
to the H02S is not open or shorted. The test
light should be connected to a known good
chassis ground, in case the H02S low or H02S
heater ground circuit is faulty.
5. This step checks the H02S heater ground
circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a hot
H02S heater element will measure a much
higher resistance than a H02S heater element
at room temperature). It is important to allow
the H02S to cool before measuring the H02S
heater element resistance.
10. This step checks for an open H02S signal or
low circuit which can cause the H02S heater to
appear not to be operating correctly. It is
important to check these circuits before
replacing the sensor.
Value(s) Yes No
Go to the
Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)
0.150V
(150 mV)
Go to
Diagnostic Aids Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2853
DTC P0161 H02S Heater Circuit Bank2 Sensor2 (cont’d)
Step Action Value(s) Yes No
Inspect the fuse for the H02S ignition feed.
3 —
Is the fuse open? Go to Step 12 Go to Step 4
1. Turn OFF the ignition switch.
2. Disconnect the H02S electrical connector.
3. Use a test light connected to a known good ground
4 (Do not use H02S heater ground or H02S low) in —
order to probe the ignition feed circuit at the H02S
electrical connector (VCM harness side).
Is the test light ON? Go to Step 5 Go to Step 7
Use a test light in order to connect the H02S ignition feed
5 and the H02S heater ground. —
Is the test light ON? Go to Step 6 Go to Step 8
1. Allow the H02S to cool for at least 10 minutes.
2. Use the J 39200 digital voltmeter (DVM) in order to
6 measure the resistance between the H02S ignition 3-10 ohms
feed and H02S heater ground at the H02S pigtail.
Is the H02S heater resistance within the specified values? Go to Step 9 Go to Step 11
Repair the open in the H02S ignition feed circuit. Refer to
7 Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Repair the open in the H02S heater ground circuit. Refer
8 to Wiring Repairs in Electrical Diagnosis. — —
Is the action complete? Go to Step 14
1. Check for a poor connection at the H02S harness
terminals.
9 2. If a poor connection is found, replace the terminals. —
Refer to Wiring Repairs in Electrical Diagnosis.
Was a poor connection found? Go to Step 14 Go to Step 10
1. Turn OFF the ignition switch.
2. Disconnect the VCM.
10 3. Use the J 39200 digital voltmeter (DVM) in order to 5 ohms
check the resistance of the H02S signal and H02S
low circuit.
Is the H02S resistance above the specified value? Go to Step 13 Go to Step 11
Replace the H02S. Refer to H02S Replacement.
11 — —
Is the action complete? Go to Step 14
1. Check for a short to ground in the battery feed
circuit and repair if necessary. Refer to Wiring
12 Repairs in Electrical Diagnosis. — —
2. Replace the open fuse.
Is action complete? Go to Step 14
6-2854 Engine Controls - 7.4L________________________________________________ Engine
DTC P0161 H02S Heater Circuit Bank2 Sensor2 (cont’d)
Step Action Value(s) Yes No
Repair the open or poor connection in the H02S signal or
H02S low circuit. Refer to Wiring Repairs in Electrical
13 Diagnosis. — —
Is the action complete? Go to Step 14
Important: If the engine has just been operating, allow the
engine to cool for about one half hour before proceeding.
1. Turn ON the ignition leaving the engine OFF.
2. Use the scan tool in order to select the DTC and the 0.150V
14
Clear DTC Information functions. 150mV
3. Monitor the H02S voltage using the scan tool.
Does the H02S voltage displayed gradually decrease by
the specified value? Go to Step 15 Go to Step 3
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
15 —
Are there any DTCs displayed that have not been the Applicable
diagnosed? DTC Table System OK
Engine________________________________ Engine Controls - 7.4L 6-2855

DTC P0171 Fuel Trim System Lean Bankl

IHot InRunAndStart!

A
J O B O IIk

VCM
Cl = BLU
C2 = RED
C3 =CLEAR
C4= BLK

Ground
Distribution
Cell 14

Circuit Description • No EVAP sensor DTCs

In order to provide the best possible combination of • No ECT sensor DTCs
driveability, fuel economy, and emission control, the • No MAF sensor DTCs
vehicle uses a Closed Loop air and fuel metering
• No IAT sensor DTCs
system. While in a Closed Loop, the VCM monitors
the oxygen sensor signal voltage. The VCM adjusts • No VS sensor DTCs
the fuel delivery based on a signal voltage. The long • No Misfire DTCs
and short term fuel values, which a scan tool can • Throttle position is less than 69.9%
monitor, indicates a change made to the fuel
• Engine speed is greater than 525 RPM but less
delivery. Ideal fuel trim values are around 128; if the
than 4500 RPM
oxygen sensor signal indicates a lean condition, the
VCM adds fuel. This results in fuel trim values • The BARO is greater than 70 kPa
above 128. If the oxygen sensor detects a rich • The ECT is greater than 0 * C but less
condition, the fuel trim values will read below 128. than 99.7 *C
This indicates that the VCM is reducing the amount • The MAP is greater than 20 kPa but less
of fuel delivered. If an excessively lean condition is than 98.9 kPa.
detected, the VCM sets this DTC.
• The IAT is greater than -20' C but less
Conditions for Setting the DTC than 69.7 *C
• No IAC or idle DTCs • The IAT is greater than -20 *C but less
• No H02S sensor DTCs than 80 *C
• No TP sensor DTCs • MAF is greater than 3 grams per second but
less than 150 grams per second
• No MAP sensor DTCs
• The vehicle speed is less than 85 mph
• No EGR sensor DTCs
6-2856 Engine Controls - 7.4L
Action Taken When the DTC Sets
Important: To complete a trip cycle for the fuel trim
diagnostic, the fuel trim diagnostic test must enable
and run according to the current DTC Will Set When
criteria above. A trip is not considered complete until
the fuel trim diagnostic has run by the VCM.
When the current DTC initially sets, a software flag
indicating an emissions related fault sets for 3 trips.
The flag will clear provided the lean condition is no
longer present. However, if the VCM detects the
conditions for setting the current DTC during a trip
while the flag is still set, the VCM turns on the MIL
(Malfunction Indicator Lamp). The MIL remains on
during all of the subsequent trips until the DTC has
been cleared by service or the lean condition has
not been detected and the conditions for checking
the fuel trim have been met for 3 consecutive trips.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 7 0 ' C
(160*F) during the same ignition cycle).
_________________________________ Engine
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
If using the diagnostic tables does not isolate the
problem, try monitoring the L. T. fuel trim and fuel
trim cell while operating the vehicle under various
loads. This may isolate the condition which caused
the setting of the current DTC.
A condition that causes the DTC P0300 Engine
Misfire Detected may also set the current DTC;
conversely an extremely lean condition which sets
the current DTC can cause a misfire at idle and the
DTC P0300 to set. If the cause of the current DTC
cannot be determined and the DTC P0300 is also
set, refer to DTC P0300 Engine Misfire Detected
On vehicles equipped with a 7.4L (California
emissions), an AIR Pump that is stuck ON may also
cause a DTC P0171, or DTC P0174 to set.
Test Description
The numbers below refer to step numbers on the
diagnostic table.
2. Visually and physically check the items that can
cause a lean condition in order to determine
the cause of the DTC being set.
6. This step checks for a fault in the EVAP purge
system which can cause DTC P0171 to be set.

DTC P0171 Fuel Trim System Lean Bankl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Visually and physically check the following items:
• The exhaust system for corrosion and loose or
missing hardware.
• The heated oxygen sensor is installed securely, and
the pigtail harness is not contacting the exhaust
manifold or ignition wires.
• The vacuum hoses for splits, kinks, and proper
connections.
• The throttle body, intake manifold, and EGR valve for
2 vacuum leaks. —
• Idle Air Control (IAC); if a high or unsteady idle is
being experienced.
• The Crankcase Ventilation Valve, spring and O-ring
for proper installation.
• The fuel for excessive water, alcohol, or other
contaminates.
• VCM and sensor grounds are clean, tight and in the
proper location.
Was a repair made? Go to Step 8 Go to Step 3
Engine____________ ____________________________________ Engine Controls - 7.4L 6-2857
DTC P0171 Fuel Trim System Lean Bankl (cont’d)
Step Action Value(s) Yes No
1. Connect a fuel pressure gauge to the fuel rail fitting.
2. Turn off the ignition for 10 seconds. Make sure the
A/C is off.
3. Turn ON the ignition.
4. The fuel pump should run for 2 seconds.
5. The ignition may have to be cycled ON more than Central SFI -
3 once in order to obtain maximum pressure. 385-430 kPa
(56-62 psi)
6. Monitor the fuel pressure with the fuel pump running.
The fuel pressure should be between the
specified value.
7. When the fuel pump stops, the fuel pressure may
vary slightly, then should hold steady.
Is pressure between the specified value and does it hold? Go to Step 4 Go to Step 11
1. Start the engine.
2. Idle the engine at the normal operating temperature. 21-69 kPa
4
Does the fuel pressure noted in the above step drop to (3-10 psi)
the specified value? Go to Step 5 Go to Step 11
Perform the Injector Balance Test. Refer to Fuel Injector
5 Balance Test. —
Was an injector problem found? Go to Step 9 Go to Step 6
Perform the Canister Purge Solenoid Check. Refer to
6 EVAP Control System Diagnosis. — Go to
Was a problem found? Go to Step 7 Diagnostic Aids
1. Repair the EVAP system. Refer to
2. Connect the scan tool.
3. Operate the vehicle in a Closed Loop while 158 counts
7 monitoring L.T. and S.T. fuel trim values.
180 counts
Does the L.T. fuel trim decrease below the specified
value and the S.T. fuel trim decrease below the second Go to
specified value? Go to Step 10 Diagnostic Aids
1. Repair the items found in Step 2.
2. Operate the vehicle in a Closed Loop while
monitoring L.T. and S.T. fuel trim values. 158 counts
8
Does the L.T. fuel trim decrease below the specified 180 counts
value and the S.T. fuel trim decrease below the second
specified value? Go to Step 10 Go to Step 3
1. Replace the fuel injector. Refer to Fuel Injector
Replacement (SFI)
2. Operate the vehicle in a Closed Loop while 158 counts
9 monitoring L.T. and S.T. fuel trim values.
180 counts
Does the L.T. fuel trim decrease below the specified
value and the S.T. fuel trim decrease below the second
specified value? Go to Step 10 Go to Step 6
The lean condition is not present. If a driveability symptom
10 still exists, refer to the Driveability Symptoms. — —
Is the action complete? Go to Step 12
Refer to Fuel System Diagnosis.
11 — —
Is the action complete? Go to Step 12
6-2858 Engine Controls - 7.4L Engine
DTC P0171 Fuel Trim System Lean Bankl (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle at the normal operating
temperature.
Select DTC, Specific.
12 3. Enter the DTC number which was set. —
4. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select Capture Info and Review Info. Go to
13 Are any DTCs displayed that have not been diagnosed? — The Applicable
DTC Table System OK
Engine_______________________________ Engine Controls - 7.4L 6-2859

DTC P0172 Fuel Trim System Rich Bankl

|Hot InRunAndStart]

A
VCM
C1= BLU
C2• RED
C3- CLEAR
C4 = BLK

Ground
Distribution
Cell 14

Circuit Description
In order to provide the best possible combination of
driveability, fuel economy, and emission control, the
vehicle uses a Closed Loop air and fuel metering
system. While in a Closed Loop, the VCM monitors
the oxygen sensor signal voltage. The VCM adjusts
the fuel delivery based on a signal voltage. The long
and short term fuel values, which a scan tool can
monitor, indicates a change made to the fuel
delivery. Ideal fuel trim values are around 128; if the
oxygen sensor signal indicates a lean condition, the
VCM adds fuel. This results in fuel trim values
above 128. If the oxygen sensor detects a rich
condition, the fuel trim values will read below 128.
This indicates that the VCM is reducing the amount
of fuel delivered. If an excessively rich condition is
detected, the VCM sets this DTC.
Conditions for Setting the DTC
• No 1AC or idle DTCs
• No H02S sensor DTCs
• No TP sensor DTCs
• No MAP sensor DTCs
• No EGR sensor DTCs
• No EVAP sensor DTCs
• No ECT sensor DTCs
200042
• No MAF sensor DTCs
• No IAT sensor DTCs
• No VS sensor DTCs
• No Misfire DTCs
• Throttle position less than 69.9%
• Engine speed is greater than 525 RPM but less
than 4500 RPM
• The BARO is greater than 70 kPa
• The ECT is greater than 60 * C but less
than 99.7‘ C
• The MAP is greater than 20 kPa but less
than 98.9 kPa.
• The IAT is greater than -2 0 ' C but less
than 80 *C
• The air flow greater than 3 grams per second
but less than 200 grams per
• The vehicle speed less than 85 mph
Action Taken When the DTC Sets
Important: To complete a trip cycle for the fuel trim
diagnostic, the fuel trim diagnostic test must enable
and run according to the current DTC Will Set When
criteria above. A trip is not considered complete until
the fuel trim diagnostic has run by the VCM.
6-2860 Engine Controls - 7.4L__________
When the current DTC initially sets, a software flag
indicating an emissions related fault sets for 3 trips.
The flag will clear provided the lean condition is no
longer present. However, if the VCM detects the
conditions for setting the current DTC during a trip
while the flag is still set, the VCM turns on the MIL
(Malfunction Indicator Lamp). The MIL remains on
during all of the subsequent trips until the DTC has
been cleared by service or the lean condition has
not been detected and the conditions for checking
the fuel trim have been met for 3 consecutive trips.
Conditions for Clearing the MILVDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ’ C (40’ F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ’ C (160“ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
DTC P0172 Fuel Trim System Rich Bankl
Step Action
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 the Clear DTC Information function.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Visually and physically check the following items:
• The air intake duct for being collapsed or restricted
• The air filter for being plugged
• IAC: If a low or unsteady idle is being experienced.
• Check for throttle body coking or objects blocking the
IAC passages.
• Check the fuel pressure regulator for proper
operation. Refer to Fuel System Diagnosis.
2
• Check the Throttle Position sensor for loose or
missing mounting bolts. Monitor the TP Sensor with
the scan tool while slowly opening throttle - TP
Sensor. The throttle position will increase steadily
and evenly from closed throttle TP specified voltage
to over the wide open throttle specified value.
• If not, replace the TP sensor.
Did any of the above checks isolate a condition
requiring repair?
Engine
Diagnostic Aids
If using the diagnostic tables does not isolate the
problem, try monitoring the L. T. fuel trim and fuel
trim cell while operating the vehicle under various
loads. This may isolate the condition which caused
the setting of the current DTC.
A condition that causes the DTC P0300 Engine
Misfire Detected may also set the current DTC;
conversely an extremely rich condition which sets the
current DTC can cause a misfire at idle and the
DTC P0300 to set. If the cause of the current DTC
cannot be determined and the DTC P0300 is also
set, refer to DTC P0300 Engine Misfire Detected.
On vehicles equipped with a 7.4L (California
emissions), an AIR Pump that is stuck ON may also
cause a DTC P0172, or DTC P0175 to set.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Visually and physically checking items which
may cause a rich condition may determine the
cause of the DTC P0172 being set.
3. This step checks the fuel system for problems.
5. A silicon contamination of the Heated Oxygen
Sensor (H02S Bank 1, Sensor 1) can cause a
false rich indication to be seen by the VCM.
The VCM then reduces the amount of fuel
delivered, possibly causing severe driveability
symptoms.
Value(s) Yes No
Go to Powertrain
—
OBD System
Check (OBD
Go to Step 2 System Check)
0.2-0.74V
4.0V
Go to Step 8 Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2861
DTC P0172 Fuel Trim System Rich Bankl (cont’d)
Step Action Value(s) Yes No
1. Connect fuel pressure gage to fitting at fuel rail.
Refer to Fuel System Pressure Check.
2. Turn off the ignition for 10 seconds.
3. Turn off the A/C.
4. Turn ON the ignition.
5. The fuel pump will run for about 2 seconds. 385 - 430 kPa
3 6. It may be necessary to cycle the ignition ON more (56-62 psi)
than once in order to obtain maximum pressure.
7. Monitor the fuel pressure with the pump running. The
pressure should be between the specified value.
8. When the pump stops, the pressure may vary slightly
then should hold steady.
Is pressure correct and does it hold? Go to Step 4 Go to Step 11
Perform the Fuel Injector Balance Test.
4 —
Was an injector problem found? Go to Step 9 Go to Step 5
Remove and visually and physically inspect the Heated
Oxygen Sensor for a silicon contamination. This will be
5 indicated by a powdery white deposit on the portion of the —
sensor exposed to the exhaust stream.
Is the silicon contamination evident? Go to Step 12 Go to Step 6
Perform the EVAP Control System Diagnosis. Go to
6 —
Was a problem found? Go to Step 7 Diagnostic Aids
1. Repair the EVAP System.
2. Operate the vehicle in a Closed Loop while
monitoring the L.T. and the S.T. fuel trim values. 100
7
Does the L.T. fuel trim value increase above the specified 94
value and the S.T. fuel trim value increase above the Go to
second specified value? Go to Step 10 Diagnostic Aids
1. Repair the items found in Step 2.
2. Operate the vehicle in a Closed Loop while
monitoring the L.T. and the S.T. fuel trim values. 100
8
Does the L.T. fuel trim value increase above the specified 94
value and the S.T. fuel trim value increase above the
second specified value? Go to Step 10 Go to Step 3
1. Replace the fuel injector. Refer to Fuel Injector
Replacement (SFI).
2. Operate the vehicle in a Closed Loop while 100
9 monitoring the L.T. and the S.T. fuel trim values.
94
Does the L.T. fuel trim value increase above the specified
value and the S.T. fuel trim value increase above the
second specified value? Go to Step 10 Go to Step 5
Rich condition not present. If a driveability symptom still
10 — — —
exists, refer to Driveability Symptoms.
11 Refer to Fuel System Diagnosis for diagnosis. — — —
Replace the H02S (Bank 2, Sensorl). Refer to H02S
12 Replacement. — —
Is the action complete? Go to Step 13
6-2862 Engine Controls - 7.4L Engine
DTC P0172 Fuel Trim System Rich Bankl (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
13 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
14 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine________________________________ Engine Controls - 7.4L 6-2863
DTC P0174 Fuel Trim System Lean Bank2
|Hot InRunAndStart|

VCM
C1=BLU
C2-RED
C3-CLEAR
C4-BLK

200113
Circuit Description • No ECT sensor DTCs
In order to provide the best possible combination of • No MAF sensor DTCs
driveability, fuel economy, and emission control, the • No IAT sensor DTCs
vehicle uses a Closed Loop air and fuel metering
• No VS sensor DTCs
system. While in a Closed Loop, the VCM monitors
the oxygen sensor signal voltage. The VCM adjusts • No Misfire DTCs
the fuel delivery based on a signal voltage. The long • Throttle position less than 69.9%
and short term fuel values, which a scan tool can • Engine speed is greater than 525 RPM but less
monitor, indicates a change made to the fuel than 4500 RPM
delivery. Ideal fuel trim values are around 128; if the
• The BARO is greater than 70 kPa
oxygen sensor signal indicates a lean condition, the
VCM adds fuel. This results in fuel trim values • The ECT is greater than 60 *C but less
above 128. If the oxygen sensor detects a rich than 99.7 * C
condition, the fuel trim values will read below 128. • The MAP is greater than 20 kPa but less
This indicates that the VCM is reducing the amount than 98.9 kPa.
of fuel delivered. If an excessively lean condition is • The IAT is greater than -20 *C but less
detected, the VCM sets this DTC. than 80 *C
Conditions for Setting the DTC • MAF is greater than 3 grams per second but
• No IAC or idle DTCs less than 200 grams per
• No H02S sensor DTCs • The vehicle speed less than 85 mph
• No TP sensor DTCs • The average of short term fuel trim is at
least 1.0
• No MAP sensor DTCs
• The average of adaptive index multipier
• No EGR sensor DTCs samples is at least 1.23
• No EVAP sensor DTCs
6-2864 Engine Controls - 7.4L
Action Taken When the DTC Sets
Important: To complete a trip cycle for the fuel trim
diagnostic, the fuel trim diagnostic test must enable
and run according to the current DTC Will Set When
criteria above. A trip is not considered complete until
the fuel trim diagnostic has run by the VCM.
When the current DTC initially sets, a software flag
indicating an emissions related fault sets for 3 trips.
The flag will clear provided the lean condition is no
longer present. However, if the VCM detects the
conditions for setting the current DTC during a trip
while the flag is still set, the VCM turns on the MIL
(Malfunction Indicator Lamp). The MIL remains on
during all of the subsequent trips until the DTC has
been cleared by service or the lean condition has
not been detected and the conditions for checking
the fuel trim have been met for 3 consecutive trips.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ’ C (40‘ F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ’ C (160*F) during the same ignition cycle).
_________________________________ Engine
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
If using the diagnostic tables does not isolate the
problem, try monitoring the L. T. fuel trim and fuel
trim cell while operating the vehicle under various
loads. This may isolate the condition which caused
the setting of the current DTC.
A condition that causes the DTC P0300 Engine
Misfire Detected may also set the current DTC;
conversely an extremely lean condition which sets
the current DTC can cause a misfire at idle and the
DTC P0300 to set. If the cause of the current DTC
cannot be determined and the DTC P0300 is also
set, refer to DTC P0300 Engine Misfire Detected
On vehicles equipped with a 7.4L (California
emissions), an AIR Pump that is stuck ON may also
cause a DTC P0171, or DTC P0174 to set.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Visually and physically checking the items
which may cause a lean condition may
determine the cause of the DTC being set.
3. This step checks for a fault in the EVAP purge
system which may cause DTC P0174 to be set.

DTC P0174 Fuel Trim System Lean Bank2

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool
capture info function to store the Freeze Frame and the
Failure records for reference. This data will be lost during
1 — Go to Powertrain
the Clear DTC Information function.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Visually and physically check the following items:
• The exhaust system for corrosion, loose or missing
hardware.
• The heated oxygen sensor is installed securely and
the pigtail harness is not contacting the exhaust
manifold or ignition wires.
• The vacuum hoses for splits, kinks and proper
connections. Throttle body, intake manifold and EGR
valve for vacuum leaks.
2 • The IAC: if a high or unsteady idle is being —

experienced.
• The crankcase Ventilation Valve, spring and O-ring
for proper installation.
• Fuel for excessive water, alcohol, or other
contaminants.
• The VCM and sensor grounds are clean, tight and in
their proper locations.
Did any of the above checks isolate a condition
requiring repair? Go to Step 8 Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2865
DTC P0174 Fuel Trim System Lean Bank2 (cont’d)
Step Action Value(s) Yes No
1. Connect a fuel pressure gage to the fuel rail fitting.
2. Turn off the ignition for 10 seconds.
3. Leave the A/C off.
4. Turn ON the ignition.
5. The fuel pump will run for about 2 seconds It may
be necessary to cycle the ignition ON more than SFI -
3 once in order to obtain maximum pressure. 385-430 kPa
(56-62 psi)
6. Monitor the fuel pressure with the pump running, the
pressure should be between the specified value.
7. When the pump stops, the pressure may vary slightly
then should hold steady.
Is the pressure between the specified value, and does
it hold? Go to Step 4 Go to Step 11
1. Start the engine.
2. Idle engine at normal operating temperature. 21-69 kPa
4
Does the fuel pressure noted in the above step drop by (3-10 psi)
the specified value? Go to Step 5 Go to Step 11
Perform the Injector Balance Test. Refer to Fuel Injector
5 Balance Test. —
Was an injector problem found? Go to Step 9 Go to Step 6
Perform Canister Purge Solenoid Check. Refer to EVAP
6 Control System Diagnosis. — Go to
Was a problem found? Go to Step 7 Diagnostic Aids
1. Repair the EVAP system.
2. Connect the scan tool.
3. Operate the vehicle in a Closed Loop while 158
7 monitoring L.T. and S.T. fuel trim valves.
180
Does the L.T. fuel trim decrease below the specified
value and the S.T. fuel trim decrease below the second Go to
specified value? Go to Step 10 Diagnostic Aids
1. Repair the items found in step 2.
2. Operate the vehicle in a Closed Loop while
monitoring L.T. and S.T. fuel trim values. 158
8
Does the L.T. fuel trim decrease below the specified 180
value and the S.T. fuel trim decrease below the second
specified value? Go to Step 10 Go to Step 3
1. Replace the fuel injector.Refer to Fuel Injector
Replacement (SFI).
2. Operate the vehicle in a Closed Loop while 158
9 monitoring L.T. and S.T. fuel trim values.
180
Does the L.T. fuel trim decrease below the specified
value and the S.T. fuel trim decrease below the second
specified value? Go to Step 10 Go to Step 6
The lean condition is not present. If a driveability symptom
10 — — —
still exists, refer to Driveability Symptoms
11 For diagnosis, refer to Fuel System Diagnosis. — — —
6-2866 Engine Controls - 7.4L Engine
DTC P0174 Fuel Trim System Lean Bank2 (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
12 —

5. Enter the DTC number which was set.

6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
13 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine________________________________ Engine Controls - 7.4L 6-2867

DTC P0175 Fuel Trim System Rich Bank2

|Hot In RunAndStart]

VCM
Cl =BLU
C2-RED
C3- CLEAR
C4»BLK

200113
Circuit Description • No EGR sensor DTCs
In order to provide the best possible combination of • No EVAP sensor DTCs
driveability, fuel economy, and emission control, the • No ECT sensor DTCs
vehicle uses a Closed Loop air and fuel metering
• No MAF sensor DTCs
system. While in a Closed Loop, the VCM monitors
the oxygen sensor signal voltage. The VCM adjusts • No IAT sensor DTCs
the fuel delivery based on a signal voltage. The long • No VS sensor DTCs
and short term fuel values, which a scan tool can • No Misfire DTCs
monitor, indicates a change made to the fuel
delivery. Ideal fuel trim values are around 128; if the • Throttle position is less than 69.9%
oxygen sensor signal indicates a lean condition, the • Engine speed is greater than 525 RPM but less
VCM adds fuel. This results in fuel trim values than 4500 RPM
above 128. If the oxygen sensor detects a rich • The BARO is greater than 70 kPa
condition, the fuel trim values will read below 128. • The ECT is greater than 60 *C but less
This indicates that the VCM is reducing the amount than 99.7 *C
of fuel delivered. If an excessively lean condition is
detected, the VCM sets this DTC. • The MAP is greater than 20 kPa but less
than 98.9 kPa.
Conditions for Setting the DTC • The IAT is greater than -20 * C but less
• No 1AC or idle DTCs than 80 *C
• No H02S sensor DTCs • MAF is greater than 3 grams per second but
• No TP sensor DTCs less than 200 grams per
• No MAP sensor DTCs • The vehicle speed less than 85 mph
6-2868 Engine Controls - 7.4L___________
Action Taken When the DTC Sets
Im portant: To complete a trip cycle for the fuel trim
diagnostic, the fuel trim diagnostic test must enable
and run according to the current DTC Will Set When
criteria above. A trip is not considered complete until
the fuel trim diagnostic has run by the VCM.
When the current DTC initially sets, a software flag
indicating an emissions related fault sets for 3 trips.
The flag will clear provided rich condition is no
longer present. However, if the VCM detects the
conditions for setting the current DTC during a trip
while the flag is still set, the VCM turns ON the MIL
(Malfunction Indicator Lamp). The MIL remains ON
for all of the subsequent trips until the DTC has
been cleared by service or the rich condition has not
been detected and the conditions for checking the
fuel trim have been met for 3 consecutive trips.
Conditions for Clearing the MIUDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160 * F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
DTC P0175 Fuel Trim System Rich Bank2
Step Action
Important: Before clearing DTCs, use the scan tool in
order to record freeze frame and the failure records for
reference because the Clear Info function will lose
1 —
the data.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Visually and physically check the following items:
• The air intake duct for being collapsed or restricted.
• The air filter for being plugged.
• IAC: If a low or unsteady idle is being experienced.
• Also, check for throttle body coking or objects
blocking the IAC passages.
• Check the fuel pressure regulator for proper
operation. Refer to Fuel System Diagnosis.
2
• Check the Throttle Position sensor for loose or
missing mounting bolts. Also, monitor the TP sensor
with the scan tool while slowly opening the throttle.
The TP sensor should increase steadily and evenly
from closed throttle (TP specified voltage) to over the
wide open throttle (TP specified value).
• If not, replace the TP sensor.
Did any of the above checks isolate a condition
requiring repair?
Engine
Diagnostic Aids
If using the diagnostic tables does not isolate the
problem, try monitoring the L. T. fuel trim and fuel
trim cell while operating the vehicle under various
loads. This may isolate the condition which caused
the setting of the current DTC.
A condition that causes the DTC P0300 Engine
Misfire Detected may also set the current DTC;
conversely an extremely rich condition which sets the
current DTC can cause a misfire at idle and the
DTC P0300 to set. If the cause of the current DTC
cannot be determined and the DTC P0300 is also
set, refer to DTC P0300 Engine Misfire Detected
On vehicles equipped with a 7.4L (California
emissions), an AIR Pump that is stuck ON may also
cause a DTC P0172, or DTC P0175 to set.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Visually and physically checking items which
may cause a rich condition may determine the
cause of the DTC P0175 being set.
3. Checks the fuel system for problems
4. Silicon contamination of the Heated Oxygen
Sensor (H02S 1) can cause a false rich
indication to be seen by the VCM. The VCM
will then reduce the amount of fuel delivered,
possibly causing severe driveability symptoms.
Value(s) Yes No
Go to Powertrain
OBD System
Check (OBD
Go to Step 2 System Check)
0.2-0.74V
4.0V
Go to Step 8 Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2869
DTC P0175 Fuel Trim System Rich Bank2 (cont’d)
Step Action Value(s) Yes No
1. Connect a fuel pressure gage to the fitting at the
fuel rail.
2. Turn OFF the ignition for 10 seconds.
3. Turn the A/C off.
4. Turn ON the ignition.
5. The fuel pump will run for about 2 seconds.
SFI -
3 6. It may be necessary to cycle the ignition ON more 385-430 kPa
than once in order to obtain the maximum pressure. (56-62 psi)
7. Observe the fuel pressure with the pump running.
The pressure should be between the specified
values.
8. When the pump stops, the pressure may vary slightly
then it should hold steady.
Is the fuel pressure correct and does it hold? Go to Step 4 Go to Step 11
Perform the Injector BalanceTest. Refer to Fuel Injector
4 Balance Test. —
Was an injector problem found? Go to Step 9 Go to Step 5
1. Remove the Heated Oxygen Sensor.
2. Visually and physically inspect the Heated Oxygen
Sensor for a silicon contamination. A powdery white
5 —
deposit on the portion of the sensor exposed to the
exhaust stream indicates a contamination.
Is a silicon contamination evident? Go to Step 12 Go to Step 6
Perform Canister Purge Solenoid Check. Refer to EVAP
6 Control System Diagnosis. — Go to
Was a problem found? Go to Step 7 Diagnostic Aids
1. Repair the EVAP system.
2. Operate the vehicle in a Closed Loop while
monitoring the L.T. and the S.T. fuel trim values. 100
7
Does the L.T. fuel trim value increase above the specified 94
value and the S.T. fuel trim increase above the second Go to
specified value? Go to Step 10 Diagnostic Aids
1. Repair the items found in step 2.
2. Operate the vehicle in a Closed Loop while
monitoring the L.T. and the S.T. fuel trim values. 100
8
Does the L.T. fuel trim value increase above the specified 94
value and the S.T. fuel trim value above the second
specified value? Go to Step 10 Go to Step 3
1. Replace the injector. Refer to Fuel Injector
Replacement (SFI).
2. Operate the vehicle in a Closed Loop while 100
9 monitoring the L.T. and the S.T. fuel trim values.
94
Does the L.T. fuel trim value increase above the specified
value and the S.T. fuel trim value above the second
specified value? Go to Step 10 Go to Step 5
Rich condition not present. If a driveability symptom still
10 — — —
exists, refer to Driveability Symptoms.
11 Refer to Fuel System Diagnosis. — — —
Replace the H02S 2. Refer to H02S Replacement
12 — —
Is the action complete? Go to Step 13
6-2870 Engine Controls - 7.4L Engine
DTC P0175 Fuel Trim System Rich Bank2 (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
13 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to The
14 Review Info. — Driveability
Are any DTCs displayed that have not been diagnosed? Symptoms System OK
Engine__________________________ Engine Controls - 7.4L 6-2871
DTC P0300 Engine Misfire Detected
|Hot InRunAndStart]
Power 1 Underhood
Distribution ENG1 Fuse-Relay
Ceil 10 Fuse Center
La'’1 20A
PNK A
J O B O IIL

VCM
PNK 539 C1=BLU
FuseBlock PNK C2=RED
Details C3=CLEAR
Cell 11 PNK C4=BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

A
PNK/BLK

8A . . . ----3 a. ---- ---------

31A---- -28
- -AC1
CMP 1xCMP 4xCKP CKP
Sensor Sensor Sensor Sensor
Ground Signal Signal Ground

33715
Circuit Description Conditions for Setting the DTC
The crankshaft position (CKP) sensor and the • No TP sensor DTCs
camshaft position (CMP) sensor are used in order to • No MAF sensor DTCs
detect an engine misfire. The VCM monitors the
• No Camshaft Position sensor DTCs
speed of the crankshaft. The VCM detects a
deceleration of the crankshaft that is not associated • No VS sensor DTCs
with a normal engine speed reduction. In order to • No Crankshaft Position sensor DTCs
determine if a misfire occurred, the VCM compares • The engine speed between 450 RPM
the deceleration information to the engine speed and and 5000 RPM
the engine load. If a misfire event is determined, the
VCM compares the crankshaft position to the cam • The system voltage between 11 volts and
sensor signal in order to determine which cylinder 16 volts
misfired. The VCM stores the information in separate • The positive throttle position change is less
accumulators for each cylinder. Upon completion (or than 1.9% for 100 msec.
failure) of the test, the VCM evaluates the number of • The negative throttle position change is less
misfires in each accumulator. If the accumulators are than 1.9% for 100 msec.
somewhat even or if 3 or more cylinders are
misfiring, then this determines that a random misfire Action Taken When the DTC Sets
has occurred. The VCM also utilizes the input from If the VCM determines that the engine misfire is
the ABS wheel speed sensor in order to determine if significant enough to have a negative impact on
a rough road condition exists which could cause a emissions, the VCM turns ON the MIL after the
crankshaft acceleration and deceleration. If a rough misfire has been detected on 2 non-consecutive trips
road condition exists, the diagnostic will not run. under the same operating conditions. If the misfire is
severe enough that catalytic converter damage could
result, the MIL flashes while the misfire is present.
6-2872 Engine Controls - 7.4L
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 "C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
The Misfire Index counts the number of misfires. The
scan tool can monitor the Misfire Index. There is a
current and history misfire counter for each cylinder.
Use the current misfire counter in order to determine
which cylinder is misfiring.
Many different condition could cause an intermittent
misfire.
Check for the following conditions:
1. Check the spark plug wires and the coil wire for
the following conditions:
• Ensure that the spark plug wires are securely
attached to the spark plugs and the
distributor cap.
• Check the wire routing in order to ensure
that crossfiring is not occurring.
DTC P0300 Engine Misfire Detected
Step Action
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC
1 —
Information function.
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?
Review the Failure Records data.
2 Are there any other DTCs stored?
Perform the CKP System Variation Learning Procedure.
3 Refer to CKP System Variation Learn Procedure.
Is the action complete?
1. Install a scan tool.
2. With engine idling, monitor the MAP sensor voltage
4 on the scan tool.
Is the MAP sensor voltage greater than the
specified value?
Duplicate the conditions when the misfire occurred, using
5 the Freeze Frame and the Failure Records,.
Does the scan tool indicate this DTC failed this ignition?
Engine
• If the misfire occurs when the weather is
damp, the problem could be due to worn
plug wires.
In order to test for this condition, spray the
wires with water and with the engine running,
watch for spark to jump from the wires. If a
spark is visible, replace the wires.
2. Check for contaminated and a low fuel level
and the following conditions:
• Check the fuel condition and quality. Dirty or
contaminated fuel could cause a misfire
condition.
• If the fuel level is low, contaminants in the
bottom of the fuel tank could enter into the
fuel metering system.
For more information, refer to fuel supply system.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. If DTCs P0337 (Crankshaft Position Sensor
Circuit Low Input) or P0338 (Crankshaft
Position Sensor Circuit - High Input) are set,
this could result in a misfire condition.
5. In order to duplicate the conditions under which
the misfire occurred, it may be necessary to
drive the vehicle and monitor the scan tool DTC
Set This Ignition Cycle variable.
6. When checking the spark at the spark plug
wires, the spark should be consistent. A few
sparks then nothing is no spark.
8. At this point, the ignition system is OK and the
problem may be in the fuel system. Fuel
System Diagnosis must be performed in order
to determine the cause of the problem.
Value(s) Yes No
Go to Powertrain
OBD System
Check (OBD
Go to Step 2 System Check)
Go to
— the applicable
DTC table Go to Step 3
— —
Go to Step 4
Go to DTC P0108
4.0 V MAP Sensor
Circuit High
Voltage Go to Step 5
—
Go to Step 6 Go to Step 11
Engine Engine Controls - 7.4L 6-2873
DTC P0300 Engine Misfire Detected (cont’d)
Step Action Value(s) Yes No
Review the Misfire Index with a scan tool. Is the Misfire Go to
6 —
Index increasing for more than one cylinder? Diagnostic Aids Go to Step 7
1. Install the J 26792 spark plug tester on number 1
spark plug wire.
2. Disconnect the fuel injector harness at the intake
7 manifold. —
3. Crank the engine, spark should jump the tester gap.
Go to Enhanced
4. Repeat for each spark plug wire. Ignition System
Was the spark adequate on all of the spark plug wires? Go to Step 8 Diagnosis
Inspect the spark plugs for wear, excessive air gaps,
8 cracks, or fouling. —
Are the spark plugs OK? Go to Step 9 Go to Step 12
Perform a cylinder compression test. If a engine
mechanical problem is found, repair the condition. Refer to
9 Engine Mechanical. —
Was a problem found? Go to Step 14 Go to Step 10
Refer to Fuel System Diagnosis.
10 —
Is the fuel system OK? Go to Step 11 Go to Step 13
Misfire is intermittent. Go to
11 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
Replace the spark plugs.
12 — —
Is the action complete? Go to Step 14
Perform the repairs as indicated in the Fuel System
13 Diagnosis. Refer to Fuel System Diagnosis. — —
Is the action complete? Go to Step 14
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
14 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
15 function with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
6-2874 Engine Controls - 7.4L
DTC P0325 Knock Sensor Module Circuit
0.8
DK BLU 496
19 C2 (RED)
KS ” 11 Vehicle
signal 1Control
L ____ J (v c m )
S145+
0.8
DK BLU 496
A A.
Y
-L Knock
X X
Sensor
(KS)
Circuit Description
The VCM uses the Knock Sensors in order to detect
engine detonation. This detection allows the VCM to
retard the Ignition Control (IC) spark timing based on
the KS signal the VCM receives. The circuitry within
the knock sensor pulls down the VCM-supplied 5 volt
signal, so that under a no knock condition the signal
on the KS circuit measures about 1.3 volts. The
knock sensors produce an AC signal that rides on
the 1.3 volts DC. The signal amplitude and frequency
are dependent upon the amount of the knock being
experienced.
The VCM contains a replaceable Knock Sensor (KS)
module. The KS module contains the circuitry that
allows the VCM to utilize the KS signal and to
diagnose the KS sensors and circuitry. If the KS
module is missing or faulty which causes a
continuous knock condition, the VCM sets this DTC.
Conditions for Setting the DTC
• The DTC P0327 is not active
• Engine run time is at least 120 seconds.
• System voltage is greater than 10 volts but is
no more than 17.1 volts.
• Knock is detected for exceesive amount of time
Action Taken When DTC Sets
• The VCM will not illuminate the MIL
• The VCM will store the conditions which were
present when the DTC set as a Fail Records
data only. This information will not store as
Freeze Frame Data.
• The VCM will use a calculated spark retard
value in order to minimize the knock during the
conditions when the knock is most likely to
occur. The calculated value will vary based on
the engine speed and load.
Engine
Module A
7.4LOnly|
0.8
DK BLU 496
Y Knock
-L
Sensor
(KS)
33289
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 'C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 “ C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Check for the following conditions:
• A poor connection at the VCM. Inspect the KS
module connector for the following conditions:
- Backed out terminals
- Broken locks
- Improperly formed or damaged terminals
• A damaged or improperly installed KS module.
Check for the following items:
- Bent pins
- Deformed terminals
- KS module not completely seated
• Improper Knock Sensor torque specification.
Torque the Knock sensor to 19 N.m (14 lb ft).
Notice: Refer to Fastener Notice.
Review the Fail Records vehicle mileage since the
diagnostic test last failed in order to help determine
how often the conditions that caused the DTC to set
occur. This may assist in diagnosing the condition.
Engine Engine Controls - 7.4L 6-2875
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step ensures that the fault is present.
5. This step checks for an improperly installed KS
module.

DTC P0325 Knock Sensor Module Circuit

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool to
record freeze frame and failure records for reference
because data will be lost when the Clear Info function
1 — Go to Powertrain
is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Important: If you can hear the engine knock, repair the
engine mechanical problem before proceeding with this
diagnostic.
1. Operate the engine within the conditions specified in
the diagnostic support text Conditions for Setting
2 the DTC. —
2. Using a scan tool, monitor the Specific DTC info for
the DTC P0325 until the DTC P0325 test runs.
3. Observe the test results.
Does the scan tool indicate the DTC P0325 Failed
This Ign? Go to Step 4 Go to Step 3
1. Turn ON the ignition leaving the engine off.
2. Review the scan tool Fail Records data for
DTC P0325.
3. Record the scan tool Fail Records data for
DTC P0325.
3 4. Operate the vehicle within the Fail Records —
conditions.
5. Using a scan tool, monitor the SPECIFIC DTC info
for DTC P0325 test runs.
Does the scan tool indicate DTC P0325 test Failed Go to The
This Ign? Go to Step 4 Diagnostic Aids
1. Check the KS signal circuit for incorrect routing near
the secondary wires.
4 —
2. If a problem, repair as necessary.
Was a problem found? Go to Step 8 Go to Step 5
1. Check the KS signal circuit for not being fully seated
or for correct installation.
5 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 8 Go to Step 6
. 1. Replace the KS module.
2. Operate the engine within the conditions specified in
the diagnostic supporting text Conditions for Setting
the DTC.
6 3. Using a scan tool, monitor the Specific DTC info for —
DTC P0325 until the DTC P0325 test runs.
4. Observe the test results.
Does the scan tool indicate the DTC P0325 Failed
This Ign? Go to Step 7 Go to Step 8
6-2876 Engine Controls - 7.4L Engine
DTC P0325 Knock Sensor Module Circuit (cont’d)
Step Action Value(s) Yes No
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
7 — —
to Password Leam Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 8
1. Using the scan tool, select DTC, Clear Info.
2. Start engine and idle at normal operating
temperature.
3. Select DTC and Specific.
8 4. Enter the DTC number which was set. —
5. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 9 Go to Step 2
Using the scan tool, select Capture Info and Review Info. Go to
9 Are any DTCs displayed that have not been diagnosed? — The Applicable
DTC Table System OK
Engine___________________________________________
DTC P0327 Knock Sensor Noise Channel Low Voltage
0.8
DK BLU 496
19 C2 (RED)
• KS
sig n a l JControl
Module A
[ .____ J (VCM)
S145i
0.8
DK BLU 496
A4,
Y JY
Knock
X L
Sensor
X (KS)
Circuit Description
The VCM uses the Knock Sensors (KS) in order to
detect engine detonation. This allows the VCM to
retard the Ignition Control (IC) spark timing based on
the KS signal which the VCM receives. The circuitry
within the knock sensor pulls down the
VCM-supplied 5 volt signal, so that under a no
knock condition the signal on the KS circuit
measures about 1.3 volts. The knock sensors
produce an AC signal that rides on the 1.3 volts DC.
The amplitude and frequency of the AC signal are
dependent upon the amount of the knock being
experienced.
The VCM determines whether the knock is occurring
by comparing the signal level on the KS circuit with
a voltage level on the noise channel. The noise
channel allows the VCM to reject any false knock
signal by indicating the amount of normal engine
mechanical noise present. The normal engine noise
varies depending on the engine speed and load.
When the VCM determines that an abnormally high
noise channel voltage level is being experienced, a
DTC P0326 sets.
Conditions for Setting the DTC
Knock Sensor Update Test
• The timing retard is no more than 0 degrees.
• System voltage is greater than 10 volts but no
more than 17.1 volts
• The ECT sensor is greater than 60 *C (140*F)
• Engine run time is greater than 2 minutes
• Engine speed is between 525 RPM and
750 RPM
• Learned minimum noise value updated every
50 milliseconds
Active Noise Channel Test
• No ECT DTCs set
• No TP sensor DTCs set
Engine Controls - 7.4L 6-2877
Vehicle
7.4LOnly |
0.8
DK BLU 496
A.
Knock
Sensor
X (KS)
33289
• The Knock Sensor update test is complete
. The ECT is at least 60 *C (140‘ F)
• The engine speed is greater than or equal to
2000 RPM and less than 10000 RPM
• The throttle angle is at least 5.8%
• The engine has been running for at least
2 minutes
• The system voltage is greater than 10 volts but
no more than 17.1 volts
• The timing retard is no more than 0 degrees.
• KS sensor noise at least 25 counts but less
than 255 counts
Action Taken When DTC Sets
• The VCM will not illuminate the MIL
• The VCM will store the conditions which were
present when the DTC set as a Fail Records
data only. This information will not store as
Freeze Frame Data.
• The VCM will use a calculated spark retard
value in order to minimize the knock during the
conditions when the knock is most likely to
occur. The calculated value will vary based on
the engine speed and load.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160'F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
6-2878 Engine Controls - 7.4L
Diagnostic Aids
Check for the following conditions:
• A poor connection at the VCM. Inspect the
knock sensor and the VCM connectors for the
following items:
- Backed out terminals
- Broken locks
- Improperly formed or damaged terminals
• A misrouted harness. Inspect the knock sensor
harness in order to ensure that it is not routed
too close to high voltage wires such as spark
plug leads.
• Improper Knock Sensor torque specification.
Torque the Knock Sensor to 19 N.m (14 lbs ft).
Engine
Notice: Refer to Fastener Notice in General
Information.
Review the Fail Records vehicle mileage since the
diagnostic test last failed in order to help determine
how often the conditions that caused the DTC to set
occur. This may assist in diagnosing the condition.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Ensures that the fault is present.
6. Ensures that the knock sensor is capable of
detecting detonation.

DTC P0327 Knock Sensor Noise Channel Low Voltage

Step Action Value(s) Yes No
Important: Before clearing the DTCs use the scan tool in
order to record the Freeze Frame and Failure Records for
reference because the data will be lost when the Clear Go to Powertrain
1 Info function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Operate the engine within the conditions specified in
the diagnostic support Conditions for Setting
the DTC.
2. Using a scan tool, monitor the Specific DTC info for
2 DTC P0327 until the DTC P0327 test runs.
—

3. Observe the test results.

Does the scan tool indicate the DTC P0327 failed this
ignition? Go to Step 4 Go to Step 3
1. Turn ON the Ignition leaving the engine off.
2. Review the scan tool Fail Records data.
3. Record the scan tool Fail Records data.
4. Operate the vehicle within the Fail Records
conditions.
3 —
5. Using a scan tool, monitor the Specific DTC info for
the DTC P0327 until the DTC P0327 test runs.
6. Observe the test results.
Does the scan tool indicate the DTC P0327 Failed Go to
This Ign? Go to Step 4 Diagnostic Aids
1. Disconnect both KS sensor electrical connectors.
2. Using a DVM J 39200, measure the voltage between
4 the KS signal circuit at the knock sensor harness 5V
connectors and ground.
Is the voltage approximately at the specified value? Go to Step 5 Go to Step 8
Measure the resistance of each KS sensor by connecting
the DVM between the KS sensor terminal and the
5 engine block. 100KC2
Is the resistance of each KS sensor near the
specified value? Go to Step 6 Go to Step 12
Engine Engine Controls - 7.4L 6-2879
DTC P0327 Knock Sensor Noise Channel Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Connect the DVM in order to monitor the voltage
between the KS sensor terminal and the engine
ground.
6 2. Tap on the engine lift bracket while observing the —
signal indicated on the DVM.
Is any signal indicated on the DVM while tapping on the
engine lift bracket? Go to Step 7 Go to Step 9
1. Check the KS signal circuit for a poor terminal
connection at the knock sensor.
7 2. If a problem is found, repair as necessary. Refer to —

Wiring Repairs in Engine Electrical.

Was a problem found? Go to Step 14 Go to Step 10
1. Turn OFF the ignition.
2. Disconnect the VCM.
3. Turn ON the Ignition.
4. Check the KS signal circuit between the VCM and
8 the KS sensor connector for an open, a short to —
voltage, or a short to ground.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs in Engine Electrical.
Was a problem found? Go to Step 14 Go to Step 10
Replace the Knock Sensor. Refer to Knock Sensor
9 Replacement — —
Is action complete? Go to Step 14
1. Turn off the ignition.
2. Disconnect the VCM.
3. Check the KS signal circuit for a poor terminal
10 —
connection at the VCM.
4. If a problem is found, replace the faulty terminal.
Was a problem found? Go to Step 14 Go to Step 11
1. Check the KS module for not being fully seated or
for incorrect installation.
11 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 14 Go to Step 12
1. Replace the KS module.
2. Operate the engine within the conditions specified in
the diagnostic supporting text; Conditions for Setting
the DTC.
12 —
3. Using a scan tool, monitor the Specific DTC info for
the DTC P0327 until the DTC P0327 test runs.
4. Observe the test results.
Does the scan tool indicate DTC P0327 Failed This Ign? Go to Step 13 Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
13 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
6-2880 Engine Controls - 7.4L Engine
DTC P0327 Knock Sensor Noise Channel Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
14 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine___________________________________ Engine Controls - 7.4L 6-2881

DTC P0336 CKP Sensor Circuit Performance

[HotJnJ2unAndiStart]
r ----------- "I Underhood
I Power
Distribution ENG1 H7*> ECM1 Fuse-Relay
> Cell 10 Fuse
LflT 20A
Fuse
J8 20A
Center
H
PNK 439

< VCM
PNK 53S Cl =BLU
FuseBlock PNK 439 C2-RED
Details C3-CLEAR
Cell 11 PNK C4-BLK
439
•~ 1
Camshaft Crankshaft I
Position (CMP) Position FuseBlock
Details
Sensor (CKP) Call 11
Sensor
ICMand
Ignition
Coil
A
PNK/BLK

8A 3 31 28 C1
---- -------- . . . . A . . _. . - A
...

jcMP 1xCMP 4xCKP CKP

• Sensor Sensor Sensor Sensor
1 Ground Signal Signal Ground
L —

33715
Circuit Description • Use the scan tool Clear Information function.
The Crankshaft Position (CKP) sensor sends a • Disconnect the VCM battery feed for
reference signal to the Vehicle Control Module (VCM) 30 seconds.
in order to indicate the crankshaft position and the
RPM so that the VCM can determine when to pulse Diagnostic Aids
the ignition coil, the fuel injectors, and the control A poor connection, a rubbed through wire insulation,
ignition timing. or a wire that is broken inside the insulation may
cause an intermittent problem.
Conditions for Setting the DTC
Thoroughly check any circuitry, that is suspected of
The following conditions will set the DTC: causing the intermittent complaint for the following
• The Engine cranking conditions:
• 4 or more Cam Shaft Position signals present • Backed out terminals
• CKP sensor signal missing for .5 or more • Improper mating
seconds • Broken locks
Action Taken When the DTC Sets • Improperly formed or damaged terminals
The VCM stores the DTC to the History if the VCM • Poor terminal to wiring connections
detects an intermittent problem. • Physical damage to the wiring harness
Inspect the face of the CKP sensor for metal
Conditions for Clearing the MIL/DTC
shavings. This could result in an intermittent
• The VCM turns the MIL OFF after 3 DTC P0339.
consecutive drive trips when the test has Run
Refer to Intermittent Condition.
and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 7 0 ’ C
(160*F) during the same ignition cycle).
6-2882 Engine Controls - 7.4L___________ Engine
Test Description 4. This step checks the ignition feed circuit to the
The numbers below refer to the step numbers on the Crankshaft Position sensor.
diagnostic table. 5. This step checks the Crankshaft Position sensor
2. This step determines if the DTC P0336 is the low circuit.
result of a hard failure or an intermittent 6. This step checks the Crankshaft Position
condition. Sensor.
3. This step determines if the VCM is receiving
the Crankshaft Position sensor pulses.

DTC P0336 CKP Sensor Circuit Performance

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data. OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Does the vehicle start and continue to run? Go to
2 —
Diagnostic Aids Go to Step 3
1. Disconnect the Crankshaft Position (CKP) sensor.
2. Connect a test lamp to a ground.
3. Turn ON the ignition, but leave the engine off.
3 —
4. Probe the Crankshaft Position sensor ignition feed
circuit at the engine side of the harness connector.
Is the test lamp on? Go to Step 4 Go to Step 6
Connect the test lamp between the CKP sensor ignition
4 feed and the CKP sensor Low circuit. —
Is the test lamp on? Go to Step 5 Go to Step 7
1. Turn off the ignition.
2. Install the gray jumpers from the connector Tester Kit
J 35616-A between the engine harness connector
and the CKP sensor ignition feed and ground
circuits.
5 3. Install a DVM set to the duty cycle position (select 20%-40%
AC voltage and press Hz button twice to display duty
cycle) between the CKP sensor (4x) signal circuit
and the CKP sensor Low circuit.
4. Crank the engine.
Is the duty cycle within the specified value? Go to Step 8 Go to Step 9
Repair the open or short to ground in the CKP sensor
ignition feed circuit. Refer to Wiring Repairs in Engine
6 — —
Electrical.
Is the action complete? Go to Step 12
Check the CKP sensor Low circuit for an open.
7 —
Was the problem found? Go to Step 10 Go to Step 11
Check for an open in the CKP sensor (4X) signal circuit or
8 an open in the CKP sensor Low circuit. —
Was a problem, found? Go to Step 10 Go to Step 11
Engine________________________________________________ Engine Controls - 7.4L 6-2883
DTC P0336 CKP Sensor Circuit Performance (cont'd)
Step Action Value(s) Yes No
Important: Inspect the CKP sensor mounting surface to
insure the surface is clean and free of debris.
1. Replace the CKP sensor. Refer to Crankshaft
9 Position Sensor Repiacement. — —
2. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 12
Repair as necessary.
10 — —
Is the action complete? Go to Step 12
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
11
to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 12
1. Using the scan tool, select DTC, Clear Info.
2. Start engine and idle at normal operating
temperature.
3. Select DTC Specific, then enter the DTC number
12 which was set. —
4. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select Capture Info and Review Info. Go to
13 Are any DTCs displayed that have not been diagnosed? — The Applicable
DTC Table System OK
6-2884 Engine Controls - 7.4L_______________ Engine

DTC P0337 CKP Sensor Circuit Low Frequency

|Hot2n_RiJ£iAnd_Stertj
I Power 7 Underhood
Distribution
■ Cell 10
ENG1 Fuse-Relay
Fuse
I Lb 1 20A

PNK A
iO S O I I k

VCM
PNK 539 Cl =BLU
FuseBlock PNK C2=RED
Details C3=CLEAR
Cell 11 PNK C4=BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

Coil
A
PNK/BLK

* -A. _ _ ----------------- -------- . . A

I CMP 1 x CMP 4xCKP CKP

. Sensor Sensor Sensor Sensor
1 Ground Signal Signal Ground

33715
Circuit Description • Use the scan tool Clear Information function.
The Crankshaft Position (CKP) sensor sends a • Disconnect the VCM battery feed for
reference signal to the Vehicle Control Module (VCM) 30 seconds.
in order to indicate the crankshaft position and the
RPM so that the VCM can determine when to pulse Diagnostic Aids
the ignition coil, the fuel injectors, and the control A poor connection, a rubbed through wire insulation,
ignition timing. or a wire that is broken inside the insulation may
cause an intermittent problem.
Conditions for Setting the DTC Thoroughly check any circuitry, that is suspected of
The following conditions will set the DTC: causing the intermittent complaint for the following
• The engine speed is less than 4000 RPM conditions:
• The MAF sensor is at least 5 g/s • Backed out terminals
• CKP sensor duty cycle is greater than • Improper mating
50 percent • Broken locks
Action Taken When the DTC Sets • Improperly formed or damaged terminals
The VCM stores the DTC to the History if the VCM • Poor terminal to wiring connections
detects an intermittent problem. • Physical damage to the wiring harness
Inspect the face of the CKP sensor for metal
Conditions for Clearing the MIL/DTC shavings. This could result in an intermittent
• The VCM turns the MIL OFF after DTC P0339.
3 consecutive drive trips when the test Refer to Intermittent Condition.
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
Engine Engine Controls - 7.4L 6-2885
Test D escription 4. If the feed circuit is shorted to ground, the test
The numbers below refer to the step numbers on the lamp will light. This step determines if the
diagnostic table. circuit is open or shorted to ground. If the
circuit is OK, then the VCM connections or
2. This step determines if DTC P0337 is the result VCM is faulty.
of a hard failure or an intermittent condition.
5. This test checks the crank sensor, the crank
3. Determines if voltage is available to the CKP sensor signal circuit and the VCM.
through the VCM.

DTC P0337 CKP S ensor C ircuit Low Frequency

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and failure records for reference,
Go to Powertrain
1 as data will be lost when Clear Info function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Disconnect the CKP sensor electrical connector.
2. Turn ON the ignition leaving the engine off.
2 3. With a test lamp connected to ground, probe the —
CKP sensor ignition feed circuit harness connector
terminal A (engine side).
Is the lamp on? Go to Step 3 Go to Step 8
1. Turn OFF the ignition.
3 2. With a test lamp connected to the B+, probe the
—
cavity B of the CKP sensor connector (engine side).
Is the lamp on? Go to Step 4 Go to Step 7
1. Disconnect the VCM blue connector.
4 2. With the test lamp still connected to the B+, probe
—
the terminal C of the CKP connector (engine side).
Is the test lamp on? Go to Step 10 Go to Step 5
1. Connect the VCM blue connector.
2. Install the gray jumpers from the connector test
adapter kit J 35616-A between the engine harness
and the CKP sensor connector.
5 3. Start the engine. 30%
4. Using the DVM, measure the duty cycle (select the
AC scale, and select the Hz twice in order to display
the % duty cycle) on the (4X) signal circuit.
Is the duty cycle less than the specified value? Go to Step 11 Go to Step 6
Check for a faulty connection at the CKP sensor.
6 — —
Was a problem found? Go to Step 12
Check for an open in the CKP sensor low circuit.
7 —
Was a problem found? Go to Step 12 Go to Step 9
Check for an open or a short to a ground in the CKP
8 sensor feed circuit. — —
Was a problem found? Go to Step 12
Check for a faulty connection at the VCM.
9 —
Was a problem found Go to Step 12 Go to Step 13
Repair short to ground in Crankshaft Position sensor 4X
10 signal circuit. Refer to Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 14
6-2886 Engine Controls - 7.4L Engine
DTC P0337 CKP Sensor C ircuit Low Frequency (cont’d)
Step Action Value(s) Yes No
Important: Inspect the CKP sensor mounting surface to
insure the surface is clean and free of debris.
1. Replace the CKP sensor. Refer to Crankshaft
11 Position Sensor Replacement. — —
2. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
Repair the circuit as necessary. Refer to Wiring Repairs in
12 Engine Electrical. — —

Is the action complete? Go to Step 14

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Using the scan tool, select DTC and Clear Info.
2. Start engine and idle at normal operating
temperature.
3. Select DTC and Specific.
14 4. Enter the DTC number which was set. —
5. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select Capture Info and Review Info. Go to
15 Are any DTCs displayed that have not been diagnosed? — The Applicable
DTC Table System OK
Engine_____________________________________ Engine Controls - 7.4L 6-2887

DTC P0338 CKP Sensor Circuit High Frequency

| H o t In R u n A nd S ta rt]

r -----------
■ P o w er
Underhood
D istrib u tio n
ENG1 Fuse-Relay
' C e ll 10 Fuse
L8T 20 A

PNK

VCM
PNK 539 C1 = B LU
F u se B lo ck PNK C 2 - RED
D e ta ils C 3 - C LE A R
CeH 11 PNK C 4 -B L K

439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor
IC M an d
Ig n itio n
C o il

A
PNK/BLK

| CM P 1 * CM I 4x CKP
c k p ^ Vehicle Control a
. S ensor S ensor Sensor S ensor j Module (V C M )^ ^
1 G ro u n d S ig n a l S ig n a l G ro u n d
j

33715

C ircuit Description 2. Use the scan tool Clear Information function.

The Crankshaft Position (CKP) sensor sends a 3. Disconnect the VCM battery feed for
reference signal to the Vehicle Control Module 30 seconds.
(VCM). The CKP reference signal is used to
determine crankshaft position and engine RPM. This D iagnostic Aids
information is used by the VCM in order to A poor connection, a rubbed through wire insulation,
determine when to pulse the ignition coil and to or a wire that is broken inside the insulation may
control the ignition timing. This diagnostic will detect cause an intermittent problem.
a low duty cycle from the crankshaft sensor. Thoroughly check any circuitry, that is suspected of
causing the intermittent complaint for the following
C onditions fo r S etting th e DTC
conditions:
The following conditions will set the DTC: • Backed out terminals
• The engine speed is less than 4000 RPM • Improper mating
• The MAF is at least 5 g/s • Broken locks
• CKP sensor duty cycle is greater than • Improperly formed or damaged terminals
50 percent
• Poor terminal to wiring connections
A ction Taken W hen th e DTC Sets • Physical damage to the wiring harness
The VCM will turn ON the MIL after 2 consecutive Inspect the face of the CKP sensor for metal
driving cycles with the fault active. shavings. This could result in an intermittent
DTC P0339.
C onditions fo r C learing th e M IL/DTC
Refer to Intermittent Condition.
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 ’ C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160‘ F) during the same ignition cycle.
6-2888 Engine Controls - 7.4L Engine
Test Description 6. If the feed circuit is shorted to ground, the test
The numbers below refer to the step numbers on the light will be ON. This step determines if the
diagnostic table. circuit is open or shorted to ground. If the
circuit is OK, then the VCM connections or
3. This step determines if DTC P0338 is the result VCM is faulty.
of a hard failure or an intermittent condition.
7. This test checks the crank sensor, crank sensor
5. Determines if voltage is available to the CKP signal circuit and the VCM.
through the VCM.

DTC P0338 CKP Sensor Circuit High Frequency

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records
for reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
2 Does the engine start? — Go to Step 4 Go to Step 3
Clear DTCs crank the engine for 10 seconds. Go to Engine
3 Does DTC P0338 set? — Cranks but Does
Go to Step 4 Not Run
Start the engine, observe the engine RPM on the
4 scan tool. —
Does the RPM fluctuate (up to twice desired RPM)? Go to Step 14 Go to Step 5
1. Turn ON the ignition leaving the engine off.
2. Disconnect the Crankshaft Position sensor electrical
connector.
5 3. With a test lamp connected to ground, probe cavity —
A of the Crankshaft Position sensor connector
(engine side).
Is the test lamp on? Go to Step 6 Go to Step 8
Jumper the test lamp between cavities B and C of the
6 Crankshaft Position sensor electrical connector. —
Is the test lamp on? Go to Step 7 Go to Step 12
1. Turn off the ignition.
2. Install the gray jumpers from J 35616-A connector
test adapter kit.
7 3. Allow engine to run 2-3 V
4. Using a DVM, measure voltage on the 4X signal
circuit.
Is the voltage between the specified value? Go to Step 16 Go to Step 9
1. Turn OFF the ignition.
2. Disconnect the VCM BLUE connector.
8 3. With a test lamp connected to B+, again probe —
cavity C of Crankshaft Position sensor.
Is the test lamp off? Go to Step 15 Go to Step 11
Check the Crankshaft Position sensor signal circuit for
9 an open. —
Was a problem found? Go to Step 17 Go to Step 10
Check the Crankshaft Position sensor signal circuit for a
10 short to ground. —
Was a problem found? Go to Step 17 Go to Step 13
Repair short to ground in Crankshaft Position sensor feed
11 circuit. Refer to Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 19
Engine Engine Controls - 7.4L 6-2889
DTC P0338 CKP Sensor Circuit High Frequency (cont’d)
Step Action Value(s) Yes No
Repair the open in the Crankshaft Position sensor ground
12 circuit. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 19
Check for a faulty connection at the Crankshaft Position
13 sensor. —
Was a problem found? Go to Step 17 Go to Step 14
Important: Inspect the CKP sensor mounting surface to
insure the surface is clean and free of debris.
1. Replace the CKP sensor. Refer to Crankshaft
14 Position Sensor Replacement. — —
2. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 19
Check for an open in the Crankshaft Position sensor feed
15 circuit. —
Was a problem found? Go to Step 17 Go to Step 16
Check for a faulty connection at the VCM.
16 —
Was a problem found? Go to Step 17 Go to Step 18
Repair the circuit as necessary. Refer to Wiring Repairs in
17 Engine Electrical. — —
Is the action complete? Go to Step 19
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
18 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Learn Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 19
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
19 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 20 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
20 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2890 Engine Controls ■ 7.4L___________ Engine

DTC P0339 CKP Sensor Circuit Intermittent

[HotJn_Run^ndStart]
r —— 7 Underhood
I Power
Distribution ENG1 Fuse-Relay
Cell 10 Fuse Center
L8 T 20A

PNK A
JO B O IIk

VCM
PNK 539 C1=BLU
FuseBlock PNK C2=RED
Details C3=CLEAR
Cell 11 PNK C4= BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

A
PNK/BLK

| CMP 1xCMI 4x c k p ckp ’ Vehicle Control^

. Sensor Sensor Sensor Sanaa. Module (VCMWSk
1 Ground Signal Signal Ground M

Circuit Description • Use the scan tool Clear Information function.

The Crankshaft Position (CKP) sensor sends a
reference signal to the Vehicle Control Module (VCM)
in order to indicate the crankshaft position and RPM.
The VCM uses this information in order to determine
when to pulse the ignition coil, the fuel injectors and
the control ignition timing.
Conditions for Setting the DTC
The following conditions will set the DTC:
• The MAF sensor is at least 5 g/s.
• The calculated engine speed change is at
least 1000
Action Taken When the DTC Sets
The VCM will turn ON the MIL after 2 consecutive
driving cycles with the fault active.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40'F )
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ‘ C (160‘ F) during the same ignition cycle).
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
A poor connection, a rubbed through wire insulation,
or a wire that is broken inside the insulation may
cause an intermittent problem.
Thoroughly check any circuitry, that is suspected of
causing the intermittent complaint for the following
conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections
• Physical damage to the wiring harness
Inspect the face of the CKP sensor for metal
shavings. This could result in an intermittent
DTC P0339.
Refer to Intermittent Condition.
Engine Engine Controls - 7.4L 6-2891
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. Checks the ignition feed circuit to the
Crankshaft Position sensor
5. Checks the duty cycle of the Crankshaft
Position sensor

DTC P0339 CKP Sensor Circuit Intermittent

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and failure records for
reference because using the Clear Info function will lose Go to Powertrain
1 the data. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Does the vehicle start and continue to run? Go to
2 —
Diagnostic Aids Go to Step 3
1. Disconnect the Crankshaft Position (CKP) sensor.
2. Connect a test lamp to ground.
3. Turn the ignition ON leaving the engine off.
3 —
4. Probe the Crankshaft Position sensor ignition feed
circuit at the engine side of the harness connector.
Is the test lamp on? Go to Step 4 Go to Step 6
Connect the test lamp between the CKP sensor ignition
4 feed and the CKP sensor Low circuit. —
Is the test lamp on? Go to Step 5 Go to Step 7
1. Turn the ignition off.
2. Install the gray jumpers from the Connector Tester
Kit J 35616-A between the engine harness connector
and the CKP sensor.
5 3. Install a DVM set to the Duty Cycle position, 40%-60%
between the CKP sensor (4X) signal circuit and the
CKP sensor Low circuit.
4. Crank the engine.
Is the duty cycle within the specified range? Go to Step 8 Go to Step 10
Repair the open or short to ground in the CKP sensor
ignition feed circuit. Refer to Wiring Repairs in Engine
6 Electrical. — —
Is the action complete? Go to Step 13
Check the CKP sensor Low circuit for an open.
7 —
Was a problem found? Go to Step 11 Go to Step 9
1. With the DVM still connected between the CKP
sensor (4X) signal circuit and the CKP sensor Low
8 circuit, select the AC volt scale on the DVM. 10.0V
2. Crank the engine.
Is the voltage above the specified value? Go to Step 11 Go to Step 9
Check for an open in the CKP sensor (4X) signal circuit or
9 an open in the CKP sensor Low circuit. —
Was a problem found? Go to Step 11 Go to Step 12
6-2892 Engine Controls - 7.4L________________________________________________ Engine
DTC P0339 CKP Sensor Circuit Intermittent (cont’d)
Step Action Value(s) Yes No
Notice: In order to avoid damaging the replacement
three-way catalytic converter, correct the engine misfire or
mechanical fault before replacing the three-way catalytic
converter.
Important: Inspect the CKP sensor mounting surface to
10 insure the surface is clean and free of debris. — —

1. Replace the CKP sensor. Refer to Crankshaft

Position Sensor Replacement.
2. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
Repair as necessary.
11 — —
Is action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
12
to Password Learn Procedure.
— —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
13 —

5. Enter the DTC number which was set.

6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
14 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine______________________ Engine Controls - 7.4L 6-2893

DTC P0340 CMP Sensor Circuit

IHot InRunAndStart!
■ Power "I Underhood
Distribution ENG1 Fuse-Relay
1 Cell 10 C Fuse Center
■ L8 T 20 A

PNK A
iO B O IIk ,

VCM
PNK 539 Cl =BLU
FuseBlock PNK C2- RED
Details C3=CLEAR
Cell 11 PNK C4=BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

Coil
A
PNK/BLK

8A- . . _ -3A __---------31

-A----- _28
. A C1
CMP 1xCMP 4xCKP CKP
Sensor Sensor Sensor Sensor
Ground Signal Signal Ground

Circuit Description
The Camshaft Position (CMP) sensor is used to
indicate the camshaft position. The VCM uses the
CMP sensor in order to determine which cylinder is
misfiring. This DTC is also used to check for a
properly installed High Voltage switch.
Conditions for Setting the DTC
The following conditions will set the DTC:
• The engine running
• Cam sensor reference pulse is not seen once
every 8 cylinders
Action Taken When the DTC Sets
The VCM will turn ON the MIL after 2 consecutive
driving cycles with the fault active.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
33715
Diagnostic Aids
A poor connection, rubbed through wire insulation, or
a wire that is broken inside the insulation may cause
an intermittent.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for the following conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections or
• Physical damage to the wiring harness.
Refer to Intermittent Condition.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. This step determines if the DTC P0340 is the
result of a hard failure or an intermittent
condition.
3. Determines if the voltage is available to the
CMP through the VCM.
4. If the feed circuit is shorted to ground, the test
lamp will be ON. This step determines if the
circuit is open or shorted to ground. If the
circuit is OK, then the VCM connections or
VCM is faulty.
6-2894 Engine Controls - 7.4L Engine
DTC P0340 CMP Sensor Circuit
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool to
record the freeze frame and failure records for reference,
because the data will be lost when Clear Info function
1 — Go to Powertrain
is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Allow the engine to idle.
2. Install the scan tool.
3. Record the freeze frame and failure records for DTC.
4. Wait 1 minute with the engine idling.
2 —
5. Observe the last test failed for the DTC that was
recorded in the freeze frame.
6. If failed, turn the engine OFF and restart.
Is MIL (Malfunction Indicator Lamp) on? Go to Step 3 Go to Step 8
1. Turn ON the ignition leaving the engine off.
2. Disconnect the Camshaft Position sensor electrical
connector.
3 —
3. With a test lamp connected to a ground, probe the
cavity C of the connector.
Is the test lamp? Go to Step 4 Go to Step 9
Jumper the test lamp between cavities A and C of the
4 Camshaft Position sensor connector (engine side). —
Is the test lamp ON? Go to Step 5 Go to Step 11
1. Turn OFF the ignition.
2. Install the gray jumpers from J 35616-A connector
test adapter kit.
5 3. Allow the engine run. 5-7V
4. Using a DVM, measure voltage on the 1X cam
signal circuit.
Is the voltage between the specified value? Go to Step 15 Go to Step 6
Check the Camshaft Position sensor signal circuit for
6 an open. —
Was a problem found? Go to Step 13 Go to Step 7
Check the Camshaft Position sensor signal circuit for
7 a short. —
Was a problem found? Go to Step 13 Go to Step 12
DTC is intermittent. If no other DTCs are stored, refer to
8 the Diagnostic Aids. — —
Are any additional DTCs stored? Go to Step 17
Check for an open in the Camshaft Position sensor feed
9 circuit. —
Was a problem found? Go to Step 13 Go to Step 10
Repair short to ground in the Camshaft Position sensor
10 feed circuit. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 17
Repair open in the Camshaft Position sensor Low circuit.
11 Refer to Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 17
Check for a faulty connection at the Camshaft Position
12 sensor. —
Was a problem found? Go to Step 13 Go to Step 14
Engine Engine Controls - 7.4L 6-2895
DTC P0340 CMP Sensor Circuit (cont’d)
Step Action Value(s) Yes No
Repair the circuit as necessary. Refer to Wiring Repairs in
13 Engine Electrical. — —
Is the action complete? Go to Step 17
Replace the Camshaft Position sensor. Refer to Camshaft
14 Position Sensor Replacement. — —

Is the action complete? Go to Step 17

Check for a faulty connection at the VCM.
15 —
Was a problem found? Go to Step 13 Go to Step 16
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
16 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 17
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
17 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 18 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
18 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2896 Engine Controls - 7.4L_____________ Engine
DTC P0341 CMP Sensor Circuit Performance
[HotJnR^un_AndSta^
r -------— —
I Power 7 Underhood
Distribution ENG1 Fuse-Relay
■ Ceil 10 Fuse Center
L8T 20A

PNK A .
JQ B O IIk

VCM
PNK 539 C1=BLU
FuseBlock PNK C2=RED
Details C3=CLEAR
Cell 11 PNK C4=BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

Coil
A
PNK/BLK

8A ... _ _3A - - - ----------------------

31 _28
. JvC1
CMP 1x CMP 4xCKP CKP
Sensor Sensor Sensor Sensor
Ground Signal Signal Ground

Circuit Description Diagnostic Aids

This DTC identifies that the cam and the crank A poor connection, rubbed through wire insulation, or
relationship is skewed and that the cam pulses are a wire that is broken inside the insulation may cause
read in a haphazard ratio to the crank pulses. This an intermittent.
fault is not a solid or consistent failure. The fault Any circuitry, that is suspected as causing the
may not act the same way twice. intermittent complaint, should be thoroughly checked
for the following conditions:
Conditions for Setting the DTC
• Backed out terminals
• The engine running
• Improper mating
• Cam sensor reference pulse is not detected at
the correct interval every 8 cylinders • Broken locks
• Improperly formed or damaged terminals
Action Taken When the DTC Sets
• Poor terminal to wiring connections or
The VCM will turn ON the MIL (Malfunction Indicator
Lamp) after 2 consecutive test failures. • Physical damage to the wiring harness.
Refer to Intermittent Condition.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
Test Description
3 consecutive drive trips when the test The step number below refers to the step number in
has Run and Passed and not Failed. the diagnostic table.
• A history DTC will clear if no fault conditions 2. This step determines if DTC P0341 is the result
have been detected for 40 warm-up cycles of a hard failure or an intermittent condition.
(coolant temperature has risen 22 * C (40 * F) Determines, also, if voltage is available to the
from the startup coolant temperature and the CMP through the VCM.
engine coolant temperature exceeds 70 *C If the ignition feed circuit is shorted to ground,
(160’ F) during the same ignition cycle). the test light will be ON. This step determines if
• Use the scan tool Clear Information function. the circuit is open or shorted to ground. If the
circuit is OK, then the VCM connections or
• Disconnect the VCM battery feed for
VCM is faulty.
30 seconds.
Engine________________________________________________ Engine Controls - 7.4L 6-2897
DTC P0341 CMP Sensor Circuit Performance
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Check for an intermittent short to the voltage or EMI
(electromagnetic interference) such as the wires which run
along side the spark plug wires or the high power
2 transmitters (like the mobile radios operating in the vicinity) —
on the Camshaft Position sensor wires.
Was a problem found? Go to Step 3 Go to Step 4
Repair short to voltage or EMI as necessary. Refer to
3 Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 4
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
4 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 5 Go to step 2
Using the scan tool, select the Capture Info and the Go to
5 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2898 Engine Controls - 7.4L__________ Engine

DTC P0401 EGR System Flow Insufficient

MAPand Fuel Tank

PressureSensors
T
i

Circuit Description
The VCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open.
The pressure in the intake manifold increases when
the EGR valve is open. The VCM monitors the
Manifold Absolute Pressure (MAP) sensor signal
during the EGR system diagnostic in order to
determine the amount of EGR flow. The VCM
calculates an error based on the difference between
the actual MAP increase and a predetermined value.
The VCM records the error and adjusts an internal
fail counter towards the fail threshold if the error is
too great. The VCM sets a DTC P0401 when the fail
counter exceeds the fail threshold. The number of
test samples required to exceed the fail threshold
varies according to the magnitude of the detected
flow errors.
The VCM allows only one EGR flow test sample to
be taken during an ignition cycle. Following a scan
tool Clear Info or a battery disconnect, the VCM
allows twelve test samples during the first ignition
cycle in order to aid in verifying a repair.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensors DTCs
• No MAP sensors DTCs
190380
• No VS sensors DTCs
• No IAT sensors DTCs
• No ECT sensors DTCs
• No IAC sensors DTCs
• No Linear EGR Pintle position DTCs
• No misfire DTCs
• ECT is greater than 50.2' C
• BARO is greater than 75 kPa
• Vehicle speed is greater than 15 mph
• IAC change is less than 5 counts
• Transmission status is unchanged
• AC clutch status is unchanged
• Engine run time is greater than 120 seconds
Start Test
• Throttle position is greater than 4% but less
than 30%
• Throttle position change is less than 2 percent
• EGR position is greater than 15 %
• Engine speed is greater than 1200 rpm but less
than 2200 rpm
• MAP change is less than 1 A/D count
(0.39 kPa)
• Compensated MAP is greater than 40 kPa but
less than 60 kPa
• No change in DFCO state
Engine
Run Test
• Stabilized MAP (valve closed) recorded and
EGR valve ramped open over a time interval
and peak MAP value recorded and MAP
change computed.
• EGR valve closed
Action Taken When the DTC Sets
With a current DTC set, the VCM turns ON the MIL.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Notice: In order to prevent further damage if the
EGR valve shows signs of excessive heat, check the
exhaust system for blockage (possibly a plugged
converter) using the procedure found on the
restricted exhaust system check. If the exhaust
system is restricted, repair the cause; one of which
might be an injector which is open due to one of the
following reasons:
• Stuck
• Grounded driver circuit
• Possible faulty Control Module.
DTC P0401 EGR System Flow Insufficient
Step Action
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 the data.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1. Install the scan tool.
2. Start the engine.
3. Run the engine above the specified value
4. select Special Functions, Engine Output Controls,
2 then EGR Solenoid. Using the scan tool, cycle the
EGR Valve to 100%, the RPM should decrease and
the engine should run rough as the EGR Valve is
cycled.
Does the engine run rough as the EGR Valve is cycled?
Engine Controls - 7.4L 6-2899
Check the oil for possible fuel contamination if a
stuck open fuel injector is found.
Check for the following conditions:
• Poor connection or damaged harness - Inspect
VCM harness connectors for the following
conditions:
- Backed out terminal EGR Control circuit
- Improper mating
- Broken locks
- Improperly formed or damaged terminal
- Poor terminal to wire connection
- Damaged harness
• Intermittent test - If connections and harness
check OK, monitor a digital voltmeter connected
between terminal EGR Control circuit and
ground while moving related connectors and
wiring harness. If the failure is induced, the
voltage reading will change.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Ensures that the EGR valve is allowing EGR
flow and the VCM is capable of controlling the
EGR valve.
3. Ensures that the EGR LOW signal circuit is not
shorted to ground.
4. Ensures that the EGR LOW signal circuit is not
open and that the VCM quad-driver for the
EGR LOW signal circuit is functioning properly.
16. Clearing the DTCs is a very important step in
this diagnostic procedure. The clearing function
allows the EGR Valve to relearn a new
minimum pintle position, as the old position was
inaccurate due to the malfunction that caused
this DTC.
Value(s) Yes No
Go to Powertrain
—
OBD System
Check (OBD
Go to Step 2 System Check)
1500 RPM
Go to Step 5 Go to Step 3
6-2900 Engine Controls - 7.4L Engine
DTC P0401 EGR System Flow Insufficient (cont’d)
Step Action Value(s) Yes No
1. Turn ON the ignition
2. Disconnect the EGR Valve electrical connector.
3. Turn ON the ignition leaving the engine OFF.
3 —
4. Connect a test lamp between the EGR valve harness
connector terminal A and E.
Is the test lamp off? Go to Step 4 Go to Step 7
1. Start the engine.
2. Connect a test lamp between the EGR valve harness
4 —
connector A and E.
Is the test lampOFF? Go to Step 8 Go to Step 11
1. Remove the EGR Valve.
2. Inspect the valve and passages for restrictions.
5 3. Inspect the valve pintle to ensure that it is not —
sticking partially open.
Was a problem found? Go to Step 10 Go to Step 6
This DTC is intermittent. Go to applicable Go to
6 —
Are any additional DTCs stored? DTC table Diagnostic Aids
Check for a short to voltage in the EGR Feed Control
7 circuit. —
Was a problem found? Go to Step 14 Go to Step 15
Check for a restriction in the EGR tube or passage.
8 —
Was a problem found? Go to Step 16 Go to Step 9
Check for a poor electrical connection at the EGR Valve.
9 —
Was a problem found? Go to Step 14 Go to Step 10
Replace the EGR Valve. Refer to EGR Valve Replacement
10 (DR Utility). — —
Is the action complete? Go to Step 16
Check for an open in EGR Valve ground circuit.
11 —
Was a problem found? Go to Step 14 Go to Step 12
Check for an open in EGR Valve control circuit.
12 —
Was a problem found? Go to Step 14 Go to Step 13
Check for a poor connection at the VCM.
13 —
Was a problem found? Go to Step 14 Go to Step 15
Repair the circuit as necessary. Refer to Wiring Repairs in
14 Engine Electrical. — —
Is the action complete? Go to Step 16
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
15 to Password Leam Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 16
Engine________________________________________________ Engine Controls - 7.4L 6-2901
DTC P0401 EGR System Flow Insufficient (cont'd)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
16 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 17 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
17 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2902 Engine Controls - 7.4L____________ Engine

DTC P0404 EGR Valve Open Pintle Position

MAPand Fuel Tank

PressureSensors

VCM
GRY Cl =BLU
C2=RED
474 C3=CLEAR
E JL C4=BLK
Exhaust Gas
^-“WV Recirculation
(EGR) Valve

B'

BLK 470

r Sensors

RED 1676 WHT 257 BLK 470

BRN 1456 GRY 474
16 A. . . . . . . 20 C4 10 AC2 19A. - 27 C3
EGR EGR EGR Sensor 5Volt ■* Vehicle
Valve Valve Pintle Ground ReferenceB 1 Control
Feed Ground Position J Module £
Control Signal
\ (VCM)

Circuit Description
The VCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open.
The pressure in the intake manifold increases when
the EGR valve is open. The VCM monitors the
Manifold Absolute Pressure (MAP) sensor signal
during the EGR system diagnostic in order to
determine the amount of EGR flow. The VCM
calculates an error based on the difference between
the actual MAP increase and a predetermined value.
The VCM records the error and adjusts an internal
fail counter towards the fail threshold if the error is
too great. The VCM sets a DTC P0401 when the fail
counter exceeds the fail threshold. The number of
test samples required to exceed the fail threshold
varies according to the magnitude of the detected
flow errors.
The VCM allows only one EGR flow test sample to
be taken during an ignition cycle. Following a scan
tool Clear Info or a battery disconnect, the VCM
allows twelve test samples during the first ignition
cycle in order to aid in verifying a repair.
Conditions for Setting the DTC
. DTCs P0106, P0107, P0108, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0300, P0440, P0442, P0446, P0506, P0507,
P1336, P1404 and P1441 not set.
• Ignition voltage is greater than 11.7V.
190380
• EGR commanded ON ( Desired EGR Position is
greater than 0%).
• Actual EGR Position differs from Desired EGR
Position by more than 9% for 18 seconds.
Action Taken When the DTC Sets
• The Malfunction Indicator Lamp (MIL) will
illuminate.
• The VCM will record operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records will store this information.
• A history DTC is stored
• The EGR Valve is disabled.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ’ C (4 0 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ’ C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
Due to the moisture associated with exhaust
systems, the EGR valve may freeze and stick in
colder weather at times. After the vehicle is brought
into a warm shop for repairs, the valve warms and
the problem disappears. By watching the Actual EGR
and Desired EGR Positions on a cold vehicle with a
scan tool, the fault can be verified easily. Check the
freeze frame data to determine if the DTC set when
the vehicle was cold by viewing the Engine Coolant
Temperature (ECT).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Commanding the EGR valve open determines
whether the VCM can control the EGR valve
accurately and if the malfunction is present.
Engine Controls - 7.4L 6-2903
4. A test light will glow dimly when the EGR valve
is commanded to 20%, and brighter as the
EGR valve is commanded to 100%.
12. If the EGR valve 5 volt reference is shorted to
voltage, the DMM will read battery voltage and
additional DTCs may be set.
15. A problem may exist within the terminals which
would not show up in probe type testing. Be
sure to check the terminals for being backed
out, improperly formed, or damaged.
21. The replacement VCM must be programmed
and the Crankshaft Position System Variation
Learn Procedure must be performed. Refer to
the latest Techline procedures for VCM
programming.
22. Clearing the DTCs is a very important step for
this diagnostic. The clearing function allows the
EGR valve to relearn a new minimum pintle
position.

DTC P0404 EGR Valve Open Pintle Position

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. This data will be lost when the Clear DTC
1 Information function is used. —
Go to Powertrain
Was the Powertrain On-Board Diagnostic (OBD) System OBD System
Check performed? Go to Step 2 Check
1. Turn the ignition switch ON, with the engine OFF.
2. Install a scan tool.
20%, 50%,
2 3. Command the EGR Valve to the specified values. 70%, 100%
Does the Actual EGR Position follow the Commanded
EGR Position? Go to Step 5 Go to Step 3
1. Turn the ignition switch OFF.
2. Disconnect the EGR Valve electrical connector.
3. Turn the ignition switch ON, with the engine OFF.
3 —
4. Connect a test light to B+ and probe the EGR valve
sensor ground circuit.
Is the test light ON? Go to Step 4 Go to Step 7
1. Connect the test light to ground.
2. Probe the EGR Feed Control circuit at the EGR
valve harness connector.
20%, 50%,
4 3. Command the EGR valve to the specified values 70%, 100%
using a scan tool.
As the command is raised, does the test light glow
brighter, flash or maintain a steady dim glow? Go to Step 6 Go to Step 10
This DTC is intermittent. Go to
5 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
1. Turn the ignition switch ON.
2. Connect the test light to B+.
6 —
3. Probe the EGR valve ground circuit.
Is the test light ON? Go to Step 9 Go to Step 8
Check for an open or poor connection in the EGR Valve
7 Ground circuit and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
6-2904 Engine Controls - 7.4L________________________________________________ Engine
DTC P0404 EGR Valve Open Pintle Position (cont’d)
Step Action Value(s) Yes No
Check for an open or poor connection in the EGR Valve
8 Feed Control circuit and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
With the test light connected to ground, probe the Pintle
9 Position signal circuit. —

Is the test light ON? Go to Step 11 Go to Step 12

With the test light still connected to ground, again probe
the EGR Valve Feed Control circuit without commanding
10 the EGR valve with the scan tool. —
Is the test light ON? Go to Step 13 Go to Step 14
Check the signal circuit for a short to voltage and repair
11 as necessary. —

Was a repair necessary? Go to Step 22 Go to Step 20

With a DMM connected to ground, probe the 5V reference
12 circuit. 5V
Is the voltage near the specified value? Go to Step 15 Go to Step 16
Check the EGR Valve Feed Control circuit for a short to
13 voltage and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
Connect the test light to B+ and again probe the EGR
14 Valve Feed Control circuit. —
Is the test light ON? Go to Step 17 Go to Step 18
Check the EGR Sensor Ground circuit for a poor
15 connection at the EGR and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 19
Check the 5V reference circuit for a short to voltage and
16 repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
Check the EGR Valve Feed Control circuit for a short to
17 ground and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
Check the EGR Valve Feed Control circuit for an open or
poor connection at the EGR valve electrical connector and
18 repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 20
Replace the EGR valve. Refer to EGR Valve Replacement
19 in Repair Instructions. — —
Is the action complete? Go to Step 22
Check the VCM electrical connector for a poor connection
20 and repair as necessary. —
Was a repair necessary? Go to Step 22 Go to Step 21
1. Replace the VCM.
2. Program the VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
21 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 22
Engine Engine Controls - 7.4L 6-2905
DTC P0404 EGR Valve Open Pintle Position (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool in order to select the DTC and
the Clear DTC Information function.
2. Start the engine.
3. Idle the engine until normal operating temperature is
reached.
22 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 23 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions.
23 —
Are there any DTCs displayed that have not been Go to applicable
diagnosed? DTC table System OK
6-2906 Engine Controls - 7.4L Engine

DTC P0405 EGR Pintle Position Circuit Low Voltage

MAPand Fuel Tank

PressureSensors
T
i
VCM
GRY C1=BLU
C2- RED
474 C3=CLEAR
C4=BLK
t -VW Exhaust Gas
Recirculation
(EGR) Valve
B'

BLK 470

i I----◄ Sensors

RED 1676 WHT 257 BLK 470

BRN 1456 GRY 474
16 20 C4 10 A 19A- . . . . . . 27 C3
EGR EGR EGR Sensor 5Volt '1 Vehicle
Valve Valve Pintle Ground ReferenceB 1 Control
Feed Ground Position J Module ^
Control Signal
J (VCM)

Circuit Description
The VCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open.
The pressure in the intake manifold increases when
the EGR valve is open. The VCM monitors the
Manifold Absolute Pressure (MAP) sensor signal
during the EGR system diagnostic in order to
determine the amount of EGR flow. The VCM
calculates an error based on the difference between
the actual MAP increase and a predetermined value.
The VCM records the error and adjusts an internal
fail counter towards the fail threshold if the error is
too great. The VCM sets a DTC P0401 when the fail
counter exceeds the fail threshold. The number of
test samples required to exceed the fail threshold
varies according to the magnitude of the detected
flow errors.
The VCM allows only one EGR flow test sample to
be taken during an ignition cycle. Following a scan
tool Clear Info or a battery disconnect, the VCM
allows twelve test samples during the first ignition
cycle in order to aid in verifying a repair.
Conditions for Setting the DTC
. DTCs P0106, P0107, P0108, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0300, P0440, P0442, P0446, P0502, P0506,
P0507, P1336, P1404 and P1441 not set.
• Ignition voltage is greater than 11.7 V.
190380
• The VCM sees less than 0.11 volts from the
EGR valve sensor.
• A malfunction is present for 25 seconds.
Action Taken When the DTC Sets
• The Malfunction1Indicator Lamp (MIL) will
illuminate.
• The VCM will record operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records will store this information.
• A history DTC is stored
• The EGR Valve is disabled.
Conditions for Clearing the MILVDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 • C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160 ’ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
Due to the moisture associated with exhaust
systems, the EGR valve may freeze and stick in
colder weather at times. After the vehicle is brought
into a warm shop for repairs, the valve warms and
the problem disappears. By watching the Actual EGR
and Desired EGR Positions on a cold vehicle with a
scan tool, the fault can be verified easily. Check the
freeze frame data to determine if the DTC set when
the vehicle was cold by viewing the Engine Coolant
Temperature (ECT).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Commanding the EGR valve open determines
whether the EGR system can control the EGR
valve accurately and if the fault is present.
Engine Controls - 7.4L 6-2907
4. Jumping the 5 volt reference circuit to the
signal circuit checks the signal circuit and VCM.
13. Check the terminals for being backed out,
improperly formed, damaged, and for poor
tension.
14. The replacement VCM must be programmed
and the Crankshaft Position System Variation
Learn Procedure must be performed. Refer to
the latest Techline procedures for VCM
programming.
15. Clearing the DTCs is a very important step for
this diagnostic. The clearing function allows the
EGR valve to relearn a new minimum pintle
position.

DTC P0405 EGR Pintle Position Circuit Low Voltage

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure records
for reference. This data will be lost when the Clear DTC
1 Information function is used. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
1. Turn the ignition switch ON, with the engine OFF.
2. Install a scan tool.
20%, 50%,
2 3. Command the EGR valve to the specified values. 70%, 100%
Does the Actual EGR Position follow the Commanded
EGR Position? Go to Step 5 Go to Step 3
1. Turn the ignition switch OFF.
2. Disconnect the EGR valve electrical connector.
3 3. Turn the ignition switch ON, with the engine OFF.
5.0V
4. With a DMM connected to ground, probe the 5V
reference circuit to the EGR valve.
Is the voltage less than the specified value? Go to Step 8 Go to Step 4
Jumper the EGR valve 5.0 volt reference circuit to the
4 signal circuit. 100%
Does the Actual EGR Position display the specified value? Go to Step 6 Go to Step 7
This DTC is intermittent. Go to applicable Go to
5 —
Are there any additional DTCs stored? DTC table Diagnostic Aids
Check the 5.0V reference circuit and signal circuit for a
poor connection or proper terminal tension and repair as
6 necessary. —

Was a repair necessary? Go to Step 15 Go to Step 10

1. Connect the test light to B+.
7 2. Probe the signal circuit to the EGR valve. —
Is the test light ON? Go to Step 11 Go to Step 12
Check for a short to ground in the EGR valve 5V
8 reference circuit and repair as necessary. —
Was a repair necessary? Go to Step 15 Go to Step 9
6-2908 Engine Controls - 7.4L________________________________________________ Engine
DTC P0405 EGR Pintle Position Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Check for an open in the EGR valve 5V reference circuit
9 and repair as necessary. —
Was a repair necessary? Go to Step 15 Go to Step 13
Replace the EGR valve. Refer to EGR Valve Replacement
10 in Repair Instructions. — —
Is the action complete? Go to Step 15
Check for a short to ground in the EGR valve signal circuit
11 and repair as necessary. —
Was a repair necessary? Go to Step 15 Go to Step 13
Check for an open in the EGR valve signal circuit and
12 repair as necessary. —

Was a repair necessary? Go to Step 15 Go to Step 13

Check the affected circuit for a poor connection at the
13 VCM and repair as necessary. —

Was a repair necessary? Go to Step 15 Go to Step 14

1. Replace the VCM.
2. Program the VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer —
14 —
to Password Leam Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 15
1. Use the scan tool in order to select the DTC and
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
15 4. Select the DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 16 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
16 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine Engine Controls - 7.4L 6-2909

DTC P0410 AIR System

Refer to Secondary Air Injection Controls. • Air/Fuel Ratio 14.7:1
Circuit Description • Engine Speed Above 550 RPM
A fused ignition voltage is supplied to the AIR relay. • Closed Loop for a period of greater than
The VCM controls the AIR pump by grounding the 15 seconds
AIR relay control circuit. This energizes the relay and • Engine Load less than 50%
supplies voltage to the AIR pump clutch. When the • MAF less than 100 g/s
fuel system goes to the Closed Loop mode, the
• System voltage greater than 10 volts
VCM opens the ground to the AIR control circuit.
• ECT between 7 5 ‘ C and 105*C
Conditions for Setting the DTC • IAT is greater than 0 ' C
AIR Passive Test Enable • Integrator is greater than 0.95 but less than 1.0
• No ECT sensor DTCs for 3 seconds
• No IAC sensor DTCs
Action Taken When the DTC Sets
• No 02S sensor DTCs
The VCM will turn ON the Malfunction Indicator
• No Misfire DTCs Lamp (MIL) after two consecutive test cycles with the
. No MAP DTCs. fault active.
• No Fuel Trim DTCs
Conditions for Clearing the MIL7DTC
• No EVAP DTCs
• The VCM turns the MIL OFF after
• No TP Sensor DTCs 3 consecutive drive trips when the test
. No IAT DTCs has Run and Passed and not Failed.
. No MAF DTCs • A history DTC will clear if no fault conditions
• System voltage is greater than 10 volts for a have been detected for 40 warm-up cycles
period greater than 3 seconds (coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
• IAT is greater than 0 * C engine coolant temperature exceeds
• Engine run time is greater than 3 seconds 70 *C (160*F) during the same ignition cycle).
AIR Passive Test 1 • Use the scan tool Clear Information function.
• AIR pump ON • Disconnect the VCM battery feed for
A/F Ratio is at least 12:1 30 seconds.
• Startup ECT is 56.25 *C or less
Diagnostic Aids
• Hot/Cold rich time ratio is at least .39 or more
An intermittent may be caused by a poor connection,
• Or Hot/Cold lean time is less than .60 rubbed through wire insulation, or a broken wire
AIR Passive Test 2 inside the insulation.
• AIR Passive Test 1 not run or failed Check for the following conditions:
• AIR Pump ON • Poor connection or damaged harness - Inspect
• 0 2 sensor 1 is at least than 451 mV or more the harness connectors for backed out
for at least 5 seconds terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor
AIR Active Test Enable terminal to wire connection, and damaged
• AIR passive tests 1 and 2 failed harness.
• AIR Pump ON • Worn or loose AIR pump drive belt.
• 0 2 sensor voltage is less than 299 mV • Pinched, kinked, or restricted AIR pipes, hoses,
• No ECT sensor DTCs or fittings.
• No IAC sensor DTCs Test Description
• No 02S sensor DTCs Number(s) below refer to the step numbers) on the
• No Misfire DTCs Diagnostic Table.
. No MAP DTCs. 2. This step will determine if the VCM is capable
• No Fuel Trim DTCs of controlling the AIR system.
. No EVAP DTCs 5. This step will ensure that the VCM is capable
• No TP Sensor DTCs of turning the AIR pump OFF.
. No IAT DTCs 9. This step will determine if there is a problem in
the circuit between the AIR relay and AIR pump
. No MAF DTCs clutch ground.
• Power enrichment not active 17. This step will determine if the problem is in the
• Decel Fuel Cutoff not active AIR relay control circuit or the VCM.
6-2910 Engine Controls - 7.4L Engine
DTC P0410 AIR System
Step Action Value(s) Yes No
Important: Before clearing DTC(s) use the scan tool to Go to the
record Freeze Frame and Failure Records for reference,
Powertrain OBD
1 as data will be lost when the Clear Info function is used. — System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check)
1. install a scan tool.
2. Start and run the engine for greater than the
specified value.
3. Verify the engine is running at normal operating 2 min
2
temperature. 6%
4. Using a scan tool, command the AIR ON.
Does the Short Term Fuel Trim indicate a change of more
than the specified value within 30 seconds? 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 are stored, Go to
3 refer to those Table(s). —
the Applicable
Are any additional DTCs stored? DTC Table Go to Step 28
1. With the engine still running, command the AIR
pump ON.
4 —
2. Observe the AIR pump clutch.
Is the AIR pump clutch engaged? Go to Step 5 Go to Step 6
1. With the engine still running, command the AIR
pump OFF.
5 —
2. Observe the AIR pump clutch.
Is the AIR pump clutch engaged? Go to Step 7 Go to Step 25
1. Disconnect the AIR relay.
2. Connect a test light to the ignition feed circuit and
6 —
ground.
Is the test light ON? Go to Step 7 Go to Step 14
With the AIR relay still disconnected, connect a test light
7 to the AIR relay control circuit and B+. —
Is the test light ON? Go to Step 17 Go to Step 8
1. Connect a test light to the AIR relay control circuit
and B+.
8 —
2. Using the scan tool, command the AIR pump ON.
Is the test light ON? Go to Step 10 Go to Step 15
Connect a fused jumper to the AIR pump clutch control
9 circuit and B+. —
Is the AIR pump clutch engaged? Go to Step 20 Go to Step 11
Connect a test light to the AIR pump clutch control circuit
10 and ground. —
Is the test light ON? Go to Step 22 Go to Step 9
Check for an open in the AIR pump clutch control circuit.
11 —
Was a problem found? Go to Step 24 Go to Step 12
Check for an open in the AIR pump ground circuit.
12 —
Was a problem found? Go to Step 24 Go to Step 13
Check for an open in the AIR pump clutch coil.
13 —
Was a problem found? Go to Step 24 Go to Step 2
Check for an open fuse in the AIR ignition feed circuit.
14 —
Was a problem found? Go to Step 18 Go to Step 19
Engine Engine Controls - 7.4L 6-2911
DTC P0410 AIR System (cont’d)
Step Action Value(s) Yes No
Check for an open in the AIR relay control circuit.
15 —
Was a problem found? Go to Step 24 Go to Step 16
Check the terminal contact at the VCM for the AIR relay
16 control circuit. —
Was a problem found? Go to Step 24 Go to Step 23
1. Turn the ignition OFF.
2. Disconnect the Blue VCM connector.
17 3. Connect a test light between the AIR relay control —

circuit and B+.

Is the test light ON? Go to Step 21 Go to Step 23
Repair the short to ground in the ignition feed circuit to the
18 AIR relay. — —
Is the action complete? Go to Step 28
Repair the open in the ignition feed circuit to the AIR relay.
19 — —
Is the action complete? Go to Step 28
Replace the AIR relay.
20 — —
Is the action complete? Go to Step 28
Repair the short to ground in the AIR relay control circuit.
21 — —
Is the action complete? Go to Step 28
Repair the short to voltage on the AIR pump clutch control
22 circuit. — —
Is the action complete? Go to Step 28
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
23 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 28
Repair as necessary.
24 — —
Is the action complete? Go to Step 28
1. Disconnect the AIR pump output hose at the
AIR valve.
2. Using the scan tool, command the AIR ON.
25 3. Accelerate the engine to approximately the —
specified value.
4. Observe the airflow coming from the hose.
Does the airflow increase as the engine is accelerated? Go to Step 26 Go to Step 27
1. Check for a worn or loose AIR pump drive belt.
2. Check for leaks or restrictions in the AIR pipes,
26 —
hoses, and fittings.
Was a problem found? Go to Step 24 Go to Step 2
Replace the AIR pump. Refer to Secondary Air Injection
27 Pump Replacement. — —
Is the action complete? Go to Step 28
6-2912 Engine Controls - 7.4L Engine
DTC P0410 AIR System (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
28 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 29 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
29 Are any DTCs displayed that have not been diagnosed? — the Applicable
DTC Table System OK
Engine_____________________________________
DTC P0420 TWC System Low Efficiency Bankl
Circuit Description
In order to control emissions of Hydrocarbons (HC),
Carbon Monoxide (CO) and Oxides of Nitrogen
(NOx), The system uses a three-way catalytic
converter. The catalyst within the converter promotes
a chemical reaction which oxidizes the HC and CO
present in the exhaust gas, converting them into
harmless water vapor and carbon dioxide. The
catalyst also reduces NOx, converting it to nitrogen.
The VCM has the capability to monitor this process
using the H02S (Bank 1, Sensor 1). The H02S
Bank 1, Sensor 2 located in the exhaust stream past
the three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst; this in turn indicates the catalyst’s ability
to convert exhaust emissions effectively. If the
catalyst is functioning correctly, the H02S Bank 1,
Engine Controis - 7.4L 6-2913
37750
Sensor 2 signal will be far less active than that
produced by the H02S Bank 1, Sensor 1. If a
problem exists which causes the VCM to detect an
excessive H02S Bank 1, Sensor 2 activity outside of
an acceptable range for an extended period of time,
the VCM sets the DTC P0420. This DTC indicates
that the three-way catalytic converter’s oxygen
storage capacity is below a threshold considered
acceptable.
Conditions for Setting the DTC
Converter Warm Up Status
• Closed Loop
• The commanded Air to Fuel ratio is 14.7:1
• The MAF is greater than 15 g/s
• The predicted Catalyst warm up temperature is
greater than 450' C
6-2914 Engine Controls - 7.4L_____________________________________________
Test Enabled
• Converter Warm Up Status passed
• No VS sensor DTCs
• No TP sensor DTCs
. No 02S DTCs
• No misfire DTCs
• No MAP sensor DTCs
• No fuel trim DTCs
• No IAT sensor DTCs
• No ECT sensor DTCs
• No MAF sensor DTCs
. ECT is above 75 *C (167*F)
• Engine load change is no more than
8.9 percent
• Vehicle speed is at least 25 mph and no more
than 85 mph
• The IAT is at least -9.75 ’ C
• The MAF sensor is greater than 15 grams per
second and less than 50 grams per second
• The engine speed is no more than 4700 RPM
• Engine air load is less than 99 percent
• The TP sensor is greater than 1.9%
Action Taken When the DTC Sets
The VCM will turn ON the Malfunction Indicator
Lamp (MIL).
Conditions for Clearing the MIL7DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 'C (40'F )
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ’ C (160'F ) during the same ignition cycle).
Engine
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Difficulty running the OBD II status DTC P0420 test
may be encountered in areas where the test
conditions cannot be maintained easily, especially in
urban areas.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
3. This table includes checks for conditions that
can cause the three-way catalytic converter
efficiency to appear degraded. Inspect and
repair exhaust system as necessary. Inspect the
H02S (Bank 1, Sensor 2 ) pigtail and engine
harness for any damage that can cause an
intermittent fault in H02S (Bank 1, Sensor 2)
circuits.
Notice: In order to avoid damaging the
replacement three-way catalytic converter,
correct the engine misfire or mechanical fault
before replacing the three-way catalytic
converter.
8. If the three-way catalytic converter needs to be
replaced, make sure that the following
conditions are not present to caused the
catalyst to be damaged:
• Misfire
• High engine oil consumption or coolant
consumption
• Retarded spark timing or weak spark.

DTC P0420 TWC System Low Efficiency Bankl

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Important: If any MAP sensor, H02S (Bank 1, Sensor 1)
(Bank 1 Sensor 2), Misfire, Fuel Trim, Vehicle Speed
2 sensor, or ECT sensor DTCs are set, diagnose those — Go to
DTCs before using this table.
The Applicable
Are any other DTCs set? DTC Table Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2915
DTC P0420 TWC System Low Efficiency Bankl (cont’d)
Step Action Value(s) Yes No
Visually and physically check the following:
• Verify that the Three-Way Catalytic Converter is an
original equipment manufacturer part.
• The Three-Way Catalytic Converter for damage such
as the following conditions:
- Dents
- Severe discoloration caused by excessive
temperatures
- Holes, etc.
• Ensure that the internal converter rattle (caused by
3 the damaged catalyst) is not present. —
• The exhaust system between the Three-Way
Catalytic Converter and the rear converter flange for
the following conditions:
- Leaks
- Damage
- Loose or missing hardware
• Ensure that the H02S (Bank 1, Sensor 2) is secure
and that the(Bank 1, Sensor 2 ) pigtail and wiring is
not damaged or contacting the exhaust.
Was a problem found? Go to Step 9 Go to Step 4
Check all the VCM grounds.
4 —
Was a problem found? Go to Step 9 Go to Step 5
Check all the sensor grounds.
5 —
Was a problem found? Go to Step 9 Go to Step 6
Check the H02S(Bank 1, Sensor 2)circuits for an
6 intermittent open. —
Was a problem found? Go to Step 9 Go to Step 7
Check the H02S (Bank 1, Sensor 2) circuits for a
7 intermittent short to ground. —
Was a problem found? Go to Step 9 Go to Step 8
Notice: In order to avoid damaging the replacement
three-way catalytic converter, correct the engine misfire or
mechanical fault before replacing the three-way catalytic
converter.
8 Important: If Three-Way Catalytic Converter needs to be — —

replaced, check for a possible misfire (refer to DTC 300)

or an engine mechanical problem.
Replace the Three-Way Catalytic Converter.
Is the action complete? Go to Step 10
Repair the problem as necessary.
9 — —
Is the repair complete? Go to Step 10
6-2916 Engine Controls - 7.4L Engine
DTC P0420 TWC System Low Efficiency Bankl (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
10 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 11 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
11 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine_____________________________________ Engine Controls - 7.4L 6-2917
DTC P0430 TWC System Low Efficiency Bank2

3 7 7 51

Circuit Description VCM will set DTC P0430, indicating that the
In order to control emissions of Hydrocarbons (HC), three-way catalytic converter[prime ]s oxygen
Carbon Monoxide (CO) and Oxides of Nitrogen storage capacity is below a threshold considered
(NOx), a three-way catalytic converter is used. The acceptable.
catalyst within the converter promotes a chemical Conditions for Setting the DTC
reaction which oxidizes the HC and CO present in
the exhaust gas, converting them into harmless Converter Warm Up Test
water vapor and carbon dioxide. The catalyst also • Closed Loop
reduces NOx, converting it to nitrogen. The VCM has • The commanded Air to Fuel ratio is 14.7:1
the capability to monitor this process using H02S 2.
• The MAF is greater than 15 g/s
H02S 2, located in the exhaust stream past the
three-way catalytic converter, produces an output • The predicted Catalyst warm up temperature is
signal which indicates the oxygen storage capacity of greater than 450 *C
the catalyst; this in turn indicates the catalyst[prime Test Enabled
]s ability to convert exhaust emissions effectively. If • Converter Warm Up Status passed
the catalyst is functioning correctly, the H02S 2
• No VS sensor DTCs
signal will be far less active than that produced by
H02S 1. If a problem exists which causes the VCM • No TP sensor DTCs
to detect excessive H02S 2 activity outside of an . No 02S DTCs
acceptable range for an extended period of time, the • No misfire DTCs
6-2918 Engine Controls - 7.4L _______
• No MAP sensor DTCs
• No fuel trim DTCs
• No IAT sensor DTCs
• No ECT sensor DTCs
• No MAF sensor DTCs
• ECT is above 75 *C (167'F)
• Engine load change is no more than
8.9 percent
• Vehicle speed is at least 25 mph and no more
than 85 mph
• The IAT is at least -9.75 * C
• The MAF sensor is greater than 15 grams per
second and less than 50 grams per second
• The engine speed is no more than 4700 RPM
• Engine air load is less than 99 percent
• The TP sensor is greater than 1.9%
Action Taken When the DTC Sets
The VCM will turn ON the Malfunction Indicator
Lamp (MIL).
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 ‘ C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
(160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
DTC P0430 TWC System Low Efficiency Bank2
Step Action
Important: Before clearing DTC(s) use the scan tool to
record freeze frame and failure records for reference, as
1 data will be lost when Clear Info function is used.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Important: If any MAP sensor, H02S 1 or H02S 2,
Misfire, Fuel Trim, Vehicle Speed sensor, or ECT sensor
2 DTC(s) are set, diagnose those DTC(s) before using
this table.
Are any other DTC(s) set?
Engine
Diagnostic Aids
Difficulty running the OBD II status DTC P0430 test
may be encountered in areas where test conditions
cannot be maintained easily, especially in urban
areas. To minimize the amount of driving required to
complete the test, use the following procedure
• Catalyst can be warmed up in service bay
previous to drive cycle.
• Engine also can be warmed up in bay also.
H02S 2 activity test: Using a scan tool, monitor
MAP, H02S 1, and H02S 2 displays in Park or
Neutral above idle. Compare H02S 1 and
H02S 2 activity (amplitude and frequency) to
each other during a 30 second period. If H02S
2 activity is nearly as great as H02S 1 activity,
a problem exists; use diagnostic table on facing
page. If much less activity is noted, system is
functioning properly.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This table includes checks for conditions that
can cause the three-way catalytic converter
efficiency to appear degraded. Inspect and
repair exhaust system as necessary per
Exhaust System. Also inspect the H02S 2
pigtail and engine harness for any damage that
can cause an intermittent fault in H02S 2
sensor signal HIGH and LOW circuits.
3. If the three-way catalytic converter needs to be
replaced, make sure that another condition is
not present which caused the catalyst to be
damaged. These conditions include a) misfire;
b) high engine oil consumption or coolant
consumption; c) retarded spark timing or weak
spark. To avoid damaging the replacement
three-way catalytic converter, correct engine
misfire or mechanical fault before replacing
three-way catalytic converter.
Value(s) Yes No
Go to the
Powertrain OBD
— System Check
(OBD System
Go to Step 2 Check)
—
Go to Step 4 Go to Step 3
Engine________________________________________________ Engine Controls - 7.4L 6-2919
DTC P0430 TWC System Low Efficiency Bank2 (cont’d)
Step Action Va!ue(s) Yes No
Visually/physically check the following:
• Verify that the Three-Way Catalytic Converter is an
original equipment manufacturer part.
• Three-Way Catalytic Converter for damage (dents,
severe discoloration caused by excessive
temperatures, holes, etc).
• Ensure that internal converter rattle (caused by
3 damaged catalyst) is not present. —
• Exhaust system between the Three-Way Catalytic
Converter and the rear converter flange for leaks,
damage, or loose or missing hardware.
• Ensure that the H02S 2 is secure and that the
H02S 2 pigtail and wiring is not damaged or
contacting the exhaust.
Was a problem found? Go to Step 10 Go to Step 5
4 Go to appropriate DTC(s). — — —
Check all the VCM grounds.
5 —
Was a problem found? Go to Step 10 Go to Step 6
Check all the sensor grounds.
6 —
Was a problem found? Go to Step 10 Go to Step 7
Check the H02S 2 sensor high and low circuits for an
7 intermittent open. —
Was a problem found? Go to Step 10 Go to Step 8
Check the H02S 2 sensor high and low circuits for a
8 intermittent short to ground. —

Was a problem found? Go to Step 10 Go to Step 9

Important: If Three-Way Catalytic Converter needs to be
replaced, check for a possible misfire (refer to DTC P0300
Table) or an engine mechanical problem (refer to Engine
9 Mechanical). — —
Replace the Three-Way Catalytic Converter.
Is the action complete? Go to Step 11
Repair the problem as necessary.
10 — —
Is the action complete? Go to Step 11
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
11 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 12 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
12 Are any DTCs displayed that have not been diagnosed? — the Applicable
DTC Table System OK
6-2920 Engine Controls - 7.4L Engine

DTC P0440 EVAP System

|Hot In Run And Start1

A
VCM
C1 = BLU
C2 = RED
C3 = CLEAR
C4 = BLK

190385

Circuit Description malfunctioning EVAP purge solenoid is indicated. The

The evaporative system includes the following
components:
• The fuel tank
• The EVAP vent solenoid
• The fuel tank pressure sensor
• The fuel pipes and hoses
• The vapor lines
• The fuel cap
• The evaporative emission canister
• The purge lines
• The EVAP purge solenoid
The evaporative leak detection diagnostic strategy is
based on applying the vacuum to the EVAP system
and monitoring the vacuum decay. The VCM monitors
the vacuum level via the fuel tank vacuum sensor
input. At an appropriate time, the EVAP purge solenoid
and the EVAP vent solenoid turn ON, allowing the
engine vacuum to draw a small vacuum on the entire
evaporative emission system. If a sufficient vacuum
level cannot be achieved, a large leak or a
following conditions can cause this problem and set a
DTC P0440:
• A missing, malfunctioning, improperly installed,
or loose fuel cap
• A disconnected or malfunctioning fuel tank
pressure sensor
• A disconnected, damaged, pinched, or blocked
EVAP purge line
• A disconnected or damaged EVAP vent hose
• A disconnected, damaged, pinched, or blocked
fuel tank vapor line
• A disconnected or malfunctioning EVAP purge
solenoid
• A disconnected or malfunctioning EVAP vent
solenoid
• An open ignition feed circuit to the EVAP vent
or purge solenoid
• A damaged EVAP canister
• A leaking fuel sender assembly O-ring
• A leaking fuel tank or fuel filler neck
Engine
Conditions for Setting the DTC
Test Enable
• No MAP sensor DTCs
• No TP sensor DTCs
. No VSS DTCs
. No 02S DTCs
. No ECT DTCs
• The DTC P0125 not active
• No IAT sensor DTCs
• The Fuel Level is greater than 12.5% but less
than 87.5%
• Powerup Vacuum Test Fail is false
• The System Voltage is greater than 10 volts but
less than 17 volts
Cold Start Test
• The ECT is greater than 3.75* C but less
than 30 *C
• The IAT is greater than 3.75‘ C but less
than 30 * C
• Start up ECT is not more than 8.25 *C greater
than the start up IAT
• Start up IAT is not more than 1.5 * C greater
than the start up ECT
• The Baro is greater than 72.5 kPa
• Fuel tank vacuum is less than 9 in. H20
• Fuel level input test has passed
Warm Start Test
• Cold start test failed.
• Fuel tank vacuum is less than 11 in. H20.
• If HC vapor is not present and the small leak
test has failed.
Action Taken When the DTC Sets
• The VCM illuminates the MIL during the second
key cycle in which the diagnostic reports a fail.
• The VCM stores the conditions which were
present when the DTC sets as a Freeze Frame
and Fail Records data.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ' C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine Controls - 7.4L 6-2921
Diagnostic Aids
Check for the following conditions:
• A loose, missing, damaged, or improperly
installed fuel cap
• Missing or damaged O-rings at EVAP canister
fuel vapor and purge line fittings
• A cracked or punctured EVAP canister
• A damaged or disconnected source vacuum
line, EVAP purge line, vent hose or fuel tank
vapor line
• A poor connection at the VCM: Inspect the
harness connectors for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- poor terminal to wire connection
• A damaged harness: Inspect the wiring harness
to the EVAP vent solenoid EVAP purge
solenoid and the fuel tank pressure sensor for
an intermittent open or short circuit
• A kinked, pinched or plugged vacuum source,
EVAP purge, or fuel tank vapor line. Verify that
the lines are not restricted
Refer to Carbon Particle Removal from EVAP
System before starting repairs.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be set
occurs. This may assist in diagnosing the condition.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step checks the fuel tank pressure sensor
at atmospheric pressure.
4. This step determines if the EVAP system has a
restriction or leak.
5. This step deterimines if there is a restiction in
the Fuel Tank Vapor Line or Canister.
8. This step checks for a restriction in the EVAP
Canister.
6-2922 Engine Controls - 7.4L Engine
DTC P0440 EVAP System
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool
to record the Freeze Frame and the Failure Records for
reference. This data will be lost when the Clear Info Go to Powertrain
1 function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Is DTC P0446, P0452, or P0453 set? Go to applicable
2 —
DTC table Go to Step 3
1. Turn OFF the ignition.
2. Install a scan tool.
3. Remove the fuel cap. 0 in. H20
3
4. Turn ON the ignition. ±1 in. H20
Go to Fuel Tank
5. Observe the Fuel Tank Pressure on the scan tool. Pressure Sensor
Is the Fuel Tank Pressure at the specified value? Go to Step 4 Diagnosis
Important: Before continuing with the diagnosis, zero the
EVAP Pressure and Vacuum gauges on the Enhanced
EVAP Pressure Purge Diagnostic Cart J 41413. Refer to
the tool operating instructions.
Important: Make sure the fuel cap is secured properly. A
poorly installed or loose fuel cap can cause DTC P0440.
1. Install the fuel cap
2. Connect the Enhanced EVAP Pressure Purge 5 in. H20
4
Diagnostic Cart J 41413 to the EVAP service port.
3. Using the scan tool, command the EVAP vent
valve ON (Closed).
4. Attempt to pressurize the EVAP system using
the Cart.
5. Monitor pressure using gauge on Cart for
2 minutes.
Can the specified value be obtained and held? Go to Step 5 Go to Step 6
1. Maintain fuel tank pressure at 5 inches of H20
(Turn the rotary switch on the cart to the HOLD
position). 5 in.H20
5
(±2 in.H20
2. Observe the Fuel Tank Pressure on the scan tool.
Is the Fuel Tank Pressure within the specified value? Go to Step 9 Go to Step 8
1. Disconnect the Fuel Tank Vapor Line and the
EVAP Purge Line from the EVAP Canister.
2. Block the canister fitting for the Fuel Tank
Vapor Line.
3. Connect a hand vacuum pump to the canister
6 fitting for the EVAP Purge Line. 5 in.Hg
4. Ensure that the EVAP Vent Valve is still
commanded ON(Closed).
5. Attempt to apply vacuum to the EVAP canister.
Can the specified value of vacuum be obtained
and held? Go to Step 12 Go to Step 7
Engine Engine Controls - 7.4L 6-2923
DTC P0440 EVAP System (cont’d)
Step Action Value(s) Yes No
1. Leave system connected as in step 6.
2. Disconnect the Vent hose at the Vent Valve.
3. Plug end of the Vent hose.
7 4. Using the hand vacuum pump apply vacuum up to 5 in.Hg
the specified value.
Can the specified value of vacuum be obtained
and held? Go to Step 17 Go to Step 11
1. Disconnect Fuel Tank Vapor Line from the Canister.
2. Attempt to pressurize the EVAP system using the
Enhanced EVAP Pressure Purge Diagnostic Cart
8 J 41413. 5 in.H20
3. Monitor pressure using gauge on cart.
Can the specified value of pressure be obtained
and held? Go to Step 18 Go to Step 15
1. Disconnect Purge Line at the Canister.
2. Connect the in. Hg vacuum gauge on the
Enhanced EVAP Pressure Purge Diagnostic Cart
9 J 41413 to the Purge Line. 12 in. Hg
3. Start engine
4. Command EVAP Purge Solenoid Valve to 100%. Go to
Is the vacuum gauge at or above the specified value? Diagnostic Aids Go to Step 10
1. Disconnect Purge Line from the Purge
Solenoid Valve.
2. Connect the in. Hg vacuum gauge on the
Enhanced EVAP Pressure Purge Diagnostic Cart
10 J 41413 to the Purge Solenoid Valve. 12 in. Hg
3. Start engine
4. Command EVAP Purge Solenoid Valve to 100%.
Is the vacuum gauge at or above the specified value? Go to Step 14 Go to Step 16
Check the Vent hose for possible cause of vacuum leak
11 and repair as necessary. —
Was a repair necessary? Go to Step 19 Go to Step 18
1. Check for the following:
• Missing or faulty fuel cap.
• Disconnected or, leaking fuel Tank Vapor Line.
12 —
• Disconnected or damaged EVAP Purge Line.
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 19 Go to Step 13
6*2924 Engine Controls - 7.4L________________________________________________ Engine
DTC P0440 EVAP System (cont’d)
Step Action Value(s) Yes No
Important: Do not exceed the pressure given in the
specified value.
1. Using the scan tool, command the EVAP Vent
Valve ON.
2. With the Enhanced EVAP Pressure Purge
Diagnostic Cart J 41413 connected to the EVAP
service port continuously attempt to pressurize the
EVAP system by leaving the cart control knob in
13 15 in.H20 —
the pressurize position.
3. Using the Enhanced EVAP Ultrasonic Leak
Detector J 41416, locate the leak in the EVAP
system. It may be necessary to partially lower the
fuel tank in order to examine the connections on
the top of the fuel tank . Refer to Diagnostic Aids.
4. Repair the leak in the EVAP system.
Is the action complete? Go to Step 19
Repair restriction in EVAP Purge Line.
14 — —
Is action complete? Go to Step 19
Repair restriction in Fuel Tank Vapor Line.
15 — —
Is action complete? Go to Step 19
Replace the EVAP Purge Solenoid Valve. Refer to
Diagnostic Aids. Refer to EVAP Canister Purge Solenoid
16 Valve Replacement in Repair Instructions. — —
Is the action complete? Go to Step 19
Replace the EVAP Vent Valve. Refer to Diagnostic Aids.
Refer to EVAP Vent Valve Replacement in Repair
17 Instructions. — —
Is the action complete? Go to Step 19
Replace EVAP Canister. Refer to EVAP Canister
18 Replacement in Repair Instructions. — —
Is the action complete? Go to Step 19
Important: Do not exceed the pressure given in the first
specified value.
1. Turn the ignition ON leaving the engine OFF.
2. Using the scan tool, command the EVAP Vent
Valve ON (Closed).
3. Pressurize the EVAP system to the first specified 15 in. H20
19 value using the Enhanced EVAP Pressure Purge 10 in. H20
Diagnostic Cart J 41413 (monitor pressure using
the gauge on the cart).
4. Turn the rotary switch on the cart to the HOLD
position and observe the EVAP pressure gauge.
Does the pressure decrease to less than the second
specified value within 2 minutes? Go to Step 2 Go to Step 20
1. Use the scan tool in order to select the DTC and
the Clear DTC Information functions.
20 — —
2. Perform the Service Bay Test for EVAP.
is action complete? Go to Step 21
Does the scan tool display any DTCs in the Freeze Go to applicable
21 — System OK
Frame and Failure Records? DTC table
Engine____________________________________________ Engine Controls - 7.4L 6-2925

DTC P0442 EVAP Control System Small Leak Detected

| Hot In Run And Start]

VCM
C1 = BLU
C2 = RED
C3=CLEAR
C4 = BLK

190385

Circuit Description Conditions for Setting the DTC

The evaporative system includes the following The following conditions will set the DTC:
components: Test Enable
• The fuel tank 1. No MAP sensor DTCs
• The EVAP vent solenoid 2. No TP sensor DTCs
• The fuel tank pressure sensor 3. No VSS DTCs
• The fuel pipes and hoses 4. No 02S DTCs
• The vapor lines 5. No ECT DTCs
• The fuel cap 6. The DTC P0125 not active
• The evaporative emission canister 7. No IAT sensor DTCs
• The purge lines 8. The Fuel Level is greater than 12.5% but less
• The EVAP purge solenoid than 87.5%
The evaporative leak detection diagnostic strategy is Cold Start Test
based on applying a vacuum to the EVAP system • The ECT is greater than 3.75 *C (38.75’ F) but
and monitoring the vacuum decay. The VCM less than 30 * C (86 * F).
monitors vacuum level via the fuel tank vacuum
sensor input. At an appropriate time, the EVAP • The IAT is greater than 3.75 *C (38.75 * F) but
purge solenoid and the EVAP vent solenoid are less than 30 *C (86 *F).
turned ON, allowing the engine vacuum to draw a • Start up ECT is not more than 8.25 * C
small vacuum on the entire evaporative emission (46.85' F) greater than the start up IAT.
system. After the desired vacuum level has been • Start up IAT is not more than 1.5 * C (34.7 * F)
achieved, the EVAP purge solenoid turns OFF, greater than the start up ECT.
sealing the system. A leak is detected by monitoring • The BARO is greater than 72.5 kPa.
for a decrease in the vacuum level over a given time
period with all other variables remaining constant. A • The fuel level input is true
small leak in the system will cause DTC P0442 to • The fuel level present test is true
be set.
6-2926 Engine Controis - 7.4L
Fuel Slosh Test
Tank vacuum change is less than .6 in of H20 or
fuel level is greater than 7.8%.
Weak Vacuum Test
• Throttle Position is less than 75%.
• Vehicle speed is less than 65 mph.
• Tank vacuum is at least 9 inches of H20 within
30 seconds.
Action Taken When the DTC Sets
• The VCM illuminates the MIL during the second
key cycle in which the DTC sets.
• The VCM stores the conditions which were
present when the DTC sets as the Freeze
Frame and the Fail Records data.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
Check for the following conditions:
• Damaged O-rings at the EVAP canister fuel
vapor and purge line fittings
• A cracked or punctured EVAP canister
• A damaged source vacuum line, an EVAP
purge line, a vent hose or fuel tank vapor line
• A poor connection at the VCM: Inspect the
harness connectors for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection
• A damaged harness: Inspect the wiring harness
to the EVAP vent solenoid EVAP purge
solenoid and the fuel tank pressure sensor for
an intermittent open or short circuit.
• A missing or damaged weather-pack on the
EVAP Purge Solenoid connector.
Refer to Carbon Particle Removal from EVAP
System before starting the repairs.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to set
occurs. This may assist in diagnosing the condition.
Test Description
The numbers below refer to the step numbers on the
diagnostic table
3. This step checks the fuel tank pressure sensor
at atmospheric pressure.
4. This step checks the EVAP System for a
small leak.

DTC P0442 EVAP Control System Small Leak Detected

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool to
record the Freeze Frame and the Failure Records for
reference. This data will be lost when the Clear Info
1 — Go to Powertrain
function is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Is DTC P0446, P0452, or P0453 set? Go to applicable
2 —
DTC table Go to Step 3
1. Turn OFF the ignition.
2. Install a scan tool.
3. Remove the fuel cap. 0 in. H20
3
4. Turn ON the ignition. ±1 in. H20
Go to Fuel Tank
5. Observe the Fuel Tank Pressure on the scan tool. Pressure Sensor
Is the Fuel Tank Pressure at the specified value? Go to Step 4 Diagnosis
Engine________________________________________________ Engine Controls - 7.4L 6-2927
DTC P0442 EVAP Control System Small Leak Detected (cont’d)
Step Action Value(s) Yes No
Important: Before continuing with the diagnosis, zero the
EVAP Pressure and Vacuum gauges on the Enhanced
EVAP Pressure Purge Diagnostic Cart J 41413. Refer to
tool operating instructions.
Important: Do not exceed the pressure given in the first
specified value.
1. Turn the ignition ON leaving the engine OFF.
2. Using the scan tool, command the EVAP Vent Valve 15 in. H20
4 ON (Closed).
10 in. H20
3. Pressurize the EVAP system to the first specified
value using the Enhanced EVAP Pressure Purge
Diagnostic Cart J 41413.
4. Monitor pressure using gauge on cart.
5. Switch the rotary switch on the cart to HOLD and
observe the EVAP pressure gauge.
Does the pressure decrease to less than the second Go to
specified value within 2 minutes? Go to Step 5 Diagnostic Aids
1. Disconnect the Fuel Tank Vapor Line and the EVAP
Purge Line from the EVAP canister.
2. Block the Fuel Tank Vapor Line fitting on the
canister.
3. Connect a hand vacuum pump to the EVAP Purge
5 Line fitting on the canister. 5 in. Hg

4. Ensure that the EVAP Vent Valve is still commanded

ON (Closed).
5. Attempt to apply vacuum to the canister.
Can the specified value of vacuum be obtained and held? Go to Step 10 Go to Step 6
1. Leave system connected as in previous step.
2. Disconnect the Vent hose at the Vent Valve.
3. Plug end of Vent hose.
6 5 in. Hg
4. Using the hand vacuum pump apply vacuum to the
specified value.
Can the specified value of vacuum be obtained and held? Go to Step 8 Go to Step 7
Check the Vent hose for possible cause of vacuum leak
7 and repair as necessary. —
Was a repair necessary? Go to Step 12 Go to Step 9
Replace the EVAP Vent Valve. Refer to Diagnostic Aids.
8 Refer to EVAP Vent Valve Replacement. — —
Is action complete? Go to Step 12
Replace the EVAP Canister. Refer to EVAP Canister
9 Replacement in Repair Instructions. — —
Is the action complete? Go to Step 12
1. Check for the following conditions:
• Faulty fuel cap
• Leaking fuel tank vapor line
10 • Damaged EVAP purge line —
2. If a problem is found, repair as necessary. Refer to
Diagnostic Aids.
Was a problem found? Go to Step 12 Go to Step 11
6-2928 Engine Controls - 7.4L________________________________________________ Engine
DTC P0442 EVAP Control System Small Leak Detected (cont’d)
Step Action Value(s) Yes No
Important: Do not exceed the pressure given in the
specified value.
1. Using the scan tool, command the EVAP vent valve
ON (Closed).
2. With the Enhanced EVAP Pressure Purge Diagnostic
Cart J 41413 connected to the EVAP service port
attempt to pressurize the EVAP system by leaving
11 the cart control knob in the pressurize position. 15 in.H20 —
3. Using the Enhanced EVAP Ultrasonic Leak Detector
J 41416, locate the leak in the EVAP system.
4. It may be necessary to partially lower the fuel tank
to examine the connections on the top of the tank.
Refer to Diagnostic Aids.
5. Repair the leak in the EVAP system.
Is the action complete? Go to Step 12
Important: Do not exceed the pressure given in the first
specified value.
1. Turn the ignition ON leaving the engine OFF.
2. Using the scan tool, command the EVAP Vent Valve
ON (Closed).
3. Pressurize the EVAP system to the first specified
15 in. H20
12 value using the Enhanced EVAP Pressure Purge
10 in. H20
Diagnostic Cart J 41413.
4. Monitor pressure using gauge on cart.
5. Switch the rotary switch on the cart to HOLD.
6. Observe the EVAP pressure gauge.
Does the pressure decrease to less than the second
specified value within 2 minutes? Go to Step 2 Go to Step 13
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
13 — —
2. Perform the Service Bay Test for EVAP.
Is action complete? Go to Step 14
Does the scan tool display any DTCs in the Freeze Frame Go to applicable
14 —
and Failure Records? DTC table System OK
Engine________________________________ Engine Controls - 7.4L 6-2929

DTC P0446 EVAP Vent Valve Performance

|Hot In Run And Start!
r "JUnderhood
I Powar
Distribution , Fuse-Relay
I ENG 1
Cell 10 Fuse 15 i Center
20 A
I I
L.

PNK 539 VCM

C1=BLU
C 2-R ED
C3-CLEAR
hise Block C4-B LK
Details
Cell 11
PNK 539 PNK 539
A,
rB,■"* Evaporative Evaporative
• Emissions (EVAP) Emission
CMP and MAF Sensors,
EGFt Valve I Canister (EVAP)
L — J Vent Canister
A bY Purge
Valve
WHT 1310 DK GRN/ 428
WHT
2. ,C2 2,v C3
Vent EVAP "j Vehicle
Control Canister I Control
Purge
Value i Module A
Driver , (VCM)

190385

Circuit Description • No IAT sensor DTCs

The evaporative system includes the following • No Fuel Level DTCs
components: • The ECT is greater than 3.75 *C (38.75 *F) but
• The fuel tank less than 3 0 *C (86*F).
• The EVAP vent solenoid • The IAT is greater than 3.75 * C (38.75 * F) but
• The fuel tank pressure sensor less than 3 0 'C (86 *F).
• The fuel pipes and hoses • Start up ECT is not more than 8.25 * C
(46.85 * F) greater than the start up IAT.
• The vapor lines
• Start up IAT is not more than 1.5 *C (34.7 *F)
• The fuel cap greater than the start up ECT.
• The evaporative emission canister • The Fuel Level is greater than 10% and 85%.
• The purge lines • The Baro is greater than 72.5 kPa.
• The EVAP purge solenoid • The System Voltage is greater than 10 volts but
Conditions for Setting the DTC less than 17 volts.
The following conditions will set the DTC: • Excess vacuum present in the EVAP system.
• No MAP sensor DTCs Action Taken When the DTC Sets
• No TP sensor DTCs • The VCM illuminates the MIL during the first
. No VSS DTCs key cycle in which the DTC sets.
. No H02S DTCs • The VCM stores the conditions which were
present when the DTC sets as a Freeze Frame
. No ECT DTCs
and Fail Records data.
• The DTC P0125 not active
6-2930 Engine Controls - 7.4L
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ' C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 °C (160°F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Check for the following conditions:
• A poor connection at the VCM: Inspect the
harness connectors for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connection.
Engine
• A damaged harness: Inspect the wiring harness
to the EVAP vent solenoid EVAP purge
solenoid and the fuel tank pressure sensor for
an intermittent open or short circuit.
• A kinked, pinched or plugged vent hose. Verify
that the vent hose between the canister and
the EVAP vent solenoid is not restricted.
Refer to Carbon Particle Removal from EVAP
System before starting repairs.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be set
occurs. This may assist in diagnosing the condition.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. This step checks the Fuel Tank Pressure
sensor at atmospheric pressure.
3. This step verifies that the Fuel Tank Pressure
sensor accurately reacts to EVAP system
pressure changes.
5. Checks for a blocked EVAP Canister.

DTC P0446 EVAP Vent Valve Performance

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool to
record the Freeze Frame and the Failure Records for
reference. This data will be lost when the Clear Info
1 — Go to Powertrain
function is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn OFF the ignition.
2. Remove the fuel cap.
0 in. H20
2 3. Turn ON the ignition.
±1 in. H20 Go to Fuel Tank
4. Observe the Fuel Tank Pressure on the scan tool. Pressure Sensor
Is the Fuel Tank Pressure at the specified value? Go to Step 3 Diagnosis
Important: Before continuing with the diagnosis, zero the
EVAP Pressure and Vacuum gauges on the Enhanced
EVAP Pressure Purge Diagnostic Cart J 41413. Refer to
the tool operating instructions.
1. Install the fuel cap.
2. Connect the Enhanced EVAP Pressure Purge
Diagnostic Cart J 41413 to the EVAP service port. 5 in. H20
3 3. Using the scan tool, command the EVAP Vent Valve 5 in. H20
ON (Closed).
±1 in. H20
4. Attempt to pressurize the EVAP system using the
Enhanced EVAP Pressure Purge Diagnostic
Cart J 41413.
5. Monitor pressure using the gauge on the EVAP cart
and maintain the first specified EVAP pressure. Go to EVAP
Does the scan tool indicate the fuel tank pressure at the Control System
second specified value? Go to Step 4 Diagnosis
Engine________________________________________________ Engine Controls - 7.4L 6-2931
DTC P0446 EVAP Vent Valve Performance (cont’d)
Step Action Value(s) Yes No
1. Maintain the first specified EVAP pressure.
2. Using the scan tool, command the EVAP Vent Valve 5 in. H20
OFF (Open) while observing the Fuel Tank Pressure
4 0 in. H20
sensor on the scan tool.
±1 in. H20
Does the EVAP pressure return to the second specified Refer to
value within 10 seconds? Diagnostic Aids Go to Step 5
1. Turn the rotary switch on the Cart to the Release
Pressure position.
2. Disconnect the vent hose from the EVAP Canister.
3. Disconnect the Fuel Tank Vapor line and the EVAP
Purge line from the EVAP Canister.
5 5 in.Hg
4. Block the Fuel Tank Vapor line fitting on the EVAP
Canister.
5. Connect a hand vacuum pump to the EVAP Purge
line fitting on the EVAP Canister.
Can the specified value of vacuum be obtained? Go to Step 11 Go to Step 6
1. Inspect the vent hose between the EVAP Canister
and the EVAP Vent Valve for being kinked, pinched,
or otherwise blocked.
6 —
2. If a problem is found, repair as necessary. Refer to
Diagnostic Aids.
Was a problem found? Go to Step 13 Go to Step 7
1. Turn OFF the ignition.
2. Disconnect Vent Valve Connector.
7 3. Turn ON the ignition with the engine OFF. —
4. Connect test light to B+ and probe terminal A.
Is test light ON? Go to Step 8 Go to Step 10
1. Turn OFF the ignition.
2. Disconnect the VCM Red connector.
8 3. Connect test light to B+ and probe terminal A at the —
EVAP Vent Valve connector.
Is the test light ON? Go to Step 9 Go to Step 12
Repair short to ground in EVAP Vent Control circuit. Refer
9 to Wiring Repairs in Electrical Diagnosis. — —
Is action complete? Go to Step 13
Replace the EVAP Vent Valve. Refer to Diagnostic Aids.
10 Refer to EVAP Vent Valve Replacement — —
Is the action complete? Go to Step 13
Replace EVAP Canister. Refer to Diagnostic Aids. Refer to
11 EVAP Canister Replacement — —
Is the action complete? Go to Step 13
1. Replace the VCM.
■ 2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
12 — —
to Password Leam Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
6-2932 Engine Controls - 7.4L________________________________________________ Engine
DTC P0446 EVAP Vent Valve Performance (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, command the EVAP Vent Valve
ON (Closed).
2. Pressurize the EVAP system to the first
specified value.
3. Switch the rotary switch on the Cart J 41413 to Hold. 5 in. H20
13
4. Using the scan tool, command the EVAP Vent Valve 0 in. H20
OFF (Open) while observing the EVAP pressure
gauge on the Cart (J 41413).
Does the EVAP pressure return to the second specified
value within 10 seconds? Go to Step 14 Go to Step 2
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
14 — —
2. Perform the Service Bay Test for EVAP.
Is action complete? Go to Step 15
Does the scan tool display any DTCs in the Freeze Frame Go to applicable
15 —
and Failure Records? DTC table System OK
Engine_________________________________________ Engine Controls - 7.4L 6-2933

DTC P0452 Fuel Tank Pressure Sensor Low Voltage

. EGR EGR MAP Sensor Fuel Tank TP Sensor

1 Valve Pintle Sensor Ground Pressure Sensor Ground ■
I Ground Position Signal Sensor signal |
Signal Signal

£ Vehicle Control
ie A Module (VCM)

Circuit Description
The Fuel Tank Pressure Sensor responds to
changes in the fuel tank pressure or vacuum. This
information is used in order to detect vacuum decay
or an excessive vacuum during the EVAP diagnostic
routing. The fuel tank pressure sensor signal voltage
to the VCM varies from a minimum of about
0.1 volts with pressure in the fuel tank to above
4.0 volts with a high vacuum in the fuel tank.
The Fuel Tank Pressure sensor display on the scan
tool has an auto zero feature which occurs at each
ignition cycle and is corrected according to the
barometric pressure. Because of this, the Fuel Tank
193226
Pressure sensor display may not accurately reflect
the actual output of the sensor or the conditions
within the fuel tank.
The Fuel Tank Pressure Sensor diagnosis table is
intended to isolate and diagnose the electrical
problems with the sensor wiring or the sensor.
Conditions for Setting the DTC
The Fuel Tank Pressure Sensor voltage is less
than 0.1 volt for more than 5 seconds.
Action Taken When the DTC Sets
The VCM turns ON the MIL after 2 consecutive
driving cycles with the fault active.
6-2934 Engine Controls - 7.4L
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
1. Inspect the Control Module harness connectors
for the following conditions:
• Improper mating
• Broken locks
Engine
• Improperly formed
• Damaged terminals
2. Inspect the wiring harness for damage. If the
harness appears to be OK, observe the Fuel
Tank Pressure sensor display on the scan tool
while moving the connectors and the wiring
harnesses related to the sensor. A change in
the display will indicate the location of the fault.
Refer to Wiring Repairs in Electrical Diagnosis if
a fault in the wiring is found.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
5. A normal Fuel Tank Pressure Sensor signal
voltage without any pressure or vacuum in the
fuel system should be between 1.30 volts and
2.0 volts. If the voltage is out of this range, a
scewed (out of range) sensor or damaged
wiring could be at fault.

DTC P0452 Fuel Tank Pressure Sensor Low Voltage

Step Action Value(s) Yes No
Important: Use the scan tool to store the failed DTC
information. This information will be erased when the clear
Go to Powertrain
1 DTC function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install the scan tool.
2. Turn ON the ignition leaving the engine OFF.
-1.0 - 1.0 in
2 3. Monitor the Fuel Tank Pressure Sensor reading. H20
Does the scan tool display indicate the Fuel Tank Pressure
Sensor within the specified value? Go to Step 3 Go to Step 4
This DTC is intermittent. Go to
3 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
1. Turn OFF the ignition.
2. Disconnect the Fuel Tank Pressure Sensor electrical
connector.
3. Turn ON the ignition leaving the engine OFF.
4 4. Measure the voltage between the 5 V reference 5.0 V
circuit and the sensor ground circuit at the Fuel Tank
Pressure Sensor harness connector using a
DMM J 39200.
Is the voltage near the specified value? Go to Step 5 Go to Step 6
Engine________________________________________________ Engine Controls - 7.4L 6-2935
DTC P0452 Fuel Tank Pressure Sensor Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Connect a jumper between the Fuel Tank Pressure
Sensor 5 volt reference (harness side) and the 5 volt
reference on the sensor using the Connector Test
Adapter Kit J 35616-A.
3. Connect a jumper between the Fuel Tank Pressure
5 Sensor ground (harness side) and the sensor ground 1.3 V -2.0 V
using the Connector Test Adapter Kit J 35616-A.
4. Turn ON the ignition leaving the engine OFF.
5. Measure the voltage at the Fuel Tank Pressure
Sensor signal terminal using a DMM J 39200
connected to ground.
Is the voltage between the specified values? Go to Step 13 Go to Step 11
Check for an open in the 5 V reference circuit.
6 —
Was a problem found? Go to Step 15 Go to Step 7
Check for a short to ground in the 5 V Reference circuit.
7 —
Was a problem found? Go to Step 15 Go to Step 8
Check the 5 V reference circuit for a poor terminal
8 connection at the VCM. —
Was a problem found? Go to Step 15 Go to Step 9
Check for an open in the sensor ground circuit.
9 —
Was a problem found? Go to Step 15 Go to Step 10
Check the sensor ground circuit for a poor terminal
10 connection at the VCM. —
Was a problem found? Go to Step 15 Go to Step 16
Check the Fuel Tank Pressure Sensor signal for a short to
11 ground. —
Was a problem found? Go to Step 15 Go to Step 12
Check the Fuel Tank Pressure Sensor signal terminal
12 connection at the VCM. —
Was a problem found? Go to Step 15 Go to Step 16
Check the connector at the Fuel Tank Pressure Sensor for
• Salt or water intrusion
• Backed out terminals
13 —
• Improper terminal mating
• Poor terminal to wire connections
Was a problem found? Go to Step 15 Go to Step 14
Replace the Fuel Tank Pressure Sensor. Refer to Fuel
14 Tank Pressure Sensor Replacement. — —
Is the action complete? Go to Step 17
Repair the circuit as necessary. Refer to Wiring Repairs in
15 Electrical Diagnosis. — —
is the action complete? Go to Step 17
6-2936 Engine Controls ■ 7.4L________________________________________________ Engine
DTC P0452 Fuel Tank Pressure Sensor Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Replace the VCM.
2. Program the new VGM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
16 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Learn Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 17
1. Clear the DTCs using a scan tool.
2. Operate the vehicle within the Conditions for Setting
17 this DTC as specified in the supporting text. —
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 18 Go to Step 2
Determine if any additional DTCs have been set using a Go to
18 scan tool. — the Applicable
Are any new DTCs displayed? DTC Table System OK
Engine__________________________________________
DTC P0453 Fuel Tank Pressure Sensor High Voltage
| Ground Position Signal
Signal
Circuit Description
The Fuel Tank Pressure Sensor responds to
changes in the fuel tank pressure or vacuum. This
information is used in order to detect vacuum decay
or an excessive vacuum during the EVAP diagnostic
routing. The fuel tank pressure sensor signal voltage
to the VCM varies from a minimum of about
0.1 volts with pressure in the fuel tank to above
4.0 volts with a high vacuum in the fuel tank.
The Fuel Tank Pressure sensor display on the scan
tool has an auto zero feature which occurs at each
ignition cycle and is corrected according to the
Engine Controls - 7.4L 6-2937
Sensor Signal
Signal
£ Vehicle Control
Module (VCM)
193226
barometric pressure. Because of this, the Fuel Tank
Pressure sensor display may not accurately reflect
the actual output of the sensor or the conditions
within the fuel tank.
The Fuel Tank Pressure Sensor diagnosis table is
intended to isolate and diagnose the electrical
problems with the sensor wiring or the sensor.
Conditions for Setting the DTC
The Fuel Tank Pressure Sensor voltage is greater
than 4.98 volts for more than 5 seconds.
Action Taken When the DTC Sets
The VCM turns ON the MIL after 2 consecutive
driving cycles with the fault active.
6-2938 Engine Controls - 7.4L
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 'C (160’ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
1. Inspect the Control Module harness connectors
for the following conditions:
• Improper mating
• Broken locks
• Improperly formed
• Damaged terminals
Engine
2. Inspect the wiring harness for damage. If the
harness appears to be OK, observe the Fuel
Tank Pressure sensor display on the scan tool
while moving the connectors and the wiring
harnesses related to the sensor. A change in
the display will indicate the location of the fault.
Refer to Wiring Repairs in Electrical Diagnosis if
a fault in the wiring is found.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
4. If the Fuel Tank Pressure Sensor value is less
than 0.22 volts, the fault is the Fuel Tank
Pressure Sensor or the reference voltage to the
sensor is greater than 5.0 volts.
5. The VCM terminals CLR 12 and CLR 27 are
spliced together inside the VCM. When
checking the 5.0 volt reference for a short to
ground, both the 5.0 volt reference circuits and
all the components on the 5.0 volt reference
circuits must be checked.

DTC P0453 Fuel Tank Pressure Sensor High Voltage

Step Action Value(s) Yes No
Important: Use the scan tool to store the failed DTC
information. This information will be erased when the clear
Go to Powertrain
1 DTC function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install the scan tool.
2. Turn ON the ignition leaving the engine OFF.
-1.0 - 1.0 in
2 3. Monitor the Fuel Tank Pressure Sensor reading. H20
Does the scan tool display indicate the Fuel Tank Pressure
Sensor within the specified value? Go to Step 3 Go to Step 4
This DTC is intermittent. Go to
3 Are any additional DTCs stored? — the applicable Go to
DTC table Diagnostic Aids
1. Turn the Ignition OFF
2. Disconnect the Fuel Tank Pressure Sensor electrical
connector.
3. Turn ON the ignition leaving the engine OFF.
4 4. Measure the voltage between the Fuel Tank 0.22 V
Pressure Sensor signal circuit and the sensor ground
circuit at the Fuel Tank Pressure Sensor harness
connector using a J 39200 DMM.
Is the Fuel Tank Pressure Sensor signal circuit voltage
less than the specified value? Go to Step 5 Go to Step 6
Measure the voltage between the 5 V reference circuit and
the sensor ground circuit at the Fuel Tank Pressure
5 Sensor harness connector using a J 39200 DMM. 5.0 V
Is the voltage near the specified value? Go to Step 9 Go to Step 7
Measure the voltage between the Fuel Tank Pressure
6 Sensor signal circuit and ground using a J 39200 DMM. 0.5 V
Is the voltage higher than the specified value? Go to Step 8 Go to Step 10
Engine________________________________________________ Engine Controls - 7.4L 6-2939
DTC P0453 Fuel Tank Pressure Sensor High Voltage (cont’d)
Step Action Value(s) Yes No
Check for a short to voltage in the 5 V Reference circuit.
7 —
Was a problem found? Go to Step 11 Go to Step 9
Check for a short to voltage in the Fuel Tank Pressure
8 Sensor signal circuit. —
Was a problem found? Go to Step 11 Go to Step 12
Check the connector at the Fuel Tank Pressure Sensor for:
• Salt or water intrusion
• Backed out terminals
9 —
• Improper terminal mating
• Poor terminal to wire connections
Was a problem found? Go to Step 11 Go to Step 12
Check the terminal contact at the VCM.
10 —
Was a problem found? Go to Step 11 Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 Electrical Diagnosis. — —
Is the action complete? Go to Step 14
Replace the Fuel Tank Pressure Sensor. Refer to Fuel
12 Tank Pressure Sensor Replacement. — —
Is the action complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 to Password Learn Procedure.
— —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Clear the DTCs using a scan tool.
2. Operate the vehicle within the Conditions for Setting
14 this DTC as specified in the supporting text. —
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Determine if any additional DTCs have been set using a
15 scan tool. — Go to applicable
Are any new DTCs displayed? DTC table System OK
6-2940 Engine Controls - 7.4L Engine

DTC P0461 Fuel Level Sensor Circuit Performance

|Hot In RunAndStart|
IP
I Power
I Distribution
Cell 10
GAUGES Fuse
I
I
Fuse4
10A
Block
N
L J

PNK 39
FuseBlock
Details
Cell 11
PNK 39
AA
Ignition Fuel Level Sender
Buffered Fuel Fuel VCM Voltage Fuel Level Fuel Gauge Module
Level Output Level 5Volt Module Level
ToGauge Sensor Reference Output Output
C' B)/ M'l/ /
D1
PPL/WHT 1589 GRV 474 BLK/WHT 533 PPL/WHT 1589
PPL 30

PPL/WHT 1589
GRY 474 BLK/WHT 533 PPL/WHT 1589
Instrument Fuel Level Sender -------1►
Cluster and Pump
Cell 81 GRY 474
I 27 C3 (GRY) 12 14 C4 (BLK)
I
* 5Volt Fuel Level Fuel Level ^ Vehicle
MAPand EGRSensor Reference Module Return [ Control
Volt Reference Output Return Module A
(VCM)

Circuit Description
The Fuel Level sensor is an important input to the
VCM for the Enhanced Evaporative System
Diagnostic. The VCM needs the fuel level information
in order to know the volume of fuel in the tank. The
fuel level affects the rate of change in the air
pressure in the EVAP system. Several of the
Enhanced Evaporative System Diagnostic sub-test
are dependent upon the correct fuel level
information. The diagnostic will not run when the
tank is greater than 85% or less than 15% full.
(This sensor signal disables the misfire when the
fuel levels are less than 15%). This DTC is a
type D DTC.
Conditions for Setting the DTC
• The fuel tank level slosh test is completed
• The tank level main test is completed
• The fuel tank level data is valid
• The fuel level signal is unchanged over a
distance of 200 miles
Action Taken When the DTC Sets
The VCM will not turn ON the MIL.
53090
Conditions for Clearing the MIUDTC
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 * F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
This diagnostic will not run when the volume of fuel
in the fuel tank is greater than 85% or less than
15% full. The fuel level sensor will also disable the
misfire diagnosis when the fuel level is less
than 15%.
Test Description
Number(s) below refer to the step number(s) on the
diagnostic table.
3. This step determines if the problem is a VCM
problem or a wiring problem.
4. This step determines if the fuel gauge and the
fuel level sender module are operating correctly.
Engine________________________________________________ Engine Controls - 7.4L 6-2941
DTC P0461 Fuel Level Sensor Circuit Performance
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear Info Go to Powertrain
1 function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install a scan tool.
2. Turn the ignition ON.
2 3. Compare the Fuel Level parameter on the scan tool —
with the vehicle fuel gauge.
Are the readings approximately the same? Go to Step 3 Go to Step 5
1. Record the vehicle fuel gauge reading.
2. Turn the ignition OFF.
3 3. Disconnect the black VCM connector. —
4. Turn the ignition ON.
Did the vehicle fuel gauge reading change? Go to Step 9 Go to Step 4
Check for a short to ground between the VCM and the Go to Engine
4 splice. — Electrical for Fuel
Was a problem found? Go to Step 8 Gauge Diagnosis
1. Disconnect the black VCM connector.
2. Turn the ignition ON.
5 3. Measure the voltage on the fuel level input circuit 1.0V
(harness side) with a DVM to ground.
Is the voltage displayed greater than the specified value? Go to Step 7 Go to Step 6
Repair the open in the fuel level sensor signal circuit
6 between the VCM and the splice. — —
Is the action complete? Go to Step 10
Check the terminal contact at the VCM for the fuel level
7 sensor signal circuit. —
Was a problem found? Go to Step 8 Go to Step 9
Repair as necessary.
8 — —
Is the action complete? Go to Step 10
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
9 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 10
6-2942 Engine Controls - 7.4L________________________________________________ Engine
DTC P0461 Fuel Level Sensor Circuit Performance (cont’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select the DTC and the
Clear Info.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
10 4. Select the DTC and the Specific. —

5. Enter the DTC number which was set.

6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 11 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Info. Go to
11 —
Are there any DTCs displayed that have not been Step Applicable
diagnosed? DTC Table System OK
Engine________________________________________ Engine Controls - 7.4L 6-2943

DTC P0462 Fuel Level Sensor Circuit Low Voltage

|Hot In BunAndStart)

1
I Power ■J'P
, Distribution GAUGES . Fuse
j Cell 10 Fuse4 , Block
10A
I I

PNK 39
FuseBlock
Details
Cell 11
PNK 39
A
Ignition Fuel Level Sender
Buffered Fuel Fuel VCM Voltage Fuel Level Fuel Gauge Module
Level Output Level 5Volt Module Level
ToGauge Sensor Reference Output Output
LY CY BY MY DY
PPL/WHT 1589 QRY 474 BLK/WHT 533 PPL/WHT 1589
PPL 30
PPL/WHT 1589
GRY 474 BLK/WHT 533 PPL/WHT 1589
Instrument Fuel Level Sender
Cluster and Pump
Cell 81 GRY 474
27 C3(GRY) 12 14 C4 (BLK)
r —— —— — —— n Vehicle
* . 5Volt Fuel Level Fuel Level
MAPand EGRSensor Reference Module Return [ Control
Volt Reference ■ Output Return Module A
1 J (VCM) lu g

53090

Circuit Description Conditions for Clearing the MILVDTC

The Fuel Level sensor is an important input to the
VCM for the Enhanced Evaporative System
Diagnostic. The VCM needs the fuel level information
in order to know the volume of fuel in the tank. The
fuel level affects the rate of change in the air
pressure in the EVAP system. Several of the
Enhanced Evaporative System Diagnostic sub-test
are dependent upon the correct fuel level
information. The diagnostic will not run when the
tank is greater than 85% or less than 15% full. (This
sensor signal disables the misfire when the fuel
levels are less than 15%). This DTC is a
type D DTC.
Conditions for Setting the DTC
• The fuel tank slosh test is completed
• The fuel tank main level test is completed
• The fuel tank level data is valid
• The fuel level signal voltage is less than
0.39 volts for a period greater than 20 seconds
Action Taken When the DTC Sets
The VCM will not turn ON the MIL.
The VCM turns OFF the MIL after 3 consecutive
driving trips without a fault condition present. A
history DTC will clear if no fault conditions have
been detected for 40 warm-up cycles (the coolant
temperature has risen 40 *F from the start-up coolant
temperature and the engine coolant temperature
exceeds 160*F during that same ignition cycle) or
the scan tool clearing feature has been used.
Diagnostic Aids
This diagnostic will not run when the volume of fuel
in the fuel tank is greater than 85% or less than
15% full. The fuel level sensor will also disable the
misfire diagnosis when the fuel level is less
than 15%.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
4. This step checks the wiring, the connections,
and the VCM.
6. This step checks the wiring, the connections,
and the VCM.
8. This step checks the wiring, the connections,
and the VCM.
6-2944 Engine Controls - 7.4L________________________________________________ Engine
DTC P0462 Fuel Level Sensor Circuit Low Voltage
Step Action Value(s) Yes No
important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear Info
1 — Go to Powertrain
function is used.
OBD System
Was the On-Board Diagnostic (OBD) System Check Check (OBD
performed? Go to Step 2 System Check)
1. Install the scan tool.
2 2. Observe the fuel level ON the scan tool. 0%-1%
Does the scan tool display the specified value? Go to Step 4 Go to Step 3
Refer to Fuel Level Sender Guage Module Diagnosis in
3 — — —
section 8A.
With a DVM to ground, probe the fuel level sensor input at
4 the Fuel Level Sender Gauge Module. 0.13V
Is the voltage less than the specified value? Go to Step 5 Go to Step 6
Check for an open in the fuel level sensor input circuit.
5 —
Was a problem found? Go to Step 9 Go to Step 6
With a DVM to ground, probe the fuel level output at the
6 Fuel Level Sender Gauge Module. 0.13V
Is the voltage less than the specified value? Go to Step 7 Go to Step 8
Check for an open in the fuel level output circuit.
7 —
Was a problem found? Go to Step 10 Go to Step 8
With a DVM to ground, probe the fuel level module output
8 at the Fuel Level Sender Gauge Module. 2.9V
Is the voltage greater than the specified value? Go to Step 11 Go to Step 12
Repair the open in the fuel level sensor input circuit.
9 — —
Is the action complete? Go to Step 13
Repair the open in the fuel level output circuit.
10 —
Is the action complete? Go to Step 13
Repair the short to voltage in the fuel level module output
11 circuit. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
Engine________________________________________________ Engine Controls - 7.4L 6-2945
DTC P0462 Fuel Level Sensor Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select the DTC and the
Clear Info.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
13 4. Select the DTC and the Specific. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Info. Go to
14 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
6-2946 Engine Controls ■ 7.4L__________________ Engine

DTC P0463 Fuel Level Sensor Circuit High Voltage

|Hot InRunAndStart]
| Power IP
, Distribution GAUGES Fuse
Cell 10 Fuse4 Block
10A

PNK 39
FuseBlack
Details
Cell 11
PNK 39
A
Ignition Fuel Level Sender
Buffered Fuel Fuel VCM Voltage Fuel Level Fuel Gauge Module
Level Output Level 5Volt Module Level
ToGauge Sensor Reference Output Output
LY CY BY MY DY
PPL/WHT 1589 GRY 474 BLK/WHT 533 PPL/WHT 1589
PPL 30
PPL/WHT 1589
GRY 474 BLK/WHT 533 PPL/WHT 1589
Instrument Fuel Level Sender
Cluster and Pump
Cell 81 GRY 474
I
27 C3 (GRY) 12 14 C4 (BLK)
* 5Volt Fuel Level Fuel Level Vehicle
MAPand EGRSensor Reference Module Return [ Control
Volt Reference Output Return Module A
_|(VCM) l l A

53090

Circuit Description Conditions for Clearing the MIL7DTC

The Fuel Level sensor is an important input to the The VCM turns OFF the MIL after 3 consecutive
VCM for the Enhanced Evaporative System driving trips without a fault condition present. A
Diagnostic. The VCM needs the fuel level information history DTC will clear if no fault conditions have
in order to know the volume of fuel in the tank. The been detected for 40 warm-up cycles (the coolant
fuel level affects the rate of change in the air temperature has risen 4 0 'F from the start-up coolant
pressure in the EVAP system. Several of the temperature and the engine coolant temperature
Enhanced Evaporative System Diagnostic sub-test exceeds 160°F during that same ignition cycle) or
are dependent upon the correct fuel level the scan tool clearing feature has been used.
information. The diagnostic will not run when the
tank is greater than 85% or less than 15% full. (This Diagnostic Aids
sensor signal disables the misfire when the fuel This diagnostic will not run when the volume of fuel
levels are less than 15%). This DTC is a in the fuel tank is greater than 85% or less than
type D DTC. 15% full. The fuel level sensor will also disable the
misfire diagnosis when the fuel level is less
Conditions for Setting the DTC than 15%.
• The fuel tank level slosh test is completed
Test Description
• The fuel tank level main test is completed
The numbers below refer to the step numbers in the
• The fuel tank level data is valid
diagnostic table.
• The fuel level signal voltage is greater than 5. This step checks the wiring, the connections,
2.9 volts for a period greater than 20 seconds
and the VCM.
Action Taken When the DTC Sets 7. This step checks the wiring, the connections,
The VCM will not turn ON the MIL. and the VCM.
8. This step checks the wiring, the connections,
and the VCM.
Engine________________________________________________ Engine Controls - 7.4L 6-2947
DTC P0463 Fuel Level S ensor C ircuit High Voltage
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear Info Go to Powertrain
1 function is used. —
OBD System
Was the On-Board Diagnostic (OBD) System Check Check (OBD
performed? Go to Step 2 System Check)
1. Install the scan tool.
2 2. Observe the fuel level on the scan tool. 99%-100%
Does the scan tool display the specified value? Go to Step 4 Go to Step 3
3 Refer to the Fuel Sender Guage Module Diagnosis. — — —
With a DVM connected to ground, probe the fuel level
4 sensor, cavity C, at the Fuel Level Sensor Guage Module. 2.9V
Is the voltage greater than the specified value? Go to Step 5 Go to Step 6
Check for a short to voltage in the Fuel Level Input circuit.
5 —
Was a problem found? Go to Step 9 Go to Step 6
With a DVM to ground, probe the fuel level output, cavity
6 D, at the Fuel Level Buffer Module. 2.9V
Is the voltage greater than the specified value? Go to Step 7 Go to Step 8
Check for a short to voltage in the fuel level output circuit.
7 —
Was a problem found? Go to StepIO Go to Step 8
Check for an open in the Fuel Level Buffer Module sensor
8 ground. —
Was a problem found? Go to Step 11 Go to Step 12
Repair the short to voltage in the fuel level input circuit.
9 Refer to Wiring Repair in Engine Electrical. — —
Is the action complete? Go to Step 13
Repair the short to voltage in the fuel level output circuit.
10 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 13
Repair the open in the fuel Level Buffer Module sensor
11 ground. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 13
6-2948 Engine Controls - 7.4L________________________________________________ Engine
DTC P0463 Fuel Level Sensor C ircuit High Voltage (co n t’d)
Step Action Value(s) Yes No
1. Use the scan tool in order to select the DTC and the
Clear Info.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
13 4. Select the DTC and the Specific. —
5. Enter the DTC number which was set.
6. Operate the vehicle withnin the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Info. Go to
14 —
Are there any DTCs displayed that have not been the Applicable
diagnosed? DTC Table System OK
Engine_______________________________ Engine Controls - 7.4L 6-2949

DTC P0500 Vehicle Speed Sensor Circuit

190382
C ircu it Description C onditions fo r S etting the DTC
The Vehicle Speed Sensor (VSS) circuit is of the The following conditions will set the DTC:
magnetic induction type. The gear teeth are pressed . No MAP DTCs
on the outside diameter of the output shaft assembly.
• Vehicle speed is 0 mph
The gear teeth induce an alternating current in the
sensor as the shaft rotates. The signal goes directly • Engine coolant temperature above 60 * C
to the VCM. This pulsing action takes place about • Engine speed is at least 1400 but no more
40 times per revolution of output shaft of than 4400 RPM.
transmission. The VCM calculates the vehicle speed • MAP below 20 kPa
based on the time between pulses.
• TP is less than 3.125 percent
A ction Taken W hen the DTC Sets
None.
6-2950 Engine Controls - 7.4L Engine
C onditions fo r C learing the MIL7DTC D iagnostic A ids
• The VCM turns the MIL OFF after Check proper calibration for the speedometer.
3 consecutive drive trips when the test
has Run and Passed and not Failed. Test Description
• A history DTC will clear if no fault conditions The numbers below refer to the step numbers in the
have been detected for 40 warm-up cycles diagnostic table.
(coolant temperature has risen 22 *C (40 *F) 2. This step determines if the DTC P0500 is the
from the startup coolant temperature and the result of a hard failure or an intermittent
engine coolant temperature exceeds condition.
7 0 ’ C (160*F) during the same ignition cycle). 5. This step checks VSS.
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.

DTC P0500 Vehicle Speed Sensor C ircuit

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Clear the DTCs.
3. Back probe across the VSS signal circuits High and
Low using the J 35616-A connector test adapter kit.
2 —
4. Raise the wheels of the vehicle.
5. Operate the engine in gear.
6. Set the voltmeter on the AC 200 volt scale.
Is the voltage constant? Go to Step 5 Go to Step 3
Does the voltage vary? Go to
3 —
Diagnostic Aids Go to Step 4
4 Does the voltmeter read NO voltage? — Go to Step 11 Go to Step 12
1. With vehicle still raised, disconnect the Vehicle
Speed Sensor (VSS).
2. Operate the engine.
3. Transmission in gear.
5 —
4. The voltmeter on the AC 200 scale
5. Measure the voltage across the Vehicle Speed
Sensor terminals A and B.
Does the voltage vary with the RPM? Go to Step 7 Go to Step 6
Replace the Vehicle Speed Sensor.
6 — —
Is the action complete? Go to Step 12
1. Check for a poor connection at the VCM harness
connector.
7 2. Check for a poor connection at the Vehicle Speed —
Sensor connector.
Was a problem found? Go to Step 9 Go to Step 8
Engine_______________________________________________ Engine Controls - 7.4L 6-2951
DTC P0500 Vehicle Speed Sensor C ircuit (cont’d)
Step Action Value(s) Yes No
1. Check for an open or a short circuit between the
VCM connector terminal for the VSS signal low
circuit and the Vehicle Speed Sensor connector
terminal A.
8 2. Check for an open or a short circuit between the —
VCM connector terminal for the VSS signal high
circuit and the Vehicle Speed Sensor connector
terminal B.
Was a problem found? Go to Step 10 Go to Step 12
Repair the connection as necessary.
9 — —
Is the action complete? Go to Step 12
Repair the open or short as necessary. Refer to Wiring
10 Repairs in Engine Electrical. — —
Is the action complete? Go to Step 12
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
11 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 12
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
12 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
13 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2952 Engine Controls - 7.4L Engine
DTC P0506 Idle Control System Low RPM
Idle Air
Stepper
Motor Control (IAC)
Coil Coil
Valve
B 0 A

B
LT LT VCM
GRN/WHT 1749 BLU/BLK 1748 C1 = BLU
C 2-R ED
C3“ CLEAR
LT LT C4-BLK
GRN/BLK 444 BLU/WHT 1747

_ .1 4 ^ 0 2

IAC IAC IAC IAC Vehicle

Coil B CoilB Coil A Coil A Control
High Low Low High Module A
(VCM) ia A

33140

C ircuit D escription • Vehicle Speed is less than 2 mph

The VCM controls the idle speed with an Idle Air • System voltage is between 10 volts and
Control (IAC) valve to a calculated desired RPM 16 volts
based on the sensor inputs and the actual engine • Engine run time is greater than 30 seconds.
RPM. The VCM uses 4 circuits in order to move an
• TP is less than 1%
Idle Air Control (IAC) valve, allowing a varying
amount of air flow into the intake manifold. • Above met for a time greater than 3 seconds
In order to increase the idle RPM, the VCM moves If the non-intrusive test fails, the intrusive test is run.
the IAC valve out, allowing more air to bypass the Intrusive
throttle plate. In order to decrease the RPM, the • Air Flow is greater than 17.5 grams per second
VCM moves the IAC valve in, reducing the amount but less than 50 grams per second
of air bypassing the throttle plate. A scan tool reads • Vehicle Speed is greater than 25 MPH but less
the VCM commands to the IAC valve in counts. The
than 85 MPH
higher the counts, the more air is allowed to bypass
the throttle plate (higher idle). The lower the counts, • Change in TP Sensor is less than 1%
the less air that is allowed to bypass the throttle • Change in engine speed is less than 50 RPM
plates (lower idle). • IAC motor is commanded to 10% for 100 msec
C onditions For S etting DTC A ction Taken W hen the DTC Sets
Non-intrusive The VCM will turn ON the MIL after 2 consecutive
• No TP sensor DTCs set driving cycles with the fault active.
• No ECT DTCs set C onditions fo r Clearing th e MILVDTC
. No VSS DTCs set • The VCM turns the MIL OFF after
• No MAP DTCs set 3 consecutive drive trips when the test
• No transmission DTCs has Run and Passed and not Failed.
. No PRNDL DTCs • A history DTC will clear if no fault conditions
• No Misfire DTCs have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (4 0 ' F)
. No IAT DTCs from the startup coolant temperature and the
. No MAF DTCs engine coolant temperature exceeds
• ECT is greater than 50 *C 70 * C (160 * F) during the same ignition cycle).
• IAT is greater than -25 *C • Use the scan tool Clear Information function.
• BARO is greater than 75 kPa • Disconnect the VCM battery feed for
30 seconds.
Engine Engine Controls - 7.4L 6-2953
Diagnostic Aids scan tool counts will read above 60 if the idle is too
The following items could cause this DTC: low and zero if the idle is too high. Check for the
following:
• An IAC valve which is stopped and cannot
respond to the VCM • Fuel system too lean and rich
• A throttle stop screw which has been • Throttle body - inspect the bore for foreign
tampered with material.
• A damaged throttle or linkage • Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
A slow, unstable, or fast idle may be caused by a
non - IAC valve system problem that cannot be • IAC reset is done with the scan tool misc.
overcome by the IAC valve. Out of range control IAC functions mode.

DTC P0506 Idle Control System Low RPM

Step Action Value(s) Yes No
important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Install the scan tool. Go to
2 Are any other DTCs set? — The Applicable
DTC Table Go to Step 3
3 Is the DTC P0506 active this ignition cycle? — Go to Step 5 Go to Step 4
This DTC is an intermittent. Refer to the Diagnostic Aids.
4 — —
Is the action complete? Go to Step 6
Problem is engine mechanical related. Refer to Engine
5 Mechanical. — —
Is the action complete? Go to Step 7
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
6 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 7 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
7 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2954 Engine Controls - 7.4L__________ Engine

DTC P0507 Idle Control System High RPM

Stepper
Idle Air
Motor Control (IAC)
Coil Coil Valve
B 0 A

±-
c
LT LT VCM
GRN/WHT 1749 BLU/BLK 1748 C1=BLU
C2 = RED
C3 = CLEAR
LT LT C4 = BLK
GRN/BLK 444 BLU/WHT 1747

291

1o
l i t
>:
IAC IAC IAC IAC Vehicle
Coil B Coil B Coil A Coil A Control
High Low Low High Module A
(VCM)

33140
Circuit Description • Vehicle Speed is less than 2 mph
The VCM controls the idle speed with an Idle Air • System voltage is between 10 volts and
Control (IAC) valve to a calculated desired RPM 16 volts
based on the sensor inputs and the actual engine • Engine run time is greater than 30 seconds.
RPM. The VCM uses 4 circuits in order to move an
• TP is less than 1%
Idle Air Control (IAC) valve, allowing a varying
amount of air flow into the intake manifold. • Above met for a time greater than 3 seconds
In order to increase the idle RPM, the VCM moves If the non-intrusive test fails, the intrusive test is ran.
the IAC valve out, allowing more air to bypass the Intrusive
throttle plate. In order to decrease the RPM, the • Air Flow is greater than 17.5 grams per second
VCM moves the IAC valve in, reducing the amount but less than 50 grams per second
of air bypassing the throttle plate. A scan tool reads
• Vehicle Speed is greater than 25 MPH but less
the VCM commands to the IAC valve in counts. The
than 85 MPH
higher the counts, the more air is allowed to bypass
the throttle plate (higher idle). The lower the counts, • Change in TP Sensor is less than 1%
the less air that is allowed to bypass the throttle • Change in engine speed is less than 50 RPM
plates (lower idle). • IAC motor is commanded to 10% for 100 msec
Conditions For Setting DTC Action Taken When the DTC Sets
Non-intrusive The VCM will turn ON the MIL after 2 consecutive
• No TP sensor DTCs set driving cycles with the fault active.
• No ECT DTCs set Conditions for Clearing the MILVDTC
. No VSS DTCs set • The VCM turns the MIL OFF after
• No MAP DTCs set 3 consecutive drive trips when the test
• No transmission DTCs has Run and Passed and not Failed.
. No PRNDL DTCs • A history DTC will clear if no fault conditions
• No Misfire DTCs have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 'C (40 °F)
• No IAT DTCs from the startup coolant temperature and the
. No MAF DTCs engine coolant temperature exceeds
• ECT is greater than 50 * C 7 0 ‘ C (160*F) during the same ignition cycle).
• IAT is greater than -2 5 ' C • Use the scan tool Clear Information function.
• BARO is greater than 75 kPa • Disconnect the VCM battery feed for
30 seconds.
Engine_________________________________
Diagnostic Aids
The following items could cause this DTC:
• An IAC valve which is stopped and cannot
respond to the VCM
• A throttle stop screw which has been
tampered with
• A damaged throttle or linkage
A slow, unstable, or fast idle may be caused by a
non - IAC valve system problem that cannot be
overcome by the IAC valve. Out of range control IAC
___________ Engine Controls - 7.4L 6-2955
scan tool counts will read above 60 if the idle is too
low and zero if the idle is too high. Check for the
following:
• Fuel system too lean and rich
• Throttle body - inspect the bore for foreign
material.
• Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• IAC reset is done with the scan tool misc.
functions mode.

DTC P0507 Idle Control System High RPM

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and the failure records for
reference because the data will be lost when the Clear Go to Powertrain
1 Info function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Install the scan tool. Go to
2 Are any other DTCs set? — The Applicable
DTC Table Go to Step 3
3 Is DTC P0507 active this ignition cycle? — Go to Step 5 Go to Step 4
DTC is intermittent. Refer to the Diagnostic Aids.
4 — —
Is the action complete? Go to Step 6
Problem is engine mechanical related. Refer to Engine
5 Mechanical. — —

Is the action complete? Go to Step 6

1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at normal operating temperature.
4. Select the DTC and the Specific.
6 —
5. Then enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic ran and
passed? Go to Step 7 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
7 Review Info. —
The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2956 Engine Controls - 7.4L Engine

DTC P0601 VCM Memory

Circuit Description
The VCM Program Memory contains data which is
essential to running the engine and transmission. At
powereup, the VCM continuously checks the integrity
of this data. If the checksum of the Program
Memory does not match a predetermined value,
DTC P0601 sets.
Conditions for Setting the DTC
The VCM is unable to correctly read data from the
flash memory.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
• The VCM records the operating conditions at
the time the diagnostic fails. The VCM stores
this information in the scan tools Freeze Frame
and/or the Failure Records.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (4 0 ' F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ' C (160* F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Replace the VCM even if this DTC exists only in
history.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Replace the VCM even if this DTC exists only
in history.

DTC P0601 VCM Memory

Step Action Value(s) Yes No
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC
1 — Go to Powertrain
Information function.
OBD System
Did you perform the Powertrain On-Board Diagnostic Check (OBD
(OBD) System Check? Go to Step 2 System Check)
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
2 — —
Replace the VCM.
Is the action complete? Go to Step 3
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
3 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 4 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
4 function with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
Engine Engine Controls - 7.4L 6-2957

DTC P0602 VCM Not Programmed

Circuit Description
This DTC indicates that the VCMs internal Program
Memory is not flashed with any vehicle software. If
you install a service VCM and do not flash the
Program Memory, the engine will not run. This DTC
indicates that an un-flashed VCM will cause an
engine cranks but will not run situation.
Conditions for Setting the DTC
There is no software data is present in the VCM.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
• The VCM records the operating conditions at
the time the diagnostic fails. The VCM stores
this information in the scan tools Freeze Frame
and/or the Failure Records.
Conditions for Clearing the MIL7DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 7 0 ' C
(160'F ) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. If the flashing procedure fails, verify that the
equipment being used is functioning properly
and that all cable connections are clean and
tight. Also, make sure that the software you
download is correct for the VCM being flashed.
If everything checks out OK, and a second
attempt fails, the VCM is faulty.

DTC P0602 VCM Not Programmed

Step Action Value(s) Yes No
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC Go to Powertrain
1 Information function. —
OBD System
Did you perform the Powertrain On-Board Diagnostic Check (OBD
(OBD) System Check? Go to Step 2 System Check)
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
2 —
Replace the VCM.
Does DTC P0602 reset? Go to Step 3 Go to Step 5
1. Verify that the equipment being used is functioning
properly and that all the cable connections are clean
3 and tight. —
2. Attempt to flash the VCM again.
Does DTC P0602 reset? Go to Step 4 Go to Step 5
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
4 — —
Replace the VCM.
Is the action complete? Go to Step 5
6-2958 Engine Controls - 7.4L________________________________________________ Engine
DTC P0602 VCM Not Programmed (conf d)
Step Action Value(s) Yes No
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
5 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 6 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
6 function with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
Engine Engine Controls - 7.4L 6-2959

DTC P0603 VCM Memory Reset

Circuit Description
The VCM contains a memory area where it stores
certain data it needs to save when the ignition is
turned OFF. This area is called Keep Alive Memory.
This diagnostic test monitors the VCMs keep alive
memory for a loss or unintended change of data. If
such a condition occurs, DTC P0603 sets.
Conditions for Setting the DTC
If the checksum data of the Keep Alive Memory
stored at power-down does not match the checksum
data of the Keep Alive Memory at power-up, and the
data read from memory does not match the data
which is stored in the check memory function,
DTC P0603 will set.
Action Taken When the DTC Sets
• The VCM will illuminate the Malfunction
Indicator Lamp (MIL) when the diagnostic runs
and fails.
• The VCM will record the operating conditions at
the time the diagnostic fails. This information
will be stored in the Freeze Frame and/or
Failure Records.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
If the battery has been disconnected for any reason
DTC P0603 will set. The VCM checks the memory at
powerup. If the memory changes, it will reset. An
intermittent loss of power or ground to the VCM will
also cause a reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Replace the VCM even if this DTC exists only
in history.

DTC P0603 VCM Memory Reset

Step Action Value(s) Yes No
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC
1 — Go to Powertrain
Information function.
OBD System
Did you perform the Powertrain On-Board Diagnostic Check (OBD
(OBD) System Check? Go to Step 2 System Check)
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
2 — —
Replace the VCM.
Is the action complete? Go to Step 3
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
3 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 4 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
4 function with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
6-2960 Engine Controls - 7.4L
DTC P0604 VCM Random Access Memory (RAM)
Circuit Description Conditions for Clearing the MIL7DTC
The VCM contains a memory area where it stores
certain data it does not need to save when the
ignition is turned OFF. This area is called the Volatile
section of memory. The Volatile section of memory is
cleared and then tested when the ignition is first
turned ON.This diagnostic test monitors the VCMs
Volatile section of memory to make sure it is stored
correctly. If the information is not stored correctly,
DTC P0604 will set.
Conditions for Setting the DTC
If the data from the memory location does not match
the test data which was just saved to memory,
DTC P0604 will set.
Action Taken When the DTC Sets
• The VCM will illuminate the Malfunction
Indicator Lamp (MIL) when the diagnostic runs
and fails.
• The VCM will record the operating conditions at
the time the diagnostic fails. This information
will be stored in the Freeze Frame and/or
Failure Records.
Engine
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 "C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Replace the VCM even if this DTC exists only
in history.

DTC P0604 VCM Random Access Memory (RAM)

Step Action Value(s) Yes No
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC
1 — Go to Powertrain
Information function.
OBD System
Did you perform the Powertrain On-Board Diagnostic Check (OBD
(OBD) System Check? Go to Step 2 System Check)
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
2 — —
Replace the VCM.
Is the action complete? Go to Step 3
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
3 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 4 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
4 function with a scan tool. — the applicable
Are any new DTCs displayed? DTC table System OK
Engine Engine Controls - 7.4L 6-2961

DTC P0605 VCM Read Only Memory (ROM)

Circuit Description
The VCM memory contains data which is essential
to running the engine and transmission. The VCM
checks the integrity of this data. If the checksum of
the Boot Flash section of memory does not match a
predetermined value, DTC P0605 sets.
Conditions for Setting the DTC
The VCM is unable to correctly read data from the
Boot Flash memory.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
• The VCM records the operating conditions at
the time the diagnostic fails. The VCM stores
this information in the scan tools Freeze Frame
and/or the Failure Records.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Replace the VCM even if this DTC exists only
in history.

DTC P0605 VCM Read Only Memory (ROM)

Step Action Value(s) Yes No
Important: Before clearing the DTCs, record the Freeze
Frame and the Failure records for reference with a scan
tool. This data will be lost when you use the Clear DTC
1 Go to Powertrain
Information function. —
OBD System
Did you perform the Powertrain On-Board Diagnostic Check (OBD
(OBD) System Check? Go to Step 2 System Check)
Important: Program the new VCM. Refer to VCM
Replacement/Programming.
2 — —
Replace the VCM.
Is the action complete? Go to Step 3
1. Select DTC and the Clear DTC Information function
with a scan tool.
2. Start the Engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
3 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC that the supporting text specifies.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 4 Go to Step 2
Display the Capture Info and the Review Capture Info Go to
4 function with a scan tool. —
the applicable
Are any new DTCs displayed? DTC table System OK
6-2962 Engine Controls - 7.4L
DTC P0704 Clutch Switch Circuit
Circuit Description
This DTC determines if the Transmission Clutch
Switch has failed by looking for a clutch switch
transition within a range from 0 mph to some
higher speed.
Conditions for Setting the DTC
The following conditions will set the DTC:
. No VSS DTCs
• Vehicle speed is greater than 50 mph
• Clutch transitions not detected
Action Taken When the DTC Sets
The VCM turns the MIL (Malfunction Indicator Lamp)
ON after 2 consecutive trips with the fault present.
Engine
VCM
C1=BLU
C2=RED
C3- CLEAR
C4=BLK
221069
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine________________________________________________ Engine Controls - 7.4L 6-2963
DTC P0704 Clutch Switch Circuit
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn off the ignition.
2. Install a scan tool.
3. Turn ON the ignition leaving the engine off.
4. Using the scan tool, display the Clutch Switch
2 parameter. —
5. Engage the clutch, and disengage the clutch. Repeat
this several times
Does the scan tool display change states when the Clutch
is engaged and disengaged? Go to Step 7 Go to Step 3
Check for a open brake fuse.
3 —
Was the fuse open? Go to Step 8 Go to Step 4
1. Turn OFF the ignition.
2. Disconnect the Clutch Switch connector.
4 3. Jumper the Clutch Switch ignition feed to the Clutch
—
Switch signal circuit.
4. Turn the ignition ON leaving the engine off.
Does the scan tool display Clutch Switch on? Go to Step 5 Go to Step 6
Remove the jumper.
5 —
Does the scan tool display Clutch Switch OFF? Go to Step 11 Go to Step 9
Check for an open in the Clutch signal circuit.
6 —
Was a problem found? Go to Step 12 Go to Step 10
7 Problem is intermittent, Refer to Intermittent Condition. — — —
1. Check for the conditions for the open brake fuse.
2. Repair as necessary.
8 — —
3. Replace the open fuse.
Is the action complete? Go to Step 14
Check for a short to B+ on the Clutch Switch signal circuit.
9 —
Was a problem found? Go to Step 12 Go to Step 13
Check for poor terminal contact for the Clutch Switch
10 signal circuit at the VCM connector. —
Was a problem found? Go to Step 12 Go to Step 13
Replace the Clutch Switch.
11 — —
Is the action complete? Go to Step 14
Repair as necessary.
12 — —
Js the action complete? Go to Step 14
6-2964 Engine Controls - 7.4L Engine
DTC P0704 Clutch Switch Circuit (cont’d)
Step Action Value(s) Yes No
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
14 —

5. Enter the DTC number which was set.

6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine____________________________________________
DTC P1106 MAP Sensor CKT Intermittent High Voltage
Vehicle
Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in the intake manifold pressure
(vacuum). A 5 volt reference is applied to the sensor
on the 5 volt reference circuit. A variable resistor
moves in relation to the manifold pressure and a
voltage signal is sent back to the vVCM on the MAP
sensor signal circuit. This voltage signal will vary
from 1.0-1.5 volts at closed throttle to 4.0-4.6 volts
at wide open throttle (low vacuum). The VCM utilizes
the MAP signal and the throttle position in order to
determine the correct amount of fuel delivered to the
engine.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No TP sensor DTCs are set
• Throttle Position is no more than 0.4% when
engine speed is no more than 1200 RPM
• Or the Throttle Position is no more than 19.9%
when engine speed is greater than 1200 RPM
• MAP is greater than 4.34 v
Action Taken When the DTC Sets
The VCM turns the MIL ON when this DTC is
reported and 1 failure has occurred. The VCM
substitutes a calculated value for the MAP sensor
value so that acceptable performance is maintained.
Engine Controls - 7.4L 6-2965
VCM
Cl =BLU
C2=RED
C3=CLEAR
C4=BLK
IATandFuel Tank
■4 PressureSensors
and EGRValve
190358
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 'C (160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
With the ignition ON and the engine off, the manifold
pressure is equal to atmospheric pressure with the
signal voltage high. The VCM uses this information
as an indication of the vehicle’s altitude. Comparison
of this reading with a known good vehicle using the
same sensor is a good way to check the accuracy
of a suspect sensor. Readings should be the
same ±0.4 volts.
Refer to Intermittent Condition.
Important: The electrical connector must remain
securely fastened.
important: Disconnect the sensor from the bracket
and twist the sensor by hand (only) in order to check
for intermittent connections. The output changes
greater than 0.1 volt indicates a bad connector or
connection. If OK, replace the sensor.
6-2966 Engine Controls - 7.4L__________ Engine
Important: After removing the MAP sensor from the 6. This step checks the integrity of the MAP
intake manifold, replace the MAP Sensor to intake sensor ground circuit.
manifold seal. 10. VCM pins GR12 and GR27 are spliced together
inside the VCM. This step isolates the two pins
Test Description
from one another.
Number(s) below refer to the step number(s) on the
Diagnostic Table.
5. This step checks for a short to voltage on the
5 volt reference circuit.

DTC P1106 MAP Sensor CKT Intermittent High Voltage

Step Action Value(s) Yes No
Important: Before clearing the DTC(s) use the scan tool
to record the Freeze Frame and Failure Records for
reference. This data will be lost when the Clear Info Go to Powertrain
1 function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. If the engine idle is unstable, incorrect, or if the
manifold vacuum at idle is less than the specified
value, correct the fault before using this table. Refer
to Engine Symptoms. 15 in Hg
2 2. Connect a scan tool. 4.0V
3. Engine at idle.
Does the scan tool display a voltage less than the
specified value? Go to Step 3 Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the MAP sensor electrical connector.
3 3. Turn the ignition ON. 1.0V
Does the scan tool display a voltage less than the
specified value? Go to Step 5 Go to Step 9
The DTC is intermittent. If no other DTCs are stored, go to
4 Diagnostic Aids. — Go to Applicable —
Are any additional DTCs stored? DTC Table
With a DVM connected to ground, probe the 5 volt
5 reference circuit (at the MAP sensor harness connector). 5.2V
Is the voltage greater than the specified value? Go to Step 10 Go to Step 6
Probe the MAP sensor ground circuit (at the MAP sensor
6 connector) with a test light to B+. —
Is the test light ON? Go to Step 7 Go to Step 14
Check the MAP sensor vacuum source for a restriction.
7 —
Was a problem found? Go to Step 15 Go to Step 8
Replace the MAP sensor. Refer to MAP Sensor
8 Replacement. — —
Is the action complete? Go to Step 19
Check for a short to voltage in the MAP sensor signal
9 circuit. —
Was a problem found? Go to Step 15 Go to Step 18
1. Turn the ignition OFF.
2. Disconnect the VCM gray connector.
3. Turn the ignition ON.
10 4. With a DVM connected to ground, measure the 5.2V
voltage on the 5 volt reference circuit (at the VCM
harness connector).
Is the voltage greater than the specified value? Go to Step 11 Go to Step 13
Engine Engine Controls - 7.4L 6-2967
DTC P1106 MAP Sensor CKT intermittent High Voltage (cont’d)
Step Action Value(s) Yes No
1. Disconnect the EGR valve electrical connector.
2. Measure the voltage on the 5 volt reference circuit
11 5.2V
(at the VCM harness connector).
Is the voltage greater than the specified value? Go to Step 12 Go to Step 16
Repair the short to voltage on the 5 volt reference circuit
12 — —
Is the action complete? Go to Step 19
With a DVM to ground, measure the voltage on the VCM
13 connector terminal GR 12. 5.2V
Is the voltage greater than the specified value? Go to Step 17 Go to Step 18
Repair the sensor ground circuit.
14 — —
Is the action complete? Go to Step 19
Repair as necessary.
15 —
Is the action complete? Go to Step 19
Replace the EGR valve. Refer to EGR Valve Replacement
16 (DR Utility) — —
Is the action complete? Go to Step 19
Repair the short to voltage on the 5 volt reference circuit
17 (terminal GR 12). — —
Is the action complete? Go to Step 19
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
18 to Password Leam Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 19
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
19 which was set. —

4. Operate the vehicle within the conditions for setting

this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 20 Go to Step 2
Using the scan tool, select Capture Info, Review Info.
20 Are any additional DTCs displayed that have not been — Go to Applicable
diagnosed? DTC Table System OK
6-2968 Engine Controls - 7.4L
DTC P1107 MAP Sensor CKT Intermittent Low Voltage
Vehicle
Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in the intake manifold pressure
(vacuum). A 5 volt reference is applied to the sensor
on the 5 volt reference circuit. A variable resistor
moves in relation to the manifold pressure and a
voltage signal is sent back to the VCM on the MAP
sensor signal circuit. This voltage signal will vary
from 1.0-1.5 volts at closed throttle to 4.0-4.6 volts
at wide open throttle (low vacuum). The VCM utilizes
the MAP signal and the throttle position in order to
determine the correct amount of fuel delivered to the
engine.
Conditions for Setting the DTC
The following conditions will set the DTC:
1. No TP DTCs
2. The engine is operating
3. The TP is at least 0% when engine speed is
no more than 800 RPM
4. Or the TP is at least 12.5% when the engine
speed is greater than 800 RPM
5. MAP is less than .2 v
Action Taken When the DTC Sets
The VCM turns the MIL ON when this DTC is
reported and 1 failure has occurred. The VCM
substitutes a calculated value for the MAP sensor
value so that acceptable performance is maintained.
Engine
A
JOBOIIk
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK
IATandFuel Tank
•4 PressureSensors
and EGRValve
190358
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ’ C (160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
An intermittent open in the MAP sensor signal circuit
or the 5 volt reference circuit will result in a
DTC P1107.
With the ignition ON and the engine OFF, the
manifold pressure is equal to the atmospheric
pressure with the signal voltage high. The VCM uses
this information as an indication of the altitude of the
vehicle.
Comparison of this reading with a known good
vehicle using the same sensor is a good way to
check the accuracy of a suspect sensor. Readings
should be the same ±0.4 volt.
Refer to Intermittent Condition.
Important: The electrical connector must remain
securely fastened.
Engine Engine Controls - 7.4L 6-2969
Im portant: After removing the MAP sensor from the 3. Jumpering the 5 volt reference to the signal
intake manifold, replace the MAP Sensor to intake circuit will determine if sensor is at fault or if
manifold seal. there is a problem with the VCM, or the wiring.
Remove the MAP sensor. Twist the sensor by hand 4. The scan tool may not display 5 volts. The
(only) in order to check for intermittent connections. important thing is that the VCM recognized the
Output changes greater than 0.1 volt indicates a bad voltage as more than 4 volts, indicating that the
connector or connection. If OK, replace sensor. VCM and MAP sensor signal circuit are OK.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the DTC P1107 is the
result of a hard failure or an intermittent
condition.

DTC P1107 MAP Sensor CKT Intermittent Low Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and failure records for reference
because the data will be lost when the Clear Info function
1 — Go to Powertrain
is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install the scan tool.
2. Leave the engine idling.
2 0.5V
Does the scan tool display a MAP sensor voltage less
than the specified value? Go to Step 3 Go to Step 5
1. Turn OFF the ignition.
2. Disconnect the MAP sensor electrical connector.
3. Jumper the MAP sensor 5 volt reference to the MAP
3 sensor signal circuit. 4.7V
4. Turn ON the ignition.
Does the scan tool display a MAP sensor voltage greater
then the specified value? Go to Step 6 Go to Step 4
1. Turn off the ignition.
2. Remove the jumper wire.
3. Probe terminal B of the MAP sensor harness with a
4 test lamp to B+. 4.7V
Turn ON the ignition.
Does the scan tool display a MAP sensor voltage greater
the specified value? Go to Step 9 Go to Step 7
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored Go to
5 refer to those tables first. — —
The Applicable
Are any additional DTCs stored? DTC Table
Check for a faulty connection at the MAP sensor.
6 —
Was a problem found? Go to Step 12 Go to Step 11
Check for an open MAP sensor signal circuit.
7 —
Was a problem found? Go to Step 12 Go to Step 8
Check the MAP sensor signal circuit for a short to ground.
8 —
Was a problem found? Go to Step 12 Go to Step 13
Check for an open in the MAP sensor 5 volt reference
9 circuit. _
Was a problem found? Go to Step 12 Go to Step 10
6-2970 Engine Controls - 7.4L Engine
DTC P1107 MAP Sensor CKT Intermittent Low Voltage (cont’d)
Step Action Value(s) Yes No
Check for a short to ground in the MAP sensor 5 volt
10 reference circuit. —

Was a problem found? Go to Step 12 Go to Step 13

Replace the MAP sensor.Refer to MAP Sensor
11 Replacement. — —
Is the action complete? Go to Step 12
Repair the circuit as necessary. Refer to Wiring Repairs in
12 Engine Electrical. — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at normal operating temperature.
4. Select the DTC and the Specific.
14 —
5. Then enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine__________________________________________
DTC P1111 IAT Sensor CKT Intermittent High Voltage
MAPandFuel Tank
PressureSensors ►
and EGRValve
Circuit Description
The Intake Air Temperature (IAT) sensor is located in
the fresh air duct to the throttle body. The Intake Air
Temperature (IAT) sensor is a thermistor. The VCM
uses the IAT to monitor the temperature of the air
entering the throttle body. The VCM applies 5 volts
to the sensor on the 5 volt reference circuit. When
the air is cool, the resistance in the sensor will read
high, and the VCM will sense a high voltage signal.
If the air is warm, the sensor resistance will read
low, and the VCM will sense a low voltage signal.
Conditions for Setting the DTC
The following conditions will set the DTC:
. No ECT DTCs
. No VS DTCs
. No MAF DTCs
• The vehicle speed is less than 2 mph
• MAF is less than 250 grams per second
• The ECT is greater than 84.7 * C
• Engine run time is greater than 100 seconds
Action Taken When the DTC Sets
The VCM stores the DTC to the History if the VCM
detects an intermittent problem.
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Engine Controls ■ 7.4L 6-2971
ia t "! Vehicle
Sensor ! Control
l - !L9ni ' _ 1 Module (VCM)
VCM
Cl =BLU
C2-RED
C3-CLEAR
C4-BLK
190377
Diagnostic Aids
A scan tool indicates the temperature of the ambient
air entering the throttle body. The air temperature
should read very close to the temperature of the
outside air. The air temperature should rise gradually
as the engine warms up and the underhood
temperature increases. If the DTC P1111 is set, the
problem is intermittent. Check for poor connections
at the VCM and IAT sensor by wiggling the
connector gently and monitoring the IAT temperature
or IAT voltage on the scan tool. If the voltage
waivers, repair the connector that caused the waiver.
Also, a sensor may become skewed or mis-scaled.
The Temperature vs. Resistance Value Table will
help to detect a skewed sensor. Refer to
Temperature vs Resistance.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
Im portant: Be sure to use the same diagnostic test
equipment for all measurements.
2. If IAT sensor temperature is less than -37 *C,
then the conditions for the DTC are still present
and the problem is not an intermittent.
3. This test will bypass the IAT sensor and will
confirm that the IAT signal circuit and the
sensor ground circuit to the VCM are sound.
Grounding the signal circuit will provide a low
voltage input to the VCM. The VCM should
recognize this low voltage and indicate a high
IAT temperature.
4. This test will determine if the IAT sensor signal
circuit is OK. If the scan tool indicates a high
IAT temperature, the sensor ground is open. If
the scan tool does not indicate a high
temperature, the IAT signal circuit is open.
6-2972 Engine Controls - 7.4L________________________________________________ Engine
DTC P1111 IAT Sensor CKT Intermittent High Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and failure records for reference
because the data will be lost when the Clear Info function Go to Powertrain
1 is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 4.9V
3. Monitor the IAT sensor voltage.
Is the IAT sensor voltage greater than the specified value? Go to Step 3 Go to Step 6
1. Turn OFF the engine.
2. Turn ON the ignition.
3. Disconnect the IAT sensor connector.
3 0.82V
4. Jumper the IAT harness terminals together.
Does the scan tool display a IAT sensor voltage less the
specified value? Go to Step 7 Go to Step 4
Jumper the IAT sensor signal circuit to a known good
ground.
4 0.82V
Does the scan tool display a IAT sensor voltage less the
specified value? Go to Step 8 Go to Step 5
Is DTC P0123 also set? Go to DTC P0123
5 — TP Sensor Circuit
High Voltage Go to Step 9
DTC is intermittent. If no additional DTCs are stored, refer
to the Diagnostic Aids.
6 — Go to
If additional DTCs are stored refer to those Tables first. The Applicable
Are any additional DTCs stored? DTC Table Go to Step 7
Inspect the sensor connector and VCM connector for
7 proper connection. —
Was a problem found? Go to Step 10 Go to Step 12
Check the IAT sensor ground circuit for an open between
8 the IAT sensor and the VCM. —
Was a problem found? Go to Step 10 Go to Step 12
Check the IAT sensor signal circuit for an open between
9 the IAT sensor and the VCM. —
Was a problem found? Go to. Step 10 Go to Step 12
Repair the circuit as necessary. Refer to Wiring Repairs in
10 Engine Electrical. — ' —
Is the action complete? Go to Step 13
Replace the IAT sensor. Refer to IAT Sensor Replacement.
11 — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
Engine Engine Controls - 7.4L 6-2973
DTC P1111 IAT Sensor CKT Intermittent High Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
13 —
5. Then enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
14 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2974 Engine Controls - 7.4L____________________ Engine

DTC P1112 IAT Sensor CKT Intermittent Low Voltage

ia t“ 1 Vehicle
-
Sensor Control A
_ Signal _
j Modij|e (VCM) l i A
22YC2
TAN 472

| Intake Air

MAPandFuel Tank
PressureSensors ►
andEGRValve
BLK
470
r Temperature
(IAT)
Sensor
VCM
C1 =
C2 =
C3 =
G4 =
B LU
RED
CLEAR
B LK

BLK 470 BLK 470

P
TFTSenso”
■"eZc” ” n Vehicle Cell 39
I Ground I Control A
L ------------------------- j Module (VCM) Am

190377

Circuit Description Diagnostic Aids

The Intake A ir Temperature (IAT) sensor is a
therm istor located in the fresh air duct to the throttle
body. The IAT monitors the temperature of the air
entering the throttle body. The VCM applies 5 volts
to the sensor on 5 volt reference circuit. When the
air is cool, the resistance in the sensor will measure
high, and the VCM senses a high voltage signal. If
the air is warm, the sensor resistance will measure
low, and the VCM senses a low voltage signal.
Conditions for Setting the DTC
The following conditions will set the DTC:
• No VS sensor DTCs
• The vehicle speed is at least 2 mph
• The engine run time is greater than
100 seconds
• Low IAT resistance is less than .82 v
• High IAT resistance is less than 0 v
Action Taken When the DTC Sets
The VCM sets the DTC and turns the MIL ON when
this DTC is reported and 1 failure has occurred.
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
(160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
A scan tool indicates the temperature of the ambient
air entering the throttle body. The air temperature
should read very close to the temperature of the
outside air and should rise gradually as the engine
warms up and the underhood temperature increases.
If DTC P1112 is set, the problem is intermittent.
Check for a short to ground in the IAT sensor signal
circuit. Accomplish this by moving the VCM harness
at various locations and monitoring the IAT
temperature or the IAT voltage on the scan tool. If
the voltage varies, look for a short to ground in the
area of the harness that caused the waiver. Also, a
sensor may become skewed or mis-scaled. The
Temperature vs. Resistance Value Table will help to
detect a skewed sensor. Refer to Temperature vs
Resistance.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
Important: Be sure to use the same diagnostic test
equipment for all measurements.
2. If IAT sensor circuit voltage is less than
0.82 volts, then the conditions for the DTC are
still present and the problem is not intermittent.
3. This test bypasses the IAT sensor and confirms
that the IAT signal circuit and the sensor ground
circuit to the VCM are sound. Opening the
signal circuit provides a high voltage input to
the VCM. The VCM should recognize this high
voltage and indicate a low IAT temperature.
4. This test will determine if the IAT sensor signal
circuit is shorted to sensor ground.
Engine Engine Controls - 7.4L 6-2975
DTC P1112 IAT Sensor CKT Intermittent Low Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 0.82V
3. Monitor the IAT sensor voltage.
Is the IAT sensor voltage less than the specified value? Go to Step 3 Go to Step 5
1. Turn off the engine.
2. Turn ON the ignition.
3 4.0V
3. Disconnect the IAT sensor connector.
Is the IAT sensor voltage greater than the specified value? Go to Step 7 Go to Step 4
1. Turn the ignition OFF.

4 2. Using the J 39200, measure the resistance across oo

the IAT sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
5 refer to those tables. —
The Applicable
Are any additional DTCs stored? DTC Table Go to Step 6
Repair the short to ground in the IAT sensor signal circuit.
6 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 9
Replace the IAT sensor. Refer to IAT Sensor Replacement.
7 — —
Is the action complete? Go to Step 9
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
8 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 9
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
9 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to step 10 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
10 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2976 Engine Controls - 7.4L
DTC P1114 ECT Sensor CKT Intermittent Low Voltage
[*
ITnsor
1 _ Signal
23TC2
YEL 410
Engine Coolant
Temperature
(ECT) Sensor
A C 3 = C LE A R
BLK 452
BLK
TPSensor ► ----- 1»
452
BLK 452
4, .C3
Sensor
Ground
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
therm istor immersed in the intake manifold cooling
system passage. The VCM applies a voltage on the
5 volt reference circuit to the sensor. When the
engine is cold, the sensor (thermistor) resistance is
high; therefore, the VCM senses a high signal
voltage, and the VCM indicates the coolant
temperature. As the engine warms, the sensor
resistance becomes less and the voltage drops
indicating the high coolant temperature.
At the normal engine operating temperature
(8 5 ’ C to 9 5 *C), the voltage measures
about 1.5 to 2.0 volts.
Conditions for Setting the DTC
• Engine run time is greater than 5 seconds
• Low ECT resistance is less than .78 v
• High ECT resistance is less than .078 v
Action Taken When the DTC Sets
The VCM stores the DTC to the History if the VCM
detects an intermittent problem.
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ‘ C (160 * F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Engine
"! Vehicle
Control
J Module (VCM)
>
VCM
C1 = BLU
C 2 = RED
0 4 = B LK
■J Vehicle
Control A
1 Module (VCM) i s A
33179
Diagnostic Aids
A poor connection or an open in the 5 volt reference
circuit or the ECT sensor ground circuit results in a
DTC P1115.
The scan tool displays the engine temperature in
degrees centigrade. After the engine is started, the
temperature should rise steadily to about 90 'C then
stabilize when the thermostat opens.
Use the Temperature vs. Resistance Value scale in
order to test the coolant sensor at various
temperature levels in order to evaluate the possibility
of a skewed or mis-scaled sensor. A skewed sensor
could result in poor driveability complaints. Refer to
Temperature vs Resistance.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the fault is still present, engine coolant
voltage will be less than 0.82 volts.
3. This test simulates a DTC P0118. If the VCM
recognizes the high signal voltage (high
temperature), and the scan tool reads 4.9 volts
or above, the VCM and wiring are OK.
4. This test will determine if the 5 volt reference
circuit is open. There should be 5 volts present
at sensor connector if measured with a
J 39200. This will determine if there is a wiring
problem or a faulty VCM.
Engine________________________________________________ Engine Controls ■ 7.4L 6-2977
DTC P1114 ECT Sensor CKT Intermittent Low Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and failure records for reference
because the data will be lost when the Clear Info function
1 — Go to Powertrain
is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 3. Monitor the Engine Coolant Temperature (ECT) 0.82V
sensor voltage.
Does the scan tool display a ECT sensor voltage less than
the specified value? Go to Step 3 Go to Step 5
1. Turn OFF the engine.
2. Turn ON the ignition.
3 3. Disconnect the ECT sensor connector. 4.0V
Does the scan tool display a ECT sensor voltage greater
than the specified value? Go to Step 7 Go to Step 4
1. Turn off the ignition.
2. Using the J 39200, check the resistance across the
4 oo
ECT sensor harness connector.
Is the resistance at the specified value? Go to Step 8 Go to Step 6
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored Go to
5 refer to those tables first. —
The Applicable
Are any additional DTCs stored? DTC Table Go to Step 9
Repair the short to ground in the ECT signal circuit. Refer
6 to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 9
Replace the ECT sensor. Refer to ECT Sensor
7 Replacement. — —
Is the action complete? Go to Step 9
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
8 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Learn Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 9
6-2978 Engine Controls - 7.4L Engine
DTC P1114 ECT Sensor CKT Intermittent Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
9 —
5. Then enter the DTC number which was set.
6. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic Ran and
Passed? Go to Step 10 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
10 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine___________________________________________
DTC P1115 ECT Sensor CKT Intermittent High Voltage
ECT
Sensor
Signal
Engine Coolant
Temperature
(ECT) Sensor
f C 3 = C LE A R
A]
BLK 452
BLK
TP Sensor ►- "™1f
452
BLK 452
4jlC3
S ensor
G ro u n d
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor immersed in the intake manifold cooling
system passage. The VCM applies a voltage on the
5 volt reference circuit to the sensor. When the engine
is cold, the sensor (thermistor) resistance is high;
therefore, the VCM senses a high signal voltage, and
the VCM indicates the coolant temperature. As the
engine warms, the sensor resistance becomes less
and the voltage drops indicating the high coolant
temperature. At the normal engine operating
temperature (85 *C to 95 *C), the voltage measures
about 1.5 to 2.0 volts.
Conditions for Setting The DTC
• Engine run time is greater than 5 seconds
• Low ECT resistance is less than .78 v
• High ECT resistance is less than .078 v
Action Taken When the DTC Sets
The VCM stores the DTC to the History if the VCM
detects an intermittent problem.
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 'C (160‘ F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Engine Controls - 7.4L 6-2979
Vehicle
Control
Module (VCM)
A
jo
VC M
C l =B LU
C 2 = RED
G 4 = B LK
Vehicle
Control A
Module (VCM)
Diagnostic Aids
Check the harness routing for a potential short to
ground in the 5 volt reference circuit.
The scan tool displays the engine temperature in
degrees centigrade. After the engine is started, the
temperature should rise steadily to about 90 ’ C then
stabilize when the thermostat opens.
Use the Temperature vs. Resistance Value scale to
test the coolant sensor at various temperature levels
in order to evaluate the possibility of a skewed or
mis-scaled sensor. A skewed sensor could result in
poor driveability complaints. Refer to Temperature vs
Resistance.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. If the fault is present, the engine coolant
temperature voltage measures greater than
4.9 volts.
3. This test simulates the conditions for a
DTC P0117. If the VCM recognizes the
grounded circuit (low voltage) and displays a
low voltage, the VCM and the wiring are OK.
4. This test checks for an open or grounded signal
sensor circuit. Also being checked are the ECT
sensor ground circuit and the VCM.
6-2980 Engine Controls - 7.4L________________________________________________ Engine
DTC P1115 ECT Sensor CKT Intermittent High Voltage
Step Action Value(s) Yes No
important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose Go to Powertrain
1 the data. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Start the engine.
2 3. Monitor the ECT sensor voltage 4.9V
Does the scan tool display the ECT sensor voltage greater
than the specified value? Go to Step 3 Go to Step 5
1. Turn off the engine.
2. Turn ON the ignition.
3. Disconnect the ECT sensor connector.
3 0.82V
4. Jumper the ECT sensor harness terminals together.
Does the scan tool display the ECT sensor voltage less
than the specified value? Go to Step 6 Go to Step 4
Jumper the ECT sensor signal to a known good ground.
4 Does the scan tool display the ECT sensor voltage less 0.82V
than the specified value? Go to Step 7 Go to Step 8
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
5 refer to those tables. —
The Applicable
Are any additional DTCs stored? DTC Table Go to Step 6
Inspect the ECT sensor ground connector and the VCM
6 connector for proper connection. —
Was a problem found? Go to Step 10 Go to Step 11
Check the ECT sensor ground circuit for an open between
7 the ECT sensor and the VCM. —
Was a problem found? Go to Step 10 Go to Step 12
Is the DTC P0123 also set? Go to DTC P0123
8 — TP Sensor Circuit
High Voltage Go to Step 9
Check the ECT sensor signal circuit for an open between
9 the ECT sensor and the VCM. —
Was a problem found? Go to Step 10 Go to Step 12
Repair the circuit as necessary. Refer to Wiring Repairs in
10 Engine Electrical. — —
Is the action complete? Go to Step 13
Replace the ECT sensor. Refer to ECT Sensor
11 Replacement — —
Is the action complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Leam Procedure.
Is the action complete? Go to Step 13
Engine________________________________________________ Engine Controls - 7.4L 6-2981
DTC P1115 ECT Sensor CKT Intermittent High Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific. —
13
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
14 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2982 Engine Controls - 7.4L____________________ Engine
DTC P1121 TP Sensor CKT Intermittent High Voltage
r n Vehicle
I 5Volt A
L
ReferenceA I Control
•> Module (VCM) la A
12 C3
GRY 416
A.
T""| Throttle
> Position (TP) ECT Sensor
? Sensor ▼ VCM
Cl =BLU
B' BLK 452 C2=RED
C3-CLEAR
BLK 452 C4=BLK
DK BLU 417
BLK 452
24JLC2 4lc3
r. ---------
TP ■*Vehicle
Sensor
1 Sensor Ground 1Control A
I Signal \ Module (VCM)
L ______________

Circuit Description
The Throttle Position (TP) sensor provides a voltage
signal which changes relative to the throttle blade
angle. The signal voltage varies from about 0.5 volt
at idle to about 4.0 volts at Wide Open
Throttle (WOT).
The TP signal is one of the most important inputs
used by the VCM for fuel control and for most of the
VCM control outputs.
Conditions for Setting the DTC
• Engine running.
• TP voltage is greater than 4.9 v
Action Taken When the DTC Sets
The VCM stores the DTC to the History if the VCM
detects an intermittent problem.
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160‘ F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
33237
Diagnostic Aids
The scan tool reads the throttle position in volts. The
scan tool should read about 0.45 to 0.85 volt with
the throttle closed and the ignition switch turned ON
or at idle. The voltage should increase at a steady
rate as the throttle is moved toward the Wide Open
Throttle (WOT).
Also, some scan tools will read the throttle angle.
0% = closed throttle. 100% = WOT.
Scan the TP sensor while depressing the accelerator
pedal with the engine turned off and the ignition
turned on. The display Should vary from below the
1.25 volts (1250 mV) when the throttle was closed to
over 4.5 volts (4500 mV) when the throttle is held at
WOT position.
This DTC will result if the TP ground circuit is open
or the TP signal circuit is shorted to the voltage.
Refer to the Intermittent Condition.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. If the TP signal is greater than 4.8 volts, then
the fault is present.
3. With the TP sensor disconnected, the TP
signal voltage should go low if the VCM and
wiring is OK.
4. Probing the TP sensor ground circuit with a test
lamp checks the 5 volt return circuit. This step
isolates a faulty sensor, VCM or an open TP
sensor ground circuit.
Engine________________________________________________ Engine Controls ■ 7.4L 6-2983
DTC P1121 TP Sensor CKT Intermittent High Voltage
Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose Go to Powertrain
1 the data. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Close the throttle closed.
2 4.8V
Does the scan tool display TP sensor signal greater than
the specified value. Go to Step 3 Go to Step 6
Disconnect the TP sensor.
3 Does the scan tool display a TP sensor signal below the 0.2V
specified value? Go to Step 4 Go to Step 5
Probe the TP sensor ground circuit with a test lamp
4 connected to B+. —
Is the test lamp on? Go to Step 7 Go to Step 9
Is DTC P0108 also set? Go to DTC P0108
MAP Sensor
5 —
Circuit High
Voltage Go to Step 8
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
6 refer to those tables. —
The Applicable
Are any additional DTCs stored? DTC Table Go to Step 7
Check the connections at the TP sensor.
7 —
Was a problem found? Go to Step 10 Go to Step 11
Check for a short to voltage in the TP sensor signal
8 circuit. —
Was a problem found? Go to Step 10 Go to Step 12
Check for an open in the TP sensor ground circuit.
9 — —
Was a problem found? Go to Step 10
Repair the circuit as necessary. Refer to Wiring Repairs in
10 Engine Electrical. — —
Is the action complete? Go to Step 13
Replace the TP sensor. Refer to TP Sensor Replacement.
11 — —
Is the repair complete? Go to Step 13
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
12 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 13
6-2984 Engine Controls - 7.4L________________________________________________ Engine
DTC P1121 TP Sensor CKT Intermittent High Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. idle at the normal operating temperature.
4. Select the DTC and the Specific.
13 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 14 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
14 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine__________________________________________ Engine Controls - 7.4L 6-2985

DTC P1122 TP Sensor CKT Intermittent Low Voltage

r ------------------ i Vehicle

A
iOBOIIk

VCM
=BLU
-RED
-CLEAR
—BLK

I Signal 'Module (VCM)

L __ __________________ ____ ________________________________________________________________ _____________ ____ J

33237
Circuit Description Diagnostic Aids
The Throttle Position (TP) sensor provides a voltage The scan tool reads throttle position in volts. The TP
signal which changes relative to the throttle blade should read about 0.45 to 0.85 volts with the throttle
angle. The signal voltage varies from about 0.5 volt closed and the ignition ON or at idle. The voltage
at idle to about 4.0 volts at Wide Open should increase at a steady rate as the throttle is
Throttle (WOT). moved toward Wide Open Throttle (WOT).
The VCM uses the TP signal, one of the most An open or short to ground in the 5 volt reference
important inputs, for fuel control and for most of the circuit or the TP sensor signal circuit results in a
VCM control outputs. DTC P0122.
Each time the voltage drops below 1.25 volts and Refer to the Intermittent Condition.
stops, the VCM assumes this value as the 0 throttle Scan the TP sensor signal while depressing the
angle, and the VCM measures the percent throttle accelerator pedal with the engine stopped and the
from this point on. ignition ON. The display should vary from below
1.25 volts (1250 mV) when throttle was closed, to
The Conditions for Setting the DTC
over 4.5 volts (4500 mV) when throttle is held at the
• Engine running. Wide Open Throttle (WOT) position.
• TP voltage is less than .15 v
Test Description
Action Taken When the DTC Sets The numbers below refer to the step numbers in the
The VCM stores the DTC to the History if the VCM diagnostic table.
detects an intermittent problem. 2. If the TP signal is less than 0.2 volt, then the
fault is present.
Conditions for Clearing the MILVDTC
3. This step simulates the DTC P0123: (high
1. A history DTC will clear if no fault conditions
voltage) - If the VCM recognizes the high signal
have been detected for 40 warm-up cycles
voltage, the VCM and the wiring are OK.
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the 4. The VCM recognizes the voltage as over
engine coolant temperature exceeds 4 volts, indicating that the TP sensor signal
7 0 'C (160*F) during the same ignition cycle. circuit and the VCM are OK.
2. Use the scan tool Clear Information function. 5. This simulates a high signal voltage in order to
check for an open in the TP sensor signal
3. Disconnect the VCM battery feed for
circuit.
30 seconds.
6. This step checks the 5 volt reference circuit for
an open, short to ground, or a poor connection
or a faulty VCM.
6-2986 Engine Controls - 7.4L________________________________________________ Engine
DTC P1122 TP Sensor CKT Intermittent Low Voltage
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Connect the scan tool.
2. Close the throttle
2 0.15V
Does the scan tool display a throttle position signal less
than the specified value? Go to Step 3 Go to Step 5
1. Disconnect the TP sensor.
2. Jumper the TP sensor signal circuit and the TP
3 sensor 5 volt reference circuit together. 4.0V
Does the scan tool display a throttle position signal greater
then the specified value? Go to Step 13 Go to Step 4
Probe the TP sensor signal circuit with a test lamp
connected to B+.
4 4.0V
Does the scan tool display throttle position signal over the
specified value? Go to Step 6 Go to Step 8
The DTC is intermittent. If no additional DTCs are stored,
refer to the Diagnostic Aids. If additional DTCs are stored, Go to
5 refer to those tables. —
The Applicable
Are any additional DTCs stored? DTC Table Go to Step 6
Check for an open in the 5 volt reference circuit.
6 —
Was a problem found? Go to Step 11 Go to Step 7
Check the 5 volt reference circuit for a short to ground.
7 —
Was a problem found? Go to Step 11 Go to Step 10
Check the TP sensor signal circuit for an open.
8 —
Was a problem found? Go to Step 11 Go to Step 9
Check the TP sensor signal circuit for a short to ground.
9 —
Was a problem found? Go to Step 11 Go to Step 10
Check for a faulty connection at the VCM.
10 —
Was a problem found? Go to Step 11 Go to Step 13
Repair the circuit as necessary. Refer to Wiring Repairs in
11 — —
Engine Electrical. Is the repair complete? Go to Step 14
Replace the TP sensor. Refer to TP Sensor Replacement
12 — —
Is the replacement complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming. 'i
3. Perform the VTD Password Leam Procedure. Refer
13 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
Engine________________________________________________ Engine Controls - 7.4L 6-2987
DTC P1122 TP Sensor CKT Intermittent Low Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific. —
14
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-2988 Engine Controls - 7.4L Engine

DTC P1133 H02S Insufficient Switching Bank1Sensor1

|Hot InRunAndStart!

A
JOBOIIk

VCM
Cl =BLU
C2=RED
C3-CLEAR
C4=BLK

Ground
Distribution
Cell 14

Circuit Description
Im portant: If this voltage is measured by using a
10 megaohm digital voltmeter, the voltage may read
as low as 0.32 volt.
The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1.0 volt (1000 mV) if
the exhaust is rich to as low as 0.10 volt (10 mV) if
the exhaust is lean.
The VCM supplies a reference voltage of
approximately 0.45 volts (450 mV) to the Heated
Oxygen sensor (H02S) on the H02S High signal
circuit. When the Heated Oxygen sensor is cold, less
than 200 'C (392 *F), the Heated Oxygen sensor signal
voltage will read around 0.45 volt, and the VCM will
keep the system in an Open Loop operation. When
the Heated Oxygen sensor is warm, above 200* C
(392 * F), the Heated Oxygen sensor will swing from
rich to lean rapidly, at least 1 swing every 2 seconds,
if the VCM is in control of the air fuel mixture. This
DTC sets if the Oxygen sensor is slow to respond to
changes in the exhaust oxygen content.
When the H02S temperature is below 360 *C
(600 * F), the sensor will not produce any voltage and
will behave like an open circuit. This will result in an
Open Loop operation.
The H 02S heater provides for a faster sensor
warm-up. This allows the sensor to become active in
a shorter period of time and remain active during a
long extended idle.
200042
Conditions for Setting the DTC
02 Diagnostic Enable
• Lean to Rich switches to less than 50 in
100 seconds
• Rich to Lean switches to less than 50 in
100 seconds
• There are no TP sensor DTCs
• There are no EVAP sensor DTCs
• There are no IAT sensor DTCs
• There are no MAP sensor DTCs
• There are no ECT sensor DTCs
• There are no MAF sensor DTCs
• No Misfire DTCs
• There is no intrusive test in progress
• No device controls are active
• The system voltage is at least 9.0 volts
Response Test Enable
• Lean to Rich switches to less than 50 in
100 seconds
• Rich to Lean switches to less than 50 in
100 seconds
• Closed Loop
• Closed loop low MAP is not active
. DTCs P0131, P0132, P0134, and P0135 are
not active
Engine
• The ECT is greater than 57 *C (134*F)
• The engine run time is greater than 75 seconds
• The MAF is at least 15 g/s and no more
than 55 g/s
• The engine speed is at least 1100 RPM and
no more than 3000 RPM
• The EVAP canister purge duty cycle is at
least 0%
• The above conditions are met for a time greater
than 2 seconds
Action Taken When the DTC Sets
The VCM turns the MIL (Malfunction Indicator Lamp)
ON after 2 consecutive test failures.
The VCM records the operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records store this information.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 ‘ C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Im portant: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
___________ Engine Controls - 7.4L 6-2989
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and proper
connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Diagnose other DTCs first because they may
have set this DTC.
3. With the engine running warm, coolant at least
85 *C (185 * F) and at fast idle, the H02S
voltage should rapidly swing above 0.60 volts
and below 0.30 volts.
5. This step checks to see if the Oxygen sensor
voltage is swinging between rich and lean very
slowly or not at all.
8. This step checks for causes of the H02S
failure. If the sensor is replaced without finding
the cause of the contamination, the
replacement sensor may become contaminated.

DTC P1133 H02S Insufficient Switching Bankl Sensor!

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC Go to Powertrain
1 Information function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Connect the scan tool. Go to
2 Are any other DTCs stored? — the applicable
DTC table Go to Step 3
1. Start the engine.
2. Allow the engine to idle until the normal operating
temperature is reached.
1200-2000 RPM
3 3. Operate the engine at a steady speed within the
0.30-0.60 V
specified range for two minutes.
After 2 minutes, does the H02S voltage rapidly fluctuate
above and below the specified value? Go to Step 4 Go to Step 5
6-2990 Engine Controls - 7.4L________________________________________________ Engine
DTC P1133 H02S Insufficient Switching Bankl Sensor! (cont’d)
Step Action Value(s) Yes No
Operate the engine at a steady speed within the
4 specified range. 1200-2000 RPM Go to
Does the scan tool display indicate a Closed Loop? Diagnostic Aids Go to Step 8
1. Operate the engine at a steady speed within the
specified range.
2. Use the scan tool in order to monitor the H02S 1200-2000 RPM
5
voltage. 0.30-0.60 V
Does the H02S voltage stay within the specified value
longer than it swings outside this value? Go to Step 8 Go to Step 6
Check the VCM connector terminal contact at the H02S
6 Signal and Low circuits. —

Was a problem found? Go to Step 10 Go to Step 7

Check for a poor connection at the H02S connector.
7 —
Was a problem found? Go to Step 10 Go to Step 9
Check the following as possible causes of H02S
contamination:
• Silicon poisoning
• Leading
8 —
• Incorrect gasket sealer
• Rich fuel mixture operation
• Antifreeze
Was a problem found and repaired? Go to Step 9 Go to Step 11
Replace the H02S. Refer to H02S Replacement.
9 — —
Is the action complete? Go to Step 11
Repair as necessary.
10 — —
Is the action complete? Go to Step 11
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
11 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 12 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
12 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine____________________________________________
DTC P1134 H02S Transition Time Ratio Bankl Sensorl
Circuit Description
Important: If this voltage is measured by using a
10 megaohm digital voltmeter, the voltage may read
as low as 0.32 volt.
The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1.0 volt (1000 mV) if
the exhaust is rich to as low as 0.10 volt (10 mV) if
the exhaust is lean.
The VCM supplies a reference voltage of
approximately 0.45 volts (450 mV) to the Heated
Oxygen sensor (H02S) on the H02S High signal
circuit. When the Heated Oxygen sensor is cold, less
than 200 *C (392'F ), the Heated Oxygen sensor signal
voltage will read around 0.45 volt, and the VCM will
keep the system in an Open Loop operation. When
the Heated Oxygen sensor is warm, above 200‘ C
(392 *F), the Heated Oxygen sensor will swing from
rich to lean rapidly, at least 1 swing every 2 seconds,
if the VCM is in control of the air fuel mixture. This
DTC sets if the Oxygen sensor is slow to respond to
changes in the exhaust oxygen content.
When the H02S temperature is below 360 ’ C
(600 * F), the sensor will not produce any voltage and
will behave like an open circuit. This will result in an
Open Loop operation.
The H02S heater provides for a faster sensor
warm-up. This allows the sensor to become active in
a shorter period of time and remain active during a
long extended idle.
Engine Controls - 7.4L 6-2991
l Hot InRunAndStart|
VCM
Cl =BLU
C2-RED
C3=CLEAR
C4-BLK
Ground
Distribution
Cell 14
200042
Conditions for Setting the DTC
• 0 2 voltage is less than 300 mV lean
• 0 2 voltage is greater than 600 mV rich
• There are no TP sensor DTCs
• There are no EVAP sensor DTCs
• There are no IAT sensor DTCs
• There are no MAP sensor DTCs
• There are no ECT sensor DTCs
• There are no MAF sensor DTCs
• No Misfire DTCs
• There is no intrusive test in progress
• No device controls are active
• The system voltage is at least 9.0 volts
Response Test Enable
• 0 2 voltage is less than 300 mV lean
• 0 2 voltage is greater than 600 mV rich
• Closed Loop
• Closed loop low MAP is not active
. DTCs P0131, P0132, P0134, and P0135 are
not active
• The ECT is greater than 5 7 ' C (134 * F)
• The engine run time is greater than 75 seconds
• The MAF is at least 15 g/s and no more than
55 g/s
6-2992 Engine Controls - 7.4L
• The engine speed is at least 1100 RPM and no
more than 3000 RPM
• The EVAP canister purge duty cycle is at
least 0%
• The above conditions are met for a time greater
than 2 seconds.
Action Taken When the DTC Sets
The VCM turns the MIL (Malfunction Indicator Lamp)
ON after 2 consecutive test failures.
The VCM records the operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records store this information.
Conditions for Clearing the MILVDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160‘ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Im portant: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
Engine
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and proper
connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Diagnose other DTCs first because they may
have set this DTC.
3. With the engine running warm, coolant at least
85 *C (185*F) and at fast idle, the H02S
voltage should rapidly swing above 0.60 volts
and below 0.30 volts.
5. This step checks to see if the Oxygen sensor
voltage is swinging between rich and lean very
slowly or not at all.
8. This step checks for causes of the H02S
failure. If the sensor is replaced without finding
the cause of the contamination, the
replacement sensor may become contaminated.

DTC P1134 H02S Transition Time Ratio Bankl Sensorl

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 Go to Powertrain
Information function is used. —

OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Connect the scan tool. Go to
2 Are any other DTCs stored? — the applicable
DTC table Go to Step 3
1. Start the engine.
2. Allow the engine to idle until the normal operating
temperature is reached.
1200-2000 RPM
3 3. Operate the engine at a steady speed within the
0.30-0.60 V
specified range for two minutes.
After 2 minutes, does the H02S voltage rapidly fluctuate
above and below the specified value? Go to Step 4 Go to Step 5
Engine Engine Controls - 7.4L 6-2993
DTC P1134 H02S Transition Time Ratio Bankl Sensorl (cont’d)
Step Action Value(s) Yes No
Operate the engine at a steady speed within the
4 specified range. 1200-2000 RPM Go to
Does the scan tool display indicate a Closed Loop? Diagnostic Aids Go to Step 8
1. Operate the engine at a steady speed within the
specified range.
2. Use the scan tool in order to monitor the H02S 1200-2000 RPM
5
voltage. 0.30-0.60 V
Does the H02S voltage stay within the specified value
longer than it swings outside this value? Go to Step 8 Go to Step 6
Check the VCM connector terminal contact at the H02S
6 Signal and Low circuits. —

Was a problem found? Go to Step 10 Go to Step 7

Check for a poor connection at the H02S connector.
7 —
Was a problem found? Go to Step 10 Go to Step 9
Check the following as possible causes of H02S
contamination:
• Silicon poisoning
• Leading
8 —
• Incorrect gasket sealer
• Rich fuel mixture operation
• Antifreeze
Was a problem found and repaired? Go to Step 9 Go to Step 11
Replace the H02S. Refer to H02S Replacement
9 — —
Is the action complete? Go to Step 11
Repair as necessary.
10 — —
Is the action complete? Go to Step 11
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
11 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 12 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
12 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
6-2994 Engine Controls - 7.4L________________
DTC P1153 Insufficient Switching Bank2 Sensoii
lHot InRunAndStart!
Circuit Description
Important: If this voltage is measured by using a
10 megaohm digital voltmeter, the voltage may read
as low as 0.32 volt.
The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1.0 volt (1000 mV) if
the exhaust is rich to as low as 0.10 volt (10 mV) if
the exhaust is lean.
The VCM supplies a reference voltage of
approximately 0.45 volts (450 mV) to the Heated
Oxygen sensor (H02S) on the H02S High signal
circuit. When the Heated Oxygen sensor is cold, less
than 200 *C (392’ F), the Heated Oxygen sensor signal
voltage will read around 0.45 volt, and the VCM will
keep the system in an Open Loop operation. When
the Heated Oxygen sensor is warm, above 200 *C
(392 * F), the Heated Oxygen sensor will swing from
rich to lean rapidly, at least 1 swing every 2 seconds,
if the VCM is in control of the air fuel mixture. This
DTC sets if the Oxygen sensor is slow to respond to
changes in the exhaust oxygen content.
When the H02S temperature is below 360 *C
(600 °F), the sensor will not produce any voltage and
will behave like an open circuit. This will result in an
Open Loop operation.
The H02S heater provides for a faster sensor
warm-up. This allows the sensor to become active in
a shorter period of time and remain active during a
long extended idle.
Engine
VCM
C1=BLU
C2=RED
C3=CLEAR
C4=BLK
200113
Conditions for Setting the DTC
• Lean to Rich switches to less than 50
• Rich to Lean switches to less than 50
• There are no TP sensor DTCs
• There are no EVAP sensor DTCs
• There are no IAT sensor DTCs
• There are no MAP sensor DTCs
• There are no ECT sensor DTCs
• There are no MAF sensor DTCs
• No Misfire DTCs
• There is no intrusive test in progress
• No device controls are active
• The system voltage is at least 9.0 volts
Response Test Enable
• Lean to Rich switches to less than 50
• Rich to Lean switches to less than 50
• Closed Loop
• Closed loop low MAP is not active
. DTCs P0151, P0152, P0154, and P0155 are
not active
• The ECT is greater than 57 *C (134*F)
• The engine run time is greater than 75 seconds
• The MAF is at least 15 g/s and no more than
55 g/s
Engine
• The engine speed is at least 1100 RPM and no
more than 3000 RPM
• The EVAP canister purge duty cycle is at
least 0%
• The above conditions are met for a time greater
than 2 seconds.
Action Taken When the DTC Sets
The VCM turns the MIL (Malfunction Indicator Lamp)
ON after 2 consecutive test failures.
The VCM records the operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records store this information.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 * C (160 * F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Im portant: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
___________ Engine Controls - 7.4L 6-2995
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and proper
connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Diagnose other DTCs first because they may
have set this DTC.
3. With the engine running warm, coolant at least
8 5 ‘ C (185 * F) and at fast Idle, the H02S
voltage should rapidly swing above 0.60 volts
and below 0.30 volts.
5. This step checks to see if the Oxygen sensor
voltage is swinging between rich and lean very
slowly or not at all.
8. This step checks for causes of the H02S
failure. If the sensor is replaced without finding
the cause of the contamination, the
replacement sensor may become contaminated.

DTC P1153 Insufficient Switching Bank2 Sensorl

Step Action Value(s) Yes No
important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 Go to Powertrain
Information function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Connect the scan tool. Go to
2 Are any other DTCs stored? — the applicable
DTC table Go to Step 3
1. Start the engine.
2. Allow the engine to idle until the normal operating
temperature is reached.
1200-2000 RPM
3 3. Operate the engine at a steady speed within the
0.30-0.60 V
specified range for two minutes.
After 2 minutes, does the H02S voltage rapidly fluctuate
above and below the specified value? Go to Step 4 Go to Step 5
6-2996 Engine Controls - 7.4L________________________________________________ Engine
DTC P1153 Insufficient Switching Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
Operate the engine at a steady speed within the
4 specified range. 1200-2000 RPM Go to
Does the scan tool display indicate a Closed Loop? Diagnostic Aids Go to Step 8
1. Operate the engine at a steady speed within the
specified range.
2. Use the scan tool in order to monitor the H02S 1200-2000 RPM
5
voltage. 0.30-0.60 V
Does the H02S voltage stay within the specified value
longer than it swings outside this value? Go to Step 8 Go to Step 6
Check the VCM connector terminal contact at the H02S
6 Signal and Low circuits. —
Was a problem found? Go to Step 10 Go to Step 7
Check for a poor connection at the H02S connector.
7 —
Was a problem found? Go to Step 10 Go to Step 9
Check the following as possible causes of H02S
contamination:
• Silicon poisoning
• Leading
8 —
• Incorrect gasket sealer
• Rich fuel mixture operation
• Antifreeze
Was a problem found and repaired? Go to Step 9 Go to Step 11
Replace the H02S. Refer to H02S Replacement
9 — —
Is the action complete? Go to Step 11
Repair as necessary.
10 — —
Is the action complete? Go to Step 11
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
11 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 12 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
12 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine____________________________________________
DTC P1154 H02S Transition Time Ratio Bank2 Sensorl
|Hot InRunAnd Start|
Circuit Description
Im portant: If this voltage is measured by using a
10 megaohm digital voltmeter, the voltage may read
as low as 0.32 volt.
The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1.0 volt (1000 mV) if
the exhaust is rich to as low as 0.10 volt (10 mV) if
the exhaust is lean.
The VCM supplies a reference voltage of
approximately 0.45 volts (450 mV) to the Heated
Oxygen sensor (H02S) on the H02S High signal
circuit. When the Heated Oxygen sensor is cold, less
than 200'C (392 *F), the Heated Oxygen sensor signal
voltage will read around 0.45 volt, and the VCM will
keep the system in an Open Loop operation. When
the Heated Oxygen sensor is warm, above 200 *C
(392 * F), the Heated Oxygen sensor will swing from
rich to lean rapidly, at least 1 swing every 2 seconds,
if the VCM is in control of the air fuel mixture. This
DTC sets if the Oxygen sensor is slow to respond to
changes in the exhaust oxygen content.
When the H02S temperature is below 360 *C
(600 * F), the sensor will not produce any voltage and
will behave like an open circuit. This will result in an
Open Loop operation.
The H02S heater provides for a faster sensor
warm-up. This allows the sensor to become active in
a shorter period of time and remain active during a
long extended idle.
Engine Controls - 7.4L 6-2997
VCM
Cl =BLU
C2=RED
C3=CLEAR
C4=BLK
200113
Conditions for Setting the DTC
• 0 2 voltage is less than 300 mV lean
• 0 2 voltage is greater than 600 mV rich
• There are no TP sensor DTCs
• There are no EVAP sensor DTCs
• There are no IAT sensor DTCs
• There are no MAP sensor DTCs
• There are no ECT sensor DTCs
• There are no MAF sensor DTCs
• No Misfire DTCs
• There is no intrusive test in progress
• No device controls are active
• The system voltage is at least 9.0 volts
Response Test Enable
• 0 2 voltage is less than 300 mV lean
• 0 2 voltage is greater than 600 mV rich
• Closed Loop
• Closed loop low MAP is not active
. DTCs P0151, P0152, P0154, and P0155 are
not active
• The ECT is greater than 57 * C (134 * F)
• The engine run time is greater than 75 seconds
• The MAF is at least 15 g/s and no more than
55 g/s
6-2998 Engine Controls - 7.4L
• The engine speed is at least 1100 RPM and no
more than 3000 RPM
• The EVAP canister purge duty cycle is at
least 0%
• The above conditions are met for a time greater
than 2 seconds.
Action Taken When the DTC Sets
The VCM turns the MIL (Malfunction Indicator Lamp)
ON after 2 consecutive test failures.
The VCM records the operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records store this information.
Conditions for Clearing the MILVDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 ’ C (160* F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
Im portant: Never solder the H02S wires. For proper
wire and connector repairs, refer to Wiring Repairs in
Electrical Diagnosis.
Engine
Check for the following conditions:
• An improperly installed air intake duct
• The air intake duct for collapsed ducting,
restrictions, or a missing or plugged air filter
• Throttle body and intake manifold vacuum leaks
• A damaged or blocked throttle body inlet
• Exhaust system for corrosion, leaks, or loose or
missing hardware
• The H02S is installed securely and the pigtail
harness is not contacting the exhaust manifold
or wires
• H02S contamination
• The vacuum hoses for splits, kinks, and proper
connections
• Excessive water, alcohol, or other contaminants
in the fuel
• VCM sensor grounds that are clean, tight, and
properly positioned
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. Diagnose other DTCs first because they may
have set this DTC.
3. With the engine running warm, coolant at least
85 *C (185*F) and at fast idle, the H02S
voltage should rapidly swing above 0.60 volts
and below 0.30 volts.
5. This step checks to see if the Oxygen sensor
voltage is swinging between rich and lean very
slowly or not at all.
8. This step checks for causes of the H02S
failure. If the sensor is replaced without finding
the cause of the contamination, the
replacement sensor may become contaminated.

DTC P1154 H02S Transition Time Ratio Bank2 Sensorl

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 — Go to Powertrain
Information function is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Connect the scan tool. Go to
2 Are any other DTCs stored? — the applicable
DTC table Go to Step 3
1. Start the engine.
2. Allow the engine to idle until the normal operating
temperature is reached.
1200-2000 RPM
3 3. Operate the engine at a steady speed within the
0.30-0.60 V
specified range for two minutes.
After 2 minutes, does the H02S voltage rapidly fluctuate
above and below the specified value? Go to Step 4 Go to Step 5
Engine________________________________________________ Engine Controls - 7.4L 6-2999
DTC P1154 H02S Transition Time Ratio Bank2 Sensorl (cont’d)
Step Action Value(s) Yes No
Operate the engine at a steady speed within the
4 specified range. 1200-2000 RPM Go to
Does the scan tool display indicate a Closed Loop? Diagnostic Aids Go to Step 8
1. Operate the engine at a steady speed within the
specified range.
2. Use the scan tool in order to monitor the H02S 1200-2000 RPM
5
voltage. 0.30-0.60 V
Does the H02S voltage stay within the specified value
longer than it swings outside this value? Go to Step 8 Go to Step 6
Check the VCM connector terminal contact at the H02S
6 Signal and Low circuits. —
Was a problem found? Go to Step 10 Go to Step 7
Check for a poor connection at the H02S connector.
7 —
Was a problem found? Go to Step 10 Go to Step 9
Check the following as possible causes of H02S
contamination:
• Silicon poisoning
• Leading
a —
• Incorrect gasket sealer
• Rich fuel mixture operation
• Antifreeze
W is a problem found and repaired? Go to Step 9 Go to Step 11
Replace the H02S. Refer to H02S Replacement.
9 — —
Is the action complete? Go to Step 11
Repair as necessary.
10 — —
Is the action complete? Go to Step 11
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
11 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 12 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
12 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
6-3000 Engine Controls - 7.4L
DTC P1336 CKP System Variation Not Learned
Circuit Description Conditions for Setting the DTC
The Crankshaft Position (CKP) sensor sends pulses
to the VCM as the reluctor wheel teeth rotate past
the CKP sensor. The VCM uses the CKP pulses to
synchronize the ignition and fuel injector operation,
and to time the interval between each CKP pulse.
The VCM determines when an excessive change in
crankshaft speed occurrs by comparing each new
time interval with the previous interval. A misfire
causes an unexpected change in the crankshaft
speed. A certain amount of acceleration/deceleration
is expected between each firing stroke, but if the
crankshaft speed changes more than an expected
amount, the VCM interprets this as a misfire. The
interval between CKP sensor pulses is extremely
small. At high engine speeds, slight variations in the
following components make misfire detection difficult:
• Crankshaft
• Reluctor wheel
• CKP sensor
The VCM learns variations during the Crankshaft
Position System Variation Learning Procedure. The
VCM compensates for these variations when
performing detect misfire calculations. Only a scan
tool can command the VCM to perform the
Crankshaft Position System Variation Learning
Procedure again.
Perform the learning procedure after the following
actions:
• A VCM replacement
• Any operation or repair involving the crankshaft,
the CKP sensor, or the CKP sensor to reluctor
wheel gap relationship
• An engine replacement
• The ignition switch is in the ON position until
the battery is drained
Im portant: A VCM power disconnect with the ignition
ON may erase the stored pulse value and set the
DTC P1336.
Disconnecting the VCM will not erase the learned
Crankshaft Position System Variation as long as the
ignition switch is in the OFF position.
Im portant: Reprogramming the VCM does not
require running the Crankshaft Position System
Variation Learn Procedure unless the VCM is new or
from another vehicle.
If the Crankshaft Position System Variation is not
within an acceptable range, or can not be learned,
DTC P1336 sets.
Engine
• There are no crankshaft position (CKP) or
camshaft position (CMP) sensor DTCs
• The VCM has not learned the Crankshaft
Position System Variation
Action Taken When the DTC Sets
The VCM will illuminate the Malfunction Indicator
Lamp (MIL) on the first drive trip that the diagnostic
runs and fails.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ‘ C (4 0 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
If the Crankshaft Position System Variation Learn
Procedure cannot be learned, check for the following
conditions:
• A chipped or damaged reluctor wheel
• Incorrect alignment of the CKP sensor to the
reluctor wheel
• Excessive crankshaft run-out
• Interference in the signal circuit to the CKP
sensor
• Incorrect ratio of crankshaft to camshaft pulses
Im portant: The VCM will not allow the scan tool to
enable the learn procedure, if the VCM receives an
incorrect crankshaft to camshaft ratio.
Engine diagnostic misfire is not operable when the
engine is above 1000 RPM and DTC P1336 is set.
When the learn procedure is in progress and the
engine speed is at 4000 RPM, a decrease in engine
speed will occur. During the engine coastdown, the
VCM monitors the CKP sensor signal and stores the
pattern. This pattern is used to determine if the
crankshaft speed variations are due to misfire.
Engine Engine Controls - 7.4L 6-3001

Test Description 4. If a repair is necessary due to a condition

The number(s) below refer to the step number(s) on which prevented the learn procedure from
the diagnostic table. enabling, the Crankshaft Position System
Variation Learning Procedure must be
2. The VCM enables the learn process after 65 * C performed.
(150‘ F) is reached. Engine deceleration occurs
when the learn procedure is in progress. The 5. The ignition must be in the OFF position for at
VCM monitors and records the CKP sensor least 10 seconds after the learn procedure is
signal during engine coastdown conditions. complete and the engine RPM has returned to
idle. The VCM saves the signal data after these
3. Test in Progress on the scan tool indicates the conditions are met.
VCM is performing the learn procedure. If the
VCM receives an incorrect crankshaft to
camshaft pulse ratio, an incorrect transmission
range signal input, corrupted communication, or
no change in the brake switch input, the learn
procedure will not be allowed.

DTC P1336 CKP System Variation Not Learned

Step Action Value(s) Yes No
Did you perform the On-Board Diagnostic (OBD) Go to Powertrain
System Check? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
Perform the Crankshaft Position System Variation Learning
Procedure as follows.
1. Install the scan tool.
2. Apply the vehicle’s parking brake.
3. Block the drive wheels.
4. Close the hood.
5. Place the vehicle’s transmission in Park (A/T) or
Neutral (M/T).
6. Idle the engine until the specified engine coolant
temperature value is reached.
7. Turn OFF all the accessories.
65 *C (150-F)
2 8. Enable the Crankshaft Position System Variation
Learning Procedure with the scan tool. 4000 RPM
9. Apply the brakes for the duration of the procedure.
Important: While the learn procedure is in progress,
release the throttle immediately when the engine
starts to decelerate. The engine control is returned to
the operator and the engine will respond to throttle
position after the leam procedure is complete.
10. Slowly raise the engine RPM to the specified value.
11. Immediately release the throttle when the engine
speed decreases.
Does the scan tool indicate that Crankshaft Position
System Variation Leam Procedure is completed? Go to Step 5 Go to Step 3
Attempt the Crankshaft Position System Variation Leam
Procedure as many times as the specified value.
3 3
Does the scan tool indicate that Crankshaft Position
System Variation Leam Procedure is completed? Go to Step 5 Go to Step 4
6-3002 Engine Controls ■ 7.4L Engine
DTC P1336 CKP System Variation Not Learned (cont’d)
Step Action Value(s) Yes No
Check the Crankshaft Position (CKP) sensor to the
4 crankshaft reluctor wheel relationship. — Go to
Was a problem found? Go to Step 6 Diagnostic Aids
Turn OFF the ignition for 15 seconds,
5 — —
is the action complete? Go to Step 7
Reset the relationship between the Crankshaft Position
6 (CKP) sensor and reluctor wheel. — —

Is the action complete? Go to Step 7

1. Turn ON the ignition while leaving the engine OFF.
2. Using the scan tool, clear the DTCs.
3. Start the engine.
4. Idle the engine until the normal operating
7 temperature is reached. —
5. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 8 Go to Step 2
Check if any additional DTCs set. Go to
8 Does the scan tool display any DTCs that you have not — the Applicable
diagnosed? DTC Table System OK
Engine________________________ Engine Controls - 7.4L 6-3003

DTC P1345 CKP/CMP Correlation

IHot InRunAndStart!
r “ —~ “ 1 Underhood
■ Power
Distribution ENG1 Fuse-Relay
> Cell 10 Fuse Center
18T 20A

PNK A
iOBDilV
VCM
PNK 539 C1=BLU
FuseBlock PNK C2=RED
Details C3«CLEAR
Cell 11 PNK C4=BLK
439

Camshaft Crankshaft
Position (CMP) Position
Sensor (CKP)
Sensor

A
PNK/BLK

3
-_A----------- . 31
- _ _ .28
- -AC1
1xCMP 4xCKP CKP Vehicle Control a
Sensor Sensor Sensor j Module (VCM)
Ground Signal Signal Ground

33715
Circuit Description Conditions for Clearing the MIL/DTC
This DTC determines if the Camshaft Sensor is • The VCM turns the MIL OFF after
installed incorrectly. 3 consecutive drive trips when the test
has Run and Passed and not Failed.
Conditions for Setting the DTC
• A history DTC will clear if no fault conditions
When the engine is running, the cam sensor have been detected for 40 warm-up cycles
reference pulse is not detected at the correct relative (coolant temperature has risen 22 * C (40 * F)
position to the crankshaft position sensor pulse. from the startup coolant temperature and the
Action Taken When The DTC Sets engine coolant temperature exceeds
70 ’ C (160 * F) during the same ignition cycle).
• The VCM turns the MIL ON when this DTC is
reported and one failure has occured. • Use the scan tool Clear Information function.
• The VCM records the operating conditions at • Disconnect the VCM battery feed for
the time the Diagnostic Fails. Freeze Frame 30 seconds.
and Failure Records store this information.
6-3004 Engine Controls - 7.4L Engine
DTC P1345 CKP/CMP Correlation
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 — Go to Powertrain
Information function is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install the scan tool.
2. Start the engine.
2 3. Use the scan tool in order to monitor the engine —
speed.
Does the engine speed fluctuate (up to twice
desired RPM)? Go to Step 3 Go to Step 4
Replace the Crankshaft Position Sensor. Refer to
Crankshaft Position Sensor Replacement Removal
3 Procedure. — —

Is the action complete? Go to Step 8

1. Remove the distributor cap. Refer to Distributor
Removal Procedure in Engine Mechanical.
4 2. Grasp the distributor rotor and gently attempt to —
rotate the rotor.
Does the rotor turn on the distributor shaft? Go to Step 7 Go to Step 5
Check for proper installation of the distributor.
Refer to Distributor Installation Procedure in Engine
5 —
Mechanical.
Was a problem found? Go to Step 6 Go to Step 8
Repair as necessary.
6 — —
Is the action complete? Go to Step 8
Replace the distributor. Refer to Distributor Removal
7 Procedure in Engine Mechanical. — —
Is the action complete? Go to Step 8
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the Engine.
3. Allow the engine to Idle until the normal operating
temperature is reached.
8 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 9 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
9 —
Are there any DTCs displayed that have not been The Applicable
diagnosed? DTC Table System OK
Engine_________________________ Engine Controls - 7.4L 6-3005

DTC P1351 IC Circuit High Voltage

[H^in^Run^d^rtj
L°c
Power J Underhood
Distribution ecmi , Fuse-Relay “ A,
Celt 10 Fuse . Center T
Instrument N
J8T 20 A
Cluster1 1
Tachometer
Input 1 A
J060Ilk.
PNK 439 A [ " ~ 6~
FuseBlock
Details WHT 121 VCM
Cell 11 C1=BLU
PNK 439 C2- RED
C3=CLEAR
C4=BLK

PNK 439
FuseBlock
Details WHT 121
Cell 11
PNK 439 PNK 439
o f WHT/BLK 1847
Crankshaft Ignition Ignition Tachometer
Position Control Positive Signal
Voltage
(CKP) Module Ignition
Sensor (ICM) Timing
Signal Ground Ignition
Coil
C'

BLK/WHT 451
WHT 423
Coil Wire
9 a C3
Distributor
4xCKP CKP IC n Vehicle
Sensor Sensor Control JControl
Signal Ground ! Module A
j(VCM)
----------------------- 1
I ” ‘
(around BLK/WHT 451 r n
Distribution
Call U ____ Spark Plugs

33671

Circuit Description Conditions for Setting the DTC

The enhanced ignition system uses the crank sensor
in order to provide the timing input to the VCM. The
VCM uses this reference pulse in order to determine
the individual ignition spark timing for each cylinder.
Once the VCM calculates the ignition timing, the
ignition coil module on the IC circuit receives the
timing signal. Each timing pulse received by the
ignition coil module on the IC circuit triggers the coil
module in order to operate the ignition coil. The
secondary ignition voltage is induced, and then the
secondary ignition voltage is sent to the distributor
for distribution to each spark plug.
The IC signal voltage ranges from about 0.5 volt to
4.5 volts.
• EST enabled
• Engine speed is less than 250 RPM.
• EST voltage is greater than 4.9 v
Action Taken When The DTC Sets
• The VCM turns the MIL ON when this DTC is
reported and one failure has occured.
• The VCM records the operating conditions at
the time the Diagnostic Fails. Freeze Frame
and Failure Records store this information.
6-3006 Engine Controls - 7.4L
Conditions for Clearing the MILJDTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160'F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
A poor connection, a rubbed through wire in the
insulation, or a wire broken inside the insulation will
cause an intermittent.
Check for the following conditions:
• Poor connection
• Damaged harness: Inspect the VCM harness
connectors for the following conditions:
- Backed out terminals GRY 9 and BLK 18
- Improper mating
Engine
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection and
- Damage to the harness.
• Intermittent test - If the connections and the
harness check OK, monitor a digital voltmeter
connected between VCM terminal GRY 9 and
BLK 18 while moving related connectors and
wiring harness. If the failure is induced, the
voltage reading will change. This may help to
isolate the location of the malfunction.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. This determines if the DTC is an intermittent.
3. This check determines if the IC signal from the
VCM is available at the ignition coil driver.
4. The remaining tests begin to check that the coil
driver circuitry is OK.

DTC P1351 IC Circuit High Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose Go to Powertrain
1 the data. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Clear the DTCs.
2. Disconnect the injector connector.
2 —
3. Crank the engine for 30 seconds. Go to
Does DTC P1351 set? Go to Step 3 Diagnostic Aids
1. Turn OFF the ignition.
2. Reconnect the injector connector.
3. Disconnect the ignition coil module connector.
4. Probe the ignition coil module connector terminal B
3 with a voltmeter to ground. 1-4V
5. With the voltmeter on the AC scale, crank the
engine.
6. Monitor the voltage reading.
Is the voltage reading within the specified value? Go to Step 9 Go to Step 4
1. Turn OFF the ignition.
2. Disconnect the VCM gray harness connector.
4 3. Check the resistance between the VCM Ignition 10 O
Control and the ignition coil module connector
terminal B.
Is the resistance less than the specified value? Go to Step 6 Go to Step 5
Engine________________________________________________ Engine Controls - 7.4L 6-3007
DTC P1351 1C Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
Repair the open IC circuit between the VCM and the
ignition coil module. Refer to Wiring Repairs in Engine
5 Electrical. — —

Is the action complete? Go to Step 16

Check for a faulty VCM connection.
6 —
Was a problem found? Go to Step 7 Go to Step 8
Repair the faulty VCM connection. Refer to Wiring Repairs
7 in Engine Electrical. — —
Is the action complete? Go to Step 16
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
8 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 16
1. Turn OFF the ignition.
2. Connect a test lamp to B+.
9 3. Probe the ignition coil module harness connector —
terminal C.
Is the test lamp on? Go to Step 11 Go to Step 10
Repair the open ignition coil module ground circuit. Refer
10 to Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 16
1. Turn ON the ignition.
2. Connect a test lamp to a ground.
11 3. Probe the ignition coil module harness connector —
terminals D and A.
Is the test lamp on both terminals? Go to Step 13 Go to Step 12
Repair the faulty ignition coil module feed circuit. Refer to
12 Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 16
Check for a faulty ignition coil module connection.
13 —
Was a problem found? Go to Step 15 Go to Step 14
Replace the ignition coil module. Refer to Ignition Coil
14 Driver Module. — —
Is the action complete? Go to Step 16
Repair the ignition coil module connection. Refer to Wiring
15 Repairs in Engine Electrical. — —
Is the action complete? Go to Step 16
6-3008 Engine Controls - 7.4L Engine
DTC P1351 IC Circuit High Voltage (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
16 —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 17 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
17 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
Engine_________________________ Engine Controls - 7.4L 6-3009

DTC P1361 IC Circuit Low Voltage

iHoHnMRwT^AndSlart]
Power Underhood
Distribution
ECM 1 i Fuse-Relay
1 C e ll 10
I Fuse i Center Instrument1-
I 1 20 A
i Cluster1 T a c h o m e te r
^ I Input
■joamiL
PNK 439 L ” e“
F u s e B lock
D etails
WHT 121 VCM

C e ll 11 C l = BLU
C 2 -R E D
PNK 439 C 3 > CLEAR
C 4 -B L K

PNK 439
F u s e B lock
D etails WHT 121
C ell 11

PNK 439 PNK 439

WHT/BLK 1847
Crankshaft Ignition Ignition T a c h o m e te r
Position Control Positive S ig n al
V o lta g e
(CKP) Module Ignition
Sensor (1CM) Tim ing
S ignal G ro u n d Ignition
Coil
B C'

BLK/WHT 451
WHT 423
Coil Wire
9. ,C3
Distributor
ic , Vehicle
C ontrol | Control

I Module A '
J(VCM)

G ro u n d
BLK/WHT 451 r n
D istribution
C e ll 14 Spark Plugs

33671
Circuit Description Conditions for Setting the DTC
The enhanced ignition system uses the crank sensor • EST enabled
in order to provide the timing input to the VCM. The • Engine speed is less than 250 rpm
VCM uses this reference pulse in order to determine
• EST voltage is less than .04 v
the individual ignition spark timing for each cylinder.
Once the VCM calculates the ignition timing, the Action Taken When The DTC Sets
ignition coil module on the IC circuit receives the • The VCM turns the MIL ON when this DTC is
timing signal. Each timing pulse received by the reported and one failure has occured.
ignition coil module on the IC circuit triggers the coil
module in order to operate the ignition coil. The • The VCM records the operating conditions at
secondary ignition voltage is induced, and then the the time the Diagnostic Fails. Freeze Frame
secondary ignition voltage is sent to the distributor and Failure Records store this information.
for distribution to each spark plug.
The IC signal voltage ranges from about 0.5 volt to
4.5 volts.
6-3010 Engine Controls - 7.4L
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ' C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160’ F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
A poor connection, a rubbed through wire in the
insulation, or a wire broken inside the insulation will
cause an intermittent.
Check for the following conditions:
• Poor connection
• Damaged harness: Inspect the VCM harness
connectors for the following conditions:
- Backed out terminals GRY 9 and BLK 18
- Improper mating
Engine
- Broken locks
- Improperly formed or damaged terminals
- A poor terminal to wire connection and
- Damage to the harness.
• Intermittent test - If the connections and the
harness check OK, monitor a digital voltmeter
connected between VCM terminal GRY 9 and
BLK 18 while moving related connectors and
wiring harness. If the failure is induced, the
voltage reading will change. This may help to
isolate the location of the malfunction.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. If the engine starts at this point, the DTC 1361
is an intermittent.
3. This check determines if the IC signal from the
VCM is available at the ignition coil module.
9. The remaining tests begins to check that the
ignition coil module circuitry is OK. If the
ignition coil module loses its voltage source, the
secondary voltage will not be produced, and a
DTC P1361 will set.

DTC P1361 IC Circuit Low Voltage

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the freeze frame and the failure records for
reference because the Clear Info function will lose
1 — Go to Powertrain
the data. OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Clear the DTCs.
2. Disconnect the injector connector.
2 —
3. Crank the engine for 15 seconds. Go to The
Does DTC P1361 set? Go to Step 3 Diagnostic Aids
1. Turn OFF the ignition.
2. Reconnect the injector connector.
3. Disconnect the ignition coil module connector.
4. With a voltmeter on an AC scale, probe the ignition
3 1-4V
coil module connector terminal B to a ground.
5. Crank engine.
6. Observe voltage.
Is voltage within the specified value? Go to Step 9 Go to Step 4
1. Turn OFF the ignition.
2. Disconnect the VCM gray harness connector.
4 3. Connect a test lamp B+.
—
4. Probe the VCM gray harness connector terminal for
the Ignition Control circuit.
Is the test lamp ON? Go to Step 5 Go to Step 6
Engine________________________________________________ Engine Controls - 7.4L 6-3011
DTC P1361 IC Circuit Low Voltage (cont’d)
Step Action Value(s) Yes No
Repair the short to voltage in the IC circuit. Refer to
5 Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 14
1. Connect a test lamp to a ground.
2. Probe the VCM harness terminal for the Ignition
6 —
Control circuit.
Is the test lamp on? Go to Step 7 Go to Step 8
Repair the short to voltage in the IC circuit. Refer to
7 Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
8 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Turn OFF the ignition.
2. Connect a test lamp to B+.
9 3. Probe the ignition coil module harness connector —
terminal C.
Is the test lamp on? Go to Step 11 Go to Step 12
Repair the open ignition coil module ground circuit. Refer
10 to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 14
Check for a faulty ignition coil module connection.
11 —
Was a problem found? Go to Step 13 Go to Step 12
Replace the ignition coil module. Refer to Ignition Coil
12 Driver Module. — —
Is the action complete? Go to Step 14
Repair the faulty ignition coil module connection. Refer to
13 Wiring Repairs in Engine Electrical. — —
Is the repair complete? Go to Step 14
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the Engine.
3. Idle at the normal operating temperature.
14 4. Select the DTC and the Specific.
—
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 15 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
15 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-3012 Engine Controls - 7.4L Engine

DTC P1380 EBCM DTC Rough Road Data Unstable

■■Vehicle
Serial Data 1Control
1 <ciass id 1Module (VCM)
11 C4 (BLK)

0.5 PPL 1807

S150O
0.5 PPL 1807
0.5 PPL 1807 g I ci
!s7riJData'I Electronic
B7: :C100 J(Class ii) I Brake Control
i
L. _ _ _ J 1
I Module A
0.5 PPL 1807 (EBCM) ia A
Data Link
2 Connector (DLC)

33013

Circuit Description Conditions for Clearing the MILVDTC

This diagnostic will determine if the ABS system is
capable of detecting a rough road situation.
Conditions for Setting the DTC
• Vehicle speed is at least 1 MPH.
• Engine speed is no more than 5800 RPM.
• Engine load is no more than 89.9%.
Action Taken When the DTC Sets
The Malfunction Indicator Lamp (MIL) will not be
illuminated. A history DTC P1380 will be stored.
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
(160* F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step isolates an open serial data circuit
from the EBCM system.
Engine________________________________________________ Engine Controls - 7.4L 6-3013
DTC P1380 EBCM DTC Rough Road Data Unstable
Step Action Value(s) Yes No
Important: Before clearing DTC(s) use the scan tool to
Go to
record Freeze Frame and Failure Records for reference,
the Powertrain
1 as data will be lost when the Clear Info function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Disconnect the VCM and EBCM.
2 2. Check the serial data circuit between the VCM and Go to
—
the EBCM for an open. Antilock Brake
Was a problem found? Go to Step 3 System (ABS)
Repair as necessary.
3 — —
Is the action complete? Go to Step 4
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
4 which was set. — —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 5
Using the scan tool, select Capture Info, Review Info. Go to
5 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
6-3014 Engine Controls - 7.4L Engine

DTC P1381 Misfire Detected No EBCM/VCM Serial Data

*■ Vehicle
i 1 Control >
Serial Data
i (Class II) 1 Module (VCM)
L
11TC4 (BLK)

0.5 PPL 1807

S150O-
0.5 PPL 1807
0.5 PPL 1807 g I ci
[seriaTDaia*! Electronic
B7: iCIOO !(Class ii) | Brake Control
l i Module A
0.5 PPL 1807 Ji(EBCM) ia A
Data Link
Connector (DLC)

Circuit Description
This diagnostic will detect a serial data malfunction
which could inhibit the transfer of ABS rough road
data to the VCM.
Conditions for Setting the DTC
• Misfire DTC is present and requesting MIL
• No Rough Road data
Action Taken When the DTC Sets
The Malfunction Indicator Lamp (MIL) will not be
illuminated. A history DTC P1381 will be stored.
33013
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22* C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
(160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step isolates an open serial data circuit
from the EBCM system.
Engine________________________________________________ Engine Controls - 7.4L 6-3015
DTC P1381 Misfire Detected No EBCM/VCM Serial Data
Step Action Value(s) Yes No
Important: Before clearing DTC(s) use the scan tool to
Go to
record Freeze Frame and Failure Records for reference,
the Powertrain
1 as data will be lost when the Clear Info function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Disconnect the VCM and EBCM.
2 2. Check the serial data circuit between the VCM and Go to
—
the EBCM for an open. Antilock Brake
Was a problem found? Go to Step 3 System (ABS)
Repair as necessary.
3 — —
Is the action complete? Go to Step 4
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature is reached.
3. Select DTC, Specific, then enter the DTC number
4 which was set. — —

4. Operate the vehicle within the conditions for setting

this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 5
Using the scan tool, select Capture Info, Review Info. Go to
5 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
6-3016 Engine Controls - 7.4L Engine

DTC P1404 EGR Valve Closed Pintle Position

MAPandFuel Tank
PressureSensors
T
VCM
GRY C1=BLU
C2-RED
474 C3=CLEAR
C4=BLK
^-VyV Exhaust Gas
Recirculation
(EGR) Valve
B'

BLK 470

<h —◄ Sensors

RED 1676 WHT 257 BLK 470

BRN 1456 GRY 474
16 A ..................... 20 C4 10 A
C2 19A. . 27 C3
EGR EGR EGR Sensor SVolt "* Vehicle
Valva Valve Pintle Ground ReferenceB Control
Feed Ground Position l Module ^
Control Signal I
j (V C M )itt^

Circuit Description
The VCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open.
The pressure in the intake manifold increases when
the EGR valve is open. The VCM monitors the
Manifold Absolute Pressure (MAP) sensor signal
during the EGR system diagnostic in order to
determine the amount of EGR flow. The VCM
calculates an error based on the difference between
the actual MAP increase and a predetermined value.
The VCM records the error and adjusts an internal
fail counter towards the fail threshold if the error is
too great. The VCM sets a DTC P0401 when the fail
counter exceeds the fail threshold. The number of
test samples required to exceed the fail threshold
varies according to the magnitude of the detected
flow errors.
The VCM allows only one EGR flow test sample to
be taken during an ignition cycle. Following a scan
tool Clear Info or a battery disconnect, the VCM
allows twelve test samples during the first ignition
cycle in order to aid in verifying a repair.
Conditions for Setting the DTC
• ECT is greater than 80 ' C and less than
120 °C
• IAT is less than 100 * C
• The Desired EGR Position is greater than
14 percent.
190380
Action Taken When the DTC Sets
• The Malfunction Indicator Lamp (MIL) will
illuminate.
• The PCM will record operating conditions at the
time the diagnostic fails. The Freeze Frame and
Failure Records buffers will store this
information.
• A history DTC is stored
• The EGR Valve is disabled.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 2 2 ‘ C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160' F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
Due to the moisture that is associated with exhaust
systems, the EGR valve may freeze and stick in
colder weather at times. After the vehicle is brought
into a warm shop for repairs, the valve warms and
the problem disappears. By watching the Actual EGR
and the Desired EGR Positions on a cold vehicle
with a scan tool, you can easily verify the fault.
Check the freeze frame data in order to determine if
the DTC set when the vehicle was cold by viewing
the Engine Coolant Temperature (ECT).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Commanding the EGR valve open determines
whether the EGR system can control the EGR
valve accurately and if the malfunction is
present.
4. When the EGR valve electrical connector is
disconnected, the scan tool should display the
Actual EGR Position as 0%. If it does not, the
malfunction lies either in the EGR signal circuit
or the VCM.
Engine Controls - 7.4L 6-3017
6. If the EGR valve 5.0 volt reference is shorted to
voltage, the DMM will read battery voltage and
additional DTCs may be set.
11. A poor electrical connection may have caused
this DTC to set. Be sure to check the terminals
for being backed out, improperly formed,
damaged, and for poor tension.
15. The replacement VCM must be programmed
and the Crankshaft Position System Variation
Learn Procedure must be performed. Refer to
the latest Techline procedures for VCM
programming.
16. Clearing the DTCs is a very important step for
this diagnostic. The clearing function allows the
EGR valve to relearn a new minimum pintle
position as the old position was inaccurate due
to the malfunction that caused the DTC. If the
VCM sees an EGR command, the new
minimum pintle position will not be learned.
17. If no malfunctions have been found at this point
and no additional DTCs were set, refer to the
Diagnostic Aids for additional checks and
information.

DTC P1404 EGR Valve Closed Pintle Position

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear DTC
1 — Go to Powertrain
Information function is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn the ignition switch ON, with the engine OFF.
2. Install a scan tool.
2 20%, 50%,
3. Command the EGR valve to the specified values. 70%, 100%
Does the Actual EGR Position follow the Commanded
EGR Position? Go to Step 3 Go to Step 4
This DTC is intermittent. Go to applicable Go to
3 —
Are any additional DTCs stored? DTC table Diagnostic Aids
Disconnect the EGR valve electrical connector.
4 0%
Is the Actual EGR Position near the specified value? Go to Step 6 Go to Step 5
Check the EGR valve signal circuit for a short to voltage
5 and repair as necessary. —

Was a repair necessary? Go to Step 16 Go to Step 14

Connect a DMM to ground and probe the EGR valve 5.0
V reference circuit terminal at the EGR valve electrical
6 connector. 5.0 V
Is the voltage near the specified value? Go to Step 7 Go to Step 8
1. Connect the test light to ground.
7 2. Probe the EGR Valve Feed Control circuit terminal at
—
the EGR valve electrical connector.
Is the test light ON? Go to Step 9 Go to Step 10
6-3018 Engine Controls - 7.4L Engine
DTC P1404 EGR Valve Closed Pintle Position (cont’d)
Step Action Value(s) Yes No
Check the EGR Valve 5.0 V reference circuit for a short to
8 voltage and repair as necessary. —

Was a repair necessary? Go to Step 16 Go to Step 14

Check the EGR Valve Feed Control circuit for a short to
9 voltage and repair as necessary. —
Was a repair necessary? Go to Step 16 Go to Step 14
Connect a test light to B+ and probe the EGR Valve
10 Ground circuit terminal. —
Is the test light ON? Go to Step 11 Go to Step 12
Check the EGR Valve Ground circuit terminal for a poor
connection at the EGR Valve electrical connector and
11 repair as necessary. —
Was a repair necessary? Go to Step 16 Go to Step 13
Check the EGR Valve Ground circuit for an open and
12 repair as necessary. —
Was a repair necessary? Go to Step 16 Go to Step 14
Replace the EGR Valve. Refer to EGR Valve Replacement
13 (DR Utility) in Repair Instructions. — —
Is the action complete? Go to Step 16
Check the VCM electrical connector for a poor connection
14 and repair as necessary. —
Was a repair necessary? Go to Step 16 Go to Step 15
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
15 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 16
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
2. Start the engine.
3. Allow the engine to idle until the normal operating
temperature is reached.
16 4. Select the DTC and the Specific DTC functions. —
5. Enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic ran and
passed? Go to Step 17 Go to Step 2
Use the scan tool in order to display the Capture Info and
the Review Capture Info functions. Go to
16 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine Engine Controls - 7.4L 6-3019

DTC P1415 AIR System Bankl

Refer to Secondary Air Injection Controls . No MAF DTCs
• Power enrichment not active
Circuit Description
• Decel Fuel Cutoff not active
Fused ignition voltage is supplied to the AIR relay.
The VCM controls the AIR pump by grounding the • Air/Fuel ratio is equal to14.7:1
AIR relay control circuit. This energizes the relay and • Engine speed is greater than or equal to
supplies voltage to the AIR pump clutch. When the 550 rpm
fuel system goes to the Closed Loop mode, the • Closed Loop for a period of greater than
VCM opens the ground to the AIR control circuit. 15 seconds
Conditions for Setting the DTC • Engine load is less than 50%
AIR Passive test Enable • MAF is less than or equal to 100 g/sec
• System voltage is greater than 10 volts
• No ECT sensor DTCs
• ECT is greater than or equal to 75 * C but is
• No IAC sensor DTCs
less than 105*C
• No H02S sensor DTCs
• IAT greater than 0 * C
• No Misfire DTCs
• Integrator is greater than 0.95 but is less than
. No MAP DTCs. 1.0 for 3 seconds
• No Fuel Trim DTCs • AIR Pump is ON
. No EVAP DTCs • 02S voltage is less than 299Mv
. No TP DTCs • Integrator change is less than .06
. No IAT DTCs
. No MAF DTCs Action Taken When the DTC Sets
• System voltage is greater than 10 volts for a The VCM will turn ON the Malfunction Indicator
period greater than 3 seconds Lamp (MIL) after two consecutive test cycles with the
fault active.
• IAT is greater than 0 ‘ C
• Engine run time is greater than 3 seconds Conditions for Clearing the MIL7DTC
AIR Passive Test 1 • The VCM turns the MIL OFF after
• AIR Passive Test Enable conditions met 3 consecutive drive trips when the test
• AIR Pump is ON has Run and Passed and not Failed.
• A/F Ratio is greater than 12:1 • A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
• Startup ECT is less than 56.25 * C (coolant temperature has risen 22 *C (40* F)
• Hot/Cold Rich time ratio is greater than .39 from the startup coolant temperature and the
• Hot/Cold Lean time ratio is less than .60 engine coolant temperature exceeds
AIR Passive Test 2 70 *C (160*F) during the same ignition cycle).
• AIR Passive Test 1 has not run or failed • Use the scan tool Clear Information function.
• AIR Pump is ON • Disconnect the VCM battery feed for
30 seconds.
• 02S Bank 1 Sensor 1 is greater than 451 mV
longer than 5 seconds Diagnostic Aids
AIR Active Test Enable An intermittent may be caused by a poor connection,
• AIR passive tests 1 and 2 failed rubbed through wire insulation, or a broken wire
• No ECT sensor DTCs inside the insulation.
• No IAC sensor DTCs Check for the following conditions:
• No H02S sensor DTCs • Poor connection or damaged harness - Inspect
• No Misfire DTCs the harness connectors for backed out
terminals, improper mating, broken locks,
. No MAP DTCs.
improperly formed or damaged terminals, poor
• No Fuel Trim DTCs terminal to wire connection, and damaged
• No EVAP DTCs harness.
. No TP DTCs • Worn or loose AIR pump drive belt
. No IAT DTCs • Pinched, kinked, or restricted AIR pipes, hoses,
or fittings
6-3020 Engine Controls - 7.4L Engine

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if there is change in the
Bank 1 Short Term Fuel Trim more than 6%
when the AIR pump is ON.
4. This step determines if the AIR valve is
functioning properly.

DTC P1415 AIR System Bankl

Step Action Value(s) Yes No
Important: Before clearing DTC(s) use the scan tool to Go to
record Freeze Frame and Failure Records for reference, the Powertrain
1 as data will be lost when the Clear Info function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install a scan tool.
2. Start and run the engine for greater than the
specified value.
2 min.
2 3. Verify the engine is at normal operating temperature.
6%
4. Using a scan tool, command the AIR ON.
Does the Short Term Fuel Trim Bank 1 indicate a change
of more than the specified value? 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 are stored, Go to
3 refer to those Table(s). —
the Applicable
Are any additional DTCs stored? DTC Table Go to Step 8
1. Disconnect the Bank 1 AIR crossover hose from the
AIR valve.
4 —
2. Using a scan tool, command the AIR ON.
Does air flow from the AIR valve? Go to Step 5 Go to Step 7
Check for restrictions or leaks in the Bank 1 AIR pipe,
5 hoses and fittings. —
Was a problem found? Go to Step 6 Go to Step 2
Repair as necessary.
6 — —
Is the action complete? Go to Step 7
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
7 which was set. —

4. Operate the vehicle within the conditions for setting

this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 8 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
8 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
Engine Engine Controls - 7.4L 6-3021

DTC P1416 AIR System Bank2

Refer to Secondary Air Injection Controls. . No MAF DTCs
• Power enrichment not active
C ircuit Description
• Decel Fuel Cutoff not active
Fused ignition voltage is supplied to the AIR relay.
The VCM controls the AIR pump by grounding the • Air/Fuel ratio equal 14.7:1
AIR relay control circuit. This energizes the relay and • Engine speed is greater than or equal to
supplies voltage to the AIR pump clutch. When the 550 rpm
fuel system goes to the Closed Loop mode, the • Closed Loop for a period of greater than
VCM opens the ground to the AIR control circuit. 15 seconds
Conditions fo r S etting the DTC • Engine load is less than 50%
AIR Passive test Enable • MAF is less than or equal to 100 g/sec

• No ECT sensor DTCs • System voltage is greater than 10 volts

. No IAC sensor DTCs • ECT is greater than or equal to 7 5 ' C but is
less than 105*C
• No H02S sensor DTCs
• IAT greater than 0 * C
• No Misfire DTCs
• Integrator is greater than 0.95 but is less than
• No MAP DTCs. 1.0 for 3 seconds
• No Fuel Trim DTCs • AIR Pump is ON
. No EVAP DTCs • 02S voltage is less than 299Mv
• No TP DTCs • Integrator change is less than .06
. No IAT DTCs
• No MAF DTCs Action Taken When the DTC Sets
• System voltage is greater than 10 volts for a The VCM will turn ON the Malfunction Indicator
period greater than 3 seconds Lamp (MIL) after two consecutive test cycles with the
fault active.
• IAT is greater than O'C
• Engine run time is greater than 3 seconds Conditions for Clearing the MIL/DTC
AIR Passive Test 1 • The VCM turns the MIL OFF after
• AIR Passive Test Enable passed 3 consecutive drive trips when the test
• AIR Pump is ON has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
• A/F Ratio is greater than 12:1
have been detected for 40 warm-up cycles
• Startup ECT is less than 56.25 * C (coolant temperature has risen 22 * C (40 * F)
• Hot/Cold Rich time ratio is greater than .39 from the startup coolant temperature and the
• Hot/Cold Lean time ratio is less than .60 engine coolant temperature exceeds
AIR Passive Test 2 7 0 *C (160*F) during the same ignition cycle).
• AIR Passive Test 1 has not run or failed • Use the scan tool Clear Information function.
• AIR Pump is ON • Disconnect the VCM battery feed for
30 seconds.
• 02S Bank 1 Sensor 1 is greater than 451 mV
longer than 5 seconds Diagnostic Aids
AIR Active Test Enable An intermittent may be caused by a poor connection,
• AIR passive tests 1 and 2 failed rubbed through wire insulation, or a broken wire
• No ECT sensor DTCs inside the insulation.
• No IAC sensor DTCs Check for the following conditions:
• No H02S sensor DTCs • Poor connection or damaged harness - Inspect
• No Misfire DTCs the harness connectors for backed out
terminals, improper mating, broken locks,
. No MAP DTCs.
improperly formed or damaged terminals, poor
• No Fuel Trim DTCs terminal to wire connection, and damaged
. No EVAP DTCs harness.
. No TP DTCs • Worn or loose AIR pump drive belt
. No IAT DTCs • Pinched, kinked, or restricted AIR pipes, hoses,
or fittings
6-3022 Engine Controls - 7.4L Engine

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This step determines if there is change in the
Bank 2 Short Term Fuel Trim more than 6%
when the AIR pump is ON.
4. This step determines if the AIR valve is
functioning properly.

DTC P1416 AIR System Bank2

Step Action Value(s) Yes No
Important: Before clearing DTC(s) use the scan tool to Go to
record Freeze Frame and Failure Records for reference, the Powertrain
1 as data will be lost when the Clear Info function is used. — OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Install a scan tool.
2. Start and run the engine for greater than the
specified value.
2 min.
2 3. Verify the engine is at normal operating temperature.
6%
4. Using a scan tool, command the AIR ON.
Does the Short Term Fuel Trim Bank 2 indicate a change
of more than the specified value? 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 are stored, Go to
3 refer to those Table(s). —
the Applicable
Are any additional DTCs stored? DTC Table Go to Step 8
1. Disconnect the Bank 2 AIR crossover hose from the
AIR valve.
4 —
2. Using a scan tool, command the AIR ON.
Does air flow from the AIR valve? Go to Step 5 Go to Step 7
Check for restrictions or leaks in the Bank 2 AIR pipe,
5 hoses and fittings. —
Was a problem found? Go to Step 6 Go to Step 2
Repair as necessary.
6 — —
Is the action complete? Go to Step 7
1. Using the scan tool, select DTC, Clear Info.
2. Start the engine and idle until normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
7 which was set. —
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the scan tool indicate that this diagnostic Ran and
Passed? Go to Step 8 Go to Step 2
Using the scan tool, select Capture Info, Review Info. Go to
8 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
Engine Engine Controls - 7.4L 6-3023
DTC P1441 EVAP System Flow During Non-Purge
I Hot hi Run And Start!
r Underhood
Power
I Distribution ENG1 ] Fuse-Relay
Cell 10 Fuse15 i Center
I 20A
i
L

PNK 539 VCM

Cl =BLU
C2-RED
C3- CLEAR
FuseBlock C4-BLK
Details
CeM1l PNK 539
PNK 539

BA
r “ i Evaporative Evaporative
CMP and MAF Sensors, • I Emissions (EVAP) Emission
EGR Valve I I Canister (EVAP)
J Vent Canister
Purge
Valve
WHT 1310 DKGRN/ 428
WHT
C2 C3
Vent EVAP
Control Canister
Purge
Valve
Driver

190385
Circuit Description The system checks for conditions that cause the
The evaporative system includes the following EVAP system to purge continuously by commanding
components: the EVAP vent solenoid ON and the EVAP purge
solenoid OFF (EVAP vent solenoid CLOSED, EVAP
• The fuel tank purge PWM 0%). If the fuel tank pressure level
• The EVAP vent solenoid increases during the test, a continuous purge flow
• The fuel tank pressure sensor condition is indicated. The following items can cause
• The fuel pipes and hoses this condition:
• The vapor lines • A leaking EVAP purge solenoid
• The fuel cap • A grounded EVAP purge solenoid driver circuit
If any of these conditions are present, a
• The evaporative emission canister
DTC P1441 sets.
• The purge lines
• The EVAP purge solenoid Conditions for Setting the DTC
The EVAP purge solenoid valve allows the manifold The following conditions will set the DTC:
vacuum to purge the canister. The Vehicle Control • No MAP sensor DTCs
Module (VCM) supplies a ground in order to
• No TP sensor DTCs
energize the solenoid valve (purge ON). The EVAP
purge solenoid control by the VCM is Pulse Width . No VSS DTCs
Modulated (PWM) or turned ON and OFF several . No H02S DTCs
times a second. The duty cycle (pulse width) is . No ECT DTCs
determined by the engine operating conditions
• No IAT sensor DTCs
including the load, the throttle position, the coolant
temperature, and the ambient temperature. The duty • Fuel level is greater than 12.5 % and is less
cycle is calculated by the VCM, and the purge than 87.5 %
solenoid is commanded ON when certain conditions • System voltage is greater than 10 v and is less
have been met. than 17 v
6-3024 Engine Controls - 7.4L
• Throttle position is greater than 0% but is less
than 99%
• Purge solenoid is OFF (Closed)
• Engine vacuum is greater than or equal to
10 KPa
• Fuel tank vacuum is greater than or equal to
12 inH20 for 2 seconds within less than or
equal to 37.5 seconds after 30 second delay
Cold Start Test
• The Baro is greater than 75 kPa.
• ECT is greater than 3.75 * C and is less
than 30 *C
• IAT is greater than 3.75 * C and is less
than 30 *C
• IAT start up is 1.5 * C is greater than ECT
• ECT start up is 8.25 ’ C is greater than IAT
• Fuel Level input is true
• Fuel Level present test is true
Excess Vacuum Test
• Vent Valve commanded OFF
• Fuel tank vacuum is less than 7 inH20
Weak Vacuum Test
• Throttle position is less than 75 %
Action Taken When the DTC Sets
The VCM will turn ON the MIL after 2 consecutive
driving cycles with the fault active.
Conditions for Clearing the MIL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
Engine
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40* F)
from the startup coolant temperature and the
engine coolant temperature exceeds
70 *C (160*F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
A poor connection, rubbed through wire insulation, or
a wire that is broken inside the insulation may cause
an intermittent.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for the following conditions:
• Backed out terminals
• Improper mating
• Broken locks
• Improperly formed or damaged terminals
• Poor terminal to wiring connections or
• Physical damage to the wiring harness.
Refer to Intermittent Condition.
Test Description
The numbers below refer to the step numbers on the
diagnostic table:
2. Determines if the EVAP Purge Solenoid is
leaking.
3. Determines if the EVAP canister Purge Valve
Driver circuit is shorted to ground.
4. Determines if the EVAP canister Purge Valve
Driver circuit wiring or VCM is at fault.

DTC P1441 EVAP System Flow During Non-Purge

Step Action Value(s) Yes No
Important: Before clearing DTCs, use the scan tool in
order to record the Freeze Frame and the Failure Records
for reference because the Clear Info function will lose
1 the data. —
Go to
Was the Powertrain On-Board Diagnostic (OBD) System Powertrain OBD
Check performed? Go to Step 2 System Check
Important: Before continuing with diagnosis, zero the
EVAP pressure and vacuum gauges on the Enhanced
EVAP Pressure Purge Diagnostic Cart J 41413. Refer to
tool operating instructions.
1. Connect the Enhanced EVAP Pressure Purge
2 Diagnostic Cart J 41413 to the EVAP service port. -15 inH20
2. Turn the rotary switch on cart to PURGE.
3. Start the engine.
4. Monitor vacuum with the gauge on the cart.
Is vacuum more than the specified value and holding Refer to
steady? Go to Step 3 Diagnostic Aids
Engine________________________________________________ Engine Controls - 7.4L 6-3025
DTC P1441 EVAP System Flow During Non-Purge (cont’d)
Step Action Value(s) Yes No
1. Turn OFF the ignition.
2. Disconnect the EVAP Purge Solenoid electrical
connector.
3 3. Turn ON the ignition, with the engine OFF. —
4. Connect a test lamp to B+ and probe terminal B of
the EVAP Purge Solenoid connector.
Is the test lamp ON? Go to Step 4 Go to Step 6
1. Turn OFF the ignition.
2. Disconnect the VCM Gray connector.

4
3. Turn ON the ignition, with the engine OFF. —
4. Connect test light to B+ and probe terminal B of the
EVAP Purge Solenoid connector.
Is the test lamp ON? Go to Step 5 Go to Step 7
Repair the short to ground in the EVAP Canister Purge
Valve Driver circuit. Refer to Wiring Repairs in Electrical
5 Diagnosis. — —
Is action complete? Go to Step 8
Replace the EVAP canister purge solenoid. Refer EVAP
Canister Purge Solenoid Valve Replacement in Repair
6 Instructions. — —
Is the action complete? Go to Step 8
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
7 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Learn Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 8
1. Use the scan tool in order to select the DTC and the
Clear DTC Information functions.
8 — —
2. Perform the Service Bay Test for EVAP.
Is action complete? Go to Step 9
Does the scan tool display any DTCs in the Freeze Frame Go to applicable
9 —
and Failure Records? DTC table System OK
6-3026 Engine Controls - 7.4L Engine

DTC P1508 IAC System Low RPM

Idle Air
Stepper
Motor Control (IAC)
Coil Coil Valve
B 0 A

B C D
LT LT VCM
GRN/WHT 1749 BLU/BLK 1748 Cl =BLU
C2 RED
C3=CLEAR
LT LT C4=BLK
GRN/BLK 444 BLU/WHT 1747

_______ . .J4JLC2
IAC IAC IAC IAC Vehicle
Coil B Coil B Coil A Coil A Control
High Low Low High Module A
(VCM)
33140
Circuit Description • IAT is greater than -25' C
The VCM controls the idle speed with an Idle Air • Engine run time is greater than 30 seconds.
Control (IAC) valve to a calculated desired RPM • BARO is greater than 75 kPa
based on the sensor inputs and the actual engine • TP is less than 1%
RPM. The VCM uses 4 circuits to move an Idle Air
Control (IAC) valve, allowing varying amounts of air • Vehicle Speed is less than 2 mph
flow into the intake manifold. In order to increase the • Above met for a time greater than 3 seconds to
idle RPM, the VCM moves the IAC valve out, enable diagnostics
allowing more air to bypass the throttle plate. In • If non- intrusive test fails, intrusive test is run
order to decrease the RPM, the VCM will move the Intrusive Test
IAC valve in, reducing the amount of air bypassing
the throttle plate. A scan tool reads the VCM • Calculated Air Flow is greater than 17.5 grams
commands to the IAC valve in counts. The higher per second but less than 50 grams per second
the counts, the more air that is allowed to bypass • Vehicle Speed is between 25 MPH and 85 MPH
the throttle plate (higher idle). The lower the counts, • Change in TP Sensor is less than 1%
the less air that is allowed to bypass the throttle • Change in engine speed is less than 50 RPM
plates (lower idle).
• IAC motor commanded to 10% for 100 msec
Conditions For Setting DTC
Action Taken When the DTC Sets
Non - intrusive Test
The VCM will turn ON the MIL after 2 consecutive
• No TP sensor DTCs set driving cycles with the fault active.
• No ECT DTCs set
. No VSS DTCs set Conditions for Clearing the MIL/DTC
• No MAP DTCs set • The VCM turns the MIL OFF after
3 consecutive drive trips when the test
• No Transmission DTCs
has Run and Passed and not Failed.
. No PRNDL DTCs
• A history DTC will clear if no fault conditions
• No misfire DTCs have been detected for 40 warm-up cycles
. No IAT DTCs (coolant temperature has risen 22 X (40 *F)
. No MAF DTCs from the startup coolant temperature and the
engine coolant temperature exceeds
• ECT is greater than 50 * C
7 0 'C (160*F) during the same ignition cycle).
• System voltage is between 10 volts and
• Use the scan tool Clear Information function.
16 volts
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
An IAC valve which is stopped and cannot respond
to the VCM, a throttle stop screw which has been
tampered with, or a damaged throttle or linkage
could cause this DTC. A slow, unstable, or fast idle
may be caused by a non - IAC valve system
problem that cannot be overcome by the IAC valve.
Out of range control IAC scan tool counts will be
above 60 if idle is too low and zero if idle is too
high. Check for the following conditions:
• Fuel system too lean and rich.
• Throttle body - inspect bore for foreign material.
• Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• IAC reset is done with scan tool misc
functions mode.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The IAC tester is used to extend and retract
the IAC valve. The valve movement is verified
by an engine speed change. If no change in
engine speed occurs, the valve can be retested
when removed from the throttle body.
Engine Controls - 7.4L 6-3027
3. This step checks the quality of the IAC
movement in Step 2. Between 700 RPM and
about 1200 RPM, the engine speed should
change smoothly with each flash of the tester
lamp in both extend and retract. If the IAC
valve is retracted beyond the control range
(about 1500 RPM), it may take many flashes in
the extend position before engine speed will
begin to drop. This is normal on certain
engines, fully extending IAC may cause engine
stall. This may be normal.
5. Steps 2 and 3 verified proper IAC valve
operation while this step checks the IAC
circuits. Each lamp on the node lamp should
flash red and green while the IAC valve is
cycled. While the sequence of color is not
important if either lamp is OFF or does not
flash red and green, check the circuits for faults
beginning with poor terminal contacts

DTC P1508 IAC System Low RPM

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and the failure records for
reference because the data will be lost when the Clear
1 Go to Powertrain
Info function is used. —

OBD System
Was the Powertrain On Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn off the ignition.
2. Connect the IAC Driver to the IAC valve.
3. Set the parking brake and block the wheels. Leave
the A/C OFF.
2 4. Idle engine in park (A/T) or neutral (M/T).
—
5. Install the scan tool and display RPM.
6. With the IAC Driver, extend and retract the
IAC valve.
Did the Engine RPM decrease and increase as the IAC is
cycled? Go to Step 3 Go to Step 4
Observe the RPM, it should change smoothly with each
3 flash of the IAC Driver lamp. 700-1500 RPM
Does RPM change smoothly within the specified value? Go to Step 5 Go to Step 4
Check the IAC passages. If OK, replace the IAC.
Important: if a repair has been made refer to the IAC
4 Reset Procedure — —
before resetting.
Is the action complete? Go to Step 12
6-3028 Engine Controls ■ 7.4L Engine
DTC P1508 IAC System Low RPM (cont’d)
Step Action Value(s) Yes No
1. Install the appropriate IAC Node Lamp J 37027-A in
the control module harness.
2. Cycle the IAC Driver and note the lamps.
5 —
3. Both lamps should cycle Green and Red but never
off as the RPM is changed over its range.
Do both Green and Red lamps flash on and off? Go to Step 8 Go to Step 6
If circuits did not test green and red check for the
following:
• Faulty connector terminal contacts.
6 • Open circuits including connections. —
• Circuits shorted to ground or voltage.
• Faulty Control Module connection.
Was a problem found? Go to Step 7 Go to Step 11
Repair the connections and terminal contacts as
7 necessary. Refer to Wiring Repairs in Engine Electrical. — _ _

Is the action complete? Go to Step 12

1. Using the other connector on the IAC Driver Pigtail,
check the resistance across the IAC Coils.
2. Monitor the resistance between the IAC terminals A
8 and B. 40-80 Q.
3. Monitor the resistance between the IAC terminals C
and D.
Is the resistance within the specified value? Go to Step 9 Go to Step 10
1. Check the resistance between the IAC terminals B
and C.
9 2. Check the resistance between the IAC terminals A oo
and D. Go to The
Is the resistance at the specified value? Diagnostic Aids Go to Step 10
Replace the IAC valve. If a repair has been made refer to
10 IAC Reset Procedure before resetting. — —
Is the action complete? Go to Step 12
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
11 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 12
Engine________________________________________________ Engine Controls - 7.4L 6-3029
DTC P1508 IAC System Low RPM (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start engine.
3. Idle at normal operating temperature.
4. Select DTC and the Specific.
12 —
5. Then enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
13 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-3030 Engine Controls - 7.4L Engine

DTC P1509 IAC System High RPM

Stepper Idle Air

Motor Control (IAC)
Coil Coil Valve
B 0 A

V
B D
LT LT VCM
GRN/WHT 1749 BLU/BLK 1748 Cl =BLU
C2-RED
C3-CLEAR
LT LT C4»BLK
GRN/BLK 444 BLU/WHT 1747

I o
...? ? J L . „ .

!£
i;
IAC IAC IAC IAC Vehicle
Coil B Coil B Coil A Coil A Control
High Low Low High Module A
(VCM)

Circuit Description
The VCM controls the idle speed with an Idle Air
Control (IAC) valve to a calculated desired RPM
based on the sensor inputs and the actual engine
RPM. The VCM uses 4 circuits to move an Idle Air
Control (IAC) valve, allowing varying amounts of air
flow into the intake manifold. In order to increase the
idle RPM, the VCM moves the IAC valve out,
allowing more air to bypass the throttle plate. In
order to decrease the RPM, the VCM will move the
IAC valve in, reducing the amount of air bypassing
the throttle plate. A scan tool reads the VCM
commands to the IAC valve in counts. The higher
the counts, the more air that is allowed to bypass
the throttle plate (higher idle). The lower the counts,
the less air that is allowed to bypass the throttle
plates (lower idle).
Conditions For Setting DTC
Non - intrusive Test
• No TP sensor DTCs set
• No ECT DTCs set
. No VSS DTCs set
• No MAP DTCs set
• No Transmission DTCs
. No PRNDL DTCs
• No misfire DTCs
. No IAT DTCs
. No MAF DTCs
• ECT is greater than 50 *C
• System voltage is between 10 volts and
16 volts
33140
• IAT is greater than -25 * C
• Engine run time is greater than 30 seconds.
• BARO is greater than 75 kPa
• TP is less than 1%
• Vehicle Speed is less than 2 mph
• Above met for a time greater than 3 seconds to
enable diagnostics
• If non- intrusive test fails, intrusive test is run
Intrusive Test
• Calculated Air Flow is greater than 17.5 grams
per second but less than 50 grams per second
• Vehicle Speed is between 25 MPH and 85 MPH
• Change in TP Sensor is less than 1%
• Change in engine speed is less than 50 RPM
• IAC motor commanded to 10% for 100 msec
Action Taken When the DTC Sets
The VCM will turn ON the MIL after 2 consecutive
driving cycles with the fault active.
Conditions for Clearing the MiL/DTC
• The VCM turns the MIL OFF after
3 consecutive drive trips when the test
has Run and Passed and not Failed.
• A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 ‘ C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds
7 0 ‘ C (160'F) during the same ignition cycle).
• Use the scan tool Clear Information function.
• Disconnect the VCM battery feed for
30 seconds.
Engine
Diagnostic Aids
An IAC valve which is stopped and cannot respond
to the VCM, a throttle stop screw which has been
tampered with, or a damaged throttle or linkage
could cause this DTC. A slow, unstable, or fast idle
may be caused by a non - IAC valve system
problem that cannot be overcome by the IAC valve.
Out of range control IAC scan tool counts will be
above 60 if idle is too low and zero if idle is too
high. Check for the following conditions:
• Fuel system too lean and rich.
• Throttle body - inspect bore for foreign material.
• Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• IAC reset is done with scan tool misc
functions mode.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The IAC tester is used to extend and retract
the IAC valve. Valve movement is verified by
an engine speed change. If no change in
engine speed occurs, the valve can be retested
when removed from the throttle body.
Engine Controls - 7.4L 6-3031
3. This step checks the quality of the IAC
movement in Step 2. Between 700 RPM and
about 1200 RPM, the engine speed should
change smoothly with each flash of the tester
lamp in both extend and retract. If the IAC
valve is retracted beyond the control range
(about 1500 RPM), it may take many flashes in
the extend position before engine speed will
begin to drop. This is normal on certain
engines, fully extending IAC may cause engine
stall. This may be normal.
5. Steps 2 and 3 verified proper IAC valve
operation while this Step checks the IAC
circuits. Each lamp on the node lamp should
flash red and green while the IAC valve is
cycled. While the sequence of color is not
important if either lamp is OFF or does not
flash red and green, check the circuits for faults
beginning with poor terminal contacts.

DTC P1509 IAC System High RPM

Step Action Value(s) Yes No
Important: Before clearing DTCs use the scan tool to
record the freeze frame and the failure records for
reference because the data will be lost when the Clear Go to Powertrain
1 Info function is used. —
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
1. Turn off the ignition.
2. Connect the IAC Driver to the IAC valve.
3. Set the parking brake. Block the wheels. Leave the
A/C OFF.
4. Idle the engine in park (A/T) or neutral (M/T).
2 5. Install the scan tool. —
6. Display the RPM.
7. With the IAC Driver, extend and retract the
IAC valve.
Did the Engine RPM decrease and increase as the IAC is
cycled? Go to step 3 Go to Step 4
Observe the RPM. The RPM should change smoothly with
each flash of the IAC Driver lamp.
3 700-1500 RPM
Does the RPM change smoothly within the
specified value? Go to Step 5 Go to Step 4
Check the IAC passages. If OK, replace the IAC.
Important: If a repair has been made refer to IAC Reset
4 — —
Procedure before resetting.
Is the action complete? Go to Step 12
6-3032 Engine Controls - 7.4L________________________________________________ Engine
DTC P1509 IAC System High RPM (cont’d)
Step Action Value(s) Yes No
1. Install the appropriate IAC Node Lamp J 37027-A in
the control module harness.
2. Cycle the IAC Driver and note lamps.
5 —
3. Both lamps should cycle Green and Red but never
off as the RPM is changed over its range.
Do both Green and Red lamps flash on and off? Go to Step 8 Go to Step 6
Check for the following conditions:
• Faulty connector terminal contacts.
• Open circuits including connections.
6 —
• Circuits shorted to ground or voltage.
• Faulty Control Module connection.
Was a problem found? Go to Step 7 Go to Step 11
Repair the connections and terminal contacts as
7 necessary. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 12
1. Using the other connector on the IAC Driver Pigtail,
check the resistance across the IAC Coils.
2. Monitor the resistance between the IAC terminals A
8 and B. —

3. Monitor the resistance Between the IAC terminals C

and D.
Is the resistance within the specified value? Go to Step 9 Go to Step 10
1. Check the resistance between the IAC terminals B
and C.
9 2. Check the resistance between the IAC terminals A —
and D. Go to
Is the resistance at the specified value? Diagnostic Aids Go to Step 10
Replace the IAC valve. Refer to IAC Valve Replacement.
Important: If a repair has been made refer to IAC Reset
10 — —
Procedure before resetting.
Is the action complete? Go to Step 12
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
11 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 12
Engine________________________________________________ Engine Controls - 7.4L 6-3033
DTC P1509 IAC System High RPM (cont’d)
Step Action Value(s) Yes No
1. Using the scan tool, select the DTC and the
Clear Info.
2. Start the engine.
3. Idle at the normal operating temperature.
4. Select the DTC and the Specific.
12 —
5. Then enter the DTC number which was set.
6. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does scan tool indicate that this diagnostic ran and
passed? Go to Step 13 Go to Step 2
Using the scan tool, select the Capture Info and the Go to
13 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-3034 Engine Controls - 7.4L___________________
DTC P1626 Loss of Serial Communication with VTD
Circuit Description Module. If the fault is corrected and a valid
The Class II serial date circuit is used to
communicate between the VCM and the VTD
(Passlock)/EVO Control Module systems.
The VTD sends a Vehicle Security Password when
its ignition 1 input becomes active and includes its
source ID. The Vehicle Security Password includes
either a Fuel Continue or a Fuel Disable Password.
When the Passlock portion of the Vehicle Theft
Deterrent System (VTD) system has sensed the
proper operation of the ignition switch and lock
(switch and lock are not tampered with), the
Passlock system transmits a password to the VCM.
The VCM enables fuel delivery if this password
matches the password stored in the VCM’s memory.
However; if communication is lost or a VTD failure
occurs (during an ignition cycle that the VCM has
enabled fuel) the VCM will enter a fail-safe mode;
Fail Enable (VTD System Failure with Fuel Enabled).
The VCM remains in Fail Enable mode, for the
current and future ignition cycles, until the fault is
corrected and a valid pass word is received, or until
battery power is removed. If the battery power is
removed while the VCM is in the Fail Enable mode
(ignition ON or OFF) the VCM disables fuel delivery.
The vehicle will not start, or it will start then stall.
When the VCM receives an invalid password or no
password, before the Fuel Disable Decision Point,
the VCM disables fuel delivery. The Fuel Disable
Decision Point occurs at about 300 RPM during the
engine crank mode.
Conditions for Setting the DTC
• The VCM has established communications and
received the Vehicle Security Password during
the current ignition cycle from the VTD
(Passlock) Control Module.
• The VCM has not detected communications
and/or has not received Node Alive/SOH
messages from the VTD (Passlock) Control
Module for 5 seconds.
OR
• The VCM cannot establish communications with
the VTD (Passlock) Control Module and has not
received a valid password before the Fuel
Disable Decision Point.
Action Taken When the DTC Sets
When the failure occurs after the VCM enables fuel
due to the receipt of a Vehicle Security Password
containing the Fuel Continue Password:
• The vehicle starts.
• The VCM continues to enable fuel delivery
(Fuel Enabled after Security Fault mode), until
the fault is corrected and a valid password is
received from the VTD (Passlock) Control
Engine
password is received, fuel delivery is enabled.
The difference is that the Fail Enable Active bit
in the Vehicle Security Status message will now
be false while the Fuel Continue State bit will
be true.
• A DTC P1626 is stored in the VCM memory.
• The VCM will not illuminate the MIL.
When the failure occurs during ignition OFF, or
before the VCM receives a valid Passlock password
during engine cranking (about 300 RPM):
• The vehicle does not start; or it starts and
stalls.
• The VCM disables fuel delivery, until the fault is
corrected and a valid password is received from
the VTD (Passlock) Control Module.
• A DTC P1626 is stored in the VCM memory.
• The VCM will not illuminate the MIL.
Conditions for Clearing the MIL/DTC
1. The DTC P1626 requires an ignition cycle in
order to change from current to history.
2. The VCM receives a valid password from the
VTD (Passlock) Control Module.
3. A history DTC will clear after 40 consecutive
ignition cycles if the condition for the
malfunction is no longer present.
4. DTCs can be cleared by using a scan tool.
Diagnostic Aids
Important: Do not clear DTCs unless directed by a
diagnostic procedure. Clearing DTCs will also clear
valuable Freeze Frame and Failure Records data.
• Check for published service bulletins relating to
exhibited symptoms or component operation.
• Inspect all related wiring and connections
including the VCM and VTD (Passlock) Control
Module connections. These may cause an
intermittent malfunction
• Thoroughly check any circuit that can cause an
intermittent complaint for the following:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wiring connections
- Physical damage to the wiring harness
- Corrosion
Engine
• If the serial data line is shorted to ground or
shorted to voltage, then all systems connected
to the serial data line will not be able to
communicate properly. Systems capable of
storing loss of communications DTCs (DTCs
with the letter U as a prefix) will have these
codes stored in their memory. If a DTC P1626
is stored in VCM memory, then check for the
same DTC stored in the Active Transfer Case
(ACT) Control Module. The ATC Control Module
also monitors the Node Alive/SOH message
from the VTD (Passlock) Control Module. If the
ATC Control Module also has a DTC 1626
stored, check the VTD (Passlock) Control
Module for an intermittent malfunction. If the
ATC Control Module does not have a
DTC P1626 stored, then check for an open in
the serial data line between only the VCM and
the VTD (Passlock) Control module. The VCM
must also be checked for intermittent operation
due to a loss of power or ground to the VCM
itself. After repairing the cause of DTC P1626,
clear all DTCs from all systems capable of
storing this DTC.
• If the vehicle does not start, or starts and stalls:
- Turn OFF the ignition and wait at least
5 seconds before trying to restart.
- When the VCM receives a password from
the VTD (Passlock) Control Module that does
not match the stored password, a
DTC P1631 should be present. Check for
VTD codes first; if no codes are present,
then force a relearn of the password. Refer
to Password Learn Procedure.
DTC P1626 Loss of Serial Communication with VTD
Step Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1 —
Engine Controls - 7.4L 6-3035
- If both a VCM DTC P1626 and U1192 are
set, check the wiring between the VCM and
VTD (Passlock) for continuity.
- If a VCM P1626 code is set, but a VCM
DTC U1192 is not, then the VTD (Passlock)
Control Module may be malfunctioning.
- If VCM DTCs P1626, P1630, P1631, U1192
are not set, the cause of the no start is
probably not a VTD (Passlock) system
problem.
• Monitor the VCM’s VTD (Passlock) parameters
with a scan tool..
• The scan tool’s Diagnostic Circuit Check can be
used to:
- Monitor the Class II Serial Data circuit for
modules which have been or are
communicating.
- Monitor for loss of communications DTCs
(DTCs with the letter U as a prefix:
U1001-U1199).
- Clear loss of communications DTCs. When a
Clear Codes command is issued, all codes,
freeze frame, and failure records information
is cleared.
• The scan tool’s Diagnostic Circuit Check’s
Active status indicates that the module is
communicating with the scan tool; Inactive
indicates that a module that had established
communications with the scan tool is not
currently communicating. If a module is not
listed at all, then the missing module never
successfully established communications with
the scan tool; refer to Electrical Diagnosis for
any unlisted modules.
Value(s) Yes No
Go to Powertrain
OBD System
—
Check (OBD
System Check)
6-3036 Engine Controls - 7.4L_______________ Engine

DTC P1630 Theft Deterrent VCM in Learn Mode

Circuit Description Conditions for Clearing the MIL/DTC
This diagnostic test checks for the Enable Password
Learning Flag indicating the VCM is in learn
password mode. This mode allows the VCM to learn
the password from the Vehicle Theft Deterrent
control module at assembly or when being serviced.
The password needs to be learned whenever the
VCM or the VTD control module is replaced.
Conditions for Setting the DTC
When the Enable Learning Flag is set.
Action Taken When the DTC Sets
The Malfunction Indicator Lamp (MIL) will not
illuminate.
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 *C (40 *F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 * C
(160’ F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Diagnostic Aids
The VCM in learn mode is a DTC for the vehicle at
the assembly plant, dealership and outside garage
personnel as an indication that the learn mode is
enabled. This means the VCM is now ready to learn
a new password.

DTC P1630 Theft Deterrent VCM in Learn Mode

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? Go to Body OBD System
1 —
Control Module Check (OBD
(BCM) diagnosis System Check)
Engine_____________________________________
DTC P1631 Theft Deterrent Password Incorrect
Circuit Description
The Class II serial date circuit is used to
communicate between the VCM and the VTD
(Passlock)/EVO Control Module systems.
When the Passlock portion of the Vehicle Theft
Deterrent System (VTD) system has sensed the
proper operation of the ignition switch and lock
(determines that the switch and lock have not been
tampered with), the Passlock system transmits a
password to the VCM. The VCM enables fuel
delivery if this password matches the password
stored in the VCM’s memory. However; if
communication is lost or a VTD failure occurs (during
an ignition cycle that the VCM has enabled fuel) the
VCM will enter a fail-safe mode: "Fail Enable" (VTD
System Failure with Fuel Enabled). The VCM
remains in "Fail Enable" mode, for the current and
future ignition cycles, until the fault is corrected and
a valid pass word is received, or until battery power
is removed. If the battery power is removed while
the VCM is in the "Fail Enable" mode (ignition ON or
OFF) the VCM disables fuel delivery. The vehicle will
not start, or it will start then stall.
When the VCM receives an invalid password or no
password, before the "Fuel Disable Decision Point",
the VCM disables fuel delivery. The "Fuel Disable
Decision Point" occurs at about 300 RPM during the
engine crank mode.
Conditions for Setting the DTC
• DTC P1626 is not set.
• The VCM is not in password Learn Mode.
• A number of invalid passwords have been
received by the VCM, before the Fuel disable
Decision Point.
• The VCM has established communications with
the VTD (Passlock) Control Module and
received a valid password, during this
ignition cycle.
• The VCM cannot re-establish communications,
no Node Alive/SOH messages received, with
the VTD (Passlock) Control Module for
5 seconds.
. OR
• The VCM cannot establish communications with
the VTD (Passlock) Control Module and has not
received a valid password before the "Fuel
Disable Decision Point."
Action Taken When the DTC Sets
• The vehicle does not start, or it starts then
stalls.
• A DTC P1631 is stored in the VCM memory.
• The VCM will not illuminate the MIL.
• The Security lamp may be illuminated by the
VTD (Passlock) system.
• The VCM disables fuel delivery until the fault is
corrected and a valid password is received from
the VTD (Passlock) Control Module.
Engine Controls ■ 7.4L 6-3037
Conditions for Clearing the MIL/DTC
1. The DTC P1631 requires an ignition cycle in
order to change from current to history.
2. The VCM receives a valid password from the
VTD (Passlock) Control Module.
3. A history DTC will clear after 50 consecutive
ignition cycles if the condition for the
malfunction is no longer present.
4. DTC(s) can be cleared by using a scan tool.
Diagnostic Aids
Important: Do not clear DTCs unless directed by a
diagnostic procedure. Clearing DTCs will also clear
valuable Freeze Frame and Failure Records data.
• If the VCM is replaced, the VCM must re-learn
a valid password and Crankshaft variation.
• If the VTD (Passlock) Control Module is
replaced, the VCM must re-learn a valid
password.
• Check for published service bulletins relating to
exhibited symptoms or component operation.
• Inspect all related wiring and connections
including the VCM and VTD (Passlock) Control
Module connections. These may cause an
intermittent malfuction.
• Thoroughly check any circuit that can cause an
intermittent complaint for the following:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wiring connections
- Physical damage to the wiring harness
- Corrosion
• If the vehicle does not start, or starts and stalls:
- Turn OFF the ignition and wait at least
5 seconds before trying to restart.
- When the VCM receives a password from
the VTD (Passlock) Control Module that does
not match the stored password, a
DTC P1631 should be present. Check for
VTD codes first; if no codes are present,
then force a relearn of the password. Refer
to Password Learn Procedure.
• Monitor the VCM’s VTD (Passlock) parameters
with a scan tool.
• The scan tool’s Diagnostic Circuit Check can be
used to:
- Monitor the Class II Serial Data circuit for
Node Alive/SOH messages.
- Monitor for loss of communications DTCs
(DTCs with the letter U as a prefix).
- Clear loss of communications DTCs.
6-3038 Engine Controls - 7.4L_________
• The scan tool’s Diagnostic Circuit Check’s
Active status indicates that the module is
communicating with the scan tool; Inactive
indicates that a module that had established
communications with the scan tool is not
currently communicating. If a module is not
listed at all, then the missing module never
successfully established communications with
the scan tool; refer to Electrical Diagnosis for
any unlisted modules.
Conditions for Setting the DTC
• The vehicle Anti-Theft system is enabled.
• The fuel disable is set.
• An incorrect fuel continue password has been
received.
Action Taken When the DTC Sets
• The vehicle will not start.
• The Malfunction Indicator Lamp (MIL) will not
illuminate.
Engine
Conditions for Clearing the MIL/DTC
1. A history DTC will clear if no fault conditions
have been detected for 40 warm-up cycles
(coolant temperature has risen 22 * C (40 * F)
from the startup coolant temperature and the
engine coolant temperature exceeds 70 *C
(160*F) during the same ignition cycle.
2. Use the scan tool Clear Information function.
3. Disconnect the VCM battery feed for
30 seconds.
Test Description
Number(s) below refer to the step number(s) on the
diagnostic table.
3. The 11 minute and 30 second time criteria, are
a minimum required amount of time. The time
limit can exceed this limit, without interfering
with the Auto Learn Procedure. A scan tool can
be used (VTD Auto Learn Timer equals
Inactive) to determine when the 11 minutes has
expired.
8. If DTC P1631 is set, indicates that the
procedure was not followed correctly. The
Re-learn procedure will have to be
re-performed.

DTC P1631 Theft Deterrent Password Incorrect

Step Action Value(s) Yes No
Important: Before clearing the DTCs, use a scan tool to
record freeze frame and failure records for reference
because data will be lost when the Clear info function
1 — Go to Powertrain
is used.
OBD System
Was the Powertrain On-Board Diagnostic (OBD) System Check (OBD
Check performed? Go to Step 2 System Check)
Important: Before preceding with this table, check for any
Vehicle Theft Deterrent (VTD) contoller DTCs being set
(except if you were sent here from VCM replacement). If a
2 VTD controller DTC is set, refer to the approiate VTD —
controller DTC.
Is a T-50/T-60 ® available? Go to Step 5 Go to Step 3
3 Is a Tech 2 ® available? — Go to Step 6 Go to Step 4
Engine________________________________________________ Engine Controls - 7.4L 6-3039
DTC P1631 Theft Deterrent Password Incorrect (cont’d)
Step Action Value(s) Yes No
Important: While the VCM is in the Auto Leam Procedure,
battery voltage must be maintained at all times. This
procedure must be followed exactly as indicated or the
procedure will have to be repeated from the beginning.
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Turn the ignition on, engine off, for 11 minutes.
4 —
2. Turn the ignition off for 30 seconds.
3. Turn the ignition on, engine off, for 11 minutes.
4. Turn the ignition off for 30 seconds.
5. Turn the ignition on, engine off, for 11 minutes or
until DTC P1630 sets.
6. Turn the ignition off for 30 seconds.
7. Turn the ignition on and wait 30 seconds.
8. Attempt to start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Using a T-50/T-60 enter the Service Programming
System (SPS).
2. Select terminal to vehicle programming.
3. Select Done and follow instructions on Vehicle
Set-up screen.
4. Select Vehicle Theft Re-learn.
5 5. Follow the instructions on the remaining screens. —
• The VCM and the Vehicle Theft Deterrent (VTD)
control module will be prepared for re-leam.
• A security timer will be on for approximately
11 minutes or until DTC P1630 sets. It is
important that during the 11 minute-wait, the user
keep the terminal connected to the vehicle.
• When the VCM and the Vehicle Theft Deterrent
(VTD) control module are prepared to re-learn,
turn the ignition OFF for 30 seconds and then
start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
6-3040 Engine Controls - 7.4L________________________________________________ Engine
DTC P1631 Theft Deterrent Password Incorrect (cont’d)
Step Action Value(s) Yes No
Important: Performing the following procedures will cause
a DTC P1630 to set when they are completed. This is the
intended functionality. Once it is set, turn the ignition off for
30 seconds, then turn the ignition back on and P1630 will
clear. If it does not, go to DTC P1630 table.
1. Using a Tech 2 enter the Service Programming
System (SPS).
2. After entering the vehicle information, choose the
Request Info soft key on the scan tool.
3. Select Done and follow instructions on Vehicle
Set-up screen
4. Disconnect the scan tool from the vehicle and
connect to the Techline terminal.
5. At the Techline terminal select Service Programming
System (SPS) and select terminal to Tech 2
programming method. Select Done.
6. Follow the instructions on the remaining screens.
7. Select Vehicle Theft Re-learn.
6 8. Select Program at the summary screen. The terminal —
will download information to the Tech 2.
9. Return the scan tool to the vehicle and connect to
Diagnostic Link Connector (DLC).
10. Select Service Programming from the Tech 2 main
menu. Answer the prompts regarding the model year
and vehicle type. Press the Theft Re-leam soft key
on the Tech 2.
11. Follow the instructions on the remaining screens.
• The VCM and the VTD control module will be
prepared for re-learn.
• A security timer will be on for approximately
11 minutes or until DTC P1630 sets. It is
important that during the 11 minute-wait, the user
keep the terminal connected to the vehicle.
• When the VCM and the VTD control module are
prepared to re-learn, turn the ignition OFF for 30
seconds and then start the engine.
Does the engine start and operate normally? Go to Step 7 Go to Step 8
Important: Before Clearing DTCs, monitor all DTC status
parameters and note any additional DTCs.
1. Clear VCM DTCs.
7 —
2. Turn the ignition off for 30 seconds.
3. Attempt to start the engine.
Does the engine start and operate normally? System OK Go to Step 8
Are DTCs P1626, P1630 or P1631 set? Go to Applicable
8 —
DTC table Go to Step 2
Engine Engine Controls - 7.4L 6-3041
Symptoms
Checks Action
Before Using This Section Before using this section, you should have performed the Powertrain On-Board
Diagnostic System Check and determined that:
1. The VCM (Vehicle Control Module) and MIL (Malfunction Indicator Lamp) are
operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but
without a MIL.
Several of the following symptom procedures call for a careful visual and physical
check. The visual and physical checks are very important. The checks can lead to
correcting a problem without further checks which may save valuable time.
Visual and Physical Checks • Check the VCM grounds for being clean, tight and in their proper location.
Refer to VCM Description.
• Check the vacuum hoses for splits, kinks and proper connections, as shown
on the Vehicle Emission Control Information label.
• Check thoroughly for any type of leak or restriction.
• Check for air leaks at all the mounting areas of the intake manifold sealing
surfaces.
• Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
• Check the wiring for the following items:
- Proper connections
- Pinches
- Cuts
• The following symptom tables contain groups of possible causes for each
symptom and cover several engines. The following symptom tables cover
several engines.The order of these procedures is not important. If the scan
tool readings do not indicate the problems, then proceed in a logical order,
easiest to check or most likely to cause first. In order to determine if a
specific vehicle is using a particular system or component, refer to the Control
Module Wiring Diagrams for an application.
Symptom 1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.

Symptoms
Checks Action
Definition: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble
Code (DTC). ____________________
Preliminary Checks • Refer to Important Preliminary Checks.
• Do not use the DTC tables. If a fault is an intermittent, the use of DTC tables
may result in the replacement of good parts.
6-3042 Engine Controls - 7.4L Engine
Symptoms (cont’d)
Checks Action
Faulty Electrical Connections or Faulty electrical connections or wiring can cause most intermittent problems.
Wiring • Check the suspected circuit for the following conditions:
- Connectors poorly mated
- Terminals not fully seated in the connector body (backed out)
- Terminals improperly formed or damaged
- Terminal to wires poorly connected
• Carefully reform all the connector terminals in the problem circuit in order to
ensure the proper contact tension. If necessary replace all the connector
terminals in the problem circuit in order to ensure the proper contact tension.
• Checking for poor terminal to wire connections requires removing the terminal
from the connector body. Refer to the Wiring Repairs in Electrical Diagnosis.
Road Test If a visual and physical check does not locate the cause of the problem, drive the
vehicle with a DVM J 39200 connected to a suspected circuit or use a scan tool.
When the problem occurs, an abnormal voltage or scan reading indicates the
problem may be in that circuit.
Intermittent Malfunction Indicator The following components can cause an intermittent MIL and no DTC(s):
Lamp (MIL) • A defective relay, Control Module driven solenoid, or a switch that can cause
an electrical system interference. Normally, the problem will occur when the
faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way radios,
electric motors, etc.
• Route the Ignition Control (1C) wires away from the spark plug wires, ignition
system components and the generator. The wire for the engine ground from
the Control Module to the ignition system should be a good ground.
• The ignition secondary voltage shorted to a ground.
• The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal
intermittently shorted to a ground.
• The Control Module grounds.
Loss of DTC Memory 1. In order to check for the loss of the DTC Memory, disconnect the Throttle
Position (TP) sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.
3. The VCM should store a Throttle Position DTC.
4. The Throttle Position DTC should remain in the memory when turning off the
ignition.
5. If the Throttle Position DTC does not store and remain, the Control Module is
faulty.
Additional Checks Check for an open diode across the A/C compressor clutch and for other open
diodes. Refer to the Wiring Diagrams.

Use the following tables when diagnosing a symptom • Hesitation, Sag, Stumble
complaint. . Cuts Out, Misses
• Hard Start . p00r puej Economy
• Surges/Chuggles • Rough, Unstable, or Incorrect Idle, Stalling
• Lack of Power, Sluggishness, or Sponginess . Dieseling, Run-On
• Detonation/Spark Knock . Backfire
Engine Engine Controls - 7.4L 6-3043
Hard Start
Checks Action
Definition: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but
immediately dies. ______________________________________
Preliminary Checks • Refer to Symptoms.
• Make sure the vehicle’s operator is using the correct starting procedure.
Sensor Checks • Check the Engine Coolant Temperature (ECT) sensor with the scan tool.
Compare the engine coolant temperature with the ambient air temperature on
a cold engine. If the coolant temperature reading is more than 5 degrees
greater or less than the ambient air temperature on a cold engine, check for a
high resistance in the coolant sensor circuit. Refer to DTC P0118 ECT Sensor
Circuit High Voltage (98) or DTC P1115 ECT Sensor CKT Intermittent High
Voltage.
• Check the Throttle Position (TP) sensor. If a sticking throttle shaft or binding
linkage causes a high TP sensor voltage (open throttle indication), the Control
Module will not control the idle. While monitoring the TP sensor voltage, the
scan tool should display less than 0.85 volt with the throttle closed.
Fuel System Checks Important: A faulty in-tank fuel pump check valve will allow the fuel in the lines to
drain back to the tank after the engine stops.
• Check the fuel pump relay for proper operation. The fuel pump should operate
for the first 2 seconds when turning ON the ignition. Refer to Fuel Pump
Relay Circuit Diagnosis.
• Check the fuel pressure. Refer to the Fuel System Diagnosis (System Check).
• Check for water contamination in the fuel.
• Perform the fuel injector coil test. Refer to Fuel Injector Coil Test.
• Perform the fuel injector balance test. Refer to Fuel Injector Balance Test
Check the fuel pump check valve. Refer to the Fuel System Diagnosis
(System Check).
Ignition System Checks • Check for the proper ignition voltage output with J 26792 or the equivalent.
• Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check for bare or shorted ignition wires.
• Check for moisture in the distributor cap if applicable.
• Check for loose ignition coil connections.
• Check for loose Ignition Control Module connections.
• Check for a faulty Control Module or ignition system grounds.
• Check the Ignition Control (IC) circuit for an open or short to ground. Refer to
Enhanced Ignition System Diagnosis.
Important:
1. If the engine starts but then immediately stalls, remove the (CKP)
sensor.
2. Check for improper resistance or faulty connections.
• Check the Crankshaft Position (CKP) sensor resistance and connections.
Refer to Enhanced Ignition System Diagnosis.
6-3044 Engine Controls - 7.4L Engine
Hard Start (cont’d)
Checks Action
Engine Mechanical Checks • Check for the following:
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes Refer to Engine Mechanical
• Check the intake and exhaust manifolds for casting flash. Refer to Engine
Mechanical.
Additional Check Check the Idle Air Control (IAC) operation. Refer to Idle Air Control System
Diagnosis.

Surges/Chuggles
Checks 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 operation.
• Be sure the driver understands the A/C Compressor operation.
• Use the scan tool to make sure the reading of the Vehicle Speed Sensor
(VSS) matches the vehicle speedometer. This excludes vehicles with electronic
transmissions where some variation between the VSS and the speedometer is
normal.
Sensor Check Check the (Heated) Oxygen Sensor (H02S) performance.
• Refer to DTC P0131 H02S Circuit Low Voltage Bankl Sensorl.
• Refer to DTC P0132 H02S Circuit High Voltage Bankl Sensorl.
• Refer to DTC P0133 H02S Slow Response Bankl Sensorl.
• Refer to DTC P0134 H02S Insufficient Activity Bankl Sensorl.
• Refer to DTC P0135 H02S Heater Circuit Bankl Sensorl.
• Refer to DTC P0137 H02S Circuit Low Voltage Bankl Sensor2.
• Refer to DTC P0138 H02S Circuit High Voltage Bankl Sensor2.
• Refer to DTC P0140 H02S Insufficient Activity Bankl Sensor2.
• Refer to DTC P0141 H02S Heater Circuit Bankl Sensor2.
Fuel System Checks • Check for a Rich or Lean symptom that causes the condition. Drive the
vehicle at the speed of the complaint. Monitoring the Fuel Trim will help
identify the problem.
• Lean - The Long Term Fuel Trim will be greater than 150. Refer to DTC
P0132 H02S Circuit High Voltage Bankl Sensorl Diagnostic Aids. Refer to
DTC P0138 H02S Circuit High Voltage Bankl Sensor2 Diagnostic Aids.
• Rich - The Long Term Fuel Trim will be less than 115. Refer to DTC P0131
H02S Circuit Low Voltage Bankl Sensorl Diagnostic Aids. Refer to DTC
P0137 H02S Circuit Low Voltage Bankl Sensor2 Diagnostic Aids.
• Check the fuel pressure while the condition exists. Refer to Fuel System
Diagnosis.
• Check the in-line fuel filter for a restrictions.
Engine Engine Controls - 7.4L 6-3045
Surges/Chuggles (cont’d)
Checks Action
Ignition System Checks • Check for the proper ignition output voltage using the spark tester J 26792 or
the equivalent. Refer to Enhanced Ignition System Diagnosis.
• Check the spark plugs. Remove the plugs and inspect them for the following
conditions:
- Wetness
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check the Crankshaft Position (CKP) sensor. Refer to DTC P0339 CKP
Sensor Circuit Intermittent
Additional Checks • Check the Control Module grounds for being clean, tight, and in their proper
locations.
• Check the generator output voltage.
• Check the vacuum hoses for kinks or leaks. Refer to the Vehicle Emission
Control Information label.
• Check for an intermittent EGR problem. Refer to EGR System Diagnosis.
• Check for Torque Converter Clutch (TCC) operation. Refer to Transmissions.

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 customer’s vehicle with a similar unit. Make sure the customer
has an actual problem.
• Remove the air filter and check for dirt or a restriction.
• Check the transmission shift pattern and the downshift operation. Refer to
Transmission Controls section.
Fuel System Checks • Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure.
Refer to Fuel System Diagnosis.
• Perform the fuel injector balance test. Refer to Fuel Injector Balance Test
• Check for the proper ignition output voltage with the spark tester J 26792 or
the equivalent.
• Check the Knock Sensor (KS) system. Refer to DTC P0327 Knock Sensor
Noise Channel Low Voltage.
Exhaust System Checks • Check the exhaust system for a possible restriction. Refer to Engine Exhaust.
• Inspect the exhaust system for damaged or collapsed pipes, inspect the
muffler for heat distress or a possible internal failure.
6-3046 Engine Controls - 7.4L Engine
Lack of Power, Sluggishness, or Sponginess (cont’d)
Checks Action
Additional Checks • Check the Control Module grounds for being clean, tight, and in their proper
location.
• Check the EGR Valve for being open or partially open all the time. Refer to
EGR System Check.
• Check the Torque Converter Clutch (TCC) operation. Refer to the Torque
Converter Clutch Solenoid in Automatic Transmission.
• Check the A/C operation. Refer to A/C Compressor Control Circuit Diagnosis.
• Check the generator output voltage. Refer to Engine Electrical.
Engine Mechanical Check Check the engine for the proper operation of the following items:
• Engine compression
• Valve timing
• Improper or worn camshaft. Refer to Engine Mechanical.

Detonation/Spark Knock
Check Action
Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with the throttle opening.___________________________________________________________________
Preliminary Checks • Refer to Symptoms.
• Make sure the customer has an actual problem.
• Check the Transmission Range (TR) pressure switch assembly operation.
Refer to Transmission Fluid Pressure Switch Assembly.
Cooling System Checks • Check for an obvious overheating problem. Refer to the Diagnosis of the
Cooling System in Engine Cooling.
• Check for a low engine coolant level.
• Check for the proper tension on the drive belts.
• Check for restricted air flow through the radiator, or restricted coolant flow.
• Check for a faulty thermostat, refer to Diagnosis of the Thermostat in Engine
Cooling.
• Check for a correct coolant solution. The coolant should be a 50/50 mix of
antifreeze and water.
Sensor Check Check for an Engine Coolant Temperature (ECT) sensor that has a shift in value.
Refer to DTC P1115 ECT Sensor CKT Intermittent High Voltage Diagnostic Aids.
Refer to DTC P0118 ECT Sensor Circuit High Voltage (98) Diagnostic Aids.
Fuel System Checks • Check if a Lean system causes this condition. Drive the vehicle at the speed
of the complaint. Monitoring the Fuel Trim will help identify the problem.
• If the system is Lean, the Long Term Fuel Trim will be greater than 150. Refer
to DTC P0132 H02S Circuit High Voltage Bankl Sensorl Diagnostic Aids.
Refer to DTC P0118 ECT Sensor Circuit High Voltage (98) Diagnostic Aids.
• Check the fuel pressure. Refer to Fuel System Diagnosis.
• Check for a poor fuel quality and a proper octane rating.
• If the scan tool readings are normal and there are no engine mechanical
faults, fill the fuel tank with a premium gasoline that has a minimum octane
rating of 92 and re-evaluate the vehicle’s performance.
Ignition System Checks • Check the spark plugs for their proper heat range and gap.
• Check the Knock Sensor (KS) system operation. Refer to DTC P0327 Knock
Sensor Noise Channel Low Voltage.
• Check the ignition timing. Refer to Setting Timing for the 5.0L, 5.7L, 7.4L.
Engine Engine Controls - 7.4L 6-3047
Detonation/Spark Knock (cont’d)
Check Action
Engine Mechanical Checks • Check for carbon build up. Remove the carbon with a top engine cleaner.
Follow the instructions on the can.
• Check the combustion chamber pressure by performing a compression test.
Refer to Engine Mechanical.
Additional Checks • Check for the proper operation of the EGR Valve. Refer to EGR System
Diagnosis.
• Check for the proper operation of the Air Intake system. Refer to Air Intake
System Description.
• Check for the proper operation of the transmission shift points. Refer to the
Transmission Controls section.
• Check the Torque Converter Clutch (TCC) operation. Refer to Torque
Converter Clutch Solenoid in Automatic Transmission.
• Check the Service Bulletins for PROM updates.

Hesitation, Sag, Stumble

Checks Action
Definition: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any
vehicle speed. The condition is usually most severe when trying to make the vehicle move, as from a stop sign. The
condition may cause the engine to stall if it’s severe enough.__________________________________________________
Preliminary Check Refer to Symptoms.
Fuel System Checks • Check the fuel pressure. Refer to Fuel System Diagnosis.
• Check the Throttle Position (TP) sensor for binding or sticking. Voltage
should increase at a steady rate as the throttle moves toward Wide Open
Throttle (WOT).
• Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
• Check for water contamination in the fuel. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
• Check the Canister Purge system for proper operation. Refer to EVAP Control
System Diagnosis.
• Perform the fuel injector coil test. Refer to Fuel Injector Coil Test.
• Perform the fuel injector balance test. Refer to Fuel Injector Balance Test.
• Check for low fuel pressure after a cold start or during a moderate or full
throttle acceleration. If the fuel pressure drops below specification, there is
possibly a faulty fuel pump or a restriction in the fuel system.
Ignition System Checks • Check for faulty spark plug wires.
• Check for fouled spark plugs.
• Check for an open ignition system ground. Refer to Enhanced Ignition System
Diagnosis.
Additional Checks • Check the Service Bulletins for PROM updates.
• Check the generator output voltage. Refer to Engine electrical.
• Check the EGR Valve operation. Refer to EGR System Diagnosis.
6-3048 Engine Controls - 7.4L
Checks
Definition: A steady or jerking that follows engine speed, usually more pronounced as the engine load increases which is
not normally felt above 1500 RPM or 48 km/h (30 mph). The exhaust has a steady spitting sound at idle, low speed, or
hard acceleration for the fuel starvation that can cause the engine to cut-out.____________________________
Preliminary Check
Ignition System Checks
Engine Mechanical Checks
Engine
Cuts Out, Misses
Action
Refer to Symptoms.
Confirm that the distributor is adjusted so that CMP Retard is 0*± 2*. If it is not,
refer to the Camshaft Retard Offset Adjustment procedure .
Check for a cylinder misfire:
1. Start the engine.
2. Allow the engine to stabilize.
3. Then disconnect the Idle Air Control (IAC) motor.
Notice: Do not perform this test for more than 2 minutes in order to prevent
damaging the catalytic converter.
4. Remove one spark plug wire at a time using insulated pliers.
5. If there is a RPM drop on all cylinders (equal to within 50 RPM), go to Rough,
Unstable, or Incorrect Idle, Stalling.
6. Reconnect the IAC motor with the ignition OFF.
7. If there is no RPM drop on one or more of the cylinders, or excessive
variation in drop, check for spark on the suspected cylinders with a J 26792 or
the equivalent.
8. If there is no spark, refer to Enhanced Ignition System Diagnosis.
9. If there is spark, remove the spark plugs in these cylinders and check for the
following conditions:
• Insulation cracks
• Wear
• Improper gap
• Burned electrodes
• Heavy deposits
- Check the spark plug wire resistance (should not exceed 30,000 Q).
- Check the distributor rotor and the distributor cap.
- If the previous check did not find the problem, visually check the
following items:
• The ignition system for moisture, dust, cracks, bums, etc.
• With the engine running, spray the plug wires with a fine water mist to
check for shorts.
• Perform a cylinder compression check. Refer to Engine Mechanical.
• Check the engine for the following:
- Improper valve timing
- Bent pushrods,
- Worn rocker arms
- Worn camshaft lobes
- Broken or weak valve springs Refer to Engine Mechanical.
• Check the intake and exhaust manifold passages for casting flash. Refer to
Engine Mechanical.
Engine Engine Controls - 7.4L 6-3049
Cuts Out, Misses (cont’d)
Checks Action
Fuel System Checks • Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to
Fuel System Diagnosis.
• Check for water contamination in the fuel.
• Check the fuel injector driver circuit.
• Perform the fuel injector coil test. Refer to Fuel Injector Coil Test.
• Perform the fuel injector balance test. Refer to Fuel Injector Balance Test.
Additional Check Check for Electromagnetic Interference (EMI).
• EMI on the reference circuit can cause a missing condition.
• Monitoring the engine RPM with a scan tool can detect an EMI.
• A sudden increase in the RPM with little change in the actual engine RPM,
indicates EMI is present.
• If the problem exists, check the routing of the secondary wires and the ground
circuit.

Poor Fuel Economy

Checks Action
Definition: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, the economy is
noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test._______________
Preliminary Checks • Refer to Symptoms.
• Check the air cleaner element (filter) for dirt or being plugged.
• Visually (physically) check the vacuum hoses for splits, kinks, and proper
connections as shown on the Vehicle Emission Control Information label.
• Check the owner’s driving habits for the following items:
• The operation of the thermostatic air cleaner.
- The A/C ON full time (Defroster mode ON)?
- The tires for being at the correct air pressure.
- Excessively heavy loads being carried?
- The acceleration too much, too often?
• Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
• Suggest to the driver to refer to Important Facts on Fuel Economy in the
owner’s manual.
Fuel System Checks • Check the fuel type, quality, and alcohol content. Refer to the Fuel System
section.
• Check the fuel pressure. Refer to Fuel System Diagnosis.
Ignition System Checks • Check the spark plugs. Remove the spark plugs and check for the following:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check for an open Ignition Control (1C) circuit.
• Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
• Check the Knock Sensor (KS) system operation. Refer to DTC P0327 Knock
Sensor Noise Channel Low Voltage.
6-3050 Engine Controls - 7.4L Engine
Poor Fuel Economy (cont’d)
Checks Action
Cooling System Checks • Check the engine coolant level.
• Check the engine thermostat for always being open or for the wrong heat
range. Refer to Diagnosis of the Thermostat in Engine Cooling.
Additional Checks • Check the transmission shift pattern. Refer to the Transmission Controls
section.
• Check for Torque Converter Clutch (TCC) operation. Refer to Torque
Converter Clutch Solenoid in Automatic Transmission.
• Check for proper calibration of the speedometer.
• Check for dragging brakes. Refer to Section 5 of the appropriate service
manual.

Rough, Unstable, or Incorrect Idle, Stalling

Checks Action
Definition: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed
may vary in RPM. Either condition may be severe enough to stall the engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks • Check the Heated Oxygen Sensor (H02S).
• Check for silicon contamination from fuel or improperly used sealant. The
sensor will have a white powdery coating. The sensor will result in a high but
false signal voltage (rich exhaust indication). The Control Module will reduce
the amount of fuel delivered to the engine causing a severe driveability
problem.
- Refer to DTC P0131 H02S Circuit Low Voltage Bankl Sensorl.
- Refer to DTC P0132 H02S Circuit High Voltage Bankl Sensorl.
- Refer to DTC P0133 H02S Slow Response Bankl Sensorl.
- Refer to DTC P0134 H02S Insufficient Activity Bankl Sensorl.
- Refer to DTC P0135 H02S Heater Circuit Bankl Sensorl.
- Refer to DTC P0137 H02S Circuit Low Voltage Bankl Sensor2.
- Refer to DTC P0138 H02S Circuit High Voltage Bankl Sensor2.
- Refer to DTC P0140 H02S Insufficient Activity Bankl Sensor2.
- Refer to DTC P0141 H02S Heater Circuit Bankl Sensor2.
• Check the Throttle Position (TP) sensor. If a sticking throttle shaft or binding
linkage causes a high TP sensor open throttle indication, the Control Module
will not control the idle. Monitor the TP sensor voltage. A scan tool and/or
voltmeter should read less than .85 volts with the throttle closed.
• Check the Engine Coolant Temperature (ECT) sensor using the scan tool to
compare the engine coolant temperature with the ambient air temperature on
a cold engine. If the coolant temperature reading is more than 5 degrees
greater than 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. Refer to
DTC P1115 ECT Sensor CKT Intermittent High Voltage Diagnostic Aids or
DTC P0118 ECT Sensor Circuit High Voltage (98) Diagnostic Aids.
• Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
Engine ___________________________________Engine Controls - 7.4L 6-3051
Rough, Unstable, or Incorrect Idle, Stalling (cont’d)
Checks Action
Fuel System Checks • Check to determine if a Rich or Lean system causes the condition. Drive the
vehicle at the speed of the complaint. Monitoring the Fuel Trim will help
identify the problem.
- Lean - The Long Term Fuel Trim is greater than 150. Refer to DTC P0132
H02S Circuit High Voltage Bankl Sensorl Diagnostic Aids. Refer to
DTC P0138 H02S Circuit High Voltage Bankl Sensor2 Diagnostic Aids.
- Rich - The Long Term Fuel Trim is less than 115. Refer to DTC P0131
H02S Circuit Low Voltage Bankl Sensorl Diagnostic Aids. Refer to
DTC P0137 H02S Circuit Low Voltage Bankl Sensor2 Diagnostic Aids.
• Check the fuel injector driver circuit.
- Disconnect the injector harness connector at the injectors.
- Connect an injector test light between the terminals of each injector
connector and note the light while cranking.
- If the test light fails to blink at any connector, it is a faulty injector drive
circuit harness, connector, or terminal.
• Perform the fuel injector coil test. Refer to Fuel Injector Coil Test.
• Perform the fuel injector balance test. Refer to Fuel Injector Balance Test
• Check for fuel in the pressure regulator vacuum hose. If fuel is present,
replace the regulator assembly.
• Check the Evaporative Emission (EVAP) control system. Refer to EVAP
Control System Diagnosis.
• Perform a cylinder compression test. Refer to Engine Mechanical.
• Check for leaking fuel injectors. Refer to Injector Circuit Diagnosis
• Check the fuel pressure. Refer to Fuel System Diagnosis.
• Check the scan tool for an injector fault which could indicate one or more
faulty injectors or wiring.
Ignition System Checks • Check the ignition output voltage using the spark tester J 26792 or the
equivalent. Refer to Enhanced Ignition System Diagnosis
• Check for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
• Check the spark plug wires by connecting an ohmmeter to the ends of each
wire in question. If the meter reads over 30,000 ohms, replace the wires.
6-3052 Engine Controls - 7.4L________________________________________________ Engine
Rough, Unstable, or Incorrect Idle, Stalling (cont’d)
Checks Action
Additional Checks • Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle
and low Idle Air Control (IAC) counts.
• Check the IAC operation. Refer to DTC P1121 TP Sensor CKT Intermittent
High Voltage. Refer to DTC P0507 Idle Control System High RPM. Refer to
DTC P1509 IAC System High RPM.
• Check the Control Module grounds for being clean, tight, and in their proper
locations. Refer to Engine Controls Component Location for the 7.4L.
• Check the Automatic Transmission Fluid Pressure (TPF) manual valve
indicator. Refer to Transmission Fluid Pressure Switch Assembly.
• Check the scan tool to determine if the Control Module is receiving an A/C
signal. Refer to A/C Compressor Control Circuit Diagnosis. If a problem exists
with the A/C ON, check the A/C system operation. Refer to Section 1B of the
appropriate service manual.
• Check for the EGR being ON while idling which will cause roughness, stalling,
and hard starting. Refer to EGR System Diagnosis.
• Check the battery cables and ground straps. They should be clean and
secure. Erratic voltage will cause the IAC to change its position resulting in
poor idle quality.
• Check the IAC Valve. The IAC will not move if the system voltage is not
within 9 to 16 volts.
• Check the A/C refrigerant pressure for being too high or for a faulty high
pressure switch.
• Check the Crankcase Ventilation Valve for proper operation by placing a finger
over the inlet hole in the valve end several times. The valve should snap
back. If not, replace the valve. Refer to Crankcase Ventilation System
Description.
Engine Mechanical Check Check for the following:
- Broken motor mounts.
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs.
- Worn camshaft lobes
- Refer to Engine Mechanical.

Dieseling, Run-On
Checks Action
Definition: The engine continues to run when turn the key OFF, but runs very roughly. If the engine runs smoothly, check
the ignition switch and adjustment.
Preliminary Check Refer to Symptoms.
Fuel System Checks • Check the Evaporative Emission (EVAP) system and fuel tank venting.
• Check the fuel injector(s) for leakage.
• Perform a fuel system diagnosis. Refer to Fuel System Diagnosis.
Engine Engine Controls - 7.4L 6-3053
Backfire
Checks Action
Definition: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check Refer to Symptoms.
Ignition System Checks • Check for the proper ignition coil output voltage with the spark tester J 26792
or the equivalent.
• Check the spark plugs.
• Remove the spark plugs.
• Check for the following items:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check the ignition system. Refer to Enhanced Ignition System Diagnosis.
• Check for crossfire between spark plugs (distributor cap, spark plug wires, and
proper routing of the plug wires). Refer to Engine Electrical.
Engine Mechanical Checks • Check the engine for the following the items:
- Engine compression
- Improper valve timing
- Intake manifold gaskets, refer to Engine Mechanical.
- Sticking or leaking valves, refer to Engine Mechanical.
• Check the EGR operation for being open all the time. Refer to EGR System
Diagnosis.
• Check the intake and exhaust system for casting flash or other restrictions.
Refer to Engine Mechanical.
Fuel System Checks • Perform a fuel system diagnosis. Refer to Fuel System Diagnosis.
• Perform a fuel injector coil test. Refer to Fuel Injector Coil Test.
• Perform a fuel injector balance test. Refer to Fuel Injector Balance Test
Additional Checks * Check the EGR gasket for a faulty or loose fit.
• Check the EGR Valve operation for being open all the time. Refer to EGR
System Diagnosis.
6-3054 Engine Controls - 7.4L Engine
Restricted Exhaust System Check

Legend
(1) Back Pressure Gauge
(2) Heated Oxygen Sensor (H02S)
(3) Exhaust Pipe

Restricted Exhaust System Check

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Carefully remove the Heated Oxygen
Sensor (H02S).
2. Install the exhaust backpressure tester 8.6 kPa
2 J 35314-A/BT-8515/BT-8515A in place of the H02S. (1.25 psi)
3. Start the engine and idle.
Is the reading greater than the specified value? Go to Step 4 Go to Step 3
1. Increase the engine speed to the specified value.
2000 RPM
3 2. Observe the backpressure gauge.
20.7 kPa (3 psi)
Does the reading exceed the specified value? Go to Step 4 Go to Step 6
1. Check the exhaust system for a collapsed pipe,
internal muffler failure, or any kind of heat distress.
4 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 6 Go to Step 5
Replace the catalytic converter. Refer to Engine Controls
5 or Exhaust of the appropriate service manual. — —
Is the action complete? Go to Step 6
Operate the vehicle within the conditions under which the
6 original symptom was noted. —
Does the system now operate properly? System OK Go to Step 2
Engine
Vehicle Control Module Diagnosis
The Diagnostic Tables incorporate diagnosis
procedures using a scan tool where possible.
The scan tool saves time in diagnosis. The scan tool
also prevents the replacement of good parts. In
order to use the scan tool successfully for diagnosis,
the technician must understand the system being
diagnosed as well as understanding the tool’s
limitations.
Refer to Serial Data Communications.
In order to read the DTCs, use a scan tool. The
technician cannot flash the DTCs by grounding
the DLC.
In order to clear the DTCs from the memory, use the
scan tool.
If a diagnostic table indicates that a VCM connection
or the VCM is the cause of a problem and the
technician replaces the VCM but the problem is not
eliminated, one of the following items may be the
reason.
1. After replacing the VCM, the EEPROM was not
reprogrammed correctly.Refer to VCM
Repiacement/Programming.
2. A problem may exist with the VCM terminal
connections: In order to check the connections
properly, remove the terminals from the
connections.
The VCM is not correct for the application: The
incorrect components may cause a malfunction
and may or may not set a DTC.
___________ Engine Controls - 7.4L 6-3055
3. The problem is an intermittent. Make a careful
physical inspection of all portions of the system
involved. Refer to Symptoms.
4. A shorted solenoid, relay coil or harness may
exist: The VCM turns the solenoids and relays
on and off by the VCM using an internal
electronic switches called drivers. Each driver is
a part of a group of 4 called quad-drivers.
Failure of 1 driver can damage any other driver
in the set.
5. The replacement VCM may be faulty: After
replacing the VCM, recheck the system for
proper operation. If the diagnostic table again
indicates that the VCM is the problem,
substitute a known good VCM.
A shorted solenoid, relay coil, or harness will not
damage the quad drivers in the VCM. A shorted
solenoid, relay coil, or harness will cause the circuit
and the controlled component to be inoperative.
When the circuit fault is not present or the technician
has repaired the fault, the quad driver will again
operate in a normal manner due to its fault protected
design.
If the technician has repaired a fault in the a circuit
controlled by a quad-driver, reinstall the original
VCM. Check the circuit for proper operation.
A VCM replacement is not necessary if the repaired
circuit or component operates correctly.
A J 39200 tester provides a fast, accurate means of
checking for a shorted coil or a short to battery
voltage.
6-3056 Engine Controls - 7.4L_____________ Engine
VCM Outputs Diagnosis (IAC System Check)

Idle Air
Stopper
Motor Control (IAC)
Coil
B
0 Coil
A
Valve

B
LT LT VCM
GRN/WHT 1749 BLU/BLK 1748 C1=BLU
C2- RED
LT LT
C3=CLEAR
C4=BLK
GRN/BLK 444 BLU/WHT 1747

13J.____ ____ _ J 4 ^C 2
IAC IAC IAC IAC Vehicle
Coil B Coil B Coil A Coil A Control
High Low Low High i Module A
i (VCM)
33140

Circuit Description maintain desired idle. If the engine has another

The VCM controls idle RPM with the IAC valve. To
increase idle RPM, the VCM retracts the IAC pintle
from the seat, allowing more air to bypass the
throttle plate. To decrease RPM, it extends the IAC
pintle valve in towards the seat, reducing air flow
through the IAC valve port in the throttle body. A
scan tool will read the VCM commands to the IAC
valve in counts. The higher the counts, the more air
allowed (higher idle). The lower the counts, the less
air allowed (lower idle).
IAC Valve Reset Procedure Without A
Scan Tool
1. Turn ON the ignition leaving the engine OFF for
5 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Start the engine and check for proper
operation.
IAC Valve Reset Procedure With Scan Tool
1. Turn ON the ignition leaving the engine OFF.
2. Install a scan tool.
3. Select F4 Misc. Tests.
4. Select F3 IAC System.
5. Select F1 IAC Reset.
6. Use up arrow to reset IAC.
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a
non-IAC system problem that cannot be overcome
by the IAC valve. The following checks should be
made to repair a non-IAC system problem.
Important: If for some reason the air intake to the
engine is restricted, the VCM will attempt to
compensate by backing out the IAC pintle to
source of air to the intake, the VCM will compensate
by extending the IAC pintle, scan IAC counts may
reach zero as the VCM tries to maintain desired idle.
• Vacuum Leak (High Idle) - If idle is too high,
stop the engine. Fully extend (low) IAC with
tester.
Start engine. If idle speed is above 800 RPM,
locate and correct vacuum leak including
crankcase ventilation system. Also, check for
binding of throttle blade or linkage.
• System lean (high air/fuel ratio) - Idle speed
may be too high or too low. Engine speed may
vary up and down, disconnecting IAC does not
help. May set DTC P0171. The scan tool will
read Heated Oxygen Sensor (H02S) output
less than 300 mV (0.3 volt). Check for low
regulated fuel pressure or water in fuel.
• System rich (low air/fuel ratio) - Idle speed too
low. Scan IAC counts are usually above 80.
System obviously rich and may exhibit black
smoke exhaust. May set DTC P0172. The scan
tool will read Heated Oxygen Sensor (H02S)
signal fixed above 800 mV (.8 volt).
Check for high fuel pressure, leaking or sticking
injector. Silicone contaminated H02S scan
voltage will be slow to respond.
• Throttle body - Remove IAC valve and inspect
bore for foreign material.
• IAC Valve Electrical Connections - IAC valve
connections should be carefully checked for
proper contact.
• Crankcase Ventilation Valve - An incorrect or
faulty crankcase ventilation valve may result in
an incorrect idle speed.
Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
Engine
• A/C Compressor - Refer to A/C Compressor
Clutch Control Diagnosis if circuit is shorted to
ground. If the relay is faulty, an idle problem
may exist.
Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• If intermittent poor driveability or idle symptoms
are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance
or replace IAC.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. The IAC tester is used to extend and retract
the IAC valve. Valve movement is verified by
an engine speed change. If no change in
engine speed occurs, the valve can be retested
when removed from the throttle body.
Engine Controls - 7.4L 6-3057
3. This step checks the quality of the IAC
movement in Step 2. Between 700 RPM and
about 1500 RPM the engine speed should
change smoothly with each flash of the tester
light in both extend and retract. If the IAC valve
is retracted beyond the control range (about
1500 RPM), it may take many flashes in the
extend position before engine speed will begin
to drop. This is normal on certain engines, fully
extending IAC may cause engine stall. This
may be normal.
4. Steps 2 and 3 verified proper IAC valve
operation while this step checks the IAC
circuits. Each lamp on the node light should
flash red and green while the IAC valve is
cycled. While the sequence of color is not
important if either light is OFF or does not flash
red and green, check the circuits for faults
beginning with poor terminal contacts.

Idle Air Control (IAC) System Check

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to the
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Connect IAC driver (J 37027-A) to the IAC valve.
3. Set the parking brake and block the drive wheels.
4. Turn the A/C OFF.
2 5. Start the engine and let it idle in Park (A/T) or —
Neutral (M/T).
6. Install a scan tool and display RPM.
7. Extend and retract the IAC valve using the IAC
driver.
Does the RPM change? Go to Step 3 Go to Step 11
Does the RPM change smoothly with each flash of the
3 700-1500 RPM
IAC driver within the specified range? Go to Step 4 Go to Step 11
1. Install the appropriate node light into the control
module harness.
4 —
2. Cycle the IAC driver and observe the lights.
Do the lights flash red and green but never OFF? Go to Step 5 Go to Step 7
Using the other connector on the IAC driver pigtail, check
the resistance across the IAC coils.
5 40 to 80 ohms
Are the readings within the specified value between
terminal A to B and C to D? Go to Step 6 Go to Step 12
Check the resistance between IAC terminals B to C
6 and A to D. oo Go to
Are the resistances at the specified value? Diagnostic Aids Go to Step 12
1. Check for faulty connector terminal contacts.
7 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 8
1. Check for open circuits including connections.
8 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 9
6-3058 Engine Controls - 7.4L________________________________________________ Engine
Idle Air Control (IAC) System Check (cont’d)
Step Action Value(s) Yes No
1. Check for circuits shorted to ground or voltage.
9 2. If a problem is found, repair as necessary. —

Was a problem found? Go to Step 14 Go to Step 10

1. Check the VCM for faulty connections.
10 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 13
1. Check IAC passages for blockages or restrictions.
11 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 12
Replace the IAC valve. Refer to IAC Valve Replacement.
12 — —
Is the action complete? Go to Step 14
Replace the VCM. Refer to VCM
13 Replacement/Programming. — —
Is the action complete? Go to Step 14
1. Turn the ignition ON, engine OFF.
2. Using the IAC driver, command the component to
14 —
extend and retract.
Does the component now operate properly? System OK Go to Step 2
Engine Engine Controls ■ 7.4L 6-3059

A/C Compressor Control Circuit Diagnosis
Refer to Engine Controls Schematics.
Circuit Description
The VCM control of the A/C clutch improves idle
quality and performance by performing the following
conditions:
• Delaying clutch engagement until the idle speed
is increased
• Releasing the clutch when the idle speed is
too low
• Providing additional fuel at the instant the clutch
is applied
The additional fuel smooths the cycling of the
compressor.
Turning the air conditioning ON supplies battery
voltage through the pressure switches to the VCM.
When the VCM receives the voltage on the A/C
request signal, the A/C enable relay circuit is
grounded. The A/C compressor clutch then engages.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Checks for low refrigerant as the cause for
no A/C.
3. This and the following tests, check for a faulty
A/C control relay and high and low cutout
switches.

A/C Compressor Control Circuit Diagnosis

Step Action Value(s) Yes No
Important: Before using this table confirm that the A/C
Go to A/C
1 system has an adequate state of charge. — System Diagnosis
Does the A/C system have an adequate state of charge? Go to Step 2 in Section 1B
1. Turn ON the engine.
2. Idle the engine until the normal operating
temperature is reached.
2 3. Leave the engine at normal idle. 60 sec
4. Turn ON the A/C. Go to A/C
Does the A/C clutch engage and disengage within the System Diagnosis
specified value? in Section 1B Go to Step 3
1. Connect the scan tool to the DLC.
2. Turn ON the A/C.
3 3. Monitor the A/C Request in data stream (A/C —

Request should display YES).

Does the display read YES? Go to Step 4 Go to Step 8
1. Disconnect the A/C compressor clutch harness
connector.

4 2. Connect a test lamp between the terminals of the

—
A/C clutch signal circuit and the ground circuit of the
A/C compressor clutch harness connector.
Is the test lamp ON? Go to Step 5 Go to Step 12
Check for a faulty compressor clutch harness connector.
5 —
Was a problem found? Go to Step 6 Go to Step 7
Repair the A/C compressor clutch harness connector.
6 — —
Is the action complete? Go to Step 27
Replace the A/C compressor clutch. Refer to Section 1B.
7 — —
Is the action complete? Go to Step 27
1. Turn OFF the ignition.
2. Disconnect the gray VCM connector.
3. Turn ON the ignition.
8 4. Connect a test lamp between the harness connector —
terminal cavity of the A/C request signal circuit and a
ground.
Is the test lamp on? Go to Step 9 Go to Step 11
6-3060 Engine Controls - 7.4L ____________________________________________ Engine
A/C Compressor Control Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
Check for a faulty connection at the gray VCM harness
9 connector. —
Was a problem found? Go to Step 10 Go to Step 26
Repair the VCM harness connector.
10 — —
Is the action complete? Go to Step 27
1. Repair the open or short to ground in the harness
between the circuit A/C Request signal circuit to the
A/C pressure switch if necessary. Refer to Wiring
Repairs in Engine Electrical.
11 2. Repair the open or short to ground in the harness — —
circuit A/C Request signal circuit to the A/C control
switch of necessary. Refer to Wiring Repairs in
Engine Electrical.
Is the action complete? Go to Step 27
Connect a test lamp between the A/C clutch signal circuit
of the A/C clutch harness connector and the engine
12 ground. —

Is the test lamp on? Go to Step 13 Go to Step 14

Repair the ground circuit of the A/C clutch harness
13 connector. Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 27
1. Connect the scan tool.
2. Turn ON the ignition leaving the engine off.
14 3. Using the output test function of the scan tool, —
command the A/C relay to turn ON.
Does the A/C relay click? Go to Step 23 Go to Step 15
1. Disconnect the A/C relay.
2. Connect a teat lamp between the terminal cavity of
15 the A/C relay harness connector ignition feed circuit —
and a ground.
Is the test lamp on? Go to Step 17 Go to Step 16
Repair the open or short to ground in the harness for the
A/C relay ignition feed circuit. Refer to Wiring Repairs in
16 Engine Electrical. — —
Is the action complete? Go to Step 27
1. Connect a test lamp between the A/C relay harness
connector terminal cavities of the A/C relay control
circuit and the ignition feed circuit.
17 2. Connect the scan tool. —
3. Using the output test function of the scan tool,
command the A/C relay to turn ON.
Is the test lamp on? Go to Step 18 Go to Step 19
Replace the A/C relay. Refer to A/C Relay Repair and
18 Replacement in Section 1B. — —
Is the action complete? Go to Step 27
Check for a faulty connection at the VCM harness
19 connector for the A/C relay control circuit. —
Was a problem found? Go to Step 20 Go to Step 21
Repair the connection at the VCM connector. Refer to
20 Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 27
Engine________________________________________________ Engine Controls - 7.4L 6-3061
A/C Compressor Control Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
Check for an open in the circuit between the A/C relay
harness connector terminal cavity and the VCM connector
21 terminal cavity. —
Was a problem found? Go to Step 22 Go to Step 26
Repair the open in the circuit between the A/C relay
harness connector terminal cavity and the VCM connector
22 terminal cavity. Refer to Wiring Repairs in Engine — —

Electrical.
Is the action complete? Go to Step 27
1. Remove the A/C relay.
2. With a fused jumper, jumper the A/C relay harness
23 connector terminal cavity of the battery feed circuit —
and the compressor clutch control circuit.
Does the A/C Clutch engage? Go to Step 24 Go to Step 25
Replace the A/C relay. Refer to A/C Relay Repair and
24 Replacement in Section 1B. — —

Is the action complete? Go to Step 27

Repair the open or short to the ground in the compressor
clutch control circuit. Refer to Wiring Repairs in Engine
25 Electrical. — —

Was a problem found? Go to Step 27

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
26 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 27
1. Using the scan tool, select the DTC and the
Clear Info.
27 —
2. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 28 Go to Step 2
1. Allow the engine to idle until the engine reaches the
normal operating temperature. Go to
28 —
2. Select the DTC Failed This Ign. The Applicable
Are any DTCs displayed? DTC Table Go to Step 29
Using the scan tool, select the Capture Info and the Go to
29 Review Info. — The Applicable
Are any DTCs displayed that have not been diagnosed? DTC Table System OK
6-3062 Engine Controls - 7.4L Engine

Electric Cooling Fan Diagnosis

| H o t A t All T im e s |

Power 1 Underhood
i <■
A/C
i Distribution
Fuse
| Fuse - Relay
Cell 10
i 10 A i Center

ORN 1240
85 ,.
J" “I Auxiliary
■ * Fan VCM
It . ___i * Relay Cl = BLU
C 2-R ED
86 Y C 3» CLEAR
G4-BLK
DK BLU 473
14 JLci
r Auxiliary Vehicle
I Fan 1Control
I Control
1Module Jk
I
L
'(V C M )i^
196161
Circuit Description: If the engine is overheating and the cooling fan is
The auxilary cooling fan is controlled by the VCM ON, the cooling system should be checked, refer to
based on various inputs. Battery voltage is supplied Section 6B.
to the auxilary cooling fan relay. Ignition voltage is The VCM will command the auxiliary cooling fan on
supplied to the auxilary fan relay (coil side). The at 107’ C (225*F) and OFF at 103*C (218*F).
VCM controls the cooling fan relay by providing a
ground path. Test Description
Number(s) below refer to step numbers on the
Diagnostic Aids diagnostic table.
If the driver complaint is an overheating problem, it 3. Engine coolant temperature must be below
must be determined if the complaint was due to an 100*C (212‘ F) to perform this test.
actual boil over, or the warning indicator light, or
8. This check can detect a partially shorted coil
engine coolant temperature gage indicated
which would cause excessive current flow.
overheating. The gage accuracy can also be
Leaving the circuit energized for 2 minutes
checked by comparing the Engine Coolant
allows the coil to warm up. When warm the coil
Temperature (ECT) sensor reading using a scan tool
may open (amps drop to 0), or short (goes
and comparing its reading with the gage reading. If
above 0.75 Amp).
the engine is actually overheating and the gage
indicated overheating, but the cooling fan is not 12. Listen for an audible click when the relay
coming ON, the Engine Coolant Temperature (ECT) operates. Be sure that both the ON and OFF
sensor has probably shifted out of calibration and states are commanded. Repeat the commands
should be replaced. as necessary.
24. If no trouble is found in the control circuit or the
connection at the VCM, the VCM may be faulty,
however, this is an extremely unlikely failure.

Electric Cooling Fan Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Install scan tool. Go to
2 —
Are any DTCs set? applicable table. Go to Step 3
1. Engine coolant temperature must be below the
specified value to diagnose the cooling fan system
3 10CTC (212*F)
2. Turn ignition on engine Off
Is the cooling fan Off? Go to step 4 Go to Step 5
Engine________________________________________________ Engine Controls - 7.4L 6-3063
Electric Cooling Fan Diagnosis (cont’d)
Step Action Values) Yes No
Using the scan tool, command the cooling fan relay On
and then Off.
4 —
Does the cooling fan turn On and Off with each System OK Refer
command? to Diagnostic Aids Go to Step 6
Disconnect the cooling fan relay.
5 —
Does the fan stop? Go to Step 10 Go to Step 16
1. Turn the ignition Off
2. Disconnect the fan relay.
3. Turn the ignition ON. —
6
4. Connect a test light to ground and probe the battery
feed circuits at the relay connector.
Is the test light ON at both circuits? Go to Step 7 Go to Step 19
1. Disconnect the fan relay.
2. Connect a test light between a battery feed circuit
and the auxiliary fan relay control circuit at the relay
harness.
7 —
3. Turn the ignition ON.
4. Using a scan tool, command the fan ON and
then OFF.
Does the test light turn ON and OFF with each command Go to Step 8 Go to Step 11
1. Reconnect the fan relay.
2. Turn the ignition OFF.
3. Disconnect the VCM connector containing the relay
control circuit.
4. Turn the ignition ON. 2 Minutes
8
0.75 amp
5. Using the DVM J 39200 on 10 amp scale, measure
current draw on the relay control circuit from the
VCM harness connector to ground for the
specified value.
Is the current draw less than the specified value? Go to Step 22 Go to Step 11
1. Disconnect the fan electrical connector
9 2. Connect a test light across the fan electrical —
connector terminals.
Is the test light ON? Go to Step 16 Go to Step 10
1. Disconnect the VCM connector containing the relay
control circuit.
10 2. Using DVM J 39200, measure the resistance oo
between the relay control circuit at the VCM harness
connector and ground.
Is the resistance at the specified value? Go to Step 24 Go to Step 20
Connect a fused jumper wire between the battery feed
11 circuit and circuit leading to the fan motor —
Does the fan operate? Go to Step 12 Go to Step 15
1. Turn the ignition OFF.
2. Reconnect the fan relay.
3. Disconnect the VCM connector containing the fan
relay control circuit.
12 4. Turn the ignition ON. —
5. Connect a fused jumper wire to ground and probe
the fan relay control circuit at the VCM harness
connector.
Does the relay operate? Go to Step 14 Go to Step 13
6-3064 Engine Controls - 7.4L________________________________________________ Engine
Electric Cooling Fan Diagnosis (cont’d)
Step Action Value(s) Yes No
Check the connections at the fan relay. If faulty connection
13 is found, repair as necessary. Refer to Engine Electrical. —
Was a problem found? System OK Go to Step 14
Check the connections at the VCM. If faulty connection is
14 found, repair as necessary. Refer to Engine Electrical. —

Was a problem found? System OK Go to Step 21

Check the connections at the fan motor harness connector.
If faulty connection is found, repair as necessary. Refer to
15 Engine Electrical. —

Was a problem found? System OK Go to Step 17

Repair a short to voltage in the power feed circuit between
16 the fan relay and the fan motor. — —
Is action complete? System OK
Check for an open in the power feed circuit between the
17 fan relay and the fan motor. Refer to Engine Electrical. —
Was a problem found? System OK Go to Step 18
Check for an open in the fan motor ground circuit. Refer
18 to Engine Electrical. —
Was a problem found and repaired? System OK Go to Step 23
Repair an open in the battery feed circuit that did not light
19 the test light. Refer to Engine Electrical. — —
Is the action complete? System OK
Repair short to ground in the relay control circuit.
20 —
Was a problem found and repaired? System OK Go to Step 22
Check for an open in the fan relay control circuit and
21 repair as necessary. Refer to Engine Electrical. —
Was a problem found and repaired? System OK Go to Step 22
Replace the auxiliary fan relay.
22 —
Is the fan OFF? System OK Go to Step 24
Replace the auxiliary fan motor.
23 — —
Is the action complete? System OK
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
24 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? System OK
Engine_______________________ Engine Controls - 7.4L 6-3065

Manual Transmission Shift Light

l Hot InRunAndStart|
I Power IP
GAGES Fuse
Fuse
, Distribution

I
Cell 10 1 Block
I
L . _ —_ _ _ _ _ _ _ _____ J

PNK 39
VCM
Fuse Block
i Details Cl = BLU
Cell 11 C2-RED
C3 = CLEAR
PNK 39 C4-BLK

22 .
11nstrument
Instrument
Cluster
Cell 81
- i UPSHIFT JCluster
0 Indicator I
I
i _ _ _ _ _ J

20' /
TAN/BLK 456
>
>*
TAN/BLK 456

15. C4
— — — — i
UPSHIFT Vehicle
1 Control
Indicator
Control 1 Module ^
________ j
(VCM)

32861

Circuit Description Test Description

The control module controls the shift lamp using the The numbers below refer to the step numbers on the
following inputs: diagnostic table.
• The Engine Coolant Temperature (ECT) sensor 1. This step checks the control module’s ability to
• The Throttle Position (TP) sensor control the shift lamp.
• The Vehicle Speed sensor (VSS)
• The Engine RPM
The control module uses the measured RPM and the
vehicle speed in order to calculate what gear the
vehicle is in. This calculation determines when the
shift lamp should be turned ON.

Manual Transmission Shift Light

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Install a scan tool.
2 3. Turn the ignition ON. —
4. Using the scan tool, command the shift lamp ON.
Is the shift lamp ON? Go to Step 4 Go to Step 3
6-3066 Engine Controls - 7.4L________________________________________________ Engine
Manual Transmission Shift Light (cont’d)
Step Action Value(s) Yes No
1. Disconnect the control module connector that
contains the shift lamp control circuit.
2. Turn the ignition ON.
3 —
3. Connect a fused jumper between the shift lamp
control circuit and ground.
Is the shift lamp ON? Go to Step 5 Go to Step 6
Using the scan tool, command the shift lamp OFF
4 and ON. —
Does the shift lamp respond to the scan tool command? System OK Go to Step 8
Check the terminal connect at the control module for the
5 shift lamp control circuit. —
Was a problem found? Go to step 7 Go to Step 10
Repair the open in the shift lamp circuit.
6 — —
Is the action complete? Go to Step 11
Repair as necessary.
7 — —
Is the action complete? Go to Step 11
1. Turn the ignition OFF.
2. Disconnect the control module connector that
8 contains the shift lamp control circuit. —
3. Turn the ignition ON.
Is the shift lamp ON? Go to Step 9 Go to Step 10
Repair the short to ground in the shift lamp control circuit.
9 — —
Is the action complete? Go to Step 11
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
10 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 11
1. Allow the engine to idle until normal operating
temperature is reached. Go to
11 — the Applicable
2. Select DTC Failed This Ignition.
DTC Table
Are any additional DTCs displayed? Go to Step 12
Using the scan tool, select Capture Info, Review Info. Go to
12 Are any additional DTCs displayed that have not been — the Applicable
diagnosed? DTC Table System OK
Engine________________________________________________ Engine Controls - 7.4L 6-3067

Fuel Injector Balance Test

17713

Injector Balance Test Example

Cylinder 1 2 3 4 5 6
1st Reading 434 kPa (63 psi) 434 kPa (63 psi) 434 kPa (63 psi) 434 kPa (63 psi) 434 kPa (63 psi) 434 kPa (63 psi)
2nd Reading 351 kPa (51 psi) 331 kPa (48 psi) 351 kPa (51 psi) 365 kPa (53 psi) 344 kPa (50 psi) 344 kPa (50 psi)
Amount of Drop 83 kPa (12 psi) 103 kPa (15 psi) 83 kPa (12 psi) 69 kPa (10 psi) 90 kPa (13 psi) 90 kPa (13 psi)
Acceptable Range
Average ±10 kPa:
86 ±10 kPa Faulty injector - Faulty injector -
Injector OK too much Injector OK too little Injector OK Injector OK
76-96 kPa fuel drop fuel drop
(12 psi ± 1.5 psi
11-14 psi)

Circuit Description 5. The fuel pressure should be within the specified

The Fuel Injector Tester J 39021, the Injector Switch
Box J 39021-210 and the Injector Harness Connector
J 39021-303 energize the injector for a precise
amount of time allowing a measured amount of fuel
into the manifold. This causes a drop in system fuel
pressure that can be recorded and used to compare
each injector. All injectors should be within the same
pressure drop range, the average pressure drop
value for all injectors is ±10 kPa (1.5 psi).
Test Description
C a u tio n : W ra p a s h o p to w e l a r o u n d th e fu e l
p r e s s u r e c o n n e c tio n In o r d e r to r e d u c e th e r is k
o f f ir e a n d p e r s o n a l In ju r y . T h e to w e l w ill a b s o r b
a n y f u e l le a k a g e t h a t o c c u r s d u r in g th e
c o n n e c tio n o f t h e f u e l p r e s s u r e g a u g e . P la c e
to w e l In a n a p p r o v e d c o n ta in e r w h e n th e
c o n n e c t io n o f th e f u e l p r e s s u r e g a u g e Is
c o m p le te .
range. If the fuel pressure is not within the
specified range, go to Fuel System Diagnosis.
6. Allow the fuel pressure to stabilize about 3
minutes. On a hot vehicle fuel pressure may
increase due to fuel expansion after the pump
stops running. This is a normal condition but
the fuel pressure should stabilize and hold. The
fuel pressure should reach a steady value. If
the fuel pressure does not reach a steady
value, refer to Fuel System Diagnosis.
7. If the pressure drop value for each fuel injector
is within 10 kPa (1.5 psi) of the average
pressure drop value, the fuel injectors are
flowing properly. Calculate the pressure drop
th e value for each fuel injector by subtracting the
second pressure reading from the first pressure
reading. Refer to the illustration above.

4. The engine coolant temperature must be below

the operating temperature in order to avoid
irregular fuel pressure readings due to Hot
Soak fuel boiling.
6-3068 Engine Controls - 7.4L Engine
Fuel Injector Balance Test
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
Was the Fuel Injector Coil Test performed? Go to Fuel
2 —
Go to Step 3 Injector Coil Test
Is the engine coolant temperature above the specified
3 94 *C (201* F)
value? Go to Step 4 Go to Step 5
Allow the engine to cool below the specified value.
4 94’ C (201 ’ F) —
Is the action complete? Go to Step 5
1. Turn ignition OFF.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Install the fuel pressure gauge.
4. Turn ON the ignition leaving the engine OFF.
5. Energize the fuel pump using the scan tool.
6. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container. Central SFI -
5 7. Bleed the air out of fuel pressure gauge. 415-455 kPa
8. Use a scan tool in order to pressurize the fuel (60-66 psi)
system.
9. Wait for the fuel pressure to build.
Important: The fuel pump will run for approximately
2 seconds. Repeat Step 5 as necessary in order to
achieve the highest possible fuel pressure.
10. Observe the reading on the fuel pressure gauge. Go to Fuel
Is the fuel pressure within the specified limits? Go to Step 6 System Diagnosis
Turn the fuel pump OFF. Go to Fuel
6 —
Does the fuel pressure remain constant? Go to Step 7 System Diagnosis
Engine________________________________________________ Engine Controls - 7.4L 6-3069
Fuel Injector Balance Test (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Connect the J 39021 Fuel Injector Tester, the
J 39021-301 Injector Harness Connector and the
J 39021-210 Injector Switch Box to the fuel meter
body (L30/L31 applications use Injector Harness
Connector J 39021-302, L29 use J 39021-303).
3. Set the amperage supply selector switch on the fuel
injector tester to the Balance Test 0.5-2.5 amp
position.
4. Select the injector to be tested on the Injector
Switch Box.
5. Turn ON the ignition leaving the engine OFF.
6. Use a scan tool in order to pressurize the fuel
system.
7. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the 1st pressure reading.
7 8. Energize the fuel injector by depressing the Push to 10 kPa (1.5 psi)
Start Test button on the fuel injector tester.
9. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge needle
has stopped moving. This is the 2nd pressure
reading.
10. Repeat Steps 4 through 9 for each fuel injector.
11. Subtract the 2nd pressure reading from the 1st
pressure reading for one fuel injector. The result is
the pressure drop value.
12. Obtain a pressure drop value for each fuel injector.
13. Add all of the individual pressure drop values. This is
the total pressure drop.
14. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that is
either higher than the average pressure drop or lower than
the average pressure drop by the specified value? Go to Step 8 Go to Symptoms
Do not repeat any portion of this test before
N o tic e :
running the engine in order to prevent the engine from
flooding.

8 Re-test any fuel injector that does not meet the

10 kPa (1.5 psi)
specification. Refer to the procedure in Step 7.
Does any fuel injector still have a pressure drop value that
is either higher than the average pressure drop or lower
than the average pressure drop by the specified value? Go to Step 9 Go to Symptoms
6-3070 Engine Controls - 7.4L Engine
Fuel Injector Balance Test (cont’d)
Step Action Value(s) Yes No
Replace the malfunctioning fuel injector(s). Refer to Fuel
9 Injector Replacement (SFI). — —
Is the actionr complete? Go to Step 10
1. Turn ignition OFF.
2. Remove test equipment.
3. Re-connect all harnesses and fuel lines.
4. Install a scan tool.
5. Turn ON the ignition leaving the engine OFF.
10 6. Check for fuel leaks —
7. Use the scan tool in order to display the Capture
Info and the Review Capture Info function.
8. Start the engine. Go to
9. Idle until normal operating temperature is reached. the applicable
Are any DTCs displayed that have not been diagnosed? DTC table System OK
Engine______________
Fuel Injector Coil Test
TESTER J 39021
Test Description
The numbers below refer to the step numbers on the
diagnostic able.
2. This step is the setup step for performing the
injector coil test. Also read the instructions
included with the tools used for this test.
3. Engine coolant temperature affects the tool’s
ability to detect a faulty injector. If the engine
coolant temperature is not between 50 ’ F and
95 ‘ F, allow the vehicle to warm or cool as
necessary.
Engine Controls - 7.4L 6-3071
35909
4. Due to a current surge, the first second of the
voltage reading may be inaccurate; therefore,
begin recording after the first second of the
voltage reading. The voltage specification
should be within range. The voltage reading
may increase throughout the test as the injector
windings warm up and the resistance changes.
An erratic voltage reading (one that jumps up
and down) would indicate an intermittent
connection within the fuel injector.
6-3072 Engine Controls - 7.4L Engine
Fuel Injector Coil Test
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Turn OFF the engine.
2. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
3. Connect the fuel injector tester J 39021 to B+.
4. Connect the injector switch box J 39021-210.
5. Set the amperage supply selection to the 0.5 amp
position.
2 10 * -3 5 'C
6. Connect the injector harness connector J 39021-303.
7. Connect the leads from J 39200 digital volt meter
(DVM to the tenths scale (0.0).
8. Connect the scan tool.
9. Monitor the engine coolant temperature.
Is the engine coolant temperature within the
specified value? Go to Step 4 Go to Step 3
Allow the engine to warm or cool as necessary.
3 Is the engine coolant temperature within the 10*-35'C —
specified value? Go to Step 4
Important: Perform the following test for each injector.
1. Press the Push To Start Test button.
2. Monitor the DVM.
4 Important: Voltage may climb during the test. Watch for 5.44-7.53V
erratic readings (voltage that jumps up and down).
Refer to
Do any of the injector voltage readings fall outside the Fuel Injector
specified value? Go to Step 5 Balance Test
Replace the fuel injector and poppet nozzle assembly that
was not within the specified value. Refer to Fuel Injector
5 Replacement (SFI). 5.44-7.53V —
Is the action complete? Go to Step 6
1. Using the scan tool, select the DTC and the
Clear Info.
6 —
2. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 7 Go to Step 2
1. Allow the engine to idle until reaching the normal
operating temperature.
7 — Go to
2. Select the DTC and the Failed This Ign. the applicable
Are any DTCs displayed? DTC table Go to Step 8
Use the scan tool in order to display the Capture Info and Go to
8 the Review Capture Info function. — the applicable
Are any DTCs displayed that have not been diagnosed? DTC table System OK
Engine Engine Controls - 7.4L 6-3073

Fuel Injector Circuit Diagnosis Test Description

Refer to Fuel Injector Controls.
Diagnostic Aids
The VCM has integrated circuits that are fault
protected; therefore, if a circuit has failed, the
integrated circuits may not be damaged. If this is the
case, the 1C will keep the circuit open until you have
corrected the fault in the circuit. When you have
corrected the fault, reinstall the VCM. Check the
circuit. Replace the VCM only if the circuit is still
inoperative.
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the ignition feed circuit
to the injectors are OK.
3. This step determines if the injector control
circuits are OK.
5. This step determines if there is an internal VCM
short to ground for an injector control circuit.

Fuel Injector Circuit Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Disconnect the injector connector at the intake
manifold.
2. Connect a test lamp to a ground.
2 3. Turn ON the ignition leaving the engine off. —
4. Using the test lamp, probe the injector ignition feed
circuits.
Is the test lamp on for all the injector feed circuits? Go to Step 3 Go to Step 7
1. Install an injector test lamp J 34730-350 into each
injector circuit one at a time.
3 —
2. Crank the engine. Go to Fuel
Does the injector test lamp flash for each injector? Injector Coil Test Go to Step 4
4 Is the injector test lamp on steady for any injector circuit? — Go to Step 5 Go to Step 6
1. Install an injector test lamp in the affected circuit.
2. Turn off the ignition.
5 3. Disconnect the VCM Blue and Red connectors. —
4. Turn ON the ignition leaving the engine off.
Is the injector test lamp OFF? Go to Step 11 Go to Step 8
Check for an open or short to B+ for the affected injector
6 control circuit. —
Was a problem found? Go to Step 7 Go to Step 9
Repair circuit as necessary. Refer to Wiring Repairs in
7 Engine Electrical. — —
Is the action complete? Go to Step 12
Repair short to ground in the injector control circuit. Refer
8 to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 12
Check the terminal contact at the VCM.
9 —
Was a problem found? Go to Step 10 Go to Step 11
Repair terminal contact as necessary.
10 — —
Is action complete? Go to Step 12
6-3074 Engine Controls ■ 7.4L Engine
Fuel Injector Circuit Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Replace the VCM.Refer to VCM
Replacement/Programming
2. Program the VCM. Refer to VCM
11 Replacement/Programming. — —
3. Perform the VTD Password Learn Procedure. Refer
to Password Learn Procedure.
Is the action complete? Go to Step 12
1. Using the scan tool, select the DTC and the
Clear Info.
12 —
2. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 13 Go to Step 2
1. Allow the engine to idle until normal operating
temperature is reached.
13 — Go to
2. Select the DTC and the Failed This Ign. the applicable
Are any DTCs displayed that have not been diagnosed? DTC table Go to Step 14
Use the scan tool in order to display the Capture Info and
the Review Capture Info function. Go to
14 —
Are there any DTCs displayed that have not been the applicable
diagnosed? DTC table System OK
Engine_________________________________ Engine Controls - 7.4L 6-3075

Fuel Tank Pressure Sensor Diagnosis
Circuit Description
The fuel tank vapor pressure sensor is used in order
to detect a vacuum decay or an excessive vacuum
during the EVAP diagnostic routine. The sensor
responds to the changes in the fuel tank pressure or
vacuum. The signal voltage to the Control Module
varies from a minimum of about 0.2 volts with
pressure in the fuel tank to above 4 volts with a high
vacuum in the fuel tank.
The Fuel Tank Vacuum display on the scan tool has
an auto zero feature which occurs at each ignition
cycle and is corrected according to the barometric
pressure. Because of this, the Fuel Tank Vacuum
may not accurately reflect the actual output of the
sensor or the conditions within the fuel tank.
The Fuel Tank Vapor Pressure Sensor Diagnosis
Table is intended to isolate and diagnose the
electrical problems in the sensor wiring or the
sensor.
Diagnostic Aids
Check for the following conditions:
• Inspect the Control Module harness connectors
for the following conditions:
- Improper mating
- Broken locks
- Improperly formed
- Damaged terminals
• Inspect the wiring harness for damage. If the
harness appears to be OK, observe the Fuel
Tank Vacuum display on the scan tool while
moving the connectors and the wiring
harnesses related to the sensor. A change in
the display will indicate the location of the fault.
Refer to Carbon Particle Removal from EVAP
System before starting repairs.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
1. The Powertrain OBD System Check prompts
the technician to do some basic checks and
store the Freeze Frame Data and Failure
Records in the scan tool if applicable. This
creates an electronic copy of the freeze frame
data taken when the fault occurred that can be
referred to later.
5. A normal fuel tank pressure sensor voltage
output with no pressure or vacuum on the fuel
system should be between 1.3V and 1.7V.
14. Reprogram the replacement Control Module.
Refer to the latest Techline information for
programming procedures.

Fuel Tank Pressure Sensor Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Disconnect the fuel tank pressure sensor electrical
connector.

2 2. Using a DVM, measure the voltage between the

5V
5 volt reference circuit and the sensor ground circuit
at the fuel tank pressure sensor harness connector.
Is voltage near the specified value? Go to Step 5 Go to Step 3
Check the 5 volt reference circuit for a poor terminal
3 connection at the Control Module. —
Was a problem found? Go to Step 11 Go to Step 4
Check for an open 5 volt reference circuit to the fuel tank
4 pressure sensor harness connector. —
Was a problem found? Go to Step 10 Go to Step 8
6-3076 Engine Controls - 7.4L________________________________________________ Engine
Fuel Tank Pressure Sensor Diagnosis (cont’d)
Step Action Value(s) Yes No
1. Remove the fuel cap.
2. Using the correct test adapter from J 35616-A
connector test adapter kit, connect a jumper between
terminal A at the fuel tank pressure sensor pigtail
and terminal A at the harness connector (Control
Module side).
5 1.3-1.7V
3. Connect a second jumper between terminal C at the
fuel tank pressure sensor pigtail and terminal C at
the harness connector (Control Module side).
4. Using a DVM, measure voltage at terminal B at the
fuel tank pressure sensor pigtail.
Is voltage between the specified values? Go to Step 6 Go to Step 13
1. Check the fuel tank pressure sensor signal circuit for
a poor terminal connection at the Control Module.
6 —
2. Repair as necessary. Refer to Wiring Repairs.
Was a repair necessary? Go to Step 11 Go to Step 7
1. Check the fuel tank pressure signal circuit between
the fuel tank vapor pressure sensor connector and
the Control Module for an open, short to ground, or
7 short to voltage. —
2. Repair as necessary. Refer to Wiring Repairs.
Was a repair necessary? Go to Step 12 Go to Step 14
1. Check the sensor ground circuit for a poor terminal
connection at the Control Module.
8 —
2. Repair as necessary. Refer to Wiring Repairs.
Was a repair necessary? Go to Step 11 Go to Step 9
Check for an open in the sensor ground circuit.
9 —
Was a problem found? Go to Step 12 Go to Step 14
1. Check for a poor circuit terminal connection at the
fuel tank pressure sensor connector.
10 2. Repair as necessary. Refer to Wiring Repairs in —
Engine Electrical.
Was a repair necessary? Go to Step 11 Go to Step 13
Replace the faulty harness connector terminals as Go to
11 necessary. Refer to Wiring Repairs in Engine Electrical. — EVAP Control —
Is the action complete? System Diagnosis
Locate and repair open or short circuit in wiring harness Go to
12 as necessary. Refer to Wiring Repairs in Engine Electrical. — EVAP Control —
Is the action complete? System Diagnosis
Replace the fuel tank pressure sensor. Refer to Diagnostic Go to
13 Aids. Refer to Fuel Tank Pressure Sensor Replacement — EVAP Control —
Is the action complete? System Diagnosis
Replace the Control Module. Refer to VCM Go to
14 Replacement/Programming — EVAP Control —
Is the action complete? System Diagnosis
Engine_________________________________
Alcohol/Contaminants-in-Fuel Diagnosis
Alcohol-ln-Fuel
Notice: Do not use fuels containing methanol in
order to prevent damage and corrosion to the fuel
system.
Alcohol-in-fuel can be detrimental to the fuel system
components. Alcohol-in-fuel can cause driveability
problems such as hesitation, lack of power, stall, no
start, etc.
The problems may be due to fuel system corrosion
and subsequent fuel filter plugging, deterioration of
rubber components, and air fuel mixture leaning.
Various types and concentrations of alcohol are used
in commercial fuel. Some alcohol is more detrimental
to fuel system components than others. If an
excessive amount of alcohol in the fuel is suspected
as the cause of a driveability condition, the following
procedure may be used in order to detect the
presence of alcohol in the fuel. In this procedure,
water is used to extract the alcohol from the fuel.
Engine Controls - 7.4L 6-3077
Testing Procedure
The fuel sample should be drawn from the bottom of
the tank so that any water present in the tank will be
detected. The sample should be bright and clear. If
the sample appears cloudy, or contaminated with
water (as indicated by a water layer at the bottom of
the sample), this procedure should not be used and
the fuel system should be cleaned. Refer to Fuel
System Cleaning (Fuel Tank)
1. Using a 100 ml cylinder with 1 ml graduation
marks, fill with fuel to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid
volume to 100 ml.
3. Install a stopper.
4. Shake vigorously for 10 to 15 seconds.
5. Carefully loosen the stopper to release the
pressure.
6. Close the stopper.
7. Shake vigorously again for 10 to 15 seconds.
8. Put the graduated cylinder on a level surface
for approximately 5 minutes in order to allow
adequate liquid separation.
If alcohol is present in the fuel, the volume of the
lower layer (which would now contain both alcohol
and water) will measure greater than 10 ml.
For example, if the volume of the lower layer is
increased to 15 ml, it will indicate at least 5% alcohol
in fuel. The actual amount of alcohol may be
somewhat greater because this procedure does not
extract all of the alcohol from the fuel.
6-3078 Engine Controls - 7.4L Engine

EVAP Control System Diagnosis

|Hot It Run And Start!

Powsr Underhood
Distribution K7 *) EKIG1 | Fuse - Relay
Call 10
l aC Fu8#15 I Center
L8>l 20 A !

Mock' 0.8 PNK 539

Datals ■x
Ce»11 S
N
\
\ S108 0.5 PNK egr
539 Valve
0.8 PNK 539
A.
Evaporative Evaporative
0.8 PNK 539 Emission Emission
7 (EVAP) (EVAP)
B Canister Canister
MAFSensor B" Purge
0.8 Vacuum
BLK/ 451 Switch Valve
0.5 BLK/WHT 451 0.5
WHT
DK
S103 GRN/ 428
r~ 0.5 BRN 1982 WHT
Ground
Distribution 15 C3<GRY) 12 C1(BLU)
Call 14
• EVAP _Vehicle
1 BLK/WHT 451 1 Canister canister1Control
I Vacuum 1Module >
4G104 Switch
Signal D^L _|(VCM)itt^
33299
Circuit Description Test Description
12 volts is applied to the ignition feed circuit at Number(s) below refer to the step numbers on the
terminal A when the ignition key is turned ON. As Diagnostic Table
the engine coolant temperature rises during engine 2. Checks to see if a vacuum source is present,
operation (less than 45 *C (113 *F) or when Short along with certain conditions before the purge
Term Fuel Trim count is greater than 122, the control solenoid is commanded ON. Also shows a
module will then ground the EVAP canister purge change of vacuum as the purge solenoid is
control circuit at terminal B. The purge solenoid will being cycled.
then open the EVAP canister to purge the fuel to the 3. Checks for power to the solenoid, the ground
intake manifold for normal combustion when needed. circuit, the connections at the purge solenoid
and the solenoid itself.
4. Checks for an open or grounded ignition feed
circuit.
5. Checks for an open EVAP canister purge
control circuit or faulty control module.
Engine________________________________________________ Engine Controls - 7.4L 6-3079
EVAP Control System Diagnosis
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to the
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Set the parking brake and block the drive wheels.
2. Make sure the engine coolant temperature is greater
than the specified value.
3. Start the engine and run at idle.
4. Check the vacuum source.
5. If no vacuum, repair the cause of no vacuum. If OK,
continue with this table.
45 *C (113 *F)
2 6. Disconnect the purge outlet hose from the solenoid 2000 RPM
and connect a vacuum gauge.
7. Connect a scan tool and select the EVAP purge
solenoid control.
8. Raise the engine speed to the specified value.
9. Command the EVAP purge solenoid ON using the
scan tool.
Is vacuum present when the solenoid is energized? Go to Step 6 Go to Step 3
1. Disconnect the purge solenoid harness connector.
2. Connect a test light between the EVAP canister
purge control signal and the ignition feed circuit.
3 —
3. Command the EVAP purge solenoid ON using the
scan tool.
Is the test light ON? Go to Step 7 Go to Step 4
1. Connect the test light to an alternate ground.
4 2. Probe the ignition feed circuit. —
Is the test light ON? Go to Step 5 Go to Step 8
1. Connect the test light to B+.
2. Probe the EVAP canister purge control circuit at the
control module.
5 —
3. Command the EVAP purge solenoid ON with the
scan tool.
Is the test light ON? Go to Step 9 Go to Step 10
Check the purge line to the EVAP canister and repair if
necessary. If the purge line is OK, then no problem
6 is found. — —
Is the action complete? Go to Step 13
1. Check for faulty connections at the EVAP purge
solenoid.
7 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 11
Repair the open in the ignition feed circuit.
8 — —
Is the action complete? Go to Step 13
Repair the open in the EVAP canister purge control circuit
9 to the EVAP purge solenoid. — —
Is the action complete? Go to Step 13
1. Check for any faulty connections at the control
module.
10 —
2. If a problem is found, repair as necessary.
Was a problem found? Go to Step 13 Go to Step 12
6-3080 Engine Controls - 7.4L Engine
EVAP Control System Diagnosis (cont’d)
Step Action Value(s) Yes No
Replace the EVAP purge solenoid. Refer to the EVAP
11 Canister Purge Solenoid. — —
Is the action complete? Go to Step 13
Replace the control module. Refer to VCM
12 Repiacement/Programming. — —
Is the action complete? Go to Step 13
1. Turn the ignition ON, engine OFF.
2. Using a scan tool, command the component ON
13 —
and OFF.
Does the component operate properly? System OK Go to Step 2
Engine___________________________ Engine Controls - 7.4L 6-3081

Enhanced Ignition System Diagnosis

|HoHnJJunAndjStarlj
L°c
J" Pomr "! Underhood
i ? S rS J,ion H?i)? ECM1 i F u se- Relay
J
Ce,M0
ja ^ '
Fuse
20 a |
Center Instrument T \
Cluster1
A
. T a c h o m e te r
' Input 1
L ____ _ _ OBDIlk
A
PNK 439 6'
F u s e B lock
D etails
WHT 121 VCM
C ell 11 C1 = B LU
C 2 = RED
PNK 439 C 3 = CLEAR
C 4 = BLK

PNK 439
F u s e B lock
D etails WHT 121
C ell 11

PNK 439 PNK 439

o [ WHT/BLK 1847
Crankshaft Ignition Ignition T a c h o m e te r

Position Control Positive S ig n a l

V o lta g e
(CKP) Module Ignition
Sensor (ICM) Tim ing
S ignal G ro u n d Ignition
Coil
B CY

BLK/WHT 451
WHT 423
Coil Wire
9. ,C3
Distributor
| 4x CKP 1C
■*Vehicle
• Sensor Control j Control
1 S ignal Module A
J (VCM)
I " '
G ro u n d
Distribution
BLK/WHT 451 111 it n
C e ll 14 Spark Plugs

3 36 71

System Description be necessary to disconnect the gray ignition

This system includes the Distributor, the CAM
position sensor ignition coil with the ignition coil
driver, the secondary wires, spark plugs, the (KS)
sensors and the crank sensors. The ignition system
is controlled by the Vehicle Control Module (VCM).
The VCM monitors the information from various
engine sensors, computes the desired spark timing
and controls the dwell and firing of the ignition coil
via an (IC) line to the coil driver.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
The battery should be fully charged prior to
any tests.
1. Perform the OBD system check before
proceeding unless it was already performed. In
order to disconnect the tachometer lead, it will
coil connector from the ignition coil and jumper
the B terminal of the harness connector to the
B terminal of the ignition coil using a fused
jumper and terminal test adapter kit J 35616-A.
2. Checks for proper output from the enhanced
ignition system. The spark tester requires a
minimum of 25,000 volts to operate. This check
can be used in case of an ignition miss,
because the system may provide enough
voltage to run the engine but not enough to
operate a spark plug under heavy load. This
test also separates the distributor cap, rotor and
ignition wires from the ignition coil in order to
help identify a secondary ignition system
problem.
3. This step determines if the proper available
voltage exists in the primary ignition circuit. Also
checks ignition coil and wiring.
6-3082 Engine Controls - 7.4L
4. This check begins to determine if the VCM is
providing a signal to the ignition coil module or
not. If the VCM is not providing a signal to the
ignition coil driver module, the problem exists
between the distributor and VCM.
Engine
5. This test checks the coil driver module,
connections and wiring.
6. This test checks the wiring from the VCM to the
coil driver module and finally the VCM.

Enhanced Ignition System Diagnosis

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Check the spark plug wires for open circuits, cracks
or improper seating of terminals at the spark plugs,
distributor and ignition coil before proceeding with
the test.
2 2. Check spark at plug with J 26792 spark tester or the —
equivalent while cranking. (If there is no spark on
one wire, check a second wire). A few sparks then
nothing is considered no spark.
Is adequate spark present? Go to Hard Start Go to Step 3
1. Remove the coil wire from the ignition coil.
2. Insert J 26792 spark tester into coil wire and clamp
3 onto coil tower terminal. —
3. Crank the engine.
Is adequate spark present? Go to Step 7 Go to Step 4
1. Disconnect the ignition coil driver module connector.
2. Turn the Ignition ON.
4 3. With a DVM J 39200, check voltage on terminals A 10.0V
and D to ground.
Do both terminals measure above the specified value? Go to Step 5 Go to Step 13
1. Connect a DVM J 39200 on the DC scale to the
ignition coil driver module connector terminal B and
5 ground. 1.0-4.0V
2. Crank the engine and observe the voltage.
Is the voltage between the specified values? Go to Step 6 Go to Step 10
Probe the ignition coil driver module connector terminal C
6 with test light to B+. —
is the test lamp illuminated? Go to Step 12 Go to Step 20
1. Check the coil wire resistance using a DVM J 39200.
• The resistance should be approximately the
specified value.
7 • If J 39200 indicates an open circuit or extremely 1000 £2/inch
high resistance, replace the coil wire.
2. Retest for spark at spark plug using a J 26792 spark
tester.
Is adequate spark present? Go to Step 27 Go to Step 8
1. Remove the distributor cap.
2. Check for the following conditions:
• Cracks
8 —
• Carbon tracks
• Physical damage.
Did you find damage to the distributor cap? Go to Step 19 Go to Step 9
Engine Engine Controls - 7.4L 6-3083
Enhanced Ignition System Diagnosis (cont’d)
Step Action Value(s) Yes No
With the distributor cap removed, crank the engine and
9 check for rotation of the distributor rotor. —
Does the distributor rotor turn? Go to Step 18 Go to Step 17
1. Turn the Ignition OFF.
2. Disconnect the VCM Gray connector.
10 3. Check for continuity between the VCM connector —
terminal Ignition Control (IC) circuit and the ignition
coil driver module connector terminal B.
Is the circuit open? Go to Step 22 Go to Step 11
With a test lamp to B+, probe the VCM harness terminal
11 Ignition Control (IC) circuit. —
Is the test light on? Go to Step 23 Go to Step 26
1. Reconnect the Ignition Control Module connector.
2. Disconnect the Ignition Coil connector.
3. Connect the test light to B+.
12 4. Probe the ignition coil connector terminal C —
(engine side).
5. Crank the engine.
Does the test lamp flash? Go to Step 16 Go to Step 21
Do both of the terminals measure under the
13 10.0V
specified value? Go to Step 14 Go to Step 15
Check the following:
• A faulty ignition feed circuit to ignition coil
14 —
• A grounded external ignition coil circuit.
Was a problem found? Go to Step 19 Go to Step 24
Check the following:
• The circuit from the ignition coil to terminal D of the
15 Ignition Control Module for an open —
• A faulty ignition coil connection.
Was a problem found? Go to Step 19 Go to Step 16
1. Connect the test lamp to a ground.
2. Disconnect the Ignition Coil connector.
16 3. Turn the ignition ON. —
4. Probe terminal A of the Ignition Coil connector.
Is the test lamp on? Go to Step 24 Go to Step 14
1. Remove the distributor
17 2. Inspect the distributor. — Refer to
Was a problem found? Go to Step 25 Engine Electrical
Replace the spark plug wires.
18 — —
Is the action complete? Go to Step 27
Repair as necessary.
19 — —
Is the action complete? Go to Step 27
Repair open ignition coil driver module ground circuit.
20 Refer to Wiring Repairs in Engine Electrical. — —
Is the action complete? Go to Step 27
1. Check for a faulty ignition coil driver module
connection.
21 2. If OK, replace the ignition coil module. Refer to — —
Engine Electrical On-Vehicle.
Is the action complete? Go to Step 27
6-3084 Engine Controls - 7.4L Engine
Enhanced Ignition System Diagnosis (cont’d)
Step Action Value(s) Yes No
Repair the open 1C circuit between the VCM and the
ignition coil driver module. Refer to Wiring Repairs in
22 Engine Electrical. — —
Is the action complete? Go to Step 27
Repair the grounded 1C circuit between the VCM and the
ignition coil driver module. Refer to Wiring Repairs in
23 Engine Electrical. — —
Is the action complete? Go to Step 27
Replace the ignition coil. Refer to Engine Electrical
24 On-Vehicle. — —
Is the action complete? Go to Step 27
Replace or repair the distributor. Refer to Distributor
25 Overhaul in Engine Electrical. — —

Is the action complete? Go to Step 27

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Repiacement/Programming.
3. Perform the VTD Password Leam Procedure. Refer
26 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Leam Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 27
Operate vehicle within the conditions under which the
27 original symptom was noted. —
Does the system now operate properly? System OK Go to Step 1
Engine Engine Controls - 7.4L 6-3085

Knock Sensor System Diagnosis Circuit Description

The self check used by the control module
monitors the voltage on the KS circuit and if the
voltage is below about 0.4 or over about 4.6, a
DTC P0327 sets.
Knock Sensor (KS) DTCs: DTC P0327
A DTC set when system is in a self check, and
voltage on the KS circuit is above or below the
specified range. Refer to the applicable table.
Secondary Air Injection System
Diagnosis (overview)
Refer to Secondary Air Injection Controls
A problem with the AIR system may set one of the
following DTCs:
. DTC P0410
. DTC P1415
. DTC P1416
Air flowing to the exhaust ports at the wrong time
can cause a false lean H02S indication and cause
the VCM to add extra fuel. This will result in
increased catalytic converter temperature, because
more fuel and air will be oxidizing in the converter.
The AIR system is not completely noiseless. Under
normal conditions noises rises in pitch as engine
speed increases.
If noise is caused by the AIR system, check for the
following:
• A seized AIR pump
• Proper mounting and bolt torque of the pump
• Proper routing and connections of the hoses
A fused ignition voltage is supplied to the AIR relay.
The VCM controls the AIR pump by grounding the
AIR relay control circuit. This energizes the relay and
supplies voltage to the AIR pump clutch. When the
fuel system goes to the Closed Loop mode, the
VCM opens the ground to the AIR control circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation, or a broken wire
inside the insulation.
Check for the following conditions:
• Poor connection or damaged harness - Inspect
the harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor
terminal to wire connection, and a damaged
harness.
• Worn or loose AIR pump drive belt
• Pinched, kinked, or restricted AIR pipes, hoses,
or fittings
Test Description
Number(s) below refer to step numbers on the
Diagnostic Table
2. This step will determine if the VCM is capable
of controlling the AIR system.
3. Leaks in the AIR system may affect other
sensor operations.

Secondary Air Injection System Diagnosis (overview)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
Check performed? the Powertrain
1 — OBD System
Check (OBD
Go to Step 2 System Check)
1. Install a scan tool.
2. Start and run the engine for greater than the
specified value.
3. Verify the engine is running at normal operating 2 min
2
temperature. 6%
4. Using a scan tool, command the AIR ON.
Does the Short Term Fuel Trim indicate a change of more
than the specified value with 30 seconds? Go to Step 3 Go to Step 4
Check all AIR pipes, hoses, and fittings for leaks.
3 —
Was a problem found? Go to Step 24 System OK
1. With the engine still running, command the AIR ON.
4 2. Observe the AIR pump clutch. —

Is the AIR pump clutch engaged? Go to Step 5 Go to Step 6

6-3086 Engine Controls - 7.4L Engine
Secondary Air Injection System Diagnosis (overview) (cont’d)
Step Action Value(s) Yes No
1. With the engine still running, command the AIR
pump OFF.
5 —
2. Observe the AIR pump clutch.
Is the AIR pump clutch engaged? Go to Step 7 Go to Step 25
1. Disconnect the AIR relay.
2. Connect a test light to the ignition feed circuit and
6 —
ground.
Is the test light ON? Go to Step 7 Go to Step 14
With the AIR relay still disconnected, connect a test light
7 to the AIR relay control circuit and B+. —
Is the test light ON? Go to Step 17 Go to Step 8
1. Connect a test light to the AIR relay control circuit
and B+.
8 —
2. Using the scan tool, command the AIR pump ON.
Is the test light ON? Go to Step 10 Go to Step 15
Connect a fused jumper to the AIR pump clutch control
9 circuit and B+. —

Is the AIR pump clutch engaged? Go to Step 20 Go to Step 11

Connect a test light to the AIR pump clutch control circuit
10 and ground. —
Is the test light ON? Go to Step 22 Go to Step 9
Check for an open in the AIR pump clutch control circuit.
11 —
Was a problem found? Go to Step 24 Go to Step 12
Check for an open in the AIR pump ground circuit.
12 —
Was a problem found? Go to Step 24 Go to Step 13
Check for an open in the AIR pump clutch coil.
13 —
Was a problem found? Go to Step 24 Go to Step 2
Check for an open fuse in the AIR ignition feed circuit.
14 —
Was a problem found? Go to Step 18 Go to Step 19
Check for an open in the AIR relay control circuit.
15 —
Was a problem found? Go to Step 24 Go to Step 16
Check the terminal contact at the VCM for the AIR relay
16 control circuit. —
Was a problem found? Go to Step 24 Go to Step 23
1. Turn the ignition OFF.
2. Disconnect the Blue VCM connector.
17 3. Connect a test light between the AIR relay control —
circuit and B+.
Is the test light ON? Go to Step 21 Go to Step 23
Repair the short to ground in the ignition feed circuit to the
18 AIR relay. — —
Is the action complete? Go to Step 28
Repair the open in the ignition feed circuit to the AIR relay.
19 — —
Is the action complete? Go to Step 28
Replace the AIR relay.
20 — —
Is the action complete? Go to Step 28
Repair the short to ground in the AIR relay control circuit.
21 — —
Is the action complete? Go to Step 28
Engine________________________________________________ Engine Controls - 7.4L 6-3087
Secondary Air Injection System Diagnosis (overview) (cont’d)
Step Action Value(s) Yes No
Repair the short to voltage on the AIR pump clutch control
22 circuit. — —

Is the action complete? Go to Step 28

1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
23 to Password Learn Procedure. — —

4. Perform the Crankshaft Variation Leam Procedure.

Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 28
Repair as necessary.
24 — —
Is the action complete? Go to Step 28
1. Disconnect the AIR pump output hose at the AIR
valve.
2. Using the scan tool, command the AIR pump ON.
25 3. Accelerate the engine to approximately the 1500 RPM
specified value.
4. Observe the airflow coming from the hose.
Does the airflow increase as the engine is accelerated? Go to Step 26 Go to Step 27
1. Check for a loose or worn AIR pump drive belt.
2. Check for leaks or restrictions in the AIR pipes,
26 —
hoses, and fittings.
Was a problem found? Go to Step 24 Go to Step 28
Replace the AIR pump. Refer to Secondary Air Injection
27 Pump Replacement. — —
Is the action complete? Go to Step 28
1. Turn the ignition ON, engine OFF.
28 2. Using the scan tool, command the component ON
—
and OFF.
Does the component operate properly? System OK Go to Step 2
6-3088 Engine Controls - 7.4L Engine

EGR System Diagnosis

MAPand Fuel Tank

PressureSensors
T
VCM
GRY C1=BLU
C2=RED
474 C3- CLEAR
D JL C4=BLK
Exhaust Gas
Recirculation
(EGR) Valve
B'

BLK 470

\ I--- <4 Sensors

RED 1676 WHT 257 BLK 470

BRN 1456 GRY 474
16 A ___ __________ 20 C4 10 C2 19A . . .
27 C3
EGR EGR EGR Sensor 5Volt 11 Vehicle
Valve Valve Pintle Ground ReferenceB 1 Control
Feed Ground Position 1 Module £
Control Signal \ (VCM)

Circuit Description
In order to control the Exhaust Gas Recirculation
(EGR), the control module operates the linear EGR
valve. The linear EGR valve is a small motor with a
pintle that is normally closed. By providing a ground
path, the control module will open the pintle and
allow the exhaust gasses to pass through the valve.
The control module of the EGR is based on the
following inputs:
• The engine coolant temperature - above 25 *C.
. The TP OFF idle
. MAP
. BARO
• Park/Neutral position
• The pintle position sensor.
If DTC P0401 or P1406 is stored, refer to the
applicable DTC table. This chart is used for a
malfunctioning valve, plugged EGR passages, or
improper wiring connections.
190380
Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. At idle, the EGR valve should not be open
greater than 3%. A faulty park/neutral position
Trans Range (TR) position pressure switch or
the EGR valve stuck open will allow exhaust
gasses to enter the combustion chamber and
create a rough idle condition.
3. This step checks the ability of the pintle to be
manually commanded to the desired positions.
11. This step checks the electrical circuit of the
EGR valve and connecting components.
13. This step checks for plugged EGR passages or
a faulty EGR valve.
Engine________________________________________________ Engine Controls - 7.4L 6-3089
EGR System Check With Linear EGR Valve
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
1 —
Check (OBD
Go to Step 2 System Check)
1. Set the parking brake and block the drive wheels.
2. Install a scan tool.
3. Check the Transmission Range (TR) switch position.
4. Have the engine idling at the normal operating 0%
2 temperature. 2000 RPM
5. With a scan tool command the EGR pintle position
3%
to the specified value.
6. Increase the RPM to specified value.
Is the actual EGR pintle position greater than the
specified value? Go to Step 15 Go to Step 3
1. With a scan tool command a 25% position step
increase (0% To 25%, 25% To 50%, 50% To 75%,
75% To 100%).
2. 2. Observe the MAP and actual EGR pintle position
for the specified value. The EGR should increase by 3 sec
3
about 25% of position, and the MAP should also 2 sec
increase.
Is the actual EGR pintle position stable, and within 10% of
position of desired EGR pintle position command after the
specified value? Go to Step 4 Go to Step 6
Set the EGR pintle position to the specified value.
4 25%
Did the MAP increase when the actual pintle responded? Go to Step 5 Go to Step 13
Set desired EGR pintle position to specified value.
5 100% —
Is the desired EGR pintle position at the specified value? Go to Step 14
1. Check the fuse.
6 2. Replace the fuse if necessary. —
Is the action complete? Go to Step 16 Go to Step 7
1. Check for any open circuits in wiring to EGR
valve coil.
7 2. Repair if necessary. Refer to Wiring Repairs in —
Engine Electrical.
Is the action complete? Go to Step 16 Go to Step 8
1. Check for any faulty connections to the EGR
valve coil.
8 2. Repair if necessary. Refer to Wiring Repairs in —
Engine Electrical.
Is the action complete? Go to Step 16 Go to Step 9
1. Connect the J 39200 DVM.
9 2. Check for reference the voltage at EGR valve. 5V
Is the voltage at the specified value? Go to Step 10 Go to Step 11
1. Turn ON the ignition leaving the engine off.
2. Remove the EGR valve, leaving the connector on.
3. Push in the pintle of EGR valve.
10 Hold in the pintle of EGR valve. —
4. Check for voltage at position sensor signal
from valve.
Is any voltage present? Go to Step 11 Go to Step 14
6-3090 Engine Controls - 7.4L Engine
EGR System Check With Linear EGR Valve (cont’d)
Step Action Value(s) Yes No
1. Check for an open in circuit from control module to
EGR valve in the pintle position circuit.
11 2. Repair if necessary. Refer to Refer to Wiring Repairs —
in Engine Electrical.
Is the action complete? Go to Step 16 Go to Step 12
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
12 — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 16
1. Check the EGR valve passages for blockages.
13 2. Repair if necessary. — —
Is the action complete? Go to Step 16
Replace the EGR valve. Refer to EGR
14 Valve Replacement. — —
Is the action complete? Go to Step 16
1. EGR valve is stuck open.
2. Replace the EGR valve. Refer to EGR Valve —
15 —
Replacement.
Is the action complete? Go to Step 16
1. Turn ON the ignition leaving the engine off.
2. Using a scan tool, command the component ON
16 —
and off.
Does the component operate properly? System OK Go to Step 1
Engine________________________________
Crankcase Ventilation System Diagnosis
Results Of Incorrect Operation
• A plugged valve or hose may cause the
following conditions:
- Rough idle
- Stalling or slow idle speed
- Oil leaks
- Oil in air cleaner
- Sludge in engine
• A leaking crankcase ventilation valve or hose
may cause the following conditions:
- Rough idle
- Stalling
- High idle speed.
Functional Check
With these systems, any blow-by in excess of the
system capacity (from a badly worn engine,
sustained heavy load, etc.) is exhausted into the air
cleaner and is drawn into the engine.
Engine Controls - 7.4L 6-3091
Proper operation of the crankcase ventilation system
depends upon a sealed engine. If oil slugging or
dilution is noted and the crankcase ventilation
system is functioning properly, check the engine for
a possible cause. Correct any problems.
If an engine is idling rough, check for a clogged
crankcase ventilation valve, a dirty vent filter, air
cleaner element, or plugged hose. Replace as
required. Use the following procedure:
1. Remove the crankcase ventilation valve from
the rocker arm cover.
2. Operate the engine at idle.
3. Place your thumb over the end of the valve in
order to check for a vacuum. If there is no
vacuum at the valve, check for the
following items:
• Plugged hoses
• The manifold port
• The crankcase ventilation valve
4. Turn OFF the engine. Remove the crankcase
ventilation valve. Shake the valve. Listen for the
rattle of the check needle inside of the valve. If
valve does not rattle, replace the valve.
6-3092 Engine Controls - 7.4L Engine

Idle Air Control System Diagnosis

Idle Air
Stopper
Motor Control (IAC)
Coil Coil
Valve
B 0 A

B
LT LT VCM
C1= BLU
GRN/WHT 1749 BLU/BLK 1748
C2-RED
C3 =CLEAR
LT LT C4-BLK
GRN/BLK 444 BLU/WHT 1747

13,,____ __ 30, _____ 14>vC2

IAC IAC IAC IAC
Vehicle
Coil B Coil B Coil A Coil A . Control
High Low Low High i Module A
i(VCM)
33140
Circuit Description Important: If for some reason the air intake to the
The VCM controls idle RPM with the IAC valve. To engine is restricted, the VCM will attempt to
increase idle RPM, the VCM retracts the IAC pintle compensate by backing out the IAC pintle to
from the seat, allowing more air to bypass the maintain desired idle. If the engine has another
throttle plate. To decrease RPM, it extends the IAC source of air to the intake, the VCM will compensate
pintle valve in towards the seat, reducing air flow by extending the IAC pintle, scan IAC counts may
through the IAC valve port in the throttle body. A reach zero as the VCM tries to maintain desired idle.
scan tool will read the VCM commands to the IAC • Vacuum Leak (High Idle) - If idle is too high,
valve in counts. The higher the counts, the more air stop the engine. Fully extend (low) IAC with
allowed (higher idle). The lower the counts, the less tester.
air allowed (lower idle).
Start engine. If idle speed is above 800 RPM,
IAC Valve Reset Procedure Without A locate and correct vacuum leak including
crankcase ventilation system. Also, check for
Scan Tool
binding of throttle blade or linkage.
1. Turn ON the ignition leaving the engine OFF for
• System lean (high air/fuel ratio) - Idle speed
5 seconds.
may be too high or too low. Engine speed may
2. Turn OFF the ignition for 10 seconds. vary up and down, disconnecting IAC does not
3. Start the engine and check for proper help. May set DTC P0171. The scan tool will
operation. read Heated Oxygen Sensor (H02S) output
less than 300 mV (0.3 volt). Check for low
IAC Valve Reset Procedure With Scan Tool regulated fuel pressure or water in fuel.
1. Turn ON the ignition leaving the engine OFF. • System rich (low air/fuel ratio) - Idle speed too
2. Install a scan tool. low. Scan IAC counts are usually above 80.
System obviously rich and may exhibit black
3. Select F4 Misc. Tests. smoke exhaust. May set DTC P0172. The scan
4. Select F3 IAC System. tool will read Heated Oxygen Sensor (H02S)
5. Select F1 IAC Reset. signal fixed above 800 mV (.8 volt).

6. Use up arrow to reset IAC.
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a
non-IAC system problem that cannot be overcome
by the IAC valve. The following checks should be
made to repair a non-IAC system problem.
Check for high fuel pressure, leaking or sticking
injector. Silicone contaminated H02S scan
voltage will be slow to respond.
• Throttle body - Remove IAC valve and inspect
bore for foreign material.
• IAC Valve Electrical Connections - IAC valve
connections should be carefully checked for
proper contact.
Engine
• Crankcase Ventilation Valve - An incorrect or
faulty crankcase ventilation valve may result in
an incorrect idle speed.
Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• A/C Compressor - Refer to A/C Compressor
Control Circuit Diagnosis if circuit is shorted to
ground. If the relay is faulty, an idle problem
may exist.
Refer to Rough, Unstable, or Incorrect Idle,
Stalling.
• If intermittent poor driveability or idle symptoms
are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance
or replace IAC.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. The IAC tester is used to extend and retract
the IAC valve. Valve movement is verified by
an engine speed change. If no change in
engine speed occurs, the valve can be retested
when removed from the throttle body.
Engine Controls - 7.4L 6-3093
3. This step checks the quality of the IAC
movement in Step 2. Between 700 RPM and
about 1500 RPM the engine speed should
change smoothly with each flash of the tester
light in both extend and retract. If the IAC valve
is retracted beyond the control range (about
1500 RPM), it may take many flashes in the
extend position before engine speed will begin
to drop. This is normal on certain engines, fully
extending IAC may cause engine stall. This
may be normal.
4. Steps 2 and 3 verified proper IAC valve
operation while this step checks the IAC
circuits. Each lamp on the node light should
flash red and green while the IAC valve is
cycled. While the sequence of color is not
important if either light is OFF or does not flash
red and green, check the circuits for faults
beginning with poor terminal contacts.

Idle Air Control (IAC) System Check

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
Check performed? the Powertrain
1 — OBD System
Check (OBD
Go to Step 2 System Check)
1. Turn the ignition OFF.
2. Connect IAC driver (J 37027-A) to the IAC valve.
3. Set the parking brake and block the drive wheels.
4. Turn the A/C OFF.
2 5. Start the engine and let it idle in Park (A/T) or —
Neutral (M/T).
6. Install a scan tool and display RPM.
7. Extend and retract the IAC valve using the IAC
driver.
Does the RPM change? Go to Step 3 Go to Step 11
Does the RPM change smoothly with each flash of the
3 700-1500 RPM
IAC driver within the specified range? Go to Step 4 Go to Step 11
1. Install the appropriate node light into the control
module harness.
4 —
2. Cycle the IAC driver and observe the lights.
Do the lights flash red and green but never OFF? Go to Step 5 Go to Step 7
Using the other connector on the IAC driver pigtail, check
the resistance across the IAC coils.
5 40 to 80 ohms
Are the readings within the specified value between
terminal A to B and C to D? Go to Step 6 Go to Step 12
Check the resistance between IAC terminals B to C
6 and A to D. CO Go to
Are the resistances at the specified value? Diagnostic Aids Go to Step 12
6-3094 Engine Controls - 7.4L Engine
Idle Air Control (IAC) System Check (cont’d)
Step Action Value(s) Yes No
1. Check for faulty connector terminal contacts.
7 2. If a problem is found, repair as necessary. _ _

Was a problem found? Go to Step 14 Go to Step 8

1. Check for open circuits including connections.
8 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 9
1. Check for circuits shorted to ground or voltage.
9 2. If a problem is found, repair as necessary. —

Was a problem found? Go to Step 14 Go to Step 10

1. Check the VCM for faulty connections.
10 2. If a problem is found, repair as necessary. —

Was a problem found? Go to Step 14 Go to Step 13

1. Check IAC passages for blockages or restrictions.
11 2. If a problem is found, repair as necessary. —
Was a problem found? Go to Step 14 Go to Step 12
Replace the IAC valve. Refer to IAC Valve Replacement.
12 — —
Is the action complete? Go to Step 14
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
3. Perform the VTD Password Learn Procedure. Refer
13 to Password Learn Procedure. — —
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
Is the action complete? Go to Step 14
1. Turn the ignition ON, engine OFF.
2. Using the IAC driver, command the component to
14 —
extend and retract.
Does the component now operate properly? System OK Go to Step 2
Engine Engine Controls - 7.4L 6-3095
Inspection/Maintenance Status Following a DTC Info Clear, battery disconnect, or a
Reset Procedures control module replacement, all of the System Status
information will be set to Not Complete.
System Status For Satisfying the Federal Refer to the diagnostic support information
Inspection/Maintenance (l/M) Regulations associated with each DTC in order to obtain the
The scan tool System Info menu includes the Conditions for Running the DTC. The vehicle
System Status selection. operating conditions that the system must meet in
order for a DTC to run are the Conditions for
Several states require that the vehicle pass on-board
Running the DTC.
(OBD II system) tests for the major diagnostics prior
to having a vehicle l/M emission inspection. Some The System Status table shows the DTCs that must
areas may require that the vehicle pass the OBD II run in order for the System Status to indicate a
system tests and the l/M emission inspection in system test has been Completed.
order to renew license plates.
System Status
Using a scan tool, the technician can observe the
System Status (Complete or Not Complete) in order DTC(s) Used to Set
to verify that the vehicle meets the criteria which System Status System Status
complies with the local area requirements. Using the Catalyst P0420, P0430
System Status display, monitor any of the following
P0131, P0132, P0133,
systems or a combination of the systems (depending
P0134, P0137, P0138,
on vehicle make and model) for l/M Readiness: H02S (depending P0140, P0143, P0144,
• Catalyst on application) P0146, P0151, P0152,
• Heated Oxygen Sensor (H02S) P0153, P0154, P1133,
P1134, P1153, and P1154
• Heated Oxygen Sensor (H02S) Heater
P0135, P0141, P0147,
• Exhaust Gas Recirculation (EGR) H02S Heater
and P0155
• Evaporative Emission (EVAP)
P0401, P0404,
• Secondary Air Injection System (AIR) EGR System
P0405, P1404
Important: The System Status display indicates only P0440, P0442, P0446,
if the VCM has completed the required tests (DTCs). EVAP System P0452, P0453, P1441, or
The System Status display does not necessarily the Service Bay Test
mean that the test has passed. If a failure indication AIR System (if so equipped) P0410, P1415, and P1416
is present for a DTC associated with one of the
above systems, that test has failed. Diagnosis and
repair are necessary in order to meet the l/M
requirement. Verify that the vehicle passes all of the
diagnostic tests associated with the displayed
System Status prior to returning the vehicle to the
customer.
6-3096 Engine Controls - 7.4L Engine

Repair Instructions
VCM Replacement/Programming
Notice: In order to prevent possible electrostatic
discharge (ESD) damage to the VCM, do not touch
the connector pins or soldered components on the
circuit board.
Important: To prevent internal VCM damage, the
ignition must be turned OFF before disconnecting or
reconnecting power to the VCM (for example, battery
cable, VCM fuse, jumper cables, etc.).
Important: When replacing the production VCM with
a service VCM (controller), it is important to transfer
the broadcast code and production VCM number to
the service VCM label. This will allow positive
identification of VCM parts throughout the service life
of the vehicle.
Service of the VCM consists of either replacement of
46188 the VCM or reprogramming of the VCM. If the
diagnostics call for replacement of the VCM, it will
be necessary to transfer the Elecronic Spark Control
Module (PROM) and program the VCM using the
procedure in this section.
Removal Procedure
Important:
• The PROM / Electronic Spark Control Module
must be transferred to the replacement VCM.
• Do not remove the cover of the PROM. Use of
an unapproved PROM removal method may
cause damage to the PROM or the socket.
• The replacement VCM must be programmed
before the vehicle will run.
• The replacement VCM must also have the VTD
Password Learn Procedure completed before
the vehicle will run.
• The replacement VCM must also have the CKP
System Variation Learn Procedure completed. If
this procedure is not completed a DTC P1336
will set.
1. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Remove the connectors from the VCM.
3. Remove the spring retainer off the edge of
the VCM.
4. Slide the VCM out of the bracket at an angle.
Engine Engine Controls - 7.4L 6-3097
5. Remove the PROM / Electronic Spark Control
Module access cover.

2315
6. Remove the PROM / Electronic Spark Control
Module by gently squeezing the PROM locks
together.

10783
Installation Procedure
Important: Press only on the ends of the PROM /
Electronic Spark Control Module. Gently press on the
PROM until it is firmly seated in the socket. Listen
for the click.
Notice: In order to prevent possible electrostatic
discharge (ESD) damage to the VCM, do not touch
the connector pins or soldered components on the
circuit board.
1. Align the notches of the PROM / Electronic
Spark Control Module with the notches in the
PROM socket.

10783
6-3098 Engine Controls - 7.4L Engine
2. Install the PROM in the PROM socket.

3. Install the access cover on the VCM.

4. Install the VCM in the engine compartment.
5. Install the spring retainer over the edge of
the VCM.

2315

6. Install the connectors to the VCM.

7. The MIL, antilock and brake lamps will continue
to be enabled until the VCM is programmed.
Once the programming is complete, the lamps
will turn off and normal operation will occur.
8. Connect the negative battery cable.
9. Proceed to the VCM programming.
VCM Programming
1. Take the following steps in order to set-up for
the VCM (EEPROM) Programming.
• The battery is fully charged.
• The ignition is ON.
• The Data Link Connector (DLC) is secure.
2. Refer to up-to-date Techline terminal and
equipment user’s instructions.
3. Perform the IAC valve reset procedure with the
scan tool.
4. For a functional check perform the Powertrain
On-Board Diagnostic (OBD) System Check.
Engine Engine Controls - 7.4L 6-3099
5. If the VCM fails to program, do the following
functions:
• Check all the VCM connections.
• Check the Techline terminal and equipment
for the latest software version.
• Try again to program the VCM. If it fails
again, replace the VCM.

CKP System Variation Learn Procedure

Important: Perform the CKP System Variation Learn
Procedure, on vehicles equipped with Federal
Emissions, (RPO NF2) only.
Important: While the learn procedure is in progress,
release the throttle immediately when the engine
starts to decelerate. The engine control is returned to
the operator and the engine will respond to throttle
position after the learn procedure is complete.
Important: If the CKP System Variation Learn
Procedure cannot be completed successfully, refer to
DTC P1336 CKP System Variation Not Learned for
additional diagnostic information.
1. Install the scan tool.
2. Apply the vehicle’s parking brake.
3. Block the drive wheels.
4. Close the hood.
5. Place the vehicle’s transmission in Park (A/T) or
Neutral (M/T).
6. Idle the engine until the coolant temperature
reaches 6 5 ’ C (150'F).
7. Turn OFF all the accessories.
8. Enable the Crankshaft Position System
Variation Learn Procedure with the scan tool.
9. Apply the brakes for the duration of the
procedure.
10. Slowly raise the engine speed to 4000 RPM.
11. Immediately release the throttle when the
engine speed decreases.
12. Turn OFF the ignition for 15 seconds after the
learn procedure is completed successfully.

Password Learn Procedure

VTD Password Auto Learn Procedure
Information not present at this time.
6-3100 Engine Controls - 7.4L Engine

ECT Sensor Replacement

Removal Procedure
Notice: Use care when handling the coolant sensor.
Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Relieve the coolant pressure.
2. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect
Caution.
3. Drain the cooling system below the level
of the sensor.
4. Disconnect the electrical connector releasing
locking tab.
5. Remove the coolant sensor from engine.

Installation Procedure
1. Coat the threads (only) with sealer
P/N 9985253 or equivalent.
Tighten
Tighten the sensor to 13 N-m (10 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the coolant sensor in the engine.
3. Connect the electrical connector.
4. Refill the coolant system.
5. Connect the negative battery cable.

MAF Sensor Replacement

Removal Procedure
Important: Take care when handling the MAF. Do
Not dent, puncture, or otherwise damage the
honeywell located at the air inlet end of the MAF. Do
Not touch the sensing elements or allow anything
(including solvents and lubricants) to come in contact
with them. A small amount of GM lubricant
(P/N 99855406) may be used on the air duct only to
aid in installation. Do Not drop or roughly handle
the MAF.
1. Disconnect the 3 wire electrical connector.
2. Loosen the clamp on the intake duct.
3. Carefully remove the MAF sensor.

18380
Engine______________ Engine Controls - 7.4L 6-3101

Installation Procedure
1. Install the MAF sensor.

18380
2. Install the intake ducts.
3. Tighten the clamp.
4. Connect the electrical connector.

MAP Sensor Replacement

Other than checking for a worn grommet and loose
electrical connections, the only service possible is
unit replacement, if the diagnosis shows the sensor
to be faulty.
Removal Procedure
1. Disconnect the negative battery cable.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Disconnect the vacuum harness assembly.

3. Disconnect the electrical connector releasing
locking tab.
4. Remove the bolts or release lock tabs and
remove the sensor.

19673
6-3102 Engine Controls - 7.4L Engine
Installation Procedure
1. Install the bolts or snap sensor on bracket.
2. Connect the electrical connector.
3. Connect the vacuum harness.
4. Connect the negative battery cable.

H02S Replacement
Removal Procedure
Notice: Do not remove this pigtail from either the
heated oxygen sensor (H02S) or the oxygen sensor
(02S). Removing the pigtail or the connector will
affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the
H02S. Keep the in-line electrical connector and the
louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals.
Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way
of the oxygen sensor signal and heater wires. Any
attempt to repair the wires, connectors, or terminals
could result in the obstruction of the air reference
and degraded sensor performance.
The following guidelines should be used when
servicing the heated oxygen sensor:
• Do not apply contact cleaner or other materials
to the sensor or vehicle harness connectors.
These materials may get into the sensor
causing poor performance.
• Do not damage the sensor pigtail and harness
wires in such a way that the wires inside are
exposed. This could provide a path for foreign
materials to enter the sensor and cause
performance problems.
• Ensure the sensor or vehicle lead wires should
be bent sharply or kinked. Sharp bends or
kinks could block the reference air path through
the lead wire.
• Do not remove or defeat the oxygen sensor
ground wire (where applicable). Vehicles that
utilize the ground wired sensor may rely on this
ground as the only ground contact to the
sensor. Removal of the ground wire will cause
poor engine performance.
Engine Engine Controls - 7.4L 6-3103
• Ensure that the peripheral seal remains intact
on the vehicle harness connector in order to
prevent damage due to water intrusion. The
engine harness may be repaired using
Packard’s Crimp and Splice Seals Terminal
Repair Kit. Under no circumstances should
repairs be soldered since this could result in
the air reference being obstructed.
The Heated Oxygen Sensor (H02S) may be difficult
to remove when the engine temperature is below
48 *C (120*F). Excessive force may damage the
threads in the exhaust manifold or the exhaust pipe.
1. Disconnect the negative battery cable.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Remove the electrical connector by releasing

the locking tab.

3. Carefully back out the heated oxygen sensor.

18374
6-3104 Engine Controls - 7.4L Engine
Installation Procedure
Important: A special anti-seize compound is used on
the Heated Oxygen Sensor (H02S) threads. The
compound consists of liquid graphite and glass
beads. The graphite tends to burn away, but the
glass beads remain, making the sensor easier to
remove. New, or service replacement sensors
already have the compound applied to the threads. If
the sensor is removed from an engine and if for any
reason it is to be reinstalled, the threads must have
anti-seize compound applied before the reinstallation.
1. Coat the threads of the oxygen sensor with
anti-seize compound GM P/N 5613695 or the
equivalent if necessary.
2. Install the sensor.
Tighten
Tighten the sensor to 41 N-m (30 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices
3. Install the electrical connector.
4. Connect the negative battery cable.

TP Sensor Replacement
Removal Procedure
Notice: The TP sensor is an electrical component.
Do not soak the TP sensor in any liquid cleaner or
solvent, as damage may result.
1. Remove the air cleaner and adapter.
2. Disconnect the electrical connector releasing
locking tab.
3. Remove the two TP sensor attaching screw
assemblies.

10935
Engine Engine Controls - 7.4L 6-3105
4. Remove the TP sensor from throttle body
assembly.
5. Remove the TP sensor seal.

10936
Installation Procedure
1. Install the TP sensor seal over throttle shaft.
2. With throttle valve closed, install the TP sensor
on the throttle shaft. Rotate counterclockwise to
align mounting holes.

10936
3. Install the two TP sensor attaching screw
assemblies.
Tighten
Tighten the screw assemblies to
2.0 N.m (18.0 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices
4. Connect the electrical connector.
5. Install the air cleaner and adapter.

10935
6-3106 Engine Controls - 7.4L Engine

IAT Sensor Replacement

Removal Procedure
1. Disconnect the electrical connector releasing
locking tab.
2. Remove the IAT sensor by grasping sensor,
twist and puli out from air cleaner.

Installation Procedure
1. Install the IAT sensor.
2. Connect the electrical connector.

IAC Valve Replacement

Removal Procedure
1. Disconnect the electrical connector from the
IAC valve.

12886
Engine Engine Controls - 7.4L 6-3107

Notice: If the IAC valve has been, in service: DO

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

Cleaning and Inspection Procedure

1. Clean the IAC valve O-ring sealing surface, the
pintle valve seat, and the air passage.
• Use the carburetor cleaner and a parts
cleaning brush in order to remove carbon
deposits. Follow instructions on the container.
• Do not use a cleaner that contains methyl
ethyl ketone, an extremely strong solvent and
not necessary for this type of deposit.
• Shiny spots on the pintle or seat are normal.
They do not indicate misalignment or a bent
pintle shaft.
• If air passage has heavy deposits, remove
the throttle body for a complete cleaning.
2. Inspect the IAC valve O-ring for cuts, cracks, or
distortion. Replace if damaged.
Important: If installing a new IAC valve,
replace with an identical part. The IAC valve
pintle shape and diameter are designed for the
specific application.
6-3108 Engine Controls - 7.4L _________________________________ Engine
3. Measure the distance A between tip of IAC
valve pintle and mounting flange.
If greater than 28 mm, use finger pressure in
order to slowly retract the pintle. The force
required to retract the pintle of a new valve will
not cause damage to the valve.
Installation Procedure
1. Lubricate the IAC valve O-ring with clean
engine oil.
2. Install the IAC valve assembly.

3. Install the attaching screws.

Tighten
Tighten the IAC valve attaching screws to
3.0 N-m (26 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices

12909
Engine_____________________________ Engine Controls - 7.4L 6-3109
4. Connect the electrical connector.
5. Reset the IAC valve pintle position.
5.1. Turn the ignition switch to the ON
position for 5 seconds.
5.2. Turn the ignition switch to the OFF
position for 10 seconds.
5.3. Start the engine.
5.4. Check for the proper idle operation.

Accelerator Controls Cable Replacement

Removal Procedure
1. Remove the throttle cable from the
throttle lever.

2. Remove the accelerator cable from the engine

cable bracket.

26766
6-3110 Engine Controls - 7.4L Engine
3. Remove the accelerator cable from the cable
routing bracket.

4. Remove the accelerator cable from the

accelerator pedal (2).

5. Remove the accelerator cable from the dash

panel (1).

26786
Engine___________________________ Engine Controls - 7.4L 6-3111
Installation Procedure
1. Install the accelerator cable to the dash
panel (1).

26764
6-3112 Engine Controls - 7.4L Engine
4. Install the accelerator cable to the engine cable
bracket.

Accelerator Controls Pedal Replacement

The accelerator pedal (3) through a cable (2)
controls the throttle. There are no linkage
adjustments. Replace the accelerator control cable
with an identical replacement part.
Check all linkages and cables in order to assure free
movement with no rubbing, chafing, or binding. The
accelerator pedal must operate freely, without
binding, between the full closed and the Wide Open
Throttle (WOT).
Observe the following when performing service on
the accelerator pedal:
• The mounting surface between the support and
the dash panel must be free of insulation. The
carpet and padding in the pedal and tunnel
area must be positioned to lay flat and be free
of wrinkles and bunches.

17457
Engine Engine Controls ■ 7.4L 6-3113
• Slip the accelerator control cable through the
slot in the rod (4) before installing the
retainer (1) in the rod. Make sure it is seated
properly. Use care in pressing the retainer into
the hole, so the cable is not kinked or
damaged.
• The linkage must operate freely without binding
between the closed throttle and the full throttle
position.
• Do not place the wire, hoses, cable, and other
flexible components within 13 mm (0.52 in.) of
the cable or rod, at any point in their travel.
Throttle Body Assembly Replacement
Thread-locking Compound
Notice: Do not use a higher strength locking
compound than recommended when precoating the
screws. Doing so could make removing the screw
extremely difficult or result in damaging the
screw head.
The service repair kits are supplied with a small vial
of thread-locking compound with directions for use. If
the material is not available, use Loctite 262 or the
equivalent.
Notice: Do not immerse the TP sensor and IAC
valve in any type of cleaner. This cleaning method
may damage these electronic components.
Do not use a cleaner that contains methyl ethyl
ketone, an extremely strong solvent, and not
necessary for this type of deposit.
The throttle body metal parts may be cleaned
following the disassembly in a cold immersion-type
cleaner such as GM X-55 or the equivalent.
Cleaning Procedure 9
The throttle body assembly repair procedures cover
component replacement with the unit on the vehicle.
However, the throttle body replacement requires that
the complete unit be removed from the engine.
An 8 digit part identification number is stamped on
the bottom of the throttle body casting. Refer to this
number if servicing, or part replacement is required.
While on-vehicle or off, clean the throttle bore and
valve deposits using the carburetor cleaner and a
parts cleaning brush. Follow the instructions on
container.
The throttle body metal parts may be cleaned
following disassembly in a cold immersion-type
cleaner such as GM X-55 or equivalent.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air inlet duct fastener and duct. 18393
3. Disconnect the IAC valve and TP sensor
electrical connectors.
4. Disconnect the throttle, and cruise control
cables.
5. Remove the accelerator cable bracket bolts and
bracket.
6-3114 Engine Controls - 7.4L Engine
6. Remove the wiring harness fastener nut and
throttle body retaining studs

7. Remove the throttle body assembly.

8. Remove the flange gasket and discard.

9. Clean the gasket surface of the intake manifold.

18303
Engine________________________________________________ Engine Controls - 7.4L 6-3115

Installation Procedure
1. Install the new flange gasket.

18303
2. Install the throttle body assembly.

3. Install the throttle body retaining studs and

wiring harness fastener and nuts.
Tighten
Tighten to 25 N.m (18 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices
4. Connect the throttle and cruise control cables.
5. Install the accelerator cable bracket and bolts.
6. Connect the IAC valve and TP sensor electrical
connectors.

18299
6-3116 Engine Controls - 7.4L________________________________________________ Engine
7. Install the air inlet duct and retaining nut.
Tighten
Tighten the nut to 2 N-m (18 lb in).
8. Connect the negative battery cable.
9. With the engine OFF, check to see that the
accelerator pedal is free. Depress the pedal to
the floor and release.

18393
Engine ___________ Engine Controls - 7.4L 6-3117

Camshaft Retard Offset Adjustment
Camshaft Retard Offset Test
The ignition timing cannot be adjusted. The
distributor may need adjusting to prevent crossfire.
To insure proper alignment of the distributor, perform
the following:
1. With the ignition OFF, install a scan tool to
the DLC.
2. Start the engine and bring to normal operating
temperature.
Important: Cam Retard Offset reading will not
be accurate below 1000 RPM
3. Increase engine speed to 1000 RPM.
4. Monitor the Cam Retard Offset.
5. If the Cam Retard indicates a value of 0 ’ ± 2 *,
the distributor is properly adjusted.
6. If the Cam Retard does not indicate 0* ± 2*,
the distributor must be adjusted.1 2
Adjusting Camshaft Retard Offset
3. Using a scan tool monitor Cam Retard Offset.
4. Rotate the distributor as follows:
4.1. To compensate for a negative reading,
rotate the distributor in the
counterclockwise direction.
4.2. To compensate for a positive reading,
rotate the distributor in the clockwise
direction.
5. Repeat step 4 until 0* ±2" is obtained.
6. Turn the ignition OFF.
7. Tighten the distributor hold-down bolt to
3 N-m (25 lb. ft.).
8. Start the engine, raise engine speed to
1000 RPM and recheck Camshaft Retard
Offset.
Fuel Pressure Relief Procedure
Tools Required
J 34730 Fuel Pressure Gauge
C a u t io n : R e lie v e th e f u e l s y s t e m p re s s u r e b e fo re
s e r v ic in g fu e l s y s te m c o m p o n e n ts in o r d e r to
r e d u c e th e r is k o f f ir e a n d p e r s o n a l in ju r y .

A f t e r r e lie v in g th e s y s te m p re s s u r e , a s m a ll
a m o u n t o f fu e l m a y b e r e le a s e d w h e n s e r v ic in g
th e fu e l lin e s o r c o n n e c tio n s . In o r d e r t o re d u c e
t h e c h a n c e o f p e r s o n a l in ju r y , c o v e r t h e r e g u la t o r
a n d th e fu e l lin e fittin g s w ith a s h o p to w e l b e fo re
d is c o n n e c t in g . T h is w ill c a t c h a n y f u e l t h a t m a y
le a k o u t. P la c e th e to w e l in a n a p p ro v e d
c o n ta in e r w h e n th e d is c o n n e c tio n is c o m p le te .

1. Disconnect the negative battery cable in order

to avoid possible fuel discharge if an accidental
attempt is made to start the engine.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Loosen the fuel filler cap in order to relieve the

1. With the engine OFF, slightly loosen the
distributor hold down bolt.
Important: Cam Retard Offset reading will not
be accurate below 1000 RPM
2. Start the engine and raise engine speed to
1000 RPM.
tank vapor pressure.
3. Wrap a shop towel around the fitting while
connecting the gauge in order to avoid spillage.
4. Connect the gauge J 34730-1A or the
equivalent to the fuel pressure connection.
5. Install the bleed hose into an approved
container and open valve in order to bleed the
system pressure. The fuel connections are now
safe for servicing.
6. Drain any fuel remaining in gauge into an
approved container.
6-3118 Engine Controls - 7.4L Engine

Quick Connect Fitting(s) Service

(Metal Collar)
Removal Procedure
Tools Required
J 37088 Tool Set, Fuel Line Quick-Connect
Separator
Important: Relieve the fuel system pressure before
servicing any fuel system connection. Refer to the
Fuel Pressure Relief Procedure.
1. Slide the dust cover from the quick-connect
fitting.

2. Grasp both sides of the fitting. Twist the female

connector 1/4 turn in each direction to loosen
any dirt within the fitting.

12775

C a u tio n : W e a r s a f e t y g la s s e s w h e n u s in g
c o m p r e s s e d a ir , a s f l y i n g d ir t p a r tic le s m a y
c a u s e e y e In ju r y .

3. Blow dirt out of the fitting using compressed air.

12776
Engine Engine Controls - 7.4L 6-3119
4. Choose the correct tool from J 37088 Tool Set
for the size of the fitting. Insert the tool into the
female connector, then push inward to release
the locking tabs.

12780
5. Pull the connection apart.
N o t i c e : If it is necessary to remove rust or
burrs from a fuel pipe, use emery cloth in a
radial motion with the fuel pipe end in order to
prevent damage to the O-ring sealing surface.
6. Using a clean shop towel, wipe off the male
pipe end.
7. Inspect both ends of the fitting for dirt and
burrs. Clean or replace the components as
required.

12782
Installation Procedure
C a u tio n : In o r d e r to r e d u c e th e r is k o f fir e a n d
p e r s o n a l I n ju r y , b e fo r e c o n n e c t in g f u e l p ip e
f it t in g s , a lw a y s a p p ly a f e w d r o p s o f c le a n e n g in e
o il to th e m a le p ip e e n d s .

T h is w ill e n s u r e p r o p e r r e c o n n e c t io n a n d p r e v e n t
a p o s s ib le f u e l le a k .

D u r in g n o r m a l o p e r a tio n , t h e O - r ln g s lo c a t e d In
t h e f e m a le c o n n e c t o r w ill s w e ll a n d m a y p r e v e n t
p r o p e r r e c o n n e c t io n I f n o t lu b r ic a t e d .

1. Apply a few drops of clean engine oil to the

male pipe end.

12784
6-3120 Engine Controls - 7.4L Engine
2. Push both sides of the fitting together to cause
the retaining tabs to snap into place.

3. Once installed, pull on both sides of the fitting

to make sure the connection is secure.

12787
4. Reposition the dust cover over the
quick-connect fitting.

12789
Engine Engine Controls - 7.4L 6-3121

Quick Connect Fitting(s) Service

(Plastic Collar)
Removal Procedure
1. Grasp both sides of the quick-connect fitting.
Twist the female connector 1/4 turn in each
direction in order to loosen any dirt within the
quick-connect fitting.
C a u tio n : W e a r s a f e t y g la s s e s w h e n u s in g
c o m p r e s s e d a ir In o r d e r to p r e v e n t e y e
In ju ly .

2. Using compressed air, blow any dirt out of the

quick-connect fitting.

3. Squeeze the plastic retainer release tabs.

4. Puli the connection apart.

12778
6-3122 Engine Controls - 7.4L Engine
installation Procedure
Caution: In order to reduce the ris k o f fire and
personal Injury, before connecting fuel pipe
fittings, always apply a few drops o f clean engine
o il to the male pipe ends.
This w ill ensure proper reconnection and prevent
a possible fuel leak.
During norm al operation, the O-rlngs located In
the female connector w ill sw ell and may prevent
proper reconnection If not lubricated.
1. Apply a few drops of clean engine oil to the
male fuel pipe end.

2. Push both sides of the quick-connect fitting

together in order to cause the retaining
tabs/fingers to snap into place.

21855

3. Once installed, pull on both sides of the

quick-connect fitting in order to make sure the
connection is secure.

155399
Engine Engine Controls - 7.4L 6-3123

In-Line Fuel Filter Replacement

(Exc. Cart type)
Removal Procedure
Important: If the in-line filter is plugged, the fuel
tank should be inspected internally and cleaned if
necessary.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Disconnect the fuel feed pipes at the filter.
4. Remove the in-line fuel filter clamp attaching
hardware.
5. Remove the clamp from the filter.

Installation Procedure
1. Remove the protective caps from the new filter.
2. Install the clamp to the filter.
3. Install the in-line filter clamp attaching
hardware.
Install in the same positions as on the old filter
noting direction of fuel flow arrow.
4. Connect the fuel feed pipes to the filter and
tighten.
5. Connect the negative battery cable.
6. Inspect for fuel leaks.
6.1. Turn ON the ignition switch for
2 seconds.
6.2. Turn OFF the ignition switch for
10 seconds.
6.3. Again, turn the ignition switch to the ON
position.
6.4. Check for fuel leaks.
In-Line Fuel Filter Replacement
(Exc. Cart, type 4DR Utility)
Removal Procedure
Important: If the in-line filter is plugged, the fuel
tank should be inspected internally and cleaned if
necessary.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Disconnect the fuel feed pipes at the filter.
4. Remove the in-line fuel filter clamp attaching
hardware.
5. Remove the clamp from the filter.

18430
6-3124 Engine Controls - 7.4L Engine
Installation Procedure
1. Remove the protective caps from the new filter.
2. Install the clamp to the filter.
3. Install the in-line filter clamp attaching
hardware.
Install in the same positions as on the old filter
noting direction of fuel flow arrow.
4. Connect the fuel feed pipes to the filter and
tighten.
5. Connect the negative battery cable.
6. Check for fuel leaks.
6.1. Turn ON the ignition switch for
2 seconds.
6.2. Turn OFF the ignition switch for
10 seconds.
6.3. Again, turn the ignition switch to the ON
position.
6.4. Check for fuel leaks.
Fuel Filter Element Replacement
Removal Procedure
Important: If the in-line filter is plugged, the fuel
tank should be inspected internally and cleaned if
necessary.
C a u tio n : D o n o t d r a in th e fu e l In to a n open
c o n ta in e r . N e v e r s t o r e th e fu e l In a n open
c o n ta in e r d u e to th e p o s s ib ilit y o f a fir e o r an
e x p lo s io n .

1. Disconnect the negative battery cable.

2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
Have a dry chemical (Class B) fire extinguisher
nearby.
3. Turn the filter housing counterclockwise and
allow the fuel remaining in the filter housing to
drain into an approved container.
4. Remove the fuel filter housing and gasket from
the base.
5. Remove the fuel filter cartridge.
6. Inspect the inside of the housing for signs of
rust or corrosion. Discard the housing if rust or
corrosion is present.
Engine________________________________ Engine Controls - 7.4L 6-3125
Installation Procedure
1. Install a new housing gasket.
Apply a few drops of clean engine oil to the
gasket.
2. Install the new filter cartridge.
3. Connect the housing to the base.
Tighten
• Tighten the filter housing until the
gasket seats.
• Tighten filter housing 3/4 of a turn more.
4. Check for fuel leaks.
4.1. Turn ON the ignition switch for
2 seconds.
4.2. Turn OFF the ignition switch for
10 seconds.
4.3. Again, turn the ignition switch to the ON
position.
4.4. Check for fuel leaks.

Fuel Tank Draining Procedure

Draining Procedure
C a u tio n : G a s o lin e o r g a s o lin e v a p o rs a re h ig h ly
fla m m a b le . A fir e c o u ld o c c u r i f a n ig n itio n
s o u r c e is p r e s e n t N e v e r d r a in o r s t o r e g a s o lin e
o r d ie s e l f u e l in a n o p e n c o n ta in e r , d u e to th e
p o s s ib ilit y o f fir e o r e x p lo s io n . H a v e a d r y
c h e m ic a l ( C la s s B ) f ir e e x t in g u is h e r n e a r b y .

1. Disconnect the negative battery cable.

C a u tio n : R e fe r to B a t t e r y D is c o n n e c t C a u tio n
I n C a u t io n s a n d N o tic e s .
2. Use a hand operated pump device in order to
remove the fuel through the filler neck.
If the pump is equipped, make sure to hook up
the static ground wire to a metal part of the
gas tank before you begin.
Fuel Tank Replacement (Suburban)
Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Remove the fuel tank off-road shield, if
equipped.

18322
6-3126 Engine Controls - 7.4L Engine
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

5. Support the fuel tank and remove the tank

straps and insulator strips, if equipped.

6. Lower fuel tank shield.

18313
Engine Engine Controls - 7.4L 6-3127
7. Lower the fuel tank. Disconnect the fuel feed
and vapor hoses. Disconnect the electrical
connections at the sender.

1S321

8. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

65287
6-3128 Engine Controls - 7.4L Engine
3. Raise the tank fully.

4. Reinstall the fuel tank filler neck to the tank.

Tighten the clamp.

Tighten the strap nuts by steps, alternating

N o tic e :
between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
N o tic e : Refer to Fastener Notice
5. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).

18311
Engine Engine Controls - 7.4L 6-3129
6. Install the fuel tank off-road shield, if equipped.
7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.

Fuel Tank Replacement (2DR Utility)

Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Remove the fuel tank off-road shield, if
equipped.

18318
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18442
6-3130 Engine Controls ■ 7.4L Engine
5. Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

6. Lower the fuel tank shield.

7. Lower the fuel tank. Disconnect the fuel feed

and vapor hoses. Disconnect the electrical
connections at the sender.

18321
Engine Engine Controls - 7.4L 6-3131
8. Remove the fuel sender assembly and seal
ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

65287
3. Raise the tank fully.

18321
6-3132 Engine Controls - 7.4L Engine
4. Reinstall the fuel tank filler neck to the tank.
Tighten the clamp.

N o t i c e : Tighten the strap nuts by steps, alternating

between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
N o tic e : Refer to Fastener Notice
5. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N.m (33 lb ft).

6. Install the fuel tank off-road shield, if equipped.

7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.

18318
Engine Engine Controls - 7.4L 6-3133

Fuel Tank Replacement (Extended Cab -

Side Tank)
Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

4. Support the fuel tank and remove the tank

straps and insulator strips, if equipped.

5. Lower the fuel tank shield.

18414
6-3134 Engine Controls - 7.4L Engine
6. Lower the fuel tank.

7. Disconnect the fuel feed and vapor hoses.

8. Disconnect the electrical connections at the
sender.

9. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

65287
Engine ____________________ Engine Controls - 7.4L 6-3135
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.

65287
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

3. Raise the tank fully.

18415
6-3136 Engine Controls - 7.4L _______________________________ Engine
4. Install the fuel tank shield.

5. Reinstall the fuel tank filler neck to the tank.

Tighten the clamp.

Notice: Tighten the strap nuts by steps, alternating

between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice
6. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N.m (33 lb ft).
7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
Engine Engine Controls - 7.4L 6-3137
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.
Fuel Tank Replacement
(Pick-up - Side Tank)
Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

4. Support the fuel tank and remove the tank

straps and insulator strips, if equipped.

18407
6-3138 Engine Controls - 7.4L Engine
5. Remove the frame mounted bracket.

6. Lower the fuel tank shield.

7. Lower the fuel tank.

18409
Engine Engine Controls * 7.4L 6-3139
8. Disconnect the fuel feed and vapor hoses.
Disconnect the electrical connections at the
sender.

9. Remove the fuel sender assembly and seal

ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

65287
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.

65287
6-3140 Engine Controls - 7.4L Engine
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

3. Raise the tank fully.

4. Install the fuel tank shield.

18408
Engine Engine Controls - 7.4L 6-3141
5. Reinstall the fuel tank filler neck to the tank.
Tighten the clamp.

Notice: Tighten the strap nuts by steps, alternating

between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice
7. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).
8. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
9. 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.
6-3142 Engine Controls - 7.4L Engine
10. Check for fuel leaks.
10.1. Turn ON the ignition switch for
2 seconds.
10.2. Turn OFF the ignition switch for
10 seconds.
10.3. Again, turn the ignition switch to the ON
position.
10.4. Check for fuel leaks.
Fuel Tank Replacement (Cab and Chassis
- Side Tank)
Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18440
4. Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

18418
Engine_________________ Engine Controls - 7.4L 6-3143
5. Lower the fuel tank shield.

6. Lower the fuel tank.

7. Disconnect the fuel feed and vapor hoses.

8. Disconnect the electrical connections at the
sender.

19204
6-3144 Engine Controls - 7.4L Engine
9. Remove the fuel sender assembly and seal
ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

65287
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.

2. Raise the tank slightly and reconnect the fuel

feed and vapor hoses and the electrical
connections at the sender.

19204
Engine____________ Engine Controls - 7.4L 6-3145
3. Raise the tank fully.

18420
4. Install the fuel tank shield.

18419
5. Reinstall the fuel tank filler neck to the tank.
Tighten the clamp.

18440
6-3146 Engine Controls ■ 7.4L Engine
N o t i c e : Tighten the strap nuts by steps, alternating
between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
N o tic e : Refer to Fastener Notice
6. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).
7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.
Fuel Tank Replacement (Cab and
Chassis - Rear Tank)
Removal Procedure
1. Drain the fuel from the tank. Refer to Fuel Tank
Draining Procedure.
2. Raise the vehicle.
3. Remove the fuel tank off-road shield, if
equipped.

1B426
Engine Engine Controls - 7.4L 6-3147
4. Loosen the filler neck hose clamp at the fuel
tank and disconnect the fuel tank filler neck
from the fuel tank.

18440
5. Support the fuel tank and remove the tank
straps and insulator strips, if equipped.

6. Lower the fuel tank.

7. Disconnect the fuel feed and vapor hoses.
8. Disconnect the electrical connections at the
sender.

18425
6-3148 Engine Controls - 7.4L Engine
Remove the fuel sender assembly and seal
ring, using tool J 39765. Discard the old seal
ring. Purge the tank, if the tank is being
repaired.

Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel
feed and vapor hoses and the electrical
connections at the sender.

3. Raise the tank fully.

18425
Engine Engine Controls - 7.4L 6-3149
4. Reinstall the fuel tank filler neck to the tank.
Tighten the clamp.

Notice: Tighten the strap nuts by steps, alternating

between the four nuts, until the specified torque is
reached. A failure to tighten the strap nuts as
specified will cause the bottom of the tank to flex
upward. This will result in the fuel gauge indicating
that there is fuel remaining in the tank when the tank
runs dry.
Notice: Refer to Fastener Notice
5. Install the fuel tank brackets with insulator strips
in place.
Tighten
Tighten the strap nuts to 45 N-m (33 lb ft).

6. Install the fuel tank off-road shield, if equipped.

7. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
8. 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.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.

18426
6-3150 Engine Controls ■ 7.4L Engine

Fuel Tank Replacement (4DR Utility)

Removal Procedure
1. Drain the fuel from the fuel tank. Refer to Fuel
Tank Draining Procedure.
2. Raise the vehicle. (This must be done with a
frame hoist to allow the rear suspension
to hang.)
3. Remove the filler hose and vent hose from the
fuel tank.

1B431

4. Support the fuel tank and remove the fuel tank

straps.

5. Lower the fuel tank shield and the fuel tank.

18437
Engine Engine Controls - 7.4L 6-3151
6. Disconnect the fuel feed and vapor hoses.
Refer to Quick Connect Fitting(s) Service (Metal
Collar).
7. Disconnect the electrical connector at the
sender.

8. Remove the fuel tank.

9. Remove the fuel sender and the seal ring,

using tool J 39765. Discard the old seal ring.
Purge the tank, if the tank is being repaired.

65287
6-3152 Engine Controls ■ 7.4L Engine
Installation Procedure
1. Install the new seal ring and reinstall the
sender using tool J 39765.
2. Raise the tank and reconnect the electrical
connector at the sender.

3. Reconnect the fuel feed and vapor hoses.

Refer to Quick Connect Fitting(s) Service (Metal
Collar).

4. Raise the tank fully and reinstall the tank

shield.

18437
Engine Engine Controls - 7.4L 6-3153
5. Reinstall the tank straps.
Tighten
Tighten the bolts to 12 N-m (10 lb ft).
Notice: Refer to Fastener Notice

6. Reinstall the filler hose and the vent hose to

the tank.
7. Replenish the fuel. Reinstall the fuel tank
filler cap.
8. Reconnect the negative battery cable.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for
2 seconds.
9.2. Turn OFF the ignition switch for
10 seconds.
9.3. Again, turn the ignition switch to the ON
position.
9.4. Check for fuel leaks.

Fuel Tank Pressure Sensor Replacement

Fuel Vapor Pressure Sensor Removal
1. Lower fuel tank.
2. Relieve the fuel pressure. Refer to fuel
pressure Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank.
Refer to the following procedures:
• Fuel Tank Replacement (Extended Cab -
Side Tank) for the extended cab (side tank)
• Fuel Tank Replacement (Pick-up - Side Tank)
for the pick-up side tank
• Fuel Tank Replacement (Cab and Chassis -
Side Tank) for the cab and chassis-
side tank

64998
6-3154 Engine Controls - 7.4L________________________________________________ Engine
• Fuel Tank Replacement (Cab and Chassis -
Rear Tank) for the cab and chassis -
rear tank.
5. Disconnect electrical connector.
6. Remove Fuel Vapor Pressure sensor (1) from
fuel sender assembly (2)
Fuel Vapor Pressure Sensor Installation
1. Install the Fuel Vapor Pressure Sensor (1) on
the fuel sender assembly (2).
2. Reconnect electrical connector
3. Install the fuel tank.
Refer to the following procedures:
• Fuel Tank Replacement (Extended Cab -
Side Tank) for the extended cab (side tank)
• Fuel Tank Replacement (Pick-up - Side Tank)
for the pick-up side tank
• Fuel Tank Replacement (Cab and Chassis -
Side Tank) for the cab and chassis-
side tank
• Fuel Tank Replacement (Cab and Chassis -
Rear Tank) for the cab and chassis -
rear tank.

Filler Tube Replacement (Fleetside)

Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Raise the vehicle.

18439
Engine Engine Controls - 7.4L 6-3155
4. Wipe the vent hose connection at the fuel tank
and then disconnect the fuel filler tube
and clamp.
5. Wipe the fuel filler tube connection at the fuel
tank and then disconnect the fuel filler tube
and clamp.
6. Remove the fuel tube attaching screws (2) and
the fuel filler tube.

16440
Installation Procedure
1. Install the fuel filler tube and the fuel filler tube
attaching screws (2).
2. Connect the fuel filler vent hose and clamp.
3. Connect the fuel filler tube hose and clamp.

18440
4. Reinstall the fuel tank filler cap.
5. Reconnect the negative battery cable.
6. Check for leaks.

18439
6-3156 Engine Controls - 7.4L Engine

Filler Tube Replacement (Stepside)

Removal Procedure
1. Disconnect the negative battery cable.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Relieve the fuel system pressure. Refer to Fuel

Pressure Relief Procedure.
3. Raise the vehicle.

4. Wipe the vent hose connection at the fuel

tank and then disconnect the fuel filler tube
and clamp.
5. Wipe the fuel filler tube connection at the fuel
tank and then disconnect the fuel filler tube
and clamp.
6. Remove the fuel tube attaching screws (2) and
the fuel filler tube.

Installation Procedure
1. Install the fuel filler tube and the fuel filler tube
attaching screws (2).
2. Connect the fuel filler vent hose and clamp.
3. Connect the fuel filler tube hose and clamp.

18442
Engine Engine Controls - 7.4L 6-3157
4. Reinstall the fuel tank filler cap.
5. Reconnect the negative battery cable.
6. Check for leaks.

Fuel Sender Assembly Replacement

Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank and sender assembly.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Yukon/Tahoe.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.

Disassemble Procedure
1. Note the position of the fuel pump strainer on
the fuel pump.
2. Support the pump with one hand and grasp the
strainer with the other hand.
3. Rotate the strainer in one direction and pull off
the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the
strainer if it has contaminates and clean the
fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If
found, replace the pump.
6-3158 Engine Controls - 7.4L Engine
Assemble Procedure
N o t i c e : Do not fold or twist the strainer when
installing the sending unit. This action restricts
fuel flow.
1. Push on the outer edge of the ferrule until fully
seated.
2. Support the pump with one hand and position
the new pump strainer on pump in the same
position as noted during disassembly.

Installation Procedure
1. Install a new seal, sending assembly and lock
ring. Make sure the lock ring alignment holes fit
over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam
lock clockwise to lock it.
3. Install the fuel tank.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Yukon/Tahoe.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
4. Add fuel removed from the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.
6.1. Turn the ignition ON for 2 seconds.
6.2. Turn OFF the ignition for 10 seconds.
6.3. Again, turn the ignition switch to the ON
position.
6.4. Check for fuel leaks.
Engine Engine Controls - 7.4L 6-3159

Fuel Pump Replacement (Main)

Removal Procedure
1. Remove the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure
3. Raise the vehicle.
4. Remove the fuel tank.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Yukon/Tahoe.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
5. Reomove the fuel sender unit assembly by
turning the cam lock counterclockwise using
tool J 39765.
6. Disconnect the fuel pump from the sender
assembly.
• Pull the fuel pump up into the attaching hose
while pulling outward from the bottom
support.
• Do Not damage the rubber insulator or the
strainer.
7. Inspect the fuel pump attaching hose for signs
of deterioration.
8. Inspect the rubber sound insulation at the
bottom of the pump.
9. Inspect the strainer.
6-3160 Engine Controls - 7.4L Engine
Installation Procedure
1. Connect the fuel pump assembly into the
attaching hose.
2. Install the fuel sender assembly into the fuel
tank. Insert a new O-ring seal.
3. Install the cam lock assembly. Turn the cam
lock clockwise to lock it.
4. Install the fuel tank.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Yukon/Tahoe.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
5. Add fuel removed from the tank.
6. Check for fuel leaks.
6.1. Turn the ignition ON for 2 seconds.
6.2. Turn OFF the ignition for 10 seconds.
6.3. Again, turn the ignition switch to the ON
position.
6.4. Check for fuel leaks.
Fuel Balance Pump Replacement (Balance)
Removal Procedure
C a u t io n : R e p la c e th e O - r in g s e a ls e x p o s e d d u r in g
c o m p o n e n t s e r v ic e In o r d e r to re d u c e th e r is k o f
fir e a n d p e r s o n a l In ju r y th a t m a y r e s u lt fr o m a
f u e l le a k .

1. Disconnect the negative battery cable.

2. Loosen the filler cap(s) to relieve fuel tank
pressure.
3. Disconnect the electrical connector.

19669
Engine Engine Controls - 7.4L 6-3161
4. Clean both fuel pipe connections and
surrounding areas at the fuel pump before
disconnecting to avoid possible contamination of
the fuel system.
5. Disconnect both fuel pipes from the pump.

Installation Procedure
1. Install the new fuel pipe O-rings.
2. Position the new pump in the pump bracket.

19671
6-3162 Engine Controls - 7.4L _______________________________ Engine
3. Connect the fuel feed pipe and suction pipe to
the fuel pump.
Tighten
• Use a backup wrench to prevent the pump
from turning.
• Tighten the fittings to 30 N-m (22 lb ft).
N o tic e : Refer to Fastener Notice

4. Connect the electrical connector.

5. Connect the negative battery cable.
6. Check for fuel leaks.
6.1. Turn the ignition ON for 2 seconds.
6.2. Turn OFF the ignition for 10 seconds.
6.3. Again, turn the ignition switch to the ON
position.
6.4. Check for fuel leaks.

19669

Fuel Hose/Pipes Replacement

(Engine Compartment)
An eight digit identification number is located on the
fuel rail assembly. Refer to this number if servicing
or part replacement is required. Before removal, the
fuel rail assembly may be cleaned with a spray type
engine cleaner, GM X-30A or equivalent, following
package instructions. Do Not soak fuel rails in liquid
cleaning solvent.
N o tic e :

• Remove the 5 attaching bolts securing the fuel

rail assembly to the lower intake manifold in
order to prevent damage to the fuel rail
assembly.
• Carefully remove the fuel rail assembly in order
to prevent damage to the injector electrical
connector terminals and the injector spray tips.

19162
Engine____________________________ ____________________ Engine Controls - 7.4L 6-3163
• Cap the fittings and plug the holes plugged
when servicing the fuel rail in order to prevent
dirt and other contaminants from entering open
lines and passages. Clean the fuel rail
assembly with a GM X-30A spray type engine
cleaner or the equivalent before removal. Do
Not submerge the fuel rail in a cleaning solvent

Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Remove the intake manifold plenum. Refer to
Engine Mechanical.
4. Remove the high voltage switch assembly.
5. Disconnect the engine fuel pipes at the rail.
6. Remove the engine fuel pipe bracket bolt.
7. Remove the fuel inlet and return line O-rings
and discard.
8. Disconnect the injector electrical connectors and
remove from the coil bracket.
9. Remove the fuel rail retaining bolts (5).
10. Disconnect the vacuum hose line to pressure
regulator.
11. Remove the fuel rail from the intake manifold.
12. Remove the injector O-ring seal from the spray
tip end of each injector. Discard the seals. With
the O-ring removed, the O-ring backup may slip
off of the injector. Be sure to retain O-ring
backup for reuse.

19164
6-3164 Engine Controls - 7.4L Engine
Installation Procedure
Important: Ensure that the O-ring backups are on
the injectors before installing the new O-rings.
Lubricate the new injector O-ring seals with clean
engine oil and install on the spray tip end of each
injector.
1. Install the fuel rail assembly in intake manifold.
Tilt the rail assembly to install the injectors.

2. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolts to
10 N-m (89 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Connect the injector electrical connectors.
4. Install the new O-rings on the fuel pipes.
5. Connect the fuel feed and return lines.
Tighten
• Engine fuel pipe nuts to 27 N-m (20 lb ft).
• Use a back-up wrench on the fittings to
prevent them from turning.
Notice: Refer to Fastener Notice in Cautions
and Notices.
6. Connect the negative battery cable.
19162
7. Install the fuel filler cap.
8. Check for fuel leaks.
8.1. Turn the ignition switch to the ON
position for 2 seconds.
8.2. Turn the ignition switch to the OFF
position for 10 seconds.
8.3. Again, turn the ignition switch to the ON
position.
8.4. Check for fuel leaks.
9. Install the intake manifold plenum. Refer to
Engine Mechanical.
Engine Engine Controls - 7.4L 6-3165

Fuel Hose/Pipes Assembly Replacement

(Steel Fuel Pipe Repair)
Steel fuel lines - These are welded steel tubes,
meeting GM specifications 124-M, or its equivalent.
The fuel feed line is 3/8 inches diameter and the fuel
return line is 5/16 inches diameter. Do not use
copper or aluminum tubing to replace steel tubing.
Those materials do not have satisfactory durability to
withstand normal vehicle vibration.
Coupled hose - Do not repair the hoses. Replace
them only as an assembly.
Uncoupled hose - Use only reinforced fuel resistant
hose, made of Fluoroelastomer material. Do not use
a hose within 4 inches (100 mm) of any part of the
exhaust system, or within 10 inches (2154 mm) of
the catalytic converter. The hoses inside diameter
must match the outside diameter of the steel tubing.
Clamps - These are stainless steel, screw bank-type
clamps, #2494772, or equivalent.
Steel Fuel Line Repair
1. Cut a piece of fuel hose 4 inches (100 mm)
longer than the section of line to be removed. If
you remove more than 6 inches (152 mm), use
a combination of steel pipe and hose. The hose
length should not be more than 10 inches total.
2. With a tube cutter, cut a section of the pipe to
replace. Use the first step to form a bead on
the ends of the pipe and, also, on the new
section of pipe, if used.
3. Slide the hose clamps onto the pipe and push
the hose 2 inches (51 mm) onto each portion of
the fuel pipe. Tighten a clamp on each side of
the repair.
4. Secure fuel line to the frame.
5. Check for leaks.

Fuel Hose/Pipes Assembly Replacement

(Vapor Pipe - 4DR Utility)
Removal Procedure
N o tic e :

• Do not attempt to straighten kinked nylon pipes.

Replace any kinked nylon pipes in order to
prevent damage to the vehicle.
• Do not attempt to repair sections of nylon
pipes. Replace damaged nylon pipes.
• Replace the vapor pipes with original equipment
or parts that meet GM specifications.
• Replace the vapor hoses with original
equipment or parts meeting GM specifications.
Use only reinforced fuel-resistant hose identified
with the word Fluoroelastomer or GM 6163M on
the hose.
18448
1. Remove the hardware retaining section of the
pipe to be replaced. Note the location of
attaching hardware for installation.
6-3166 Engine Controls - 7.4L _________________________________ Engine
2. Remove the section o the pipe and hoses.
3. Inspect the hoses for cuts, swelling, cracks and
distortion. Replace as required.
4. Inspect the pipes for holes, kinks, and cracks.
Replace the sections as required.
Installation Procedure
Important:
• Follow the same routing as the original pipes
and hoses.
• Secure the pipes and hoses to prevent chafing.
1. Install the section of the pipe and hoses.
2. Install the hardware retaining section of the
pipe being replaced.

Fuel Hose/Pipes Assembly Replacement

(Vapor Pipe - Ex. 4DR Utility)
Removal Procedure
N o tic e :

• Do not attempt to straighten kinked nylon pipes.

Replace any kinked nylon pipes in order to
prevent damage to the vehicle.
• Do not attempt to repair sections of nylon
pipes. Replace damaged nylon pipes.
• Replace the vapor pipes with original equipment
or parts that meet GM specifications.
• Replace the vapor hoses with original
equipment or parts meeting GM specifications.
Use only reinforced fuel-resistant hose identified
with the word Fluoroelastomer or GM 6163M on
the hose.
1. Remove the hardware retaining section of the
pipe to be replaced. Note the location of
attaching hardware for installation.
2. Remove the section of the pipe and hoses.
3. Inspect the hoses for cuts, swelling, cracks and
distortion. Replace as required.
4. Inspect the pipes for holes, kinks, and cracks.
Replace the sections as required.
Engine Engine Controls - 7.4L 6-3167
Installation Procedure
Important:
• Follow the same routing as the original pipes
and hoses.
• Secure the pipes and hoses to prevent chafing.
1. Install the section of the pipe and hoses.
2. Install the hardware retaining section of the
pipe being replaced.

Fuel Hose/Pipes Assembly Replacement

(Fuel Pipes - 4DR Utility)
Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Disconnect the fittings at the engine
compartment fuel feed and return pipes.
4. Disconnect the fuel pipe attaching hardware.
5. Disconnect the fuel feed and return pipe nuts at
the fuel inlet and fuel outlet assembly.
6. Remove the fuel tank.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Tahoe/Yukon.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
6-3168 Engine Controls - 7.4L Engine
7. Disconnect the fuel feed and vapor hoses. On
4DR Utility, the quick-connect fittings at the fuel
sender assembly. Refer to Quick Connect
Fitting(s) Service (Metai Cottar).
8. Remove the hardware retaining section of pipe
to be replaced. Note location of attaching
hardware for installation.
9. Remove the section of pipe and hoses.
10. Remove rust or burrs from the engine
compartment fuel pipes by the following
procedure:
10.1. Use emery cloth in a radial motion with
the fuel pipe end in order to prevent
damage to the O-ring sealing surface.
10.2. Using a clean shop towel, wipe off the
male tube ends.
10.3. Inspect all the connectors for dirt and
burrs. Clean or replace the
components/assemblies as required.
Installation Procedure
1. Connect the fuel pipe attaching hardware.
Tighten
Fuel pipe attaching nuts to 27 N-m (20 lb ft)
using a back-up wrench.
Notice: Refer to Fastener Notice
2. Position new fuel pipe harness in original
location and fuel pipe harness attaching
hardware.

3. Connect the quick-connect fittings at the fuel

feed and pipe near the in-line filter and at the
fuel sender assembly. Refer to Quick Connect
Fitting(s) Service (Metal Cottar).
4. Install the fuel tank and attaching hardware if
the tank was removed.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.
7. Check for fuel leaks.
7.1. Turn the ignition switch to the ON
position for 2 seconds.
7.2. Turn the ignition switch to the OFF
position for 10 seconds.
7.3. Again, turn the ignition switch to the ON
position.
7.4. Check for fuel leaks.

18447
Engine Engine Controls - 7.4L 6-3169

Fuel Hose/Pipes Assembly Replacement

(Fuel Pipes - Ex. 4DR Utility)
Removal Procedure
1. Disconnect the negative battery cable.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Relieve the fuel system pressure. Refer to Fuel

Pressure Relief Procedure.
3. Disconnect the fittings at the engine
compartment fuel feed and return pipes.
4. Disconnect the fuel pipe attaching hardware.
5. Disconnect the fuel feed and return pipe nuts at
the fuel inlet and fuel outlet assembly.
6. Remove the fuel tank.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Tahoe/Yukon.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
7. Disconnect the fuel feed and vapor hoses.
8. Remove the hardware retaining section of pipe
to be replaced. Note location of attaching
hardware for installation.
9. Remove the section of pipe and hoses.
10. Remove rust or burrs from the engine
compartment fuel pipes by the following
procedure:
10.1. Use emery cloth in a radial motion with
the fuel pipe end in order to prevent
damage to the O-ring sealing surface.
10.2. Using a clean shop towel, wipe off the
male tube ends.
10.3. Inspect all the connectors for dirt and
burrs. Clean or replace the
components/assemblies as required.

19204
6-3170 Engine Controls - 7.4L Engine
Installation Procedure
1. Connect the fuel feed and return pipes to the
fuel rail. Finger tighten only.
2. Connect the fuel pipe attaching hardware.
Tighten
Fuel pipe attaching nuts to 27 N-m (20 lb ft)
using a back-up wrench.
Notice: Refer to Fastener Notice
3. Position new fuel pipe harness in original
location and fuel pipe harness attaching
hardware.
4. Remove protective caps from one end of both
fuel pipes.
Leave caps on other end of pipes to prevent
dirt from entering.
5. Apply a few drops of clean engine oil to the
19164 male connector tube ends.
6. Connect the quick-connect fittings at the fuel
feed and pipe near the in-line filter and at the
fuel sender assembly. Refer to Quick Connect
Fitting(s) Service (Metal Collar).
7. Install the fuel tank and attaching hardware if
the tank was removed.
8. Tighten the fuel filler cap.
9. Connect the negative battery cable.
10. Check for fuel leaks.
10.1. Turn the ignition switch to the ON
position for 2 seconds.
10.2. Turn the ignition switch to the OFF
position for 10 seconds.
10.3. Again, turn the ignition switch to the ON
position.
10.4. Check for fuel leaks.

19204
Engine
Fuel System Cleaning (Fuel Tank)
Purge the fuel tank before servicing.
Removal Procedure
1. Remove the fuel tank from the vehicle.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Tahoe/Yukon.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR. Utility.
2. Remove the fuel gage sender and pump unit.
Refer to Fuel Pump Replacement (Main).
3. Remove all remaining fuel from the tank.
4. Inspect the fuel tank for any remaining fuel.
Cleaning Procedure
Important:
• Use only oil free compressed air to blow out
the fuel pipes.
• If the in-line fuel filter is plugged, inspect the
fuel tank internally and purge if necessary.
1. Clean the fuel lines by applying air pressure in
the opposite direction of fuel flow.
2. Install tap water into the tank.
• Move the tank to the flushing area
(wash rack).
• Agitate the water vigorously and then
drain it.
3. Install a gasoline emulsifying agent into the
tank. Use an available emulsifying agent, such
as Product-Sol No. 913 or the equivalent.
4. Add water to the fuel tank.
• Refer to the emulsifying agent specifications
for the mixture ratio.
• Fill the tank with water until it overflows.
• Agitate the mixture for ten minutes.
• Drain the tank completely.
• Completely flush out any remaining mixture.
• Drain the fuel tank.
• Use an explosion meter (if available) to
check for a negative reading.
• Perform the required service work.
___________ Engine Controls - 7.4L 6-3171
Installation Procedure
1. Install tap water into the tank.
• Move the tank to the flushing area
(wash rack).
• Agitate the water vigorously and then
drain it.
2. Install a gasoline emulsifying agent into the
tank. Use an available emulsifying agent, such
as Product-Sol No. 913 or the equivalent.
3. Add water to the fuel tank.
• Refer to the emulsifying agent specifications
for the mixture ratio.
• Fill the tank with water until it overflows.
• Agitate the mixture for ten minutes.
• Drain the tank completely.
• Completely flush out any remaining mixture.
• Drain the fuel tank.
• Use an explosion meter (if available) to
check for a negative reading.
• Perform the required service work.
4. Install the fuel gage sending and pump unit.
Refer to Fuel Pump Replacement (Main).
5. Install the fuel tank into the vehicle.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Tahoe/Yukon.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR. Utility.
Inspection Procedure
Important: The fuel tank filler neck clamps must be
properly positioned and aligned. Otherwise, the filler
neck may become disconnected from the fuel tank.
Turn the ignition switch ON for two seconds then
turn the switch OFF for ten seconds. Again turn the
ignition switch ON and check for fuel leaks.
Fuel System Cleaning (Fuel Pipes)
Removal Procedure
1. Disconnect the fuel feed and return pipes at the
fuel injection unit. Refer to Fuel Hose/Pipes
Replacement (Engine Compartment).
Important:
• Inspect the in-line fuel filter for
contamination.
• Replace the fuel filter if it is plugged.
6-3172 Engine Controls - 7.4L
2. Disconnect the in-line fuel filter. Refer to In-Line
Fuel Filter Replacement (Exc. Cart type). Refer
to Fuel Filter Element Replacement Refer to
In-Line Fuel Filter Replacement (Exc. Cart, type
4DR Utility).
Important:
• Use only oil free compressed air to blow
out the fuel pipes.
• If the in-line fuel filter is plugged, inspect
the fuel tank internally and purge if
necessary.
3. Clean the fuel lines by applying air pressure in
the opposite direction of fuel flow.
Installation Procedure
1. Install a new strainer (if necessary) on the fuel
sender assembly. Refer to Fuel Sender
Assembly Replacement.
N o t i c e : Do not fold or twist the strainer when
installing the sending unit. This action restricts
fuel flow.
2. Install the fuel sender assembly with a new
10.
seal into the fuel tank.
11.
3. Install the fuel tank.
12.
• Refer to Fuel Tank Replacement (Suburban)
for the Suburban.
• Refer to Fuel Tank Replacement (2DR Utility)
for the Yukon/Tahoe.
• Refer to Fuel Tank Replacement (Pick-up -
Side Tank) for the Pick-up.
• Refer to Fuel Tank Replacement (Extended
Cab - Side Tank) for the Extended Cab.
Engine
• Refer to Fuel Tank Replacement (Cab and
Chassis - Side Tank) for the Cab and
Chassis with a side tank.
• Refer to Fuel Tank Replacement (Cab and
Chassis - Rear Tank) for the Cab and
Chassis with a rear tank only.
• Refer to Fuel Tank Replacement (4DR Utility)
for the 4DR Utility.
4. Disconnect the fuel feed pipe at the fuel
injection unit.
5. Connect a hose to the fuel feed pipe at the fuel
injection unit. Insert the other end of the hose
into a 3.8 liter (one gallon) fuel can.
6. Connect the negative battery cable.
7. Add twenty-three liters (six gallons) of clean
fuel into the fuel tank.
8. Purge the fuel pump and lines.
9. Using a fused jumper, connect the fuel pump
test terminal to B+ to operate the fuel pump.
Operate the fuel pump until 2 liters (1/2 gallon)
flows into the fuel can.
Remove the jumper.
Connect the fuel line at the fuel injection unit.
Check for fuel leaks
12.1. Turn the ignition ON for 2 seconds.
12.2. Turn OFF the ignition for 10 seconds.
12.3. Again, turn the ignition switch to the ON
position.
12.4. Check for fuel leaks.
Engine Engine Controls - 7.4L 6-3173

Fuel Pressure Connection Valve

Replacement
Removal Procedure
The fuel pressure connection is non-replaceable, but
it is serviceable.
1. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Remove the fuel pressure connection cap.

4. Use a standard valve core removal tool in order

to remove the valve core assembly.
5. Discard the valve core assembly.

Installation Procedure
1. Use the standard valve core tool in order to
install a new valve core assembly.
2. Connect the negative battery cable.
3. Inspect for fuel leaks through the
following steps:
3.1. Turn ON ignition the switch for
2 seconds.
3.2. Turn the ignition switch to the OFF
position for 10 seconds.
3.3. Turn the ignition switch back eto the ON
position.
3.4. Check for fuel leaks.

16674
6-3174 Engine Controls - 7.4L _______________________________ Engine
4. Install the fuel pressure connection cap.

Fuel Rail Assembly Replacement

An eight digit identification number is located on the
fuel rail assembly. Refer to this number if servicing
or part replacement is required. Before removal, the
fuel rail assembly may be cleaned with a spray type
engine cleaner, GM X-30A or equivalent, following
package instructions. Do Not soak fuel rails in liquid
cleaning solvent.
N o tic e :

• Remove the 5 attaching bolts securing the fuel

rail assembly to the lower intake manifold in
order to prevent damage to the fuel rail
assembly.
• Carefully remove the fuel rail assembly in order
to prevent damage to the injector electrical
connector terminals and the injector spray tips.
• Cap the fittings and plug the holes plugged
when servicing the fuel rail in order to prevent
19162 dirt and other contaminants from entering open
lines and passages. Clean the fuel rail
assembly with a GM X-30A spray type engine
cleaner or the equivalent before removal. Do
Not submerge the fuel rail in a cleaning solvent
Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Remove the intake manifold plenum. Refer to
Engine Mechanical.
4. Remove the high voltage switch assembly.
5. Disconnect the engine fuel pipes at the rail.
6. Remove the engine fuel pipe bracket bolt.
7. Remove the fuel inlet and return line O-rings
and discard.
8. Disconnect the injector electrical connectors and
remove from the coil bracket.
9. Remove the fuel rail retaining bolts (5).
10. Disconnect the vacuum hose line to pressure
regulator.
Engine Engine Controls - 7.4L 6-3175
11. Remove the fuel rail from the intake manifold.
12. Remove the injector O-ring seal from the spray
tip end of each injector. Discard the seals. With
the O-ring removed, the O-ring backup may slip
off of the injector. Be sure to retain O-ring
backup for reuse.

Installation Procedure
Important: Ensure that the O-ring backups are on
the injectors before installing the new O-rings.
Lubricate the new injector O-ring seals with clean
engine oil and install on the spray tip end of each
injector.
1. Install the fuel rail assembly in intake manifold.
Tilt the rail assembly to install the injectors.

2. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolts to
10 N-m (89 lb in).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
3. Connect the injector electrical connectors.
4. Install the new O-rings on the fuel pipes.
5. Connect the fuel feed and return lines.
Tighten
• Engine fuel pipe nuts to 27 N-m (20 lb ft).
• Use a back-up wrench on the fittings to
prevent them from turning.
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
6. Connect the negative battery cable. 19162
7. Install the fuel filler cap.
6-3176 Engine Controls - 7.4L Engine
8. Check for fuel leaks.
8.1. Turn the ignition switch to the ON
position for 2 seconds.
8.2. Turn the ignition switch to the OFF
position for 10 seconds.
8.3. Again, turn the ignition switch to the ON
position.
8.4. Check for fuel leaks.
9. Install the intake manifold plenum. Refer to
Engine Mechanical.
Fuel Pressure Regulator Replacement (SFI)
Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Remove the ignition coil.
4. Remove the intake manifold plenum. Refer to
Engine Mechanical.
5. Disconnect the vacuum line to the regulator.
6. Remove the snap ring (1) from the pressure
regulator housing.
7. Place a towel under regulator to catch any fuel,
then remove pressure regulator from fuel
socket. Twist back and forth while pulling from
the socket.
13105 8. Remove the fuel pressure regulator (2) from the
fuel rail socket.
9. Remove the pressure regulator small O-ring (6),
filter (5), large O-ring (4), O-ring backup (3),
and discard.
Installation Procedure
1. Lubricate the new pressure regulator
O-rings (3), (4), (5), (6) with clean engine oil
and install on the regulator inlet as a complete
assembly.
2. Install the snap ring retainer (1) into the slot on
the fuel regulator housing.
3. Connect the vacuum line to the regulator.
Important:
• Verify that retainer is engaged in slot in
pressure regulator housing. Grasp and pull
on regulator (2) to ensure that it is
properly seated.
• Turn ignition to ON for two seconds and
then turn OFF for 10 seconds. Once again
turn the ignition to ON and check for
fuel leaks.
13105
4. Install the intake manifold plenum. Refer to
Engine Mechanical.
Engine________________________________________________ Engine Controls - 7.4L 6-3177

Fuel Injector Replacement (SFI)

Removal Procedure
Notice: Use care in removing the fuel injectors in
order to prevent damage to the fuel injector electrical
connector pins or the fuel injector nozzles. Do not
immerse the fuel injector in any type of cleaner. The
fuel injector is an electrical component and may be
damaged by this cleaning method.
1. Disconnect the negative battery cable.
2. Relieve fuel system pressure. Refer to the Fuel
Pressure Relief Procedure.
3. Remove the intake manifold plenum. Refer to
Engine Mechanical.
4. Disconnect the fuel rail assembly. Refer to Fuel
Rail Assembly Replacement
Disassemble Procedure
1. Disconnect the electrical wiring harness
2. Remove the injector retainer clip (1) and
discard.
3. Remove the fuel injector assembly (3).
Important: When ordering new fuel injectors,
be sure to order the correct injector for the
application being serviced.
4. Remove the injector O-ring seals (2), (4), (5),
from both ends of injector and discard. Save
the O-ring backups for use on reassembly.
Assemble Procedure
1. Ensure that O-ring backups (2), (4), (5), are on
injectors before installing new O-rings. Lubricate
the new injector O-ring seals with clean engine
oil and install on the injector assembly.
2. Install the fuel injector assembly (3) into the
fuel rail injector socket with the electrical
connectors facing outward.
3. Install the new injector retainer clips (1) on the
injector fuel rail assembly by sliding the clip into
the injector groove as it snaps onto the
composite fuel rail.
Installation Procedure
1. Install the fuel rail assembly. Refer to Fuel Rail
Assembly Replacement
2. Install the intake manifold plenum. Refer to
Engine Mechanical.
13106
6-3178 Engine Controls - 7.4L Engine

Fuel Pump Relay Replacement

Removal Procedure
1. Remove the underhood electrical center cover.
2. Remove the relay.
Installation Procedure
1. Install the relay.
2. Install the underhood electrical center cover.

Fuel Pump and Engine Oil PRESS Switch

Replacement
Removal Procedure
1. Remove the electrical connector.
2. Remove the fuel pump oil pressure switch,
using wrench J 35748 if required.

Installation Procedure
1. Install the fuel pump oil pressure switch.
2. Install the electrical connector.

19625
Engine Engine Controls - 7.4L 6-3179

EVAP Canister Purge Solenoid Valve

Replacement
Removal Procedure
1. Disconnect the purge solenoid electrical
connector.
2. Remove the purge solenoid retaining bolts.
3. Remove the purge solenoid from the intake
manifold.
Installation Procedure
1. Install the purge solenoid to the intake manifold.

2. Install the purge solenoid retaining bolts.

3. Connect the purge solenoid electrical connector.

219784
6-3180 Engine Controls - 7.4L Engine

EVAP Vent Valve Replacement

Removal Procecdure
1. Disconnect air hose (3).
2. Disconnect electrical connector (5).
3. Remove EVAP vent valve (6) from clip on
EVAP canister.

Installation Procedure
1. Install vent valve (6) to clip on EVAP canister.
2. Connect electrical connector (5).
3. Connect air hose (3) to vent valve.

64993
EVAP Canister Replacement
Removal Procedure
1. Remove the screw from the mounting bracket
and canister.
2. Disconnect electrical connector (5) from EVAP
vent valve (6).
3. Remove Purge hose (2) and hose to fuel
tank (7).
4. Remove canister from vehicle

64993
Engine Engine Controls - 7.4L 6-3181
Installation Procedure
1. Install the EVAP canister and bracket screw.
2. Install hose to fuel tank (7) and purge hose (2)
3. Reconnect electrical connector to EVAP vent
valve (6).

Crankshaft Position Sensor Replacement

Removal Procedure
1. Remove the electrical connector.

2. Remove the sensor hold down bolt.

10938
6-3182 Engine Controls - 7.4L Engine
3. Remove the sensor from the timing cover.
Important: When installing or removing a
crankshaft position (CKP) sensor make sure the
sensor is fully seated and held stationary in the
front cover before torquing the hold down bolt
into the front cover. A sensor which is not
seated may result in erratic operation and lead
to the setting of false codes.
4. Inspect the sensor 0-ring for wear, cracks or
leakage.
/ Replace if necessary. Lube the new o-ring with
clean engine oil before installing.

10939
Installation Procedure
Important: Make certain that the Crankshaft Position
(CKP) sensor mounting surfaces are clean and free
of burrs before installing the CKP sensor.
1. Install the sensor into the timing cover.

2. Install the sensor hold down bolt.

Tighten
Tighten the hold down bolt to 8 N-m (71 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

10938
Engine Engine Controls - 7.4L 6-3183
3. Install the electrical connector.

1 0 9 37

Camshaft Position Sensor Replacement

Removal Procedure
1. Disconnect the negative battery cable.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t
C a u tio n .

2. Disconnect the electrical connector from the

camshaft position sensor.
3. Remove the camshaft position sensor
retaining screw.
4. Remove the camshaft position sensor.

12799
6-3184 Engine Controls - 7.4L Engine
Installation Procedure
1. Install the camshaft position sensor.
2. Install the camshaft position sensor
retaining screw.
Tighten
Tighten the screw to 4-6 N-m (35-53 lb in).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
3. Connect the electrical connector.
4. Connect the negative battery cable.

12799
Knock Sensor Replacement
Removal Procedure
The knock sensor is located in areas of the cylinder
head. On most applications, the knock sensors are
installed in a hole which is exposed to engine
coolant. Care should be exercised when servicing
these sensors.
1. Disconnect the negative battery cable.
C a u t io n : R e fe r t o 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 t io n s a n d N o tic e s .

Important: On knock sensors which are

mounted in the end of the cylinder head
draining the cooling system will not be
necessary.
2. Drain the cooling system. Refer to Engine
Cooling.
3. Remove the wiring harness connector from
knock sensor.
4. Remove the knock sensor from cylinder head.
Engine Engine Controls - 7.4L 6-3185
Installation Procedure
Important: Do not use silicon tape as this will
insulate the sensor from the engine block.
N o tic e : Refer to Fastener Notice in Cautions and
Notices.
1. After applying a water base caulk to the sensor
threads, install the knock sensor into the
cylinder head.
Tighten
Tighten to 19 N-m (14 lb ft).
2. Connect the negative battery cable.
3. Refill cooling system if required. Refer to
Engine Cooling.

Secondary Air Injection Pump

Replacement
Removal Procedure
N o t i c e : The secondary air injection (AIR) pump is a
positive displacement vane type which is
permanently lubricated. The AIR pump requires no
periodic maintenance.
1. Remove the drive belt. Refer to Engine Cooling.
2. Disconnect the AIR pump electrical connector
3. Disconnect the AIR air cleaner hose to pump.

18354
4. Disconnect the AIR output hose at the
AIR pump.

18350
6-3186 Engine Controls ■ 7.4L Engine
5. Remove the bolts holding the pump to the
mounting brackets.

6. Remove the pump.

Installation Procedure
1. Install the AIR pump.

18343
Engine Engine Controls ■ 7.4L 6-3187
2. Install the AIR pump mounting bolts
3. Connect the electrical connector

4. Connect the AIR pump output hose to the

AIR pump.

5. Connect the AIR air cleaner hose to the

AIR pump.
6. Install the pump drive belt. Refer to Engine
Cooling.

18354
6-3188 Engine Controls - 7.4L _________________________________ Engine

AIR Check Valve/Pipe Replacement -

Bank 1
Removal Procedure
1. Remove the bolt for the AIR crossover Bank 1
bracket.

2. Disconnect the AIR crossover Bank 1 hose.

3. Disconnect the AIR pump output hose at the

AIR valve.

18349
Engine Engine Controls - 7.4L 6-3189
4. Disconnect the Bank 2 AIR pipe at the
AIR valve.

5. Remove the AIR valve bracket bolt.

6. Remove the valve from the bracket.

Installation Procedure
1. Install the AIR valve to the bracket.
2. Install the AIR valve bracket bolt.

18362
6-3190 Engine Controls - 7.4L Engine
3. Connect the Bank 2 AIR pipe.

4. Connect the AIR pump output hose to the

AIR Valve.

5. Connect the AIR crossover Bank 1 hose.

18366
Engine Engine Controls - 7.4L 6-3191
6. Install the bolt for the AIR crossover Bank 1
hose bracket.

EGR Valve Replacement (DR Utility)

Removal Procedure
Important: Do not try to disassemble the linear EGR
valve. Service only as a complete assembly.
Important: Carefully note the position of the EGR
valve before removal. Do not rotate the EGR valve
180 degrees.
1. Remove the electrical connector.
2. Remove the valve to flange attaching bolts.
N o t i c e : The Linear EGR valve is an electrical
componet. DO NOT soak in any liquid cleaner
or solvent because damage may result.
3. Remove the linear EGR valve (1).
4. Remove the flange gasket.
5. Clean the linear EGR valve gasket surface.

Installation Procedure
1. Install the new flange gasket.
2. Install the linear EGR valve (1).
3. Install the Valve to flange bolts.
Tighten
3.1. Tighten the bolts the first time to
10 N-m (89 lb in) each.
3.2. Tighten the bolts a final time to
25 N-m (18 lb ft) each.
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
4. Install the electrical connector.

19627
6-3192 Engine Controls ■ 7.4L Engine

Air Cleaner Element Replacement

Removal Procedure
1. Disconnect the hold down clips.
2. Remove the air cleaner cover.
3. Remove the filter. Hold the duct and remove
the filter by pulling and twisting the filter away
from the duct.
4. Clean the air cleaner housing.

Installation Procedure
1. Install the filter.
• Install the new filter by pushing it all the way
to the stops of the duct.
• Install the duct and filter in the air cleaner
housing. Make sure that the duct fits properly
into the housing.
2. Install the air cleaner cover.
3. Connect the hold down clips.
4. Push the button on the top of the indicator to
reset it to the green (Clean) filter zone.

Air Cleaner Assembly Replacement

Removal Procedure
1. Remove the duct assembly.

18389
Engine Engine Controls - 7.4L 6-3193

3. Remove the air intake duct.

To release air intake duct from the front fender,
depress the 2 ears inward.
4. Remove the air cleaner assembly with the
bracket.
Pivot the air cleaner in an upward direction to
release the top barb on the intake duct.

Installation Procedure
1. Install the air cleaner assembly with the
bracket.
2. Install the air intake duct.

18391
6-3194 Engine Controls - 7.4L Engine
3. Install the bolt.
Tighten
Tighten the bolt to 18 N-m (13 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

4. Install the duct assembly.

Air Cleaner Intake Duct Replacement

Removal Procedure
1. Remove the retainer.
2. Remove the screw.

18366
Engine Engine Controls - 7.4L 6-3195
3. Remove the air intake duct

Installation Procedure
1. Install the air intake duct.

2. Install the screw.

Tighten
Tighten the screw 2 N-m (18 lb in).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
3. Install the retainer.

18386
6-3196 Engine Controls - 7.4L Engine

* Intake Air Resonator Replacement

Removal Procedure
1. Remove the nut.
2. Loosen the duct resonator clamp.
3. Remove the resonator.

4. Loosen the duct assembly clamps.

5. Remove the duct assembly.

Installation Procedure
1. Install the duct assembly.
2. Tighten the duct assembly clamps.

18400
Engine Engine Controls - 7.4L 6-3197
3. Install the resonator.
4. Tighten the duct resonator clamp.
5. Install the nut.
Tighten
Tighten the nut to 5 N-m (46 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

18396
6-3198 Engine Controls - 7.4L Engine

Wiring Repairs Fuse Types

Current Rating Amperes Color
Circuit Protection
Auto Fuses, Mini Fuses
Important: After you make any electrical repair,
2 Gray
always test the circuit by operating the devices in
the circuit. This confirms not only that the repair is 3 Violet
correct, but also that the cause of the complaint was 5 Tan
correctly identified. 7.5 Brown
All electrical circuits are protected against excessive 10 Red
loads which might occur because of shorts or
15 Blue
overloads in the wiring system. A fuse or circuit
breaker provides such protection. A short may cause 20 Yellow
a fuse to blow or a circuit breaker to open. 25 White
30 Green
Fuses
Maxi Fuses
20 Yellow
30 Light Green
40 Orange
60 Blue

8766
The fuse is the most common method of automotive
wiring circuit protection. Whenever there is an
excessive amount of current flowing through a circuit
the fusible element will melt and create an open or
incomplete circuit. Fuses are a "one time" protection
device and must be replaced each time the circuit is
overloaded. To determine if a fuse is blown, remove
the suspect fuse and examine the element in the
fuse for a break. If the element is broken, replace
the fuse with one of equal current rating.
Circuit Breakers
A circuit breaker is a protective device that is
designed to open the circuit when a current load is
in excess of the rated breaker capacity. If there is a
short or other type of overload condition in the
circuit, the excessive current will open the circuit
between the circuit breaker terminals. Two types of
circuit breakers are used. The first is a circuit
breaker. This type will open when excessive current
passes through it for a period of time. It will close
again after a few seconds. If the cause of the high
current is still present, it will open again. It will
continue to cycle open and closed until the condition
causing the high current is removed. The second
type of circuit breaker is a positive temperature
coefficient (PTC) circuit breaker. This type greatly
increases its resistance when excessive current
passes through it. The excessive current heats the
PTC device. As the device heats, its resistance
increases. Eventually the resistance gets so high that
the circuit is effectively open. Unlike the ordinary
circuit breaker, the PTC unit will not reset until the
circuit is opened, removing the voltage from its
terminals. Once the voltage is removed, the circuit
breaker will re-close within a second or two.
Engine Engine Controls - 7.4L 6-3199
Typical Electrical Repairs 3. Strip the insulation.
An open circuit is an incomplete circuit. Power • Use wire of equal or greater size than the
cannot reach the load or the ground. If a circuit is original. The wire’s insulation must have the
open, active components do not energize. A short same or higher temperature rating.
circuit is an unwanted connection between one part • You may use general purpose insulation for
of the circuit and either the ground or another part of areas that are not subject to high
the circuit. A short circuit causes a fuse to blow or a temperatures.
circuit breaker to open.
• Use a cross-linked polyethylene insulated
Short Circuits Caused by Damaged Wire wire for areas where high temperatures are
expected.
Insulation
- Cross-linked polyethylene wire may be
If the damage is minor, locate the problem and tape
used to replace PVC, but you may not
over the wire. If the damage is more extensive,
replace cross-linked polyethylene
replace the faulty segment of the wire. Follow the
with PVC.
instructions below in order to repair copper and
shielded cables. - Cross-linked polyethylene wire is not fuel
resistant and should not be used to
Wire Size Conversion Table replace wire where there is the possibility
of fuel contact.
Metric Wire Sizes
• Select the correct size opening in the wire
(mmfsquare]) AWG Sizes
stripper or work down from the largest size.
0.22 24
0.35 22
0.5 20
0.8 18
1.0 16
2.0 14
3.0 12
5.0 10
8.0 8
13.0 6
19.0 4
32.0 2
50.0 1/0

Splicing Copper Wire Using Splice Clips

Tools Required 8787
J 38125 Terminal Repair Kit
4. Crimp the wires.
• Select the proper clip to secure the splice.
1. Open the harness. Follow the instructions in the J 38125 Kit in
• If the harness is taped, remove the tape. order to determine the proper clip size crimp
• To avoid wiring insulation damage, use a tool and anvil.
sewing ripper in order to cut open the • Overlap the two stripped wire ends and hold
harness. them between your thumb and forefinger.
• If the harness has a black plastic conduit, • Center the splice clip under the stripped
pull out the desired wire. wires and hold it in place.
2. Cut the wire.
• Cut as little wire off the harness as possible.
• Ensure that each splice is at least 40 mm
(1.5 in) away from other splices, harness
branches, and connectors. This will help
prevent moisture from bridging adjacent
splices and causing damage.
6-3200 Engine Controls - 7.4L Engine

5. Apply steady pressure until the crimp tool 7. Apply 60/40 rosin core solder to the opening in
closes. the back of the clip. Follow the manufacturer’s
• Ensure that the wires extend beyond the clip instructions for the solder equipment.
in each direction.
• Ensure that no strands of wire are cut loose.
• Ensure that no insulation is caught under
the clip.

8. Tape the splice. Roll on enough tape in order

to duplicate the thickness of the insulation on
the existing wires.
8790
6. Crimp the splice on each end.
Engine _________ Engine Controls - 7.4L 6-3201
2. Cut the wire.
• Cut as little wire off the harness as possible.
• Ensure that each splice is at least 40 mm
(1.5 in) away from other splices, harness
branches, and connectors. This will help
prevent moisture from bridging adjacent
splices and causing damage.
3. Strip the insulation.
• Find the correct wire size.
• Select the correct size opening in the wire
stripper or work down from the largest size.
• Strip approximately 7.5 mm (5/16 in) of
insulation from each wire to be spliced.
4. Select the proper splice sleeve according to the
wire size.

9. You may tape the wire again if the wire does

not belong in a conduit or another harness
covering. Use a winding motion in order to
i
J u /
cover the first piece of tape.

Splicing Copper Wire Using Crimp and Seal N3

Splice Sleeves
Crimp and seal splice sleeves may be used on all

IKdSJCI
types of insulation except tefzel and coaxial to form
a one-to-one splice. They are to be used where
there are special requirements such as moisture
sealing. Follow the instructions below in order to
splice copper wire using crimp and seal splice
sleeves.

Crimp And Seal Splice Chart

8796
Color Splice Crimp Tool Wire Gage AWG/
Sleeve Nest Color (Metric) 5. Insert the wires into the splice sleeve
and crimp.
Salmon Red 20, 18,/ (0.5, 0.8)
• Place the splice tool in the nest so that the
Blue Blue 16, 14 /(1.0, 2.0)
crimp falls at point 1 on the splice. The
Yellow Yellow 12, 10/(3.0, 5.0) sleeve has a stop in the middle of the barrel
in order to prevent the wire from going
1. Open the harness. farther.
• If the harness is taped, remove the tape. • Close the hand crimper handles slightly in
order to hold the splice sleeve firmly in the
• To avoid wiring insulation damage, use a proper nest.
sewing ripper in order to cut open the
harness. • Insert the wire into the splice until it hits the
barrel stop.
• If the harness has a black plastic conduit,
pull out the desired wire. • Close the handles of the J 38125 until the
crimper handles open when released. The
crimper handles will not reopen until the
proper amount of pressure is applied to the
splice sleeve.
6-3202 Engine Controls - 7.4L Engine
Splicing Twisted/Shielded Cable
Twisted/shielded cable is used in order to protect
wiring from electrical noise. Two-conductor cable of
this construction is used between the radio and the
Delco-Bose® speaker/amplifier units and other
applications where low level, sensitive signals must
be carried. Follow the instructions below in order to
repair the twisted/shielded cable.

8797

6. Shrink the insulation around the splice.

• Use a torch in order to apply heat where the
barrel is crimped.
• Gradually move the heat barrel to the open
end of the tubing, shrinking the tubing as the
heat is moved along the insulation. A small
amount of sealant will come out of the end
of the tubing when sufficient shrinkage is
achieved.
1. Remove the outer jacket. Use care not to cut
into the drain wire of the mylar tape.
2. Unwrap the tape. Do not remove the tape. The
tape will be used in order to rewrap the twisted
conductors after you have made the splice.
Engine Engine Controls - 7.4L 6-3203
4. Re-assemble the cable.
• Rewrap the conductors with the mylar tape.
• Use caution not to wrap the drain wire in
the tape.
• Follow the splicing instructions for copper
wire and splice the drain wire.
• Wrap the drain wire around the conductors
and tape with mylar tape.

3. Prepare the splice. Untwist the connectors and

follow the splicing instructions for copper wire.

5. Tape over the entire cable. Use a winding

motion when you apply the tape.

6800
6-3204 Engine Controls - 7.4L
Description and Operation
Vehicle Control Module Description
The Vehicle Control Module (VCM) is located in the
engine compartment. The VCM is the control center
for the engine component systems which effect
engine operation. The VCM constantly monitors and
processes information from the various information
sensors and switches. The VCM then sends the
necessary electrical responses to control the various
control system components. Review the wiring
diagrams in order to determine which systems are
controlled by the VCM. The VCM has the ability to
perform , or run, on-board diagnostic tests on itself,
the information system components, and certain
control system components. The VCM has the ability
to alert the driver of a malfunction by illuminating a
Malfunction Indicator Lamp (MIL). The VCM has the
ability to store certain information pertaining to a
malfunction, including Diagnostic Trouble Codes
(DTC)s. Using serial data communication, a scan tool
can retrieve this information in order to be viewed by
the technician. The technician can use this
information in order to identify, diagnose, and verify
the repair of the malfunction. The VCM is sometimes
referred to as the control module.
Memory
The VCM control calibrations for a particular vehicle
are based on the Vehicle Identification Number
(VIN). The calibrations are stored in the Electrically
Erasable Programmable Read Only Memory
(EEPROM). The EEPROM is part of the VCM and
can not be replaced. The EEPROM can be
reprogrammed using the Techline equipment. The
Knock Sensor (KS) module is located in the VCM.
The KS module contains the KS system calibrations.
The KS module is not part of the VCM and is
serviced separately from the VCM. The VCM has the
ability to make corrections in the fuel control system
to allow for minor vehicle variations. This information
is stored in the Random Access Memory (RAM).
RAM needs a constant voltage supply to be
retained. Short Term Fuel Trim and Long Term Fuel
Trim are stored in RAM. When the battery is
disconnected during service of the vehicle this
memory is lost and the driver may notice a change
in the performance of the vehicle. In order to restore
this memory perform the following steps:
1. Start the engine.
2. Allow the engine to reach normal operating
temperature.
3. Drive the vehicle under idle, partial throttle and
moderate acceleration conditions.
4. Continue until normal vehicle performance
returns.
Engine
Control Module Service Precautions
Important: Do not overload any circuit. The control
module is designed to withstand the normal current
draws (Amps) that are associated with the vehicle
operations. Do not ground any of the control module
circuits unless instructed to do so. Do not apply
voltage to any of the control module circuits, when
testing for an open circuit or testing for a short
circuit.
Notice: The VCM must be maintained at a
temperature below 85 *C (185'F) at all times. This is
most critical when the vehicle is put through a paint
baking process. The VCM becomes inoperative if its
temperature 8 5 ‘ C (185 * F). It is recommended that
temporary insulation be placed around the VCM or
removed from the vehicle during the time the vehicle
is in a paint oven or other high temperature process.
Do not operate the vehicle if the insulation is on
the VCM.
Basic Knowledge And Tools Required
In order to effectively use this service information, a
general understanding of basic electrical circuits and
circuit testing tools is required. The technician must
be familiar with circuit diagrams and the meaning of
terms such as voltage, ohms, amps, and the basic
theories of electricity. The technician must
understand what happens in an open circuit and a
shorted circuit.
A complete listing of the tools needed to diagnose
and repair the system is located in Special Tools and
Equipment.
Use of Circuit Testing Tools
Important: Do not use a test lamp in order to
diagnose the control module system unless
specifically instructed by the diagnostic procedures.
Use the Connector Test Adapter Kit, J 35616
whenever the diagnostic procedure instructs the
technician to probe any of the connectors.
Notice: Since the VCM is located under the hood,
its connectors are sealed and cannot be backprobed
as in the previous model years. Do not attempt to
backprobe as a connector or seal damage
could occur.
Aftermarket (Add-On) Electrical and Vacuum
Equipment
Aftermarket (add-on) electrical and vacuum
equipment is any device installed on to a vehicle
after the vehicle has left the factory that connects to
the electrical circuits or vacuum hoses of the vehicle.
Notice: Do not attach add-on vacuum operated
equipment to this vehicle. The use of add-on vacuum
equipment may result in damage to vehicle
components or systems.
Engine
N o t i c e : Connect any add-on electrically operated
equipment to the vehicle’s electrical system at the
battery (power and ground) in order to prevent
damage to the vehicle.
Add-on electrical equipment installed as instructed
can cause the system to malfunction.
Add-on electrical equipment not connected to the
vehicle electrical circuits can cause the system to
malfunction. Examples of these types of equipment
include the following:
• Portable telephones
• Portable radios
Eliminate all add-on equipment in order to diagnose
a malfunction.
Electrostatic Discharge Damage
In order to prevent possible Electrostatic
N o tic e :
Discharge damage to the PCM, Do Not touch the
connector pins or the soldered components on the
circuit board.
Visual and Physical Underhood Inspection
Carefully perform a visual and physical underhood
inspection when performing any diagnostic
procedure. This inspection will often lead to repairing
a malfunction without further action.
Typical OBD II Drive Cycle
Diagnostic Time Schedule for l/M Readiness
Vehicle Drive Status
Cold Start, coolant temperature less than 50* C (122 *F)
Idle 2.5 minutes in Drive (Auto) Neutral (Man), A/C and rear
defogger ON
A/C off, accelerate to 90 km/h (55 mph), 1/2 throttle.
3 minutes of Steady State - Cruise at 90 km/h (55 mph)
Clutch engaged (Man), no braking, decelerate to
32 km/h (20 mph)
Accelerate to 90-97 km/h (55-60 mph), 3/4 throttle
5 minutes of Steady State Cruise at
90-97 km/h (55-60 mph)
Decelerate, no breaking. End of Drive Cycle
Total time of OBD II Drive Cycle 12 minutes
Engine Controls - 7.4L 6-3205
System Status and Drive Cycle For
Inspection/Maintenance (l/M)
Some areas require that certain vehicles run and
pass on-board diagnostic test of particular emissions
systems.
Using a scan tool, the technician has the ability to
monitor the System Status of the following systems:
• The Catalyst Monitoring system
• The Evaporative (EVAP) system
• The Oxygen Sensor (H02S)
• The Heated Oxygen Sensor (H02S) heater
• The Exhaust Gas Recirculation (EGR) system
• The Air Injection Reaction (AIR) system (if so
equipped).
Important: The System Status display indicates
whether or not a diagnostic test is completed.
Diagnose and repair the system if any of the
on-board diagnostic tests has failed the last test.
Verify that all of the required diagnostic tests pass
prior to returning the vehicle to the customer. Use
the Typical Drive Cycle table as a guide to complete
the System Status test associated with l/M.
What is Monitored?
—
H02S Heater, Misfire, Secondary Air, Fuel Trim, EVAP Purge
Misfire, Fuel Trim, Purge
Misfire, EGR, Secondary Air, Fuel Trim, H02S, EVAP Purge
EGR, Fuel Trim, EVAP Purge
Misfire, Fuel Trim, EVAP Purge
Catalyst Monitor, Misfire, EGR, Fuel Trim, H02S,
EVAP Purge
EGR, EVAP Purge
—
6-3206 Engine Controls - 7.4L Engine

System Diagnostics
The system diagnostics are tests that monitor and
evaluate a particular emissions system and the effect
that system has on vehicle emissions. The system
diagnostics consist of the following:
• The Catalyst Monitor diagnostic tests.
• The Misfire Monitor diagnostic tests.
• The Fuel Trim System diagnostic tests.
• The Evaporative (EVAP) System
diagnostic tests.

Catalyst Monitor Diagnostic Tests

The emissions control system used on this vehicle
has a Three-Way Catalytic (TWC) converter in order
to reduce exhaust emissions of Hydrocarbons (HC),
Carbon Monoxide (CO), and Oxides of Nitrogen
(NOx). The catalyst material that is inside of the
converter promotes a chemical reaction in order to
combine oxygen with the HC and CO, converting
them to water vapor (H20) and harmless Carbon
Dioxide (C02). The NOx is converted to Nitrogen (N)
by the converter.
The control module has the ability to monitor the
efficiency of the catalytic converter through the use
of a Heated Oxygen Sensor (H02S) mounted in the
engine exhaust gas stream after the catalytic
converter (post-catalyst).
Three Way Catalyst (TWC) Oxygen Storage
Capacity
A malfunctioning catalytic converter is indicated
when the post-catalyst H02S signal voltage is more
active (2), similar to the pre-catalyst H02S signal
voltage (1).
In addition to catalyst monitoring the post catalyst
H02S has a limited role in fuel control.
Important: Do not use post-catalyst H02S voltage
activity in order to determine the efficiency of the
TWC converter unless directed to do so by a
diagnostic procedure.
The catalyst monitor on-board diagnostic tests can
be effected by the following:
• A slightly degraded or marginal catalyst
• Fuel containing high amounts of the following
contaminants:
- Sulfur
- Silica
- Lead
- Phosphorus
• Exhaust system leaks may cause the following :
- Prevent a degraded or marginal TWC
converter from failing a diagnostic test.
- Cause a normally functioning TWC converter
to fail a diagnostic test.
- Prevent the diagnostic test from running.
• An aftermarket H02S.
• An aftermarket catalytic converter.

The control module monitors the post catalyst H02S

signal voltage in order to measure the oxygen
storage capacity of the converter. A good catalytic
converter is indicated when the post-catalyst H02S
signal voltage is relatively steady (2) compared to
the pre-catalyst H02S signal voltage (1).
Engine
Misfire Monitor Diagnostic Tests
When the engine is running and a cylinder misfires
the crankshaft slows down momentarily. The control
module has the ability to detect this change in speed
by monitoring the input signals from the following
sensors:
• The Crankshaft Position (CKP) sensor
• The Camshaft Position (CMP) sensor.
When the control module is running the misfire
on-board diagnostic tests and a misfire is detected
the misfire counter stores (accumulates) the position
Engine Controls - 7.4L 6-3207
and the number of misfires. Two counters
(accumulators) are assigned to each of the cylinders.
The counters are as follows:
• The Current Misfire Counters. The current
misfire counters store the number misfires that
have occurred in the last 200 engine cycles.
When the control module detects a
unacceptable amount of misfires stored in a
current misfire counter the misfire on-board
diagnostic test fails and a misfire DTC will set.
• The History Misfire Counters. When a misfire
DTC is set, the history misfire counters store
the total number of misfires that have occurred
every 200 engine cycles.
6-3208 Engine Controls - 7.4L Engine

Misfire Counters

CYLS 5-8
C YL1 CYL 2 CYL 3 CYL 4.o. (AS APPLICABLE)
MISFIRES MISFIRES MISFIRES MISFIRES MISFIRES
0 - 200-0 0

HISTORY HISTORY HISTORY HISTORY HISTORY

1356 4 0 4 0

The Misfire Counters graphic illustrates how the
misfire diagnosis and the Diagnostic Executive use
the misfire counters (accumulators). When a misfire
diagnostic test fails and reports to the Diagnostic
Executive that a misfire condition exist, the
Diagnostic Executive reviews all of the misfire
counters in order to store the most current misfire
information.
In the example illustrated by the Misfire Counters
graphic, a misfire DTC has been set and the misfires
are stored in more than one History Misfire counter
(accumulator). The cylinder number 1 History Misfire
and Current Misfire counters indicates a far greater
number of misfires than the other cylinders. The
misfires stored in the cylinder number 2 and the
cylinder number 4 History Misfire counters
(accumulators) indicate the erratic rotation of the
17378
crankshaft caused by the misfire of number 1
cylinder. In this example, viewing the Current Misfire
and History Misfire counters indicate that a true
misfire is present and the malfunction is located at
cylinder number 1.
Use a scan tool in order to monitor the misfire
counters data. Identify which cylinder or cylinders are
misfiring. Inspect the systems and components
common to the cylinders if multiple cylinders indicate
a misfire is present.
Fuel Trim System Monitor Diagnostic Tests
The fuel trim monitor diagnostic tests monitor the
fuel trim values. When the diagnostic tests indicate
that the fuel trim system has reached the limits of
fuel control at certain engine operating conditions, a
fuel trim DTC will set.
Engine
Component Diagnostics
The component diagnostics are tests that monitor
and evaluate the emission related input components
and output components related to the control
module. The control module tests the components,
the components circuits, and the performance of
these components.
Serial Data Communications
Class II Serial Data
U.S. Federal regulations require that all automobile
manufacturers establish a common communications
system. This vehicle utilizes the Class II
communications system. Each bit of information can
have one of two lengths: long or short. This allows
the vehicle wiring to be reduced by the transmission
and reception of the multiple signals over a single
wire. The messages which are carried on Class II
data streams are also prioritized. In other words, if
two messages attempt to establish communications
on the data line at the same time, only the message
with the higher priority will continue. The device with
the lower priority message must wait. The most
significant result of this regulation is that the
regulation provides the scan tool manufacturers with
the capability of accessing the data from any make
or model vehicle sold in the United States.
The Diagnostic Executive
The Diagnostic Executive is a unique segment of the
software which is designed to coordinate and
prioritize the diagnostic procedures as well as define
the protocol for recording and displaying their results.
The main responsibilities of the Diagnostic
Executive are:
• Monitoring the Diagnostic Test Enabling
Conditions
• Requesting the Malfunction Indicator Light (MIL)
• Illuminating the MIL.
• Recording Pending, Current, and History DTCs
• Storing and Erasing Freeze Frame Data
• Monitoring and Recording Test Status
information
On-Board Diagnotic Tests
A diagnostic test is a series of steps which has a
beginning and an end. The result of which is a pass
or fail reported to the Diagnostic Executive. When a
diagnostic test reports a pass result, the Diagnostic
Executive records the following data:
• The diagnostic test has completed since the
last ignition cycle
• The diagnostic test has passed during the
current ignition cycle
• The fault identified by the diagnostic test is not
currently active
Engine Controls - 7.4L 6-3209
When a diagnostic test reports a fail result, the
Diagnostic Executive records the following data:
• The diagnostic test has completed since the
last ignition
• The fault identified by the diagnostic test is
currently active
• The fault has been active during this
ignition cycle
• The operating conditions at the time of the
failure
Trip
The ability for a diagnostic test to run depends
largely upon whether or not a Trip has been
completed. A Trip for a particular diagnostic is
defined as a key ON and key OFF cycle in which all
the enabling criteria for a given diagnostics as been
met allowing the diagnostic to run vehicle operation,
followed by an engine OFF period of duration and
driving mode such that any particular diagnostic test
has had sufficient time to complete at least once.
The requirements for trips vary as they may involve
items of an unrelated nature; driving style, length of
trip, ambient temperature, etc. Some diagnostic tests
run only once per trip (e.g. catalyst monitor) while
others run continuously (e.g. misfire and fuel system
monitors). If the proper enabling conditions are not
met during that ignition cycle, the tests may not be
complete or the test may not have run.
Warm-Up Cycle
A Warm-up cycle consists of an engine start-up and
vehicle operation such that the coolant temperature
has risen greater than 40 * F from the start-up
temperature and reached a minimum engine coolant
temperature of 160* F. If this condition is not met
during the ignition cycle, the diagnostic may not run.
Diagnostic Information
The diagnostic Tables and the functional checks are
designed in order to locate a poor circuit or a
malfunctioning component through a process of
logical decisions. The Tables are prepared with the
assumption that the vehicle functioned correctly at
the time of assembly and that there are no multiple
faults present.
There is a continuous self-diagnosis on certain
control functions. This diagnostic capability is
complemented by the diagnostic procedures which
are contained in this manual. The language of
communicating the source of the malfunction is a
system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code will set and the Malfunction
Indicator Lamp (MIL) will illuminate on some
applications.
6-3210 Engine Controls - 7.4L
Malfunction Indicator Lamp (MIL)
The MIL (Malfunction Indicator Lamp) is on the
instrument panel. The MIL has the following
functions:
• The MIL informs the driver that a fault that
affects the emission levels of the vehicle has
occurred. The owner should take the vehicle in
for service as soon as possible.
• As a bulb and system check, the MIL
(Malfunction Indicator Lamp) comes ON with
the key ON and the engine not running. When
the engine is started, the MIL turns OFF if no
DTCs are set.
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.
MIL Requests and History Codes
The Diagnostic Executive must acknowledge when
all the emissions related diagnostic tests have
reported a pass or fail condition since the last
ignition cycle. Each diagnostic test is separated
into 4 types:
• Type A - Is emissions related, and turns ON
the MIL the first time the diagnostic executive
reports a fault.
• Type B - Is emissions related, and turns ON
the MIL if the fault is active for 2 consecutive
driving cycles.
• Type C - Is non-emissions related, and does
not turn ON the MIL but will turn on the
service light.
• Type D - Is non -emission related and does not
turn ON the MIL or the service light.
When a type A diagnostic test reports a failure, the
Diagnostic Executive immediately requests to have
the MIL turn ON for that diagnostic test. When a
type B diagnostic test reports a failure during 2
consecutive trips, the Diagnostic Executive turns on
the MIL for that diagnostic test. The Diagnostic
Executive has the option of turning the MIL OFF
when the diagnostic test which caused the MIL to
illuminate the passes for 3 consecutive trips. In the
case of misfire or fuel trim malfunctions, there are
additional requirements as follows:
• The load conditions must be within 10% of the
vehicle load present when the diagnostic
executive reported the failure.
• The engine speed conditions must be within
375 RPM of the engine speed present when
the diagnostic executive reported the failure.
• The engine coolant temperature must have
been in the same range present when the
diagnostic executive reported the failure.
Engine
When the Diagnostic Executive requests the service
light to be turned ON or a type C diagnostic fault is
reported, a history DTC is also recorded for the
diagnostic test. The provision for clearing a history
DTC for any diagnostic tests requires 40 subsequent
warm-up cycles during which no diagnostic tests
have reported a fail, a battery disconnect, or a scan
tool clear info command.
Special Cases Of Type A Diagnostic Tests
Unique to the misfire diagnostic, the Diagnostic
Executive has the capability of alerting the driver of
potentially damaging levels of misfire. If a misfire
condition exists that could potentially damage the
catalytic converter, the Diagnostic Executive will
command the MIL to flash at a rate of once per
second during the times that the catalyst damaging
misfire condition is present.
Special Cases Of Type B Diagnostic Tests
Misfire and fuel trim malfunctions are special cases
of type B diagnostics. Each time a fuel trim
malfunction is detected, the engine load, the engine
speed, and the engine coolant temperatures are
recorded.
When the ignition is turned off, the last reported set
of conditions remain stored. During subsequent
ignition cycles, the stored conditions are used as a
reference for similar conditions. If a fuel trim
malfunction occurs during 2 consecutive trips, the
Diagnostic Executive treats the failure as a normal
type B diagnostic. The Diagnostic Executive does not
use the stored conditions. However, if a fuel trim
malfunction occurs on 2 non-consecutive trips, the
stored conditions are compared with the current
conditions. The MIL will then illuminate under the
following conditions:
• When the engine load conditions are within
10% of the previous test that failed.
• The engine speed is within 375 RPM of the
previous test that failed.
• The engine coolant temperature is in the same
range as the previous test that failed.
Storing And Erasing Freeze Frame Data
Government regulations require that the engine
operating conditions are to be captured whenever
the MIL is illuminated. The data that is captured is
called Freeze Frame data. The Freeze Frame data is
very similar to a single record of operating
conditions. Whenever the MIL is illuminated, the
corresponding record of operating conditions is
recorded to the Freeze Frame buffer.
Engine
Each time a diagnostic test reports a failure, the
current engine operating conditions are recorded in
the failure records buffer. A subsequent failure will
update the recorded operating conditions. The
following operating conditions for the diagnostic test
which failed typically include the following
parameters:
• The Air Fuel Ratio
• The Air Flow Rate
• The Fuel Trim
• The Engine Speed
• The Engine Load
• The Engine Coolant Temperature
• The Vehicle Speed
• The TP Angle
. The MAP/BARO
• The Injector Base Pulse Width
• The Loop Status
Freeze Frame data can only be overwritten with the
data associated with a misfire or a fuel trim
malfunction. The data from these faults take
precedence over data that is associated with any
other fault. The freeze frame data will not be erased
unless the associated history DTC is cleared.
Intermittent Malfunction Indicator Lamp
In the case of an intermittent fault, the MIL
(Malfunction Indicator Lamp) may illuminate and then
after 3 trips turn OFF. However, the corresponding
diagnostic trouble code will store in the memory.
When unexpected diagnostic trouble codes appear,
check for an intermittent malfunction.
Data Link Connector (DLC)
The provision for communicating with the control
module is a Data Link Connector (DLC). The DLC is
usually located under the instrument panel. The DLC
is used in order to connect to a scan tool. Some
common uses of the scan tool are listed below:
• Identifying stored Diagnostic Trouble
Codes (DTCs)
• Clearing the DTCs
• Performing the output control tests
• Reading the serial data
Control Module Learning Ability
The control module has a learning ability which
allows the control module to make corrections for
minor variations in the fuel system in order to
improve driveability. Whenever the battery cable is
disconnected, the learning process resets.
The driver may note a change in vehicle
performance. In order to allow the PCM to re-learn
to drive the vehicle at part throttle with moderate
acceleration. The vehicle may also operate at idle
conditions until the normal performance returns.
___________ Engine Controls ■ 7.4L 6-3211
Reprogramming (Flashing) The Control
Module
Some vehicles allow the reprogramming of the
control module without removal from the vehicle. This
provides a flexible and a cost-effective method of
making changes in software and calibrations.
Refer to the latest Techline information on
reprogramming or flashing procedures.
Verifying Vehicle Repair
Verification of the vehicle repair will be more
comprehensive for vehicles with OBD II system
diagnostics. Following a repair, the technician should
perform the following steps:
1. Review the fail records and the Freeze Fame
data for the DTC which was diagnosed. Record
the fail records or Freeze Fame data. The
Freeze Frame data will only store for an A or B
type diagnostic and only if the MIL has
illuminated.
2. Clear the DTCs.
3. Operate the vehicle within the conditions noted
in the fail records or the Freeze Frame data.
4. Monitor the DTC status information for the
specific DTC which has been diagnosed until
the diagnostic test associated with that
DTC runs.
Following these steps are very important in verifying
repairs on the OBD II systems. Failure to follow
these steps could result in an unnecessary repair.
Reading Diagnostic Trouble Codes
Use a diagnostic scan tool in order to read the
diagnostic trouble codes. Failure to follow this step
could result in unnecessary repairs.
Clearing Diagnostic Trouble Codes
In order to clear Diagnostic Trouble Codes (DTCs),
use the diagnostic scan tool clear DTCs or clear info
function. When clearing DTCs follow the instructions
supplied by the tool manufacturer. When a scan tool
is not available, disconnecting one of the following
sources for at least thirty (30) seconds can also
clear the DTCs:
Notice: Turn off the ignition key when disconnecting
or reconnecting battery power in order to prevent
system damage.
• The power source to the control module.
Examples include the following:
- Fuse
- Pigtail at battery Control Module
connectors etc.
• The negative battery cable
Disconnecting the negative battery cable may result
in the loss of other on-board memory data, such as
preset radio tuning.
6-3212 Engine Controls - 7.4L
DTC Modes
The OBD II vehicles have three options available in
the scan tool DTC mode in order to display the
enhanced information available. A description of the
new modes, the DTC Info and the Specific DTC,
follows. After selecting the DTC, the following menu
appears:
. The DTC Info
• The Specific DTC
• The Freeze Frame
• The Fail Records
• The Clear Info
The following is a brief description of each of the
sub menus in the DTC Info and the Specific DTC.
The order in which they appear here is alphabetical
and not necessarily the way they will appear on the
scan tool.
DTC Info Mode
Use the DTC Info mode in order to search for a
specific type of stored DTC information. There are
seven choices. The electronic service information
may instruct the technician to test for DTCs in a
certain manner. Always follow the published service
procedures.
In order to get a complete description of any status,
press the Enter key before pressing the desired
F-key. For example, pressing enter, then an F key
will display a definition of the abbreviated scan tool
status.
DTC Status
This selection displays any DTCs that have not run
during the current ignition cycle or have reported a
test failure during this ignition up to a maximum of
33 DTCs. The DTC tests which run and pass
removes that DTC number from the scan tool
screen.
Fail This Ign. (Fail This Ignition)
This selection displays all of the DTCs that have
failed during the present ignition cycle.
History
This selection displays only the DTCs that are stored
to the history memory of the control module. The
history memory will not display the Type B DTCs
that have not requested the MIL. The history
memory will display all of the type A and B DTCs
that have the MIL and have failed within the last 40
warm-up cycles. In addition, the history memory will
display ail of the type C DTCs that have failed within
the last 40 warm-up cycles.
Last Test Fail
This selection displays only the DTCs which have
failed during the last time that the test ran. The last
test may have ran during a previous ignition cycle if
the a type A or B DTC is displayed. For type C
DTCs, the last failure must have occurred during the
current ignition cycle to appear as Last Test Fail.
Engine
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.
Not Run SCC (Not Run Since Code Clear)
This option displays up to 33 DTCs that have not
run since the DTCs were last cleared. Since any
displayed DTCs have not run, their condition
(passing or failing) is unknown.
Test Fail SCC (Test Failed Since Code Clear)
This selection displays all of the active and history
DTCs that have reported a test failure since the last
time the DTCs were cleared. The DTCs that last
failed over 40 warm-up cycles (before this option is
selected) will not be displayed
Specific DTC Mode
This mode is used in order to check the status of
the individual diagnostic tests by the DTC number.
This selection can be accessed if a DTC has passed
or failed. Many OBD II DTC mode descriptions are
possible because of the extensive amount of
information that the Diagnostic Executive monitors
regarding each test. Some of the many possible
descriptions follow with a brief explanation.
This selection only allows the entry of the DTC
numbers that are supported by the vehicle that is
being tested. If an attempt is made to enter the DTC
numbers for tests which the diagnostic executive
does not recognize, the requested information will
not be displayed correctly and the scan tool may
display an error message. The same applies to using
the DTC trigger option in the Snapshot mode. If an
invalid DTC is entered, the scan tool will not trigger.
Failed Last Test
For type A and B DTCs, this message will display
during the subsequent ignition cycles until the test
passes or the DTCs are cleared. For type C DTCs,
this message clears whenever the ignition is cycled.
Failed Since Clear
This message displayed indicates that the diagnostic
test failed at least once within the last 40 warm-up
cycles since the last time the control module cleared
the DTCs.
Failed This Ign. (Failed This Ignition)
This message displayed indicates that the diagnostic
test has failed at least once during the current
ignition cycle. This message will clear when the
DTCs are cleared or the ignition is cycled.
History DTC
This message displayed indicates that the DTC has
stored to memory as a valid fault. A DTC displayed
as a History fault does not necessarily mean that the
fault is no longer present. The history description
means that all of the conditions necessary for
reporting a fault have met.
Engine ___________ Engine Controls - 7.4L 6-3213
MIL Requested Information Sensors/Switches Description
This message displayed indicates that the DTC is
currently causing the MIL to turn ON. Remember Engine Coolant Temperature (ECT) Sensor
that only type A and B DTCs can request the MIL.
The MIL request cannot determine if the DTC fault
conditions are currently being experienced. This is
because the diagnostic executive requires up to 3
trips during which the diagnostic test passes to turn
OFF the MIL.

Not Run Since Cl (Not Run Since Cleared)

This message displayed indicates that the selected
diagnostic test has not run since the last time the
DTCs were cleared. Therefore, the diagnostic test
status (passing or failing) is unknown. After the
DTCs are cleared, this message continues to be
displayed until the diagnostic test runs.

Not Run This Ign. (Not Run This Ignition)

This message displayed indicates that the selected
diagnostic test has not run this ignition cycle.

Test Ran and Passed 13578

This message displayed indicates that the selected Legend

diagnostic test has the following items:
• Passed the last test
• Ran and passed during this ignition cycle
• Ran and passed since the DTCs were last
cleared
• This test has not failed since the DTCs were
last cleared.
Whenever the indicated status of the vehicle is Test
Ran and Passed after a repair verification, the
vehicle is ready to be released to the customer.
If the indicated status of the vehicle is Failed This
Ign after a repair verification, then the repair is
incomplete. A further diagnosis is required.
Prior to repairing a vehicle, use the status
information in order to evaluate the state of the
diagnostic test and to help identify an intermittent
problem. The technician can conclude that although
the MIL is illuminated, the fault condition that caused
the code to set is not present. An intermittent
condition must be the cause.
(1) ECT Electrical Connector
(2) Connector Tab
(3) Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is a
thermistor (a resistor which changes value based on
the temperature) mounted in the engine coolant
passage. A low coolant temperature produces a high
resistance (100,000 ohms at -4 0 *C /-4 0 *F ) while a
high temperature causes a low resistance (70 ohms
at 130*C/266*F).
The VCM supplies a 5 volt signal to the engine
coolant temperature sensor through a resistor in the
VCM and then measures the voltage. The voltage
will be high when the engine is cold. The voltage will
be low when the engine is hot. By measuring the
voltage, the VCM calculates the engine coolant
temperature. The engine coolant temperature affects
most systems the VCM controls.
6-3214 Engine Controls - 7.4L
The scan tool displays the engine coolant
temperature in degrees. After engine startup, the
temperature should rise steadily to about 90 * C
(194*F), then stabilize when thermostat opens. If the
engine has not been run for several hours
(overnight), the engine coolant temperature and the
intake air temperature displays should be close to
each other. When the VCM detects a malfunction in
the ECT sensor circuit, the following DTCs will set:
• DTC P0117 circuit low
• DTC P0118 circuit high
• DTC P0125 excessive time to Closed Loop
• DTC P1114 circuit intermittent low
• DTC P1115 circuit intermittent high
The above DTCs contain a table in order to check
for sensor resistance values that are relative to
temperature.
Mass Air Flow (MAF) Sensor
13487
The Mass Air Flow (MAF) sensor measures the
amount of air entering the engine. The VCM uses
this information to determine the operating condition
of the engine in order to control the fuel delivery. A
large quantity of air indicates an acceleration. A
small quantity of air indicates a deceleration or
an idle.
The scan tool reads the MAF value and displays the
MAF value in grams per second (gm/Sec). At idle,
the MAF value should read between 5 gm/sec -
7 gm/sec on a fully warmed up engine. The values
Engine
should change rather quickly on acceleration, but
values should remain fairly stable at any given RPM.
When the VCM detects a malfunction in the MAF
sensor circuit, the following DTCs will set:
• DTC P0101 system performance
• DTC P0102 frequency low
• DTC P0103 frequency high
Intake Air Temperature (IAT) Sensor
1
2
13643
Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Electrical Harness Connector
The Intake Air Temperature (IAT) sensor is a
thermistor which changes the value based on the
temperature of the air entering the engine. A low
temperature produces a high resistance
(100,000 ohms at -4 0 *C /-4 0 ‘ F). A high temperature
causes a low resistance (70 ohms at 130*C/266*F).
The VCM supplies a 5.0 volt signal to the sensor
through a resistor in the VCM and measures the
voltage. The voltage will be high when the incoming
air is cold, and low when the air is hot. By
measuring the voltage, the VCM calculates the
incoming air temperature. The IAT sensor signal is
used in order to adjust the spark timing according to
the incoming air density.
The scan tool displays the temperature of the air
entering the engine, which should read close to the
ambient air temperature when the engine is cold.
The temperature should rise as the underhood
temperature increases. If the engine has not been
run for several hours (overnight), the IAT sensor
temperature and the engine coolant temperature
should read close to each other. If the VCM detects
a malfunction in the IAT sensor circuit, the following
DTCs will set:
• DTC P0112circuit low
• DTC P0113circuit high
• DTC P1111 circuit intermittent high
• DTC P1112circuit intermittent low
Engine_____________________________ ___________ Engine Controls - 7.4L 6-3215
Manifold Absolute Pressure (MAP) Sensor Heated Oxygen Sensor (Cutaway View)

Legend
(1) Manifold Absolute Pressure (MAP) Sensor
(2) Manifold Absolute Pressure (MAP)
Sensor seal.*•

The Manifold Absolute Pressure (MAP) sensor

responds to any changes in the intake manifold
pressure. The pressure any changes as a result of
the engine load and speed. The MAP sensor
converts this to a voltage output.
A closed throttle on the engine coast down would
produce a relatively low MAP output voltage. A wide
open throttle would produce a high MAP output
voltage. This high output voltage is produced
because the pressure inside of the manifold is the
same as outside the manifold. The MAP is inversely
proportional to what is measured on a vacuum gage.
The MAP sensor is used for the following:
13576
• Altitude determination.
• Ignition timing control.
Legend
(1) Four Wire In-Line Connector
• EGR diagnostic.
(2) Heater Termination
• Speed density fuel management default.
When the VCM detects a malfunction in the MAP (3) Water Shield Assembly
sensor circuit, the following DTCs will set: (4) Sensor Lead
• DTC P0106 circuit performance malfunction. (5) Flat Seat Shell
• DTC P0107 circuit low. (6) Seat Gasket
• DTC P0108 circuit high. (7) Outer Electrode and Protective Coating
• DTC P1106 intermittent circuit high. (8) Rod Heater
• DTC P1107 intermittent circuit low. (9) Inner Electrode
(10) Zirconia Element
(11) Insulator
(12) Clip Ring
(13) Gripper
6-3216 Engine Controls - 7.4L Engine

Heated Oxygen Sensors (H02S) NOx, converting it to nitrogen. The VCM has the
The Heated Oxygen Sensors are mounted in the ability to monitor this process using the Bank 1
exhaust system where they can monitor the oxygen Sensor 2 and the Bank 2 Sensor 2 heated oxygen
content of the exhaust gas stream. The oxygen sensors. The front H02S sensors (Bank 1 Sensor 1
present in the exhaust gas reacts with the sensor to and Bank 2 Sensor 1) produces an output signal
which indicates the amount of oxygen present in the
produce a voltage output. This voltage should
exhaust gas entering the three-way catalytic
constantly fluctuate from approximately 100 mV (high
converter. The rear H02S sensors (Bank 1 Sensor 2
oxygen content - lean mixture) to 900 mV (low
and Bank 2 Sensor 2) produces an output signal
oxygen content - rich mixture). The heated oxygen
which indicates the oxygen storage capacity of the
sensor voltage can be monitored with a scan tool.
catalyst; this in turn indicates the catalysts ability to
By monitoring the voltage output of the oxygen
convert exhaust gases efficiently. If the catalyst is
sensor, the PCM calculates what fuel mixture
operating efficiently, the front sensors will produce a
command to give to the injectors (lean mixture - low
far more active signal than that produced by the rear
H02S voltage = rich command, rich mixture - high
sensors.
H02S voltage = lean command).
The catalyst monitor sensors operate the same as the
When the VCM detects an H02S signal circuit that fuel control sensors. Although the Bank 1 Sensor 2
is low, the VCM will set the following DTCs: and Bank 2 Sensor 2 sensors main function is catalyst
• DTC P0131 Bank 1 Sensor 1. monitoring, they also play a limited role in fuel control.
• DTC P0151 Bank 2 Sensor 1. If a sensor output indicates a voltage either above or
• DTC P0137 Bank 1 Sensor 2. below the 450 millivolt bias voltage for an extended
period of time, the VCM will make a slight adjustment
• DTC P0157 Bank 2 Sensor 2. to fuel trim to ensure that fuel delivery is correct for
When the VCM detects an H02S signal circuit that catalyst monitoring.
is high, the VCM will set the following DTCs:
• DTC P0132 Bank 1 Sensor 1.
• DTC P0152 Bank 2 Sensor 1.
• DTC P0138 Bank 1 Sensor 2.
• DTC P0158 Bank 2 Sensor 2.
When the VCM detects no H02S activity, the VCM
will set the following DTCs:
• DTC P0134 Bank 1 Sensor 1.
• DTC P0154 Bank 2 Sensor 1.
• DTC P0140 Bank 1 Sensor 2.
• DTC P0160 Bank 2 Sensor 2.
A fault in the heated oxygen sensor heater element
or its ignition feed or ground will result in an
increase in time to Closed Loop fuel control. This
may cause increased emissions, especially at
start-up. When the VCM detects a malfunction in the
H02S heater circuits, the following DTCs will set:
• DTC P0135 Bank 1 Sensor 1 heater.
• DTC P0155 Bank 2 Sensor 1 heater.
• DTC P0141 Bank 1 Sensor 2 heater. 13572
• DTC P0161 Bank 2 Sensor 2 heater. Legend
The VCM also has the ability to detect H02S (1) Vehicle Control Module (VCM)
response, switching, transition time, and incorrect (2) Throttle Position (TP) Sensor
ratio voltage problems. If a H02S response (3) Throttle Valve
switching, transition time, or ratio problem is
detected, the VCM will store a DTC that indicates The Throttle Position (TP) sensor is a potentiometer.
degraded H02S performance. The TP sensor is connected to the throttle shaft on
the throttle body. By monitoring the voltage on the
Heated Oxygen Sensors (H02S) signal line, the VCM calculates the throttle position.
To control emissions of Hydrocarbons (HC), Carbon As the throttle valve angle is changed (the
Monoxide (CO), and Oxides of Nitrogen (NOx), a accelerator pedal is moved), the TP sensor signal
three-way catalytic converter is used. The catalyst also changes. At a closed throttle position, the
within the converter promotes a chemical reaction output of the TP sensor is low. As the throttle valve
which oxidizes the HC and CO present in the opens, the output increases so that at Wide Open
exhaust gas, converting them into harmless water Throttle (WOT), the output voltage should be
vapor and carbon dioxide. The catalyst also reduces above 4.0 volts.
Engine________________________________
The VCM calculates the fuel delivery based on the
throttle valve angle (driver demand). A broken or
loose TP sensor may cause intermittent bursts of
fuel from an injector. This may cause an unstable
idle because the VCM detects the throttle is moving.
When the VCM detects a malfunction with the TP
sensor circuits, the following DTCs will set:
• DTC P0121 circuit performance malfunction
• DTC P0122 circuit low
• DTC P0123 circuit high
• DTC P1121 intermittent circuit high
• DTC P1122 intermittent circuit low
EVAP Vacuum Switch
The EVAP Purge Vacuum Switch is used by the
VCM to monitor EVAP canister purge solenoid
operation and purge system integrity. The EVAP
Purge Vacuum Switch should be closed to ground
with no vacuum present (0% EVAP Purge PWM).
With EVAP Purge PWM at 25% or greater, the EVAP
Purge Vacuum Switch should open.
An incorrect EVAP Purge system flow should set a
DTC P0441. A continuous purge condition with no
purge commanded by the VCM should set a
DTC P1441. Refer to Evaporative Emission (EVAP)
Control System for a complete description of the
EVAP system.
Engine Controls - 7.4L 6-3217
Knock Sensor (KS)
The Knock Sensor (KS) system is used in order to
detect the engine detonation. The VCM will retard
the spark timing based on the signals from the KS
module. The Knock Sensor(s) produce an AC
voltage that is sent to the KS module. The amount
of the AC voltage produced is proportional to the
amount of knock.
An operating engine produces a normal amount of
engine mechanical vibration (Noise). The knock
sensor(s) will produce an AC voltage signal from this
Noise. When an engine is operating, the VCM will
learn the minimum and maximum frequency of the
noise that the engine produces. When the VCM
determines that this frequency is less than or greater
than the expected amount, a knock sensor DTC
will set.
A/C Request Signal
The A/C request circuit signals the VCM when an
A/C mode is selected at the A/C control head. The
VCM uses this information in order to enable the A/C
compressor clutch and to adjust the idle speed
before turning ON the A/C clutch. If this signal is not
available to the VCM, the A/C compressor will be
inoperative.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis of the A/C electrical system.
6-3218 Engine Controls - 7.4L Engine

Vehicle Speed Sensor (VSS) monitors the CKP sensor for a momentary drop in
the crankshaft speed in order to determine if a
misfire is occurring. When the VCM detects a misfire,
a DTC P0300 will set.
The VCM also monitors the CKP sensor signal
circuit for malfunctions. The VCM monitors CKP
signal and the High and Low resolution signals. The
VCM calculates these signals in order to determine a
ratio. When the VCM detects that the ratio is out of
normal operating range, the VCM will set a
DTC P0337 or a DTC P0338.

Camshaft Position (CMP) Sensor

The Camshaft Position (CMP) sensor is located
within the distributor. The operation of the CMP
sensor is very similar to the Crankshaft Position
(CKP) sensor. The CMP sensor will provide one
pulse per camshaft revolution (1x signal). This signal
will not affect the driveability of the vehicle. The
VCM utilizes this signal in conjunction with the
crankshaft position in order to determine which
The Vehicle Speed Sensor (VSS) is a pulse counter cylinder(s) are misfiring.
type input that informs the VCM how fast the vehicle
is being driven. The VSS system uses an inductive Electric Engine Cooling Fan Description
sensor mounted in the tail housing of the
transmission and a toothed reluctor wheel on the tail General Description
shaft. As the reluctor rotates, the teeth alternately
interfere with the magnetic field of the sensor
creating an induced voltage pulse.
The VSS produces an AC voltage signal that
increases with the vehicle speed. The VCM
processes this signal and sends it to the following
components:
• The Instrument Panel.
• The Cruise Control Module.
Crankshaft Position (CKP) Sensor

The auxiliary electric cooling fan consists of (1)

radiator support (2) wiring harness (3) bolt/scew (4)
auxiliary cooling fan assembly and provides additonal
cooling for low speed vehicle operations, extended
idle, stop and go conditions, and running the air
conditioning systerm.

The crankshaft position sensor provides the VCM

with the crankshaft speed and the crankshaft
position. The VCM utilizes this information in order to
determine if an engine Misfire is present. The VCM
Engine
Operation
The auxiliary cooling fan is controlled by the VCM.
The VCM controls the ground path for the cooling
fan relay. The relay consists of (1) under hood fuse
relay center (2) auxiliary cooling fan relay (3) wiring
harness and is used to control the high current flow
to power the cooling fan motor. The VCM determines
operation of the independent fans based on various
sensor inputs.
Auxiliary Cooling Fan
The auxiliary cooling fan is controlled by the VCM
based on the following inputs:
• The A/C system
• The Engine Coolant Temperature (ECT) sensor
• The Vehicle Speed Sensor (VSS).
The VCM will turn the auxiliary cooling fan ON when
any of the following conditions exist at idle:
• Certain VCM Diagnostic Trouble Codes (DTCs)
are set.
• ECT above 107 * C (225 * F).
• A/C head pressure above 225 psi.
Once the auxiliary cooling fan has been turned ON
by the Engine Coolant Temperature (ECT) sensor,
the VCM will turn the fan OFF when that
temperature has dropped about 4*C (7*F). If the
auxiliary cooling fan has been turned ON by high
A/C head pressure, the VCM will turn the fan OFF
when the pressure has dropped to 180 psi. The
minimum ON time for the auxiliary cooling fan is
50 seconds.
Fuel System Description - SFI
The fuel system is controlled by the control module
located in the engine compartment. The control
module is the control center of the system.
Engine Controls - 7.4L 6-3219
The basic function of the fuel system is to control
fuel delivery to the engine under all operating
conditions. The following two types of fuel injection
systems deliver the fuel to the engine:
• The Central Sequential Fuel Injection (Central
SFI) (4.3L, 5.0L, 5.7L)
• The Sequential Fuel Injection (SFI) (7.4L only)
The main control sensor is the Heated Oxygen
Sensor (H02S). The H02S is located in the exhaust
manifold. The H02S tells the control module the
amount of oxygen in the exhaust gas. The control
module changes the air to fuel ratio to the engine by
controlling the fuel injector. Efficient catalytic
converter operation requires a 14.7:1 air to fuel ratio.
Because the constant measuring and adjusting of the
air to fuel ratio, the fuel injection system is called a
Closed Loop system.
Several other important engine operation parameters
include the following items:
• The engine speed
• The manifold pressure
• The engine coolant temperature
• The throttle position
These parameters determine the mode of engine
operation.
The following are the 3 separate classifications of
fuel systems:
• The Central Sequential Fuel Injection (Central
SFI) (4.3L, 5.0L, 5.7L)
• The Sequential Fuel Injection (MFI) (7.4L)
• The fuel supply system
Modes of Operation
The control module monitors the voltages from
several sensors in order to determine how much fuel
to give the engine. The fuel is delivered under one
of several conditions called modes. The control
module controls all of the modes.
Starting Mode
When the ignition switch is turned to the ON
position, before engaging the starter, the Control
Module energizes the fuel pump relay for 2 seconds
allowing the fuel pump to build up pressure. The
Control Module then checks the Engine Coolant
Temperature (ECT) sensor and the Throttle Position
(TP) sensor in order to determine the proper air and
fuel ratio for starting. The Control Module controls
the amount of fuel delivered in the starting mode by
changing how long the injectors are energized. This
is done by pulsing the injectors for very short times.
Clear Flood Mode
If the engine floods, clear the engine by depressing
the accelerator pedal down to the floor. The control
module then pulses the injector at a 16.5:1 air to
fuel ratio. The control module holds this injector rate
as long as the throttle stays wide open and the
engine is below 600 RPM. If the throttle position
becomes less than 65%, the control module returns
to the starting mode.
6-3220 Engine Controls - 7.4L
Run Mode
The run mode is the mode under which the engine
operates most of the time. In this mode, the engine
operates in either Open Loop or Closed Loop.
Open Loop
When the engine is first started and it is above
400 RPM, the system goes into the Open Loop
operation. In the Open Loop, the control module
ignores the signal from the H02S, and the control
module calculates the air to fuel ratio based on the
inputs from the Engine Coolant Temperature (ECT)
sensor and Manifold Absolute Pressure (MAP)
sensor.
The system stays in Open Loop until the following
conditions are met:
1. The H02S has varying voltage output, showing
that it is hot enough to operate properly. This
depends on engine temperature.
2. The Engine Coolant Temperature (ECT) sensor
is above a specified temperature.
3. A specific amount of time has elapsed after
starting the engine.
A normal functioning system may go into an Open
Loop at idle if the Heated Oxygen Sensor (H02S)
temperature drops below the minimum requirement
to produce the voltage fluctuation.
Closed Loop
The specific values for the above conditions vary
with different engines. When these conditions are
met, the systems goes into a Closed Loop operation.
In a Closed Loop, the control module calculates the
air to fuel ratio (injector on-time) based on the signal
from the H02S. This allows the air to fuel ratio to
stay very close to 14.7:1.
Acceleration Mode
When the control module senses rapid changes in
the throttle position and the manifold pressure, the
system enters the acceleration mode. The system
provides the extra fuel needed for smooth
acceleration.
Engine
Deceleration Mode
When the driver releases the accelerator pedal, the
air flow into the engine is reduced. The
corresponding changes in the throttle position and
the manifold air pressure are relayed to the Control
Module, which reduces the injector pulse width, in
order to reduce the fuel flow. If the decel is very
rapid, or for long periods (such as long closed
throttle coast-down), the Control Module shuts OFF
the fuel completely in order to protect the catalytic
converter.
Fuel Cutoff Mode
In order to prevent possible engine damage from
over-speed, the Control Module cuts off fuel from the
fuel injectors when the engine speed is above
approximately 5500 RPM with the vehicle in any
forward gear or reverse. In order to prevent tire
damage, the Control Module also has a fuel cutoff in
excess of 108 mph (173 km/h) based on the speed
rating of the tires.
Fuel is also Cutoff during rapid deceleration. See
Deceleration Mode.
Converter Protection Mode
The Control Module constantly monitors engine
operation and estimates the conditions that could
result in high converter temperatures. If the Control
Module determines the converter may overheat, this
causes the system to return to the Open Loop
operation and enriches the fuel mixture.
Battery Voltage Correction Mode
When battery voltage is low, the control module can
compensate for a weak spark delivered to the
distributor by increasing the following items:
• The injector ON time
. The idle RPM
• The ignition dwell time
Engine Engine Controls - 7.4L 6-3221
1996 Controlled Idle Speed
Gear Open/Closed
Engine Transmission (Drive/Neutral) (1) idle Speed (RPM) IAC Counts (2) Loop (3)
Automatic Drive 600±25 Varies Closed Loop
4.3L
Manual Neutral 700125 Varies Closed Loop
Automatic Drive 700125 Varies Closed Loop
5.0L
Manual Manual 700125 Varies Closed Loop
5.7L (Under Automatic Drive 550125 Varies Closed Loop
8500 GVW) Manual Manual 675125 Varies Closed Loop
5.7L (Over Automatic Drive 550125 Varies Closed Loop
8500 GVW) Manual Manual 675125 Varies Closed Loop
Automatic Drive 600125 Varies Closed Loop
7.4L
Manual Manual 725125 Varies Closed Loop
Important: The engine should be at operating temperature 92 *C to 104'C (196'F to 222 *F).
(1) On manual transmission vehicles, the scan tool will display RDL in neutral
(2) Add 2 counts for engines with less than 500 miles. Add 2 counts for every 1000 ft. above sea level (4.3L and V8).
(3) Let the engine idle until the engine reaches proper fuel control status (Open/Closed Loop).
6-3222 Engine Controls ■ 7.4L________________________________________________ Engine

Fuel Supply Component Description

Legend
(1) Fuel Inlet (7) Fuel Pump Feed Hose
(2) Bleed Hose (8) In-Tank Fuel Pump
(3) J 34730-1A Fuel Pressure Gauge Assembly (9) Fuel Pump Strainer
(4) Fuel Pressure Connection (10) Return Line
(5) In-Line Fuel Filter (11) Flexible Hose
(6) Pressure Line (12) Fuel Outlet
Engine Engine Controls - 7.4L 6-3223

Legend
(1) Bleed Hose (9) Pressure Line
(2) J 34730 Fuel Pressure Gauge Assembly (10) Fuel Pump Feed Hose
(3) Fuel Pressure Connection (11) In-Tank Pump
(4) Fuel Rail (12) Fuel Pump Strainer
(5) Fuel Injectors (13) Return Line
(6) Fuel Pressure Regulator (14) Flexible Hose
(7) Fuel Inlet Line (15) Fuel Outlet
(8) In-Line Fuel Filter (16) Injector Harness Connector
6-3224 Engine Controls - 7.4L
The fuel supply system consists of the following
components:
• The fuel tank(s) (fuel balance control system
when equipped with dual tanks.
• The fuel sender assembly (fuel sender, fuel
pump and fuel pump strainer).
• The fuel filter
• The fuel feed and return pipes
• The fuel pump electrical circuit
. The accelerator control components
Fuel Tank(s)
The fuel tank, at the rear of the underbody, is held
in place by 2 metal straps. Anti-squeak pieces are
used on top of the tank to reduce rattles.
Filler Neck
In order to help prevent refueling with leaded
gasoline, the fuel filler neck on a gasoline engine
vehicles has a built-in restrictor and deflector. The
opening in the restrictor will only admit the smaller
unleaded gas nozzle spout, which must be fully
inserted to bypass the deflector.
Attempted refueling with a leaded gas nozzle or
failure to fully insert the unleaded gas nozzle results
in gasoline splashing back out of the filler neck.
Fuel Filler Cap
The fuel tank filler neck is equipped with a
screw-type cap. The threaded part of the cap
requires several turns counterclockwise in order to
remove. The long threaded area was designed in
order to allow any remaining fuel tank pressure to
escape while the cap is being removed. A built-in
torque-limiting device prevents overtightening. In
order to install the cap, turn the cap clockwise until a
clicking noise is heard. This signals that the correct
torque has been reached and the cap is fully seated.
Fuel Balance Control System (Dual Tanks)
The fuel balance control system consists of the
following components:
• Front (main) fuel tank sender
• Rear (auxiliary) fuel tank sender
• Balance fuel pump
• Balance fuel pump relay
• Fuel sender and balance module
On vehicles with dual tanks, the front tank is the
main and the rear tank is the auxiliary. The main fuel
balance pump supplies fuel to the fuel injection unit.
The low pressure (about 32 kPa or 7 psi) fuel
balance pump is used only to transfer fuel from the
auxiliary tank to the main tank in order to balance
the fuel levels in both tanks. As the main tank level
drops to about 25% below the level in the auxiliary
tank, the fuel sender and balance module energizes
the fuel pump relay. This pumps the fuel from the
auxiliary tank to the main tank. When the level in the
main tank reaches a level slightly higher than the
level in the auxiliary tank, or the auxiliary tank is
Engine
empty, the module de-energizes the balance pump
relay and fuel pump. Any malfunction in either of the
fuel gage circuits will disable the system and the fuel
will not be transferred from the main fuel tank to the
auxiliary fuel tank.
Fuel Sender Assembly
The fuel sender assembly is located inside the fuel
tank and attaches to the top of the fuel tank.
The fuel sender assembly consists of the following
major components:
• The fuel sender
• The fuel pump
• The fuel pump strainer
Fuel Pump
The fuel pump is a turbine type, electric pump, which
mounts in the fuel tank. Fuel is pumped, at a
specified flow and pressure from the fuel pump,
through the in-line filter to the pressure regulator in
the fuel injection unit. Excess fuel is returned to the
fuel tank through the fuel return line.
The fuel pump attaches to the fuel sender assembly.
A fuel strainer attaches to the fuel pump inlet line.
The strainer prevents dirt particles from entering the
fuel line and tends to separate water from the fuel.
Fuel Pump Strainer
A woven plastic filter attaches to the lower end of
the fuel pump in the fuel tank. The functions of the
strainer are to filter contaminants and to wick fuel.
The life of the fuel pump strainer is generally
considered to be that of the fuel pump. The fuel
pump strainer is self-cleaning and normally requires
no maintenance. Fuel stoppage at this point
indicates that the fuel tank contains an abnormal
amount of sediment or water. In which case the fuel
tank should have a thorough cleaning. Refer to Fuel
System Cleaning (Fuel Tank). If the fuel strainer is
plugged, replace the strainer with a new fuel pump
strainer.
In-Line Fuel Filter
A steel in-line fuel filter is used in the fuel feed pipe
ahead of the fuel injection system. The filter element
is made of paper and is designed to trap particles in
the fuel that may cause damage to the injection
system. The filter housing is constructed to withstand
maximum fuel system pressure, exposure to fuel
additives and changes in temperature.
Nylon Fuel Pipes
C a u tio n : In o r d e r to R e d u c e th e R is k o f F ir e a n d
P e r s o n a l In ju r y :
• I f n y lo n f u e l p ip e s a r e n ic k e d , s c r a t c h e d o r
d a m a g e d d u r in g I n s ta lla tio n , D o N o t a t t e m p t
to r e p a ir th e s e c t io n s o f th e n y lo n fu e l
p ip e s . R e p la c e th e m .
• W h e n I n s ta llin g n e w f u e l p ip e s , D o N o t
h a m m e r d ir e c tly o n th e fu e l h a rn e s s b o d y
c lip s a s I t m a y d a m a g e th e n y lo n p ip e s
r e s u lt in g in a p o s s ib le f u e l le a k .
Engine Engine Controls - 7.4L 6-3225
• A lw a y s c o v e r n y lo n v a p o r p ip e s w ith a w et • A lw a y s c o v e r n y lo n v a p o r p ip e s w ith a w et
to w e l b e fo r e u s in g a to r c h n e a r th e m . A ls o , to w e l b e fo r e u s in g a to r c h n e a r th e m . A ls o ,
never expose th e v e h ic le to te m p e ra tu re s never expose th e v e h ic le to te m p e ra tu re s
h ig h e r th a n 1 1 5 °C (2 3 9 °F ) f o r m o r e th a n o n e h ig h e r th a n 1 1 5 C (2 3 9 °F ) f o r m o r e th a n o n e
h o u r, o r m o re th a n 9 0 °C (1 9 4 °F ) f o r a n y h o u r, o r m o re th a n 9 0 °C (1 9 4 °F ) f o r a n y
e x t e n d e d p e r io d . e x t e n d e d p e r io d .

• B e fo r e c o n n e c tin g fu e l p ip e f it t in g s , a lw a y s • B e fo r e c o n n e c tin g fu e l p ip e f it t in g s , a lw a y s
a p p ly a fe w d r o p s o f d e a n e n g in e o i l to th e a p p ly a f e w d r o p s o f c le a n e n g in e o il to th e
m a le p ip e e n d s . T h is w ill e n s u re p r o p e r m a le p ip e e n d s . T h is w ill e n s u r e p r o p e r
r e c o n n e c tio n a n d p r e v e n t a p o s s ib le fu e l r e c o n n e c t io n a n d p r e v e n t a p o s s ib le fu e l
le a k . ( D u r in g n o r m a l o p e r a t io n , t h e O - r ln g s le a k . ( D u r in g n o r m a l o p e r a t io n , t h e O - r ln g s
lo c a te d In th e fe m a le c o n n e c t o r w ill s w e ll lo c a t e d In th e fe m a le c o n n e c t o r w ill s w e ll
a n d m a y p r e v e n t p r o p e r r e c o n n e c t io n if n o t a n d m a y p r e v e n t p r o p e r r e c o n n e c tio n if n o t
lu b r ic a te d .) lu b r ic a te d .)

Nylon fuel pipes are designed to perform the same
job as the steel or rubber fuel tubes they replace.
Nylon pipes are constructed to withstand maximum
fuel system pressure, exposure to fuel additives and
changes in temperature. There are two sizes used:
3/8 in. ID for the fuel feed and 5/16 in. ID for the
fuel return.
The fuel feed and return pipes are assembled as a
harness. Retaining clips hold the pipes together and
provide a means for attaching the pipes to the
vehicle. Quick-connect type fittings are used at the
fuel tank ends of the fuel feed/return pipes and at
the in-line fuel filter. They are described below.
Sections of the pipes that are exposed to chafing,
high temperature or vibration are protected with a
heat resistant rubber hose and/or corrugated plastic
conduit.
Nylon fuel pipes are somewhat flexible and can be
formed around gradual turns under the vehicle.
However, if forced into sharp bends, nylon pipes will
kink and restrict fuel flow. Once exposed to fuel,
nylon pipes may become stiffer and are more likely
to kink if bent too far. Special care should be taken
when working on a vehicle with nylon fuel pipes.
Quick-Connect Fittings
Quick-connect type fittings provide a simplified
means of installing and connecting the fuel system
components. The quick-connect fittings consists of a
female socket and a compatible male connector.
O-rings, located inside the female socket, provide the
fuel seal. Integral locking tabs or fingers hold the
fittings together. The metal collar quick-connect
fittings have locking tabs that require a special tool
to release. Refer to Quick Connect Fitting(s) Service
(Metal Collar).
The vapor pipe extends from the fuel sender
assembly to the charcoal canister. It is made up of
nylon pipe and is connected to the fuel sender
assembly and the EVAP canister with the fuel
resistant rubber hoses.
Fuel Pipe O-Rings
The fuel feed and return pipe threaded connections
at the fuel injection unit are sealed with replaceable
O-ring seals. These O-ring seals are made of special
material and should only be serviced with the correct
service part.
Fuel Pump Electrical Circuit
When the key is turned ON with out the engine
running, the control module turns a fuel pump relay
ON for two seconds. This builds up fuel pressure
quickly. If the engine is not started within two
seconds, the control module shuts the fuel pump
OFF and waits until the engine starts. As soon as
the engine is cranked, the control module turns the
relay ON and runs the fuel pump. When the engine
is cranking or running, the control module receives
the Crankshaft Position (CKP) sensor reference
pulses which in turn energize the fuel injectors. As a
backup system to the fuel pump relay, the fuel pump
can also be turned ON by a fuel pump oil pressure
switch. When the engine reaches about 28 kPa
(4 psi), and the fuel pump relay does not complete
the circuit, the fuel pump oil pressure switch will
close to complete the circuit to run the fuel pump.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold. The
fuel pump oil pressure switch will turn ON the fuel
pump as soon as oil pressure reaches about
28 kPa (4 psi).

Vapor Pipes and Hoses Accelerator Control

The accelerator control system is a control cable
C a u tio n : In o r d e r t o R e d u c e th e R is k o f F ir e a n d type attached at one end to an accelerator pedal
P e r s o n a l In ju r y :
assembly. On the other end is the throttle valve.
• I f n y lo n f u e l p ip e s a r e n ic k e d , s c r a t c h e d o r
d a m a g e d d u r in g In s ta lla tio n , D o N o t a tte m p t Fuel Metering System Component
to r e p a ir th e s e c tio n s o f th e n y lo n fu e l Description
p ip e s . R e p la c e th e m .

• W h e n In s ta llin g n e w f u e l p ip e s , D o N o t Purpose
h a m m e r d ir e c tly o n th e fu e l h a rn e s s b o d y The function of the fuel metering system is to deliver
c lip s a s I t m a y d a m a g e th e n y lo n p ip e s the correct amount of fuel to the engine under all
r e s u lt in g in a p o s s ib le f u e l le a k . operating conditions.
6-3226 Engine Controls - 7.4L Engine
Fuel is delivered to the engine by individual fuel Fuel Rail Assembly
injectors mounted in the intake manifold near each
cylinder.

Fuel Metering System Components

The fuel metering system consists of the
following parts:
• The fuel pump electrical circuit
• The fuel supply components (fuel tank,
pump, lines)
• The fuel rail assembly which includes the
following components:
- The fuel injectors
- The fuel pressure regulator
- The electrical wiring harness
• The lower manifold assembly which includes
MAP sensor.
• The throttle body assembly including the
following items:
- The Idle Air Control (IAC) valve assembly
- The Throttle Position (TP) sensor

Fuel Supply Components

The fuel supply is stored in the fuel tank. An electric
fuel pump, located in the fuel tank with the gauge
sending unit, pumps fuel through an in-line fuel filter
to the fuel meter body assembly.
The pump provides fuel at a pressure greater than is
needed by the injectors. The fuel pressure regulator,
part of the fuel meter body assembly, keeps the fuel Legend
to the injectors at a regulated pressure. The unused (1) Fuel Rail Assembly
fuel is returned to the fuel tank via a separate line. (2) Regulator Retainer Clip
Fuel Pump Electrical Circuit (3) Fuel Pressure Regulator Assembly
When the ignition switch is turned to the ON position (4) Back-up Ring
(before engaging the starter), the VCM energizes the (5) Regulator Seal O-ring
fuel pump relay for 2 seconds causing the fuel pump (6) Regulator Filter
to pressurize the fuel system. If the VCM does not
(7) Regulator Seal O-ring
receive the ignition reference pulses (engine cranking
or running) within 2 seconds, the control module (8) Fuel Injector Wiring Harness
shuts off the fuel pump relay, causing the fuel pump (9) Wiring Harness Retainer Clip
to stop. (10) SFI Fuel Injector Retainer Clip
As a backup system to the fuel pump relay, the fuel (11) SFI Fuel Injector Upper O-ring
pump oil pressure switch can energize the fuel
(12) SFI Fuel Injector Assembly
pump. The switch has 2 internal circuits. One circuit
operates the oil pressure indicator or gage in the (13) Back-up O-ring
instrument cluster. The other circuit is a normally (14) SFI Fuel Injector Lower O-ring
open switch which closes when the oil pressure (15) Fuel Pressure Connection Cap
reaches about 28 kPa (4 psi). If the fuel pump relay
(16) Fuel Pressure Connection Core Assembly
fails, the fuel pump oil pressure switch runs the
fuel pump.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold. The
fuel pump oil pressure switch energizes the fuel
pump as soon as oil pressure reaches about
28 kPa (4 psi).
Engine
The fuel rail assembly is made up of a single in-line
composite rail which delivers fuel to the fuel
injectors. Unused fuel returns to the fuel tank via the
fuel pressure regulator assembly. The fuel rail is
mounted to the lower section of the intake manifold
and distributes fuel to the cylinders through the
individual fuel injectors. Fuel is delivered from the
fuel pump through the fuel feed line to the inlet
fitting on the limited recirculation deadheaded fuel
rail. From there it is directed to the main plastic
supply conduit via an inlet tube. Fuel flows through
the main conduit supplying fuel at the same pressure
to each of the fuel injectors. Fuel in excess of
injector needs, flows immediately back through the
pressure regulator assembly via a bypass tube
immediately located just pass the inlet fitting on the
fuel rail. The pressure regulator assembly maintains
correct system pressure. Fuel then flows from the
pressure regulator through the fuel return line back
to the fuel tank.
Fuel Injector Assembly
Engine Controls - 7.4L 6-3227
The fuel injector assembly is a solenoid-operated
device, controlled by the VCM, that meters
pressurized fuel to a single engine cylinder. The
VCM energizes the injector solenoid, which opens a
ball valve, allowing fuel to flow past the ball valve
and through a recessed flow director plate. The
director plate has machined holes that control the
fuel flow, generating a conical spray pattern of finely
atomized fuel at the injector tip. Fuel is directed at
the intake valve, causing it to become further
atomized and vaporized before entering the
combustion chamber.
An injector that is stuck partly open would cause
loss of pressure after engine shut down, so long
cranking times would be noticed on some engines.
Dieseling could also occur because some fuel could
be delivered to the engine after the ignition is
turned OFF.
Fuel Pressure Regulator Assembly

O -H

13105
Legend
(1) SFI Fuel Injector Retainer Clip (1) Regulator Retainer Clip
(2) SFI Fuel Injector Upper O-ring (2) Fuel Pressure Regulator Assembly
(3) SFI Fuel Injector Assembly (3) Back-up Ring
(4) Back-up O-ring (4) Regulator Seal O-ring
(5) SFI Fuel Injector Lower O-ring (5) Regulator Filter
(6) Regulator Seal O-ring
C a u t io n : T h is c o m p o s it e f u e l r a i l d e s ig n u tiliz e s a
u n iq u e I n je c t o r c lip d e s ig n . T h is c lip d e s ig n does
The fuel pressure regulator is a diaphragm-operated
n o t p e r m it th e r a il a n d In je c t o r a s s e m b ly to b e
cartridge relief valve with the fuel pump pressure on
p r e s s u r iz e d w ith f u e l p u m p p r e s s u r e w hen th e
one side and the regulator spring pressure and
r a il a s s e m b ly Is n o t s e c u r e d In th e e n g in e
intake manifold vacuum on the other. A retainer
m a n ifo ld . P r e s s u r iz in g th e r a il a s s e m b ly w ith o u t
holds the fuel pressure regulator.
th e I n je c to r s e c u r e d In th e e n g in e m a n if o ld m a y
c a u s e h ig h p r e s s u r e fu e l to b y p a s s th e u p p e r The regulator’s function is to maintain a constant
I n je c t o r O - r in g s e a l r e s u lt in g I n a f u e l le a k . pressure differential across the injectors at all times.
D o N o t a p p ly fu e l p r e s s u r e to th e fu e l r a il The pressure regulator compensates for engine
a s s e m b ly u n le s s th e fu e l r a il a s s e m b ly is load by increasing the fuel pressure as engine
p r o p e r ly s e c u r e d In th e e n g in e m a n ifo ld . vacuum drops.
6-3228 Engine Controls ■ 7.4L
With the ignition ON leaving the engine off (zero
vacuum), the fuel pressure at the pressure test
connection should be 385-430 kPa (56-62 psi). If
the pressure is too low, poor performance could
result. If the pressure is too high, excessive odor
may result. The Fuel System Diagnosis has
information on diagnosing fuel pressure conditions.
Refer to Fuel System Diagnosis.
Throttle Body Assembly
Legend
(1) Throttle Body Assembly
(2) IAC Valve Assembly O-ring
(3) IAC Valve Assembly Attaching Screw
(4) Idle Air Control (IAC) Valve Assembly
The throttle body assembly is mounted on the intake
manifold plenum, and is used to control air flow into
the engine, thereby controlling engine output. The
throttle valve within the throttle body is opened by
the driver through the accelerator controls. During
engine idle, the throttle valve is almost closed, and
air flow control is handled by the Idle Air Control
(IAC) valve.
The throttle body also provides the location for
mounting the Throttle Position (TP) sensor and for
sensing changes in engine vacuum due to throttle
valve position. Vacuum ports are located at, above,
or below the throttle valve to generate vacuum
signals needed by various components.
Idle Air Control (IAC) Valve Assembly
The purpose of the IAC valve assembly is to control
the engine idle speed while preventing engine stalls
due to changes in the engine load.
The IAC valve, mounted in the throttle body
assembly, controls the bypass air around the throttle
valve. By moving a conical valve known as a pintle
IN toward the seat (in order to decrease the air
Engine
(5) TP Sensor O-ring
(6) Throttle Position (TP) Sensor
(7) TP Sensor Attaching Screw
flow), or OUT away from the seat (in order to
increase the air flow), a controlled amount of air
moves around the throttle valve.
If the engine speed is too low, more air is bypassed
around the throttle valve in order to increase the
RPM. If the engine speed is too high, less air is
bypassed around the throttle valve in order to
decrease the RPM.
The VCM moves the IAC valve in small steps, called
counts which can be measured by using a scan tool
connected to the Data Link Connector (DLC).
During idle, the proper position of the IAC valve is
calculated by the VCM. This position is based on the
battery voltage, the engine coolant temperature, the
engine load, and the engine RPM. If the RPM drops
below specification and the throttle valve is closed,
the VCM senses a near stall condition, and then the
VCM calculates a new valve position in order to
prevent stalling.
If the IAC valve is disconnected and reconnected
while the engine is running, the resulting idle RPM
may be wrong. This will require the resetting of the
IAC valve.
Engine
After running the engine, the iAC valve will reset
when the ignition is turned OFF. The IAC valve
should only be disconnected or connected with the
ignition OFF.
If the VCM is without battery power for any reason,
the programmed position of the IAC valve pintle is
lost. The control module replaces the lost position
with a default value. In order to return the IAC valve
pintle to the correct position, see the Idle Learn
Procedure.
The IAC valve affects the idle characteristics of the
vehicle. A fully retracted valve allows too much air
into the manifold causing a high idle speed. A valve
which is stuck closed allows too little air in the
manifold, causing a low idle speed. If the valve is
stuck part way open, the idle may be rough, and the
idle will not respond to the engine load changes.
Throttle Position (TP) Sensor
The non-adjustable TP sensor is mounted on the
throttle body assembly opposite the throttle lever.
The TP sensor senses the throttle valve angle and
relays that information to the VCM. Knowledge of
throttle angle is one of the inputs needed by the
VCM to generate the required injector control signals
(pulses). For further information on replacement,
refer to TP Sensor Replacement
Short Term Fuel Trim Description
Short Term Fuel Trim
The short term fuel trim is used by the control
module to control the short term injector pulse width
( injector ON time). When the control module is in
the Closed Loop mode, the control module monitors
the fuel trim oxygen sensors signals in order to
determine if the fuel system is operating rich or lean.
If the control module determines that no change in
fuel delivery is needed in order to maintain correct
short term fuel control for a particular engine
operating condition a short term fuel trim scan tool
data value of 0% (128 counts) is indicated. If the
control module determines that the fuel system is
operating rich, short term fuel trim will compensate
for the rich condition by decreasing the injector pulse
width and a short term fuel trim value of less than
0% (128 counts) is indicated. If the control module
determines that the fuel system is operating lean,
short term fuel trim will compensate for the lean
condition by increasing the injector pulse width and
a short term fuel trim value of more than 0%
(128 counts) is indicated.
When the control module is in the Power Enrichment
(PE) mode, the short term fuel trim value will
indicate 0% (128 counts) in order to prevent the fuel
trim from compensating for the commanded rich
condition of the PE mode.
Engine Controls - 7.4L 6-3229
Long Term Fuel Trim Description
Long Term Fuel Trim
The long term fuel trim consist of groups of fuel control
calibrations or cells. Each cell contains the short and
long term fuel injector control values required to
maintain the correct air and fuel mixture for a particular
long term engine operating condition. The control
module monitors the short term fuel trim values in
order to determine if the short term fuel trim values are
indicating a trend of rich or lean corrections to the fuel
control. If the control module determines that the short
term fuel trim is able to maintain control and is near
0% (128 counts), the long term fuel trim within that
particular cell will indicate a value of 0% (128). If the
control module determines that the fuel system is
operating rich, long term fuel trim will compensate for
the rich condition by decreasing the injector pulse
width, and a long term fuel trim value of less than 0%
(128 counts) is indicated. If the control module
determines that the fuel system is operating lean, long
term fuel trim will compensate for the lean condition by
increasing the injector pulse width and a long term fuel
trim value of more than 0% (128 counts) is indicated.
If the control module determines that the long term fuel
trim values indicate a trend toward a rich or a lean
correction within that cell, the control module will switch
to the appropriate cell, either rich or lean, and the
short term value will return to 0% (128).
Speed Density System Description
Three specific data sensors provide the VCM with
the basic information for fuel management portion of
its operation. That is three specific signals to the
VCM establish the engine speed and air density
factors. The engine speed signal comes from the
distributor high resolution circuit. The VCM uses this
information to determine engine speed (RPM). Air
density is derived from IAT and MAP sensor inputs.
The IAT sensor measures the air temperature that is
entering the engine. The IAT signal works in
conjunction with the MAP sensor to determine air
density. As the intake manifold pressure increases,
the air density in the intake manifold also increases
and additional fuel is required. This information from
the IAT and MAP sensors is used by the VCM to
control injector pulse width.
The speed density system is only needed when
there is a Mass Air Flow (MAF) sensor malfunction.
If the VCM detects a malfunction with the MAF
sensor circuit, the VCM will default to speed density
fuel management.
EVAP Control System Description
Purpose
The Evaporative Emission (EVAP) control system
limits the fuel vapors from escaping into the
atmosphere. The EVAP transfers the fuel vapor from
the sealed fuel tank to an activated carbon
(charcoal) storage device (EVAP canister). The EVAP
canister stores the vapors until the engine is able to
use the extra fuel vapor.
6-3230 Engine Controls - 7.4L
When the engine is able to use the extra fuel vapor,
the intake air flow purges the fuel vapor from the
carbon element, and then the normal combustion
process consumes the fuel vapor.
The fuel tank is sealed with a fuel cap that is not
normally vented to atmosphere. The fuel tank cap
has a safety valve which allows for both pressure
and vacuum relief.
Operation
Fuel vapors from the fuel tank purge and flow into
the EVAP canister tube labeled Tank and the carbon
absorbs the vapors. The canister purges when the
engine is able to use extra fuel vapor. A vacuum
source is applied to the EVAP canister tube labeled
Purge to draw fresh air through the top of the
canister. The air mixes with the fuel vapor and the
mixture is drawn in the intake manifold to be
consumed in the normal combustion process.
While the canister is purging, fresh air is drawn in
through the air inlet at the top of the canister. Air
flows to the bottom of the canister and forces the
vapors out the Purge tube.
The EVAP system in some applications uses an
electrically controlled solenoid to cycle the vacuum to
the purge canister. The control module cycles the
solenoid when the engine coolant temperature is
greater than 4 5* C or the Short Term Fuel Trim
counter is less than 122.
A vacuum switch in the purge line detects when the
system is purging. The normally closed switch will
open when less than 1 in. Hg is present in the
purge line.
EVAP Canister Location
The canister is located in the left front fender well.
Enhanced Ignition System Description
The ignition system initiates combustion by providing
a spark to ignite the compressed air and fuel mixture
at the correct time. In order to provide an improved
engine performance, fuel economy, and control of
exhaust emissions, the Control Module controls the
distributor spark advance (timing) with the Ignition
Control (IC) system.
The ignition system uses a primary and secondary
sub system in order to accomplish the timed spark
distribution. The primary system consists of a low
voltage trigger device which determines the base
timing. This signal is modified by the Ignition Control
Driver (ICD) Module. The signal travels to either or
both the engine and transmission processor (Control
Module) for base timing reference. Another signal is
sent back to the Ignition Control Driver (ICD)
Module, which has been adjusted by the Control
Module (advanced or retarded) in order to trigger the
coil, according to the requirements of the engine.
The secondary system consists of the ignition coil
which has primary (low voltage) windings and
secondary (high voltage) windings. The secondary
side of the ignition coil generates a high voltage
which high tension spark plug wires deliver to the
spark plugs.
Engine
The Control Module controller now controls the
Ignition Control (IC) and Bypass functions.
In order to properly control the ignition/combustion
timing, the Control Module needs to know the
following things:
• The crankshaft position
• The engine speed (RPM)
• The engine load (manifold pressure or vacuum)
• The atmospheric (barometric) pressure
• The engine coolant temperature
• The camshaft position sensor.
System Operation
The Enhanced Ignition system used on all OBD II
engines somewhat resembles the current Distributor
Ignition (Dl) system described in the Ignition
Systems. However, the system has been greatly
enhanced in order to make it compatible with the
new OBD II regulations. The Enhanced Ignition
system provides a spark at precisely the correct time
in order to ignite the air and fuel mixture for optimum
performance and fuel economy. The system consists
of the following components:
. VCM
• Distributor
• Ignition Coil Driver Module
• Ignition Coil
• Crankshaft Position Sensor
This system does not use the ignition module used
on the Dl systems in the past. The VCM controller
now controls the Ignition Control (IC) and Bypass
functions.
The crankshaft sensor, located in the front engine
cover, is perpendicular to a target wheel attached to
the crankshaft. The target wheel is equipped with
slots situated 60 degrees apart. As the crankshaft
rotates, the target wheel rotates past the crankshaft
position sensor. The rising and falling edges created
by the slots cause a signal to be sent back to the
VCM. This signal occurs three times per crankshaft
revolution and is referred to as the 3x signal for V6
applications. The signal occurs four times per
crankshaft revolution and is referred to as the 4x
signal for V8 applications.
The VCM then utilizes this 3x (V6) or 4x (V8) signal
in order to provide the correct spark to the engine by
way of the single coil driver module. The single coil
driver module is basically an electronic switch that
when commanded by the VCM, causes the primary
coil voltage to breakdown, energizing the secondary
coil and providing a spark via the coil wire to the
Distributor cap. The Distributor consists of the
following components:
• Cap and Rotor
• Camshaft Position Sensor
• Gear drive and shaft.
Engine Engine Controls - 7.4L 6-3231
The camshaft drives the Distributor shaft which • Distributor
rotates providing a spark to the correct cylinder by
way of the cap and rotor. The camshaft position
sensor functions much like the crankshaft sensor
previously described but provides only a 1x signal to
the VCM. That is, for every 2 rotations of the
crankshaft, there is 1 rotation of the camshaft. Note
that the camshaft position sensor will not affect
driveability. The sole purpose of the camshaft
position sensor is to provide the VCM with the
necessary information for the misfire DTCs.

Ignition Control (1C)

The VCM software controls all of the 1C and Bypass
functions. This reduces the number of circuits
outside of the controller and ultimately reduces the
possibility for shorts or opens in those circuits that
could result in driveability complaints or DTCs.

System Components
• Crankshaft Position Sensor

The Distributor is actually an assembly that

contains the Camshaft Position (CKP Sensor),
cap, rotor and shaft. The Distributor is splined
by a helical gear to the camshaft and rotates
providing a spark to each spark plug wire.
When servicing the Distributor, it is critical to
ensure proper cap sealing to the Distributor
body and correct installation to the camshaft. If
the Distributor is installed a tooth off in relation
12798 to the camshaft, a DTC sets. The Distributor is
The Crankshaft Position Sensor (CKP Sensor) not repairable and must be replaced as an
is located in the front engine cover and is assembly.
perpendicular to the crankshaft target wheel.
The air gap between the sensor and the wheel
is preset and not adjustable. The target wheel
has four slots 60 degrees apart and is keyed to
the crankshaft. As the target wheel rotates, the
slots passing by the sensor create a change in
the magnetic field of the sensor which results in
an induced voltage pulse. One revolution of the
crankshaft results in four pulses (4x signal).
Based on these pulses, the VCM is able to
determine crankshaft position and engine
speed. The VCM then activates the fuel injector
and provides a spark to the Distributor. The
relation between the crankshaft position sensor
and the target wheel is crucial. The sensor
must be exactly perpendicular to the target
wheel with the correct air gap.
6-3232 Engine Controls - 7.4L
• Camshaft Position Sensor
The Camshaft Position (CMP) sensor is located
within the Distributor. It’s operation is very
similar to the Crankshaft Position (CKP Sensor)
however it provides one pulse per camshaft
revolution (1x signal). This signal is not
detrimental to the driveability of the vehicle. The
VCM utilizes this signal in conjunction with the
crankshaft position to determine which cylinders
are misfiring.
• Ignition Coil Driver Module and Ignition Coil
The Ignition Coil Driver Module is mounted on
a bracket next to the coil. The VCM signals the
ICD to turn ON primary current to the ignition
coil by pulling the IC line high (4 volts). The
ICD turns the primary current ON and OFF by
applying and removing the ground to the
primary winding at the appropriate time. This
module is of minimum function. The module
does not contain backup calibrations that allows
the engine to continue to run if the IC signal
is lost.
Engine
Knock Sensor System Description
Purpose
12807
Varying octane levels in gasoline can cause a
detonation in an engine. This detonation is
sometimes called a spark knock.
All of the engines use a Knock Sensor (KS) system
with a knock sensor. The KS system reduces the
spark knock in the engine. This allows the engine to
have maximum spark advance for improved
driveability and fuel economy.
Operation
A Vehicle Control Module (VCM) is used in
conjunction with one knock sensor in order to control
detonation. On a VCM application no KS module will
be found as it is internal to the control module.
A 5 volt reference is applied to the knock sensor
which has an internal resistance of about
100,000 ohms. This resistance will lower the applied
voltage to about half or 2.5 volts. When a knock is
present, a small AC voltage is produced by the
knock sensor and transmitted to the control module
riding on top of the already existing 2.5 volts. An AC
voltage monitor inside the control module will detect
the knock and trigger the control module to start
retarding the spark incrementally.
Engine_________________________________
Secondary Air Injection System Description
Legend
(1) AIR Check Valve
(2) AIR Valve
(3) AIR Pump Crossover Pipe
The Secondary Air Injection (AIR) system is used on
the 7.4L to reduce Carbon Monoxide (CO) and
Hydrocarbons (HC).
The AIR system add air (oxygen) to the exhaust
manifold to continue oxidation after the exhaust
gasses have left the combustion chamber. The heat
from this reaction brings the catalytic converter up to
operating temperature faster when the engine
is cold.
This system consists of an AIR pump, VCM
controlled electronic clutch, check valves, and
necessary plumbing.
A belt driven AIR pump supplies filtered air from the
air intake system to the AIR injection pipes.
The check valves, on the AIR injection pipes,
prevent backflow of exhaust gasses in the
AIR pump.
When the engine is started with a coolant
temperature above approximately 15 ‘ C (45 * F) or if
the fuel system is in the Decel Mode, the VCM
energizes the AIR relay. The AIR relay then
energizes the AIR clutch, which directs air into the
exhaust manifold ports.
Engine Controls - 7.4L 6-3233
13114
(4) AIR Pump Output Hose
(5) AIR Pump
(6) AIR Pump Air Cleaner Hose
The control module may turn the AIR pump OFF
when any of the following conditions occur:
• The system is in the Closed Loop mode
• Any DTCs are set
• The system is in Power Enrichment mode for
more than a short period of time
• Low manifold pressure (over run)
• Quick vacuum rise (rapid decel)
EGR System Description
Purpose
The Exhaust Gas Recirculation (EGR) system lowers
the NOx (Oxides of Nitrogen) emission levels created
by the high combustion temperatures.
Operation
The EGR valve will open when the conditions of
operation have been met. This allows the exhaust
gasses to re-enter the combustion chamber. When
too much exhaust gas is allowed to enter the
chamber, the proper combustion will not occur. For
this reason, only very little exhaust gas is allowed to
re-enter the combustion chamber.
6-3234 Engine Controls - 7.4L Engine
The control module command exclusively operates
the linear EGR valve (1). The control module
monitors the following various engine parameters:
• The Throttle Position (TP) sensor
• The Manifold Absolute Pressure (MAP)
• The Engine Coolant Temperature (ECT) sensor
• The EGR Pintle position sensor
Output messages are then sent to the EGR system
indicating the proper amount of exhaust gas (2)
recirculation [with intake air (3)] necessary in order to
lower the combustion temperatures. This electronic
metering of exhaust gas is ten times faster than the
vacuum-operated models as well as an improved
diagnostic capabilities.
Positioned at the top of the linear EGR assembly are
5 terminals.
• A is the pulse width modulated negative signal
from the control module.
• B is the sensor ground.
• C is the sensor output.
• D is the +5 volts supply.
• E is the positive from ignition.

Legend
(1) Last 5 Digits of Assembly Part Number
(2) Julian Date (3 Digits) Last Digit of Year
Shift Number
(3) Plant Code Letters

The linear Exhaust Gas Recirculation (EGR) valves

look like a small motor.

A 12 volt current which enters the valve through an

electrical connector (terminal E) energizes the
solenoid (bobbin and coil) assembly (3). The 12 volt
current then flows through the solenoid assembly to
the control module and creates an electromagnetic
field. This field causes the armature assembly (4,6)
to be pulled upward, lifting the pintle (5) a variable
amount off the base.
The exhaust gas then flows from the exhaust
manifold through the orifice into the intake manifold.
The pintle position sensor (2,1-sensor cap) reads
the height of the pintle, and the control module
closes the loop on a desired position versus the
actual position read. This changes the pulse width
13596 modulated command to the solenoid accordingly,
until the actual pintle position equals the desired
pintle position.
Engine
The linear EGR valve is unique in that the control
module continuously monitors the pintle position. The
control module adjusts the pintle position in order to
obtain accurate flow, making linear EGR a Closed
Loop system.
When the solenoid is de-energized (the control
module breaks the circuit), the pintle seals against
the orifice, blocking the exhaust flow to the intake
manifold.
Engine Controls - 7.4L 6-3235
Air Intake System Description
In order to route the cool air from the exterior of the
engine compartment to the intake manifold, the
system uses an air intake system. A filter is
incorporated into the system in order to keep the dirt
from entering the engine.
Air Cleaner Restriction Indicator

Crankcase Ventilation System Description

Legend
(1) Reset Button
13561
(2) Window
A crankcase ventilation system is used in order to
provide a more complete scavenging of crankcase The air cleaner restriction indicator is located on the
vapors. The air cleaner supplies fresh air through a intake duct between the air cleaner assembly and
filter to the crankcase. The crankcase mixes the the Mass Air Flow (MAF) sensor.
fresh air with blow-by gases. This mixture then
passes through a crankcase ventilation valve into the If the area inside of the clear section is green, no air
intake manifold. filter service is required. If the area inside the clear
section is orange and Change Air Filter appears,
The primary control is through the crankcase replace the air filter.
ventilation valve (1), which meters the flow at a rate
depending on the manifold vacuum.
In order to maintain an idle quality, the crankcase
ventilation valve restricts the flow when the intake
manifold vacuum is high. If abnormal operating
conditions arise, the system is designed in order to
allow the excessive amounts of blow-by gases to
back flow through the crankcase vent tube into the
air cleaner in order to be consumed by normal
combustion.
6-3236 Engine Controls - 7.4L Engine

Special Tools and Equipment

J 35616-A/BT 8637
Connector Test Adapter Kit

J 26792/BT-7220-1
Spark Tester

5381

J 37027-A
IAC System Monitor

5398

J 23738-A/BT-8512A
Vacuum Pump

5386

J 39194
Oxygen Sensor Wrench

5388
Engine Engine Controls ■ 7.4L 6-3237

J 35748
J 34730-250 Fuel Pressure
Oil Pressure Sending Gauge and Adapter
Unit Socket

5385 5374

J 35689-A
I__ ----1 J 34730-375
Metri-Pack Terminal
Injector Test Lamp
Remover

I I
5395 5371

J 28742-A
Weather Pack Terminal J 39021 Injector Tester
Remover

5396 5380

= < l— - J 33095/BT-8234-A
Control Module Connector
Terminal Remover
fl

lM J 39021-210 Injector
Switch Box

5397 16875

J 34730-1A J 39021-301

Fuel Pressure Gauge Injector Harness

Connector (4.3L)

5389 214277
6-3238 Engine Controls - 7.4L Engine

J 39021-302
J 42873-1 3/8 Fuel Line
Injector Harness Connector Shutoff Valve
(5.0L/5.7L)

214277 214324

J 39021-303 Injector J 42873-2 5/16 Fuel Line

Harness Connector (7.4L) Shutoff Valve

16679 214327

J 41413 EVAP
J 39765 Fuel Sender
Pressure/Purge
Locknut Wrench
Diagnostic Station

16691 227620

J 37088-A Fuel Line J 41416 Ultrasonic

Quick-Connect Separator Leak Detector

12366 69758

J 41769 Fuel Line

Quick-Connect Separator
(4 Door Utility 5.7L/7.4L)

12366
Engine Turbocharger 6-3239

Turbocharger
Specifications

Fastener Tightening Specifications

Specification
Application Metric English
Actuator Bracket Bolts Air Cleaner Mounting Bracket Bolt/Nut 23 N.m 17 lb ft
Air Cleaner Large Bolt 30 N.m 22 lb ft
Air Cleaner Smaller Bolt 5 N.m 45 lb in
Exhaust Clamp 8 N.m 71 lb in
Extension (Air Intake) Bolts 23 N.m 17 lb ft
Heat Shield Bolts 6 N.m 56 lb in
Oil Drain Tube (Return) Flange Bolts 26 N.m 19 lb ft
Oil Feed Line 17 N.m 13 lb ft
Rubber Hose Connector Clamps 6 N-m 55 lb in
Rubber Inlet Elbow Clamps 2 N.m 18 lb in
Turbocharger Brace (Long) Bolt 50 N-m 37 lb ft
Turbocharger Brace (Long) Nut 34 N-m 26 lb ft
Turbocharger Brace (Short) Bolt 25 N.m 19 lb ft
Turbocharger to Exhaust Manifold Nuts 58 N.m 43 lb ft
Upper Intake Manifold Cover Bolts 11 N-m 90 lb in
6-3240 Turbocharger
Diagnostic Information and
Procedures
Problem
Insufficient fuel supply to the
injection pump
Problem
Restricted air filter
Obstructed air intake duct to the
turbocharger compressor wheel
Air leak in the compressor wheel
inlet/outlet duct
No vacuum signal to the wastegate
actuator
Ruptured wastegate actuator
diaphragm
Air leak between the intake manifold
and the engine
Exhaust gas leak between the
cylinder head exhaust ports and the
turbine inlet
Damaged turbocharger
Fuel system problem
Problem
Restriction and /or air leak in the
compressor inlet ducting and/or outlet connections and/or replace any damaged duct work.
ducting
Rotating components or turbocharger
out of balance
Compressor and/or turbine wheel
contacting the housing.
Blue Exhaust Smoke, Warm Engine Only
Problem
Lack of intake air
Restricted oil drain tube
Oil leakage past the turbo seals.
Refer to Inspection.
Engine
Lacks Power, No Black Smoke at WOT
Action
Refer to Engine Controls.
Lacks Power, Black Smoke at WOT
Action
Replace the air filter.
Remove the obstruction(s).
Inspect the inlet/outlet ducts for loose connections. Tighten the connections and /or
replace damaged duct work.
Check for DTCs. Refer to Engine Controls.
Refer to Wastegate Actuator.
Refer to Engine Mechanical and Exhaust System.
Repair the leaks.
Find the cause of damage. Refer to Turbocharger. Correct the cause of damage.
Replace the turbocharger if necessary.
Refer to Engine Controls.
Turbocharger Noise
Action
Inspect the compressor inlet/outlet ducting. Remove any restrictions. Tighten the
Replace the turbocharger. Refer to Turbocharger.
Refer to Turbocharger. Locate the reason for damage. Replace the turbocharger.
Action
Refer to Engine Controls.
Clean or replace the oil drain tube.
Replace the turbocharger. Refer to Turbocharger.
Engine Turbocharger 6-3241

Turbocharger
Turbochargers are extremely reliable units. The
majority of inoperative turbochargers are caused by
the following conditions:
• Dirt in the oil
• Oil lag (lack of oil flow)
• Foreign objects or debris entering the
turbocharger
• Plugged or restricted air cleaner systems
Problems that are frequently blamed on the
turbocharger may be caused by other engine
components. Such problems may include the
following conditions:
• Lack of power
• Black smoke
• Blue smoke (excess oil consumption)
• Engine performance problems
Completely inspect the turbocharger and all other
engine components that may cause similar conditions
before replacing the turbocharger. Refer to Engine
Mechanical for diagnosis of engine problems other
than those caused by the turbocharger.
Use the following information to diagnose problems
caused by the turbocharger.
If you cannot make a diagnosis from the
following information, refer to the tables listed
immediately below:
• Lacks Power, No Black Smoke at WOT
• Lacks Power, Black Smoke at WOT
• Turbocharger Noise
• Blue Exhaust Smoke, Warm Engine Only
If you determine that the turbocharger is the cause
of the problem, the turbocharger must be replaced
as a complete unit. THE TURBOCHARGER IS
SERVICED AS A COMPLETE UNIT. THE
WASTEGATE ACTUATOR MAY BE SERVICED
SEPARATELY.
Check for the following noises:

Problem
High-pitched whine
Cycling up and down in pitch
Sharp, high-pitched scream
Turbocharger
Action
Check for an exhaust leak or a leak in the air induction system.
Check for the following conditions:
• A blockage in the air inlet duct
• A restricted air cleaner
• A build up of dirt on the compressor wheel of the turbocharger (oil film is
normal)
Check the bearings. The bearings may have deteriorated and one (or both) of the
wheels may be rubbing on its housing (this results in blue exhaust smoke).
6-3242 Turbocharger Engine
Normal Compressor Wheel Damage by a Hard Object

Compressor Blades Show Heavy Rubbing

Ensure that the following conditions do not exist on

the compressor wheel blades:
• Cracks
• Bends
• Erosion of the blades
• Broken blades
Check the housing for signs of rubbing.
Check the compressor wheel for a build-up of dirt.
C a u tio n : D o n o t f e e l a n y c o m p o n e n t s o f th e
t u r b o c h a r g e r w h ile th e e n g in e is r u n n in g . M a k e
s u re th a t th e tu r b o c h a r g e r h a s s to p p e d r o ta tin g
a n d th e tu r b o c h a r g e r a n d e n g in e h a v e c o o le d
d o w n b e fo r e h a n d lin g . R o ta t in g p a r t s a n d
e x tre m e h e a t m a y c a u s e s e r io u s p e r s o n a l in ju r y
i f h a n d le d .
Engine Turbocharger 6-3243
Important: The wastegate actuator assembly can be replaced
• The inside of the air intake duct (rubber inlet separately from the turbocharger assembly. Use the
elbow), turbocharger compressor wheel and following procedure to check the operation of the
housing can be quite oily due to the venting of wastegate actuator:
the crankcase vapors into the intake system. 1. Turn the engine off.
The oily condition is considered normal with this
engine application. 2. Inspect the actuator rod and lever. The actuator
rod and lever should move back and forth
• The crankcase depression regulator (CDR)
without any tension.
valve does not prevent oil vapors from entering
the turbocharger compressor inlet system. Apply 5 inches HG vacuum to the actuator. The
• Carefully grasp the compressor wheel nut with actuator rod and lever should close the
your fingers and rotate the wheel in a clockwise wastegate.
direction. The wheel should turn freely with no 3. Look for the rod to move toward the front of
signs of binding or scraping (housing contact). the engine.
• Rotate the turbocharger while pushing in and
pulling out on the compressor wheel; the wheel
should rotate freely with no contact with the
housing.
• Carefully grasp the compressor wheel nut with
your fingers and rotate the wheel while moving
the wheel up and down (radially). There should
be no compressor wheel to the housing contact.
NOTE: AXIAL AND RADIAL PLAY IS NORMAL
EVEN ON A NEW TURBOCHARGER. If the
compressor wheel comes in contact with the
housing, it will be very evident when rotating the
wheel. The wheel will drag or scrape on the
housing surface and visual damage will be
evident on the wheel blades and the housing
surface.
• If the turbocharger does not pass any of these
inspections, replace the turbocharger.
Wastegate Actuator
Tools Required
J 23738-A Hand Operated Vacuum Pump With the engine running, the actuator rod should
snap back to a closed position. If not, the wastegate
actuator is defective and should be replaced. For
removal of the wastegate actuator, refer to
Wastegate Actuator Replacement.

177102
6-3244 Turbocharger Engine

Repair Instructions
Turbocharger
Removal Procedure
1. Open the hood.
C a u tio n : R e fe 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 t io n s a n d N o tic e s .

2. Disconnect the negative battery cable.

3. Remove the upper intake manifold cover.
4. Remove the crankcase depression regulator
(CDR) valve and tube from the air cleaner.
Refer to CDR Valve Replacement in Engine
Controls.
Important: Some quantity of oil will exist inside
the vent system. The crankcase vapor consists
of vaporized oil that condenses within the vent
and intake system. The inside of the air duct
and compressor wheel housing will have some
oil due to the venting of the crankcase vapors.
5. Loosen the clamps on the connector between
the upper intake manifold and the turbocharger.
Important: Silicone sealant is used between
the connector hose, the upper intake manifold,
and the turbocharger.
6. Remove the air cleaner extension and air
cleaner assembly from the turbocharger:
6.1. Break the seal between the connector
hose, turbocharger compressor inlet, and
the upper intake manifold by using a thin
flat screwdriver.
6.2. Slide the connector hose over the upper
intake manifold.
7. Remove the braces from the turbocharger.
8. Remove the vacuum line from the wastegate
actuator.

177115
Engine_________________________________________________________ Turbocharger 6-3245
9. Remove the oil feed line from the turbocharger.
Important: Removing the right front wheel and
the inner splash shield will aid in removing and
installing the attaching bolts for the
turbocharger and for the oil drain tube.
10. Remove the right front wheel and inner splash
shield. Refer to Tires and Wheels.

12. Remove the exhaust pipe clamp from the

turbocharger outlet.

177088
6-3246 Turbocharger Engine

Installation Procedure
Important: Perform the following steps before the
turbocharger is installed:
1. Check the intake and exhaust systems leading
to and from the turbocharger to make sure that
there is no foreign material that may cause
damage to the turbocharger during all levels of
operation. At the same time, check the mating
surface of the exhaust manifold for cracks and
replace as necessary.
2. Make sure that the turbocharger and the
exhaust manifold flanges are clean and free of
any foreign material. Use a high temperature
anti-seize compound, GM P/N 1052771, on all
threaded fasteners that are connected to the
turbocharger.
1. Install the studs to the turbocharger.
2. Install the turbocharger to the exhaust manifold.
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Install the studs and nuts.
Tighten
Tighten the studs and nuts to 58 N.m (43 lb ft).
Engine Turbocharger 6-3247
4. Install the oil drain tube and gasket.
5. Install the mounting bolts.
Tighten
Tighten the bolts to 26 N-m (19 lb ft).
6. Install the right front inner splash shield. Refer
to Tires and Wheels.
7. Install the right front wheel. Refer to Tires and
Wheels.

Important: Fill the oil feed hole at the top of the

turbocharger with a small amount of clean engine oil
(1 to 2 cc) while turning the compressor wheel by
hand to lubricate the bearings in the turbocharger.
8. Install the oil feed line to the turbocharger.
9. Tighten the oil feed line fitting.
Tighten
Tighten the fitting to 17 N-m (13 lb ft).

10. Install the exhaust pipe to the turbocharger.

11. Tighten the exhaust clamp.
Tighten
Tighten the clamp to 8 N-m (71 lb in).
Important: Apply a small amount of silicone
sealant, GM P/N 9985943 or the equivalent, to
a clean turbocharger compressor inlet (not the
upper intake manifold) before installing the
connector hose to prevent oil leakage from the
closed breather system.
12. Install the connector hose (with clamps) to the
upper intake manifold:
12.1. Slide the connector hose over the upper
intake manifold.
12.2. Slide the connector hose forward onto
the turbocharger compressor inlet.
12.3. Center the connector hose and tighten
the clamps.
Tighten
Tighten the clamps to 6 N-m (50 lb in).
6-3248 Turbocharger Engine
13. Install the long and short braces to the
turbocharger.
14. Install the mounting bolt for the long brace.
Tighten
Tighten the bolt (long brace) to
50 N.m (37 lb ft).
15. Install the mounting nut for the long brace.
Tighten
Tighten the nut (Long brace) to
40 N.m (30 lb ft).
16. Install the mounting bolts for the short brace.
Tighten
Tighten the bolts (short brace) to
25 N.m (19 lb ft).
17. Install the vacuum line to the wastegate
actuator.
18. Install the air cleaner extension and air cleaner
assembly.
19. Install the CDR valve and hose. Refer to
CDR Valve in Engine Controls.
20. Install the upper intake manifold cover.
21. Install the upper intake manifold cover bolts.
Tighten
Tighten the bolts to 11 N.m (90 lb in).
22. Install the negative battery cable.
23. Run the engine at idle for at least 2 minutes
after completing the installation of the
turbocharger. While running the engine,
check for any oil leaks at the oil supply and
return hoses.
Engine_________________________________ Turbocharger 6-3249
Wastegate Actuator
Removal Procedure
1. Open the hood.
C a u t io n : R e f e r t o 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 t io n s a n d N o tic e s .

2. Disconnect the negative battery cable.

3. Remove the upper intake manifold cover.
4. Remove the vacuum hose.
5. Remove the E-clip retainer from the wastegate
lever pin.

6. Remove the wastegate mounting bolts from the

turbocharger.

177419
7. Remove the wastegate assembly from the
turbocharger.

177446
6-3250 Turbocharger Engine
Installation Procedure
1. Install the wastegate to the turbocharger.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the wastegate mounting bolts to the
turbocharger.
Tighten
Tighten the bolts to 23 N.m (17 lb ft).
3. Install the E-clip to the wastegate lever pin.
4. Install the vacuum hose.

5. Install the upper intake manifold cover.

6. Connect the negative battery cable. Refer to
General Information.

174662
Engine_________________________________
Description and Operation
Turbocharger
The turbocharger is used to increase the amount of
air that enters the engine’s cylinders. The increase of
air allows a proportional increase of fuel that is
injected into the cylinders. The results are:
• Increased power output
• More complete combustion of the fuel
• Cooling of the cylinder heads, the pistons, the
valves, and the exhaust gas. This cooling effect
helps extend engine life.
Heat energy and pressures in the engine exhaust
gas drives the turbine wheel. Exhaust gas is directed
to the turbine housing. The turbine housing acts as a
nozzle to direct the exhaust gas flow to the turbine
wheel blades, which drive the shaft wheel assembly.
The compressor wheel is attached directly to the
shaft and rotates at the same speed as the turbine
wheel. Clean air from the air cleaner and crankcase
Turbocharger 6-3251
vapors are drawn into the compressor housing and
wheel, where the air is compressed and delivered
through a crossover pipe to the engine air intake
manifold, then into the cylinders. The inside of the
turbocharger compressor housing, the compressor
wheel, and the inside of the intake manifold can be
quite oily due to the ingestion of the crankcase
vapors. A wastegate valve in the exhaust housing
regulates the amount of air pressure rise and the air
volume delivered to the engine from the compressor
outlet.
The PCM monitors turbo boost pressure and controls
the position of the wastegate valve. More vacuum is
applied to the actuator to close the wastegate if
increased boost is needed. The vacuum applied to
the actuator is reduced if less turbo boost is needed.
A reduction of vacuum allows the wastegate valve to
open, resulting in additional exhaust bypassing the
turbine wheel.
For more information about the vacuum operated
wastegate controlled by the PCM, refer to Engine
Controls, Transmission, and Electrical Diagnosis.
6-3252 Turbocharger Engine

BLANK
Engine Vacuum Pump 6-3253

Vacuum Pump
Specifications

Fastener Tightening Specifications

Specification
Application Metric English
Fan Clutch Retaining Nuts 30 N-m 22 lb ft
Upper and Lower Fan Shroud Bolt/Screw 5 N.m 44 lb in
Vacuum Pump to the Generator Bracket Mounting Bolts 25 N-m 18 lb ft

Vacuum Pump Specifications

Elevation Vacuum
Sea Level -70 kPa (21 in)
152 m (5,000 ft) -60 kPa (18 in)
3048 m (10,000 ft) -49 kPa (14 in)
4572 m (15,000 ft) -40 kPa (12 in)
6-3254 Vacuum Pump Engine

Diagnostic Information and

Procedures
Vacuum Pump Diagnosis

No Vacuum
Problem Action
Important: Diagnostic procedure should be done with engine running. Vacuum should reach -70 kPa (21 in Hg) minimum at
sea level within 30 seconds. Elevation (feet/meters above sea level) will affect the vacuum reading you will see on the
vacuum gauge.
Broken drive belt Replace the drive belt.
Defective belt tensioner (if equipped) Replace the belt tensioner.
Pulley for the vacuum pump is loose Replace the pulley.
Broken vacuum line Locate and repair the break in the vacuum line.

Low Vacuum or Fluctuating Vacuum Gauge

Problem Action
Important: Diagnostic procedure should be done with engine running. Vacuum should reach -70 kPa (21 in Hg) minimum at
sea level within 30 seconds. Elevation (feet/meters above sea level) will affect the vacuum reading you will see on the
vacuum gauge.
Defective connection for Check connections and repair if necessary. If the connections are good, replace the
vacuum gauge vacuum gauge and retest.
Wrong drive belt Replace the drive belt.
Defective belt tensioner (if equipped) Replace the defective belt tensioner (if equipped).
Pulley loose on vacuum pump shaft Replace the defective belt tensioner (if equipped).
Defective vacuum pump Replace the vacuum pump.
Defective accessories Locate and repair or replace the defective accessory(s).
Engine Vacuum Pump 6-3255

Repair Instructions
Vacuum Pump Replacement
Removal Procedure
Tools Required
• J 25034-B Pump Pulley Remover
• J 25033-B Pump Pulley Installer
1. Open the hood.
C a u tio n : R e fe r t o 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 t io n s a n d N o tic e s .

2. Disconnect the negative battery cable.

3. Remove the drive belt. Refer to Drive Belt
Replacement.
4. Remove the vacuum line from the
vacuum pump.

5. Remove the vacuum pump mounting bolts.

6. Remove the vacuum pump.

7. Remove the vacuum pump pulley:

7.1. Place the vacuum pump in a vise.
7.2. Attach the J 25034-B to the pulley.
7.3. Remove the pulley from the vacuum
pump using the J 25034-B.

177202
6-3256 Vacuum Pump Engine
8. Install the vacuum pump pulley on the
vacuum pump.
8.1. Attach the J 25033-B to the vacuum
pump pulley.
8.2. Install the vacuum pump pulley to the
vacuum pump.
8.3. Remove the J 25033-B.
9. Remove the vacuum from the vise.

Installation Procedure
1. Install the vacuum pump.
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
2. Install the mounting bolts.
Tighten
Tighten the bolts to 27 N.m (20 lb ft).

3. Install the vacuum line to the vacuum pump.

4. Install the drive belt. Refer to Drive Beit
Replacement.
5. Install the negative battery cable. Refer to
General Information.

177123
Engine_________________ Vacuum Pump 6-3257

Special Tools and Equipment

Illustration Tool Number/ Description

J 25034-B
Pump Pulley Remover

675

J 25033-B
Pump Pulley Installer

676
6-3258 Vacuum Pump Engine

BLANK
Engine Engine Exhaust 6-3259

Engine Exhaust
Specifications

Fastener Tightening Specifications

Application N-m Lb Ft Lb In
Crossover Pipe to Manifold Bolt (Diesel Engine) 34 25 —
Exhaust Hanger to Frame Crossmember Bolt 34 25 —

Exhaust Hanger to Frame Nut 35 26 —

Exhaust Manifold Nuts (Gasoline Engine) 65 48 —

Exhaust Manifold Stud (Gasoline Engine) 22 16 —

Exhaust V-Band Clamp (Diesel Engine) 12 — 106

Flange Stud Nuts (Diesel Engine) 64 47 —

Flange Stud Nuts (Gasoline Engine) 64 47 —

Tailpipe Hanger to Frame Nut 48 35 —

U-Bolt Nuts 42 31 —

GM SPO Group Numbers

Application GM SPO Group Number
Exhaust Crossover Pipe (Diesel) 3.609
Exhaust Manifold Hanger 3.704
Exhaust Manifold Pipe 3.609
Exhaust Manifold Pipe Gasket 3.611
Exhaust Muffler (w/Exhaust Pipe and Tailpipe) 3.701
Heated Oxygen Sensor 3.682
Oxidation Catalytic Converter (w/Exhaust Pipe) (Diesel) 3.685
Three-Way Catalytic Converter (w/Exhaust Manifold Pipe) 3.685
6-3260 Engine Exhaust________________ Engine

Diagnostic Information and Procedures

Vibration or Rattling
Step Action Value(s) Yes No
Check for loose and/or misaligned components.
1 — —
Are there any loose or misaligned components? Go to Step 2
1. Align the components.
2. Tighten the connections.
3. Check the following components for damage:
2 • The hangers — —
• The mounting brackets
• The clamps
Is the exhaust system vibrating or rattling? System OK

Restricted Exhaust
Step Action Value(s) Yes No
Inspect the exhaust tubing.
1 —
Is the exhaust tubing kinked? Go to Step 2 Go To Step 3
If possible, repair the damaged exhaust tubing. Otherwise,
2 replace the exhaust tubing. —
Is the exhaust system restricted? Go to Step 3 System OK
Inspect the muffler.
3 —
Is the muffler restricted? Go to Step 4 Go to Step 5
1. If a restriction is likely, remove the muffler and
visually inspect it.
2. If the damage to the muffler is not repairable,
4 replace the muffler. —
3. Correct the engine malfunction. Refer to Engine
Controls.
Is the exhaust system restricted? Go to Step 5 System OK
Inspect the end of the tailpipe.
5 —
Is the end of the tailpipe obstructed? Go to Step 6 Go to Step 7
Remove the obstruction, or if the end of the tailpipe is
6 crimped, straighten the outlet. —
Is the exhaust system restricted? Go to Step 7 System OK
Inspect the catalytic converter for obstructions, which may
7 have occured as a result of a serious engine manlfunction. — —
Is the catalytic converter obstructed? Go to Step 8
1. Replace the catalytic converter.
8 2. Correct the engine malfunction. — —
Is the exhaust system restricted? System OK
Engine Engine Exhaust 6-3261
Exhaust Leakage (Not OBD II)
Step Action Value(s) Yes No
Inspect the exhaust component pipes and the couplings
for leaks.
1 —
Are there leaks at the exhaust component pipes and the
couplings? Go to Step 2 Go to Step 3
Tighten the clamps or fasteners to the specified torque.
2 Refer to Fastener Tightening Specifications. —
Is the exhaust system leaking or making noise? Go to Step 3 System OK
Inspect the components for misalignment or incorrect
3 installation. —
Are the components misaligned or improperly installed? Go to Step 4 Go to Step 5
Align the components and tighten the connections.
4 —
Is the exhaust system leaking or making noise? Go to Step 5 System OK
Inspect the exhaust manifold for cracks or damage.
5 —
Is the exhaust manifold cracked or broken? Go to Step 6 Go to Step 7
Replace the exhaust manifold.
6 —
Is the exhaust system leaking or making noise? Go to Step 7 System OK
Inspect the system for a leak between the exhaust
manifold and the cylinder head.
7 —
Is there a leak between the exhaust manifold and the
cylinder head? Go to Step 8 Go to Step 9
Tighten the manifold to cylinder head nuts and bolts to
specifications.
8 —
Refer to Fastener Tightening Specifications.
Is the exhaust system leaking or making noise? Go to Step 9 System OK
Inspect the seal for damage or excessive wear.
9 —
Are the seals damaged or worn? Go to Step 10 Go to Step 11
Replace the seals or gaskets, as necessary.
10 —
Is the exhaust system leaking or making noise? Go to Step 11 System OK
Inspect the exhaust pipe for bums or rust.
11 —
Is the exhaust pipe burned or rusted out? Go to Step 12 Go to Step 13
Replace the exhaust pipe.
12 —
Is the exhaust system leaking or making noise? Go to Step 13 System OK
Inspect the muffler for damage.
13 —
Is the muffler burned or blown out? Go to Step 14 Go to Step 15
Replace the muffler assembly.
14 —
Is the exhaust system leaking or making noise? Go to Step 15 System OK
Inspect the condition of the clamps and/or brackets.
15 — —
Are the clamps and/or brackets broken or loose? Go to Step 16
Repair or replace the damaged clamps and/or brackets, as
16 necessary. — —
Is the exhaust system leaking or making noise? System OK
6-3262 Engine Exhaust Engine

Repair Instructions
Exhaust System Inspection
Inspect the exhaust pipes, the catalytic converter(s),
the muffler, and the tailpipe for the following
conditions:
• Cracked joints
• Broken welds
• Corrosion damage (Corrosion damage could
cause leaks in the exhaust system.)
Inspect the clamps, the brackets, and the insulators
for the following conditions:
• Broken bolts
• Stripped bolt threads
• Corroded bolts
The exhaust system (including the heat shield) must
be free of the following conditions:
• Leaks
• Binding
• Grounding
• Excessive vibration
These conditions may occur if any of the following
components are loose or damaged:
• Flange bolts or flange nuts
• Heat shields
• Brackets
• Pipes
If any of these conditions exist, inspect the exhaust
system alignment. Align and replace any components
necessary, including new manifold seals, nuts, and
gaskets.

Catalytic Converter Replacement

(Gasoline Below 8600 lb GVWR)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
General Information.
2. Disconnect the oxygen sensor electrical
connections.

160895
Engine Engine Exhaust 6-3263
3. Remove the nuts from the Y-pipe flat flange.
4. Remove the Y-pipe and the catalytic converter
assembly.

5. Remove the nuts and the flange seals from the

Y-pipe and the exhaust manifold.

Installation Procedure
1. Install the new flange seals and the new nuts
to the exhaust manifold.
Tighten
Tighten the nuts to 65 N.m (48 lb ft).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
2. Position the Y-pipe and the catalytic converter
assembly to the flat flange.
3. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N.m (47 lb ft).

107617
6-3264 Engine Exhaust Engine
4. Connect the oxygen sensor electrical
connections.
5. Check for clearance and alignment.
6. Lower the vehicle.

Catalytic Converter Replacement

(Gasoline Above 8600 lb GVWR)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
General Information.
2. Disconnect the oxygen sensor electrical
connections.

160895

3. Remove the nuts from the Y-pipe flat flange.

107621
Engine Engine Exhaust 6-3265
4. Remove the nuts and the flange seals from the
Y-pipe and the exhaust manifold.

5. Remove the Y-pipe and the catalytic converter

assembly.
6. Remove the muffler and the catalytic converter
assembly.

107621

Installation Procedure
1. Install the flange seals and the nuts to the
exhaust manifold.
Tighten
Tighten the nuts to 65 N.m (48 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

78428
6-3266 Engine Exhaust _____________ Engine
2. Install the muffler and the catalytic converter
assembly.
3. Position the Y-pipe and the catalytic converter
assembly to the flat flange.
4. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).

107621

5. Connect the oxygen sensor electrical

connections.
6. Check for clearance and alignment.
7. Lower the vehicle.

Catalytic Converter Replacement (Diesel)

Rem oval Procedure
1. Raise and suitably support the vehicle. Refer to
General Information.
2. Remove the front exhaust pipe flange stud nuts
from the front of the catalytic converter
assembly.
Remove the clamp from the exhaust
manifold pipe.

164372
Engine Engine Exhaust 6-3267
3. Remove the U-bolt from the rear of the catalytic
converter assembly.
Remove the catalytic converter from the muffler
assembly.

Installation Procedure
1. Install a new flange gasket and the catalytic
converter to the front exhaust pipe flange studs.
Tighten
Tighten the nuts to 64 N.m (47 lb ft).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.

2. Install a new U-bolt to the rear of the catalytic

converter.
Tighten
Tighten the nuts to 42 N.m (31 lb ft).
Install the clamp to the exhaust manifold pipe.
Tighten
Tighten the nut to 12 N.m (1 0 6 lb in).
3. Check for clearance and alignment.
4. Lower the vehicle.

164370
6-3268 Engine Exhaust _________________________________ Engine

Catalytic Converter Replacement (Export)

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
General Information.
2. Remove the nuts from the Y-pipe flat flange.
3. Remove the muffler and the catalytic converter
assembly.

4. Remove the nuts and the flange seals from the

Y-pipe and the exhaust manifold.

Installation Procedure
1. Install the new flange seals and the new nuts
to the exhaust manifold.
Tighten
Tighten the nuts to 65 N.m (48 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

7842S
Engine Engine Exhaust 6-3269
2. Position the Y-pipe and the catalytic converter
assembly to the flat flange.
3. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).
4. Check for clearance and alignment.
5. Lower the vehicle.

201704
6-3270 Engine Exhaust
Description and Operation
Exhaust System Description
General Description
Exhaust system designs vary according to
the engine designation and intended use o f the
vehicle.
The exhaust pipe(s), muffler(s), and tailpipes are
standard equipment. The exhaust system uses a ball
joint coupling to secure the exhaust pipe to the
engine manifold. The ball joint allows angular
movement for alignment purposes.
Other connections on the gasoline engine use a
flat flange and gasket, while the diesel engine
uses a slip joint coupling design with a clamp
and U-bolt.
Engine
The exhaust system is suspended by hangers
attached to the frame members. These allow some
movement of the exhaust system and minimize the
transfer of noise and vibration into the vehicle.
Catalytic Converters
The catalytic converter is an emission control device
added to the engine exhaust system to reduce
hydrocarbon, carbon monoxide and nitrogen oxide
pollutants from the exhaust gases. The catalyst in
the converter is not serviceable.
Heat shields are used to protect the vehicle and the
environment from high temperatures developed by the
exhaust system, especially the catalytic converter.
Notice: The catalytic converters require the use of
unleaded fuel only. Using leaded fuel will damage
the catalytic converters and other emission system
components.
107616
Engine Engine Exhaust 6-3271

The catalytic converter(s) used on gasoline engine

vehicles with Light Duty Emissions (vehicles below
8,600 lb GVWR) are part of the Y-pipe and are
attached forward of the flat flange.

107621
6-3272 Engine Exhaust Engine

The catalytic converter(s) used on gasoline engine

vehicles with Heavy Duty Emissions (vehicles above
8,600 lb GVWR) are both part of the Y-pipe
assembly and the muffler assembly. One converter is
attached forward of the flat flange and the second
converter is mounted rearward of the flat flange.

The diesel engine uses a catalytic converter added
to the exhaust system to reduce smoke (particulates).
The catalytic converter operates at normal exhaust
system temperature; there is no significant
temperature increase as a result of oxidation
of particulates.
Individual exhaust system replacement components
versus one complete assembly will vary upon
body/chassis and engine designation.
Removing Exhaust Parts
C a u tio n : A lw a y s w e a r p r o te c tiv e g o g g le s a n d
g lo v e s w h e n r e m o v in g e x h a u s t p a r t s a s fa llin g
r u s t a n d s h a rp e d g e s fro m w o rn e x h a u s t
c o m p o n e n ts c o u ld r e s u lt in s e r io u s p e r s o n a l
I n ju r y .
When removing exhaust components, an
accumulation of dirt and corrosion can make work
difficult. Using a penetrating oil on the threads of
bolts can assist in the removal of these components.
Engine
Installing Exhaust Parts
Notice: When jacking or lifting the vehicle from the
frame side rails, make sure the lift pads do not
contact the catalytic converter as converter damage
will result.
Important:
• Apply sealer GM P/N 9985020 or equivalent to
all slip joint connections.
• When installing the exhaust pipe to the engine
manifold, always use a new seal and nuts.
Clean the engine manifold stud threads with a
wire brush before installing the new nuts.
Engine Exhaust 6-3273
When installing a new exhaust pipe, muffler, or
tailpipe, on any model, check for proper alignment.
Rattles and noise vibrations in the exhaust system
are usually caused by the misalignment of parts.
When aligning the system, leave all bolts and nuts
loose until all parts are properly aligned. Tighten the
exhaust system components starting with the flat
flange, then the engine, and finally the U-bolts, if
equipped.
Damaged exhaust system hangers, hanger brackets,
and clamps should be replaced to maintain exhaust
system alignment.
6-3274 Engine Exhaust Engine

BLANK
Transmission/Transaxle
Section 7
Transmission/Transaxle
M a n u a l T ra n s m is s io n - N e w V e n tu re ......... 7-7
S pecifications........................................................ 7-7
Fastener Tightening Specifications.................. 7-7
Lubrication Specifications.................................. 7-7
Diagnostic Inform ation and P rocedures......... 7-8
Manual Transmission Diagnosis.......................7-8
Clutch Spin Down Tim e.................................... 7-8
Repair In stru ctio n s...............................................7-9
Manual Transmission Fluid C heck.................. 7-9
Fluid Replacement (NV3500).......................... 7-11
Fluid Replacement (NV4500)..........................7-12
Shift Lever........................................................ 7-14
Vehicle Speed Sensor (NV3500)................... 7-15
Vehicle Speed Sensor (NV4500)................... 7-17
Backup Lamp Switch (NV3500).................... 7-19
Backup Lamp Switch (NV4500).................... 7-20
Transmission Replacement (NV3500)...........7-22
Transmission Replacement
(NV4500 RW D)........................... 7-27
Transmission Replacement
(NV4500 4WD).............................................7-31
Description and O peration............................... 7-36
Transmission Description and Operation......7-36
Special Tools and E quipm ent..........................7-37
Special Tools.................................................... 7-37
A u to m a tic T ra n s m is s io n - 4 L 6 0 -E ............. 7-39
S pecifications...................................................... 7-39
Temperature vs Resistance............................7-39
Fastener Tightening Specifications
(Overhaul)...................... ’............................. 7-39
Fastener Tightening Specifications
(On Vehicle).................................................7-40
Scan Tool Data Value Examples................... 7-41
Transmission Scan Tool Data Definitions......7-43
Diagnostic Trouble Code (DTC)
Identification................................................. 7-46
Fluid Capacity...................................................7-48
Range Reference.............................................7-49
Shift Solenoid Valve State and
Gear Ratio.................................................... 7-49
Shift Speed....................................................... 7-50
Diagnostic Inform ation and P rocedures.......7-52
Functional Test Procedure.............................. 7-52
Table of Contents 7-1
Schematic and Routing D iagram s................. 7-53
Automatic Transmission Schematic
References................................................... 7-53
Automatic Transmission
Schematic Icons...........................................7-53
Automatic Transmission Controls
Schematics (4L60).......................................7-54
Component Locator............................................7-60
Automatic Transmission Components........... 7-60
Automatic Transmission Electronic
Component Views........................................7-63
AT Inline Harness Connector End V iew ...... 7-64
Visual Identification............................................7-65
AT Internal Connector End Views................. 7-65
Diagnostic Inform ation and P rocedures...... 7-67
DTC P0218 Transmission Fluid
Overtemperature..........................................7-67
DTC P0502 Vehicle Speed Sensor
Circuit Low Input..........................................7-69
DTC P0503 Vehicle Speed Sensor
CKT Intermittent...........................................7-72
DTC P0711 Fluid Temp Sensor
CKT Range/Performance............................ 7-75
DTC P0712 Fluid Temperature Sensor
CKT Low Input............................................. 7-79
DTC P0713 Fluid Temperature Sensor
CKT High Input............................................7-83
DTC P0719 Brake Switch Circuit
Low Input..................................................... 7-87
DTC P0724 Brake Switch Circuit
High Input..................................................... 7-90
DTC P0740 TCC Enable Solenoid
Circuit Electrical...........................................7-92
DTC P0742 Torque Converter
Clutch System Stuck O n ............................ 7-95
DTC P0748 Pressure Control
Solenoid CKT Electrical.............................. 7-98
DTC P0751 1-2 Shift Solenoid
Valve Performance.....................................7-102
DTC P0753 1-2 Shift Solenoid
Circuit Electrical.........................................7-105
DTC P0756 2-3 Shift Solenoid
Valve Performance.....................................7-109
DTC P0758 2-3 Shift Solenoid
Circuit Electrical......................................... 7-112
7-2 Table of Contents
DTC P0785 3-2 Shift Solenoid
Circuit Electrical......................................... 7-116
DTC P1810 TFP Valve Position
Sw CKT Malfunction.................................7-120
DTC P1860 TCC PWM Solenoid
Circuit Electrical......................................... 7-124
DTC P1870 Transmission Component
Slipping....................................................... 7-128
DTC P1875 4 Wheel Drive Low
Switch CKT Malfunction............................7-133
Transmission Fluid Checking Procedure....7-136
Line Pressure Check Procedure.................. 7-137
Electrical/Garage Shift Procedure................ 7-137
Road Test Procedure.................................... 7-138
Noise and Vibration Analysis....................... 7-139
Flywheel/Torque Converter
Vibration Test............................................. 7-140
Torque Converter Clutch Diagnosis.............7-142
Torque Converter Clutch Shudder............... 7-143
Automatic Transmission Wiring
Harness Check.......................................... 7-144
Component Resistance.................................7-146
TFP Valve Position Switch
Resistance Check..................................... 7-147
Electronic Component Malfunctions.............7-150
Oil Pressure High or L o w .............................7-151
Harsh Shifts....................................................7-151
Inaccurate Shift Points..................................7-152
1st Gear Range Only-No Upshift................. 7-152
Slips in 1st G ear........................................... 7-152
Slipping or Rough 1-2 S hift..........................7-153
No 2-3 Shift or 2-3 Shift Slips, Rough
or Hunting...................................................7-153
2nd/3rd Gear Only or 1st/4th
Gears O nly.................................................7-154
Third Gear Only............................................. 7-154
3-2 Flare or Tie-Up........................................ 7-154
No 3-4 Shift, Slips or Rough 3-4 Shift...... 7-154
No Reverse or Slips in Reverse.................. 7-155
No Part Throttle or Delayed Downshifts.... 7-155
Harsh Garage Shift........................................ 7-156
No Overrun Braking - Manual 3-2-1............7-156
No TCC A pp ly............................................... 7-157
Torque Converter Clutch Shudder............... 7-157
No TCC Release........................................... 7-158
Drives in Neutral............................................ 7-158
2nd Gear Start.................... 7-158
No Park........................................................... 7-158
Oil Out the V ent............................................ 7-159
Vibration in Reverse and Whining
Noise in Park............................................. 7-159
Ratcheting Noise........................................... 7-159
No Drive in All Ranges.................................7-159
No Drive in Drive Range...............................7-159
Front Oil Leak................................................ 7-159
Transmission/Transaxle
Delay in Drive and Reverse....................... 7-159
Fluid Leak Diagnosis..................................... 7-160
Repair In stru ctio n s.......................................... 7-163
Shift Cable Replacement..............................7-163
Shift Cable Adjustment.................................. 7-166
Park/Neutral Back Up Switch
Replacement...............................................7-170
Park/Neutral Back Up Switch
Adjustment..................................................7-171
AT Fluid/Filter Changing................................ 7-171
Oil Cooler Line Replacement........................7-174
Transmission Oil Cooler Replacement...... 7-182
2-4 Servo (n )..................................................7-182
Filler Tube Replacement...............................7-188
Torque Converter Cover Replacement...... 7-189
Flywheel to Torque Converter Bolts............ 7-190
Oil Pan Replacement (n )..............................7-191
Valve Body...................................................... 7-195
Control and Shift Solenoids
Replacement (m)....................................... 7-202
TCC PWM Solenoid, TCC Solenoid,
and Wiring Harness (m )...........................7-207
Control Valve Assembly......................... 7-212
Extension Housing Rear Oil Seal................ 7-216
Accumulator Assembly.................................. 7-217
Vehicle Speed Sensor Replacement...........7-219
Transmission Replacement...........................7-220
AT Oil Cooler Flushing.................................. 7-227
Description and O pe ra tio n.............................7-229
Transmission ID Information.........................7-229
Transmission General Information............... 7-230
Preliminary Checking Procedure.................. 7-231
Transmission Fluid Checking Procedure....7-232
Automatic Transmission Diagnosis.............. 7-232
Electronic Component Description............... 7-233
Torque Converter Clutch Electrical
Controls...................................................... 7-237
Electrical Connector...................................... 7-238
Component Loca tor......................................... 7-239
Transmission Component Location..............7-239
Special Tools and E quipm ent....................... 7-266
Special Tools..................................................7-266
A u to m a tic T ra n s m is s io n - 4 L 8 0 -E ...........7-269
S pe cifica tio ns....................................................7-269
Temperature vs Resistance...........................7-269
Fastener Tightening Specifications
(On-Vehicle)................................................7-269
Fastener Tightening Specifications
(Overhaul)...................................................7-270
Scan Tool Data Value Examples
(Gas V C M ).................................................7-271
Scan Tool Data Value Examples
(Diesel PCM)..............................................7-272
Transmission Scan Tool Data
Definitions...................................................7-274
Transmission/Transaxle Table of Contents 7-3

Diagnostic Trouble Code (DTC) DTC P0717 Input Speed Sensor

Identification (Gas).................................... 7-276
Diagnostic Trouble Code (DTC)
Identification (Diesel)................................. 7-279
Fluid Capacity (On-Vehicle)..........................7-282
Fluid Capacity (Overhaul)............................. 7-282
Range Reference...........................................7-282
Shift Solenoid Valve State and
Gear Ratio.................................................. 7-283
Shift Speed..................................................... 7-283
Range Signal.................................................. 7-283
Transmission General Specifications........... 7-284
Line Pressure.................................................7-284
Component Resistance................................. 7-285
Diagnostic Information and P rocedures.... 7-286
Functional Test Procedure............................7-286
Schematic and Routing D ia g ra m s............... 7-287
Automatic Transmission
Schematic Icons.........................................7-287
Automatic Transmission Controls
Schematics................................................. 7-288
Component Locator..........................................7-294
Automatic Transmission Components........ 7-294
Automatic Transmission Electronic
Component Views..................................... 7-295
Visual Identification..........................................7-296
AT Internal Connector End Views............... 7-296
Diagnostic Inform ation and P ro ced u re s.... 7-298
DTC P0218 Transmission Fluid
Overtemperature (Gas)............................. 7-298
DTC P0218 Transmission Fluid
Overtemperature (Diesel)..........................7-301
DTC P0502 Vehicle Speed Sensor
Circuit Low Input (Gas Only)................... 7-304
DTC P0503 Vehicle Speed Sensor
CKT Intermittent (Gas Only).....................7-308
DTC P0560 System Voltage
Malfunction (Gas).......................................7-312
DTC P0560 System Voltage
Malfunction (Diesel).................................. 7-315
DTC P0711 Fluid Temp Sensor CKT
Range/Performance (Gas)........................7-318
DTC P0711 Fluid Temp Sensor CKT
Range/Performance (Diesel).....................7-322
DTC P0712 Fluid Temperature Sensor
CKT Low Input (G as)............................... 7-326
DTC P0712 Fluid Temperature Sensor
CKT Low Input (Diesel)............................ 7-329
DTC P0713 Fluid Temperature Sensor
CKT High Input (Gas)............................... 7-332
DTC P0713 Fluid Temperature Sensor
CKT High Input (Diesel)........................... 7-336
DTC P0716 Input Speed Sensor
Circuit Intermittent (Gas)........................... 7-340
DTC P0716 Input Speed Sensor
Circuit Intermittent (Diesel).......................7-343
Circuit Low Input (G as)............................7-347
DTC P0717 Input Speed Sensor
Circuit Low Input (Diesel).........................7-350
DTC P0719 Brake Switch Circuit
Low Input (Gas).........................................7-353
DTC P0719 Brake Switch Circuit
Low Input (Diesel)..................................... 7-357
DTC P0722 Output Speed Sensor
Circuit Low Input (Diesel O nly)................7-360
DTC P0723 Output Speed Sensor
Circuit Intermittent (Diesel O nly)............. 7-365
DTC P0724 Brake Switch Circuit
High Input (Gas)........................................7-370
DTC P0724 Brake Switch Circuit
High Input (Diesel).................................... 7-373
DTC P0730 Incorrect Gear
Ratio (Gas).................................................7-375
DTC P0730 Incorrect Gear
Ratio (Diesel).............................................7-378
DTC P0741 TCC System Stuck
Off (G as).................................................... 7-381
DTC P0741 TCC System Stuck
Off (Diesel)................................................. 7-384
DTC P0742 Torque Converter Clutch
System Stuck On (G as)........................... 7-387
DTC P0742 Torque Converter Clutch
System Stuck On (Diesel)........................7-390
DTC P0748 Pressure Control Solenoid
CKT Electrical (Gas)................................. 7-393
DTC P0748 Pressure Control Solenoid
CKT Electrical (Diesel)............................. 7-397
DTC P0751 1-2 Shift Solenoid
Valve Performance (Gas)......................... 7-401
DTC P0751 1-2 Shift Solenoid
Valve Performance (Diesel)......................7-404
DTC P0753 1-2 Shift Solenoid
Circuit Electrical (Gas).............................. 7-407
DTC P0753 1-2 Shift Solenoid
Circuit Electrical (Diesel)........................... 7-411
DTC P0756 2-3 Shift Solenoid
Valve Performance (Gas)......................... 7-415
DTC P0756 2-3 Shift Solenoid
Valve Performance (Diesel)......................7-418
DTC P0758 2-3 Shift Solenoid
Circuit Electrical (Gas).............................. 7-421
DTC P0758 2-3 Shift Solenoid
Circuit Electrical (Diesel).......................... 7-425
DTC P1810 TFP Valve Position
Sw CKT Malfunction (Gas).......................7-429
DTC P1810 TFP Valve Position
Sw CKT Malfunction (Diesel)...................7-433
DTC P1811 Maximum Adapt and
Long Shift (Diesel O nly)........................... 7-437
DTC P1860 TCC PWM Solenoid
Circuit Electrical (Gas).............................. 7-440
DTC P1860 TCC PWM Solenoid
Circuit Electrical (Diesel).......................... 7-444
7-4 Table of Contents
DTC P1870 Transmission Component
Slipping (Gas)........................................... 7-448
DTC P1870 Transmission Component
Slipping (Diesel)....................................... 7-452
DTC P1875 4 Wheel Drive Low Switch
CKT Malfunction (G as)............................7-456
DTC P1875 4 Wheel Drive Low Switch
CKT Malfunction (Diesel).........................7-459
Transmission Fluid Checking
Procedure..................................................7-461
Line Pressure Check Procedure................. 7-463
Road Test Procedure................................... 7-463
Torque Converter Clutch Diagnosis............ 7-466
Torque Converter Evaluation and
Diagnosis...................................................7-466
Torque Converter Clutch Shudder.............. 7-467
Flywheel/Torque Converter
Vibration Test............................................ 7-467
TFP Valve Position Switch
Resistance Check.................................... 7-468
Automatic Transmission Wiring
Harness Check......................................... 7-470
Clutch Plate Diagnosis................................. 7-472
Engine Coolant in Transmission................. 7-472
AT Oil Cooler Flow Test...............................7-472
Fluid Leak Diagnosis and Repair............... 7-473
Electronic Component Malfunctions............7-475
Transmission Component Fluid Leak
Diagnosis...................................................7-476
High Line Pressure....................................... 7-477
Forward Motion in Neutral...........................7-477
Inadequate Lubrication at Low Line
or Heavy Loads........................................ 7-477
Inadequate Lubrication.................................7-477
Engine Stall in Neutral.................................7-477
Loss of Power............................................... 7-478
No Torque in Reverse and Third................7-478
Transmission Overheats...............................7-478
Transmission Overheats at WOT................7-478
Low Line Pressure........................................ 7-479
Engine Starts in G ear..................................7-479
Shift Lever Indicates Wrong G ear..............7-479
No Gear Selection........................................ 7-479
Loss of D rive................................................ 7-480
No Park..........................................................7-481
Remains in Park........................................... 7-481
Difficult to Shift Out of Park........................ 7-481
Does Not Stay in Park.................................7-481
No Reverse.....................................................7-482
No First Gear - D 1........................................ 7-482
No Second Gear - D1................................... 7-482
No Overrun Braking - D1..............................7-482
No Engine Braking - D1................................7-482
No First Gear - D2........................................ 7-483
No Second Gear - D2................................. 7-483
No Overrun Braking - D2............................ 7-483
Transmission/Transaxle
No Engine Braking - D 2 ............................. 7-483
No Second Gear Engine Braking - D 2 ..... 7-484
No First Gear - D3........................................ 7-484
No Second Gear - D3................................... 7-484
No Third Gear - D3....................................... 7-484
No Overrun Braking - D3..............................7-484
No Engine Braking - D 3 ...............................7-485
No First Gear - D4........................................ 7-485
First Gear Only - D 4..................................... 7-485
First and Second Gear Only -D4................. 7-485
Second Gear Only - D4................................ 7-485
Second and Third Gear Only -D4..............7-486
First and Fourth Gear Only - D4.................. 7-486
Third and Fourth Gear Only -D4.................. 7-486
No Second Gear - D4................................... 7-486
No Third Gear - D4....................................... 7-487
No Fourth Gear - D 4 .................................... 7-487
No TCC A pply................................................7-488
Soft TCC A pp ly............................................. 7-489
Slipping T C C ..................................................7-489
TCC Stuck O n ................................................7-489
Incorrect TCC Apply or Release................. 7-489
Converter Ballooning....:................................7-490
No Torque Multiplication................................7-490
Fluid Foaming.................................................7-490
Noise............................................................... 7-490
Engine S ta ll.................................................... 7-491
Vibration.......................................................... 7-491
Oil Out the Vent Tube................................... 7-491
No Torque in Second Gear...........................7-491
Second Gear Starts....................................... 7-492
Third Gear Starts............................................7-492
Fourth Gear S tarts........................................ 7-492
Erratic Shift Q uality....................................... 7-492
Transmission Slips......................................... 7-492
Transmission Seized..................................... 7-493
Case Extension Bearing/SealFailed.............7-493
Inaccurate Shift Points.................................. 7-493
Harsh Shifts.................................................... 7-494
Harsh Shift D to R .........................................7-494
Harsh Shift 3 to 4 ......................................... 7-494
Harsh Shift 4 to 3 ......................................... 7-495
Harsh Shift D4 to D3, D2, orD 1 ..................7-495
Soft Shifts....................................................... 7-495
Soft Shift into R..............................................7-495
Soft Shift R to D ............................................7-495
Soft Shift 2 to 1............................................. 7-495
Soft Shift 2 to 3 ..............................................7-496
Soft Shift 3 to 2 ..............................................7-496
Soft Shift D3 to D 2 ....................................... 7-496
Delayed Shift 1 to 2 ...................................... 7-496
No D2 to D 1................................................... 7-496
No D3 to D 2................................................... 7-496
Oil Pan Fluid L ea k........................................ 7-497
Transmission/Transaxle
Fill Tube Fluid Leak.......................................7-497
Electrical Connector Fluid Leak....................7-497
Cooler Connector Fluid Leaks......................7-497
Case Extension Fluid Leak........................... 7-497
Manual Shaft Fluid Leak............................... 7-498
Pump Body Seal Fluid Leak.........................7-498
Vehicle Speed Sensor Fluid Leak............... 7-498
Output Shaft Seal Fluid Leak.......................7-498
Line Pressure Plug Fluid Leak.....................7-498
Repair In s tru ctio n s...........................................7-499
Shift Cable Adjustment................................. 7-499
Shift Cable Replacement.............................. 7-502
Park/Neutral Back Up Switch
Replacement.............................................. 7-506
Park/Neutral Back Up Switch
Adjustment.................................................. 7-507
AT Fluid/Filter Changing............................... 7-507
Oil Pan Replacement.................................... 7-509
Filler Tube and Seal Replacement.............. 7-510
Vehicle Speed Sensor Replacement........... 7-513
Park Lock Pawl and Actuator
Replacement.............................................. 7-514
Pressure Regulator Replacement................ 7-515
TCC Valve and Spring Replacement.......... 7-516
Accumulator Housing Replacement............. 7-517
Accumulator and 2-1 Manual Servo
Replacement.............................................. 7-518
Reverse Servo Replacement........................7-521
Forward Servo Replacement........................7-521
Oil Cooler Line Replacement........................7-522
Transmission Oil Cooler Replacement....... 7-533
Heat Shield Replacement............................. 7-533
Vent Hose....................................................... 7-534
Control Valve Body Replacement................ 7-535
Transmission Replacement...........................7-539
AT Oil Cooler Flushing.................................. 7-545
Description and O peration............................. 7-547
General Service Information.........................7-547
Abbreviations and Their Meanings.............. 7-547
Transmission Identification Information...... 7-549
General Description....................................... 7-549
Component and System Description........... 7-549
Table of Contents 7-5
Adapt Function............................................... 7-550
Electronic Component Description.............. 7-550
Component Locator..........................................7-555
Transmission Component Location............. 7-555
Special Tools and Equipm ent........................7-590
Special Tools.................................................. 7-590
C lu tc h ..................................................................... 7-593
S pecifications.................................................... 7-593
Fastener Tightening Specifications.............. 7-593
Diagnostic Inform ation and P rocedures.... 7-594
Preliminary Checking Procedure..................7-594
Clutch Spin Down Time................................ 7-594
Clutch Does Not Disengage.........................7-594
Clutch Slipping............................... 7-595
Clutch Grabbing (Chattering)........................ 7-596
Clutch Rattle (Trans Click)............................ 7-597
Release Bearing Noisy with Clutch
Engaged..................................................... 7-597
Clutch Noisy................................................... 7-597
Pedal Stays on Floor
(Clutch Disengaged)................................. 7-598
Clutch Pedal Hard To Push..........................7-599
Clutch Pedal Travels to Floor(Fluid
in Master C y l)............................................ 7-599
Clutch Master Cylinder Fluid Leaks............ 7-600
Clutch Actuator Fluid Leaks......................... 7-600
Clutch Pedal Spongy.................................... 7-600
Unable To Select G ears............................... 7-601
Clutch Pedal Sticks or Binds........................7-601
Repair in stru ctio n s...........................................7-602
Clutch Pedal Replacement........................... 7-602
Master Cylinder Replacement......................7-603
Hydraulic Clutch Bleeding............................. 7-605
Clutch Start Switch Replacement.................7-605
Clutch Assembly Replacement.....................7-606
Concentric Slave Cylinder............................. 7-608
Description and O peration............................. 7-610
Clutch Driving Members................................ 7-610
Clutch Driven Members................................ 7-610
Clutch Operating Members........................... 7-610
Special Tools and Equipm ent........................ 7-611
Special Tools...................................................7-611
7-6 Table of Contents Transmission/Transaxle

BLANK
 Manual Transmission - New Venture 7-7

Manual Transmission - New Venture

Specifications
Fastener Tightening Specifications
Application N-m Lb Ft Lb In
Backup Lamp Switch 28 21 —
Clutch housing cover bolts 10 — 89
Clutch Housing-to-Engine Studs (NV 4500) 31 23 —
Countershaft Retainer Plate-to Case Bolt 35 26 —
Lower PTO cover bolt (Oil Drain) (NV 4500) 37 27 —
Main Drive Gear Retainer-to-Case Bolt 31 23 —
Mainshaft Retainer Plate-to-Case Bolt 35 26 —
Oil Drain Plug (NV 3500) 60 44 —
Oil Fill Plug (NV 4500) 41 30 —
Oil Fill Plug (NV 3500) 60 46 —
Rear Oil Retainer-to-Case Bolt 54 40 —
Shift Housing Boot Screws 2 — 18
Shift Housing to Transmission Bolts 10 — 89
Shift Lever Cover-to-Case Bolts 23 17 —

Speed Sensor Bolt 22 16 —

Transmission-to-Clutch Housing Bolts (NV4500) 100 74 —
Transmission-to-Engine Studs (NV 3500) 47 35 —

Vibration Damper Mounting Nut (NV 4500) 4WD Models 100 74 —

Yoke Nut (NV 4500) RWD Models 441 325 —

Lubrication Specifications
Recommended
Application Lubricant Liters Quarts
New Venture Gear NV 4500 Manual Transmission Castrol Syntorq LT
3.78 4.0
Transmission Fluid
New Venture Gear NV 3500 Manual Transmission Synchromesh
Transmission Fluid 2.0 2.2
GM P/N 12345349
7-8 Manual Transmission - New Venture
Diagnostic Information and
Procedures
Manual Transmission Diagnosis
1. Raise the vehicle. Refer to Vehicle Lifting and
Jacking in General Information.
2. Support the vehicle with safety stands.
3. Try to move the transmission rear extension
housing up and down.
If the plate is loose on the crossmember,
tighten the mounting bolts.
• For the 4.3L engine, refer to Fastener
Tightening Specifications in Engine
Mechanical.
• For the 5.0L engine, refer to Fastener
Tightening Specifications in Engine
Mechanical.
• For the 5.7L engine, refer to Fastener
Tightening Specifications in Engine
Mechanical.
• For the 6.5L engine, refer to Fastener
Tightening Specifications in Engine
Mechanical.
• For the 7.4L engine, refer to Fastener
Tightening Specifications in Engine
Mechanical.
4. Replace the transmission rear mount if the
rubber is split or spongy.
• For the 4.3L engine (2WD), refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L engine (4WD), refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0 L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
. For the 5.(
Automatic Trans), retet to EnQllto MdUfft
Replacement (Rear C Model AUro
Transmission) in Engine Mechanical.
. For the 5.0L and 5.7L engines (RWD 15k
GVW and 4WD Automatic Trans), refer to
Engine Mount Replacement (Rear 15k
GVW 4WD Auto) in Engine Mechanical.
• For the 5.0L and 5.7L engines (RWD 15k
GVW and 4WD Manual Trans), refer to
Engine Mount Replacement (Rear 15k
GVW 4WD Manual) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
5. Remove the safety stands.
6. Lower the vehicle.
Clutch Spin Down Time
Check the clutch spin down time as follows:
1. Apply the parking brake. Block the vehicle
wheels.
2. Shift the transmission into neutral.
3. Start the engine. Run the engine at idle speed.
4. Engage the clutch.
5. Disengage the clutch. Wait 9 seconds.
6. Shift the transmission into reverse.
7. If you hear a grinding noise, refer to Release
Bearing Noisy with Clutch Engaged.
Transmission/Transaxle Manual Transmission - New Venture 7-9

Repair Instructions
Manual Transmission Fluid Check
1. Raise the vehicle. Refer to General Vehicle
Lifting and Jacking in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around
the fill plug.
4. Remove the oil fill plug.

102870

5. Check that the transmission fluid level Is even

with the bottom of the fill plug hole.
6. Install new transmission lubricant if required.
Refer to Lubrication Specifications.

2327

7. Install the oil fill plug.

Tighten
Tighten the oil fill plug to 41 N-m (30 lb ft).
Notice: Refer to Fastener Notice
8. Remove the safety stands.
9. Lower the vehicle.

102870
7-10 Manual Transmission - New Venture Transmission/Transaxle
1. Raise the vehicle. Refer to General Vehicle
Lifting and Jacking in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around
the fill plug.
4. Remove the oil fill plug.

5. Check that the transmission fluid level is even

with the bottom of the fill plug hole.
6. Install new transmission lubricant if required.
Refer to Lubrication Specifications.

2327
7. Install the oil fill plug.
Tighten
Tighten the oil fill plug to 41 N.m (30 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
8. Remove the safety stands.
9. Lower the vehicle.

102870
Transmission/Transaxle Manual Transmission - New Venture 7-11

Fluid Replacement (NV3500)

Removal Procedure
Tools Required
J 36511 Oil Fill/Drain Plug Hex Bit (17 MM)
Important: Drain the transmission after a short
period of operation when the oil is warm. This allows
any existing fluid in the system to be expelled when
the oil is drained.
1. Raise the vehicle. Refer to Vehicle Lifting and
Jacking in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around
the fill plug and the oil drain plug.
4. Use the J 36511 in order to remove the
oil fill plug.
5. Catch the oil in a suitable container.
6. Use the J 36511 in order to remove the
oil drain plug.
Installation Procedure
Tools Required
J 36511 Oil Fill/Drain Plug Hex Bit (17 MM)
1. Apply sealant to the oil drain plug threads. Use
Teflon® GM P/N 1052080 or the equivalent.
2. Use the J 36511 in order to install the oil
drain plug.
Tighten
Tighten the oil drain plug to 60 N.m (44 lb ft).

3. Fill the transmission to the level of the fill plug

hole. Refer to Lubrication Specifications.

2327
7-12 Manual Transmission - New Venture Transmission/Transaxle
4. Apply sealant to the oil fill plug threads. Use
Teflon® GM P/N 1052080 or the equivalent.

5. Use the J 36511 in order to install the

oil fill plug.
Tighten
Tighten the oil fill plug to 60 N.m (44 lb ft).
6. Remove the safety stands.
7. Lower the vehicle.

105611
Fluid Replacement (NV4500)
Removal Procedure
Important: Drain the transmission after a short
period of operation when the oil is warm. This allows
any existing fluid in the system to be expelled when
the oil is drained.
1. Raise the vehicle. Refer to Vehicle Lifting And
Jacking in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around
the fill plug and the oil drain plug.
4. Remove the oil fill plug.
5. Catch the oil in a suitable container.

102870
Transmission/Transaxle Manual Transmission - New Venture 7-13
7. Remove the lower PTO cover bolt. The lower
PTO cover bolt is used as a oil drain plug.

Installation Procedure
1. Install the lower PTO cover bolt.
Tighten
Tighten the bolt to 37 N-m (27 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

2. Fill the transmission to the level of the fill plug

hole. Refer to Lubrication Specifications.

2327
7-14 Manual Transmission - New Venture Transmission/Transaxle
3. Install the oil fill plug.
Tighten
Tighten the oil fill plug to 41 N.m (30 lb ft).
4. Remove the safety stands.
5. Lower the vehicle.

102870

Shift Lever
Removal Procedure
1. Remove eight screws securing the shift tower
boot to the floor panel and the insulator.
Important: Do not disassemble the
transmission shift housing. Internal parts for the
shift housing are not available. Opening the
shift housing will void the shift housing
warranty.
2. Remove the shift lever from the transmission
shift housing lever.

102874

Installation Procedure
1. Install the shift lever to the transmission shift
tower lever.
2. Install the eight screws securing the shift
housing boot to the floor panel and the
insulator.
Tighten
Tighten the screws to 2 N.m (18 lb in).

102874
Transmission/Transaxle Manual Transmission - New Venture 7-15

Vehicle Speed Sensor (NV3500)

Rem oval Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
Caution: Refer to Battery Disconnect
Caution.
2. Raise the vehicle. Refer to General Vehicle
Lifting and Jacking in General Information.
3. Support the vehicle with safety stands.

4. Disconnect the electrical connector from the

vehicle speed sensor assembly.
5. Place a drain pan under the transmission in
order to catch the oil.

6. Remove the following parts:

6.1. The bolt
6.2. The vehicle speed sensor
6.3. The O-ring seal

4779
7-16 Manual Transmission - New Venture Transmission/Transaxle
Installation Procedure
1. Coat a new O-ring seal with a thin film of
transmission oil. Use Syncromesh Transmission
Fluid or the equivalent.
2. Install the following parts:
2.1. The O-ring on the vehicle speed sensor
assembly
2.2. The vehicle speed sensor assembly
2.3. The bolt
Tighten
Tighten the bolt to 22 N-m (16 lb ft).
Notice: Refer to Fastener Notice in
Cautions and Notices.

3. Install the electrical connector on the vehicle

speed sensor assembly.
4. Remove the safety stands.
5. Lower the vehicle.

6. Connect the battery negative cable assembly to

the battery negative terminal.
Tighten
Tighten the bolt to 15 N.m (11 lb ft).

38205
Transmission/Transaxle Manual Transmission - New Venture 7-17

Vehicle Speed Sensor (NV4500)

Removal Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Raise the vehicle. Refer to General Vehicle
Lifting and Jacking in General Information.
3. Support the vehicle with safety stands.

4. Disconnect the electrical connector from the

vehicle speed sensor assembly.
5. Place a suitable container under the
transmission in order to catch the fluid.

6. Remove the following parts:

6.1. One bolt
6.2. The vehicle speed sensor
6.3. The O-ring seal

4779
7-18 Manual Transmission - New Venture Transmission/Transaxle
Installation Procedure
1. Coat a new O-ring seal with a thin film of
transmission fluid. Use Castrol Syntorq GL-4
Transmission Fluid or the equivalent.
2. Install the following parts:
2.1. The O-ring on the vehicle speed sensor
assembly
2.2. The vehicle speed sensor assembly
2.3. One bolt
Tighten
Tighten the bolt to 22 N.m (16 lb ft).
Notice: Refer to Fastener Notice in
Cautions and Notices.

3. Install the electrical connector on the vehicle

speed sensor assembly.
4. Remove the safety stands.
5. Lower the vehicle.

6. Connect the battery negative cable assembly

to the battery negative terminal.
Tighten
Tighten the bolt to 15 N.m (T1 lb ft).
7. Check the transmission fluid level.

38205
Transmission/Transaxle Manual Transmission - New Venture 7-19

Backup Lamp Switch (NV3500)

Removal Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n
In C a u t io n s a n d N o t ic e s .

2. Raise the vehicle. Refer to General Vehicle

Lifting and Jacking in General Information.
3. Support the vehicle with safety stands.
4. Disconnect the backup lamp switch electrical
connector.

5. Remove the backup lamp switch.

Installation Procedure
1. Install the backup lamp switch. The backup
lamp switch has pre-applied thread sealant
on the threads.
Tighten
Tighten the backup lamp switch to
28 N.m (21 lb ft).
N o t ic e : Refer to F a s te n e r N o tic e in Cautions
and Notices.
2. Connect the backup lamp switch electrical
connector.
3. Remove the safety stands.
4. Lower the vehicle.

4778
7-20 Manual Transmission - New Venture Transmission/Transaxle
5. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N-m (11 lb ft).

Backup Lamp Switch (NV4500)

Removal Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t
C a u t io n .

2. Raise the vehicle. Refer to Vehicle Lifting and

Jacking in General Information.
3. Support the vehicle with safety stands.

4. Disconnect the backup lamp switch electrical

connector.

102879
Transmission/Transaxle Manual Transmission - New Venture 7-21
5. Remove the backup lamp switch.

Installation Procedure
1. Install the backup lamp switch. The backup
lamp switch has pre-applied thread sealant on
the threads.
Tighten
Tighten the backup lamp witch to
28 N-m (21 lb ft).
N o t ic e : Refer to Fastener Notice in Cautions
and Notices.

2. Connect the backup lamp switch electrical

connector.
3. Remove the safety stands.
4. Lower the vehicle.

102879
7-22 Manual Transmission - New Venture Transmission/Transaxle
5. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).

Transmission Replacement (NV3500)

Removal Procedure
Tools Required
J 36221 Quick Connect Disengagement Tool
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n
in C a u t io n s a n d N o t ic e s .

2. Shift the transmission into 3RD or

4TH speed gear.
3. Remove the shift lever and boot. Refer to
Shift Lever.
4. Remove the shift housing. Refer to
Transmission Shift Housing Replacement.
5. Drain the transmission oil. Refer to
Fluid Replacement (NV3600) or Fluid
Replacement (NV4500).
6. Remove the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
7. Remove the transfer case if the vehicle is
equipped with four wheel drive. Refer to
Transfer Case Removal in Transfer Case.
8. Remove the parking brake and controls, if the
vehicle is equipped. Refer to Parking Brake
Replacement in Parking Brake.
9. Remove the exhaust pipes, if necessary. Refer
to Exhaust System in Engine Exhaust.
Transmission/Transaxle Manual Transmission - New Venture 7-23
10. Disconnect the wiring harness connector from
the vehicle speed sensor.

11. Disconnect the wiring harness connector from

the backup lamp switch.
12. Disconnect the wiring harness retainers from
the transmission.

13. Use the J 36221. Depress the white plastic

sleeve on the quick connect in order to
separate the hydraulic clutch line from the
concentric slave cylinder quick connect.
14. Remove the starter motor. Refer to Starter
Motor Replacement for diesel engine or to
Starter Motor Replacement for gasoline engine
in Engine Mechanical.

102888
7-24 Manual Transmission - New Ventura Transmission/Transaxle
15. Remove the clutch housing cover.
16. Remove the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
17. Support the transmission. Use a suitable
safety stand.
18. Remove the frame crossmember. Refer to
Rear Bumper Brace Replacement in Frame
and Bumpers.
19. Remove the transmission to the clutch housing
bolts and studs.
20. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and the clutch cover.
21. Remove the transmission from the vehicle.
22. Remove the clutch plate and the clutch cover
from the engine flywheel if needed. Refer to
Clutch Assembly Replacement in Clutch.

102890
Transmission/Transaxle Manual Transmission - New Venture 7-25
Installation Procedure
1. Install the clutch plate and the clutch cover to
the engine flywheel if removed. Refer to Clutch
Assembly Replacement in Clutch.
Important:
• Do not force the transmission into
the clutch.
• Do not let the transmission hang from
the clutch.
• Leave the safety stand under the
transmission for support.
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
2. Install the transmission:
2.1. Put a thin coat of high-temperature
grease on the main drive gear splines.
2.2. Shift the transmission into 3RD or 4TH
speed gear. 102890
2.3. Rotate the transmission clockwise onto
the clutch hub splines.
2.4. Install the bolts and the studs securing
the transmission to the engine.
Tighten
Tighten the bolts to 47 N-m (35 lb ft).
3. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
4. Install the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
5. Remove the safety stand from beneath the
transmission.
7-26 Manual Transmission - New Venture Transmission/Transaxle
6. Install the following parts:
6.1. The clutch housing cover
6.2. Four bolts
Tighten
Tighten the bolts to 10 N-m (89 lb in).
7. Install the starter motor. Refer to Starter Motor
Replacement for diesel engine or to Starter
Motor Replacement for gasoline engine in
Engine Mechanical.

8. Install the hydraulic clutch line to the concentric

slave cylinder quick connect.
9. Install the exhaust pipes, if removed. Refer to
Exhaust System in Engine Exhaust.
10. Install the wiring harness retainers to the
transmission.

102888

11. Install the electrical connector to the backup

lamp switch.

102879
Transmission/Transaxle Manual Transmission - New Venture 7-27
12. Install the electrical connector to the vehicle
speed sensor.
13. Install the transfer case if removed. Refer to
Transfer Case Removal in Transfer Case.
14. Install the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
15. Install the parking brake and controls, if
removed. Refer to Parking Brake Replacement
in Parking Brake.
16. Fill the transmission with new oil. Refer to Fluid
Replacement (NV3500) or Fluid Replacement
(NV4500).
17. Remove the safety stands.
18. Lower the vehicle.
19. Install the shift housing. Refer to Transmission
Shift Housing Replacement.
20. Install the shift lever and the boot. Refer to
Shift Lever.
102878
21. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).

Transmission Replacement (NV4500 RWD)

Removal Procedure
Tools Required
J 36221 Quick Connect Disengagement Tool
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u tio n : R e fe r t o 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 t io n s a n d N o tic e s .

2. Shift the transmission into 3RD or 4TH

speed gear.
3. Remove the transmission shift lever and the
boot. Refer to Shift Lever.
4. Remove the shift housing. Refer to
Transmission Shift Housing Replacement.
5. Drain the transmission oil. Refer to Fluid
Replacement (NV3500) or Fluid Replacement
(NV4500).
6. Remove the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
7-28 Manual Transmission - New Venture Transmission/Transaxle
7. Remove the parking brake and controls, if
used. Refer to Parking Brake Replacement in
Parking Brake.
8. Remove the exhaust pipes, if necessary. Refer
to Exhaust System in Engine Mechanical.
9. Disconnect the wiring harness connector from
the backup lamp switch and from the vehicle
speed sensor.
10. Disconnect the wiring harness retainers from
the transmission.
11. Disconnect the hydraulic clutch line from the
concentric slave cylinder using the J 36221.

102888

12. Remove the transmission vent hose from the

transmission.
13. Remove the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
14. Support the transmission. Use a suitable
safety stand.
15. Remove the frame crossmember. Refer to
Rear Bumper Brace Replacement in Frame
and Bumpers.
16. Remove the clutch plates from the flywheel.
Refer to Clutch Assembly Replacement
17. Remove the transmission to engine bolts.
18. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and clutch cover.
Transmission/Transaxle Manual Transmission - New Venture 7-29
19. Remove the transmission from the vehicle.

105648
Installation Procedure
Important:
• Do not force the transmission into the clutch.
• Do not let the transmission hang from
the clutch.
• Leave the safety stand under the transmission
for support.
1. Install the transmission.
1.1. Put a thin coat of high-temperature
grease on the main drive gear splines.
1.2. Shift the transmission into 3RD or 4TH
speed gear.
1.3. Rotate the transmission clockwise onto
the clutch hub splines.
1.4. Install the transmission to the engine
bolts and washers.
Tighten
10564B
Tighten the bolts to 100 N-m (74 lb ft).
2. Install the transmission to engine bolts.
Tighten
Tighten the studs to 31 N-m (23 lb ft).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
3. Install the clutch plates from the flywheel. Refer
to Clutch Assembly Replacement
4. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
5. Install the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
7-30 Manual Transmission - New Venture Transmission/Transaxle
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
6. Remove the safety stand from beneath the
transmission.
7. Install the transmission vent hose.

102891
8. Install the hydraulic clutch line to the concentric
slave cylinder quick connect.
9. Install the exhaust pipes, if removed. Refer to
Exhaust System in Engine Mechanical.
10. Install the wiring harness retainers to the
transmission.
11. Connect the following electrical wiring harness
connectors:
• The vehicle speed sensor
• The backup lamp switch
12. Install the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
13. Install the parking brake and controls, if
removed. Refer to Parking Brake Replacement
in Parking Brake.
14. Fill the transmission with new oil. Refer to
Fluid Replacement (NV3500) or Fluid
Replacement (NV4500).
102888
15. Remove the safety stands.
16. Lower the vehicle.
17. Install the shift housing. Refer to Transmission
Shift Housing Replacement.
18. Install the shift lever and the boot. Refer to
Shift Lever.
Transmission/Transaxle Manual Transmission - New Venture 7-31
19. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N-m (11 lb ft).

Transmission Replacement (NV4500 4WD)

Rem oval Procedure
Tools Required
J 36221 Quick Connect Disengagement Tool
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u t io n : R e fe r t o 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 t io n s a n d N o tic e s .

2. Shift the transmission into 3RD or

4TH speed gear.
3. Remove the shift lever. Refer to Shift Lever.
4. Drain the transmission oil. Refer to
Fluid Replacement (NV3500) or Fluid
Replacement (NV4500).
5. Remove the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
6. Remove the transfer case. Refer to Transfer
Case Replacement in Transfer Case.
7. Remove the parking brake and controls, if
used. Refer to Parking Replacement in
Parking Brake.
8. Remove the exhaust pipes, if necessary. Refer
to Exhaust System.
9. Disconnect the following electrical wiring
harness connectors:
• The vehicle speed sensor
• The backup lamp switch
10. Disconnect the wiring harness retainers from
the transmission.
7-32 Manual Transmission - New Venture Transmission/Transaxle
11. Disconnect the hydraulic clutch line from the
concentric slave cylinder using the J 36221.

1028B8
12. Remove the transmission vent hose.
13. Remove the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
14. Support the transmission. Use a suitable
safety stand.
15. Remove the frame crossmember. Refer to
Rear Bumper Brace Replacement in Frame
and Bumpers.
Transmission/!"ransaxle Manual Transmission - New Venture 7-33
16. Remove the transmission to engine bolts.
17. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and clutch cover.
18. Remove the transmission from the vehicle.
19. Remove the clutch plate and the clutch cover
from the engine flywheel if needed. Refer to
Clutch Assembly Replacement in Clutch.

105648
Installation Procedure
1. Install the clutch plate and the clutch cover to
the engine flywheel if removed. Refer to Clutch
Assembly Replacement in Clutch.
2. Install the clutch housing to the engine, if
removed.
Tighten
Tighten the studs to 100 N-m (74 lb ft).
Important:
• Do not force the transmission into
the clutch.
• Do not let the transmission hang from
the clutch.
• Leave the safety stand under the
transmission for support.
Notice: Refer to Fastener Notice in Cautions
and Notices. 105648

3. Install the transmission.

3.1. Put a thin coat of high-temperature
grease on the main drive gear splines.
3.2. Shift the transmission into 3RD or
4TH speed gear.
3.3. Rotate the transmission clockwise onto
the clutch hub splines.
3.4. Install the transmission to the clutch
housing bolts and washers.
Tighten
Tighten the bolts to 31 N-m (23 lb ft).
4. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
7-34 Manual Transmission - New Venture Transmission/Transaxle
5. Install the transmission rear mount.
• For the 4.3L (2WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 4.3L (4WD) engine, refer to Engine
Mount Replacement in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Manual Trans), refer to Engine Mount
Replacement (Rear C Model Manual Trans)
in Engine Mechanical.
• For the 5.0L and 5.7L engines (C-Model,
Automatic Trans), refer to Engine Mount
Replacement (Rear C Model Auto
Transmission) in Engine Mechanical.
• For the 6.5L engine, refer to Engine Mount
Replacement in Engine Mechanical.
• For the 7.4L engine, refer to Engine Mount
Replacement (Rear) in Engine Mechanical.
6. Remove the safety stand from beneath the
transmission.
7. Install the transmission vent hose.

102891
8. Install the hydraulic clutch line to the concentric
slave cylinder quick connect.
9. Install the exhaust pipes, if removed. Refer to
Exhaust System in Engine Mechanical.
10. Install the wiring harness retainers to the
transmission.
11. Connect the following electrical wiring harness
connectors:
• The vehicle speed sensor
• The backup lamp switch
12. Install the transfer case. Refer to Transfer Case
Replacement in Transfer Case.
13. Install the propeller shaft. Refer to Propeller
Shaft Replacement in Propeller Shaft.
14. Install the parking brake and controls, if
removed. Refer to Parking Brake Replacement
in Parking Brake.
15. Fill the transmission with new oil. Refer to
102888 Fluid Replacement (NV3500) or Fluid
Replacement (NV4500).
Transmission/Transaxle Manual Transmission - New Venture 7-35
16. Remove the safety stands.
17. Lower the vehicle.
18. Install the shift lever to the transmission. Refer
to Shift Lever.
19. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).
7-36 Manual Transmission - New Venture Transmission/Transaxle

Description and Operation

Transmission Description and Operation
Identify transmissions by the number of forward
gears and the measured distance (in millimeters)
between centerlines of the mainshaft and the
countershaft.

The New Venture Gear NV4500 (109 mm)

five—speed manual transmission is available
as RPO MW3.
The transmission has the following features:
• Synchronized shifting in all forward gears
• Constant mesh helical gearing for
reduced noise
The New Venture Gear NV3500 (85 mm) five— speed • Overspeed inhibitor from low to first
overdrive manual transmission is identified by the speed gears
RPO M50 for four wheel drive vehicles and
• Dual cone low speed gear and 1ST speed
RPO MG5 for rear wheel drive (RWD) vehicles.
gear synchronizer
The transmission has the following features:
• A shift tower mounted shift lever
• Constant mesh helical gearing for
reduced noise
• A two-piece aluminum housing.
• Synchronized shifting in all forward gears
• A shift tower mounted shift lever.
Identify the transmissions by the number of forward
gears and the measured distance (in millimeters)
between centerlines of the mainshaft and the
countershaft.
Transmission/Transaxle Manual Transmission - New Venture 7-37

Special Tools and Equipment

Illustration Part No. Description Illustration Part No. Description

J 38807 Extension Housing

Bearing Installer (43 J 39314 Vibration Damper
Installer

102587 102592

(d IlS il J 8092 Universal

Driver Handle
J 22828 Gear And
Bearing Installer

2015 102560

J 22834 Extension Housing J 38805 Output Shaft

Seal Installer Nut Socket

12375 102584

J 38856 Countershaft
Bearing Cone And J 23907 Slide Hammer
Retainer Installer

102588 4855
7-38 Manual Transmission - New Venture Transmission/Transaxle

Illustration Part No. Description Illustration Part No. Description

J 36511 OilFill Plug

Hex Bit (17 mm)

4869

J 36502 Output Shaft J 36825 Output Shaft Oil

Seal Installer Seal Remover

4884 4856

J 36221

J 36503 Extension Housing J 36221 Quick Connect

Seal Installer Disengagement Tool

1342 43267
Transmission/Transaxle Automatic Transmission - 4L60-E 7-39

Automatic Transmission - 4L60-E

Specifications

Temperature vs Resistance
Minimum Nominal Maximum
Temperature Temperature Resistance Resistance Resistance Signal
*F *C ft ft ft volts
-40 -40 90636 100707 110778 5.00
-22 -30 47416 52684 57952 4.78
-4 -20 25809 28677 31545 4.34
14 -10 14558 16176 17794 3.89
32 0 8481 9423 10365 3.45
50 10 5104 5671 6238 3.01
68 20 3164 3515 3867 2.56
86 30 2013 2237 2461 1.80
104 40 1313 1459 1605 1.10
122 50 876 973 1070 3.25
140 60 600 667 734 2.88
158 70 420 467 514 2.56
176 80 299 332 365 2.24
194 90 217 241 265 1.70
212 100 159 177 195 1.42
230 110 119 132 145 1.15
248 120 89.9 99.9 109.9 0.87
266 130 69.1 76.8 84.5 0.60
284 140 53.8 59.8 65.8 0.32
302 150 42.5 47.2 51.9 0.00

Fastener Tightening Specifications (Overhaul)

Application N-m Lb Ft Lb In
Accumulator Cover to Case Bolt 8.0-14.0 6-10 —

Detent Spring to Valve Body Bolt 20.0-27.0 15-20 —

Oil Passage Cover to Case Bolt 8-14.0 6-10 —

Park Brake Bracket to Case Bolt 27.0-34.0 20-25 —

Valve Body to Case Bolt 8.0-14.0 6-10 —

Solenoid Assembly to Case Bolt 8.0-14.0 6-10 —

Transmission Fluid Pressure Manual Valve Position Switch to
8.0-14.0 6-10 —
Valve Body Bolt
Transmission Oil Pan to Case Bolt 9.5-13.8 7-10 —

Forward Accumulator Cover to Valve Body Bolt 8.0-14.0 6-10 —

Pump Cover to Pump Body Bolt 20.0-27.0 15-20 —

Pump Assembly to Case Bolt 20.0-27.0 15-20 —

Pressure Control Solenoid Bracket to Valve Body Bolt 8.0-14.0 6-10 —
7-40 Automatic Transmission - 4L60-E Transmission/Transaxle

Fastener Tightening Specifications (Overhaul) (cont’d)

Application N-m Lb Ft Lb In
Manual Shaft to Inside Detent Lever Nut 27.0-34.0 20-25 —
Line Pressure Plug 8.0-14.0 6-10 —
Cooler Pipe Connector 35.0-41.0 26-30 —
Plate to Case Bolt (Shipping) 27.0-34.0 20-25 —
Plate to Converter Bolt (Shipping) 27.0-34.0 20-25 —

Case Extension to Case Bolt (4WD Shipping) 11.2-22.6 8.3-16.7 —

Transmission Oil Cooler Pipe Fitting 35.0-41.0 26-30 —
Speed Sensor Retainer Bolt 10.5-13.5 — —

B. Housing to Case Screw 18.0-22.0 — —

Case Extension to Case Bolt 42.0-48.0 35.0-39.4 —

Fastener Tightening Specifications (On Vehicle)

Application N-m Lb Ft Lb In
Accumulator Cover Bolt 11 — 97
Case Extension to Case Bolt 35 26 —
Converter Cover Bolt 10 — 89
Oil Level indicator Bolt 47 35 —
Floorshift Control Bolt 10 — 89
Flywheel to Torque Converter Bolt 63 46 —
Negative Battery Cable Bolt 15 11 —
Oil Pan to Transmission Case Bolt 11 — 97
Park/Neutral Position Switch Screw 3 — 27
Pressure Control Solenoid Bolt 11 — 97
Shift Cable Grommet Screw 1.7 — 15
Shift Control Cable Attachment 20 15 —
TCC Solenoid Bolt 11 — 97
Transmission to Engine Bolt 47 35 —
Valve Body-to-Case Bolt 11 — 97
Vehicle Speed Sensor 11 — 97
Converter Housing Bolt 75 55 —
Transmission/Transaxle Automatic Transmission - 4L60-E 7-41
Scan Tool Data Value Examples Only the parameters listed below are used in this
If you have completed the On-Board Diagnostic manual for diagnosing. If a scan tool displays other
(OBD) system check, if the diagnostics are parameters, the values are not recommended by
General Motors for use in diagnosis.
functioning properly, and if no DTCs are displayed,
you may use the Typical Scan Tool Data Values in The values below were recorded under the following
the table below for comparison. These values are an conditions:
average of display values recorded from normally • Engine is at Idle
operating vehicles. • Upper radiator hose is hot
Important: You should never use a scan tool that • Closed throttle
displays faulty data. The problem should be reported
• Gear is in Park or Neutral
to the manufacturer. The use of a faulty scan tool
can result in misdiagnosis and the unnecessary • Closed Loop
replacement of parts. • Accessories are OFF

Scan Tool Data Value Examples

Tech 2 Parameter Units Displayed Typical Scan Values
Engine Torque lb ft (N.m) varies
TP Sensor volts 0.3-0.9 V
TP Angle percent 0%
Engine Speed RPM varies
Transmission OSS RPM 0
Vehicle Speed mph (km/h) 0
Current Gear 1,2,3,4 1
1-2 Sol. On/Off On
2-3 Sol. On/Off On
3-2 Downshift Sol. On/Off On
Speed Ratio Ratio 8.00:1
1-2 Sol. Open/Short to GND Yes/No No
1-2 Sol. Short to Volts Yes/No No
2-3 Sol. Open/Short to GND Yes/No No
2-3 Sol. Short to Volts Yes/No No
3-2 Sol. Open/Short to GND Yes/No No
3-2 Sol. Short to Volts Yes/No No
TFP Switch A/B/C On/Off Off/On/Off
ECT *C (*F) varies
Trans. Fluid Temp. *C (*F) varies
TFT Sensor volts varies
IAT *C (*F) varies
Transmission Hot Mode On/Off Off
PC Sol. Actual Current amps varies (0.1-1.1 amps)
PC Sol. Ref. Current amps varies (0.1-1.1 amps)
PC Solenoid Duty Cycle percent varies
TCC Brake Switch Closed/Open Closed
TCC Enable Yes/No No
TCC Mode 0-5 0
TCC Duty Cycle percent 0%
TCC Slip Speed RPM +/- 50 RPM from the Engine Speed
7-42 Automatic Transmission - 4L60-E Transmission/Transaxle
Scan Tool Data Value Examples (cont’d)
Tech 2 Parameter Units Displayed Typical Scan Values
TCC Enable Open/Short to GND Yes/No No
TCC Enable Short to Volts Yes/No No
TCC Duty Cycle Open/
Yes/No No
Short to GND
TCC Duty Cycle Short to Volts Yes/No No
1-2 Shift Time seconds varies
2-3 Shift Time seconds varies
3-4 Shift Time seconds varies
Adaptable Shift Yes/No No
Engine Run Time hr/min/sec varies
Ignition Voltage Volts varies
Cruise Enabled/Disabled Disabled
A/C Clutch On/Off Off
4WD Enabled/Disabled Disabled
4WD Low Enabled/Disabled Disabled
1-2 Shift Error seconds varies
2-3 Shift Error seconds varies
3-4 Shift Error seconds varies
Current TAP Cell 0-16 varies
Maximum TAP Yes/No No
1-2, 2-3 TAP Cells (4-16) psi varies
TAP % of TP psi varies
Transmission/Transaxle
Transmission Scan Tool Data Definitions
1-2 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 1-2 shift time and the actual
1-2 shift time. A positive number indicates the actual
shift time was longer than the desired shift time.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
1-2 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 1-2 shift. The shift time is based on the
engine RPM drop after the commanded 1-2 shift.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
1-2 Sol: Displays On or Off. This parameter is the
commanded status of the 1-2 shift solenoid valve.
On represents a commanded energized state
(current is flowing through the solenoid). Off
represents a non-commanded state (current is not
flowing through the solenoid).
1-2 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 1-2 shift solenoid valve feedback
signal to the VCM. This parameter is valid only when
the 1-2 shift solenoid is commanded Off.
1-2 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in the
1- 2 shift solenoid valve feedback signal to the VCM.
This parameter is valid only when the 1-2 shift
solenoid is commanded On.
2- 3 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 2-3 shift time and the actual
2-3 shift time. A positive number indicates the actual
shift time was longer than the desired shift time.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
2-3 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 2-3 shift. The shift time is based on the
engine RPM drop after the commanded 2-3 shift.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
2-3 Sol: Displays On or Off. This parameter is the
commanded status of the 2-3 shift solenoid valve.
On represents a commanded energized state
(current is flowing through the solenoid). Off
represents a non-commanded state (current is not
flowing through the solenoid).
2-3 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 2-3 shift solenoid valve feedback
signal to the VCM. This parameter is valid only when
the 2-3 shift solenoid is commanded Off.
2-3 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in the
2-3 shift solenoid valve feedback signal to the VCM.
This parameter is valid only when the 2-3 shift
solenoid is commanded On.
Automatic Transmission - 4L60-E 7-43
3-2 Downshift Sol.: Displays On or Off. This
parameter indicates if the 3-2 shift solenoid valve
assembly is currently commanded On or Off. The
solenoid commanded state is based on the
transmission temperature. The solenoid will change
states during a 3-2 downshift to regulate the
appropriate pressure. The commanded state of the
solenoid occurs at approximately 30 mph with a
throttle increase.
3-2 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates when an open or a short to
ground exists in the 3-2 shift solenoid valve
assembly feedback signal to the VCM. This
parameter is valid only when the 3-2 shift solenoid is
commanded Off.
3-2 Sol. Short to Volts: Displays Yes or No. This
parameter indicates whether a short to voltage exists
in the 3-2 shift solenoid valve assembly feedback
signal to the VCM. This parameter is valid only when
the 3-2 shift solenoid is commanded On.
3-4 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 3-4 shift time and the actual
3-4 shift time. A positive number indicates the actual
shift time was longer than the desired shift time.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
3-4 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 3-4 shift. The shift time is based on the
engine RPM drop after the commanded 3-4 shift.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
4WD: Displays Enabled or Disabled. This parameter
indicates whether the vehicle is currently in a
four-wheel drive mode.
4WD Low: Displays Enabled or Disabled. This
parameter is the signal state of the four-wheel drive
low circuit. Enabled indicates a 0 voltage signal
(4WD Low requested). Disabled indicates a
B+ voltage signal (4WD Low not requested).
A/C Clutch: Displays On or Off. This parameter
indicates the commanded state of the A/C control
relay. The clutch should be engaged when On
displays.
Adaptable Shift: Displays Yes or No. Yes indicates
that the proper operating conditions were all within
the proper operating range during the last shift, and
that the shift time was accurate. This shift
information is then used through the adaptive
function in order to update the adapt cells. No
indicates that not all of the operating conditions were
met in order to enable this function, and that the
adapt cells were not updated.
Cruise: Displays Enabled or Disabled. This
parameter indicates whether the VCM is allowing
cruise operation. The VCM has the ability to disable
cruise control under certain conditions.
Current Gear: Displays 1, 2, 3, or 4. This parameter
indicates the current commanded state of the shift
solenoids.
7-44 Automatic Transmission - 4L60-E
Current TAP (Transmission Adaptive Pressure)
Cell: Displays a TP cell range of 0-16. This
parameter indicates the current throttle position cell
used for line pressure modification (adaptation).
ECT (Engine Coolant Temperature): Displays a
range of -40‘ C to 151 ”C (-40’ F to 304 *F). This
parameter is the input signal of the engine coolant
temperature sensor. The engine coolant temperature
is high (151 *C) when the signal voltage is low (0 V),
and the engine coolant temperature is low (-40 *C)
when the signal voltage is high (5 V).
Engine Run Time: Displays a range of
0:00:00-18:12:15 hr/min/sec. This parameter
measures how long the engine has been operating.
When the ignition switch is turned OFF, the value is
reset to zero.
Engine Speed: Displays a range of 0-8192 RPM.
This parameter indicates the rotational speed of the
engine expressed as revolutions per minute.
Engine Torque: Displays a range of 0-9999 lb ft.
This parameter indicates the amount of torque that is
delivered from the engine.
IAT (Intake Air Temperature): Displays a range of
-40 °C to 2 15 'C (-40*F to 419’ F). The IAT sensor is
a thermistor that is used to monitor the temperature
of the air entering the intake manifold. The VCM
applies 5 volts to the sensor on a 5-volt reference
circuit. When the air is cool, the resistance in the
sensor will be high. If the air is warm, the sensor
resistance will be low and the VCM will sense a low
voltage signal. The VCM converts the signal of the
IAT sensor to degrees Celsius. Intake air temperature
is used by the VCM to adjust fuel delivery and
spark timing.
Ignition Voltage: Displays a range of 0.0-25.5 V.
This represents the system voltage measured by
the VCM at its ignition feed.
Last TAP: Displays psi. This parameter indicates the
amount of pressure that was added to base line
pressure in order to adjust the apply effort of a
clutch or a band during the last adapting shift.
Maximum TAP (Transmission Adaptive Pressure):
Displays Yes or No. This parameter indicates when
line pressure modification (adaptation) has reached
its limit. Yes indicates that the limit has been
reached. No indicates that the limit has not been
reached.
PC Sol. Actual Current: Displays a range of
0.00-1.10 amps. This parameter is the actual current
of the pressure control solenoid circuit at the control
module. Zero amp (no current flow) indicates actual
higher line pressure. Actual lower line pressure is
indicated by 1.1 amps (high current flow).
PC Solenoid Duty Cycle: Displays a range of
0-100%. This parameter is the commanded state of
the pressure control solenoid expressed as a percent
of energized ON time. A reading of 0% indicates
zero ON time (non-energized) or no current flow.
Approximately 60% at idle indicates maximum ON
time (energized) or high current flow.
Transmission/Transaxle
PC Sol. Ref. (Reference) Current: Displays a range
of 0.00-1.10 amps. This parameter is the
commanded current of the pressure control solenoid
circuit. Zero amp (no current flow) indicates
commanded higher line pressure. Commanded
lower line pressure is indicated by 1.1 amps
(high current flow).
Speed Ratio: Displays a range of 0.00:1-8.00:1.
This parameter indicates engine speed divided by
transmission output speed. This value is used to
estimate transmission gear ratio.
1- 2 TAP Cell (4-16): Displays kPa or psi. This
parameter displays the amount of pressure varied
from a calibrated base line pressure for shifts. Each
TAP Cell is based on a calibrated shift torque value.
Each TAP Cell value is calculated from the last shift
time. This cell pressure is used in addition to
calibrated base line pressure to adjust the apply of
a clutch or band during the next shift.
2- 3 TAP Cell (4-16): See 1-2 TAP Cell (4-16).
TCC (Torque Converter Clutch) Brake Switch:
Displays Open or Closed. This parameter indicates
the state of the brake switch circuit input. Open
indicates a zero voltage input (brake switch open,
brake pedal applied). Closed indicates a B+ voltage
input (brake switch closed, brake pedal released).
TCC Duty Cycle: Displays a range of 0-100%. This
parameter is the commanded percentage of ON time
of the TCC PWM solenoid. Approximately 90%
represents an ON (energized) commanded state. A
reading of 0% represents an OFF (non-energized)
commanded state. This commanded state is applied
at a vehicle speed between approximately 0-16 km/h
(0-10 mph).
TCC Duty Cycle Open/Short to GND: Displays Yes
or No. This parameter indicates whether an open or
a short to ground exists in the TCC PWM solenoid
valve feedback signal to the VCM. This parameter is
valid only when the TCC PWM solenoid is
commanded OFF (duty cycle is 0%).
TCC Duty Cycle Short to Volts: Displays Yes or
No. This parameter indicates whether a short to
voltage exists in the TCC PWM solenoid valve
feedback signal to the VCM. This parameter is valid
only when the TCC PWM solenoid is commanded
ON (duty cycle is at maximum).
TCC Enable: Displays Yes or No. This parameter is
the commanded state of the TCC solenoid. Yes
indicates a commanded energized state (current is
flowing through the solenoid). No indicates a
commanded non-energized state (current is not
flowing through the solenoid). This commanded state
occurs at various vehicle speeds between
applications.
TCC Enable Open/Short to GND: Displays Yes or
No. This parameter indicates whether an open or a
short to ground exists in the TCC solenoid valve
feedback signal to the VCM. This parameter is valid
only when the TCC solenoid is commanded OFF.
Transmission/Transaxle
TCC Enable Short to Volts: Displays Yes or No.
This parameter indicates whether a short to voltage
exists in the TCC solenoid valve feedback signal to
the VCM. This parameter is valid only when the
TCC solenoid is commanded ON.
TCC Mode: Displays a range of 0 through 5. Zero (0)
or Off Mode indicates that the VCM commands the
TCC OFF at a calibrated minimum throttle. The
calibrated minimum throttle is different at low vehicle
speeds than it is at high vehicle speeds. Off Mode is
also active when the transmission is in the wrong gear
range, the engine or the transmission is cold, the
brake input indicates that the brakes are ON, a
downshift or upshift is initiated, the engine is at idle,
the transmission is in Hot Mode or a misfire is
detected. One (1) or Release Mode indicates that the
VCM commands the release of the TCC. Two (2) or
Apply Mode indicates that the VCM commands the
apply of the TCC. Apply pressure varies based on
normal or performance operations, hot conditions or if
the cruise control is active. Apply Mode is used under
normal driving conditions. All apply pressure is
dependent on throttle position and vehicle speed.
Three (3) or Apply Enable Mode indicates that
enabling conditions are met for applying the
TCC (enabling conditions include vehicle speed, gear
selection, transmission temperature, throttle angle,
brake switch status, etc.). Four (4) or Locked Mode
indicates that the VCM commands full capacity of the
TCC when the transmission is in fourth gear and the
vehicle speed is greater than a calibrated value. When
variable TCC apply pressure stops (Apply Mode),
maximum TCC pressure is used. Five (5) or Coast
Mode indicates that the VCM commands apply of the
TCC when the transmission is in fourth gear and the
throttle and vehicle speed are not high enough to
enable Apply Mode, but high enough to keep the
TCC applied. When Coast Mode is active, TCC apply
pressure is set to a predetermined amount.
TCC Slip Speed: Displays a range of -4080 to
4079 RPM. This parameter is the difference between
transmission output speed and engine speed. A
negative value indicates that the engine speed is
less than the output speed (deceleration). A positive
value indicates that the engine speed is greater than
the output speed (acceleration). A value of zero
indicates that the engine speed is equal to the
output speed (TCC applied).
Automatic Transmission - 4L60-E 7-45
TFP Switch A/B/C: Displays On/Off, On/Off, On/Off.
These parameters are the three inputs from the
Automatic Transmission Fluid Pressure Manual Valve
Position Switch Assembly. On represents a 0 voltage
signal. Off represents a B+ voltage signal.
TFT (Transmission Fluid Temperature) Sensor:
Displays a range of 0.00-5.00 V. When the
transmission fluid is cold, the sensor resistance is
high and the VCM will sense high signal voltage. As
the transmission fluid temperature warms to a normal
operating temperature, the sensor resistance
becomes less and the voltage decreases.
TP (Throttle Position) Angle: Displays a range
of 0-100%. The TP angle is computed by the
VCM from the TP sensor voltage. The TP angle
should read 0% at idle and 100% at Wide Open
Throttle (WOT).
TP (Throttle Position) Sensor: Displays a range of
0.00-5.00 V. The TP sensor is used by the VCM to
determine the amount of throttle demanded by the
driver. Voltage is below 1 volt at idle and above
4 volts at Wide Open Throttle (WOT).
Trans. Fluid Temp.: Displays a range of -40 *C to
151 *C (-40'F to 304 *F). This parameter is the input
signal of the transmission fluid temperature sensor.
Transmission fluid temperature is high (151 *C) when
signal voltage is low (0 V), and transmission fluid
temperature is low (-40’ C) when signal voltage
is high (5 V).
Transmission Hot Mode: Displays ON or OFF. This
parameter monitors transmission temperature. ON
indicates that the transmission temperature has
exceeded 135‘ C (275 *F).
Transmission OSS (Output Shaft Speed): Displays
a range of 0-8192 RPM. This parameter indicates
the rotational speed of the transmission output shaft
expressed as revolutions per minute.
Vehicle Speed: Displays a range of 0-255 km/h
(0-158 mph). This parameter is the input signal from
the vehicle speed sensor assembly.
7-46 Automatic Transmission - 4L60-E
Diagnostic Trouble Code (DTC) Identification
DTC Description
Transmission Fluid
P0218
Overtemperature
Vehicle Speed Sensor
P0502
Circuit—Low Input
Vehicle Speed Sensor
P0503
Circuit—Intermittent
Transmission Fluid Temperature
P0711
Sensor Circuit—Range/Performance
Transmission Fluid Temperature
P0712
Sensor Circuit—Low Input
Transmission Fluid Temperature
P0713
Sensor Circuit—High Input
P0719 Brake Switch Circuit—Low Input
P0724 Brake Switch Circuit—High Input
Torque Converter Clutch Enable
P0740
Solenoid Circuit—Electrical
Transmission/Transaxle
DTC Type* Default Action
• DTC P0218 stores in VCM history
D • The VCM freezes shift adapts from being
updated
• DTC P0502 stores in VCM history
• The VCM commands second gear only
below 3000 RPM
• The VCM commands maximum line
B
pressure
• The VCM freezes shift adapts from being
updated
• The VCM inhibits TCC engagement
• DTC P0503 stores in VCM history
• The VCM commands a soft landing to
second gear
• The VCM commands maximum line
pressure
B
• The VCM inhibits TCC engagement
• The VCM inhibits fourth gear if the
transmission is in hot mode
• The VCM freezes shift adapts from being
updated
• DTC P0711 stores in VCM history
• The VCM uses a transmission fluid
temperature default value based on engine
D
coolant, engine run time and IAT at startup
• The VCM freezes shift adapts from being
updated
• DTC P0712 stores in VCM history
• The VCM uses a transmission fluid
temperature default value based on engine
D coolant, engine run time and IAT at
startup
• The VCM freezes shift adapts from being
updated
• DTC P0713 stores in VCM history
• The VCM uses a transmission fluid
temperature default value based on engine
D
coolant, engine run time and IAT at startup
• The VCM freezes shift adapts from being
updated
D DTC P0719 stores in VCM history
D DTC P0724 stores in VCM history
• DTC P0740 stores in VCM history
• The VCM inhibits TCC engagement
• The VCM inhibits 4th gear if the
A
transmission is in hot mode
• The VCM freezes shift adapts from being
updated
Transmission/Transaxle
Diagnostic Trouble Code (DTC) Identification (cont’d)
DTC Description
Torque Converter Clutch
P0742
System—Stuck ON
Pressure Control Solenoid
P0748
Circuit—Electrical
1-2 Shift Solenoid
P0751
Valve— Performance
1-2 Shift Solenoid
P0753
Circuit—Electrical
2-3 Shift Solenoid
P0756
Valve—Performance
2-3 Shift Solenoid
P0758
Circuit—Electrical
3-2 Shift Solenoid
P0785
Circuit—Electrical
Automatic Transmission - 4L60-E 7-47
DTC Type* Default Action
• DTC P0742 stores in VCM history
B • The VCM freezes shift adapts from being
updated
• DTC P0748 stores in VCM history
• The VCM freezes shift adapts from
D
being updated
. The PC Sol. Valve is OFF
• DTC P0751 stores in VCM history
• The VCM freezes shift adapts from
being updated
A • The VCM commands D2 line pressure
• The VCM inhibits 3-2 downshifts if the
vehicle speed is greater than 48 km/h
(30 mph)
• DTC P0753 stores in VCM history
• The VCM commands D2 line pressure
• The VCM inhibits 3-2 downshifts if
A the vehicle speed is greater than
48 km/h (30 mph)
• The VCM freezes shift adapts from
being updated
• DTC P0756 stores in VCM history
• The VCM commands third gear only
• The VCM commands maximum line
A pressure
• The VCM inhibits TCC engagement
• The VCM freezes shift adapts from
being updated
• DTC P0758 stores in VCM history
• The VCM commands 3rd gear only
• The VCM freezes shift adapts from
A being updated
• The VCM commands maximum line
pressure
• The VCM inhibits TCC engagement
• DTC P0785 stores in VCM history
• The VCM commands a soft landing
to 3rd gear
• The VCM inhibits TCC engagement
• The VCM commands maximum line
A
pressure
• The VCM inhibits 4th gear if the
transmission is in hot mode
• The VCM freezes shift adapts from
being updated
7-48 Automatic Transmission - 4L60-E Transmission/Transaxle
Diagnostic Trouble Code (DTC) Identification (cont’d)
DTC Description DTC Type* Default Action
• DTC 1810 stores in VCM history
Transmission Fluid Pressure • The VCM commands D2 line pressure
P1810 Manual Valve Position Switch B . The VCM commands D4 shift pattern
Assembly Circuit Malfunction • The VCM freezes shift adapts from
being updated
• DTC P1860 stores in VCM history
• The VCM inhibits TCC engagement
Torque Converter Clutch Pulse
Width Modulation Solenoid A • The VCM inhibits 4th gear if the
P1860
Circuit—Electrical transmission is in hot mode
• The VCM freezes shift adapts from being
updated
• DTC P1870 stores in VCM history
• The VCM inhibits TCC engagement
• The VCM commands maximum line
pressure
P1870 Transmission Component Slipping B
• The VCM inhibits 4th gear if the
transmission is in hot mode
• The VCM freezes shift adapts from being
updated
*DTC Types:
A-Emission-related, turns the MIL ON after the first failure.
B-Emission-related, turns the MIL ON after two consecutive trips with failure.
C-Non-emission-related, turns the service lamp ON after the first failure.
D-Non-emission-related, no lamps.

Fluid Capacity
Application Liters Gallons Quarts
Pan Removal 4.7 — 5
Overhaul 10.6 — 11
TransmissiorVTransaxle Automatic Transmission - 4L60-E 7-49
Range Reference
Range Park Reverse Neutral OD D 2 1
Gear — — — 1st 2nd 3rd 4th 1st 2nd 3rd 1st** 2nd 1st 2nd***
1-2 Shift
ON* ON* ON* ON OFF OFF ON ON OFF OFF ON OFF ON OFF
Solenoid
2-3 Shift
ON* ON* ON* ON ON OFF OFF ON ON OFF ON ON ON ON
Solenoid
2-4 Band — — — — A — A — A — — A — A
Reverse
Input — A
Clutch
Overrun
— — — — — — — — — A A A A A
Clutch
Forward
— — — A A A A A A A A A A A
Clutch
Forward
Sprag
— — — H H H — H H H H H H H
Clutch
Assembly
3-4 Clutch — — — — — A A — — A — — — —
Lo/Roller
— — — H — — — H — — H — H —
Clutch
Lo/Rev
A A A —
Clutch
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de-energized.
•Shift Solenoid state is a function of vehicle speed and may change if the vehicle speed increases sufficiently in
Park, Reverse or Neutral. However, this does not affect the operation of the transmission.
•‘ Manual Second-First gear is electronically prevented under normal operating conditions.
••‘ Manual First-Second gear is only available above approximately 48-56 km/h (30-35 mph)._______________

Shift Solenoid Valve State and Gear Ratio

1-2 Shift 2-3 Shift

Gear Solenoid Solenoid Gear Ratio
1 ON ON 3.059:1
2 OFF ON 1.625:1
3 OFF OFF 1.000:1
4 ON OFF 0.696:1
7-50 Automatic Transmission - 4L60-E Transmission/Transaxle

Shift Speed

4.3L (L35)
3-1 @ 3-2 @ MIN
+/- 100 +/- 100 3-1 2-3 TCC
RPM RPM Wide Wide Apply
1-2 Shift @ +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open Open @ 12%
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
Shaft Speed Shaft Speed Shaft Speed Speed Speed Shift Shift (RPM)
% of TPS 12 25 50 12 25 50 12 25 50
_
Trans Cal Axle — — — —w _

A 3.08 469 619 1106 862 1125 1875 1219 1537 2437 N/A 712 1387 5000 1575
B 3.42/3.73 486 613 1121 867 1142 1882 1227 1544 2453 N/A 719 1396 5000 1586
C 3.73 469 603 1095 849 1117 1855 1207 1520 2414 N/A 760 1363 5500 1564

5.0L (L30)
3-1 @ 3-2 @ MIN
+/- 100 +/- 100 3-1 2-3 TCC
RPM RPM Wide Wide Apply
1-2 Shift @ +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open Open @ 12%
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
Shaft Speed Shaft Speed Shaft Speed Speed Speed Shift Shift (RPM)
% of TPS 12 25 50 12 25 50 12 25 50
Trans Cal Axle — — —
_ MW •MM _
A 3.42 445 600 1084 871 1064 1741 1180 1509 2438 N/A 735 1355 5000 1548
B 3.42/3.73 445 594 1081 869 1060 1738 1187 1505 2438 N/A 784 1336 5000 1590
C 3.73 443 606 1072 932 1072 1747 1188 1514 2446 N/A 862 1305 5000 1584

5.7L (L31)
3-1 @ 3-2 @ MIN
+/- 100 +/- 100 3-1 2-3 TCC
RPM RPM Wide Wide Apply
1-2 Shift @ +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open Open @ 12%
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
Shaft Speed Shaft Speed Shaft Speed Speed Speed Shift Shift (RPM)
% of TPS 12 25 50 12 25 50 12 25 50
_ _ mm^m
Trans Cal Axle — — —
A 3.08/3.42 445 600 1084 871 1064 1741 1180 1509 2438 N/A 735 1355 5000 1548
B 3.42/3.73 445 594 1081 869 1060 1738 1187 1505 2438 N/A 784 1336 5000 1590
Lux
3.73 442 589 1073 926 1137 1895 1431 1810 2652 N/A 842 1326 5000 1937
B
C 3.73 443 606 1072 932 1072 1747 1188 1514 2446 N/A 862 1305 5000 1584
C
4.10 538 666 1178 1024 1178 1920 1306 1664 2688 N/A 947 1434 5000 1741
Police
Transmission/Transaxle Automatic Transmission - 4L60-E 7-51
5.7L (L05) CPD
3-1 @ 3-2 @ MIN
+7- 100 +/- 100 3-1 2-3 TCC
RPM RPM Wide Wide Apply
1-2 Shift 9 +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open Open @ 12%
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
Shaft Speed Shaft Speed Shaft Speed Speed Speed Shift Shift (RPM)
% of TPS 12 25 50 12 25 | 50 12 25 50
Trans Cal Axle — — —
_ _

A 3.42 488 692 895 855 1302 1791 1241 1669| 2483 N/A 732 1058 4200 1750
7-52 Automatic Transmission - 4L60-E Transmission/Transaxle

Diagnostic Information and

Procedures

Functional Test Procedure

Step Action Value(s) Yes No
Perform the Transmission Fluid Checking Procedure.
1 — —
Is the fluid level correct? Go to Step 2
Check for VCM trouble codes, both current and history. Go to Diagnostic
Are VCM trouble codes present? Trouble Code
2 —
(DTC)
Identification Go to Step 3
1. Perform the Electrical/Garage Shift Procedure.
3 2. Perform the Road Test Procedure. —
Was the condition duplicated? Go to Step 4 Go to Step 12
4 Is a harsh or soft shift condition present? — Go to Step 7 Go to Step 5
Is the vehicle’s performance poor? Go to Torque
5 — Converter Clutch
Diagnosis Go to Step 6
Is the engagement into Drive or Reverse delayed or
6 —
missing? Go to Step 7 Go to Step 9
Perform the Line Pressure Check Procedure. Refer to Symptom
7 —
Is the line pressure correct? Go to Step 8 Diagnosis Tables
Inspect the transmission wire harness connectors and the
8 transmission range switch. — Refer to Symptom
Was the condition found and corrected? System OK Diagnosis Tables
Is vibration or noise a concern? Refer to
Flywheel/Torque
9 —
Converter
Vibration Test Go to Step 10
Is the fluid leaking? Refer to Fluid
10 —
Leak Diagnosis Go to Step 11
Are other transmission conditions present? Refer to Symptom
11 —
Diagnosis Tables Go to Step 12
12 Was the condition corrected? — Exit Table Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L60-E 7-53

Schematic and Routing Diagrams

Automatic Transmission Schematic References

Icon Icon Definition
Refer to Electrostatic Discharge (ESD) Sensitive Devices in Section 8A-3 Symbols

19384

Refer to On-Board Diagnostics II (OBD II) Circuits in Section 8A-5 Repair Procedures

19385
 7-54
Automatic Transmission Controls Schematics (4L60) (PWR, GND and VSS)

Underhood

Automatic Transmission - 4L60-E

Fuse-Relay
Center

Vehicle Speed
Sensor (VSS)
E
B

Fuse Block
0.5 LT GRN/BLK 822
0.5
A
jo ^ k
Details
Cell 11 4WD
PPL/WHT 821 2WD

Vehicle Speed
J
VSS
.1
VSS
Sensor (VSS) Low High
Adapter
B

0.5 LT GRN/BLK 822

Transmission/Transaxle
0.5
0.8 ORN 440 0.8 PNK 439 PPL/WHT 821
21 C3 18 C4 29 30 Cl
Battery Ignition “VSS te r “ Vehicle
Low 1 Control
Positive Positive
Voltage (B +) Voltage j Module (VCM)

—---- ——————------------------------------------------------------------------------------------------_ _ _ _ _ _ _ _
• A

26734
 Transmission/Transaxle
Automatic Transmission Controls Schematics (4L60) (Brake Switch and Solenoids)

|Ho> In Run| |Hct In Run, Bute Taet And Start!

Power 1 IP Fuse

I
I Distribution BRAKE D2 TRANS I Block
| C el10 Fuse 18 Fuse 20
2 10 A El 10 A
I
I I
j
0.35 BRN 441

0.35 BRN Fuse Block 0.35 PNK 1020

441
Details
C el 11
A2*C100 0.35 PNK 1020 E
F :^C227
2
0.5 PNK 1020 Fuse bock
0.8 BRN 441
DJL E. .C122
Details
C el 11
Automatic 0.5 RED
Transmission
0.5 RED 838 0.5 RED 838 0.5 RED 838 0.5 RED 839

A. A. Ay A
Torque Torque 3 - 2 Shift 2 -3 S h ift 1 -2 Shift
Converter Converter Solenoid Solenoid Solenoid
Clutch Clutch (3 -2 SS) (2 -3 SS) (1 - 2 SS)
Solenoid Pulse Width Valve Valve Valve
(TCC SOL) Modulation Assembly
BY Valve BY Solenoid b
(TCCPWMSOL)
Valve

Automatic Transmission - 4L60-E

0.5 BIX 422 0.5 TAN 418 0.5 WHT 687 0.5 YEL 1223 0.5 LT GRN 1222

U S A Cl22

0.5 TAN/BLK 422 0.5 WHT 687 0.5 LT GRN 1222

0.5 BRN 418 0.5 YEL/BLK 1223

10 Cl 7 C2 13 Cl 4 6 C2
Vehicle r TCC SCH. TCCPWMSOL 3 -2 S S 2 -3 S S 1 -2 S S
Contrail switch Control Valve Valve Valve Valve
Module I input Control Assembly Control Control
A (VCM) I Control

7-55
186618
 7-56
Automatic Transmission Controls Schematics (4L60) (TFP Valve Position Switch and PC Solenoid Valve)

"* Vehicle

Automatic Transmission - 4L60-E

[Control
Transmission Transmission Transmission TFT Module (VCM)
Range A Ranges Range C Sensor
Input Input Input Signal K
,r . . . - . \
23 22 ........... iT C3 27|C2
1224 0.5 RED 1226

0
0.5 DK BLU 1225 0.5 YEL/BLK 1227
A

r.
N R P C122
Automatic

t
0.5 PNK| 1224 0.5 DK BLUljl2
|1225
25 0.5 O fflsljp 0.5 BRN 1227
Cl Transmission

SlSSSUL
. . ..___Pressure _ . . _ .
T"

J
Automatic .
Trnn r m trrln n C O O tTO l SoieO C H C l
PCB0Q*l*
REV 03 04 (TFP) Manual
Switch Switch Switch Valve Position
Switch
Transmission
LO Ruid
/ Switch
02 Temperature
£ ...• Switch r (TFT)
Sensor

0.5LTBLU 1228
0.8 GRY/BLK 1694
B’
0.5 GRY 452

MY*--------- --------------
D C122 A. ,C120
470 0.5 LT BLU/WHT 1229 0.5 GRY/BLK 1694 B
r T 1 Transfer
Sensors
f 1Case
Cell 20 >S106 1 * Switch

Transmission/Transaxle
0.5
0.5 BLK 470 RED/BLK 1228
19 ............ ......... J_e, _______ JL G3 23 C4
Sensor PC SOL PC SOL 4WD Front n Vehicle
I Ground Valve Low Valve High wheel Lock • Control
I Feed I Module (VCM)
I • A
J is A

186619
 Transmissiort/Transaxle
Automatic Transmission Controls Schematics (4L60) (VCM Power and VSS )

VCM
Cl -BLU
C2 -R E D
C3 -C LR
04 =BLK
C5 =BLK

Automatic Transmission - 4L60-E

1 Vehicle
•Control
I Module (VCM)
L

7-57
186621
 7-58
Automatic Transmission Controls Schematics (4L60) (TCC and Shift Solenoid Controls)
iHotlnRunj lHot InRun, BubTest AndStart! VCM
, Power ■*IP Fuse Cl =32 BLU

Automatic Transmission - 4L60-E

1 Distribution BRAKE D2 TRANS 'Block C2-32RED
I Ceil 10 Fuse18 F C3=32 CLR
u r ' 10A E1 110use
A
20 C4-24BLK
I C5=2 BLK
k_ _ _
0.35 BRN 441
0.35 BRN FuseBlock
V
B
441
Detals
Cel 11 0.35 PNK 1020 0.35 PNK 1020
1f
B
F C227
0.8 BRN 441
A2>fc io o
0.5 PNK 1020
E C122
FuseBlock
Details
CelM1
A
*JBrake Switch 0.5RED 839 Automatic
Assembly Transmission
l (Openwith
TCC/ABS* brakepedal 0.5RED 0.5RED 0.5RED 839 0.5RED
Cruise I depressed)
-* Switch | A, A. AJk A
I Torque Torque 3-2 Shift 2-3 Shift 1-2 Shift
I Converter Converter Solenoid Solenoid Solenoid
Clutch Clutch (3-2 SS) (2-3 SS) (1-2SS)
Solenoid PulseWidth Valve Valve Valve
(TCCSOL) Modulation Assembly
0.5 PPL 420 Valve Solenoid b'
E*C227 (TOCPWMSOL)
Valve
0.5 PPL 420 0.5BLK 422 0.5TAN 418 0.5WHT 687 0.5YEL 1223 0.5LTORN 1222
S222 +
0.5 PPL 420 0.5 PPL 420
E£C200 Tr U S A C122
0.5 PPL 420 CruiseControl 0.5 TAN/BLK 422 0.5 WHT 687 0.5LTGRN 1222
Module
S152 £filU4____

0.5 PPL 420

0.5 BRN 418 0.5 YEL/BLK 1223

Transmission/Transaxle
0.5 PPL 420
EBCM
Cel 441
10 C4 10 Cl C2 13 Cl C2
Brake TCCSOL TCCPWMSOL 3-2 SS 2-3 SS 1-2 SS 1Vehicle
Switch Control Valve Valve Valve Valve | Control
Input Control Assembly Control Control Module
Control i (VCM)

18 6 6 2 3
 Transmission/Transaxle
Automatic Transmission Controls Schematics (4L60) (PC Solenoid Controls and 4WD Indicator)

■* Vehicle
! Control
Transmission Transmission Transmission TFT Module (VCM)
RangeA RangeB RangeC Sensor A
Input Input Input Signal
1 &

Automatic Transmission - 4L60-E

7-59
186624
7-60 Automatic Transmission - 4L60-E Transmission/Transaxle

Component Locator

Automatic Transmission Components

Connector End Group
Name Location Locator View View No.
In the transmission valve body 7 - Automatic
Transmission
Automatic
1-2 Shift Solenoid Valve 7 - Automatic
Transmission —
(1-2 SS Valve) Transmission
Electronic
Component
Views
In the transmission valve body 7 - Automatic
Transmission
Automatic
2-3 Shift Solenoid 7 - Automatic
Transmission —
Valve(2-3 SS Valve) Transmission
Electronic
Component
Views
In the transmission valve body 7 - Automatic
Transmission
Automatic
3-2 Shift Solenoid Valve 7 - Automatic
Transmission —
Assembly Transmission
Electronic
Component
View
Rear of the engine 7 - Automatic 7 - Automatic
Automatic Transmission —
Transmission Transmission
In the transmission valve body 7 - Automatic
Transmission
Automatic Transmission
Automatic
Fluid Pressure Manual 7 - Automatic
Transmission —
Valve Position Switch Transmission
Electronic
(TFP Val. Position Sw.)
Component
Views
In the TFP Val. Position Sw. 7 - Automatic
Transmission
Automatic Transmission Automatic
7 - Automatic
Fluid Temperature Transmission —
Transmission
Sensor (TFT Sensor) Electronic
Component
Views
Below LH side of IP, attached to the top of the 8A-201-27
Brake Switch Assembly brake pedal bracket — —
Fig 43
Lower LH side of the IP 8A-201 -23
IP Fuse Block 8A-11-0 —
Fig 35
In the transmission valve body 7 - Automatic
Transmission
Pressure Control Automatic
7 - Automatic
Solenoid Valve (PC Transmission —
Transmission
SOL Valve) Electronic
Component
Views
Transmission/Transaxle Automatic Transmission - 4L60-E 7-61
Automatic Transmission Components (cont’d)
Connector End Group
Name Location Locator View View No.
In the transmission valve body 7 - Automatic
Transmission
Torque Converter Clutch
Automatic
Pulse Width Modulation 7 - Automatic
Transmission —
Solenoid Valve Transmission
Electronic
(TCC PWM Sol. Valve)
Component
Views
In the transmission valve body 7 - Automatic
Transmission
Torque Converter Clutch Automatic
7 - Automatic
Solenoid Valve Transmission —
Transmission
(TCC Sol. Valve) Electronic
Component
Views
Transfer Case Switch On IP — — —
Underhood Fuse- LH rear of the engine compartment, on the fender 8A-201-4
8A-11-2 —
Relay Center Fig 8
Vehicle Control LH side of the engine compartment 6 - Engine
— —
Module (VCM) Controls
Engine harness to VCM, LH side of the engine 6 - Engine
C1 (32 cavities) — —
compartment Controls
Engine harness to VCM, LH side of the engine 6 - Engine
C2 (32 cavities) — —
compartment Controls
Engine harness to VCM, LH side of the engine 6 - Engine
C3 (32 cavities) — —
compartment Controls
Engine harness to VCM, LH side of the engine 6 - Engine
C4 (24 cavities) — —
compartment Controls
Rear LH side of the transmission 7 - Automatic
Transmission
Automatic
Vehicle Speed Sensor 7 - Automatic
Transmission —
(VSS) (2WD) Transmission
Electronic
Component
Views
Vehicle Speed Sensor LH side of the transfer case 7 - Automatic 7 - Automatic
—
(VSS) (4WD) Transmission Transmission
Vehicle Speed Sensor LH side of the transfer case 7 - Automatic 7 - Automatic
—
(VSS) Adapter Transmission Transmission
IP to engine harness, LH rear of the engine 8A-201-22
C100 (36 cavities) compartment, at the bulkhead 8A-202-0 —
Fig 833
Engine to 4WD harness, rear of the engine, near 8A-201-18
C120 (4 cavities) the transmission 8A-202-36 —
Fig 26
IP to engine harness, behind the RH IP, near the 8A-201-24
C200 (10 cavities) blower motor 8A-202-4 —
Fig 38
C227 Behind the LH side of the IP — — —
Engine harness, about 10 cm from the underhood
S101 — — —
fuse-relay center breakout
7-62 Automatic Transmission - 4L60-E Transmission/Transaxle
Automatic Transmission Components (cont’d)
Connector End Group
Name Location Locator View View No.
Engine harness, about 4.5 cm from the EGR valve
S106 — — —
connector breakout
Engine harness, about 11.5 cm from the ignition coil
S108 — — —
breakout
Engine harness, about 10 cm from the underhood
S152 — — —
fuse-relay center breakout
Engine harness, about 10 cm from the fuel injector
S161 — — —
harness breakout
IP harness, about 20 cm from the heater and A/C
S222 — — —
control head breakout
Transmission/Transaxle Automatic Transmission - 4L60-E 7-63
Automatic Transmission Electronic
Component Views

62792
Legend
(36) Vehicle Speed Sensor (377) Pressure Control Solenoid Valve
(66) Torque Converter Clutch Solenoid Valve (394) 3 -2 Shift Solenoid Valve Assembly
(69) Automatic Transmission Fluid Pressure (396) Torque Converter Clutch Pulse Width
Manual Valve Position Switch Modulation Solenoid Valve
(367A) 1-2 Shift Solenoid Valve
(367B) 2 -3 Shift Solenoid Valve
7-64 Automatic Transmission - 4L60-E Transmission/Transaxle

AT Inline Harness Connector End View Automatic Transmission Wiring Harness

Assembly 20-way Connector, Engine Side
Automatic Transmission Wiring
Harness Assembly 20-way Connector,
Transmission Side
/ooo©\
O00OOO i
/ u t \ 000000 I
/ 0 0 0 0 0 0 V
S R P N M L I
x^oo©©^/
\ 11 11 ° r
\ o o o o /
\ D C B A /
5892
• 12146497
Connector Part • 20-way F Micro-Pack 100W
13270 Information Series
• 12160545 • Gray
Connector Part • 20-way F Micro-Pack 100W Circuit
Information Series Pin Wire Color No. Function
• Gray 1-2 Shift Solenoid
A 0.8 LT GRN 1222
Circuit (1-2 SS) Valve Control
Pin Wire Color No. Function 2-3 Shift Solenoid
B 0.8 YEL/BLK 1223
1-2 Shift Solenoid (2-3 SS) Valve Control
A 0.5 LT GRN 1222
(1-2 SS) Valve Control Pressure Control
0.8
2-3 Shift Solenoid C 1228 Solenoid (PC Sol.)
B 0.5 YEL 1223 RED/BLK
(2-3 SS) Valve Control Valve HIGH
Pressure Control 0.8 LT
D 1229 PC Sol. Valve LOW
C 0.5 PPL 1228 Solenoid (PC Sol.) BLU/WHT
Valve HIGH Transmission
E 0.8 PNK 1020
D 0.5 LT BLU 1229 PC Sol. Valve LOW Solenoid Power
Transmission Transmission Fluid
E 0.5 RED 839
Solenoid Power L 0.8 YEL/BLK 1227 Temperature (TFT)
Transmission Fluid Sensor HIGH
L 0.5 BRN 1227 Temperature (TFT) M 0.8 BLK 470 TFT Sensor LOW
Sensor HIGH N 0.8 PNK 1224 Range Signal A
M 0.5 GRY 452 TFT Sensor LOW P 0.8 RED 1226 Range Signal C
N 0.5 PNK 1224 Range Signal A R 0.8 DK BLU 1225 Range Signal B
P 0.5 ORN 1226 Range Signal C 3-2 Shift Solenoid
R 0.5 DK BLU 1225 Range Signal B S 0.8 WHT 687 (3-2 SS) Valve
3-2 Shift Solenoid Assembly Control
S 0.5 WHT 687 (3-2 SS) Valve Torque Converter Clutch
Assembly Control T 0.8 TAN/BLK 422 Solenoid (TCC Sol.)
Torque Converter Clutch Valve Control
T 0.5 BLK 422 Solenoid (TCC Sol.) Torque Converter Clutch
Valve Control Pulse Width Modulation
U 0.8 BRN 418
Torque Converter Clutch Solenoid (TCC PWM
Pulse Width Modulation Sol.) Valve Control
U 0.5 TAN 418
Solenoid (TCC PWM
Sol.) Valve Control
Transmission/Transaxle Automatic Transmission - 4L60-E 7-65

Visual Identification 1-2 Shift Solenoid Valve Connector,

Wiring Harness Side
AT Internal Connector End Views

Automatic Transmission Fluid Pressure

Manual Valve Position Switch Connector,
Wiring Harness Side

u
A B C D E t

168428
• 12162201
Connector Part
• Conn 2F M/P 150.2 P2S
Information
• NAT
168424 Circuit
• 12162213 Pin Wire Color No. Function
Connector Part Transmission
• Conn 5F M/P 150.2 P2S A 0.5 RED 839B
Information Solenoid Power
• NAT
1-2 Shift Solenoid
Circuit B 0.5 LT GRN 1222
(1-2 SS) Valve Control
Pin Wire Color No. Function
Transmission Fluid 2-3 Shift Solenoid Valve Connector,
A 0.5 BRN 1227 Temperature (TFT)
Wiring Harness Side
Sensor Signal
B 0.5 GRA 452 TFT Sensor Ground
C 0.5 PNK 1224 Range Signal A Input
D 0.5 ORN 1226 Range Signal C Input
E 0.5 DK BLU 1225 Range Signal B Input

168428
• 12162201
Connector Part
• Conn 2F M/P 150.2 P2S
Information
• NAT
Circuit
Pin Wire Color No. Function
Transmission
A 0.5 RED 839A
Solenoid Power
2-3 Shift Solenoid
B 0.5 YEL 1223
(2-3 SS) Valve Control
7-66 Automatic Transmission - 4L60-E Transmission/Transaxle

Torque Converter Clutch Pulse Width Pressure Control Solenoid Valve

Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side
Connector, Wiring Harness Side

168421
168428 • 12146800
• 12162202 Connector Part
• Conn 2F M/P 480 SPL
Connector Part Information
• Conn 2F M/P 150.2 P2S • NAT
Information
• BLU Circuit
Circuit Pin Wire Color No. Function
Pin Wire Color No. Function Pressure Control
Transmission A 0.5 PPL 1228 Solenoid (PC Sol.)
A 0.5 RED 839E Valve HIGH Control
Solenoid Power
Torque Converter Clutch PC Sol. Valve
B 0.5 LT BLU 1229
Pulse Width Modulated LOW Control
B 0.5 TAN 418
Solenoid (TCC PWM
Sol.) Valve Torque Converter Clutch (TCC) Solenoid
Valve Connector, Wiring Harness Side
3-2 Control Solenoid Valve Connector,
Wiring Harness Side

"O
I-------
1--------------- I B
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llll i

168419
Connector Part • 10478128
168427 Information • CBL Solenoid Valve
• 12146094
Connector Part Circuit
• Conn 2F M/P 150.2 P2S Pin Wire Color No. Function
Information
• MDGRA Transmission
A 0.5 RED 839D
Circuit Solenoid Power
Pin Wire Color No. Function Torque Converter Clutch
Transmission B 0.5 BLK 422A Solenoid (TCC Sol.)
A 0.5 RED 839C
Solenoid Power Valve Control
3-2 Control
B 0.5 WHT 687
Solenoid Valve
Transmission/Transaxle
Diagnostic Information and
Procedures
DTC P0218 Transmission Fluid Overtemperature
Circuit Description
The flow of transmission fluid starts in the bottom
pan and is drawn through the filter, control valve
body assembly, transmission case and into the oil
pump assembly. The oil pump assembly pressurizes
the fluid and directs it to the pressure regulator valve
where it becomes the main supply of fluid to the
various components and hydraulic circuits in the
transmission. Hot fluid exiting the torque converter
flows through the converter clutch apply valve and
into the transmission cooler lines to the oil cooler
located in the vehicle radiator (and auxiliary cooler if
equipped). From the cooler, fluid returns to cool and
lubricate the front of the transmission. In forward
drive ranges, D4 fluid from the manual valve is
routed through an orificed cup plug in the rear of the
transmission case to feed the rear lube fluid circuit.
When the VCM detects a high transmission fluid
temperature for a long period of time, then
DTC P0218 sets. DTC P0218 is a type D DTC.
Conditions for Setting the DTC
• No TFT Sensor DTCs P0712 or P0713.
• The TFT is greater than 130*C (266 *F).
• All conditions met for 600 seconds (10 minutes).
Automatic Transmission - 4L60-E 7-67
co
3
cc
154212
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The VCM freezes shift adapts from being
updated.
• DTC P0218 stores in VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes
40 warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• DTC P0218 may set approximately
600 seconds after DTC P0711 has set. If
DTC P0711 is also set, follow the diagnostic
table for DTC P0711 before proceeding to the
diagnostic table for DTC P0218. Repairing the
condition that caused DTC P0711 will likely
eliminate DTC P0218.
7-68 Automatic Transmission - 4L60-E
• The TFT displayed on the scan tool should rise
steadily to a normal operating temperature, then
stabilize.
• Ask about the customer’s driving habits, trailer
towing, etc. Trailer towing should occur in D3.
Transmission/Transaxle
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. DTC P0711 may cause DTC P0218 to set.
4. This step checks for air flow restrictions or
damage which may result in the transmission
overheating.

DTC P0218 Transmission Fluid Overtemperature

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the
scan tool in order to record the Failure Records
for reference. Using the Clear Info function will erase
2 the stored Failure Records from the VCM. —
3. Record the DTC Failure Records, then clear
the DTC(s).
4. Perform the transmission fluid checking procedure. Go to
Refer to 4L60-E Transmission Fluid Checking Transmission
Procedure. Fluid Checking
Was the fluid checking procedure performed? Go to Step 3 Procedure
Is DTC P0711 also set? Go to
3 —
Diagnostic Aids Go to Step 4
1. Inspect the engine cooling system and transmission
cooling system for the following conditions:
• Air flow restrictions
• Air flow blockage
4 —
• Debris
2. Inspect the transmission cooling system for
damaged cooler lines.
Was a condition found? Go to Step 7 Go to Step 5
Perform the line pressure check procedure.
5 Refer to 4L60-E Line Pressure Check Procedure. —
Was a condition found? Go to Step 7 Go to Step 6
Inspect the torque converter stator for damage.
6 Refer to Torque Converter Clutch Diagnosis. — Go to
Was a condition found? Go to Step 7 Diagnostic Aids
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Ensure that the following conditions are met:
7 • With the engine OFF, the ignition switch is in —
the RUN position.
• The scan tool indicates a TFT less than
125 *C (257 *F) for at least 5 seconds. Begin the
4. Select Specific DTC. Enter DTC P0218. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0502 Vehicle Speed Sensor Circuit Low Input
Vehicle Speed vss VSS
Sensor (VSS) Low High
Adapter
B
L _________________
Circuit Description
The Vehicle Speed Sensor Assembly (VSS Assy.)
provides vehicle speed information to the Vehicle
Control Module (VCM). The VSS Assy, is a
Permanent Magnet (PM) generator. The PM
generator produces a pulsing AC voltage as rotor
teeth on the transmission output shaft pass through
the sensor’s magnetic field. The AC voltage level
and the number of pulses increase as the speed of
the vehicle increases. The output voltage varies from
a minimum of 0.5 volts AC at 100 RPM to more than
100 volts at 8000 RPM. The VCM converts the
pulsing voltage to vehicle speed. The VCM uses the
vehicle speed signal to determine shift timing and
Torque Converter Clutch (TCC) scheduling.
When the VCM detects a low vehicle speed when
there is a high engine speed in a drive gear range,
then DTC P0502 sets. DTC P0502 is a type B DTC.
Automatic Transmission - 4L60-E 7-69
A
JOBO Ilk.
2WD
Vehicle
1 Control
1Module (VCM)
! A
_________________________________ - _ J' is A
42264
Conditions for Setting the DTC
DTC P0502 sets if the following conditions occur two
consecutive times:
. No MAP Sensor DTCs P0107 or P0108.
. No TP Sensor DTCs P0122 or P0123.
• No TFP Val. Position Sw. DTC P1810.
• The transmission is not in Park or Neutral.
• The TP angle is greater than 20%.
• The engine vacuum is 0-105 kPa.
• The engine speed is greater than 3000 RPM.
• The engine torque is 40-400 ft lb.
• The transmission output speed is less than
150 RPM.
• All conditions met for 2.5 seconds.
7-70 Automatic Transmission - 4L60-E Transmission/Transaxle
Action Taken When the DTC Sets Diagnostic Aids
• The VCM illuminates the Malfunction • Inspect the wiring at the VCM, the Vehicle
Indicator Lamp (MIL). Speed Sensor (VSS) connector and all other
circuit connecting points for the following
• The VCM commands second gear only,
conditions:
below 3000 RPM.
- A bent terminal
• The VCM commands maximum line pressure.
- A backed out terminal
• The VCM freezes shift adapts from being
updated. - A damaged terminal
- Poor terminal tension
• The VCM inhibits TCC engagement.
- A chafed wire
• DTC P0502 stores in VCM history.
- A broken wire inside the insulation
Conditions for Clearing the MIL/DTC - Moisture intrusion
• The VCM turns OFF the MIL after three - Corrosion
consecutive trips without a failure reported. • When diagnosing for an intermittent short or
• A scan tool can clear the DTC from the open condition, massage the wiring harness
VCM history. The VCM clears the DTC from while watching the test equipment for a change.
the VCM history if the vehicle completes 40
Test Description
warm-up cycles without a failure reported.
The numbers below refer to the step numbers on the
• The VCM cancels the DTC default actions diagnostic table.
when the fault no longer exists and the ignition
is OFF long enough in order to power down 3. This step tests the VSS Assy, circuit.
the VCM. 5. This step tests the integrity of the VSS Assy.
8. This step tests the 5-volt and ground circuit
of the VCM.

DTC P0502 Vehicle Speed Sensor Circuit Low Input

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
2 Records from the VCM. —

3. Record the DTC Freeze Frame and Failure Records,

then clear the DTC(s).
4. Raise and support the drive axle assembly.
5. Start the engine.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the Transmission Go to
OSS increase with the drive wheel speed? Diagnostic Aids Go to Step 3
1. Turn the ignition OFF.
2. Disconnect the C1 (blue) VCM connector.
3. Using the J 39200 Digital Multimeter (DMM) and the
3 J 35616 Connector Test Adapter Kit, measure the 1470-2820 Q
resistance between VCM connector terminals
C1-29 and C1-30.
Is the resistance within the specified range? Go to Step 4 Go to Step 6
Measure the resistance between terminal C1 -30 and
4 ground. 50 KO
Is the resistance greater than the specified value? Go to Step 5 Go to Step 7
Transmission/Transaxle Automatic Transmission - 4L60-E 7-71
DTC P0502 Vehicle Speed Sensor Circuit Low Input (cont’d)
Step Action Value(s) Yes No
1. Place the transmission in Neutral.
2. Select AC volts.
3. Hold one rear wheel from turning.
5 0.5 volts
4. Rotate the other rear wheel by hand, ensuring that
the driveshaft is turning.
Is the voltage greater than the specified value? Go to Step 8 Go to Step 9
1. Inspect circuit 821 (PPL/WHT) for an open.
2. Inspect circuit 822 (LT GRN/BLK) for an open.
6 3. Repair the circuits if necessary. —

Refer to General Electrical Diagnosis Procedures.

Did you find an open condition? Go to Step 15 Go to Step 9
1. Inspect circuit 821 (PPL/WHT) for a short to ground.
2. Inspect circuit 822 (LT GRN/BLK) for a short to
ground.
7 —
3. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures. Go to
Did you find a short to ground condition? Go to Step 15 Diagnostic Aids
1. Reconnect the C1 (blue) VCM connector.
2. Disconnect the VSS Assy, harness from the
VSS Assy.
3. With the engine OFF, turn the ignition switch to
8 the RUN position. 4.0-5.1 volts
4. Using the J 39200 DMM, measure the voltage at
the VSS Assy, harness connector terminal A and
terminal B.
Is the voltage within the specified range? Go to Step 14 Go to Step 11
1. Remove the VSS Assy.
2. Check the output shaft speed sensor rotor for
9 —
damage or misalignment.
Did you find a damaged condition? Go to Step 15 Go to Step 10
Replace the VSS Assy.
10 Refer to Vehicle Speed Sensor Replacement. — —
Is the replacement complete? Go to Step 15
Was the voltage measured in Step 8 less than the voltage
11 4.0 volts
in the value column? Go to Step 14 Go to Step 12
Was the voltage measured in Step 8 greater than the
12 5.1 volts —
voltage in the value column? Go to Step 13
Repair the short to B+ in circuit 821 (PPL/WHT).
13 Refer to General Electrical Diagnosis Procedures. — —
Is the repair complete? Go to Step 15
Replace the VCM.
14 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 15
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
15 —
3. Operate the vehicle, so that the transmission output
speed is greater than 151 RPM for 3 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0502. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-72 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0503 Vehicle Speed Sensor CKT Intermittent

A
ioeoiik

2WD

J
Vehicle Speed VSS
-I
VSS
Sensor (VSS) Low High
Adapter
B

1 Vehicle
1 Control
1 Module (VCM)
! >
________ _ _ _____________ __________________ _ — J

Circuit Description
The Vehicle Speed Sensor Assembly (VSS Assy.)
provides vehicle speed information to the Vehicle
Control Module (VCM). The VSS Assy, is a
Permanent Magnet (PM) generator. The PM
generator produces a pulsing AC voltage as rotor
teeth on the transmission output shaft pass through
the sensor’s magnetic field. The AC voltage level
and the number of pulses increase as the speed of
the vehicle increases. The output voltage varies from
a minimum of 0.5 volts AC at 100 RPM to more than
100 volts at 8000 RPM. The VCM converts the
pulsing voltage to vehicle speed. The VCM uses the
vehicle speed signal to determine shift timing and
Torque Converter Clutch (TCC) scheduling.
When the VCM detects an unrealistically large drop
in vehicle speed, then DTC P0503 sets. DTC P0503
is a type B DTC.
42264
Conditions for Setting the DTC
DTC P0503 sets if the following conditions occur two
consecutive times:
• No TFP Val. Position Sw. DTC P1810.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• The time since the last gear range change
is greater than 6 seconds.
• The transmission output speed rise does
not exceed 600 RPM within 6 seconds.
• The transmission output speed drops by greater
than 1300 RPM for 3 seconds when not in
Park/Neutral.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-73
Action Taken When the DTC Sets Diagnostic Aids
• The VCM illuminates the Malfunction Indicator • Inspect the wiring at the VCM, the Vehicle Speed
Lamp (MIL). Sensor (VSS) connector and all other circuit
connecting points for the following conditions:
• The VCM commands second gear only.
- A bent terminal
• The VCM commands maximum line pressure.
- A backed out terminal
• The VCM freezes shift adapts from being - A damaged terminal
updated. - Poor terminal tension
• The VCM inhibits TCC engagement. - A chafed wire
• DTC P0503 stores in VCM history. - A broken wire inside the insulation
- Moisture intrusion
Conditions for Clearing the MIL/DTC - Corrosion
• The VCM turns OFF the MIL after three • When diagnosing for an intermittent short or
consecutive trips without a failure reported. open condition, massage the wiring harness
• A scan tool can clear the DTC from the VCM while watching the test equipment for a change.
history. The VCM clears the DTC from the VCM Test Description
history if the vehicle completes 40 warm-up
The numbers below refer to the step numbers on
cycles without a failure reported.
the diagnostic table.
• The VCM cancels the DTC default actions
3. This step tests the VSS Assy, circuit.
when the fault no longer exists and the ignition
is OFF long enough in order to power down 5. This step tests the integrity of the VSS Assy.
the VCM. 8. This step tests the 5-volt and ground circuit
of the VCM.

DTC P0503 Vehicle Speed Sensor CKT Intermittent

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the VCM.
2 3. Record the DTC Freeze Frame and Failure Records,
—
then clear the DTC(s).
4. Raise and support the drive axle assembly.
5. Start the engine.
6. Place the transmission in D3 range.
7. With the drive wheels rotating, slowly accelerate the
engine to 2000 RPM and hold (Road test the vehicle
if necessary).
Does the Transmission OSS drop or fluctuate more than Go to
the specified value? Go to Step 3 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the C1 (blue) VCM connector.
3. Using the J 39200 Digital Multimeter (DMM) and the
3 J 35616 Connector Test Adapter Kit, measure the 1470-2820 Cl
resistance between VCM connector terminals
C1-29 and C1-30.
Is the resistance within the specified range? Go to Step 4 Go to Step 6
Measure the resistance between terminal C1-30 and
4 ground. 50 K Cl
Is the resistance greater than the specified value? Go to Step 5 Go to Step 7
7-74 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0503 Vehicle Speed Sensor CKT Intermittent (cont’d)

Step Action Value(s) Yes No
1. Place the transmission in Neutral.
2. Select AC volts.
3. Hold one rear wheel from turning.
5 0.5 volts
4. Rotate the other rear wheel by hand, ensuring that
the driveshaft is turning.
Is the voltage greater than the specified value? Go to Step 8 Go to Step 9
1. Inspect circuit 821 (PPL/WHT) for an open.
2. Inspect circuit 822 (LT GRN/BLK) for an open.
6 3. Repair the circuits if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 15 Go to Step 9
1. Inspect circuit 821 (PPL/WHT) for a short to ground.
2. Inspect circuit 822 (LT GRN/BLK) for a short to
ground.
7 —
3. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures. Go to
Did you find a short to ground condition? Go to Step 15 Diagnostic Aids
1. Reconnect the C1 (blue) VCM connector.
2. Disconnect the VSS Assy, harness from the
VSS Assy.
3. With the engine OFF, turn the ignition switch to
8 the RUN position. 4.0-5.1 volts
4. Using the J 39200 DMM, measure the voltage at
the VSS Assy, harness connector terminal A and
terminal B.
Is the voltage within the specified range? Go to Step 14 Go to Step 11
1. Remove the VSS Assy.
2. Check the output shaft speed sensor rotor for
9 —
damage or misalignment.
Did you find a damaged condition? Go to Step 15 Go to Step 10
Replace the VSS Assy.
10 Refer to Vehicle Speed Sensor Replacement. — —
Is the replacement complete? Go to Step 15
Was the voltage measured in Step 8 less than the voltage
11 4.0 volts
in the value column? Go to Step 14 Go to Step 12
Was the voltage measured in Step 8 greater than the
12 5.1 volts —
voltage in the value column? Go to Step 13
Repair the short to B+ in circuit 821 (PPL/WHT).
13 Refer to General Electrical Diagnosis Procedures. — —
Is the repair complete? Go to Step 15
Replace the VCM.
14 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 15
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
15 3. Operate the vehicle, ensuring that the transmission —
output speed drop is less than 500 RPM for
2.5 seconds and output speed is greater than
600 RPM for 2.5 seconds. Begin the
4. Select Specific DTC. Enter DTC P0503. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0711 Fluid Temp Sensor CKT Range/Performance
Circuit Description
The Automatic Transmission Fluid Temperature
(TFT) Sensor is part of the Automatic Transmission
Fluid Pressure Manual Valve Position Switch
(TFP Val. Position Sw.). The TFT Sensor is a
resistor, or thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases.
The Vehicle Control Module (VCM) supplies a 5 volt
reference signal to the sensor on circuit 1227 and
measures the voltage drop in the circuit. When the
transmission fluid is cold, the sensor resistance is
high and the VCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and the
signal voltage decreases. The VCM uses this
information to control shift quality and torque
converter clutch apply.
Automatic Transmission - 4L60-E 7-75
A
jOBPlik
201904
When the VCM detects one of the following unusual
conditions, then DTC P0711 sets.
• An unrealistically large change in transmission
temperature
• A transmission temperature which remains
constant for a period of time in which a
measurable amount of change is expected
DTC P0711 is a type D DTC.
Conditions for Setting the DTC
. No VSS Assy. DTCs P0502 or P0503.
• No Transmission Component Slipping
DTC P1870.
• The system voltage is 10-16 volts.
• The engine is running for 409 seconds.
• The vehicle speed is greater than 8 km/h
(5 mph) for 409 seconds cumulative this
ignition cycle.
7-76 Automatic Transmission - 4L60-E
• The TCC slip speed is greater than 120 RPM
for 409 seconds cumulative this ignition cycle.
• The transmission fluid temperature at startup is
between -40 and +21 *C (-40 and +70 *F).
• The TFT is between -38 and +151 *C
(-36 and +304 *F).
• The engine coolant temperature is greater
than 70 *C (158*F) and the temperature has
changed by 50 * C (90 * F) since startup.
• All of the above conditions are met and either
of the following fail conditions occurs:
- The transmission fluid temperature does
not change more than 1.50*C (2.7 *F)
for 409 seconds since startup.
- The transmission fluid temperature changes
more than 20 * C (36 * F) in 200 milliseconds
14 times within 7 seconds.
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
Important: The scan tool does not indicate the
default TFT.
Important: The actions listed below are in
order of highest to lowest priority.
• The VCM determines a default Transmission
Fluid Temperature (TFT) using the following
matrix:
1. If any Engine Coolant Temperature (ECT)
DTCs P0117 or P0118 are set, then the
default TFT is equal to 135*C (275 *F).
2. If the ECT is 125* C (257 *F) or more,
then the default TFT is equal to 135*C
(275 *F).
3. If the Engine Run Time is less than
300 seconds and:
• No Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set and
IAT is available, then the default
TFT is equal to IAT.
• Any Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set or IAT
is NOT available, then the default TFT
is equal to 90 *C (194* F).
4. If the Engine Run Time is greater than
300 seconds and No Intake A ir
Temperature (IAT) DTCs P0112 or P0113
are set and IAT is available and Engine
Coolant Temperature (ECT) is between
40 and 125*C (104 and 257 *F) and:
Transmission/Transaxle
• IAT at startup is less than 15*C
(59 ‘ F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 5*C (8*F).
• IAT at startup is greater than 35 * C
(95 * F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 10 *C (16*F).
• IAT at startup is between 15 and 35 *C
(59 and 95 * F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater than
300 seconds and any Intake Air
Temperature (IAT) DTCs P0112 or P0113
are set or IAT is NOT available, then the
default TFT is equal to the Engine
Coolant Temperature (ECT).
6. If the Engine Run Time is greater than
300 seconds and ECT is less than 40 *C
(104*F) or more, then the default TFT is
equal to 6 0 ‘ C (140*F).
• The VCM freezes shift adapts from being
updated.
• DTC P0711 stores irt VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
DTC P0218 may set approximately 600 seconds
after DTC P0711 has set. Follow the diagnostic table
for DTC P0711 before proceeding to the diagnostic
table for DTC P0218. Repairing the condition that
caused DTC P0711 will likely eliminate DTC P0218.
Test Description
The numbers below refer to the step numbers on
the diagnostic table.
5. This step tests for an intermittent short or open
condition in the engine wiring harness. The test
light is used as a resistor in the circuit.
6. This step determines if the VCM or the
TFT sensor is causing a steady, unchanging
TFT reading.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-77
DTC P0711 Fluid Temp Sensor CKT Range/Performance
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the fluid checking procedure?
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
stored Failure Records from the VCM.
3. Record the DTC Failure Records, then clear
3 the DTC(s). —
4. Select TFT on the scan tool.
5. Drive the vehicle and observe the scan tool for either
of the following fail conditions:
• The TFT does not change more than 1.50 *C
(2.7' F) in 409 seconds since startup
• The TFT changes more than 20 *C (36' F) in
200 milliseconds 14 times within 7 seconds Go to
Did either of the fail conditions occur? Go to Step 4 Diagnostic Aids
Did the scan tool display a condition in which the
4 TFT does not change by more than the specified value 1.50 ’ C (2.7’ F)
in 409 seconds since startup? Go to Step 6 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Using the J 35616 Connector Test Adapter Kit,
5 connect a test light from terminal L to terminal M. 20‘ C (36*F)
5. Turn the ignition switch to the RUN position.
6. While observing the scan tool display, move or
massage the engine wiring harness from VCM
connectors C2 and C3 to the 20-way connector.
Does the TFT change by more than the specified value? Go to Step 7 Go to Step 8
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
6 3. Turn the ignition switch to the RUN position. —
Does the scan tool display the same condition
as in Step 4? Go to Step 11 Go to Step 10
1. Inspect circuit 1227 (YEL/BLK) of the engine wiring
harness for an intermittent open or short condition.
2. Inspect circuit 470 (BLK) of the engine wiring
7 harness for an intermittent open or short condition. —
3. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find an intermittent open or short condition? Go to Step 12 Go to Step 11
7-78 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0711 Fluid Temp Sensor CKT Range/Performance (cont’d)
Step Action Value(s) Yes No
1. Inspect circuit 1227 (BRN) of the Automatic
Transmission Wiring Harness Assembly (A/T Wiring
Harness Assembly) for an intermittent open or short
condition.
8 2. Inspect circuit 452 (GRY) of the A/T Wiring Harness —
Assembly for an intermittent open or short condition.
Refer to General Electrical Diagnosis Procedures.
Did you find an intermittent open or short condition? Go to Step 9 Go to Step 10
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
9 — —
Harness Replacement.
Is the replacement complete? Go to Step 12
Replace the TFT Sensor (the sensor is a part of the
TFP Valve Position Switch).
10 — —
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete? Go to Step 12
Replace the VCM.
11 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 12
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle and ensure that the following
conditions are met:
12 • The TFT changes by more than 2.25 * C (4 • F) for —
11 seconds since startup
• The TFT does not change by more than 20 * C
(36 ’ F) within 200 milliseconds for a period of at
least 11 seconds
Begin the
4. Select Specific DTC. Enter DTC P0711. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/!ransaxle
DTC P0712 Fluid Temperature Sensor CKT Low Input
Circuit Description
The Automatic Transmission Fluid Temperature
(TFT) Sensor is part of the Automatic Transmission
Fluid Pressure Manual Valve Position Switch
(TFP Val. Position Sw.). The TFT Sensor is a
resistor, or thermistor, which changes value
based on temperature. The sensor has a
negative-temperature coefficient. This means that as
the temperature increases, the resistance decreases,
and as the temperature decreases, the resistance
increases. The Vehicle Control Module (VCM)
supplies a 5 volt reference signal to the sensor on
circuit 1227 and measures the voltage drop in the
circuit. When the transmission fluid is cold, the
sensor resistance is high and the VCM detects high
signal voltage. As the fluid temperature warms to a
normal operating temperature, the resistance
becomes less and the signal voltage decreases. The
VCM uses this information to control shift quality and
torque converter clutch apply.
Automatic Transmission - 4L60-E 7-79
1 -5
201904
When the VCM detects a continuous short to ground
in the TFT signal circuit or in the TFT Sensor, then
DTC P0712 sets. DTC P0712 is a type D DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The ignition switch is in the RUN position.
• The TFT Sensor indicates a signal voltage
less than 0.2 volts.
• All conditions met for 10 seconds.
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
im portant: The scan tool does not indicate
the default TFT.
Important: The actions listed below are in
order of highest to lowest priority.
7-80 Automatic Transmission - 4L60-E
• The VCM determines a default Transmission
Fluid Temperature (TFT) using the following
matrix:
1. If any Engine Coolant Temperature (ECT)
DTCs P0117 or P0118 are set, then the
default TFT is equal to 135*C (275 *F).
2. If the ECT is 125*C (257 *F) or more,
then the default TFT is equal to
135*C (275 *F).
3. If the Engine Run Time is less than
300 seconds and:
• No Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set and
IAT is available, then the default
TFT is equal to IAT.
• Any Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set or IAT
is NOT available, then the default
TFT is equal to 90 *C (194*F).
4. If the Engine Run Time is greater than
300 seconds and No Intake Air
Temperature (IAT) DTCs P0112 or P0113
are set and IAT is available and Engine
Coolant Temperature (ECT) is between
40 and 125*C (104 and 257 * F) and:
• IAT at startup is less than 15 *C
(59 * F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 5*C (8*F).
• IAT at startup is greater than 3 5 ‘ C
(95 * F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 10*C (16*F).
• IAT at startup is between 15 and 35 *C
(59 and 95 * F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater than
300 seconds and any Intake Air
Temperature (IAT) DTCs P0112 or P0113
are set or IAT is NOT available, then the
default TFT is equal to the Engine
Coolant Temperature (ECT).
6. If the Engine Run Time is greater than
300 seconds and ECT is less than 40 * C
(104*F) or more, then the default TFT is
equal to 60 *C (140*F).
• The VCM freezes shift adapts from being
updated.
• DTC P0712 stores in VCM history.
Transmission/Transaxle
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
• The scan tool displays the transmission fluid
temperature in degrees. After the transmission
is operating, the fluid temperature should rise
steadily to a normal operating temperature, then
stabilize.
• Use the Temperature vs Resistance scale when
testing the TFT Sensor at various temperature
levels. Test the TFT Sensor in order to evaluate
the possibility of a skewed (mis-scaled) sensor.
A skewed sensor can result in delayed garage
shifts or TCC complaints.
• Verify the customer’s driving habits, trailer
towing, etc. Trailer towing should occur in D3.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests for a short to ground or a
skewed sensor.
4. This step tests for an internal fault within the
transmission by creating an open.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-81
DTC P0712 Fluid Temperature Sensor CKT Low Input
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Was the fluid checking procedure performed? Procedure
Go to Step 3
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Failure Records for
3 reference. Using the Clear Info function will erase 0.2 V
the stored Failure Records from the VCM.
3. Record the DTC Failure Records, then clear
the DTC(s).
Does the scan tool display a TFT Sensor signal Go to
voltage less than the specified value? Go to Step 4 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
4 3. With the engine OFF, turn the ignition switch to 4.92 V
the RUN position.
Does the scan tool display a TFT Sensor signal
voltage greater than the specified value? Go to Step 5 Go to Siep 8
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3088-3942 ft at
2. Using the J 39200 Digital Multimeter (DMM) and the 20‘ C (68 *F)
5 J 35616 Connector Test Adapter Kit, measure the
159-198 ft at
resistance between terminals L and M. Refer to
100-C (212-F)
connector end view. Go to
Is the resistance within the specified range? Diagnostic Aids Go to Step 6
Inspect circuit 1227 (BRN) of the Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assembly)
6 for a short to ground condition. —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 10 Go to Step 7
1. Disconnect the A/T Wiring Harness Assembly at 3088-3942 ft at
the TFT Sensor. 20’ C (68’ F)
7
2. Measure the resistance of the TFT Sensor. 159-198 ft at Go to
Is the resistance within the specified range? 100‘ C (212*F) Diagnostic Aids Go to Step 9
Inspect circuit 1227 (YEL/BLK) of the engine wiring
harness for a short to ground.
8 —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 12 Go to Step 11
Replace the TFT Sensor (this sensor is part of the
TFP Val. Position Sw.).
9 — —
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete? Go to Step 12
7-82 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0712 Fluid Temperature Sensor CKT Low Input (cont’d)

Step Action Value(s) Yes No
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and
10 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 12
Replace the VCM.
11 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 12
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
12 —
RUN position.
4. Verify that the scan tool indicates a TFT Sensor
signal voltage greater than 0.2 volts for 10 seconds.
Begin the
5. Select Specific DTC. Enter DTC P0712. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0713 Fluid Temperature Sensor CKT High Input
Circuit Description
The Automatic Transmission Fluid Temperature
(TFT) Sensor is part of the Automatic Transmission
Fluid Pressure Manual Valve Position Switch
(TFP Val. Position Sw.). The TFT Sensor is a
resistor, or thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases.
The Vehicle Control Module (VCM) supplies a 5 volt
reference signal to the sensor on circuit 1227 and
measures the voltage drop in the circuit. When the
transmission fluid is cold, the sensor resistance is
high and the VCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and the
signal voltage decreases. The VCM uses this
information to control shift quality and torque
converter clutch apply.
Automatic Transmission - 4L60-E 7-83
201904
When the VCM detects a continuous open or short
to power in the TFT signal circuit or the TFT Sensor,
then DTC P0713 sets. DTC P0713 is a type D DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The ignition switch is in the RUN position.
• The TFT Sensor indicates a signal voltage
greater than 4.92 volts.
• All conditions met for 409 seconds
(6.8 minutes).
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
Im portant: The scan tool does not indicate the
default TFT.
Important: The actions listed below are in
order of highest to lowest priority.
7-84 Automatic Transmission - 4L60-E
• The VCM determines a default Transmission
Fluid Temperature (TFT) using the following
matrix:
1. If any Engine Coolant Temperature (ECT)
DTCs P0117 or P0118 are set, then the
default TFT is equal to 135’ C (275 *F).
2. If the ECT is 125‘ C (257’ F) or
more, then the default TFT is equal to
135’ C (275’ F).
3. If the Engine Run Time is less than
300 seconds and:
• No Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set and
IAT is available, then the default
TFT is equal to IAT.
• Any Intake Air Temperature (IAT)
DTCs P0112 or P0113 are set or
IAT is NOT available, then the default
TFT is equal to 90 *C (194’ F).
4. If the Engine Run Time is greater than
300 seconds and No Intake Air
Temperature (IAT) DTCs P0112 or P0113
are set and IAT is available and Engine
Coolant Temperature (ECT) is between
40 and 125’ C (104 and 257’ F) and:
• IAT at startup is less than 15 * C
(5 9 ’ F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 5 ’ C (8 ’ F).
• IAT at startup is greater than 35 ’ C
(9 5 ' F), then the default TFT is equal
to the Engine Coolant Temperature
(ECT) plus 10 *C (16’ F).
• IAT at startup is between 15 and 35 ’ C
(59 and 95 ’ F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater than
300 seconds and any Intake Air
Temperature (IAT) DTCs P0112 or P0113
are set or IAT is NOT available, then the
default TFT is equal to the Engine
Coolant Temperature (ECT).
6. If the Engine Run Time is greater than
300 seconds and ECT is less than 40 ’ C
(104’ F) or more, then the default TFT is
equal to 6 0 ’ C (140‘ F).
• The VCM freezes shift adapts from being
updated.
• DTC P0713 stores in VCM history.
Transmission/Transaxle
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
• Use the Temperature vs Resistance scale when
testing the TFT Sensor at various temperature
levels. Test the TFT Sensor in order to evaluate
the possibility of a skewed (mis-scaled) sensor.
A skewed sensor can result in delayed garage
shifts or TCC complaints.
• The scan tool displays the transmission fluid
temperature in degrees. After the transmission
is operating, the fluid temperature should rise
steadily to a normal operating temperature, then
stabilize.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step verifies a condition in the TFT
Sensor circuit.
4. This step simulates a TFT Sensor DTC P0712.
If the VCM recognizes low signal voltage (high
temperature), the VCM and wiring are
functioning normally.
5. This step tests the TFT Sensor and Automatic
Transmission Wiring Harness Assembly
(A/T Wiring Harness Assembly).
Transmission/Transaxle Automatic Transmission - 4L60-E 7-85
DTC P0713 Fluid Temperature Sensor CKT High Input
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the fluid checking procedure? Procedure
Go to Step 3
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Failure Records for
3 reference. Using the Clear Info function will erase the 4.92 V
stored Failure Records from the VCM.
3. Record the DTC Failure Records, then clear the
DTC(s).
Does the scan tool display a TFT Sensor signal voltage Go to
greater than the specified value? Go to Step 4 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the
engine side of the 20-way connector.
4 4. Install a J 36169-A Fused Jumper Wire from 0.2 V
terminal L to terminal M on the engine harness.
5. With the engine OFF, turn the ignition switch to
the RUN position.
Does the TFT Sensor signal voltage drop to less than
the specified value? Go to Step 5 Go to Step 9
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector. 3088-3942 ft at
3. Using the J 39200 Digital Multimeter (DMM) and the 20'C (68-F)
5
J 35616 Connector Test Adapter Kit, measure the 159-198 ft at
resistance between terminal L and terminal M. 100 *C (212* F)
Refer to connector end view. Go to
Is the resistance within the specified range? Diagnostic Aids Go to Step 6
Inspect circuits 1227 (BRN) and 452 (GRY) of the
Automatic Transmission Wiring Harness Assembly
6 (A/T Wiring Harness Assembly) for an open condition. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 11 Go to Step 7
1. Disconnect the A/T Wiring Harness Assembly at 3088-3942 ft at
the TFT Sensor. 20'C (68*F)
7
2. Measure the resistance of the TFT Sensor. 159-198 ft at Go to
Is the resistance within the specified range? 100*C (212’ F) Diagnostic Aids Go to Step 8
Replace the TFT Sensor (this sensor is part of the
TFP Val. Position Sw.).
8 — —
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete? Go to Step 13
7-86 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0713 Fluid Temperature Sensor CKT High Input (cont’d)
Step Action Value(s) Yes No
Inspect circuit 1227 (YEL/BLK) of the engine wiring
harness for an open or short to B+ condition.
9 Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short condition? Go to Step 13 Go to Step 10
Inspect circuit 470 (BLK) for an open condition.
Repair the circuit if necessary.
10 —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 13 Go to Step 12
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and
11 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 13
Replace the VCM.
12 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 13
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to
13 the RUN position. —
4. Verify that the scan tool indicates a TFT Sensor
signal voltage less than 4.92 volts for 409 seconds
(6.8 minutes).
Begin the
5. Select Specific DTC. Enter DTC P0713. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0719 Brake Switch Circuit Low Input
Circuit Description
The brake switch indicates brake pedal status to the
Vehicle Control Module (VCM). The brake switch is a
normally-closed switch that supplies battery voltage
on circuit 420 to the VCM. Applying the brake pedal
opens the switch, interrupting voltage to the VCM.
When the brake pedal is released, the VCM receives
a constant voltage signal. If the VCM receives a
zero voltage signal at the brake switch input, and the
Torque Converter Clutch (TCC) is engaged, the VCM
de-energizes the Torque Converter Clutch Solenoid
Valve (TCC Sol. Valve). The VCM disregards the
brake switch input for TCC scheduling if there is a
brake switch circuit fault (Refer to Diagnostic Aids).
When the VCM detects an open brake switch circuit
(0 volts, low input) during accelerations, then
DTC P0719 sets. DTC P0719 is a type D DTC.
Automatic Transmission - 4L60-E 7-87
65686
Conditions for Setting the DTC
. No VSS Assy. DTCs P0502 or P0503.
• The VCM detects an open brake switch or
circuit (0 volts) for 15 minutes without changing
for 2 seconds, and the following events occur
seven consecutive times:
- The vehicle speed is less than 8 km/h
(5 mph);
- then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is greater than
32 km/h (20 mph) for 6 seconds.
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• DTC P0719 stores in VCM history.
7-88 Automatic Transmission - 4L60-E Transmission/Transaxle
Conditions for Clearing the DTC • When diagnosing for an intermittent short or
• A scan tool can clear the DTC from the open condition, massage the wiring harness
while watching the test equipment for a change.
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40 • If the VCM detects a brake switch fault, then
warm-up cycles without a failure reported. the brake switch input is disregarded for TCC
scheduling. The VCM then uses throttle position
• The VCM cancels the DTC default actions when and vehicle speed to determine TCC application
the fault no longer exists and the ignition is OFF and release. Use of these inputs may result in
long enough in order to power down the VCM. a noticeable harsh apply or abrupt release of
the TCC.
Diagnostic Aids
• Ask about the customer’s driving habits. Ask
• Inspect the wiring at the VCM, the brake switch about unusual driving conditions (e.g. stop and
connector and all other circuit connecting points go, expressway, etc.).
for the following conditions: • Inspect the brake switch for proper mounting
- A bent terminal and adjustment.
- A backed out terminal
Test Description
- A damaged terminal
The numbers below refer to the step numbers on the
- Poor terminal tension diagnostic table.
- A chafed wire 3. This step isolates the brake switch as a source
- A broken wire inside the insulation for setting the DTC.
- Moisture intrusion
- Corrosion

DTC P0719 Brake Switch Circuit Low Input

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
stored Failure Records from the VCM.
2 3. Record the DTC Failure Records, then clear —

the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the brake switch connector from
the brake switch.
6. Connect a test lamp from cavity D of the brake
switch connector to a known good ground.
Is the test lamp ON? Go to Step 3 Go to Step 4
Install a J 36169-A Fused Jumper Wire from terminal C to
terminal D of the brake switch connector.
3 —
Did the TCC Brake Switch status change from Open to
Closed? Go to Step 7 Go to Step 9
1. Remove the BRAKE fuse.
2. Inspect the fuse for an open.
4 —
Refer to General Electrical Diagnosis Procedures.
Is the fuse open? Go to Step 5 Go to Step 8
Inspect circuit 441 (BRN) for a short to ground condition.
Repair the circuit if necessary.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 11 Go to Step 6
Transmission/Transaxle Automatic Transmission - 4L60-E 7-89
DTC P0719 Brake Switch Circuit Low Input (cont’d)
Step Action Value(s) Yes No
Inspect circuit 420 (PPL) for a short to ground condition.
Repair the circuit if necessary.
6 —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 11 Go to Step 10
Replace the brake switch.
7 Refer to Stoplamp Switch Replacement. — —
Is the replacement complete? Go to Step 11
Inspect circuit 441 (BRN) for an open condition. Repair the
circuit if necessary.
8 — —
Refer to General Electrical Diagnosis Procedures.
Did you find and correct an open condition? Go to Step 11
Inspect circuit 420 (PPL) for an open.
9 Refer to General Electrical Diagnosis Procedures. —

Did you find an open condition? Go to Step 11 Go to Step 10

Replace the VCM.
10 Refer to VCM Replacement/Programming. — —

Is the replacement complete? Go to Step 11

In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
11 RUN position. —
4. Do not depress the brake pedal.
5. Verify that the TCC Brake Switch status indicates
Closed (12 volts) for 2 seconds. Begin the
6. Select Specific DTC. Enter DTC P0719. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-90 Automatic Transmission - 4L60-E
DTC P0724 Brake Switch Circuit High Input
Circuit Description
The brake switch indicates brake pedal status to the
Vehicle Control Module (VCM). The brake switch is a
normally-closed switch that supplies battery voltage on
circuit 420 to the VCM. Applying the brake pedal
opens the switch, interrupting voltage to the VCM.
When the brake pedal is released, the VCM receives
a constant voltage signal. If the VCM receives a zero
voltage signal at the brake switch input, and the
Torque Converter Clutch (TCC) is engaged, the VCM
de-energizes the Torque Converter Clutch Solenoid
Valve (TCC Sol. Valve). The VCM disregards the brake
switch input for TCC scheduling if there is a brake
switch circuit fault (Refer to Diagnostic Aids).
When the VCM detects a closed brake switch circuit
(12 volts, high input) during decelerations, then
DTC P0724 sets. DTC P0724 is a type D DTC.
Conditions for Setting the DTC
. No VSS Assy. DTCs P0502 or P0503.
• The VCM detects a closed brake switch circuit
(12 volts) without changing for 2 seconds and the
following events occur seven consecutive times:
- The vehicle speed is greater than 32 km/h
(20 mph) for 6 seconds;
- then the vehicle spded is between 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is less than 8 km/h
(5 mph).
Transmission/Transaxle
65686
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• DTC P0724 stores in VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the brake switch
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
Transmission/Transaxle Automatic Transmission - 4L60-E 7-91
• When diagnosing for an intermittent short or Test Description
open condition, massage the wiring harness The numbers below refer to the step numbers on the
while watching the test equipment for a change. diagnostic table.
• Ask about the customer’s driving habits. Ask 2. This step isolates the brake switch as a source
about unusual driving conditions (e.g. stop and for setting the DTC.
go, expressway, etc.).
• Inspect the brake switch for proper mounting
and adjustment.

DTC P0724 Brake Switch Circuit High Input

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
stored Failure Records from the VCM.
2 —
3. Record the DTC Failure Records, then clear
the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the brake switch connector from the
brake switch.
Did the TCC brake switch status change from
Closed to Open? Go to Step 3 Go to Step 4
Replace the brake switch.
3 Refer to Stoplamp Switch Replacement. — —
Is the replacement complete? Go to Step 6
Inspect circuit 420 (PPL) for a short to B+ condition.
Repair the circuit if necessary.
4 —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to B+ condition? Go to Step 6 Go to Step 5
Replace the VCM.
5 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 6
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to
6 the RUN position. —
4. Apply the brake pedal.
5. Verify that the TCC brake switch status indicates
Open (0 volts) for 2 seconds. Begin the
6. Select Specific DTC. Enter DTC P0724. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-92 Automatic Transmission - 4L60-E
DTC P0740 TCC Enable Solenoid Circuit Electrical
Circuit Description
The Torque Converter Clutch Solenoid Valve
(TCC Sol. Valve) is an electrical device that is used
with the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve) in
order to control TCC apply and release. The
TCC Sol. Valve attaches to the transmission case
assembly extending into the pump cover. The
TCC Sol. Valve receives ignition voltage through
circuit 1020. The Vehicle Control Module (VCM)
controls the solenoid by providing the ground path
on circuit 422. The VCM monitors the Throttle
Position (TP) voltage, the vehicle speed, and other
inputs in order to determine when to energize the
TCC Sol. Valve.
When the VCM detects a continuous open or a short
to ground in the TCC Sol. Valve circuit or in the
TCC Sol. Valve, then DTC P0740 sets. DTC P0740
is a type A DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
Transmission/Transaxle
201913
• All of the above conditions are met for
5 seconds and either of the following fail
conditions occurs for 5 seconds:
- The VCM commands the solenoid ON and
the voltage input remains high (B+).
- The VCM commands the solenoid OFF and
the voltage input remains low (0 volt).
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM inhibits TCC engagement.
• The VCM inhibits 4th gear if the transmission
is in hot mode.
• The VCM freezes shift adapts from being
updated.
• DTC P0740 stores in VCM history.
Conditions for Clearing the MIL/DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the VCM.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-93
Diagnostic Aids Test Description
• Inspect the wiring at the VCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 4. This step tests for voltage to the solenoid.
- A bent terminal 6. This step tests the ability of the VCM and
- A backed out terminal wiring to control the ground circuit.
- A damaged terminal 8. This step tests the resistance of the TCC Sol.
- Poor terminal tension Valve and the Automatic Transmission Wiring
Harness Assembly (A/T Wiring Harness
- A chafed wire
Assembly).
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
• With the TCC engaged, the TCC slip speed
should be -20 to +20 RPM.

DTC P0740 TCC Enable Solenoid Circuit Electrical

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
2 Failure Records for reference. Using the Clear Info —
function will erase the stored Freeze Frame and
Failure Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0753, P0758, P0785 and P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the TRANS fuse.
2. If the fuse is open, inspect circuit 1020 (PNK), the
solenoids and the A/T Wiring Harness Assembly for
3 a short to ground condition. Repair the circuit, the —
solenoids and the harness if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 12 Go to Step 4
1. Turn the ignition switch OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from cavity E of the J 39775
Jumper Harness to a known good ground.
Is the test lamp ON? Go to Step 6 Go to Step 5
Repair the open or short to ground in ignition feed
circuit 1020 (PNK) to the TCC Sol. Valve.
5 — —
Refer to General Electrical Diagnosis Procedures.
Is the repair complete? Go to Step 12
7-94 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0740 TCC Enable Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
1. Install the test lamp from cavity E to cavity T of the
J 39775 Jumper Harness.
2. Using the transmission output control function on the
6 scan tool, command the TCC Sol. Valve ON and —
OFF three times.
Does the test lamp turn ON when the TCC Sol. Valve is
commanded ON, and OFF when commanded OFF? Go to Step 8 Go to Step 7
1. Inspect circuit 422 (TAN/BLK) of the engine wiring
harness for an open or short to ground condition.
7 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 12 Go to Step 9
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Using the J 39200 Digital Multimeter (DMM) and the
8 J 35616 Connector Test Adapter Kit, measure the 21-33 Q
resistance between terminals T and E. Refer to
connector end view.
Is the resistance within the specified range? Go to Step 10 Go to Step 11
Replace the VCM.
9 Refer to VCM Replacement/Programming. — —

Is the replacement complete? Go to Step 12

1. Measure the resistance between terminal E
and ground.
10 2. Measure the resistance between terminal T 250 KO
and ground. Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 11
Replace the A/T Wiring Harness Assembly (this includes
the TCC Sol. Valve).
11 Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring — —
Harness Replacement.
Is the replacement complete? Go to Step 12
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 with the TCC ON and OFF.
Ensure that the following conditions are met:
12 • The VCM commands the TCC Sol. Valve ON, and —
the voltage input drops to zero.
• The VCM commands the TCC Sol. Valve OFF,
and the voltage input increases to B+.
• All conditions met for 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0740. diagnosis again.
Has the test run and passed? System OK Go to Step 1
TransmissiorVTransaxle
DTC P0742 Torque Converter Clutch System Stuck On
Vehicle r
Control
A Module
(VCM)
Automatic
Transmission
Circuit Description
The Torque Converter Clutch Solenoid Valve
(TCC Sol. Valve) is a normally-open exhaust valve
that is used with the Torque Converter Clutch Pulse
Width Modulation Solenoid Valve (TCC PWM Sol.
Valve) in order to control fluid acting on the
converter clutch apply valve. The TCC Sol. Valve
attaches to the transmission case assembly
extending into the pump cover. When grounded
(energized) by the Vehicle Control Module (VCM),
the TCC Sol. Valve stops converter signal oil from
exhausting. This causes converter signal oil pressure
Automatic Transmission - 4L60-E 7-95
201914
to increase and move the converter clutch apply
valve against spring force and into the apply
position. In this position, release fluid is open to an
exhaust port and converter feed fluid fills the apply
fluid circuit. The converter feed fluid applies the
TCC. When the VCM no longer provides a ground
path, the TCC Sol. Valve de-energizes and apply
fluid exhausts, releasing the TCC.
When the VCM detects low torque converter slip
when the TCC is commanded OFF, then DTC P0742
sets. DTC P0742 is a type B DTC.
7-96 Automatic Transmission - 4L60-E
Conditions for Setting the DTC
DTC P0742 sets if the following conditions occur
twice per ignition cycle, two consecutive times.
. No MAP Sensor DTCs P0107 or P0108.
. No TP Sensor DTCs P0122 or P0123.
. No VSS Assy. DTCs P0502 or P0503.
. No TCC Sol. Valve DTC P0740.
• No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
• The TP angle is 17-45%.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• The engine speed is 1000-3000 RPM.
• The speed ratio is 0.64 to 1.35.
• The vehicle speed is 24-80 km/h (15-50 mph).
• No gear range change within 5 seconds.
• The engine vacuum is 0-105 kPa.
• The engine torque is 50-400 lb ft.
• The commanded gear is not 1st.
• The gear range is D4.
• The TCC is commanded OFF.
• The TCC slip speed is -20 to +20 RPM.
• All conditions met for 5 seconds.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM freezes shift adapts from being
updated.
• DTC P0742 stores in VCM history.
DTC P0742 Torque Converter Clutch System Stuck On
Step Action
Was the Powertrain On-Board Diagnostic (OBD) System
1 Check performed?
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
2 will erase the stored the Freeze Frame and Failure
Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Using the scan tool, verify the TP Sensor operation.
Are the TP Sensor values within the normal range shown
in the value column?
Transmission/Transaxle
Conditions for Clearing the MIL/DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• The TCC fluid will mechanically apply the TCC,
possibly causing an engine stall, under the
following conditions:
- The TCC is mechanically stuck ON
- The parking brake is applied
- Any gear range is selected
• A stuck TP Sensor may set DTC P0742.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the mechanical state of the
TCC. When the VCM commands the TCC Sol.
Valve OFF, the slip speed should increase.
Value(s) Yes No
Go to
— Powertrain OBD
Go to Step 2 System Check
0.6 - 5.0 V
Go to
Go to Step 3 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L60-E 7-97
DTC P0742 Torque Converter Clutch System Stuck On (cont’d)
Step Action Value(s) Yes No
Drive the vehicle in the D4 drive range in fourth gear
under steady acceleration, with a TP angle greater
than 25%.
3 -20 to +20 RPM
While the displayed TCC Enable Status is NO, does
the scan tool display a TCC Slip Speed within the Go to
specified range? Go to Step 4 Diagnostic Aids
The TCC is mechanically stuck ON. Check for the
following:
• Clogged exhaust orifice in the TCC Sol. Valve.
• Converter clutch apply valve stuck in the apply
4 — —
position.
• Misaligned or damaged valve body gasket.
• Restricted release passage.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
5 3. Drive the vehicle in D4 with the TCC OFF and the —
throttle above 17%. Ensure that the TCC slip speed
is 100-2000 RPM for 5 seconds. Begin the
4. Select Specific DTC. Enter DTC P0742. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-98 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0748 Pressure Control Solenoid CKT Electrical

Automatic
Transmission

Pressure
Control Solenoid
(PC SOL) Valve
A
JOBOIIk

0.5LTBLU 1229 0.5 PPL 1228

:v J
D C C122

0.5 LT BLU/WHT 1229

0.5
RED/BLK 1228
16.'A .---------------------- 6
A C3
n Vehicle
PC SOL PC SOL.
Valve Low Valve High * Control
1Module (VCM)
1 >
J

201919

Circuit Description Conditions for Setting the DTC

The Pressure Control Solenoid Valve (PC Sol. Valve) • The system voltage is 10-16 volts.
is an electronic device that regulates transmission • The engine is running.
line pressure based on the current flow through its
• The PC Sol. duty cycle reaches its high
coil winding. The magnetic field produced by the coil
limit (approximately 95%) or low limit
moves the solenoid’s internal valve which varies
(approximately 0%).
pressure to the pressure regulator valve. The Vehicle
Control Module (VCM) controls the PC Sol. Valve by Action Taken When the DTC Sets
applying a varying amount of amperage to the
solenoid. The applied amperage can vary from 0.1 to • The VCM does not illuminate the Malfunction
1.1 amps. Low amperage (0.1 amp) indicates high Indicator Lamp (MIL).
line pressure. High amperage (1.1 amps) indicates • The VCM freezes shift adapts from being
low line pressure. The duty cycle of the PC Sol. updated.
Valve is expressed as a percentage of energized ON . The PC Sol. Valve is OFF.
time. Zero percent indicates zero ON time
• DTC P0748 stores in VCM history.
(non-energized) or no current flow. Approximately
60% at idle indicates maximum ON time (energized) Conditions for Clearing the DTC
or high current flow. The VCM determines the
• A scan tool can clear the DTC from the
appropriate line pressure for a given load by
VCM history. The VCM clears the DTC from
comparing the Throttle Position (TP) voltage, the
the VCM history if the vehicle completes 40
engine speed and other inputs.
warm-up cycles without a failure reported.
When the VCM detects a continuous open or short
• The VCM cancels the DTC default actions when
to ground in the PC Sol. Valve circuit or the PC Sol.
the fault no longer exists and the ignition is OFF
Valve, then DTC P0748 sets. DTC P0748 is a type
long enough in order to power down the VCM.
D DTC.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-99
Diagnostic Aids Test Description
• Inspect the wiring at the VCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 2. This step tests the ability of the VCM to
- A bent terminal command the PC Sol. Valve.
- A backed out terminal 3. This step tests the PC Sol. Valve and
Automatic Transmission Wiring Harness
- A damaged terminal Assembly (A/T Wiring Harness Assembly) for
- Poor terminal tension incorrect resistance.
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
• DTC P0748 may set under low voltage
conditions caused by high electrical system
demands.

DTC P0748 Pressure Control Solenoid CKT Electrical

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Failure Records for
reference. Using the Clear Info function will erase
the stored Failure Records from the VCM.
2 3. Record the DTC Failure Records, then clear 0.16 amp
the DTC(s).
4. Start the engine.
5. Using the transmission output control function on
the scan tool, apply 0.1 amp through 1.0 amp while
observing PC Sol. Ref. Current and PC Sol. Actual
Current.
Is the PC Sol. Actual Current always within the specified Go to
value of the PC Sol. Ref. Current? Diagnostic Aids Go to Step 3
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3 4. Using the J 39200 Digital Multimeter (DMM) and the 3-7 0
J 35616 Connector Test Adapter Kit, measure the
resistance between terminals C and D.
Refer to connector end view.
Is the resistance within the specified range? Go to Step 8 Go to Step 4
4 Is the resistance greater than the specified value? 70 Go to Step 5 Go to Step 6
7-100 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0748 Pressure Control Solenoid CKT Electrical (cont’d)
Step Action Value(s) Yes No
Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
A/T Wiring Harness Assembly for an open condition.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 18 Go to Step 10
6 Is the resistance less than the specified value? 3Q Go to Step 7 —

Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
A/T Wiring Harness Assembly for a shorted together
7 condition. —
Refer to General Electrical Diagnosis Procedures.
Did you find a shorted together condition? Go to Step 18 Go to Step 10
Measure the resistance from terminal C to the
8 transmission case. 9Q
Is the resistance less than the specified value? Go to Step 9 Go to Step 11
Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of
the A/T Wiring Harness Assembly for a short to ground.
9 —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 18 Go to Step 10
Replace the PC Sol. Valve.
10 Refer to Control and Shift Solenoids Replacement. — —
Is the replacement complete? Go to Step 20
1. Disconnect the J 39775 Jumper Harness from the
transmission side of the 20-way connector.
2. Reconnect the transmission 20-way connector.
11 3. Disconnect the C3 (grey/clear) VCM connector. 3-7 Q
4. Measure the resistance between terminal C3-6 and
terminal C3-16.
Is the resistance within the specified range? Go to Step 16 Go to Step 12
12 Is the resistance greater than the specified value? 7Q Go to Step 13 Go to Step 14
1. Inspect circuit 1228 (RED/BLK) of the engine wiring
harness for an open condition.
2. Inspect circuit 1229 (LT BLU/WHT) of the engine
13 wiring harness for an open condition. — —
3. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find and correct an open condition? Go to Step 20
14 Is the resistance less than the specified value? 3 Q. Go to Step 15 —
1. Inspect circuit 1228 (RED/BLK) and circuit 1229
(LT BLU/WHT) of the engine wiring harness for a
shorted together condition.
15 2. Repair the circuits if necessary. — —
Refer to General Electrical Diagnosis Procedures.
Did you find and correct a shorted together condition? Go to Step 20
Using the J 39200 DMM and the J 35616 Connector Test
Adapter Kit, measure the resistance from terminal C3-6 to
16 ground. 9 Q.
Is the resistance less than the specified value? Go to Step 17 Go to Step 19
Transmission/Transaxle Automatic Transmission - 4L60-E 7-101
DTC P0748 Pressure Control Solenoid CKT Electrical (cont’d)
Step Action Value(s) Yes No
1. Inspect circuit 1228 (RED/BLK) of the engine wiring
harness for a short to ground condition.
2. Inspect circuit 1229 (LT BLU/WHT) of the engine
17 wiring harness for a short to ground condition. — —
3. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find and conect the short to ground condition? Go to Step 20
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
18 — —
Harness Replacement.
Is the replacement complete? Go to Step 20
Replace the VCM.
19 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 20
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Start the engine and ensure that the following
20 conditions are met: —
The difference between the PC Sol. Valve actual
return amperage and the desired amperage is less
than 0.16 amp.
Begin the
4. Select Specific DTC. Enter DTC P0748. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-102 Automatic Transmission - 4L60-E
DTC P0751 1-2 Shift Solenoid Valve Performance
Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The solenoid is a normally-open exhaust valve.
With the 2-3 Shift Solenoid Valve (2-3 SS Valve),
the 1-2 SS Valve allows four different shifting
combinations.
When the VCM detects a 1-1-4-4 or a 2-2-3-3 shift
pattern, depending on the state of the mechanical
failure, then DTC P0751 sets. DTC P0751 is a
type A DTC.
Conditions for Setting the DTC
. No TP Sensor DTCs P0122 or P0123.
. No VSS Assy. DTCs P0502 or P0503.
. No TCC Sol. Valve DTC P0740.
. No TCC Stuck ON DTC P0742.
. No 1-2 SS Valve DTC P0753.
. No 2-3 SS Valve DTC P0758.
. No 3-2 SS Valve Assy. DTC P0785.
. No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
• The gear range is D4.
• The vehicle speed is greater than
8 km/h (5 mph).
Transmission/Transaxle
42270
• The engine speed is greater than 450 RPM for
5 seconds.
• The transmission fluid temperature is
2 0 -1 3 0 -C (68-266 *F).
• Not in fuel cutoff.
All the above conditions are met three times and the
combination of Conditions 1,2,3 and 4 or Conditions
1,2,3 and 5 occurs three times:
Condition 1
• The VCM commands a 1-2 shift.
• The TP angle is 10-45%.
• The TP angle is constant within +/- 7%.
• The vehicle speed is 8-56 km/h (5-35 mph).
• Within 2 seconds, the engine speed in
2nd gear is 80 RPM greater than the last
speed in 1st gear.
Condition 2
• The VCM commands a 2-3 shift.
• The TP angle is 10-45%.
• The TP angle is constant within +/- 7%.
• The vehicle speed is 32-80 km/h (20-50 mph).
• Within 2 seconds, the engine speed in
3rd gear is 100 RPM less than the last
speed in 2nd gear.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-103
Condition 3 Conditions for Clearing the MIL/DTC
• The VCM commands a 3-4 shift. • The VCM turns OFF the MIL after three
• The TP angle is 10-45%. consecutive trips without a failure reported.
• The TP angle is constant within +/- 7%. • A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
• The vehicle speed is 48-105 km/h
(30-65 mph). the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• Within 2 seconds, the engine speed in 4th gear
is 10 RPM greater than the last speed in 3rd • The VCM cancels the DTC default actions
gear. when the fault no longer exists and the ignition
is OFF long enough in order to power down
Condition 4 the VCM.
• The VCM commands 4th gear.
Diagnostic Aids
. The TCC is ON.
• Verify that the transmission meets the
• The TP angle is 8-35%. specifications in the 4L60-E Shift Speed table.
• The speed ratio is 0.85 to 1.2 (speed ratio is • Other internal transmission failures may cause
engine speed divided by output speed). more than one shift to occur.
• The TCC slip speed is 200-1000 RPM for
4 seconds. 1-2 Shift 2-3 Shift
Condition 5 Gear Solenoid Solenoid Gear Ratio
• The VCM commands 4th gear. 1 ON ON 3.059:1
. The TCC is ON. 2 OFF ON 1.625:1
• The TP is 8-35%. 3 OFF OFF 1.000:1
• The speed ratio is 0.6 to 0.8.
4 ON OFF 0.696:1
• The TCC slip speed is -20 to +50 RPM
for 4 seconds. Test Description
Action Taken When the DTC Sets The numbers below refer to the step numbers on the
diagnostic table.
• The VCM illuminates the Malfunction Indicator
Lamp (MIL). 2. This step tests that the scan tool commanded
all shifts, that all shift solenoid valves
• The VCM commands D2 line pressure. responded correctly, but that all the shifts did
• The VCM freezes shift adapts from being not occur.
updated.
• DTC P0751 stores in VCM history.

DTC P0751 1-2 Shift Solenoid Valve Performance

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
2 Records from the VCM. —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in D4 range, under the following
conditions:
Accelerate the vehicle, ensuring that the VCM
commands 1st, 2nd, 3rd, and 4th gears. Go to
Was a 1-1-4-4 or 2-2-3-3 shift pattern detected? Go to Step 3 Diagnostic Aids
7-104 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0751 1-2 Shift Solenoid Valve Performance (cont’d)

Step Action Value(s) Yes No
Check the shift solenoid/hydraulic circuit for the following
conditions:
• An internal malfunction.
3 — —
• Damaged seals on one or both of the shift solenoid
valves.
Did you find and correct the condition? Go to Step 4
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 range under the following
4 conditions (only if traffic and road conditions permit): —
Hold the throttle at 20% and accelerate to 55 mph.
If the throttle moves more than 7%, stop the vehicle
and start over. Begin the
4. Select Specific DTC. Enter DTC P0751. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0753 1-2 Shift Solenoid Circuit Electrical
Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The solenoid is a normally-open exhaust valve. With
the 2-3 Shift Solenoid Valve (2-3 SS Valve), the
1-2 SS Valve allows four different shifting combinations.
The solenoid attaches to the control valve body within
the transmission. The 1-2 SS Valve receives ignition
voltage through circuit 1020. The Vehicle Control
Module (VCM) controls the solenoid by providing the
ground path on circuit 1222.
When the VCM detects a continuous open or short
to ground in the 1-2 SS Valve circuit or the
1-2 SS Valve, then DTC P0753 sets. DTC P0753
is a type A DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• All of the above conditions are met for
5 seconds and either of the following fail
conditions occurs for 5 seconds:
- The VCM commands the solenoid ON and
the voltage input remains high (B+).
- The VCM commands the solenoid OFF and
the voltage input remains low (0 volts).
Automatic Transmission - 4L60-E 7-105
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM commands D2 line pressure.
• The VCM inhibits 3-2 downshifts if the vehicle
speed is greater than 48 km/h (30 mph).
• The VCM freezes shift adapts from being
updated.
• DTC P0753 stores in VCM history.
Conditions for Clearing the MIL/DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
7-106 Automatic Transmission - 4L60-E Transmission/Transaxle

Diagnostic Aids Test Description

. Inspect the wiring at the VCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 4. This step tests the function of the 1-2 SS Valve
- A bent terminal and the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly).
- A backed out terminal
5. This step tests for power to the 1-2 SS Valve
- A damaged terminal from the ignition through the fuse.
- Poor terminal tension 7. This step tests the ability of the VCM and of
- A chafed wire the wiring to control the ground circuit.
- A broken wire inside the insulation 10. This step measures the resistance of the
- Moisture intrusion A/T Wiring Harness Assembly and of the
1-2 SS Valve.
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
• An open ignition feed circuit can cause multiple
DTCs to set.

1-2 Shift 2-3 Shift

Gear Solenoid Solenoid Gear Ratio
1 ON ON 3.059:1
2 OFF ON 1.625:1
3 OFF OFF 1.000:1
4 ON OFF 0.696:1

DTC P0753 1-2 Shift Solenoid Circuit Electrical

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic* (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Freeze Frame and Failure
2 Records for reference. Using the Clear Info function —
will erase the stored Freeze Frame and Failure
Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0758, P0785, and P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the TRANS fuse.
2. If the fuse is open, inspect the following components
for a short to ground condition.
Refer to General Electrical Diagnosis Procedures.
. Circuit 1020 (PNK)
3 —
• The solenoids
• The A/T Wiring Harness Assembly
3. Repair the circuit, the solenoids, and the harness
if necessary.
Did you find a short to ground condition? Go to Step 16 Go to Step 5
Transmission/Transaxle Automatic Transmission - 4L60-E 7-107
DTC P0753 1-2 Shift Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
Using the transmission output control function on the
scan tool, command the 1-2 SS Valve ON and OFF three
4 times while listening to the bottom of the transmission pan —
(a stethoscope may be necessary). Go to
Did the solenoid click when commanded? Diagnostic Aids Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
5 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test lamp ON? Go to Step 7 Go to Step 6
Repair the open or short to ground in ignition feed
circuit 1020 (PNK) to the 1-2 SS Valve.
6 — —
Refer to General Electrical Diagnosis Procedures.
Did you find and correct an open or short to ground? Go to Step 16
1. Install a test lamp between cavity E and cavity A of
the J 39775 Jumper Harness.
2. Using the transmission output control function,
command the 1-2 SS Valve ON and OFF three
7 —
times.
Does the test lamp illuminate when you command the shift
solenoid ON, and does the test lamp turn off when you
command the shift solenoid OFF? Go to Step 10 Go to Step 8
1. Inspect circuit 1222 (LT GRN) of the engine wiring
harness for an open or short to ground condition.
8 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 16 Go to Step 9
Replace the VCM.
9 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 16
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. With the J 39200 DMM and the J 35616 Connector
10 Test Adapter Kit, measure the resistance between 19-31 Q
terminal A and terminal E. Refer to connector
end view.
Is the resistance within the specified range? Go to Step 12 Go to Step 11
1. Disconnect the A/T Wiring Harness Assembly from
the 1-2 SS valve.
11 19-31 Q
2. Measure the resistance of the 1-2 SS Valve.
Is the resistance within the specified range? Go to Step 14 Go to Step 15
Measure the resistance between terminals A and E
12 and ground. 250 KO Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
7-108 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0753 1-2 Shift Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
1. Disconnect the A/T Wiring Harness Assembly from
the 1-2 SS Valve.
13 2. Measure the resistance from the component’s 250 KQ
terminals to ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and
14 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 16
Replace the 1-2 SS Valve.
15 Refer to Control and Shift Solenoids Replacement. — —
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 and ensure that the following
conditions are met:
16 • The VCM commands the 1-2 SS Valve ON and —
the voltage input drops to zero.
• The VCM commands the 1-2 SS Valve OFF and
the voltage input increases to B+.
• All conditions are met for 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0753. diagnosis again.
Has the test run and passed? System OK Go to Step 1.
Transmission/Transaxle
DTC P0756 2-3 Shift Solenoid Valve Performance
Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valves. The
solenoid is a normally-open exhaust valve. With
the 1-2 Shift Solenoid Valve (1-2 SS Valve), the
2-3 SS Valve allows four different shifting
combinations.
When the VCM detects a 1-2-2-1 or a 4-3-3-4 shift
pattern, depending on the state of the mechanical
failure, then DTC P0756 sets. DTC P0756 is a
type A DTC.
Conditions for Setting the DTC
• No TP Sensor DTCs P0122 or P0123.
. No VSS Assy. DTCs P0502 or P0503.
. No TFT Sensor DTCs P0711, P0712 or P0713.
. No TCC Sol. Valve DTC P0740.
. No TCC Stuck ON DTC P0742.
. No 1-2 SS Valve DTC P0753.
. No 2-3 SS Valve DTC P0758.
. No 3-2 SS Valve Assy. DTC P0785.
• No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
Automatic Transmission - 4L60-E 7-109
42270
• The vehicle speed is greater than
8 km/h (5 mph).
• The gear range is D4.
• The engine vacuum is 0-105 kPa.
• The engine torque is 5-450 lb ft.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• The transmission fluid temperature is
20-130 *C (68-266 *F).
• All of the above conditions are met three times
and the combination of Conditions 1 and 2 or
Conditions 2 and 3 occurs three times.
Condition 1
• The TP angle is greater than 15%.
• First gear is commanded for 2 seconds.
• The speed ratio is 0.5 to 3.0 (speed ratio
is the engine speed divided by the output
speed).
• The transmission output speed is
400-1500 RPM.
• The TCC slip speed is -100 to -3000 RPM
for 1 second.
7-110 Automatic Transmission - 4L60-E Transmission/Transaxle
Condition 2 Conditions for Clearing the MIL/DTC
• The TP angle is 13-50%. • The VCM turns OFF the MIL after three
• The TP angle is within +/- 7%. consecutive trips without a failure reported.
• Third gear is commanded for 2 to 5 seconds. • A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
• The speed ratio in 3rd gear does not drop
the VCM history if the vehicle completes 40
more than 0.3 from the last speed ratio in
warm-up cycles without a failure reported.
2nd gear.
• The VCM cancels the DTC default actions
• The TCC slip speed in 3rd gear remains
when the fault no longer exists and the ignition
300 RPM higher than the last TCC slip
is OFF long enough in order to power down
speed in 2nd gear.
the VCM.
• All conditions met for 1.5 seconds.
Condition 3 Diagnostic Aids
• The TP angle is greater than 13%. • Verify that the transmission meets the
specifications in the 4L60-E Shift Speed table.
• Fourth gear is commanded for 1 second.
• Other internal transmission failures may cause
• The speed ratio is 2.05 to 8.0. more than one shift to occur.
• The transmission output speed is
1400-2500 RPM. 1-2 Shift 2-3 Shift
• The TCC slip speed is 1000-4000 RPM Gear Solenoid Solenoid Gear Ratio
for 1 second. 1 ON ON 3.059:1
Action Taken When the DTC Sets 2 OFF ON 1.625:1
• The VCM illuminates the Malfunction Indicator 3 OFF OFF 1.000:1
Lamp (MIL).
4 ON OFF 0.696:1
• The VCM commands third gear only.
• The VCM inhibits TCC engagement. Test Description
• The VCM commands maximum line pressure. The numbers below refer to the step numbers on the
• The VCM freezes shift adapts from being diagnostic table.
updated. 2. This step verifies that the scan tool commanded
• DTC P0756 stores in VCM history. all shifts, that all shift solenoids responded
correctly, but all the shifts did not occur.

DTC P0756 2-3 Shift Solenoid Valve Performance

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
2 Records from the VCM. —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in D4 range, under the following
conditions:
Accelerate the vehicle, ensuring that the VCM
commands 1st, 2nd, 3rd, and 4th gears. Go to
Did you detect a 1-2-2-1 or 4-3-3-4 shift pattern? Go to Step 3 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L60-E 7-111
DTC P0756 2-3 Shift Solenoid Valve Performance (cont’d)
Step Action Value(s) Yes No
Check the shift solenoid/hydraulic circuit for the following
conditions:
3 • An internal malfunction — —
• Damaged seals on the shift solenoid valves.
Did you find and correct the condition? Go to Step 4
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 under the following conditions
(only if traffic and road conditions permit):
4 • Hold the throttle at 50% and accelerate to —
64 km/h (40 mph).
• Stop the vehicle, engine idling.
• Hold the throttle at 25% and accelerate to
80 km/h (50 mph).
Begin the
4. Select Specific DTC. Enter DTC P0756. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-112 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P0758 2-3 Shift Solenoid Circuit Electrical

The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valves. The
solenoid is a normally-open exhaust valve. With the
1-2 Shift Solenoid Valve (1-2 SS Valve), the 2-3 SS
Valve allows four different shifting combinations. The
solenoid attaches to the control valve body within the
transmission. The 2-3 SS Valve receives ignition
voltage through circuit 1020. The Vehicle Control
Module (VCM) controls the solenoid by providing the
ground path on circuit 1223.
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM commands third gear only.
• The VCM commands maximum line pressure.
• The VCM inhibits TCC engagement.
• The VCM freezes shift adapts from being
updated.
• DTC P0758 stores in VCM history.

When the VCM detects a continuous open or short Conditions for Clearing the MIL/DTC
to ground in the 2-3 SS Valve circuit or the 2-3 SS
• The VCM turns OFF the MIL after three
Valve, then DTC P0758 sets. DTC P0758 is a type
consecutive trips without a failure reported.
A DTC.
• A scan tool can clear the DTC from the
Conditions for Setting the DTC VCM history. The VCM clears the DTC from
• The system voltage is 10-16 volts. the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The engine speed is greater than 450 RPM
for 5 seconds. • The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
• Not in fuel cutoff.
is OFF long enough in order to power down
• All of the above conditions are met for the VCM.
5 seconds and either of the following fail
conditions occurs for 5 seconds:
- The VCM commands the solenoid ON and
the voltage input remains high (B+).
- The VCM commands the solenoid OFF and
the voltage input remains low (0 volts).
Transmission/Transaxle Automatic Transmission - 4L60-E 7-113
Diagnostic Aids Test Description
• Inspect the wiring at the VCM, the transmission The numbers below refer to the step numbers on
connector and all other circuit connecting points the diagnostic table.
for the following conditions: 4. This step tests the function of the 2-3 SS Valve
- A bent terminal and the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly).
- A backed out terminal
5. This step tests for power to the 2-3 SS Valve
- A damaged terminal from the ignition through the fuse.
- Poor terminal tension 7. This step tests the ability of the VCM and of
- A chafed wire the wiring to control the ground circuit.
- A broken wire inside the insulation 10. This step measures the resistance of the
- Moisture intrusion A/T Wiring Harness Assembly and of the
2-3 SS Valve.
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.

1-2 Shift 2-3 Shift

Gear Solenoid Solenoid Gear Ratio
1 ON ON 3.059:1
2 OFF ON 1.625:1
3 OFF OFF 1.000:1
4 ON OFF 0.696:1

DTC P0758 2-3 Shift Solenoid Circuit Electrical

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
2 Failure Records for reference. Using the Clear Info —

function will erase the stored Freeze Frame and

Failure Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0785 and P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the TRANS fuse.
2. If the fuse is open, inspect the following components
for a short to ground condition.
Refer to General Electrical Diagnosis Procedures.
• Circuit 1020 (PNK)
3 —
• The solenoids
• The A/T Wiring Harness Assembly
3. Repair the circuit, the solenoids, and the harness
if necessary.
Did you find a short to ground condition? Go to Step 16 Go to Step 5
7-114 Automatic Transmission - 4L60-E TransmissiorVTransaxle

DTC P0758 2-3 Shift Solenoid Circuit Electrical (cont’d)

Step Action Value(s) Yes No
Using the transmission output control function on the
scan tool, command the 2-3 SS Valve ON and OFF three
4 times while listening to the bottom of the transmission —
pan (a stethoscope may be necessary). Go to
Did the solenoid click when commanded? Diagnostic Aids Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the
engine side of the 20-way connector.
5 —
4. With the engine OFF, turn the ignition switch to
the RUN position.
5. Connect a test lamp from J 39775 Jumper
Harness cavity E to ground.
Is the test lamp ON? Go to Step 7 Go to Step 6
Repair the open or short to ground in ignition feed
circuit 1020 (PNK) to the 2-3 SS Valve.
6 Refer to General Electrical Diagnosis Procedures. — —
Did you find and correct an open or short to ground
condition? Go to Step 16
1. Install a test lamp between cavity E and cavity B of
the J 39775 Jumper Harness.
2. Using the transmission output control function,
command the 2-3 SS Valve ON and OFF three
7 —
times.
Does the test lamp illuminate when you command the shift
solenoid ON, and does the test lamp turn off when you
command the shift solenoid OFF? Go to Step 10 Go to Step 8
1. Inspect circuit 1223 (YEL/BLK) of the engine wiring
harness for an open or short to ground condition.
8 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 16 Go to Step 9
Replace the VCM.
9 Refer to VCM Replacement/Programming. —■ —

Is the replacement complete? Go to Step 16

1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. With the J 39200 DMM and J 35616 Connector
10 Test Adapter Kit, measure the resistance between 19-31 G
terminal B and terminal E. Refer to connector
end view.
Is the resistance within the specified range? Go to Step 12 Go to Step 11
1. Disconnect the A/T Wiring Harness Assembly from
the 2-3 SS valve.
11 19-31 G
2. Measure the resistance of the 2-3 SS Valve.
Is the resistance within the specified range? Go to Step 14 Go to Step 15
Measure the resistance between terminals B and E
12 and ground. 250 K G Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
TransmissiorVTransaxle Automatic Transmission - 4L60-E 7-115
DTC P0758 2-3 Shift Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
1. Disconnect the A/T Wiring Harness Assembly
from the 2-3 SS Valve.
13 2. Measure the resistance from the component’s 250 K n
terminals to ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and
14 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 16
Replace the 2-3 SS Valve.
15 Refer to Control and Shift Solenoids Replacement. — —

Is the replacement complete? Go to Step 16

In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 and ensure the following
conditions are met:
16 • The VCM commands the 2-3 SS Valve ON and —

the voltage input drops to zero.

• The VCM commands the 2-3 SS Valve OFF and
the voltage input increases to B+.
• All conditions are met for 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0758. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-116 Automatic Transmission - 4L60-E
DTC P0785 3-2 Shift Solenoid Circuit Electrical
Circuit Description
The 3-2 Shift Solenoid Valve Assembly (3-2 SS
Valve Assy.) is a normally-closed, 3-port, on/off
device that controls the 3-2 downshift. The solenoid
attaches to the control valve body within the
transmission. The solenoid receives ignition voltage
through circuit 1020. The Vehicle Control Module
(VCM) controls the solenoid by providing a ground
path on circuit 687. During a 3-2 downshift, the
2- 4 band applies as the 3-4 clutch releases. The
VCM varies the timing between the 3-4 clutch
release and the 2-4 band apply, depending on the
vehicle speed and the throttle position.
When the VCM detects a continuous open or short
to ground in the 3-2 SS Valve Assy, circuit or the
3- 2 SS Valve Assy., then DTC P0785 sets.
DTC P0785 is a type A DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
Transmission/Transaxle
• All of the above conditions are met for
5 seconds, and either of the following fail
conditions occurs for 5 seconds:
- The VCM commands the solenoid ON and
the voltage input remains high (B+).
- The VCM commands the solenoid OFF and
the voltage input remains low (0 volts).
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction
Indicator Lamp (MIL).
• The VCM commands a soft landing to
third gear.
• The VCM commands maximum line pressure.
• The VCM inhibits TCC engagement.
• The VCM inhibits 4th gear if the transmission
is in hot mode.
• The VCM freezes shift adapts from being
updated.
• DTC P0785 stores in VCM history.
Transmission/Transaxle
Conditions for Clearing the MIL7DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
Automatic Transmission - 4L60-E 7-117
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
Test Description
The item numbers below refer to the step numbers
on the diagnostic table.
4. This step tests the ability of the VCM to control
the solenoid.
5. This step tests for voltage to the solenoid.
7. This step tests the ability of the VCM and the
wiring to control the ground circuit.
10. This step measures the resistance of the
Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly),
and the 3-2 SS Valve Assy.

DTC P0785 3-2 Shift Solenoid Circuit Electrical

Step Action Value(s) Yes No
Were you sent here from the Powertrain On-Board Go to
1 Diagnostic (OBD) System Check? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
2 Failure Records for reference. Using the Clear Info —
function will erase the stored Freeze Frame and
Failure Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0758 and P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the TRANS fuse.
2. If the fuse is open, inspect the following components
for a short to ground:
• Circuit 1020 (PNK)
• The solenoids
3 —
• The A/T Wiring Harness Assembly
3. Repair the circuit, the solenoids, and the harness
if necessary. Refer to General Electrical Diagnosis
Procedures.
Did you find a short to ground condition? Go to Step 16 Go to Step 5
Using the transmission output control function on the
scan tool, command the 3-2 SS Valve Assy. ON and
4 OFF three times, while listening to the bottom of the —
transmission pan (a stethoscope may be necessary). Go to
Does the solenoid click when commanded? Diagnostic Aids Go to Step 5
7-118 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P0785 3-2 Shift Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
5 —
4. With the engine OFF, turn the ignition switch to
the RUN position.
5. Connect a test lamp from J 39775 Jumper
Harness cavity E to ground.
Does the test lamp illuminate? Go to Step 7 Go to Step 6
Repair the open or short to ground in ignition feed
circuit 1020 (PNK) to the 3-2 SS Valve Assy.
6 Refer to General Electrical Diagnosis Procedures. — —
Did you find and correct an open or short to ground
condition? Go to Step 16
1. Install a test lamp between cavity E and cavity S of
the J 39775 Jumper Harness.
2. Using the transmission output control function on the
7 scan tool, command the 3-2 SS Valve Assy. ON and —
OFF three times.
Does the test lamp illuminate when you command the shift
solenoid ON, and turn OFF when you command OFF? Go to Step 10 Go to Step 8
1. Inspect circuit 687 (WHT) of the engine wiring
harness for an open or short to ground.
8 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 16 Go to Step 9
Replace the VCM.
9 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 16
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Using the J 39200 DMM and the J 35616 Connector
10 Test Adapter Kit, measure the resistance between 20-32 Q.
the terminal E and terminal S of the J 39775 Jumper
Harness. Refer to connector end view.
Is the resistance within the specified range? Go to Step 12 Go to Step 11
1. Disconnect the A/T Wiring Harness Assembly
from the 3-2 SS Valve Assy.
11 20-32 Q
2. Measure the resistance of the 3-2 SS Valve Assy.
Is the resistance within the specified range? Go to Step 14 Go to Step 15
1. Measure the resistance between terminal S
and ground.
12 2. Measure the resistance between terminal E 250 KQ
and ground. Go to
Are both measurements greater than the specified value? Diagnostic Aids Go to Step 13
1. Disconnect the A/T Wiring Harness Assembly from
the 3-2 SS Valve Assy.
13 2. Measure the resistance between the component’s 250 K ft
terminals and ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Transmission/Transaxle Automatic Transmission - 4L60-E 7-119
DTC P0785 3-2 Shift Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
14 — —
Harness Replacement.
Is the replacement complete? Go to Step 16
Replace the 3-2 Shift Solenoid Valve Assembly.
15 Refer to Control and Shift Solenoids Replacement. — —
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D3 or D4 and perform a
3-2 downshift. Ensure that the following conditions
are met:
16 —
• The VCM commands the 3-2 shift solenoid
ON, and the voltage input drops to zero.
• The VCM commands the 3-2 shift solenoid
OFF, and the voltage input increases to B+.
• All conditions are met for 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0785. diagnosis again.
Has the test am and passed? System OK Go to Step 1
7-120 Automatic Transmission - 4L60-E
DTC P1810 TFP Valve Position Sw CKT Malfunction
Circuit Description
The Automatic Transmission Fluid Pressure Manual
Valve Position Switch (TFP Val. Position Sw.)
consists of five pressure switches (two
normally-closed and three normally-open), and a
Transmission Fluid Temperature (TFT) sensor
combined into one unit. The combined unit mounts
on the valve body. The Vehicle Control Module
(VCM) supplies the battery voltage for each range
signal. By grounding one or more of these circuits
through various combinations of the pressure
switches, the VCM detects which manual valve
position you select. The VCM compares the actual
voltage combination of the switches to a TFP Val.
Position Sw. combination chart stored in memory.
The TFP Val. Position Sw. cannot distinguish
between Park and Neutral because the monitored
valve body pressures are identical. With the engine
OFF and the ignition switch in the RUN position, the
TFP Val. Position Sw. indicates Park/Neutral.
Transmission/Transaxle
A
iOBDIlk,
201904
Disconnecting the transmission 20-way connector
removes the ground potential for the three range
signals to the VCM. In this case, with the engine
OFF, and the ignition switch in the RUN position,
D2 will be indicated.
When the VCM detects an invalid state of the
TFP Val. Position Sw. or the TFP Val. Position Sw.
circuit by deciphering the TFP Val. Position Sw. inputs,
then DTC P1810 sets. DTC P1810 is a type B DTC.
Conditions for Setting the DTC
DTC P1810 sets if any of the following fail
Conditions occurs two consecutive times:
Condition 1 detects an illegal switch
combination.
Condition 2 detects D2, D4 or Rev during
an engine start.
Condition 3 detects Park or Neutral when
the vehicle should be in D4.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-121
Condition 1 Diagnostic Aids
• The system voltage is 10-16 volts. • Refer to TFP Val. Position Sw. Logic table for
• The engine speed is greater than 450 RPM the normal range signals and the illegal
for 5 seconds. combinations. On the table, ON is 0 volts,
• Not in fuel cutoff. OFF is B+.
• The VCM detects an illegal TFP Val. Position • Inspect the wiring at the VCM, the transmission
Sw. state. connector and all other circuit connecting points
• All conditions met for 60 seconds. for the following conditions;
Condition 2 - A bent terminal
. No VSS Assy. DTCs P0502 or P0503. - A backed out terminal
• The system voltage is 10-16 volts. - A damaged terminal
• The engine speed is less than 80 RPM for - Poor terminal tension
0.1 second; then - A chafed wire
the engine speed is 80-550 RPM for - A broken wire inside the insulation
0.1 second; then
- Moisture intrusion
the engine speed is greater than 550 RPM. - Corrosion
• The vehicle speed is less than 3 km/h (2 mph).
• When diagnosing for an intermittent short or
• The detected gear range is D2, D4 or Rev. open condition, massage the wiring harness
during an engine startup. while watching the test equipment for a change.
• All conditions met for 5 seconds. • Refer to TFP Valve Position Switch Resistance
Condition 3 Check or Functional Test Procedure for further
• No VSS Assy. DTCs P0502 or P0503. information.
• The system voltage is 10-16 volts.
• The TP angle is 10-50%. TFP Valve Position Switch Logic
• The VCM commands fourth gear. Gear Range Range Range
• The engine speed is greater than 450 RPM Position Signal A Signal B Signal C
for 5 seconds. Park OFF ON OFF
• Not in fuel cutoff. Reverse ON ON OFF
• The engine torque is 40-400 lb ft. Neutral OFF ON OFF
• The speed ratio is 0.6-0.75 (speed ratio is Overdrive OFF ON ON
engine speed divided by transmission output
Dr 3 OFF OFF ON
speed).
• The TCC is locked ON. Dr 2 OFF OFF OFF
• The detected gear range is Park or Neutral. Low ON OFF OFF
• All conditions met for 10 seconds. Illegal ON OFF ON
Illegal ON ON ON
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL). Test Description
• The VCM commands D2 line pressure. The numbers below refer to the step numbers on the
diagnostic table.
• The VCM commands a D4 shift pattern.
• The VCM freezes shift adapts from being 3. This step compares the indicated range signal
updated. to the selected manual valve.
• DTC P1810 stores in VCM history. 4. This step tests for correct voltage from the
VCM to the transmission 20-way connector.
Conditions for Clearing the MIUDTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the VCM.
7-122 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P1810 TFP Valve Position Sw CKT Malfunction

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the following inspections:
• Ensure the transmission linkage from the select lever
2 to the manual valve is adjusted properly. — —
• Perform the Transmission Fluid Checking Procedure.
Did you perform the inspections? Go to Step 3
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
Failure Records for reference. Using the Clear Info
function will erase the stored Freeze Frame and
Failure Records from the VCM.
3 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTC(s).
4. While the engine is idling at the normal operating
temperature, apply the brake pedal.
5. Select each transmission range: P, R, N, D4, D3,
D2 and D1.
Does each selected transmission range match the scan
tool TFP Switch A/B/C display? Go to
Refer to TFP Val. Position Sw. Logic table. Diagnostic Aids Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the transmission 20-way connector.
4 4. With the engine OFF, turn the ignition switch to the —
RUN position.
5. Using the J 39200 Digital Multimeter and the J 35616
Connector Test Adapter Kit, check the voltage at
connector terminals N, R and P.
Is B+ displayed on all three circuits? Go to Step 6 Go to Step 5
Inspect the circuits that did not indicate B+ for an open or
a short to ground condition.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 9 Go to Step 7
Verify that circuits 1224 (PNK), 1225 (DK BLU) and
1226 (RED) are not shorted together. Use a J 36169-A Refer to
Fused Jumper Wire to ground on each circuit while TFP Valve
6 monitoring the scan tool TFP Switch A/B/C display. —
Position Switch
When a range signal circuit is grounded, are any other Resistance
range signal circuits affected? Go to Step 8 Check.
Replace the VCM.
7 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 9
Repair the affected wiring as necessary.
8 Refer to General Electrical Diagnosis Procedures. — —
Is the repair complete? Go to Step 9
Transmission/Transaxle Automatic Transmission - 4L60-E 7-123
DTC P1810 TFP Valve Position Sw CKT Malfunction (cont’d)
Step Action Value(s) Yes No
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
3.1. With the engine OFF, turn the ignition switch
to the RUN position for at least 2 seconds.
9 —
3.2. Start the vehicle and idle for 5 seconds.
3.3. Drive in D4 until the TCC locks for
10 seconds.
3.4. Continue to run the engine for at least
60 seconds from startup.
Begin the
4. Select Specific DTC. Enter DTC P1810. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-124 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P1860 TCC PWM Solenoid Circuit Electrical

Circuit Description • The VCM commands first gear.

The Torque Converter Clutch Pulse Width Modulation • The TCC duty cycle is less than 10% or
Solenoid Valve (TCC PWM Sol. Valve) controls the greater than 90%.
fluid acting on the converter clutch valve. The • All of the above conditions are met for
converter clutch valve controls the TCC application 5 seconds and either of the following fail
and release. The solenoid attaches to the control conditions occurs for 5 seconds:
valve body within the transmission. The solenoid - The VCM commands the solenoid ON (90%)
receives ignition voltage through circuit 1020. The and the voltage input remains high (B+).
Vehicle Control Module (VCM) controls the solenoid
by providing a ground path on circuit 418. Current - The VCM commands the solenoid OFF (0%)
flows through the solenoid coil according to the duty and the voltage input remains low (0 volt).
cycle (percentage of ON and OFF time). The
Action Taken When the DTC Sets
TCC PWM Sol. Valve provides a smooth
engagement of the TCC by operating during a duty • The VCM illuminates the Malfunction Indicator
cycle percent of ON time. Lamp (MIL).
When the VCM detects a continuous open or short • The VCM inhibits TCC engagement.
to ground in the TCC PWM Sol. Valve circuit or the • The VCM inhibits 4th gear if the transmission is
TCC PWM Sol. Valve, then DTC P1860 sets. in hot mode.
DTC P1860 is a type A DTC. • The VCM freezes shift adapts from being
updated.
Conditions for Setting the DTC
• DTC P1860 stores in VCM history.
• The system voltage is 10-16 volts.
• The engine speed is greater than 450 RPM for
5 seconds.
• Not in fuel cutoff.
Transmission/Transaxle
Conditions for Clearing the MIL/DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
Automatic Transmission - 4L60-E 7-125
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open condition, massage the wiring harness
while watching the test equipment for a change.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for voltage to the solenoid.
6. This step tests the ability of the VCM and
wiring to control the ground circuit.
8. This step tests the resistance of the
TCC PWM Sol. Valve and the Automatic
Transmission Wiring Harness Assembly
(A/T Wiring Harness Assembly).

DTC P1860 TCC PWM Solenoid Circuit Electrical

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
2 Failure Records for reference. Using the Clear Info —
function will erase the stored Freeze Frame and
Failure Records from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0758 and P0785 also set? Go to Step 3 Go to Step 4
1. Inspect the TRANS fuse.
2. If the fuse is open, inspect circuit 1020 (PNK), the
solenoids and the A/T Wiring Harness Assembly for
3 a short to ground. Repair the circuit, the solenoids —
and the harness if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 15 Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install J 39775 Jumper Harness on the engine
side of the 20-way connector.
4 —
4. With the engine OFF, turn the ignition switch to
the RUN position.
5. Connect a lest lamp from J 39775 Jumper
Harness cavity E to ground.
Is the test lamp on? Go to Step 6 Go to Step 5
7-126 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P1860 TCC PWM Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
Repair the open or short to ground in ignition feed
circuit 1020 (PNK) to the TCC PWM Sol. Valve.
5 — —
Refer to General Electrical Diagnosis Procedures.
Is the repair complete? Go to Step 15
1. Install the test lamp from cavity E to cavity U of the
J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the TCC PWM Sol. Valve ON
6 —
and OFF three times.
Does the test lamp illuminate when the TCC PWM Sol.
Valve is commanded ON, and turn OFF when
commanded OFF? Go to Step 8 Go to Step 7
1. Inspect circuit 418 (BRN) of the engine wiring
harness for an open or short to ground condition.
7 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 15 Go to Step 9
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Using the J 39200 Digital Multimeter and the J 35616
8 Connector Test Adapter Kit, measure the resistance 10-15 Q
between terminal E and terminal U. Refer to
connector end view.
Is the resistance within the specified range? Go to Step 11 Go to Step 10
Replace the VCM.
9 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 15
1. Disconnect the A/T Wiring Harness Assembly at the
TCC PWM Sol. Valve.
10 10-15 Cl
2. Measure the resistance of the TCC PWM Sol. Valve.
Is the resistance within the specified range? Go to Step 13 Go to Step 14
Measure the resistance between terminal E and ground,
11 and between terminal U and ground. 250 K Cl Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 12
1. Disconnect the A/T Wiring Harness Assembly at the
TCC PWM Sol. Valve.
12 2. Measure the resistance between each of the 250 KQ
component terminals and ground.
Are both readings greater than the specified value? Go to Step 13 Go to Step 14
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and
13 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 15
Replace the TCC PWM Sol. Valve.
Refer to TCC PWM Solenoid, TCC Solenoid, and
14 — —
Wiring Harness Replacement.
Is the replacement complete? Go to Step 15
Transmission/Transaxle Automatic Transmission - 4L60-E 7-127
DTC P1860 TCC PWM Solenoid Circuit Electrical (cont’d)
Step Action Value(s) Yes No
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 with the TCC On. Ensure
that the following conditions are met:
15 • The VCM commands the TCC PWM Sol. Valve —
ON, and the voltage input drops to zero.
• The VCM commands the TCC PWM Sol. Valve
OFF, and the voltage input increases to B+.
• All conditions are met for 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P1860. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-128 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P1870 Transmission Component Slipping

42275

Shift Solenoid Torque

TCC TCC PWM Forward Converter
Range Gear 1-2 2-3 Solenoid Solenoid 2-4 Band Clutch 3-4 Clutch Clutch
Overdrive 4th ON OFF ON 90% (ON) Applied Applied Applied Applied

Circuit Description . No TCC Sol. Valve DTC P0740.

The Vehicle Control Module (VCM) monitors the
difference between engine speed and transmission
output speed. In D3 drive range with the TCC
engaged, the engine speed should closely match the
transmission output speed. In D4 drive range, with
the TCC engaged, the TCC slip speed should be
-20 to +50 RPM. The table above indicates solenoid
states and transmission components that apply
during 4th gear with the TCC commanded ON.
When the VCM detects excessive TCC slip when the
TCC should be engaged, then DTC P1870 sets.
DTC P1870 is a type B DTC.
Conditions for Setting the DTC
DTC P1870 sets if the following conditions are
met for three TCC cycles with reported excessive
TCC slip conditions, two consecutive times.
. No TP Sensor DTCs P0122 or P0123.
. No VSS Assy. DTCs P0502 or P0503.
. No TFT Sensor DTCs P0711, P0712 or P0713.
. No 1-2 SS Valve DTC P0753.
. No 2 -3 SS Valve DTC P0758.
. No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• The vehicle speed is 48-112 km/h (30-70 mph).
• The engine speed is 1500-3000 RPM.
• The speed ratio is 0.69-0.88 (speed ratio is
engine speed divided by the output speed).
• The engine torque is 50-400 lb ft.
• The engine vacuum is 0-150 kPa.
• The gear range is D4.
• Not in 1st gear.
• The TP angle is 9-35%.
. The TFT is 20-130 ‘ C (68-266 * F).
Transmission/Transaxle
• The shift solenoid performance diagnostic
counters are zero.
• The TCC is ON for 5 seconds.
• The TCC is at maximum duty cycle (95%)
for 5 seconds.
• The TCC slip speed is 130-800 RPM.
• All conditions met for 7 seconds.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM inhibits TCC engagement.
• The VCM commands maximum line pressure.
• The VCM inhibits 4th gear if the transmission
is in hot mode.
• The VCM freezes shift adapts from being
updated.
• DTC P1870 stores in VCM historv.
Automatic Transmission - 4L60-E 7-129
Conditions for Clearing the MIL7DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
Internal transmission failures could set a
DTC P1870.
Test Description
The numbers below refer to the step numbers on
the diagnostic table.
3. This step tests the torque converter for slippage
while in a commanded lock-up state.

DTC P1870 Transmission Component Slipping

Step Action Value(s) Yes No
Go to
1 Was the Powertrain On-Board Diagnostic (OBD) System — Powertrain OBD
Check performed? Go to Step 2 System Check
Go to
Perform the transmission fluid checking procedure.
Transmission
2 Refer to Transmission Fluid Checking Procedure. —
Fluid Checking
Did you perform the fluid checking procedure? Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
Failure Records for reference. Using the Clear Info
function will erase the stored Freeze Frame and
3 130-800 RPM
Failure Records from the VCM.
3. Record the DTC Freeze Frame and Failure
Records, then clear the DTC(s).
4. Drive the vehicle in 4th gear with the
TCC commanded On.
Is the TCC Slip Speed within the specified range Go to
for 7 seconds? Go to Step 4 Diagnostic Aids
1. Inspect the Torque Converter Clutch Solenoid Valve
(TCC Sol. Valve) for the following conditions:
• internal malfunction (such as sediment
or damage)
• Damaged seals

4 2. Inspect the Torque Converter Clutch Pulse Width

—
Modulation Solenoid Valve (TCC PWM Sol. Valve)
for the following conditions:
• Internal malfunction (such as sediment or
damage)
• Damaged seals
Did you find a condition? Go to Step 13 Go to Step 5
7-130 Automatic Transmission - 4L60-E Transmission/Transaxle

DTC P1870 Transmission Component Slipping (cont’d)

Step Action Value(s) Yes No
1. Inspect the 1-2 Shift Solenoid Valve (1-2 SS Valve)
for the following conditions:
• Internal malfunction (such as sediment or
damage)
• Damaged seals
5 2. Inspect the 2-3 Shift Solenoid Valve (2-3 SS Valve) —
for the following conditions:
• Internal malfunction (such as sediment or
damage)
• Damaged seals
Did you find a condition? Go to Step 13 Go to Step 6
Inspect the valve body assembly for a stuck TCC
signal valve.
6
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find a condition? Go to Step 13 Go to Step 7
Inspect the torque converter assembly for the following
conditions:
7 • Stator roller clutch not holding —
• Internal damage
Did you find a condition? Go to Step 13 Go to Step 8
Inspect the oil pump assembly for the following conditions:
• A stuck converter clutch valve
• The converter clutch valve is assembled backwards
• A mispositioned converter clutch valve retaining ring
• A mispositioned pump to case gasket
8 • Restricted orifice cup plugs —
• Damaged orifice cup plugs
• Over-tightened, or unevenly tightened pump body to
cover bolts
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find a condition? Go to Step 13 Go to Step 9
inspect the input housing and shaft assembly for the
following conditions:
• Cut turbine shaft O-ring seal
• Damaged turbine shaft O-ring seal
9 —
• Restricted turbine shaft retainer and ball assembly
• Damaged turbine shaft retainer and ball assembly
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find a condition? Go to Step 13 Go to Step 10
Transmission/Transaxle Automatic Transmission - 4L60-E 7-131
DTC P1870 Transmission Component Slipping (cont’d)
Step Action Value(s) Yes No
Inspect the 2-4 band assembly for the following conditions:
• Worn 2-4 band
• Damaged 2-4 band
• Mispositioned 2-4 band
• Misassembled 2-4 band
• The band anchor pin is not engaged.
• Restricted apply passages in the 2-4 servo assembly
• Blocked apply passages in the 2-4 servo assembly
• Nicks or burrs on the servo pin
• Nicks or burrs on the pin bore in the case
• Damaged fourth servo piston
• Misassembled fourth servo piston
• Damaged band apply pin
10 —
• Incorrect band apply pin
• Damaged servo bore in the case
• Missing piston seals
• Cut piston seals
• Damaged piston seals
• Porosity in the pistons
• Porosity in the cover
• Porosity in the case
• Damaged piston seal grooves
• Plugged orifice cup plug
• Missing orifice cup plug
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find a condition? Go to Step 13 Go to Step 11
Inspect the forward clutch assembly for the following
conditions:
• Worn clutch plates
• Porosity in the forward clutch piston
• Damaged forward clutch piston
• Missing forward clutch piston inner and outer seals
• Cut forward clutch piston inner and outer seals
• Damaged forward clutch piston inner and outer seals
• Missing input housing to forward clutch housing
O-ring seal
11 • Cut input housing to forward clutch housing —
O-ring seal
• Damaged input housing to forward clutch housing
O-ring seal
• Damaged forward clutch housing
• Damaged forward clutch housing retainer and ball
assembly
• Forward clutch housing retainer and ball assembly is
not sealing.
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find a condition? Go to Step 13 Go to Step 12
7-132 Automatic Transmission - 4L60-E Transmission/Transaxle
DTC P1870 Transmission Component Slipping (cont’d)
Step Action Value(s) Yes No
Inspect the 3-4 clutch assembly for the following
conditions:
• Worn clutch plates
• Porosity in the 3-4 clutch piston
• Damaged 3-4 clutch piston
• Missing 3-4 clutch inner and outer seals
• Cut 3-4 clutch inner and outer seals
12 • Damaged 3-4 clutch inner and outer seals —
• Damaged 3-4 clutch spring assembly
• Damaged 3-4 clutch apply ring
• Damaged piston seal grooves
• Plugged orifice cup plug
• Missing orifice cup plug
Refer to Transmission Overhaul Procedure, in Unit Repair. Go to
Did you find a condition? Go to Step 13 Diagnostic Aids
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
13 • Drive the vehicle in D4, with the TCC ON, and a —
throttle position of 9-35%.
• Ensure that the TCC Slip Speed is -20 to
+50 RPM for at least 7 seconds. Begin the
4. Select Specific DTC. Enter DTC P1870. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/!ransaxle Automatic Transmission - 4L60-E 7-133

DTC P1875 4 Wheel Drive Low Switch CKT Malfunction

0.8 GRY/BLK 1694

; C120
0.5 GRY/BLK 1694 B
T "* Transfer
/ 1Case
I ■. • i
Switch
«- - h *

Vehicle
1 Control
4WD Low
Signal 1 Module (VCM)
1 A
l ________ Ignition
r _________________
V o lta g e
j
42276

Circuit Description • The vehicle speed is greater than

The Four Wheel Drive (4WD) low circuit consists of
the Vehicle Control Module (VCM), a transfer case
switch, and the circuit wiring. The transfer case
switch controls the 4WD low signal on circuit 1694.
When the operator selects 4WD low, the transfer
case switch closes and the 4WD low signal voltage
on circuit 1694 changes from ignition voltage to zero
volts. The VCM then compensates for transfer case
gear reduction in the transmission Output Shaft
Speed (OSS) signal. The VCM uses the transmission
OSS signal to adjust shift points, line pressure and
Torque Converter Clutch (TCC) scheduling.
When the VCM detects a continuous open or short
to ground in the 4WD low circuit, then DTC P1875
sets. DTC P1875 is a type B DTC.
Conditions for Setting the DTC
DTC P1875 sets if the following conditions are met
two consecutive times:
. No TP Sensor DTCs P0122, or P0123
. No VSS Assy. DTCs P0502 or P0503
. No TCC Sol. Valve DTC P0740
. No TCC Stuck ON DTC P0742
. No 1-2 SS Valve DTC P0751 or P0753
. No 2 -3 SS Valve DTC P0756 or P0758
• No TFP Val. Position Sw. DTC P1810
. No TCC PWM Sol. Valve DTC P1860
• The engine speed is greater than 450 RPM
for 5 seconds.
• Not in fuel cutoff.
• The gear range is D4.
11 km/h (7 mph).
• The TP angle is 17-50%.
• The engine torque is between 50-400 ft. lbs.
• The engine vacuum is between 0-105 kPa.
• The shift solenoid performance counters
are zero.
. The TFT is 20-130 *C (68-266 *F).
• All of the above conditions are met and either
of the following fail conditions occurs two
consecutive times:
- Four-wheel drive low is stuck ON for
5 seconds. The TCC slip speed is -3000 to
-50 RPM. Four-wheel drive low range is not
engaged. The speed ratio is 0.8-1.2. (The
speed ratio is the engine speed divided by
the transfer case output speed).
- Four-wheel drive low is stuck OFF for
10 seconds. The TCC is commanded ON.
The TCC slip speed is 100-3000 RPM.
Four-wheel drive low range is engaged.
The speed ratio is 2.5-2.9.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM commands a normal shift pattern
(not a 4WD low shift pattern).
• DTC P1875 stores in VCM history.
7-134 Automatic Transmission - 4L60-E Transmission/Transaxle
Conditions for Clearing the MILVDTC • Poor terminal tension
• The VCM turns OFF the MIL after three • A chafed wire
consecutive trips without a failure reported. • A broken wire inside the insulation
• A scan tool can clear the DTC from the • Moisture intrusion
VCM history. The VCM clears the DTC from • Corrosion
the VCM history if the vehicle completes 40
• When diagnosing for an intermittent short or
warm-up cycles without a failure reported. open condition, massage the wiring harness
• The VCM cancels the DTC default actions while watching the test equipment for a change.
when the fault no longer exists and the ignition
is OFF long enough in order to power down Test Description
the VCM. The numbers below refer to the step numbers on
the diagnostic table.
Diagnostic Aids 3. This step tests for a short to ground in
• Inspect the wiring at the VCM, the transfer case circuit 1694.
switch connector and all other circuit connecting 4. This step tests for an open in circuit 1694 or
points for the following conditions: a faulty transfer case switch.
• A bent terminal
• A backed out terminal
• A damaged terminal

DTC P1875 4 Wheel Drive Low Switch CKT Malfunction

Step Action Value(s) Yes No
Go to
1 Was the Powertrain On-Board Diagnostic (OBD) System — Powertrain OBD
Check performed? Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the RUN position.
Important: Before clearing the DTC(s), use the
scan tool in order to record the Freeze Frame and
Failure Records for reference. Using the Clear Info
function will erase the stored Freeze Frame and
2 Failure Records from the VCM. —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Place the transmission in Neutral.
5. Select 4HI on the transfer case selector.
6. Select 4LO on the transfer case selector.
Does the scan tool 4WD Low display Disabled when Go to
you select 4HI, then Enabled when you select 4LO? Diagnostic Aids Go to Step 3
1. Turn the ignition switch OFF.
2. Disconnect the transfer case switch connector.
3 —
3. Turn the ignition switch to the RUN position.
Does the scan tool 4WD Low indicate Enabled? Go to Step 6 Go to Step 4
1. Connect terminal B of the transfer case switch
connector to a known good ground.
4 2. Observe the scan tool 4WD Low. —
Does 4WD Low indicate Enabled when circuit 1694
(GRY/BLK) is grounded? Go to Step 5 Go to Step 7
Replace the transfer case selector switch.
5 Refer to Transfer Case Switch Replacement. — —
Is the replacement complete? Go to Step 9
Transmission/Transaxle Automatic Transmission - 4L60-E 7-135
DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (cont’d)
Step Action Value(s) Yes No
1. Inspect circuit 1694 (GRY/BLK) for a short to
ground condition.
6 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition? Go to Step 9 Go to Step 8
1. Inspect circuit 1694 (GRY/BLK) for an open
condition.
7 2. Repair the circuit if necessary. —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 9 Go to Step 8
Replace the VCM.
8 Refer to VCM Replacement/Programming. — —
Is the replacement complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
3.1. Select 4LO on the transfer case selector.
3.2. Drive the vehicle in D4.
9 3.3. Verify that the speed ratio is 2.5-2.9 for —

5 seconds.
3.4. Select 2HI or 4HI on the transfer case
selector.
3.5. Drive the vehicle in D4 with the TCC ON.
3.6. Verify that the speed ratio is 0.8-1.2 for
5 seconds. Begin the
4. Select Specific DTC. Enter DTC P1875. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-136 Automatic Transmission - 4L60-E Transmission/Transaxle
Transmission Fluid Checking Procedure
Step Action Value(s) Yes No
Check the fluid color.
1 —
Is the fluid color red? Go to Step 2 Go to Step 11
2 Is the fluid level satisfactory? — Go to Step 20 Go to Step 3
Check the fluid.
3 —
Is the fluid foamy? Go to Step 8 Go to Step 4
Check the fluid level. The proper fluid level should be
4 in the middle of the X-hatch. —
Is the level high? Go to Step 9 Go to Step 5
Fluid will be low.
5 Add fluid to the proper fluid level. — —

Is the fluid level satisfactory? Go to Step 6

Check for external leaks. Refer to Fluid Leak Diagnosis.
6 —
Did you find any leaks? Go to Step 7 Go to Step 20
Correct the leak condition.
7 — —
Did you correct the leak condition? Go to Step 20
8 Is the fluid level too high? — Go to Step 9 Go to Step 10
Remove excess fluid to the proper fluid level.
9 — —
Is the fluid level satisfactory? Go to Step 20
1. Check for contaminants in the fluid.
2. Drain the fluid to determine the source of the
10 — —
contamination.
Did you drain the fluid? Go to Step 15
11 Is the fluid color non-transparent pink? — Go to Step 12 Go to Step 13
Replace the cooler.
12 — —
Is the replacement complete? Go to Step 15
The fluid color should be light brown. Transmission fluid
may turn dark with normal use. This does not always
13 indicate oxidation or contamination. — —
Is the fluid color light brown? Go to Step 14
Drain the fluid to determine if the fluid is contaminated.
A very small amount of material in the bottom pan is a
14 normal condition, but large pieces of metal or other —
material in the bottom pan require a transmission overhaul.
Was the fluid contaminated? Go to Step 15 Go to Step 18
Overhaul the transmission. Refer to the Unit
15 Repair Section. — —
Is the overhaul complete? Go to Step 16
Flush the cooler.
16 — —
Has the cooler been flushed? Go to Step 17
Add new fluid.
17 — —
Is the procedure complete? Go to Step 19
Change the fluid and the filter.
18 — —
Is this procedure complete? Go to Step 19
19 Is the fluid level satisfactory? If not, correct as necessary. — Go to Step 20 —
Perform the Functional Test Procedure.
20 — —
Is the Functional Test Procedure completed? System OK
Transmission/Transaxle Automatic Transmission - 4L60-E 7-137

Line Pressure Check Procedure 6. Start the engine and allow the engine to
warm up at idle.
7. Access the PCS Control test on the scan tool.
8. Increase DESIRED PCS in 0.1 amp increments.
Read the corresponding line pressure on the
pressure gage. Allow the pressure to stabilize
for five seconds after each current charge.
9. Compare your data to the Drive-Park-Neutral
line pressure table below.
If your pressure readings differ greatly from the line
pressure table, refer to the Diagnosis Tables.
The scan tool is only able to control the pressure
control solenoid in Park and Neutral with the vehicle
stopped. This protects the clutches from extremely
high or low pressures in Drive or Reverse ranges.

Pressure Control Solenoid Current Approximate Line

(Amp) Pressure (PSI)
0.02 170-190
0.10 165-185
0.20 160-180
Line pressures are calibrated for two sets of gear
ranges - Drive-Park-Neutral and Reverse. This 0.30 155-175
allows the transmission line pressure to be 0.40 148-168
appropriate for different pressure needs in different 0.50 140-160
gear ranges:
0.60 130-145
Gear Range Line Pressure Range 0.70 110-130
Drive, Park or Neutral 55-189 psi 0.80 90-115
Reverse 64-324 psi 0.90 65-90
0.98 55-65
Before performing a line pressure check, verify that
the pressure control solenoid for the transmission is The pressures in the table assume an engine speed
receiving the correct electrical signal from the PCM: of 1500 RPM and a temperature of 6 6 ‘ C (150*F).
1. Install a scan tool. The pressure will vary with a change in temperature.

C a u t io n : K e e p t h e b r a k e s a p p lie d a t a l l Electrical/Garage Shift Procedure

t im e s I n o r d e r to p r e v e n t u n e x p e c te d
v e h ic le m o t io n .
N o t ic e : The transmission may experience
harsh, soft or mushy shifts for up to two
days later.
2. Start the engine and set the parking brake.
3. Check for diagnostic trouble codes, including
the diagnostic code for a stored pressure
control solenoid.
4. Repair the vehicle if necessary. Include the
following areas:
• Inspect the fluid level
• Inspect the manual linkage at the
transmission
• Install or connect the scan tool.
• Install or connect the oil pressure gage at
the line pressure tap.
5. Put the gear selector in Park and set the
parking brake.
Perform this preliminary test before a hoist test or a
road test in order to make sure that the electronic
control inputs are connected and operating. If you do
not check the inputs before operating the
transmission, you could misdiagnose a simple
electrical condition as a major transmission condition.
A scan tool provides valuable information and must
be used on the HYDRA-MATIC 4L60-E transmission
for accurate diagnosis.
1. Move the gear selector to PARK, (P) and set
the parking brake.
2. Connect the scan tool to the DLC terminal.
3. Start the engine.
4. Connect the power to the scan tool.
5. Verify that the following signals are present:
• Engine speed
• Transmission OSS
• Vehicle Speed
. TFP Sw. A/B/C
. PRNDL Select
7-138 Automatic Transmission - 4L60-E
• PC Sol. Ref. Current
• PC Sol. Actual Current
• PC Sol. Duty Cycle
• TCC Brake Switch
• 4WD Low (4WD Only)
. ECT
• Trans. Fluid Temp.
• TP Angle
• Ignition Voltage
6. Monitor the BRAKE SWITCH signal while
tapping the brake pedal with your foot. The
BRAKE SWITCH should be on when the pedal
is depressed. The brake switch should come off
when the brake pedal is released.
7. Monitor the PRNDL SELECT signal and move
the gear selector through all of the ranges.
8. Verify that the PRNDL SELECT value matches
the gear range indicated on the instrument
panel or console. Gear selections should be
immediate and not harsh.
9. Move the gear selector to neutral and monitor
the TP ANGLE signal while increasing and
decreasing the engine RPM with the accelerator
pedal. The TP ANGLE should increase with the
engine RPM.
Road Test Procedure
• Perform the road test using a scan tool.
• Perform this test when the traffic and the road
conditions permit. Observe all safety
regulations.
1. Start the engine.
2. Depress the brake pedal.
Important: Gear selections should be
immediate and not harsh.
3. Move the gear selector as follows:
3.1. Park to Reverse.
3.2. Reverse to Neutral.
3.3. Neutral to D4.
4. Perform the same procedure as instructed
previously in the road test:
• Upshifts and TCC apply.
• The part throttle detent downshift
• The full throttle detent downshift
• Manual downshifts
• Coasting downshifts
• Manual gear range selection
Use the scan tool in order to see if any transmission
malfunction codes have been set. If so, perform the
transmission test. After repairing the vehicle, perform
the road test and verify that no codes have been set
again. If no codes have been set and the condition
remains, refer to the Diagnosis Charts contained in
this section. If the condition is suspected to originate
in the torque converter, refer to Torque Converter
Clutch Diagnosis.
Transmission/Transaxle
Upshift Control and TCC Apply
The PCM calculates the upshift points based
primarily on two inputs: THROTTLE ANGLE and
VEHICLE SPEED. When the PCM says a shift
should occur, an electrical signal goes to the shift
solenoids which in turn move the valves to perform
the upshift.
The shift speed charts reference the THROTTLE
ANGLE instead of MIN THROTTLE or WOT in order
to make the shift speed measurement more uniform
and accurate. Use a scan tool in order to monitor
the THROTTLE ANGLE. Some scan tools are
programmed to record shift point information. Check
the instruction manual in order to see if this test is
available.
With the gear selection in D4, do the following:
1. Look at the shift speed chart contained in this
section and choose a throttle angle of 15 or
20 percent.
2. Set up the scan tool in order to monitor the
THROTTLE ANGLE and the VEHICLE SPEED.
3. Accelerate to the chosen throttle angle and hold
the throttle steady.
Important: Shift speeds may vary due to the
slight hydraulic delays responding to electronic
controls. A change from the original equipment
tire size also affects the shift speeds.
Note when the TCC applies. This should occur
in third or fourth gear. If the apply is not
noticed by an RPM drop, refer to the
Preliminary Torque Converter Clutch Diagnosis.
The TCC should not apply unless the
transmission has reached a minimum operating
temperature of 18*C (64*F) TRAN TEMP
and an engine coolant temperature of
60 *C (140*F).
4. As the transmission upshifts, note the shift
speed and the commanded gear changes
for the following:
• 2nd gear
• 3rd gear
• 4th gear
5. Repeat steps 1-4, using several different
throttle angles.
Full Throttle Detent Downshift
At vehicle speeds of 64-88 km/h (40-55 mph) in
fourth gear, quickly increase the throttle angle to the
maximum position.
Verify that the following conditions are met:
• The TCC releases.
• The transmission downshifts to 2rd gear
immediately.
• The 1-2 shift solenoid turns off. The 2-3 shift
solenoid is on.
Transmission/Transaxle
Part Throttle Detent Downshift
At vehicle speeds of 64-88 km/h (40-55 mph) in
fourth gear, quickly increase the throttle angle.
Verify that the following conditions are met:
• The TCC releases.
• The transmission downshifts to 3rd gear
immediately.
• The 1-2 shift solenoid turns off.
Coasting Downshifts
1. With the gear selector in D4, accelerate to the
4th gear with the TCC applied.
2. Release the accelerator pedal. Lightly apply the
brakes. Observe that the following occurs:
• The TCC releases
• The downshifts occur at speeds shown on
the shift speed chart.
Manual Downshifts
The shift solenoids do not control the initial downshift
during the 4-3 and the 3-2 manual downshifts. All
manual downshifts are hydraulic except the 2-1. The
solenoid states will change during or shortly after a
manual downshift is selected.
1. At vehicle speeds of 64-88 km/h (40-55 mph)
in fourth gear, release the accelerator pedal
while moving the gear selector to D3. Observe
the following:
• The TCC releases.
• The transmission downshifts to 3rd gear
immediately.
• The engine slows down the vehicle.
2. Move the gear selector back to D4 and
accelerate to 64-72 km/h (40-45 mph). Release
the accelerator while moving the gear selector
to D2 and observe that:
• The TCC releases.
• The transmission downshifts to the 2nd gear
immediately.
• The engine slows down the vehicle.
3. Move the gear selector back to D4 and
accelerate to 48 km/h (30 mph). Release the
accelerator pedal while moving the gear
selector to D1 and observe the following
conditions:
• The TCC releases.
• The transmission downshifts to 1st gear
immediately.
• The engine slows down the vehicle.
Manual Gear Range Selection
Upshifts in the manual gear ranges are controlled
by the shift solenoids.
Perform the following tests by accelerating at
10-15 degrees TP Sensor.
Automatic Transmission - 4L60-E 7-139
Manual Third (D3)
With the vehicle stopped, move the gear selector
to D3 and accelerate in order to observe:
• 1-2 shift
• 2-3 shift
Manual Second (D2)
1. With the vehicle stopped, move the gear
selector to the D2 position and accelerate in
order to observe if the transmission starts and
remains in second gear.
2. Accelerate to 40 km/h (35 mph) and observe
the following:
• The 2-3 shift does not occur.
• The TCC does not apply.
Manual First (D1)
1. With the vehicle stopped, move the gear
selector to D1.
2. Accelerate to 32 km/h (20 mph).
3. Observe the following conditions:
• No upshifts occur.
• The TCC does not apply.
• You can upshift out of first at the fuel cut-off.
Reverse
With the engine stopped, move the gear selector to
R and slowly accelerate in order to observe that the
1-2 and 2 -3 shift solenoids are ON.
Use a scan tool in order to see if any transmission
trouble codes have been set. Refer to Trouble
Codes Diagnosis in this section and repair the
vehicle as directed. After repairing the vehicle,
perform the hoist test and verify that the code has
not set again.
If the transmission is not performing well and no
trouble codes have been set, there may be an
intermittent condition. Check all electrical connections
for damage or a loose fit. Some scan tools have a
snapshot test which can help catch an intermittent
condition that doesn’t occur long enough to set a
code.
You may want to read Electronic Component
Diagnosis in this section in order to become familiar
with the transmission conditions caused by
transmission electrical malfunctions.
If no trouble codes have been set and the condition
is suspected to be hydraulic, take the vehicle on a
road test.
Noise and Vibration Analysis
A noise or vibration that is noticeable when the
vehicle is in motion may not be cause by the
transmission.
A noise or vibration that is noticeable while the
vehicle is in the P (Park) or the N (Neutral) position
with the engine at idle, but is less noticeable as the
RPM increases, may be the result of poor engine
performance.
7-140 Automatic Transmission - 4L60-E Transmission/Transaxle
Inspect the following components for the conditions
stated:
• Tires and wheels — Uneven wear; imbalance;
mixed sizes, or types.
• Suspension components — alignment and
wear; loose fasteners. Refer to Front
Suspension.
• Engine and transmission mounts — damage;
loose bolts.
• Transmission case mounting holes — Missing
bolts, nuts, and studs; stripped threads; cracks.
• Flywheel — Missing or loose bolts; cracks;
imbalance. For flywheel balancing, refer to
Engine Flywheel Replacement in Engine
Mechanical.
• Torque converter — Missing or loose bolts or
lugs; missing or loose balance weights;
imbalance.

Flywheel/Torque Converter Vibration Test

6. Remove the converter cover.
Inspection Procedure
N o t ic e : Some Engine/Transmission combinations
cannot be balance in this manner, due to the limited
clearances between the transmission torque
converter bolts and the engine. Be sure that the
bolts do not bottom out in the lug nuts, or the
transmission converter cover could be dented, and
cause internal damage.
1. Start the engine.
2. Place the transmission in P (Park) or
N (Neutral).
3. Run the engine at idle speed.
4. Observe the vibration.
5. Shut OFF the engine.

Removal Procedure
1. Disconnect the negative battery cable.
C a u t io n : R e f e r t o th e B a t t e r y D is c o n n e c t C a u t io n
in C a u t io n s a n d N o t ic e s .
7. Remove the torque converter to flywheel bolts.
Discard the flywheel bolts.
2. Raise the vehicle. Refer to General Information.
3. Support the vehicle with safety stands.
4. Remove the starter motor. Refer to Starter
Motor Replacement in Engine Electrical.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-141

13910

8. Rotate the torque converter 120 degrees Notice: Be sure that the bolts do not bottom out in
(1/3 turn). the lug nuts, or the transmission converter cover
could be dented, and cause internal damage.
Installation Procedure
Important: Hand start all torque converter to
flywheel bolts before torquing. This will ensure
proper alignment and avoid cross threading.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the flywheel to torque converter bolts.
Use new flywheel to torque converter bolts with
retaining compound removed from the first three
threads of each bolt.
Tighten
Tighten the bolts to 63 N.m (46 lb ft).
2. Install the converter cover and the bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
3. Install the starter. Refer to Starter Motor
Replacement in Engine Electrical.
4. Lower the vehicle.
5. Connect the negative battery cable.
Tighten
Tighten the cable to 15 N-m (11 lb ft).
6. Start the engine and check for vibration. Repeat
this procedure until the best possible balance is
obtained.
7-142 Automatic Transmission - 4L60-E
Torque Converter Clutch Diagnosis
In order to properly diagnose the Torque Converter
Clutch (TCC) system, perform all of the electrical
testing first. Then do the hydraulic testing.
The TCC is applied by fluid pressure, which is
controlled by a solenoid inside of the automatic
transmission assembly. The solenoid is energized by
completing an electrical circuit through a combination
of switches and sensors.
Functional Check Procedure
1. Install a tachometer or a scan tool.
2. Operate the vehicle until you reach proper
operating temperature.
3. Drive the vehicle at 80-88 km/h (50-55 mph)
with a light throttle (road load).
4. Maintaining the throttle, lightly touch the brake
pedal. Check for the release of the TCC and a
slight increase in engine speed (RPM).
5. Release the brake. Slowly accelerate and check
for a re-apply of the converter clutch and a
slight decrease in engine speed (RPM).
Torque Converter Evaluation
Torque Converter Stator
The torque converter stator roller clutch can have
one of two different types of malfunctions:
• Stator assembly freewheels in both directions.
• Stator assembly remains locked up at all times.
Condition A — Poor Acceleration Low Speed
The car tends to have a poor acceleration from a
standstill. At speeds above 50-55 km/h (30-35 mph),
the car may act normal. If you note poor
acceleration, you should first determine that the
exhaust system is not blocked and the transmission
is in first gear when starting out.
If the engine freely accelerates to high RPM in
NEUTRAL (N), you can assume that the engine and
exhaust system are normal. Checking for poor
performance in DRIVE and REVERSE helps
determine if the stator is freewheeling at all times.
Condition B — Poor Acceleration High Speed
Engine RPM and car speed are limited or restricted
at high speeds. Performance when accelerating from
a standstill is normal. The engine may overheat.
Visual examination of the converter may reveal a
blue color from overheating.
If the converter has been removed, the stator roller
clutch can be checked by inserting two fingers into
the splined inner race of the roller clutch and try to
turn the race in both directions. The inner race
should turn freely clockwise, but the inner race
should not turn or be very difficult to turn
counterclockwise.
Transmission/Transaxle
Noise
Torque converter whine usually is noticed when the
vehicle is stopped and the transmission is in DRIVE
or REVERSE. The noise increases when the engine
RPM increases. The noise stops when the vehicle is
moving or when the torque converter clutch is
applied because both halves of the converter are
turning at the same speed.
Perform a stall test to make sure the noise actually
is coming from the converter:
1. Place a foot on the brake.
2. Put the gear selector in DRIVE.
Important: This noise should not be confused
with the pump whine noise which is usually
noticeable in PARK, NEUTRAL and all other
gear ranges. Pump whine varies with pressure
ranges.
3. Depress the accelerator to approximately
1200 RPM for no more than six seconds.
A torque converter noise increases under this
load.
4. The torque converter should be replaced under
any of the following conditions:
• External leaks in the hub weld area
• The converter hub is scored or damaged.
• The converter pillar is broken or damaged or
fits poorly into the crankshaft.
• You find steel particles after flushing the
cooler and cooler lines.
• The pump is damaged or the steel particles
are found in the converter.
• The vehicle has TCC shudder and/or no
TCC apply. Replace only after you have
made all of the hydraulic and electrical
diagnoses. (Converter clutch material may be
glazed).
• The converter has an imbalance which
cannot be corrected. (Refer to the Converter
Vibration Test Procedure).
• The converter is contaminated with engine
coolant containing antifreeze.
• Internal failure of stator roller clutch
• Excess end play.
• Heavy clutch debris due to overheating (blue
converter)
• Steel particles or clutch lining material found
in fluid filter or on magnet when no internal
parts in the unit are worn or damaged -
indicates that the lining material came from
the converter.
Transmission/Transaxle
5. The torque converter should not be replaced if
any of the following conditions exist:
• The oil has an odor, is discolored, and there
is no evidence of metal or clutch facing
particles.
• The threads in one or more of the converter
bolt holes are damaged. Correct with thread
insert.
• Transmission failure did not display evidence
of damage or worn internal parts, steel
particles or the clutch plate lining material in
the unit and inside the fluid filter.
• The vehicle has been exposed to high
mileage (only). The exception may be where
the torque converter clutch damper plate
lining has seen excess wear by the vehicles
operated in heavy and/or constant traffic,
such as a taxi, deliver or police use.
Torque Converter Clutch Shudder
The key to diagnosing the Torque Converter Clutch
(TCC) shudder is to note when the shudder happens
and under what conditions:
The TCC shudder should not only occur during the
APPLY and/or RELEASE of the converter clutch, and
SELDOM after the TCC plate is fully applied.
While the TCC is Applying or Releasing
If the shudder occurs while the TCC is applying, the
problem can be within the transmission or the torque
converter. Something is not allowing the clutch to
release, or the TCC is trying to release and apply
the clutch at the same time. This could be caused
by leaking turbine shaft seals, a restricted release
orifice, a distorted clutch or a housing surface due to
long converter bolts, or defective friction material on
the TCC plate.
Shudder Occurs after the TCC has Applied
Important: Once the TCC is applied there is no
torque converter (fluid coupling) assistance. Engine
or driveline vibrations could be unnoticeable before
the TCC engagement.
When the sudden occurs after the TCC has applied,
most of the time there is nothing wrong with the
transmission. As mentioned above, once the TCC
has been applied, it is very unlikely that it will slip.
Engine problems may go unnoticed under light
throttle and load, but engine problems may become
noticeable after TCC apply when going up a hill or
accelerating, due to the mechanical coupling
between the engine and the transmission.
Automatic Transmission - 4L60-E 7-143
Inspect the following components in order to avoid
misdiagnosis of the TCC shudder and possibly
disassembling a transmission and/or replacing a
torque converter unnecessarily:
• Spark plugs - Inspect for cracks, high
resistance or broken insulator.
• Plug wires - Look in each end. If there is a red
dust (ozone) or a black substance (carbon)
present, then the wires are bad. Also look for a
white discoloration of the wire indicating arcing
during hard acceleration.
• Distributor cap and rotor - Look for broken or
uncrimped parts.
• Coil - Look for black on bottom indication
arching while engine is misfiring.
• Fuel injector - Filter may be plugged.
• Vacuum leak - Engine won’t get correct amount
of fuel and may run rick or lean, depending on
where the leak is located.
• EGR valve - Valve may let in too much
unburnable exhaust has causes engine to run
lean.
• MAP/MAF sensor - Like the vacuum leak, the
engine won’t get the correct amount of fuel for
proper engine operation.
• Carbon on intake valves - Restricts proper flow
or air/fuel mixture into cylinders.
• Flat cam - Valves don’t open enough to let
proper fuel/air mixture into cylinders.
• Oxygen sensor - May command engine too rich
or too lean for too long.
• Fuel pressure - May be too low.
• Engine mounts - Vibration of mounts can be
multiplied by TCC engagement.
• Axle joints - Check for vibration.
• TPS - TCC apply and release depends on TPS
in many engines. IF TPS is out of specification,
TCC may remain applied during the initial
engine crowd.
• Cylinder balance - Bad piston rings or vaives
that seal poorly can cause low power in a
cylinder.
• Fuel contamination - Causes poor engine
performance.
7-144 Automatic Transmission - 4L60-E Transmission/Transaxle

Automatic Transmission Wiring Harness Check

Test Description
Tools Required
• J 39775 Jumper Harness
• J 39200 Digital Multimeter (DMM)
• J 35616 Connector Test Adapter Kit
Important: This procedure cannot be used for
checking the Automatic Transmission Fluid Pressure
Manual Valve Position Switch (TFP Val. Position Sw.)
circuit, or the Automatic Transmission Fluid
Temperature (TFT) Sensor circuit. Refer to
TFP Valve Position Switch Resistance Check,
for those circuits.

Automatic Transmission Wiring Harness Check

Step Action Value(s) Yes No
1. Install the J 39775 Jumper Harness on the
transmission 20-way connector.
19-24 £2 @
2. Using a J 39200 Digital Multimeter (DMM) and a 20 *C (68' F)
1 J 35616 Connector Test Adapter Kit, measure the
resistance between terminals A and E (1-2 Shift 24-31 £2 @
Solenoid Valve). 100*C (212*F)
Is the resistance within the specified range? Go to Step 3 Go to Step 2
1. Disconnect the 1-2 Shift Solenoid Valve (1-2 SS
Valve) from the Automatic Transmission Wiring 19-24 £2 @
Harness Assembly (A/T Wiring Harness Assembly). 20 *C (68 * F)
2
2. Using the J 39200 DMM, measure the resistance of 24-31 £2 @
the 1-2 SS Valve. 100 X (212 *F)
Is the resistance within the specified range? Go to Step 14 Go to Step 16
Measure the resistance between terminals B and E 19-24 £2 @
(2-3 Shift Solenoid Valve). 20 *C (68' F)
3
Is the resistance within the specified range? 24-31 £2 @
100 X (212 *F) Go to Step 5 Go to Step 4
1. Disconnect the 2-3 Shift Solenoid Valve (2-3 SS
19-24 £2 @
Valve) from the A/T Wiring Harness Assembly.
20 X (68 ’ F)
4 2. Using the J 39200 DMM, measure the resistance
of the 2-3 SS Valve. 24-31 £2 @
100*C (212*F)
Is the resistance within the specified range? Go to Step 14 Go to Step 16
Measure the resistance between terminals T and E 21-26 £2 @
(Torque Converter Clutch Solenoid Valve). 20 X (68 * F)
5
Is the resistance within the specified range? 26-33 £2 @
100 X (212 *F) Go to Step 6 Go to Step 14
Measure the resistance between terminals U and E 10-11 £2 @
(Torque Converter Clutch Pulse Width Modulation Solenoid 20*C (6 8 -F)
6 Valve). 13-15 £2 @
Is the resistance within the specified range? 100 *C (212 *F) Go to Step 8 Go to Step 7
1. Disconnect the TCC PWM Sol. Valve from the
10-11 £2 @
A/T Wiring Harness Assembly.
2 0 X (68*F)
7 2. Using the J 39200 DMM, measure the resistance
13-15 £2 @
of the TCC PWM Sol. Valve.
100 X (212* F)
Is the resistance within the specified range? Go to Step 14 Go to Step 16
Measure the resistance between terminals S and E 20-24 £2 @
(3-2 Shift Solenoid Valve assembly). 20*C (68*F)
8
Is the resistance within the specified range? 29-32 £2 @
100 X (212 *F) Go to Step 10 Go to Step 9
Transmission/Transaxle Automatic Transmission - 4L60-E 7-145
Automatic Transmission Wiring Harness Check (cont’d)
Step Action Value(s) Yes No
1. Disconnect the 3-2 Shift Solenoid Valve assembly
(3-2 SS Valve Assy.) from the A/T Wiring Harness 20-24 Q @
Assembly. 20‘ C (68*F)
9
2. Using the J 39200 DMM, measure the resistance 29-32 Q @
of the 3-2 SS Valve Assy. 100’ C (212-F)
Is the resistance within the specified range? Go to Step 14 Go to Step 16
Measure the resistance between terminals C and D 3-5 Q @ 20*C
(Pressure Control Solenoid Valve). (68 *F)
10
Is the resistance within the specified range? 4-7 £2 @
100 *C (212 *F) Go to Step 12 Go to Step 11
1. Disconnect the Pressure Control Solenoid Valve
(PC Sol. Valve) from the A/T Wiring Harness 3- 5 0 0
Assembly. 20'C (68 * F)
11
2. Using the J 39200 DMM, measure the resistance 4- 7 Q @
of the PC Sol. Valve. 100 *C (212 *F)
Is the resistance within the specified range? Go to Step 14 Go to Step 16
Using the J 39200 DMM and the J 35616 Connector
Test Adapter Kit, measure the resistance from terminals A,
B, C, D, E, S, T and U of the A/T Wiring Harness
12 Assembly at the transmission 20-way connector to the 250 K £2
transmission case. System OK, exit
Is the resistance more than the specified value? the table Go to Step 13
1. Disconnect the A/T Wiring Harness Assembly from
all the components.
13 2. Measure the resistance from all the component 250 KQ
terminals to the transmission case.
Is the resistance more than the specified value? Go to Step 14 Go to Step 16
Inspect for high resistance or a short.
• Inspect the A/T Wiring Harness Assembly at the
transmission 20-way connector, and the component
connectors for the following conditions:
- Poor electrical connections
- Bent, backed-out, or damaged terminals
- Weak terminal tension
- A chafed wire that could short to bare metal —
14
or other wiring
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• If diagnosing for a possible intermittent condition,
move or massage the A/T Wiring Harness Assembly
while observing the test equipment for a change. Verify the repair.
Did you find a high resistance or a short? Go to Step 1 Go to Step 15
Replace the Automatic Transmission Wiring Harness
15 Assembly (A/T Wiring Harness Assembly). — Verify the repair. —
Is the replacement complete? Go to Step 1
Replace the faulty component. Verify the repair.
16 — —
Is the replacement complete? Go to Step 1
7-146 Automatic Transmission - 4L60-E Transmission/Transaxle
Component Resistance
Component Pass Thru Pins Resistance at 20*C Resistance at 100*C Resistance to Ground (Case)
1-2 Shift Solenoid
A, E 19-24 0 24-31 O Greater than 250 K O
Valve
2-3 Shift
B, E 19-24 0 24-31 O Greater than 250 K O
Solenoid Valve
TCC Solenoid
T, E 21-26 O 26-33 0 Greater than 250 K O
Valve
TCC PWM
U, E 10-11 O 13-15 0 Greater than 250 K O
Solenoid Valve
3-2 Shift Solenoid
S, E 20-24 O 29-32 O Greater than 250 K O
Valve Assy.
Pressure Control
C, D 3 -5 0 4-7 0 Greater than 250 K O
Solenoid Valve
Transmission Fluid
Pressure (TFP)
Refer to TFP Valve Position Switch Resistance Check.
Manual Valve
Position Switch
•Transmission Ruid
Temperature M, L 3088-3942 O 159.3-198.0 0 Greater than 10 M O
(TFT) Sensor
Vehicle Speed A, B VSS
1470-2220 O 1800-2820 O Greater than 10 M O
Sensor CONN
Important: The resistance of this device is necessarily temperature dependent and will therefore vary far more than any
other device. Refer to the Transmission Fluid Temperature Sensor portion of Electronic Component Description.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-147

TFP Valve Position Switch Resistance Check

Test Description
Tools Required
• J 39775 4L60-E Jumper Harness
• J 39200 Digital Multimeter
• J 35616 Connector Test Adapter Kit
Important: Whenever the transmission 20-way
connector is disconnected and the engine is running,
multiple DTCs will set. Be sure to clear these codes
when you are finished with this procedure.
Important: This procedure tests the Automatic
Transmission Fluid Pressure Manual Valve Position
Switch (TFP Val. Position Sw.) circuits and the
Automatic Transmission Fluid Temperature (TFT)
Sensor circuit. Do not use this procedure to test
other Automatic Transmission circuits. Refer to
4L60-E Automatic Transmission Wiring
Harness Check.

TFP Valve Position Switch Resistance Check

Step Action Value(s) Yes No
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Using the J 39200 Digital Multimeter and the J 35616
1 50 K ft
Connector Test Adapter Kit, measure the resistance
from terminal N to the transmission case.
Is the resistance greater than the specified value? Go to Step 3 Go to Step 2
1. Disconnect the TFP Val. Position Sw. from the
A/T Wiring Harness Assy.
2 2. Measure the resistance from terminal C of the 50 KO
TFP Val. Position Sw. to the switch housing.
Is the resistance greater than the specified value? Go to Step 16 Go to Step 19
Measure the resistance from terminal R to the
3 transmission case. 200 ft
Is the resistance less than the specified value? Go to Step 5 Go to Step 4
1. Disconnect the TFP Val. Position Sw. from the
A/T Wiring Harness Assy.
4 2. Measure the resistance from terminal E of the 200 £2
TFP Val. Position Sw. to the switch housing.
Is the resistance less than the specified value? Go to Step 16 Go to Step 19
Measure the resistance from terminal P to the
5 transmission case. 50 K ft
Is the resistance greater than the specified value? Go to Step 7 Go to Step 6
1. Disconnect the TFP Val. Position Sw. from the
A/T Wiring Harness Assy.
6 2. Measure the resistance from terminal D of the 50 K ft
TFP Val. Position Sw. to the switch housing.
Is the resistance greater than the specified value? Go to Step 16 Go to Step 19
7-148 Automatic Transmission - 4L60-E Transmission/Transaxle
TFP Valve Position Switch Resistance Check (cont’d)
Step Action Value(s) Yea No
1. Start the engine.
2. Allow the engine to idle.
3. Set the parking brake.
7 4. Place the gear selector in Reverse. 200 ft
5. Measure the resistance from terminal N to the
transmission case.
Is the resistance less than the specified value? Go to Step 8 Go to Step 16
1. Place the gear selector in Low (D1).
2. Measure the resistance from terminal N to the
8 200 ft
transmission case.
Is the resistance less than the specified value? Go to Step 9 Go to Step 16
1. Place the gear selector in Manual Third (D3).
2. Measure the resistance from terminal R to the
9 50 K ft
transmission case.
Is the resistance greater than the specified value? Go to Step 10 Go to Step 16
1. Place the gear selector in Drive (D4).
2. Measure the resistance from terminal P to the
10 200 ft
transmission case.
Is the resistance less than the specified value? Go to Step 11 Go to Step 16
1. Place the gear selector in Manual Second (D2).
2. Measure the resistance from terminal P to the
11 50 K ft
transmission case.
Is the resistance greater than the specified value? Go to Step 12 Go to Step 16
1. Turn the ignition OFF.
Important: The resistance of the TFT Sensor is
temperature dependent, and therefore varies far 3088-3942 ft @
more than any other device. Refer to Transmission 20'C (68-F)
12 Fluid Temperature Sensor in Electronic Component
Description. 159-198 ft @
100 *C (212*F)
2. Measure the resistance from terminal L to terminal M
(TFT Sensor) of the Jumper Harness.
Is the resistance within the specified range? Go to Step 13 Go to Step 14
1. Measure the resistance from terminal L to the
transmission case.
13 2. Measure the resistance from terminal M to the 10 M ft No condition
transmission case. found. Exit the
Are both resistances greater than the specified value? table. Go to Step 14
1. Disconnect the TFP Val. Position Sw. from the
A/T Wiring Harness Assy.
Important: The resistance of the TFT Sensor is
temperature dependent, and therefore varies far 3088-3942 ft @
more than any other device. Refer to Transmission 20'C (68 * F)
14 Fluid Temperature Sensor in Electronic Component
Description. 159-198 ft @
100‘ C (212-F)
2. Using the J 39200 Digital Multimeter, measure the
resistance between terminal A and terminal B of the
TFP Val. Position Sw. (TFT Sensor).
Is the resistance within the specified range? Go to Step 15 Go to Step 19
Transmission/Transaxle Automatic Transmission - 4L60-E 7-149
TFP Valve Position Switch Resistance Check (cont’d)
Step Action Value(s) Yes No
1. Measure the resistance from TFP Val. Position Sw.
terminal A to the transmission case.
15 2. Measure the resistance from TFP Val. Position Sw. 10 M Q
terminal B to the transmission case.
Are both resistances greater than the specified value? Go to Step 16 Go to Step 19
Inspect for high resistance or a short:
• Inspect the A/T Wiring Harness Assy, for poor
electrical connections at the A/T 20-way connector,
and at the TFP Val. Position Sw. Look for the
following conditions:
- A bent terminal
- A backed out terminal
16 - A damaged terminal —
- Poor terminal tension
- Moisture Intrusion
- Corrosion
• If diagnosing for an intermittent condition, massage
the wiring harness while watching the test equipment
for a change. Verify the repair.
Did you find high resistance or a short? Go to Step 1 Go to Step 17
1. Disconnect the TFP Val. Position Sw. from the
A/T Wiring Harness Assy.
2. Inspect the following circuits for an open or short:
• Circuit 1224
17 —
. Circuit 1225
• Circuit 1226
• Circuit 1227
Did you find an open or shorted condition? Go to Step 18 Go to Step 19
Replace the A/T Wiring Harness Assy.
Refer to TCC PWM Solenoid, TCC Solenoid, and
18 — —
Wiring Harness Replacement. Verify the repair.
Is the replacement complete? Go to Step 1
Replace the TFP Val. Position Sw.
19 Refer to Valve Body and Pressure Switch Replacement. — Verify the repair. —
Is the replacement complete? Go to Step 1
7-150 Automatic Transmission - 4L60-E
This table gives some general information about
electronic component malfunctions. Use this
information to become familiar with possible
conditions caused by transmission/vehicle electrical
components. Refer to the Diagnosis Tables for
more specific information.
Electronic Component Malfunctions
COMPONENT/SYSTEM
Throttle Position Sensor
Automatic Transmission Output Shaft Speed Sensor
Transmission Fluid Pressure (TFP) Manual
Valve Position Switch
AutomaticTransmission Fluid Temperature (TFT) Sensor
Engine Coolant Temperature Sensor
Shift Solenoid valves
Brake Switch
System Voltage
3-2 Control Shift Solenoid Valve Assembly
Pressure Control Solenoid
TCC Sol Valve
Cruise Control
Acceleration Slip Reulation (ASR)
Transmission/Transaxle
CAN EFFECT
• Shift Pattern (erratic).
• Shift quality (firm or soft).
• Engine (rough)
• Shift Pattern (erratic).
• TCC Sol Valve apply (at wrong time).
• Shift quality (harsh or soft).
• TCC Sol Valve apply (no apply if diagnostic code is set).
• Shift pattern (no fourth gear in hot mode).
• Shift quality (harsh).
• Line pressure (high).
• Manual downshift (erratic).
• TCC Sol Valve control (on or off).
• Shift quality (harsh or soft.).
• TCC Sol Valve control (no apply).
• Shift quality (harsh).
Gear application (wrong gear, only two gears, no shift).
• TCC apply (no apply).
• No 4th gear if in hot mode.
• Line pressure (high).
• Gear application (third gear only).
• TCC control (no apply).
• No 4th gear if in hot mode).
• Gear application (third gear only).
• 3-2 Downshifts (flare or tie-up).
• Line pressure (high or low)
• Shift quality (harsh or soft).
• TCC Sol Valve apply (no apply)
• No 4th gear if in hot mode.
Delays 3-4 upshift and TCC apply during heavy throttle.
Downshifts.
TransmissiorVTransaxle Automatic Transmission - 4L60-E 7-151
Oil Pressure High or Low
Checks Causes
Oil Pump Assembly • Pressure regulator valve stuck.
• Pressure regulator valve spring.
• Rotor guide omitted or misassembled.
• Rotor cracked or broken.
• Reverse boost valve or sleeve stuck, damaged or incorrectly assembled.
• Orifice hole in pressure regulator valve plugged.
• Sticking slide or excessive rotor clearance.
• Pressure relief ball not seated or damaged.
• Porosity in pump cover or body.
• Wrong pump cover.
• Pump faces not flat.
• Excessive rotor clearance.
Oil Filter • Intake pipe restricted by casting flash.
• Cracks in filter body or intake pipe.
• O-ring seal missing, cut or damaged.
• Wrong grease used on rebuild.
Control Valve Body • Manual valve scored or damaged.
• Spacer plate or gaskets incorrect, misassembled or damaged.
• Face not flat.
• 2-3 Shift valve stuck.
• Checkballs omitted or misassembled.
Pressure Control Solenoid • Damage to pins
Transmission Fluid Pressure Manual • Contamination
Valve Position Switch • Damaged seals.
Case • Case to control valve body face not flat
System Voltage • 12 volts not supplied to transmission.
• Electrical short (pinched solenoid wire).
• Solenoid not grounded.

Harsh Shifts
Checks Causes
Throttle Position Sensor Open or shorted circuit.
Vehicle Speed Sensor Open or shorted circuit.
Pressure Switch Assembly • Contamination
• Damaged seals
Trans Fluid Temperature Sensor Open or shorted circuit.
Engine Coolant Temperature Sensor Open or shorted circuit.
Pressure Control Solenoid • Damage to pins
• Contamination
7-152 Automatic Transmission - 4L60-E
Checks
Oil Pump Assembly
Valve Body Assembly
Case
Throttle Position Sensor
Vehicle Speed Sensor
4WD Low Switch
Checks
Valve Body (60)
Case (8)
Shift Solenoid Valves (379)
2-4 Servo Assembly (12-29)
2 -4 Band Assembly (602)
Checks
Forward Clutch Assembly
Forward Clutch Accumulator
Input Housing and Shaft Assembly
Transmission/Transaxle
Inaccurate Shift Points
Causes
• Stuck pressure regulator valve.
• Sticking pump slide.
Spacer plate or gaskets misassembled, damaged or incorrect
• Porous or damaged valve body pad.
• 2-4 Servo Assembly.
- 2-4 accumulator porosity
- Damaged servo piston seals.
- Apply pin damaged or improper length.
• 2-4 Band Assembly.
- Burned
- Anchor pin not engaged.
• Disconnected
• Damage
• Disconnected
• Damaged
• Bolt not tightened
• Disconnected
• Damaged.
1st Gear Range Only-No Upshift
Causes
• The 1-2 Shift valve (366) is sticking
• The spacer plate (48) or gaskets (47, 52) are mispositioned or damaged
The case to valve body face is damaged or is not flat
• Stuck or damaged
• Faulty electrical connection
• The apply passage case is restricted or blocked
• Nicks or burrs on the servo pin (13) or on the pin bore in the case
• Fourth servo piston (25) is installed backwards
• The 2-4 band (602) is worn or damaged
• The band anchor pin is not engaged
Slips in 1st Gear
Causes
• Clutch plates worn
• Porosity or damage in forward clutch piston
• Forward clutch piston inner and outer seals missing, cut or damaged.
• Damaged forward clutch housing.
• Forward clutch housing retainer and ball assembly not sealing or damaged.
• Piston seal missing, cut or damaged.
• Piston out of its bore.
• Porosity in the piston or valve body.
• Stuck abuse valve.
Turbine shaft seals missing, cut or damaged.
Transmission/Transaxle Automatic Transmission - 4L60-E 7*153
Slips in 1st Gear (cont’d)
Checks Causes
Valve Body • 1-2 Accumulator valve stuck.
• Face not flat, damaged lands or interconnected passages.
• Spacer plate or gaskets incorrect, mispositioned or damaged.
Low Roller Clutch • Damage to lugs to inner ramps.
• Rollers not free moving.
• Inadequate spring tension.
• Damage to inner splines.
• Lube passage plugged.
Torque Converter Stator roller clutch not holding.
1-2 Accumulator Assembly . Porosity in piston or 1-2 Accumulator cover and pin assembly.
• Damaged ring grooves on piston.
• Piston seal missing, cut or damaged.
• Valve body to spacer plate gasket at 1-2 Accumulator cover,
missing or damaged.
• Leak between piston and pin.
• Broken 1-2 Accumulator spring.
Line Pressure Refer to Oil Pressure High or Low
2-4 Servo Assembly 4th Servo piston in backwards.

Slipping or Rough 1-2 Shift

Checks Causes
Valve Body Assembly • 1-2 Shift valve train stuck.
• Gaskets or spacer plate incorrect, mispositioned or damaged.
• 1-2 Accumulator valve stuck.
• Face not flat.
2-4 Servo Assembly • Apply pin too long or too short.
• 2nd servo apply piston seal missing, cut or damaged.
• Restricted or missing oil passages.
• Servo bore in case damaged.
2nd Accumulator • Porosity in 1-2 accumulator housing or piston.
• Piston seal or groove damaged.
• Nicks or burrs in 1-2 accumulator housing.
• Missing or restricted oil passage.
2-4 Band Worn or mispositioned.
Oil Pump Assembly or Case Faces not flat.

No 2-3 Shift or 2-3 Shift Slips, Rough or Hunting

Checks Causes
Valve Body Assembly • 1-2 Shift valve train stuck.
• Gaskets or spacer plate incorrect, mispositioned or damaged.
• 1-2 Accumulator valve stuck.
• Face not flat.
2-4 Servo Assembly • Apply pin too long or too short.
• 2nd servo apply piston seal missing, cut or damaged.
• Restricted or missing oil passages.
• Servo bore in case damaged.
7-154 Automatic Transmission - 4L60-E Transmission/Transaxle
No 2-3 Shift or 2-3 Shift Slips, Rough or Hunting (cont’d)
Checks Causes
2nd Accumulator • Porosity in 1-2 accumulator housing or piston.
• Piston seal or groove damaged.
• Nicks or burrs in 1-2 accumulator housing.
• Missing or restricted oil passage.
2-4 Band Worn or mispositioned.
Oil Pump Assembly or Case Faces not flat.

2nd/3rd Gear Only or 1st/4th Gears Only

Checks Causes
Shift Solenoid Valves (379) • Sediment is in the valves
• The electrical connection is faulty
• Damaged seal

Third Gear Only

Checks Causes
System Voltage • 12 volts not supplied to transmission.
• Electrical short (pinched solenoid wire).
• Solenoid not grounded.
3-2 Control Solenoid (394) • Shorted or damaged.
• Contamination.
• Damaged Seal.

3-2 Flare or Tie-Up

Checks Causes
3-2 Control Solenoid • Shorted or damaged.
• Contamination
• Damaged Seal

No 3-4 Shift, Slips or Rough 3-4 Shift

Checks Causes
Oil Pump Assembly • Pump cover retainer and ball assembly omitted or damaged
• Faces not flat
Valve Body Assembly • Valves stuck
- 2-3 Shift valve train
- Accumulator valve
- 1-2 Shift valve train
- 3-2 Control valve
• Spacer plate or gaskets incorrect, mispositioned or damaged
2-4 Servo Assembly • Incorrect band apply pin.
• Missing or damaged servo seals.
• Porosity in piston, cover or case.
• Damaged piston seal grooves.
• Plugged or missing orifice cup plug.
Transmission/!ransaxle
No 3-4 Shift, Slips or Rough 3-4 Shift (cont’d)
Checks
Case
Input Housing Assembly
2-4 Band Assembly
Checks
Input Housing Assembly
Manual Valve Link
Valve Body Assembly
Reverse Input Clutch Assembly
Lo and Reverse Clutch
Automatic Transmission - 4L60-E 7-155
Causes
• 3rd Accumulator retainer and ball assembly leaking.
• Porosity in 3-4 accumulator piston or bore.
• 3-4 Accumulator piston seal or seal grooves damaged.
• Plugged or missing orifice cup plug.
• Restricted oil passage.
Refer to Slipping 2-3 Shift.
Warn or misassembled
No Reverse or Slips in Reverse
Causes
• 3-4 Apply ring stuck in applied position.
• Forward clutch not releasing
• Turbine shaft seals missing, cut or damaged
Disconnect
• 2-3 Shift valve stuck.
• Manual linkage not adjusted
• Spacer plate and gaskets incorrect, mispositioned or damaged.
• Lo overrun valve stuck
• Orificed cup plug restricted, missing or damaged.
• Clutch plate worn.
• Reverse input housing and drum assembly cracked at weld.
• Clutch plate retaining ring out of groove.
• Return spring assembly retaining ring out of groove.
• Seals cut or damaged
• Restricted apply passage
• Porosity in piston
• Belleville plate installed incorrectly
• Excessive clutch plate travel
• Oversized housing
• Clutch plates worn
• Porosity in piston
• Seals damaged.
• Return spring assembly retaining ring mispositioned
• Restricted apply passage
7-156 Automatic Transmission - 4L60-E
No Part Throttle or Delayed Downshifts
Checks
Input Housing Assembly
Manual Valve Link
Valve Body Assembly
Reverse Input Clutch Assembly
Lo and Reverse Clutch
Checks
Valve Body Assembly
Checks
External Linkage
Valve Body Assembly
Input Clutch Assembly
Transmission/Transaxle
Causes
• 3-4 Apply ring stuck in applied position.
• Forward clutch not releasing
• Turbine shaft seals missing, cut or damaged
Disconnect
• 2-3 Shift valve stuck.
• Manual linkage not adjusted
• Spacer plate and gaskets incorrect, mispositioned or damaged.
• Lo overrun valve stuck
• Orificed cup plug restricted, missing or damaged.
• Clutch plate worn.
• Reverse input housing and drum assembly cracked at weld.
• Clutch plate retaining ring out of groove.
• Return spring assembly retaining ring out of groove.
• Seals cut or damaged
• Restricted apply passage
• Porosity in piston
• Belleville plate installed incorrectly
• Excessive clutch plate travel
• Oversized housing
• Clutch plates worn
• Porosity in piston
• Seals damaged.
• Return spring assembly retaining ring mispositioned
• Restricted apply passage
Harsh Garage Shift
Causes
• Orifice cup plug missing
• Checkball missing
No Overrun Braking - Manual 3-2-1
Causes
Not adjusted properly
• 4-3 Sequence valve stuck.
• Checkball mispositioned
• Spacer plate and gaskets incorrect, damaged or mispositioned
• Turbine shaft oil passages plugged or not drilled.
• Turbine shaft seal rings damaged.
• Turbine shaft sealing balls loose or missing.
• Turbine shaft sealing balls loose or missing.
• Porosity in forward or overrun clutch piston.
• Overrun piston seals cut or damaged.
• Overrun piston checkball not sealing.
Transmission/Transaxle
Checks
Electrical
Torque Converter Clutch
Oil Pump Assembly
Input Housing and Shaft
Transmission Fluid Pressure Manual
Valve Position Switch
Control Valve Body Assembly
Solenoid Screen
TCC Solenoid Valve
Engine Speed Sensor
Engine Coolant Temperature Sensor
Automatic Transmission Fluid
Temperature Sensor
Brake Switch
Automatic Transmission - 4L60-E 7-157
No TCC Apply
Causes
• 12 volts not supplied to transmission
• Outside electrical connector damaged.
• Inside electrical connector, wiring harness or solenoid damaged.
• Electrical short (pinched solenoid wire).
• Solenoid not grounded.
Internal damage.
• Converter clutch valve stuck or assembled backwards.
• Converter clutch valve retaining ring mispositioned.
• Pump to case gasket mispositioned
• Orifice cup plug restricted or damaged
• Solenoid O-ring seal cut or damaged.
• High or uneven bolt torque (pump body to cover).
• Turbine shaft O-ring seal cut or damaged.
• Turbine shaft retainer and ball assembly restricted or damaged.
• Contamination
* Damaged seals.
• TCC signal valve stuck
• Solenoid O-ring leaking
Blocked
Internal damage.
Internal damage.
Internal damage.
Internal damage.
Internal damage.

Torque Converter Clutch Shudder

Checks Causes
Electrical • 12 Volts not supplied to transmission
• Outside electrical connector damaged.
• Inside electrical connector, wiring harness or solenoid damaged.
• Electrical short (pinched solenoid wire).
• Solenoid not grounded.
Converter Internal damage.
Oil Pump Assembly • Converter clutch valve stuck or assembled backwards.
• Converter clutch valve retaining ring mispositioned.
• Pump to case gasket mispositioned
• Orifice cup plug restricted or damaged
• Solenoid O-ring seal cut or damaged.
• High or uneven bolt torque (pump body to cover).
Input Housing and Shaft • Turbine shaft O-ring seal cut or damaged.
• Turbine shaft retainer and ball assembly restricted or damaged.
7-158 Automatic Transmission - 4L60-E TransmissiorVTransaxle
Torque Converter Clutch Shudder (cont’d)
Checks Causes
Pressure Switch Assembly • Contamination
• Damaged seals.
Valve Body Assembly • TCC signal valve stuck
• Solenoid O-ring leaking
Solenoid Screen Blocked

No TCC Release
Checks Causes
TCC Solenoid Valve • External ground
• Clogged exhaust orifice
Converter (1) Internal damage
Valve Body Assembly (60) The converter clutch apply valve is stuck in the apply position
Oil Pump Assembly (4) The converter clutch valve (224) is stuck
PCM External ground

Drives in Neutral
Checks Causes
Forward Clutch The clutch does not release
Manual Valve Link (705) Disconnected
Case (8) • The face is not flat
• Internal leakage exists

2nd Gear Start

Checks Causes
Forward Clutch Sprag Assembly (642) The sprag assembly is installed backwards

No Park
Checks Causes
Parking Linkage • Actuator rod assembly bent or damaged.
• Actuator rod spring binding or improperly crimped.
• Actuator rod not attached to inside detent lever.
• Parking lock bracket damaged or not torqued properly.
• Inside detent lever not torqued properly.
• Parking pawl binding or damaged.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-159
Oil Out the Vent
Checks Causes
Oil Pump Chamber in pump body rotor pocket
Miscellaneous Fluid level - overfilled

Vibration in Reverse and Whining Noise in Park

Checks Causes
Oil Pump Chamber in pump body rotor pocket
Miscellaneous Fluid level - overfilled

Ratcheting Noise
Checks Causes
Parking Pawl (81) The parking pawl return spring (80) is weak, damaged, or misassembled

No Drive in All Ranges

Checks Causes
Torque Converter (1) The converter to flex plate bolts are missing

No Drive in Drive Range

Checks Causes
Torque Converter (1) • The stator roller clutch is not holding
• The converter is not bolted to the flex plate

Front Oil Leak

Checks
Torque Converter (1)
Torque Converter Seal (243)
Causes
• The welded seam is leaking
• The converter hub is damaged
• The seal assembly is damaged
• The garter spring is missing

Delay in Drive and Reverse

Checks Causes
Torque Converter (1) Converter drainback
7-160 Automatic Transmission - 4L60-E
Fluid Leak Diagnosis
General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until
normal operating temperatures are reached.
4. Park the vehicle over clean paper or cardboard.
5. Shut OFF the engine.
6. Look for fluid spots on the paper.
7. Make the necessary repairs.
Powder Method
1. Thoroughly clean the suspected leak area
with solvent.
2. Apply an aerosol type powder, such as foot
powder, to the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until
normal operating temperatures are reached.
4. Shut OFF the engine.
5. Inspect the suspected leak area.
6. Trace the leak path through the powder in
order to find the source of the leak.
7. Make the necessary repairs.
Dye and Black Light Method
A fluid dye and black light kit is available from
various tool manufacturers.
1. Follow the manufacturer’s instructions in order
to determine the amount of dye to use.
2. Detect the leak with the black light.
3. Make the necessary repairs.
Repairing the Leak
Pinpoint the leak and trace it back to the source.
You must determine the cause of the leak in order to
repair the leak properly. For example, if you replace
a gasket, but the sealing flange is bent, the new
gasket will not repair the leak. You must also repair
the bent flange. Before you attempt to repair a leak,
check for the following conditions, and make repairs
as necessary:
Gaskets
• Fluid level/pressure is too high
• Plugged vent or drain-back holes
• Improperly tightened fasteners
• Dirty or damaged threads
• Warped flanges or sealing surface
• Scratches, burrs, or other damage to the
sealing surface
• Damaged or worn gasket
• Cracking or porosity of the component
• Improper sealant used, where applicable
• Incorrect gasket
Transmission/Transaxle
Seals
• Fluid level/pressure is too high
• Plugged vent or drain-back holes
• Damaged seal bore
• Damaged or worn seal
• Improper installation
• Cracks in component
• Manual or output shaft surface is scratched,
nicked, or damaged
• Loose or worn bearing causing excess
seal wear
Possible Points of Fluid Leaks
Transmission Oil Pan
• Incorrectly tightened oil pan bolts.
• Improperly installed or damaged oil pan gasket.
• Damaged oil pan or mounting face.
• Incorrect oil pan gasket.
Case Leak
• Damaged or missing fill tube seal.
• Mislocated fill tube bracket.
• Damaged vehicle speed sensor seal.
• Damaged manual shift seal.
• Loose or damaged oil cooler connector fittings.
• Worn or damaged propeller shaft oil seal.
• Loose line pressure pipe plug.
• Porous casting.
Leak at the Torque Converter End
• Converter leak in the weld area.
• Converter seal lip cut. Check the converter
hub for damage.
• Converter seal bushing moved forward
and damaged.
• Converter seal garter spring missing from
the seal.
• Porous casting of the transmission case or
the oil pump.
Leak at the Vent Pipe or the Fluid Fill Tube
• Overfilled system.
• Water or coolant in the fluid. The fluid
will appear milky.
• Transmission case porous.
• Incorrect fluid level indicator.
• Plugged vent.
• Drain-back holes plugged.
• Mispositioned oil pump to case gasket,
if equipped.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-161
Leak Inspection Points

208613
Legend
(1) Wiring Harness Pass-Through Connector (9) Pump to Case Oil Seal
O-Ring Seal (10) Pump Oil Seal Assembly
(2) Transmission Vent Assembly (11) Internal Transmission Speed Sensor to
(3) Converter Housing to Case Joint (Pump to Case O-Ring Seal
Case Oil Seal)
(12) 2-4 Servo Cover O-Ring Seal
(4) Line Pressure Plug
(13) Oil Fill Tube Seal
(5) Case Extension to Case Seal
(14) Oil Cooler Pipe Connectors
(6) Manual Shaft Seal
(15) Transmission Case
(7) Case Extension Oil Seal Assembly
(16) Transmission Oil Pan Gasket
(8) Torque Converter Assembly
7-162 Automatic Transmission - 4L60-E Transmission/Transaxle

Case Porosity Repair

1. Clean the leak area with solvent.
2. Allow the area to air dry.
C a u tio n : E p o x y a d h e s iv e m a y c a u s e s k in
ir r ita tio n s a n d e y e d a m a g e . R e a d a n d fo llo w
a ll in f o r m a t io n o n th e c o n ta in e r la b e l a s
p r o v id e d b y th e m a n u fa c tu re r.

3. Mix a sufficient amount of epoxy adhesive,

P/N 1052533, or equivalent.
Follow the manufacturer’s recommendations.
4. While the transmission case is hot, apply the
epoxy adhesive with a clean, dry soldering
acid brush.
5. Allow the epoxy adhesive to cure for three
hours before starting the engine.
6. Repeat the fluid leak diagnosis procedures in
order to determine if the leak is fixed.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-163

Repair Instructions
Shift Cable Replacement
Removal Procedure
1. Position the steering column transmission shift
lever to PARK (P).
2. Apply the parking brake.
3. Remove the front seat. Refer to Seats.
4. Remove the door sill trim plate. Refer to Door
Sill Plate Replacement in Interior Trim.
5. Remove the hinge pillar trim panel. Refer to
Hinge Pillar Trim Panel Replacement in
Interior Trim.
6. Remove the carpet and the carpet retainers on
the driver’s side to expose the range select
lever cable.
7. Remove the steering column filler panel from
the steering column.
8. Disconnect the range select lever cable from
the steering column shift control.

9. Disconnect the range select lever cable from

the retainers on the cab floor pan.
10. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.

102220
7-164 Automatic Transmission - 4L60-E Transmission/Transaxle
11. Remove the cable retainer from the
transmission mounted bracket. Squeeze the
cable retainer while pulling the cable towards
the rear of the vehicle.
12. Disconnect the cable end from the transmission
range select lever ball stud.
13. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until the lever reaches the full
clockwise stop position.

14. Remove the range select lever cable from

under the fuel line and from the rear
transmission bracket.
15. Note the routing of the range select lever
cable on the vehicle before removal.
16. Remove the safety stands.
17. Lower the vehicle.
18. Remove the range select lever cable grommet
from the floor panel.
19. Remove the range select lever cable from
the vehicle.

Installation Procedure
1. Position the steering column transmission
PR N ® 3 2 1 shift lever to PARK (P).

102215
Transmission/Transaxle Automatic Transmission - 4L60-E 7-165
2. Ensure that the transmission is in the
mechanical park position. Position the
transmission range select lever to PARK (P).
Rotate the range select lever clockwise until the
lever reaches the full clockwise stop position.
3. Install the range select lever cable to the
vehicle. Route the cable in the original location
noted during removal.

4. Install the range select lever cable grommet

to the floor panel.
5. Install the range select lever cable retainers
on the cab floor pan.

6. Install the range select lever cable end to the

steering column shift control.
7. Install the steering column filler panel to the
steering column.
8. Install the carpet and the carpet retainers on
the driver’s side.
9. Install the door sill trim plate. Refer to Door Sill
Plate Replacement in Interior Trim.
10. Install the hinge pillar trim panel. Refer to Hinge
Pillar Trim Panel Replacement in Interior Trim.
11. Install the front seat. Refer to Seats.
12. Make sure that the steering column
transmission shift lever is in Park (P).
13. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
in General Information.

102218
7-166 Automatic Transmission - 4L60-E Transmission/Transaxle
14. Route the range select lever cable under
the fuel lines.
15. Connect the range select lever cable to the
rear transmission bracket.
16. Install the range select lever cable retainer
to the transmission cable bracket.

17. Remove the black shipping clip from the new

range select lever cable. Discard the clip.
18. Install the range select lever cable end to the
transmission range select lever. Push the cable
end onto the transmission range select lever
stud ball.
19. Adjust the range select lever cable. Refer
to Shift Cable Adjustment.

Shift Cable Adjustment

1. Position the steering column transmission
PRN0321 shift lever to PARK (P).
2. Apply the parking brake.
3. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.

102215
Transmission/Transaxle Automatic Transmission - 4L60-E 7-167
4. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until it reaches the full mechanical
stop position.

102224
5. Slide the black retaining clip forward on the
range select lever cable end. This will allow the
white lock button to be pushed out.

6. Push the white lock button on the range select

lever cable end out. This will free the metal core
adjust body which is inside the cable end. Do not
push the white lock button completely out.
7. Inspect the metal core adjust body on the cable
end for dirt or debris that may restrict the
travel. Remove any debris by washing the
cable end, the metal core adjust body, and the
white lock button with soap and water. If the
travel of the metal core adjust body remains
restricted after the cleaning, replace the cable
assembly. Refer to Shift Cable Replacement.
8. Remove the safety stands.
9. Lower the vehicle.
10. Ensure that the parking brake is applied.
11. Turn ON the ignition switch.

102241
7-168 Automatic Transmission - 4L60-E Transmission/Transaxle
12. Move the transmission shift lever from
PARK (P) to 1 and back to PARK (P)
ten times.

13. Place the steering column transmission shift

lever in the Park (P) position.
PR N ® 3 2 1 14. Turn the ignition switch to the OFF position.
15. Raise the vehicle. Support the vehicle with
safety stands.

102215
16. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until it reaches the mechanical
stop position.

102224
Transmission/Transaxle Automatic Transmission - 4L60-E 7-169
17. Push in the white lock button in order to secure
the core adjuster body inside the range select
lever cable end.

18. Slide the black retainer clip rearward over the

cable end until it covers the white lock button.
Lock the clip over the cable end.
19. Remove the safety stands.
20. Lower the vehicle.
21. Turn ON the ignition switch.
22. Ensure that all the transmission shift light
positions (P, R, N, D, 3, 2, 1) engaged and
illuminate. If you cannot perform this task,
repeat the cable adjustment procedures.
C a u t io n : W ith t h e s e l e c t o r l e v e r i n th e P A R K
p o s it io n , th e p a r k in g p a w l s h o u ld fr e e ly
e n g a g e w ith in th e r e a r r e a c t io n in t e r n a l g e a r
lu g s o r o u tp u t r in g h e a r lu g s a n d p r e v e n t
th e v e h ic le f r o m r o llin g , w h ic h c o u ld c a u s e
p e r s o n a l in ju r y .

23. Position the steering column transmission shift

lever to PARK (P). The shift position light
should illuminate. If you cannot perform this
task, repeat the cable adjust procedures.
24. Ensure that the engine starts in PARK (P) and
in NEUTRAL (N) positions only. If the engine
does not start in PARK (P) and in NEUTRAL
(N), the Park/Neutral Position Switch may need
adjustment. Refer to Park/Neutral Back Up
Switch Adjustment
25. Turn the ignition switch to LOCK.
26. Ensure that the ignition key can only be
removed with the transmission shift lever in
the PARK (P) position.
27. Start the engine and check the vehicle
transmission shifting. The range select lever
cable is properly adjusted if the steering column
shift light positions are the same as the
transmission engagements.
28. Release the parking brake.
7-170 Automatic Transmission - 4L60-E Transmission/Transaxle

Park/Neutral Back Up Switch Replacement

Removal Procedure
1. Apply the parking brake.
2. Shift the transmission into neutral.
3. Disconnect the negative battery cable.
4. Remove the nut securing the transmission
control lever to the manual shaft.
5. Remove the transmission control lever from
the manual shaft.
6. Disconnect the wiring harness connector from
the park/neutral position switch.
7. Remove two bolts securing the park/neutral
position switch to the transmission.
8. Remove the park/neutral position switch from
the manual shaft.

Installation Procedure
Tools Required
J 41364-A
1. Position the J 41364-A onto the park/neutral
position switch. Ensure that the two slots on the
switch where the manual shaft is inserted are
lined up with the lower two tabs on the tool.
2. Rotate the tool until the upper locator pin on
the tool is lined up with the slot on the top of
the switch.

3. If the park/neutral position switch did not slide

off the manual shaft, file the outer edge of the
manual shaft in order to remove any burrs.
4. Install the switch to the transmission manual
shaft by aligning the switch hub flats with the
manual shaft flats.
5. Slide the switch onto the transmission manual
shaft until the switch mounting bracket contacts
the mounting bosses on the transmission.
6. Install the switch to the transmission with
two bolts.
Tighten
Tighten the bolts securing the switch to
28 N.m (21 lb ft).
Remove the J 41364-A from the switch.
Install the wiring harness connectors to
the switch.

32650
Transmission/Transaxle Automatic Transmission - 4L60-E 7-171
9. Install the transmission control lever to
the manual shaft with the nut.
Tighten
Tighten the control lever nut to
28 N-m (21 lb ft).
10. Lower the vehicle.
11. Connect the negative battery cable. Refer to
Battery.
12. Inspect the switch for proper operation. The
engine must start in the Park or Neutral
positions only. If adjustment is required, loosen
the switch retaining bolts and rotate the switch
slightly, then tighten the bolts and check the
switch for proper operation.

Park/Neutral Back Up Switch Adjustment

Adjustment Procedure
• Check the switch for proper operation.
• The engine must be in the P (Park) or
N (Neutral) positions only. If adjustment is
required, loosen the switch retaining bolts
and rotate the switch slightly.
• Tighten the bolts and check the switch for
proper operation.
• Repeat the switch adjustment procedure
until the engine starts when the shift lever
is positioned in park and neutral.
AT Fluid/Filter Changing
Removal Procedure
1. Raise the vehicle. Refer to Section 0A.
2. Support the vehicle with safety stands.
3. Remove the upper and lower underbody
braces, if equipped. Refer to Section 10-3
4. Place the drain pan under the transmission
oil pan.
Notice: When removing the oil pan bolts, be
careful not to damage the oil pan sealing
surfaces. Such damage may result in oil leaks
in this area.
5. Remove the oil pan bolts from the front and
sides only.
6. Loosen the rear oil pan bolts approximately
4 turns. 23578
7. Lightly tap the oil pan with a rubber mallet or
pry gently in order to allow the fluid to drain.
7-172 Automatic Transmission - 4L60-E Transmission/Transaxle
8. Remove the remaining oil pan bolts.

9. Remove the oil pan and the gasket.

10. Remove the fluid filter and the seal. The

seal may stick in the transmission case.
11. Inspect the fluid color.
12. Inspect the filter. Pry the metal crimping away
from the top of the filter and pull apart. The
filter may contain the following evidence for root
cause diagnosis:
• Clutch material
• Bronze slivers indicating bushing wear
• Steel particles
13. Clean the transmission case and the oil pan
gasket surfaces with solvent, and air dry. You
must remove all traces of the old gasket
material.

13958
Transmission/Transaxle Automatic Transmission - 4L60-E 7-173
Installation Procedure
Tools Required
J 36850 Transmission Assembly Lube
1. Coat the new filter neck seal with a small
amount of J 36850, or equivalent.
2. Install the new filter neck seal into the
transmission case. Tap the seal into place
using a suitable size socket.
3. Install the new filter into the case.

13958
4. Install the oil pan and a new gasket.

13955
N o t i c e : Do not reuse automatic transmission bolts
and washers if the conical washer is reversed.
Failure to replace the oil pan bolts and washers may
result in improper fastening of the system
components.
N o tic e : Refer to Fastener Notice in Cautions and
Notices.
5. Install the oil pan bolts.
Tighten
Alternately, and evenly, tighten the oil pan to
transmission case bolts to 11 N-m (97 lb in).
6. Install the upper and lower underbody braces,
if equipped. Refer to Section 10-3.
7. Lower the vehicle.
N o t i c e : Do not overfill the transmission.
Overfilling will result in foaming, loss of fluid,
and possible damage to the transmission. 13952
7-174 Automatic Transmission - 4L60-E Transmission/Transaxle
8. Fill the transmission to the proper level. Use
DEXRON® III, or if unavailable, DEXRON® HE.
9. Check the COLD fluid level reading for initial fill
only. Refer to Transmission Fluid Checking
Procedure.
10. Inspect the oil pan gasket for leaks.
Oil Cooler Line Replacement
Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to
General Vehicle Lifting and Jacking in General
Information.
2. For the 4.3L Engine, remove the retainer clips
and the brackets that secure the transmission
cooler lines to the engine.

3. For the 5.0L Engine, remove the retainer clips,

the bolts and the brackets that secure the
transmission cooler lines to the engine.

106944
Transmission/Transaxle Automatic Transmission - 4L60-E 7-175
4. For the 5.7L Engine, remove the retainer clips,
the bolts and the brackets that secure the
transmission cooler lines to the engine.

5. For the 5.7L Engine, in order to remove the

cooler line and the cooler, remove the bolts and
clips that secure the transmission cooler lines
and the cooler to the engine.

6. Disconnect the oil cooler pipe from the

connector at the radiator.
Important: Perform the following procedures
when removing the retaining ring and cooler
line from the quick connect fitting on the
transmission.
7. Pull the plastic cap back from the quick connect
fitting and down along the cooler line about
two inches.

106047
7-176 Automatic Transmission - 4L60-E Transmission/Transaxle
8. Using a bent-tip screwdriver, pull on one of the
open ends of the retaining ring in order to
rotate the retaining ring around the quick
connect fitting until the retaining ring is out of
position and can be completely removed.

104737
9. Remove the retaining ring from the quick
connect fitting.
10. Discard the retaining ring.

11. Pull the cooler line straight out from the quick
connect fitting.
12. Remove the retaining ring (E-clips) securing the
cooler line to the quick connect in order to
remove the remaining cooler lines from the
remaining quick connect fittings.
13. Remove the cooler lines from the vehicle.

104740
Transmission/Transaxle Automatic Transmission - 4L60-E 7-177
Installation Procedure
1. Install the transmission oil cooler line to
the vehicle.
important:
• Do not reuse any of the existing retaining
rings that were removed from the existing
quick connect fittings. All retaining rings
being installed must be new.
• Ensure the following procedures are
performed when installing the new
retaining rings onto the fittings.
2. Install a new retaining ring (E-clip) into the
quick connect fitting using the following
procedure:
3. Hook one of the open ends of the retaining ring
in one of the slots in the quick connect fitting.

104743
4. Rotate the retaining ring around the fitting until
the retaining ring is positioned with all three
ears through the three slots on the fitting.

5. Do not install the new retaining ring onto the

fitting by pushing the retaining ring.

104741
7-178 Automatic Transmission - 4L60-E Transmission/Transaxle
Ensure that the three retaining ring ears are
seen from inside the fitting and that the
retaining ring moves freely in the fitting slots.
7. Install the new retaining ring (E-clip) into the
remaining quick connect fittings.

Notice: Ensure that the cooler line being installed

has a plastic cap on each end that connects to a
quick connect fitting. If no plastic cap exists, or the
plastic cap is damaged, obtain a new plastic cap
and position on to the cooler line prior to the
cooler line installation.
8. Install the cooler lines to the vehicle.

104740
9. Install the cooler line into the quick
connect fitting.
10. Insert the cooler line end into the quick connect
fitting until a click is either heard or felt.

104752
Transmission/Transaxle Automatic Transmission - 4L60-E 7-179
11. Do not use the plastic cap on the cooler line in
order to install the cooler line into the fitting.
12. Pull back sharply on the cooler line in order to
ensure that the cooler line is fastened into the
quick connect fitting.

104750
13. Position (snap) the plastic cap onto the fitting.
Do not manually depress the retaining ring
when installing the plastic cap onto the quick
connect fitting.
14. Ensure that the plastic cap is fully seated
against the fitting.

104753
15. Ensure that no gap is present between the cap
and the fitting.

104754
7-180 Automatic Transmission - 4L60-E Transmission/Ttansaxle
16. Ensure that the yellow identification band on
the tube is hidden within the quick connect
fitting. A hidden yellow identification band
indicates proper joint seating.

17. Do not install the cooler line end into the

fitting incorrectly.
18. If you cannot position the plastic cap against
the fitting, remove the retaining ring from the
quick connect fitting per Step 5 of the cooler
line removal procedure. Check the retaining ring
and the tube end in order to ensure neither is
bent. Replace the cooler line or the retaining
ring if necessary, and reinstall per Step 2 of the
cooler line installation procedure.
19. Install the cooler line into the quick connect
fitting again in order to install the remaining
cooler lines into the remaining quick connect
fittings.
20. Install the engine or transmission cooler lines to
the engine and transmission clips and brackets
as applicable. Refer to Cooling and Radiator,
4L60-E Automatic Transmission On-vehicle
104755 Service, or 4L80-E Automatic Transmission
On-vehicle Service.
21. For the 5.7L Engine, in order to install the
cooler line and the cooler, remove the bolts and
clips that secure the transmission cooler lines
and the cooler to the engine.

106946
Transmission/Transaxle Automatic Transmission - 4L60-E 7-181
22. For the 5.7L Engine, install the retainer dips,
the bolts and the brackets that secure the
transmission cooler lines to the engine.

23. For the 5.0L Engine, install the retainer clips,

the bolts and the brackets that secure the
transmission cooler lines to the engine.

106944
24. For the 4.3L Engine, install the retainer clips
and the brackets that secure the transmission
cooler lines to the engine.
25. Install the flair nuts securing the oil cooler lines
to the radiator or the auxiliary oil cooler if
equipped.
Tighten
Tighten the flair nuts to 45 N.m (33 lb ft).

106943
7-182 Automatic Transmission - 4L60-E Transmission/Transaxle
Transmission Oil Cooler Replacement
Removal Procedure
1. Disconnect the oil cooler line from the oil
cooler. Refer to Oil Cooler Line Replacement
2. Remove the four bolts securing the auxiliary oil
cooler brackets to the radiator support.
3. Remove the four bolts and the nuts securing
the auxiliary oil cooler to the two brackets.

Installation Procedure
1. Install the four bolts and the nuts securing the
auxiliary oil cooler to the two brackets.
Tighten
Tighten the bolts to 6 N.m (53 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the four bolts securing the oil cooler
brackets to the radiator support.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
3. Connect the oil cooler line to the oil cooler.
Refer to Oil Cooler Line Replacement

2-4 Servo (n)

Removal Procedure
Tools Required
J 29714-A Servo Cover Depressor
1. Raise the vehicle. Refer to General Vehicle
Lifting and Jacking in General Information.
2. Support the vehicle with safety stands.
3. Lower the transmission if needed for clearance.
Refer to Transmission Replacement
4. Install the J 29714-A.
TransmissiorVTransaxle Automatic Transmission - 4L60-E 7-183
5. Tighten the bolt in order to compress the
servo cover.
6. Remove the servo cover retaining ring.
7. Remove the J 29714-A.

8. Remove the servo cover and the O-ring seal.

If the servo cover seems to be hung up on
the seal, cut and remove the O-ring seal
before removing the cover.
9. Remove the 2 -4 servo assembly.

Disassembly Procedure
Tools Required
J 22269-01 Piston Remover
1. Remove the following parts:
• The 4th apply piston
• The servo return spring

102349
7-184 Automatic Transmission - 4L60-E Transmission/Transaxle
2. Remove the following parts:
2.1. The retainerring
2.2. The washer
2.3. The spring
2.4. The 2nd applypiston pin

3. Install the J 22269-01 in order to compress the

second apply piston.
4. Remove the second apply piston retaining ring.
5. Remove the servo cushion spring retainer and
the servo cushion spring.

6. Remove the seals from the cover, the housing,

and the pistons.
Important: Check the case servo bore for
damage and sharp edges.
7. Clean all the parts using solvent.
8. Air dry all the parts.
9. Inspect the pistons for porosity and damage.
10. Inspect the seal grooves for damage.
11. Inspect the cover for porosity and damage.
12. Inspect for nicks, cuts, and binding in the seal
grooves. If damage is found, check for the
cause of the damage.
13. Inspect the springs for kinks and bending.
14. Inspect the pin for wear and burrs.

7758
Transmission/Transaxle Automatic Transmission - 4L60-E 7-185
Tools Required
J 33037 Band Apply Pin Tool
1. Install the band apply pin and the J 33037.
2. Install the sen/o cover retaining ring to
secure the tool.

3. Apply 11 N.m (98 lb in) torque. If the white

line appears in the gauge slot, the pin length
is correct.
4. If the white line is not seen in the slot, replace
the pin using the following pin identification:
• One groove, pin length 65.82—66.12 mm
(2.59—2.60 in)
• Two grooves, pin length 67.23—67.53 mm
(2.65—2.66 in)
• No grooves, pin length 68.64—68.94 mm
(2.70—2.71 in)
5. Remove the pin and the J 33037.

6. Check the 2nd apply piston and the housing

dimension.
7. Measure the piston (25) dimension (1)
8. Measure the housing (22) dimension (2)
9. Check the chart for the transmission and
piston/housing specifications. Refer to Forward
Clutch Piston Travel Check.

102350
7-186 Automatic Transmission - 4L60-E Transmission/Transaxle

Assembly Procedure
Tools Required
J 22269-01 Piston Remover
1. Install new seals on all the 2 -4 servo pistons
and the cover.

7758
2. Install the servo cushion spring and the cushion
spring retainer in the 2nd apply piston. Use the
J 22269-01 in order to compress the second
apply piston.
3. Install the second apply piston retaining ring.

4. Install the following parts:

4.1. The 2nd apply piston pin
4.2. The spring
4.3. The washer
4.4. The retainerring

5430
Transmission/Transaxle Automatic Transmission - 4L60-E 7-187
5. Install the following parts:
5.1. The servo return spring
5.2. The 4th apply piston

Installation Procedure
Tools Required
J 29714-A Servo Cover Compressor
1. Install the 2-4 servo assembly into the
2-4 servo bore.
2. Install the J 29714-A.

3. Tighten the bolt in order to compress the

servo cover.
4. Install the servo cover retaining ring.
5. Remove the J 29714-A from the oil pan flange.
6. Install the oil pan bolt.
Tighten
Tighten the oil pan bolt to 11 N.m (97 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
7. Remove the safety stands.
8. Lower the vehicle.
9. Check the automatic transmission fluid level
and install new automatic transmission fluid as
needed. Refer to Transmission Fluid Checking
Procedure and to Fluid Capacity.

14478
7-188 Automatic Transmission - 4L60-E Transmission/Transaxle
Filler Tube Replacement
Removal Procedure
1. Remove the engine air cleaner. Refer to
Engine Controls.
2. Remove the transmission fluid level indicator
from the fluid fill tube.
3. For the 4.3L engine, remove the stud and the
nut securing the transmission fluid level
indicator tube bracket to the transmission.

4. For the 5.0L or the 5.7L engine, remove the

bolt securing the transmission fluid level
indicator tube bracket to the transmission.
5. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.
6. Remove the transmission fluid fill tube from the
transmission. Pull the tube upward from the
transmission.
7. Remove the transmission fill tube seal.
8. Clean the metal parts using solvent. Do not
allow the solvent to enter the transmission.
9. Air dry the parts.

Installation Procedure
1. Install a new oil level indicator tube seal into
the transmission case.
2. Install the oil level indicator tube into the seal.
3. For the 4.3L engine, install the stud and the nut
that secures the oil level indicator tube bracket
to the transmission.
Tighten
• Tighten the nut to 25 N-m (18 lb ft).
• Tighten the stud to 47 N-m (35 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

102289
Transmission/Transaxle Automatic Transmission - 4L60-E 7-189
4. For the 5.0L or 5.7L engine, install the bolt
securing the oil level indicator tube bracket to
the transmission.
Tighten
Tighten the bolt to 47 N-m (35 lb ft).
5. Remove the safety stands.
6. Lower the vehicle.
7. Install the air cleaner. Refer to Engine Controls.
8. Install the oil level indicator.
9. Check the transmission fluid level. Refer to
Transmission Fluid Checking Procedure.

102291
Torque Converter Cover Replacement
Removal Procedure
1. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Raise the vehicle. Refer to Section OA.
3. Support the vehicle with safety stands.
4. Remove the starter. Refer to Starter Motor
Replacement in Engine Electrical.
5. Remove the converter cover bolts.
6. Remove the cover.

Installation Procedure
1. Install the cover.
2. Install the converter cover bolts.
Tighten
Tighten the bolts to 10 N-m (89 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Install the starter. Refer to Starter Motor
Replacement in Engine Electrical.
4. Lower the vehicle.
5. Connect the negative battery cable.

13902
7-190 Automatic Transmission - 4L60-E TransmissionTTransaxle

Flywheel to Torque Converter Bolts

Removal Procedure
1. Disconnect the negative battery.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.
3. Remove the starter. Refer to Starter Motor
Replacement in Engine Electrical.
4. 4L60-E transmissions connecting to 4.3L engines
have a full bellhousing, no torque converter cover.
In order to gain access to the converter bolts,
remove the dust plug in the starter mounting port.
5. Remove the converter cover bolts and the
converter cover.

Important: Mark the alignment of the flywheel and

the converter in order to retain a proper balance.
6. Remove the flywheel to converter bolts.

Installation Procedure
Important: All flywheel to converter bolts should be
hand started before tightening in order to ensure
proper alignment, and in order to avoid
cross-threading.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the flywheel to converter bolts. Hand
start the bolts.
Tighten
Tighten the bolts to 63 N-m (46 lb ft).

1390S
Transmission/Transaxle Automatic Transmission - 4L60-E 7-191
2. Install the converter cover and the converter
cover bolts.
Tighten
Tighten the bolts to 10 N-m (89 lb in).
3. Install the starter motor. Refer to Starter Motor
Replacement in Engine Electrical.
4. Lower the vehicle.
5. Connect the negative battery cable.

13902

Oil Pan Replacement

Removal Procedure
Notice: Use Transjel™ J 36850 or equivalent during
assembly in order to retain checkballs or to lubricate
components. Greases other than the recommended
assembly lube will change the transmission fluid
characteristics and will cause undesirable shift
conditions or filter clogging.
Notice: Do not overfill the transmission. Overfilling
will result in foaming, loss of fluid, and possible
damage to the transmission.
When service requires the removal of the case side
cover and/or bottom oil pan, the washers on the
bolts must be inspected. A new bolt and washer
assembly should be installed if the washer is
inverted.
1. Raise and suitably support the vehicle. Refer to
General Vehicle Lifting and Jacking in General
Information.
2. Place the drain pan under the transaxle bottom
oil pan.
3. Remove the oil pan bolts/screws from the front
and the sides.
Notice: When removing the oil pan bolts, be
careful not to damage the oil pan sealing
surfaces. Such damage may result in oil leaks
in this area.
4. Loosen the rear oil pan bolts/screws
approximately four turns. Care must be taken
not to damage mating surfaces of oil pan and
case. Such damage may result in oil leaks in
this area.
5. Lightly tap the oil pan with the rubber mallet.
6. Pry the oil pan loose with a screwdriver and
allow fluid to drain.
7. Remove the remaining oil pan bolts/screws.
7-192 Automatic Transmission - 4L60-E Transmission/Transaxle
8. Remove the oil pan.

9. Remove the gasket,

inspection
Inspect the oil pan and the filter screen for
foreign material for the following items:
- Metal particles
- Clutch facing material
- Rubber particles
- Engine coolant

10. Determine and correct the source of

contamination.
11. Inspect the oil pan flange for distortion.
12. Straighten the oil pan flange if necessary.
13. Clean the case and the oil pan gasket surfaces
with solvent and air dry.
Notice: If the case and oil pan flanges are not
dry and free of any oil film, leakage may result.
14. Clean all traces of the old gasket materials.

99077
Transmission/Transaxle Automatic Transmission - 4L60-E 7-193
Installation Procedure
1. Install the oil gasket.

2. Install the oil pan.

Tighten
Tighten the bolts/screws to 11 N-m (97 lb in).
Notice: Refer to Fastener Notice in General
Information.
3. Lower the vehicle.
4. Fill the transaxle with the proper quantity of
Dexron-lll.
5. Place the gear selector in PARK.
6. Start engine and run at slow idle. Do not race
the engine.
7. Adjust fluid level.
Inspection
• Inspect the proper completion of repairs.
• Inspect the proper fluid level. Refer to
Transmission Fluid Checking Procedure.
• Inspect the fluid leaks. Refer to Fluid Leak 97331
Diagnosis.
Important: Anytime the transmission and the oil pan
are off the engine at the same time, install the
transmission before the oil pan. This will allow for
the proper measurement of the oil pan tolerance.
Notice: Refer to Fastener Notice in Cautions and
Notices.
7. Use a feeler gage in order to check the
clearance between the three oil
pan-to-transmission contact points. If the
clearance exceeds 0.254 mm (0.010 in.) at any
of the three points repeat the installation steps
until the clearance is within specification.
Tighten
Tighten the oil pan bolts and the studs in
sequence to 25 N-m (18 lb ft).
8. Reconnect the transmission oil cooler lines.
9. Install the starter shield.
10. Install the starter. Refer to Engine Electrical.
7-194 Automatic Transmission - 4L60-E Transmission/Transaxle
11. Install the oil filter adapter.

12. Install the oil cooler lines.

4557
Transmission/Transaxle Automatic Transmission - 4L60-E 7-195
Valve Body
Removal Procedure
C a u tio n : R e f e r t o 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. Disconnect the battery negative cable assembly

from the battery negative terminal.
2. Remove the transmission fluid and the fluid
filter. Refer to AT Fluid/Filter Changing.

3. Remove all electrical connectors from

the electrical components.

5443
7-196 Automatic Transmission - 4L60-E Transmission/Transaxle
4. Remove the TCC PWM retainer clip.
5. Remove the TCC PWM solenoid.

6. Remove the TCC solenoid bolts; and remove

the valve body bolts that hold the wiring
harness down.

7. Remove the TCC solenoid and the

wiring harness.

5446
Transmission/Transaxle Automatic Transmission - 4L60-E 7-197
8. Remove the pressure switch assembly bolts.
9. Remove the pressure switch assembly.

10. Remove all valve body bolts.

11. Remove the oil level indicator gauge
stop bracket.

12. Lower the valve body carefully so that the

checkballs remain on the spacer plate in the
correct location. While lowering the valve body,
disconnect the manual valve link from the
transmission manual valve.

5449
7-198 Automatic Transmission - 4L60-E Transmission/Transaxle
13. Remove the seven valve body checkballs.

Installation Procedure
Tools Required
J 36850 Transjel® Transmission Assembly Lubricant
1. Install the seven check balls in the valve body
and retain check balls with J 36850 or the
equivalent.

2. Install the valve body and connect the manual

valve link to the inside detent lever.

7742
Transmission/Transaxle Automatic Transmission - 4L60-E 7-199
3. Install the oil level indicator gauge stop bracket
and the valve body bolts that are shown only.
4. Finger tighten the bolts.

5. Inspect the transmission pressure switch

assembly for the following defects:
• Damage
• Debris

7744

7745
7-200 Automatic Transmission - 4L60-E Transmission/Transaxle
7. Inspect the wiring harness solenoid assembly
for the following defects:
• Damage
• Cracked connectors
• Exposed wires
• Loose pins

8. Install the transmission wiring harness on the

valve body.
9. Install the TCC solenoid and bolts to hold the
wiring harness.

N o t i c e : Torque valve body bolts in a spiral pattern

starting from the center. If the bolts are torqued at
random, valve bores may be distorted and inhibit
valve operation.
N o t ic e : Refer to Fastener Notice in Cautions and
Notices.
10. Install the remaining valve body attaching bolts.
Tighten
Tighten the valve body bolts to 11 N-m (8 lb ft).

7748
Transmission/Transaxle Automatic Transmission - 4L60-E 7-201
11. Install the TCC PWM solenoid.
12. Install the TCC PWM retainer clip.

13. Install all the electrical connectors to all the

electrical components.
14. Install the oil pan, the oil filter, and the oil pan
gasket. Refer to Oil Pan Replacement.

15. Remove the safety stands.

16. Lower the vehicle.
17. Connect the battery negative cable assembly
to the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N-m (11 lb ft).
18. Install new automatic transmission fluid. Refer
to Fluid Capacity and to Transmission Fluid
Checking Procedure.

38205
7-202 Automatic Transmission - 4L60-E Transmission/Transaxle

Control and Shift Solenoids Replacement

Removal Procedure
1. Remove the oil pan and the oil filter. Refer to
AT Fluid/Filter Changing.
2. Remove the accumulator cover bolts.

3. Remove the 1-2 accumulator cover.

4. Remove the piston.
5. Remove the springs.
6. Disconnect the component electrical connectors.

7. Remove the pressure control solenoid retainer

bolt/screw.

13B76
Transmission/Transaxle Automatic Transmission - 4L60-E 7-203
8. Remove the pressure control solenoid retainer.
9. Remove the pressure control solenoid.

10. Remove the shift solenoid retainers.

11. Remove the shift solenoids.

13364
7-204 Automatic Transmission - 4L60-E Transmission/Transaxle
12. Remove the 3-2 control solenoid retainer.

13. Remove the control solenoid.

Installation Procedure
1. Install the 3-2 control solenoid.

13886
Transmission/Transaxle___________ Automatic Transmission - 4L60-E 7-205
2. Install the 3-2 control solenoid retainer.

13365
3. Install the shift solenoids.

13364
4. Install the shift solenoid retainers.

13884
7-206 Automatic Transmission - 4L60-E Transmission/Transaxle
5. Install the pressure control solenoid.
6. Install the pressure control solenoid retainer.

7. Install the pressure control solenoid retainer

bolt/screw.
Position the pressure control solenoid with the
electrical tabs facing outboard.
8. Connect the component electrical connectors.

9. Install the 1-2 accumulator piston to the

accumulator cover.
The piston legs must face toward the
case when installed.
10. Install the 1-2 accumulator springs into
the piston.
11. Install the 1-2 accumulator cover.

14467
Transmission/Transaxle Automatic Transmission - 4L60-E 7-207
12. Install the 1-2 accumulator cover bolts.
Tighten
Tighten the bolts to 11 N-m (97 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
13. Install the oil pan and the oil filter. Refer to
AT Fluid/Filter Changing.

TCC PWM Solenoid, TCC Solenoid, and

Wiring Harness
Removal Procedure
Tools Required
J 28458 Power Piston Seal Protector and Diaphragm
Retainer Installer
1. Remove the warm-up three-way catalytic
converter and the heat shield. Refer to Catalytic
Converter Replacement in Engine Exhaust.
2. Remove the oil pan and the oil filter. Refer to
AT Fluid/Filter Changing.
3. Remove the external wiring harness connector
from the transmission pass-through connector.
Squeeze the fore and aft flats on the connector
in order to release the locking tabs. Pull the
connector.
4. Remove the accumulator cover bolts.
5. Remove the 1-2 accumulator cover.
6. Remove the piston.
7. Remove the springs.
8. Remove the component electrical connectors.

14467
7-208 Automatic Transmission - 4L60-E Transmission/Transaxle
9. Remove the TCC PWM solenoid retainer.

10. Remove the TCC PWM solenoid from the

control valve body.

13886
11. Remove the pressure control solenoid retainer
bolt/screw.

13876
TransmissionTTransaxle_________________ Automatic Transmission - 4L60-E 7-209
12. Remove the pressure control solenoid retainer.
13. Remove the pressure control solenoid.

14. Remove the TCC solenoid valve bolts.

15. Use the J 28458 in order to remove the
pass-through electrical connector from the
transmission case.
Place the small end of the J 28458 over the
top of the connector.
Twist the J 28458 in order to release the four
tabs while pulling the harness connector from
the transmission case.
16. Remove the TCC solenoid valve with the
wiring harness from the transmission case.

Installation Procedure
1. Install the TCC solenoid with the wiring
harness to the transmission case.
2. Install the pass-through electrical connector
to the transmission case.
3. Install the TCC solenoid bolts and screws.

5445
7-210 Automatic Transmission - 4L60-E Transmission/Transaxle
4. install the pressure control solenoid.
5. Install the pressure control solenoid retainer.

6. Install the pressure control solenoid retainer

bolt and screw.
Tighten
• Tighten the TCC solenoid bolts/screws to
11 N.m (97 lb in).
• Tighten the pressure control solenoid
bolt/screw to 11 N.m (97 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.

13876

7. Install the TCC PWM solenoid to the

control valve body.

13886
Transmission/Transaxle Automatic Transmission - 4L60-E 7-211
8. Install the TCC PWM solenoid retainer.
Important: The piston legs must face toward
the case when installed.
9. Connect the component electrical connectors.

13365
10. Install the 1-2 accumulator piston to the
accumulator cover.
11. Install the 1-2 accumulator springs onto
the piston.
12. Install the 1-2 accumulator cover.

13. Install the 1-2 accumulator cover bolts.

Tighten
Tighten the bolts to 11 N-m (97 lb in).
14. Install the wiring harness connector to the
transmission pass-through connector.
15. Install the oil pan and the oil filter. Refer to
AT Fluid/Filter Changing.
16. Install the warm-up three way catalytic
converter and the catalytic converter heat
shield. Refer to Catalytic Converter
Replacement in Engine Exhaust.

14464
7-212 Automatic Transmission - 4L60-E Transmission/Transaxle

Control Valve Assembly

Cleaning Procedure
C a u t io n : S o m e v a lv e s a r e u n d e r p r e s s u r e . C o v e r
th e b o re s w h ile r e m o v in g th e r o ll p in s o r
p e r s o n a l in ju r y c o u ld r e s u lt.

1. Clean the control valve assembly thoroughly in

clean solvent.
2. Move the valve with a pick or small screwdriver
in order to dislodge any dirt or debris that may
have accumulated.
3. Air dry.

Disassemble Procedure
Important: Valves, springs, and bushings must be
laid out on a clean surface in the exact sequence
they were removed.
1. Disassemble the pressure control solenoid
retainer bolt, retainer, and solenoid.
2. Disassemble the bore plug retainer clip,
bore plug, and valve train.

3. Disassemble the 2-3 shift solenoid retainer,

solenoid, and valve train.

7636
Transmission/Transaxle Automatic Transmission - 4L60-E 7-213
4. Disassemble the 1-2 shift solenoid retainer,
solenoid, and valve train.

5. Disassemble the accumulator valve train

retainer pin, more plug, and valve train.
6. Disassemble the forward accumulator
cover bolts and cover.
7. Disassemble the forward accumulator spring,
piston, and pin.
8. Disassemble the low overrun valve spring
and valve.
9. Disassemble the retainer pin, bore plug,
and the 3-2 control valve train.
10. Disassemble the manual valve.
11. Disassemble the 3-2 control solenoid
retainer clip and solenoid.

12. Disassemble the bore plug retainer, bore plug,

and 3-2 control valve train.
13. Disassemble the 3-2 downshift bore plug
retainer, bore plug, and valve train.
14. Disassemble the reverse abuse more plug
retainer pin, bore plug, and valve train.
15. Disassemble the 3-4 shift valve bore plug
retainer, bore plug, and valve train.
16. Disassemble the torque converter clutch signal
valve bore plug retainer, bore plug, and valve.
17. Clean all of the valves, springs, bushings, and
control valve body in clean solvent.
18. Dry using compressed air.

7633
7-214 Automatic Transmission - 4L60-E Transmission/Transaxle
Inspection Procedure
1. Inspect all of the valves and bushings for the
following conditions:
- Porosity
- Scoring
- Nicks
- Scratching
2. Inspect the springs for damaged or distorted
coils
3. Inspect the valve body casting for the following
conditions
- Porosity
- Cracks
- Interconnected oil passages
- Damaged machined surfaces

Assembly Procedure
1. When assembling the control valve assembly,
notice the position of the valve lands and
bushing passages.
2. Position the pressure control solenoid so that
the connectors face outward.

Installation Procedure
1. Install the checkballs into the valve body
assembly. Retain with Transjel® or an
equivalent.
2. Install the valve body assembly.
• Connect the manual valve link to the inside
detent lever.
• Do not damage the screens when installing
the valve body assembly.
Notice: Torque valve body bolts in a spiral
pattern starting from the center. If the bolts are
torqued at random, valve bores may be
distorted and inhibit valve operation.
3. Install the wiring harness, manual spring
assembly, pressure switch assembly, and all of
the remaining valve body bolts.

5445
TransmissioiVTransaxle Automatic Transmission - 4L60-E 7-215
4. install the TCC solenoid and bolts.
Tighten
Tighten the bolts to 11 N-m (97 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
5. Install the wiring harness connections to the
electrical components. The pressure control
solenoid has two different colored connectors.
The black connector should be installed on the
tab farthest from the valve body.

6. Install the parking bracket.

Tighten
Tighten the bolts to 31 N-m (23 lb ft).

7. Install the 1-2 accumulator piston seal onto

the 1-2 accumulator piston.
Important: The three legs on the piston must
face toward the case when installed.
8. Install the 1-2 accumulator piston into the
1-2 accumulator cover and pin assembly.

7733
7-216 Automatic Transmission - 4L60-E ____ ___ Transmission/Transaxle
9. The 1-2 accumulator spring on the piston.
10. The 1-2 accumulator cover and pin assembly
onto the case.
Tighten
Tighten the bolts to 11 N-m (97 lb in).
11. Install the new filter and gasket, pan bolts
and new fluid.
12. Lower the vehicle.
13. Install the negative battery cable.
14. Adjust the fluid level. Use Dexron® III
Automatic Transmission Fluid or the equivalent.
15. Inspect for leaks.

Extension Housing Rear Oil Seal

Rear Extension Oil Seal Removal Procedure
1. Raise and support the vehicle.
2. Remove the transmission fluid. Refer to
AT Oil Cooler Flushing.
3. Remove the propeller shaft. Refer to Propeller
Shaft in Driveline/Axle.
4. Remove the rear extension oil seal.

Installation Procedure
Required Tools
J 21426 Rear Extension Seal Installer
1. Install the new seal using J 21426.
2. Coat the outer edge of the seal case with
a non-hardening sealer.
3. Install the propeller shaft. Refer to Propeller
Shaft in Driveline/Axle.
4. Lower the vehicle.
5. Install the new transmission fluid.
6. Fill the transmission to the proper level with
Dexron® III Transmission Fluid.

7774
Transmission/Transaxle Automatic Transmission - 4L60-E 7-217

Accumulator Assembly
Removal Procedure
1. Remove the oil pan and filter. Refer to
AT Fluid/Filter Changing.
2. Remove the bolts attaching the cover and
pin to the transmission case.
3. Remove the cover and pin.

4. Remove the piston, ring, and springs. The

piston and ring may remain inside the cover
and pin.
5. Remove the control valve, if replacing the
3 -4 accumulator. Refer to Control Valve
Assembly.

6. Remove the spring, piston, ring, and pin.

7. Inspect the accumulators. Refer to Control
Valve Body and Pressure Switch (Accumulator
Disassembly).

97226
7-218 Automatic Transmission - 4L60-E Transmission/Transaxle
Installation Procedure
1. Install the spring, piston, ring, and pin.
2. Install the control valve, if removed. Refer to
Control Valve Body and Pressure Switch.

97226

3. Install the springs, ring, and piston.

14467

4. Install the cover and pin.

5. Install the bolts attaching the cover and pin
to the transmission case.
Tighten
Tighten the bolts to 11 N.m (97 lb in)
Notice: Refer to Fastener Notice in Cautions
and Notices.
6. Install the oil pan and filter. Refer to
AT Fluid/Filter Changing.

14464
Transmission/Transaxle Automatic Transmission - 4L60-E 7-219

Vehicle Speed Sensor Replacement

Removal Procedure
1. Disconnect the negative battery cable from the
battery negative terminal.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Raise the vehicle. Support the vehicle. Refer to
General Information.
3. Remove the electrical connector at the vehicle
speed sensor.
4. Remove the retaining bolt and the sensor.

Installation Procedure
1. Install the vehicle speed sensor and the
retaining bolt.
Tighten
Tighten the bolt to 10 N-m (89 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the electrical connector at the sensor.
3. Remove the safety stands.
4. Lower the vehicle.
5. Connect the negative battery cable.
Tighten
Tighten the terminal bolt to 15 N-m (11 lb ft).

11835
7-220 Automatic Transmission - 4L60-E Transmission/Transaxle
Transmission Replacement
Removal Procedure
Tools Required
J 21366 Converter Holding Strap
1. Disconnect the battery negative cable.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n
In C a u t io n s a n d N o t ic e s .

2. Raise the vehicle. Support the vehicle. Refer to

General Vehicle Lifting and Jacking in General
Information.
3. Disconnect the range selector cable from the
transmission bracket and from the transmission
range select lever. Refer to Shift Cable
Replacement
4. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in Propeller Shaft.
5. Support the transmission with a transmission
jack.
6. Remove the transfer case if equipped. Refer to
Transfer Case Replacement in Transfer Case.
7. Gasoline Engine—Remove the following
components:
7.1. Two bolts
7.2. Two washers
7.3. One nut
7.4. The transmission to engine brace
8. Diesel Engine—Remove the following
components:
8.1. Two bolts
8.2. Two washers
8.3. One nut
8.4. The transmission to engine brace
9. Remove the transmission rear mount.
10. Remove the frame crossmember.
11. Remove the exhaust pipe from the exhaust
manifolds. Remove the muffler assembly from
the exhaust pipe, if required. Refer to Exhaust
System.

102332
Transmission/Transaxle Automatic Transmission - 4L60-E 7-221
12. For the 5.0L Gasoline Engine: Remove the
six bolts securing the converter cover to the
transmission.
13. For the 4.3L Gasoline Engine: Remove the dust
plug at the end of the starter mounting port in
order to gain access to the converter bolts.

✓
14. For the Diesel Engine and 7.4L/5.7L Engines:
Remove the four bolts securing the converter
cover to the transmission.
15. Mark the flywheel and the torque converter
alignment.

102335
16. Remove the bolts that attach the torque
converter to the engine flywheel.

102211
7-222 Automatic Transmission - 4L60-E Transmission/Transaxie
17. Remove the transmission vent hose.
18. Disconnect the wiring harness connectors from
the vehicle speed sensors and from the park
neutral position switch.
19. Remove all vehicle electrical harness wires,
harness clips, tubes, and brackets that may
interfere with the removal of the transmission.
20. Remove the fluid fill tube and the fill tube seal
from the transmission. Refer to Filler Tube
Replacement
21. Plug the fluid fill tube opening in the
transmission.
22. Disconnect the transmission oil cooler pipes
from the transmission. Refer to the oil cooler
pipe quick connect fittings removal procedure in
Oil Cooler Line Replacement
23. Plug the transmission oil cooler pipe connectors
in the transmission case.
24. Install the J 21366 in order to keep the torque
converter from sliding off of the transmission
turbine shaft.
25. Support the engine with a suitable jack stand
before removing the transmission from the
engine.
26. 5.0L and 5.7L Gasoline Engine: Remove the
studs and bolts securing the transmission to
the engine.

102341
Transmission/Transaxle Automatic Transmission - 4L60-E 7-223
27. 4.3L Gasoline Engine: Remove the studs and
bolts securing the transmission to the engine.
28. Pull the transmission straight back from
the engine.
29. Lower the transmission using the
transmission jack.
30. Flush the transmission oil cooler and the pipes
whenever you remove the transmission for
overhaul, or replacement of the torque
converter, the pump, or the transmission case.
Refer to AT Oil Cooler Flushing.
31. Clean the transmission case using a solvent
dampened cloth. Do not allow solvent to enter
the transmission.
32. Air dry the transmission.
33. Clean all hardware and the flywheel cover
using solvent. Air dry all the parts.
102343
34. Inspect all the components for wear and
damage.
35. Inspect all the seals and the fittings for
signs of wear.
36. Inspect the torque converter for stripped
or broken weld nuts.
37. Inspect the transmission case for cracks.
Installation Procedure
Tools Required
J 21366 Converter Holding Strap
Important:
• The torque converter and the flywheel must
be aligned and must rotate freely.
• Install the brackets, the clips, and the
harnesses to the original locations.
• Install the oil level indicator tube after installing
the transmission.
1. Install the J 21366 in order to keep the torque
converter from sliding off of the transmission
turbine shaft.
2. Raise the transmission into place and remove
the J 21366.
3. Support the transmission with a
transmission jack.
4. Slide the transmission straight onto the locating
pins while lining up the marks on the flywheel
and the torque converter.
5. 5.0L and 5.7L Gasoline Engine: Install the
studs and the bolts securing the transmission
to the engine.
Tighten
Tighten the studs and the bolts to
47 N.m (34 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
7-224 Automatic Transmission - 4L60-E Transmission/Transaxle
6. 4.3L Gasoline Engine: Install the studs and the
bolts securing the transmission to the engine.
Tighten
Tighten the studs and the bolts to
47 N-m (34 lb ft).

7. Install the transmission vent hose.

8. Connect the wiring harness connectors to the
vehicle speed sensors and to the park neutral
position switch.
9. Install all vehicle electrical harness wires,
harness clips, tubes, and brackets removed
before transmission removal.
10. Remove the two plugs from the transmission
case cooler pipe connectors.
11. Install the transmission cooler pipes. Refer to
the oil cooler quick connect fitting installation
procedure in Oil Cooler Line Replacement
12. Install the transmission fluid fill tube and the fill
tube seal. Refer to Filler Tube Replacement

13. Install the three bolts securing the torque

converter to the engine flywheel.
Tighten
13.1. Tighten the bolts finger tight to insure
proper converter seating.
13.2. Tighten the bolts to 63 N-m (46 lb ft).

102211
Transmission/Transaxle Automatic Transmission - 4L60-E 7-225
14. 7.4L and 5.7L Gasoline Engine: Install the bolts
securing the converter cover to the
transmission.
Tighten
Tighten the converter cover bolts to
10 N-m (89 lb in).
15. 5.0L Gasoline Engine: Install the bolts securing
the converter cover to the transmission.

102335
16. Gasoline Engine: Install the converter cover
plug in the starter mounting port.
Tighten
Tighten the converter cover bolts to
33 N-m (24 lb ft).
17. Install the exhaust pipe from the exhaust
manifolds and the muffler assembly from the
exhaust pipe if required. Refer to Engine
Mechanical.
18. Install the frame crossmember.
19. Install the rear transmission mount.

102208
20. Gasoline Engine— Install the following parts:
20.1. The transmission to engine brace
20.2. Two bolts
20.3. Two washers
20.4. One nut
Tighten
Tighten the bolts to 55 N-m (41 lb ft).

102329
7-226 Automatic Transmission - 4L60-E Transmission/Transaxle
21. Diesel Engine— Install the following parts:
21.1. The transmission to engine brace
21.2. Two bolts
21.3. Two washers
21.4. One nut
Tighten
Tighten the bolts to 70 N-m (51 lb ft).
22. Install the transfer case to the transmission if
removed. Refer to Transfer Case Replacement
in Transfer Case.
23. Remove the transmission jack and the engine
support stands.
24. Install the rear propeller shaft. Refer to Rear
propeller Shaft in Propeller Shaft.
25. Install the transmission range select cable to
the transmission range select lever and the
transmission bracket. Refer to Shift Cable
Replacement.
26. Remove the safety stands.
27. Lower the vehicle.
28. Fill the transmission yvith new transmission fluid.
29. Connect the battery negative cable.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).
Transmission/!ransaxle
AT Oil Cooler Flushing
Oil Cooler Flushing
Tools Required
• J 35944-A Cooler Flushing Tool
• J 35944-20 Biodegradable Flushing Solution
Notice: Whenever you remove the transmission for
service, you must perform the automatic transmission
oil cooler flushing procedure in order to remove the
existing fluid which may be contaminated. This will
prevent contamination of the new fluid. You must
perform the flushing procedure after the installation
of the overhauled or replacement transmission.
Notice: Only use J 35944-20 Cooler Flushing Fluid
with the J 35944-A Oil Cooler and Line Flusher. Use
of any other fluid can result in damage to the tool,
damage to the automatic transmission oil cooler
components, or improper flushing of the cooler. Do
not reconnect the oil cooler pipes after you reinstall
the overhauled or service replacement transmission
in the vehicle.
1. Remove the fill cap on J 35944-A.
2. Fill the can with 0.6 liter ( 20-21 ounces) of
J 35944-20.
3. Follow the manufacturer’s suggested
procedures for proper handling of the solution.
Notice: Shop air supply must be equipped with
a water/oil filter and not exceed 825 kPa
(120 psi), or personal injury may result.
4. Secure the fill cap, and pressurize the flusher
can with shop air to 550-700 kPa (80-100 psi).
5. Connect the discharge hose to the transmission
end of the air cooler pipe that goes to the top
fitting at the radiator.
6. Clip the discharge hose to the oil drain
container.
7. Mount the flushing tool to the undercarriage of
the vehicle with the hook provided.
8. Connect the hose from the flushing tool to the
remaining oil cooler pipe.
9. With the water valve on the tool in the OFF
position, connect the water hose from the water
supply to the tool.
10. Turrt ON the water supply at the faucet.
Initial Flushing
Notice: If water does not flow through the oil cooler
(system is completely plugged), do not continue the
flushing procedure, or damage to the tool or
components could result. Turn the water OFF
immediately. Inspect the pipes and the cooler for
restrictions. Replace the oil pipe(s) and/or the oil
cooler.
1. Switch the water valve on the tool to the ON
position. Allow the water to flow through the oil
cooler for 10 seconds in order to remove the
transmission fluid in the system.
Automatic Transmission - 4L60-E 7-227
2. Switch the water valve on the tool to the OFF
position. Clip the discharge hose onto a
5-gallon pail with a lid. If there is no lid, place
a shop towel over the end of the hose in order
to prevent splash. The discharge will foam
vigorously when you introduce solution into the
water stream.
3. Switch the water valve on the tool to the ON
position. Depress the trigger that mixes the
flushing solution into the water flow. Use the
bale clip on the handle in order to hold down
the trigger.
4. Flush the oil cooler with water and solution for
2 minutes. During the flush, attach the air
supply to the air valve on the tool for 3 to
5 seconds after every 15 to 20 second interval
in order to create a surging action.
5. Release the trigger. Switch the water valve
on the tool to the OFF position.
6. Disconnect both hoses from the oil
cooler pipes.
Backflush
• Connect the hoses to the oil cooler pipes
opposite from the initial flush in order to
perform a backflush.
• Switch the water valve on the tool to the ON
position. Depress the trigger in order to mix the
flushing solution with the water flow. Use the
bale clip on the handle to hold down the
trigger.
• Flush the oil cooler with water and solution for
2 minutes. During this flush, attach the air
supply to the air valve on the tool for 3 to
5 seconds after each 15 to 20 second interval
in order to create a surging action.
• Release the trigger. Allow water only to rinse
the oil cooler for 1 minute.
• Switch the water valve on the tool to the
OFF position.
• Turn the water supply OFF at the faucet.
• Attach the air supply to the air valve on the
tool. Dry out the system with air for at least
2 minutes. Dry out the system longer than
2 minutes, if moisture from the oil cooler line
discharge hose is visible. If available, use an
air chuck clip to secure the air chuck onto the
air valve for ease of operation.
Important: The top fitting at the transmissions
the cooler return. The bottom fitting at the
transmission is the cooler feed.
• Connect the cooler feed pipe to the
transmission.
• If not already connected, attach the discharge
hose to the cooler return pipe. Place the hose
into an appropriate drain container.
7-228 Automatic Transmission - 4L60-E
• After filling the transmission with DEXRON®-lll
automatic transmission fluid, or equivalent, start
the engine. Run the engine for 30 seconds.
This removes any residual moisture from the oil
cooler and the cooler pipes, protects all the
components from corrosion, and checks the
flow rate through the cooler.
You should get a minimum of 1.9 liters
(2 quarts) of transmission fluid during this
30 second run. If the flow of fluid is insufficient,
disconnect the oil cooler feed line at the
* radiator and restart the engine.
Depending on the flow rate, do the following
inspections:
• Insufficient Feed Flow — Inspect the
transmission for the cause.
• Sufficient Feed Flow — Inspect the oil cooler
pipes and the fittings for restrictions or leaks.
Repeat the oil cooler flushing procedure.
Repeat the check of fluid flow out of the
return line. If the flow is still restricted,
replace the transmission oil cooler. Refer to
Oil Cooler Line Replacement.
• Remove the discharge hose.
• Reconnect the cooler return pipe to the
transmission.
• Refill the unit to the proper fluid level. Refer to
Transmission Fluid Checking Procedure.
Transmission/Transaxle
Tool Cleaning Procedure
1. Clean the tool with every third use.
2. Disconnect the water supply hose from the tool.
3. Bleed air pressure from the can, remove the fill
cap, return any unused solution to the container
and rinse the can out with water. Do not store
the tool with the solution in the tank.
4. Remove the screen from the plumbing and
wash it with water.
5. Use the cleaning pin in order to remove any
material in the solution orifice. The orifice is
located in the plumbing below the screen.
6. Reconnect the plumbing and fill the can half
with water. Secure the fill cap and pressurize
the can to 550-700 kPa (80-100 psi).
7. Aim the tool into the 18.92 **[litre]** (5 gallon)
pail or floor drain and depress the trigger. Allow
the water from the can to flow through the
solution orifice for 30 seconds in order to
ensure proper cleaning.
8. Bleed air pressure from can, remove the fill
cap, and empty the can.
9. Reconnect the fill cap to the flushing tool.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-229

Description and Operation

Transmission ID Information

174260
Legend
(1) (8 = 1998) (5) Shift Built (A, B, J = First Shift; C, H,
(2) Model W = Second Shift)
(3) Hydra-Matic 4L60-E (6) Serial No.
(4) Julian Date (or Day of the Year) (7) Transmission ID Location
7-230 Automatic Transmission - 4L60-E Transmission/Transaxle
Transmission General Information
The HYDRA-MATIC 4L60-E transmission has the
identification information stamped into the case
pan rail.

174265

This information helps the service technician order

the correct replacement parts from a GM parts
catalog.
Transmission/Transaxle
Additional transmission identification information is
provided on the Service Parts Identification label.
This label shows the Regular Production Options
(RPO) as well as the standard and mandatory
options. This label is affixed to the inside of each
vehicle at the assembly plant. For more information,
refer to Section OA.
6480
Legend
(1) Vehicle Identification Number
(2) Wheel Base
(3) Part Number Location
(4) Model Designation
(5) Order Number
(6) Exterior Color
(7) Paint Technology
How to Use This Section
This section provides the following information:
• General diagnosis information on transmissions
• A detailed description of the Hydra-matic
transmission operation
• Procedures for diagnosing the Hydra-matic
transmission
When you diagnose any condition of the Hydra-matic
transmission, begin with the Functional Test
Procedure. This procedure indicates the proper
path of diagnosing the transmission by describing
the basic checks. This procedure will then refer
you to the locations of specific checks. After you
have determined the cause of a condition, refer
to On-Vehicle Service for repair procedures.
Automatic Transmission - 4L60-E 7-231
If the faulty component is not serviceable without
removing the transmission from the vehicle, refer to
Unit Repair for repair information.
Basic Knowledge
Notice: Do not, under any circumstances, attempt to
diagnose a powertrain condition without basic
knowledge of this powertrain. If you perform
diagnostic procedures without this basic knowledge,
you may incorrectly diagnose the condition or
damage the powertrain components.
You must be familiar with some basic electronics in
order to use this section of the service manual. You
should also be able to use the following special tools:
• A Digital Multimeter (DMM)
• A circuit tester
• Jumper wires or leads
• A line pressure gage set
The Functional Test Procedures verify the correct
operation of electronic components in the
transmission. These procedures will eliminate the
unnecessary removal of transmission components.
Diagnosis
Notice: If you probe a wire with a sharp instrument
and do not properly seal the wire afterward, the wire
will corrode and an open circuit will result.
Diagnostic test probes are now available that allow
you to probe individual wires without leaving the wire
open to the environment. These probe devices are
inexpensive and easy to install, and they
permanently seal the wire from corrosion.
Preliminary Checking Procedure
Transmission performance may be influenced by
one, or more of the following items:
• Fluid level high/low.
• Engine performance.
• Manual linkage adjustment.
• Internal fluid leaks.
• Electrical system.
• Transmission or other mechanical component.
• Vacuum Modulator System
These items should be checked and corrected, if
necessary, before attempting transmission diagnosis.
7-232 Automatic Transmission - 4L60-E
Transmission Fluid Checking Procedure
Checking fluid level, color, and condition at regular
intervals will provide early diagnostic information
about the transmission. This information may then be
used to correct a condition that, if not detected early,
could result in major transmission repair.
Refer to Section OB for maintenance information and
servicing intervals.
Important: New automatic transmission fluid is red.
Red dye is added in order to help the assembly
plant distinguish this fluid from engine oil and
antifreeze. The red dye is not permanent. After some
driving, the transmission fluid will look darker.
Eventually, the fluid may appear light brown.
• Wait at least 30 minutes before checking the
transmission fluid, if the vehicle has been
driven under the following conditions:
- Outside temperature is above 32 *C (90 *F)
- At high speed for more than 15 minutes
- In heavy traffic during hot weather
- While pulling a trailer
• In order to get the correct reading, the fluid
should be at a normal operating temperature,
which is 82 * C-94 * C (180*F-200*F).
• Do the following for a hot check:
Warm up the vehicle by driving about
24 km (15 miles), when the outside
temperature is above 10 ° C (50' F).
If the temperature is colder than 10 ‘ C (50’ F),
you may have to drive the vehicle longer.
• Do the following for a cold check:
Do a cold check when the transmission
temperature is 2 4 ’ C-29*C (75*F-85*F).
Let the engine run at slow idle for 5 minutes,
if the outside temperature is 10 *C (50 *F)
or higher.
If the outside temperature is colder than
10 *C (50 *F), you may have to idle the
engine longer than 5 minutes.
• Do the following for a hot or a cold
transmission fluid check:
1. Idle the engine.
2. Park the vehicle on a level surface.
3. Place the shift lever in the P (Park)
position.
4. Apply the parking brake.
5. With you foot on the brake pedal, move
the shift lever through each gear,
pausing for about 3 seconds in each
range. Then, put the shift lever in
P (Park).
6. Idle the engine for 3 minutes or more.
Transmission/Transaxle
• Now, do the following in order to check the
fluid level:
1. Pull out the dipstick. Wipe the dipstick
well with a clean rag or a paper towel.
2. Push the dipstick in all the way. Wait
3 seconds. Then, pull the dipstick back
out again.
3. Check bolt sides of the dipstick, reading
the lower level.
• For a cold check, the fluid level must
be in the COLD area.
• For a hot check, the fluid level must
be in the HOT or crosshatched area.
4. If the fluid level is OK, push the dipstick
back in all the way.
Notice: Do not overfill the transmission.
Overfilling will result in foaming, loss of
fluid, and possible damage to the
transmission.
5. If the fluid level is low, add only enough
DEXRON®-lll (or, if unavailable,
DEXRON®-IIE) to bring the fluid level up
to the COLD area for a cold check or the
HOT area for a hot check.
Generally, this will require less than a
pint of fluid. Do not overfill.
6. After adding the fluid, recheck the fluid
level as described above. When the fluid
level is correct, push the dipstick in all
the way.
• Transmission fluid should be red in color when
the fluid is new.
Automatic Transmission Diagnosis
Throttle Positions
Minimum Throttle: The least amount of throttle
opening required for upshift.
Light Throttle: Approximately 1/4 of the
accelerator pedal.
Medium Throttle: Approximately 1/2 of the
accelerator pedal travel.
Heavy Throttle: Approximately 3/4 of the
accelerator pedal travel.
Wide Open Throttle (WOT): Full travel of the
accelerator pedal.
Full Throttle Detent Densified: A quick application
of the accelerator pedal to its full travel in order to
force a downshift.
Engine Braking: A condition in which you use the
engine in order to slow the car by downshifting
manually during a zero-throttle coastdown.
Zero Throttle Coastdown: A full release of the
accelerator pedal while the car is in motion and in
drive range.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-233
Shift Conditions Transmission Abbreviations
Bump: A sudden and forceful engagement of a • PCM-Powertrain Control Module
clutch or band. • TCC-Torque Converter Clutch
Chuggle: A bucking or jerking that is most • TP Sensor-Throttle Position Sensor
noticeable when the converter clutch is engaged. A
Chuggle is similar to the feel of towing a trailer. • ECT Sensor-Engine Coolant Temperature
Sensor
Delayed: A condition in which a shift is expected but
does not occur for a period of time. Delayed is also • VSS Sensor-Vehicle Speed Sensor
defined as late or Extended. • RWD-Rear Wheel Drive
Double Bump (Double Feel): Two sudden and • 2WD-2 Wheel Drive
forceful engagements of a clutch or a band. • TFP Val. Position Sw.-Automatic Transmission
Early: A condition in which the shift occurs before Fluid Pressure Manual Valve Position Switch
the car has reached the proper speed. The early • TFT Sensor-Automatic Transmission Fluid
condition tends to labor the engine after the upshift. Temperature Sensor
End Bump: A firmer feel at the end of a shift as
compared to the feel at the start of the shift. End Electronic Component Description
bump also is define as END FEEL or SLIP BUMP.
Firm: A noticeably quick engagement of a clutch or 1-2 and 2-3 Shift Solenoid Valves
band that is considered normal with a medium to
heavy throttle. This should not be confused with
HARSH or ROUGH.
Flare: A quick increase in engine rpm along with a
momentary loss of torque. This generally occurs
during a shift. Flare is also defined as SLIPPING.
Harsh (Rough): A more noticeable engagement of a
clutch or a band as compared with FIRM. This
condition is considered undesirable at any throttle
position.
Hunting: A repeating quick series of upshifts and
downshifts that causes a noticeable change in
engine rpm. An example is a 4-3-4 shift pattern.
Hunting also is defined as BUSYNESS.
Initial Feel: A distinct sturdy feel at the start of a
shift as compared to the end of the shift.
Late : A shift occurs when the engine is at a higher
than normal rpm for a given amount of throttle.
Shudder: A continuous jerking condition similar to
CHUGGLE but more severe and rapid. This
condition is most noticeable during certain car speed Important: The shift solenoid valve resistance should
ranges. measure 19-24 ohms minimum when measured at
Slipping: A noticeable increase in engine rpm 20 * C (68 * F). The shift solenoid current flow should
without a car speed increase. A slip usually occurs not exceed 0.75 amps. The shift solenoid should
during or after the initial clutch or band engagement. energize at a voltage of 7.5 volts or more (measured
Soft: A slow, almost unnoticeable clutch or band across the terminals). The shift solenoid should
engagement with very little shift feel. de-energize when the voltage is one volt or less.
Surge: A repeating acceleration and deceleration If both solenoids lose power, third gear only results.
that is engine-related. This condition is less intense
than CHUGGLE. The 1-2 and 2-3 shift solenoid valves (also called A
and B solenoids) are identical devices that control
Tie Up: A condition in which two opposing clutches the movement of the 1-2 and 2-3 shift valves (the
and/or bands are attempting to engage at the same 3-4 shift valve is not directly controlled by a shift
time, causing the engine to labor with a noticeable
solenoid). The solenoids are normally open exhaust
loss of engine rpm.
valves that work in four combinations to shift the
Noise Conditions transmission into different gears.
Planetary Gear Noise: A whine related to the car The PCM energizes each solenoid by grounding the
speed that is most noticeable in the first gear or solenoid through an internal quad driver. This sends
reverse. Planetary Gear Noise is less noticeable current through the coil winding in the solenoid and
after an upshift. moves the internal plunger out of the exhaust
Pump Noise: A high pitch whine that increases with position. When ON, the solenoid redirects fluid to
engine rpm. move a shift valve.
7-234 Automatic Transmission - 4L60-E
The PCM-controlled shift solenoids eliminate the
need for TV and governor pressures to control
shift valve operation.
Important: The manual valve hydraulically can
override the shift solenoids. Only in D4 do the shift
solenoid states totally determine what gear the
transmission is in. In the other manual valve
positions, the transmission shifts hydraulically and
the shift solenoid states CATCH UP when the throttle
position and the vehicle speed fall into the correct
ranges. Diagnostic trouble codes P0753 and P0758
indicate shift solenoid circuit voltage faults.
3-2 Shift Solenoid Valve Assembly
Important: The 3-2 shift solenoid valve assembly
resistance should be a minimum of 20-24 ohms at
20 *C (68 *F).
The 3-2 shift solenoid valve assembly is an ON/OFF
solenoid that is used in order to improve the 3-2
downshift. The solenoid regulates the release of the
3-4 clutch and the 2-4 band apply.
If a voltage fault is detected in the 3-2 shift solenoid
circuit, diagnostic trouble code P0785 will set.
Transmission/Transaxle
Transmission Pressure Control Solenoid
Important: Transmission pressure control solenoid
resistance should measure 3 -5 Q when measured
at 2 0 'C (68 *F).
The transmission pressure control solenoid (or force
motor) is an electronic pressure regulator that
controls pressure based on the current flow through
its coil winding. The magnetic field produced by the
coil moves the solenoid’s internal valve which varies
pressure to the pressure regulator valve.
The PCM controls the pressure control solenoid by
commanding current between 0 and 1.1 amps. This
changes the duty cycle of the solenoid, which can
range between 0% and 60%. 1.1 amps correspond
to the minimum line pressure, and 0 amps is the
maximum line pressure (if the solenoid loses power,
the transmission still has the maximum line
pressure).
The PCM calculates the line pressure values, using
inputs such as the throttle position sensor.
The pressure control solenoid takes the place of the
throttle valve that was used .on the past model
transmissions.
If there is a difference between the amperage
commanded by the PCM and the actual amperage,
the diagnostic trouble code P0748 will set. Unlike the
pressure control solenoid on the HYDRA-MATIC
4L80-E, the 4L60-E pressure control solenoid does
not pulse every 10 seconds for a cleaning cycle.
Transmission/Transaxle
Torque Converter Clutch Solenoid Valve
Important: The TCC solenoid resistance should
be 21-26 ohms minimum when measured at
20 *C (68 *F).
If a fault is detected in the TCC solenoid circuit,
code P0740 will set.
The torque converter clutch solenoid valve is a
normally open exhaust valve that is used to control
torque converter clutch apply and release. When
grounded (energized) by the PCM, the TCC solenoid
valve stops converter signal oil from exhausting. This
causes converter signal oil pressure to increase and
shifts the TCC solenoid valve into the apply position.
The brake switch is an input to the PCM, and the
PCM directly controls the TCC apply based on the
brake switch status.
Automatic Transmission - 4L60-E 7-235
Torque Converter Clutch PWM Solenoid Valve
10336
Important: TCC PWM solenoid valve resistance
should be 10-11 ohms when measured at
20 *C (68 *F), and 13-15 ohms when measured
at 100 *C (212*F).
The torque converter clutch PWM solenoid valve
controls the fluid acting on the converter clutch
valve, which then controls the TCC apply and
release. This solenoid is attached to the control
valve body assembly within the transmission. The
TCC PWM solenoid valve provides smooth
engagement of the torque converter clutch by
operating on a negative duty cycle a variable percent
of ON time.
If a fault is detected in the TCC PWM circuit, code
P1860 will set.
7-236 Automatic Transmission - 4L60-E Transmission/Transaxle
Transmission Fluid Pressure (TFP) Manual The transmission fluid pressure (TFP) Manual Valve
Valve Position Switch Position switch is a set of five pressure switches on
the valve body that sense whether fluid pressure is
present in five different valve body passages. The
combination of which switches are open and closed
is used by the PCM in order to determine actual
manual valve position. The TFP assembly, however,
cannot distinguish between PARK and NEUTRAL
because the monitored valve body pressures are
identical in both cases.
The switches are wired to provide three signal lines
that are monitored by the PCM. These inputs are
used to help control the line pressure, the torque
converter clutch apply and the shift solenoid
operation. Voltage at each of the signal lines is
either zero or twelve volts.
In order to monitor the TFP assembly operation, the
PCM compares the actual voltage combination of the
switches to a TFP combination chart stored in its
memory. If the PCM sees one of two illegal voltage
combinations, a code P1810 will result. A code
8889 P1810 indicates a short circuit condition in either the
Important: Seven valid components and two invalid range signal A or the range signal C circuits.
combinations are available from the TFP: The TFP assembly signal voltage can be measured
Valid/invalid combinations for Circuits A, B and from each pin-to-ground and compared to the
C are shown below. combination chart. On the transmission wiring harness,
pin N is range signal A, pin R is range signal B and
TFP Valve Position Switch Logic pin P is range signal C. With the wiring harness
connected and the engine running, a voltage
Gear Range Range Range
measurement of these three lines will indicate a high
Position Signal A Signal B Signal C
reading (near 12 volts) when a circuit is open, and a
Park OFF ON OFF low (zero volts) when the circuit is switched to ground.
Reverse ON ON OFF The transmission temperature sensor is part of the
Neutral OFF ON OFF transmission fluid pressure switch assembly.
Overdrive OFF ON ON
Dr 3 OFF OFF ON
Dr 2 OFF OFF OFF
Low ON OFF OFF
Illegal ON OFF ON
Illegal ON ON ON
Transmission/Transaxle
Vehicle Speed Sensor
Important: The sensor resistance should be
1470-2220 ohms when measured at 2 0 ‘ C (68 *F).
Output voltage varies with speed from a minimum of
0.5 volts AC at 100 RPM to more than 100 volts
AC at 8000 RPM.
The vehicle speed sensor (or transmission output
speed sensor) controls shift points and calculates
the TCC slip.
The speed sensor contains a coil that gives off a
continuous magnetic field. A rotor rotates past the
sensor and the rotor teeth break the magnetic field.
Each break in the field sends a pulse to the
VSSB (Vehicle Speed Sensor Buffer). The
VSSB sends two signals to the PCM. The first is
a 2002 pulse per mile (PPM) signal that is used by
the engine. The second is the transmission/transfer
case 40 pulse per revolution (PPR) signal that is
used in order to control the transmission.
In two wheel drive (2WD) applications, the vehicle
speed sensor is located on the transmission
extension housing. Trans Output Speed = Transfer
Case Speed.
Code P0502 will set if a fault exists in the vehicle
speed sensor circuit 40 PPR line.
Automatic Transmission Fluid Temperature
Sensor
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position (TFP Val. Position)
switch assembly. This sensor helps control torque
converter clutch apply and shift quality.
Automatic Transmission - 4L60-E 7-237
The temperature sensor is a resistor, or thermistor,
which changes value based on temperature. At low
temperatures the resistance is high, and at high
temperatures the resistance is low.
The PCM sends a 5-volt signal to the temperature
sensor and the PCM measures the voltage drop in
the circuit. You will measure a high voltage when the
transmission is cold and a low voltage when the
transmission is hot.
If the temperature sensor circuit has a fault, code
P0712 or P0713 is set. A code P0712 indicates a
short circuit condition, while a code P0713 indicates
an open circuit condition. Code P0218 is set if the
transmission is operating at a high temperature for a
period of time.
Refer to Temperature vs Resistance table, in the
specifications.
Torque Converter Clutch Electrical
Controls
The Torque Converter Clutch (TCC) system uses
controls that are internal as well as external to the
transmission.
The TCC system includes the following external
control components:
• Cruise Control Release Switch — In order to
avoid stalling the engine when braking, the
converter clutch releases anytime the brake
pedal is applied.
• Powertrain Control Module (PCM) — The
PCM receives input signals and grounds
TCC solenoid to apply clutch when the
proper operating conditions are met.
• Throttle Position (TP) Sensor — The TP Sensor
sends throttle position information to the
Powertrain Control Module (PCM).
• Vehicle Speed Sensor (VSS) — The VSS
sends vehicle speed information to the
Powertrain Control Module (PCM).
• Manifold Absolute Pressure (MAP) Sensor —
The MAP Sensor sends engine vacuum (load)
information to the Powertrain Control
Module (PCM).
• Engine Coolant Temperature (ECT) Sensor —
The ECT Sensor sends engine coolant
temperature information to the Powertrain
Control Module (PCM).
7-238 Automatic Transmission - 4L60-E
Electrical Connector
Remember the following points:
13265
The transmission electrical connector is an important
part of the transmission operating system. Any
interference with the electrical connection can cause
the transmission to set Diagnostic Trouble Codes
(DTCs) or affect proper operation.
The following items can affect the electrical
connection:
• Bent pins in the connector from rough handling
during connection and disconnection
• Wires backing away from the pins or coming
uncrimped (in either the internal or the external
wiring harness)
• Dirt contamination entering the connector
when disconnected
Transmission/Transaxle
• Pins in the internal wiring connector backing out
of the connector or pushed out of the connector
during reconnection
• Excessive transmission fluid leaking into the
connector, wicking up into the external wiring
harness and degrading the wire insulation
• Moisture intrusion in the connector
• Low pin retention in the external connector from
excessive connection and disconnection of the
wiring connector assembly
• Pin corrosion from contamination
• Damaged connector assembly
• In order to remove the connector, squeeze the
two tabs toward each other and pull straight up.
• Limit twisting or wiggling the connector during
removal. Bent pins can occur.
• Do not pry the connector off with a screwdriver
or other tool.
• In order to reinstall the external wiring
connector, first orient the pins by lining up the
arrows on each half of the connector. Push the
connector straight down into the transmission
without twisting or angling the mating parts.
• The connector should click into place with a
positive feel and/or noise.
• Whenever the transmission external wiring
connector is disconnected from the internal
harness and the engine is operating, DTCs will
set. Clear these DTCs after reconnecting the
external connector.
Transmission/Transaxle Automatic Transmission - 4L60-E 7-239

Component Locator
Transmission Component Location
Com ponent Locator View

1 2 3 4 5 6 7 8 9 10 11 12

23 22 21 20 19 18 17 16 15 14 13

154995

Legend
(1) Converter Housing (14) Case Extension
(2) Reverse Input Clutch (15) Case, Main Section
(3) Input Clutch Housing (16) Parking Pawl
(4) Overrun Clutch (17) Parking Lock Actuator Assembly
(5) Forward Clutch (18) Control Valve Assembly
(6) Forward Sprag Clutch Assembly (19) Manual Shaft
(7) 3-4 Clutch (20) Inside Detent Lever
(8) Input Planetary Gear Set (21) 2-4 Band Assembly
(9) Lo and Reverse Clutch (22) Pump Assembly
(10) Lo Roller Clutch Assembly (23) Stator Roller Clutch
(11) Reaction Planetary Gear Set (24) Torque Converter Assembly
(12) Speed Sensor (25) Turbine Shaft
(13) Output Shaft
7-240 Automatic Transmission - 4L60-E Transmission/Transaxle
Case and Associated Parts (1 of 2)

181603

Legend
(1) Torque Converter Assembly (18) Ring, Oil Seal (2nd Apply Piston - Outer)
(2) Bolt, Pump to Case (19) Ring, Oil Seal (2nd Apply Piston - Inner)
(3) O-Ring, Pump to Case Bolt (20) Housing, Servo Piston (Inner)
(4) Pump Assembly, Oil (21) Seal, O-Ring
(5) Seal, Oil (Pump to Case) (22) Spring, Servo Apply Pin
(6) Gasket, Pump Cover to Case (23) Washer, Servo Apply Pin
(7) Bushing, Case (24) Ring, Retainer (Apply Pin)
(9) Vent Assembly, Transmission (25) Piston, 4th Apply
(10) Connector, Oil Cooler Pipe (26) Ring, Oil Seal (4th Apply Piston - Outer)
(11) Plug, Case Servo (27) Seal, O-Ring (2-4 Servo Cover)
(12) Spring, Servo Return (28) Cover, 2-4 Servo
(13) Pin, 2nd Apply Piston (29) Ring, Servo Cover Retaining
(14) Ring, Retainer (2nd Apply Piston) (30) Seal, Case Extension to Case
(15) Retainer, Servo Cushion Spring (31) Extension, Case
(16) Spring, Servo Cushion (Outer) (32) Bolt, Case Extension to Case
(17) Piston, 2nd Apply (33) Bushing, Case Extension
Transmission/Transaxle Automatic Transmission - 4L60-E 7-241
(34) Seal Assembly, Case Extension Oil (95) Connector, Oil Cooler Quick
(35) Bolt, Speed Sensor Retaining (96) Clip, Oil Cooler Quick Connect
(36) Speed Sensor, Internal Transmission (97) Plug, Converter Housing Access Hole
(37) Seal, O-Ring (ITSS to Case Extension) (98) Plate, Converter Bolt Inspection
(71) Seal, Filter (99) Plug, Cup D4 Orifice
(72) Filter Assembly, Transmission Oil (Model (100) Stud, A/Trans. Case
Dependent) (101) Plug Asm., A/Trans. Oil Pan
(73) Gasket, Transmission Oil Pan (102) Housing, Converter
(74) Magnet, Chip Collector (103) Case, Main Section
(75) Pan, Transmission Oil (Model Dependent) (105) Spring, Servo Cushion (Inner)
(76) Screw, Transmission Oil Pan (106) Seal Assembly, Case Oil (Y-Car Only)
(94) Bolt, Converter Housing to Case
Case and Associated Parts (2 of 2) Legend
(38) Plug, Transmission Case (Accumulator Bleed)
(39) Plug, Pressure
(40) Retainer and Ball Assembly, Third
Accumulator
(41) Pin, Band Anchor
(42) Retainer and Ball Assembly (Double Orifice)
(43) Pin, Accumulator Piston
(44) Piston, 3-4 Accumulator
(45) Ring, Oil Seal (3-4 Accumulator Piston)
(46) Spring, 3-4 Accumulator (Model Dependent)
(47) Gasket, Spacer Plate to Case
(48) Plate, Valve Body Spacer
(49) Screen, Shift Solenoids
(50) Screen, Pressure Control Solenoid
(52) Gasket, Spacer Plate to Valve Body
(53) Plate, Spacer Plate Support
(54) Spring, 1-2 Accumulator
(55) Ring, Oil Seal (1-2 Accumulator)
(56) Piston, 1-2 Accumulator
(57) Cover and Pin Assembly, 1-2 Accumulator
(58) Bolt, Accumulator Cover
(59) Bolt, Accumulator Cover
(60) Valve Assembly, Control Body
(61) Checkball
(62) Bolt, Valve Body
(63) Spring Assembly, Manual Detent
(64) Bolt, Manual Detent Spring
(65) Seal, Wiring Harness Pass-through
Connector O-Ring
(66) Solenoid Assembly, Wiring Harness
(67) Seal, O-Ring (Solenoid)
(68) Bolt, Hex Washer Head (Solenoid)
(69) Switch Assembly, Transmission Pressure
181604 (70) Bolt, Pressure Switch Assembly
(77) Bolt, Spacer Plate Support
(91) Number 10 Checkball
(93) Bracket, Dipstick Stop (Model Dependent)
(103) Case, Main Section
(104) Spring, 1-2 Accumulator (Inner)
7-242 Automatic Transmission - 4L60-E Transmission/Transaxle
Oil Pump Assembly

55916

Legend
(200) Body, Pump (216) Valve, Pressure Regulator
(201) Ring, Oil Seal (Slide to Wear Plate) (217) Spring, Pressure Regulator Valve
(202) Seal, O-Ring (Slide Seal Back-Up) (218) Spring, Pressure Regulator Isolator
(203) Slide, Pump (219) Valve, Reverse Boost
(204) Spring, Pivot Pin (220) Sleeve, Reverse Boost Valve
(205) Pin, Pivot Slide (221) Ring, Oil Pump Reverse Boost
(206) Spring, Pump Slide (Outer) Valve Retaining
(207) Spring, Pump Slide (Inner) (222) Ring, Oil Pump Converter Clutch
(208) Support, Pump Slide Seal Valve Retaining
(209) Seal, Pump Slide (223) Valve, Stop
(210) Ring, Pump Vane (224) Valve, Converter Clutch
(211) Guide, Rotor (225) Spring, Converter Clutch Valve (Inner)
(212) Rotor, Oil Pump (226) Spring, Converter Clutch Valve (Outer)
(213) Vane, Pump (227) Rivet, Pressure Relief Bolt
(214) Shaft, Stator (228) Ball, Pressure Relief
(215) Cover, Pump (229) Spring Pressure Relief
Transmission/Transaxle Automatic Transmission - 4L60-E 7-243
(230) Ring, Oil Seal (Stator Shaft) (237) Retainer and Ball Assembly, Check Valve
(231) Seal, Oil Pump Cover Screen (238) Orifice, Converter Clutch Signal (Cup Plug)
(232) Screen, Oil Pump Cover (240) Plug, Cup Orifice
(233) Bolt, M8 X 1.25 X 40 (Cover to Body) (241) Bushing, Stator Shaft (Rear)
(234) Bushing, Stator Shaft (Front) (242) Bushing, Pump Body
(235) Plug, Oil Pump Cover (FWD Clutch Feed) (243) Seal Assembly, Oil
(236) Plug, Oil Pump Cover (244) Retainer, Front Helix

Control Valve Body 1 of 2

Legend
(350) Valve Assembly, Control Body
(353) Seal, Forward Accumulator Oil
(354) Piston, Forward Accumulator
(355) Pin, Forward Accumulator
(356) Spring, Forward Accumulator
(357) Valve, Forward Abuse
(358) Spring, Forward Abuse Valve
(359) Plug, Bore
(360) Pin, Coiled Spring
(361) Valve, Low Overrun
(362) Spring, Low Overrun Valve
(363) Cover, Forward Accumulator
(364) Bolt, Forward Accumulator Cover
(365) Spring, 1-2 Shift Valve
(366) Valve, 1-2 Shift
155000
(367A) 1-2 Shift Solenoid Valve
(367B) 2-3 Shift Solenoid Valve
(368) Valve, 2-3 Shift
(369) Valve, 2-3 Shuttle
(370) Spring, 1-2 Accumulator Valve
(371) Valve, 1-2 Accumulator
(372) Sleeve, 1-2 Accumulator Valve
(374) Valve, Actuator Feed Limit
(375) Spring, Actuator Feed Limit Valve
(376) Plug, Bore
(377) Pressure Control Solenoid Valve
(378) Retainer, Pressure Control Solenoid
(379) Retainer, Solenoid
(395) Retainer, Bore Plug
7-244 Automatic Transmission - 4L60-E Transmission/Transaxle
Control Valve Body 2 of 2

Legend
(340) Manual Valve (387) Valve, Reverse Abuse
(350) Control Valve Body Assembly (388) Spring, Reverse Abuse Valve
(359) Bore Plug (389) Valve, 3-2 Downshift
(360) Pin, Coiled Spring (390) Spring, 3-2 Downshift Valve
(379) Retainer, Solenoid (391) Valve, 3-2 Control
(380) Valve, Regulator Apply (392) Spring, 3-2 Control Valve
(381) Bore Plug (394) 3-2 Control Solenoid
(382) Spring, 4-3 Sequence Valve (395) Retainer, Bore Plug
(383) Valve, 4-3 Sequence (396) TCC PWM Solenoid Valve
(384) Valve, 3-4 Relay (397) Spring, Regulator Apply
(385) Valve, 3-4 Shift (398) Valve, Isolator
(386) Spring, 3-4 Shift Valve
Transmission/Transaxle
Internal Parts (1 of 2)
Legend
(600) Spring Asm., 3-4 Clutch Boost (5)
(601) Washer, Thrust (Pump to Drum)
(602) Band Assembly, 2-4
(603) Bushing, Reverse Input Clutch (Front)
(605) Housing and Drum Assembly, Reverse
Input Clutch
(606) Bushing, Reverse Input Clutch (Rear)
(607) Piston Asm., Reverse Input Clutch
(608) Seals, Reverse Input Clutch (Inner and
Outer)
(609) Spring Asm., Reverse Input Clutch
(610) Ring, Reverse Input Clutch Spring Retainer
(611) Plate, Reverse Input Clutch (Belleville)
(612A) Plate, Reverse Input Clutch Turbulator
(Steel)
Automatic Transmission - 4L60-E 7-245
213098
(612B) Plate Asm., Reverse Input Clutch (Fiber)
(613) Plate, Reverse Input Clutch Backing
(Selective)
(614) Ring, Reverse Input Clutch Retaining
(615) Bearing Assembly, Stator Shaft/Selective
Washer
(616) Washer, Thrust (Selective)
(617) Retainer and Ball Asm., Check Valve
(618) Seal, O-Ring (Turbine Shaft/Selective
Washer)
(619) Ring, Oil Seal (Solid)
(620) Retainer and Checkball Assembly
(621) Housing and Shaft Assembly, Input
(622) Seal, O-Ring Input to Forward Clutch
Housing
7-246 Automatic Transmission - 4L60-E Transmission/Transaxle
(623) Piston, 3rd and 4th Clutch (645A) Plate Assembly, Overrun Clutch (Steel)
(625) Ring, 3rd and 4th Clutch (Apply) (645B) Plate, Overrun Clutch(Fiber)
(626) Spring Assembly, 3rd and 4th Clutch (646) Plate, Forward Clutch(Apply)
(627) Retainer and Ball Assembly, Forward (648) Plate, Forward Clutch(Waved)
Clutch Housing (649A) Plate Assembly, Forward Clutch (Steel)
(628) Housing, Forward Clutch (649B) Plate, Forward Clutch(Fiber)
(630) Piston, Forward Clutch (650) Plate, Forward Clutch Backing (Selective)
(632) Piston, Overrun Clutch (651) Ring, Forward Clutch Backing Plate
Retainer
(633) Ball, Overrun Clutch
(653) Plate, 3rd and 4th Clutch Apply (Stepped)
(634) Spring Assembly, Overrun Clutch
(654A) Plate Assembly, 3rd and 4th Clutch (Fiber)
(635) Snap Ring, Overrun Clutch Spring Retainer
(654B) Plate, 3rd and 4th Clutch (Steel)
(636) Seal, Input Housing to Output Shaft
(655) Plate, 3rd and 4th Clutch Backing
(637) Bearing Assembly, Input Sun Gear (Selective)
(638) Snap Ring, Overrun Clutch Hub Retaining (656) Ring, 3rd and 4th Clutch Backing
(639) Hub, Overrun Clutch Plate Retainer
(640) Forward Sprag Clutch Inner Race and (657) Bushing, Input Sun Gear Front
Input Sun Gear Assembly (659) Bushing, Input Sun Gear Rear
(642) Forward Sprag Assembly (698) Plug, Orificed Cup
(643) Retainer Rings, Sprag Assembly (699) Plug, Orificed Cup
(644) Race, Forward Clutch (Outer)
Transmission/Transaxle Automatic Transmission - 4L60-E 7-247
Internal Parts (2 of 2)

668
661 662 663 664 665 666 667

'> M m 4
0

-6+<» oaiH^O&j)
669 670 671 672 673 674 675 676 677 678 679 677 681 697

-680

682C 682D 682B 682A 683 684 685 686

687 699 690 691692 693 694 695 696

OCT >w—M
i_- _____ i

213103
Legend
(661) Retainer, Output Shaft to Input Carrier (674) Washer, Thrust (Race/Reaction Shell)
(662) Carrier Assembly, Input (675) Race, Lo and Reverse Roller Clutch
(663) Bearing Assembly, Thrust (Input Carrier (676) Retainer Ring, Lo and Reverse Support
to Reaction Shaft) to Case
(664) Gear, Input Internal (677) Retainer Ring, Lo and Reverse Roller
(665) Bushing, Reaction Carrier Shaft Front Assembly (Cam)
(666) Shaft, Reaction Carrier (678) Clutch Assembly, Lo and Reverse Roller
(667) Bushing, Reaction Carrier Shaft Rear (679) Support Assembly, Lo and Reverse Clutch
(668) Retainer Ring, Reaction Shaft/lnternal Gear (680) Spring, Lo and Reverse Clutch Support
Retainer
(669) Washer, Thrust (Reaction Shaft Shell)
(681) Carrier Assembly, Reaction
(670) Shell, Reaction Sun
(682A) Plate, Lo and Reverse Clutch (Waved)
(671) Retainer Ring, Reaction Sun Gear
(682B) Plate, Spacer Lo and Reverse Clutch
(672) Bushing, Reaction Sun
(Selective)
(673) Gear, Reaction Sun
7-248 Automatic Transmission - 4L60-E Transmission/Transaxle
(682C) Plate Assembly, Lo and Reverse (690) Sleeve, Output Shaft
Clutch (Fiber) (691) Seal, Output Shaft
(682D) Plate, Lo and Reverse Clutch (692) Bearing, Reaction Gear Support to Case
Turbulator (Steel)
(693) Retainer Ring, Lo and Reverse Clutch
(683) Bearing Assembly, Thrust (Reaction
(694) Spring Assembly, Lo and Reverse Clutch
Carrier/Support)
(684) Gear, Internal Reaction (695) Piston, Lo and Reverse Clutch
(685) Support, Internal Reaction Gear (696) Seal, Lo and Reverse Clutch (Outer, Center
and Inner)
(686) Retainer Ring, Reaction Gear/Support
(697) Deflector, Oil (High Output Models Only)
(687) Shaft, Output
(699) Rotor, Internal Transmission Speed Sensor
Parking Lock and Manual Legend
Shift Shaft Assembly (78) Plug, Steel Cup
(79) Shaft, Parking Brake Pawl
(80) Spring, Parking Pawl Return
(81) Pawl, Parking Brake
(82) Seal, Manual Shaft
(83) Retainer, Manual Shaft
(84) Shaft, Manual (Model Dependent)
(85) Actuator Assembly, Parking Lock
(86) Bracket, Parking Lock
(87) Bolt, Parking Lock Bracket
(88) Lever, Inside Detent
(89) Link, Manual Valve
(90) Nut, Hex Head

65111
Transmission/Transaxle Automatic Transmission - 4L60-E 7-249
Seal Locations

55917
Legend
(3) O-Ring, Pump to Case Bolt (608) Seals, Reverse Input Clutch
(5) Seal, Oil (Pump to Case) (inner and outer)
(18) Ring, Oil Seal (2nd Apply Piston-Outer) (618) Seal, O-Ring (Turbine Shaft/Selective
Washer)
(19) Ring, Oil Seal (2nd Apply Piston-Inner)
(619) Ring, Oil Seal (Solid)
(21) Seal, O-Ring
(622) Seal, O-Ring Input to Forward Housing
(26) Ring, Oil Seal (4th Apply Piston-Outer)
(623) Piston, 3rd and 4th Clutch
(27) Seal, O-Ring (2-4 Servo Cover)
(630) Piston, Forward Clutch
(30) Seal, Case Extension to Case
(632) Piston, Overrun Clutch
(34) Seal Assembly, Case Extension Oil
(636) Seal, Input Housing to Output Shaft
(37) Seal, O-Ring (ITSS to Case Extension)
(691) Seal, Output Shaft
(106) Seal Assembly, Case Oil (Y-Car Only)
(696) Seal, Transmission (Lo and Reverse
(230) Ring, Oil Seal (Stator Shaft)
Clutch-Outer, Center, Inner
(243) Seal Assembly, Oil
7-250 Automatic Transmission - 4L60-E
Bearings and Bushings
Legend
(7) Bushing, Case
(33) Bushing, Case Extension
(234) Bushing, Stator Shaft (Front)
(241) Bushing, Stator Shaft (Rear)
(242) Bushing, Oil Pump Body
(601) Washer, Thrust (Pump to Drum)
(603) Bushing, Reverse Input Cl. (Front)
(606) Bushing, Reverse Input Clutch (Rear)
(615) Bearing Assembly, Stator Shaft/Selective
Washer
(616) Washer, Thrust (Selective)
(637) Bearing Assembly, Input Sun Gear
Transmission/Transaxle
13165
(657) Bushing, Input Sun Gear (Front)
(659) Bushing, Input Sun Gear (Rear)
(663) Bearing Assembly, Thrust (Input Carrier
to Reaction Shaft)
(665) Bushing, Reaction Carrier Shaft (Front)
(667) Bushing, Reaction Carrier Shaft (Rear)
(669) Washer, Thrust (Reaction Shaft/Shell)
(672) Bushing, Reaction Gear
(674) Washer, Thrust (Race/Reaction Shell)
(683) Bearing Assembly, Thrust (Reaction
Carrier/Support)
(692) Bearing, Reaction Gear Support to Case
Transmission/Transaxle Automatic Transmission - 4L60-E 7-251
Torque Converter Housing Identification

Legend
(1) Domestic Large Bell V-8 (Y-Car)
(2) Domestic Gen III Large Bell V-8 (300 mm)
(3) Domestic Gen l/ll Large Bell V-8/Small
Bell V-6
213108
(4) Holden Small Bell V-6
(5) Holden Gen III Large Bell V-8
(6) Domestic Small Bell V-6
7-252 Automatic Transmission - 4L60-E
374
Legend
(340) Valve, Manual
(353) Seal, Forward Accumulator Oil
(354) Piston, Forward Accumulator
(355) Pin, Forward Accumulator
(356) Spring, Forward Accumulator
(357) Valve, Forward Abuse
(358) Spring, Forward Abuse Valve
(359) Plug, Bore
(360) Pin, Coiled Spring
(361) Valve, Low Overrun
(362) Spring, Low Overrun Valve
(363) Cover, Forward Accumulator
(364) Bolt, Forward Accumulator Cover
(365) Spring, 1-2 Shift Valve
(366) Valve, 1-2 Shift
Transmission/Transaxle
Valve Trains
375 395 376 364 378 377
340 353 354 355 356
10125
(367) 2-3 Shift Solenoid
(368) Valve, 2-3 Shift
(369) Valve, 2-3 Shuttle
(370) Spring, 1-2 Accumulator Valve
(371) Valve, 1-2 Accumulator
(372) Sleeve, 1-2 Accumulator Valve
(374) Valve, Actuator Feed Limit
(375) Spring, Actuator Feed Limit Valve
(376) Plug, Bore
(377) Pressure Control Solenoid
(378) Retainer, Pressure Control Solenoid
(379) Retainer, Solenoid
(380) Valve, Converter Clutch Signal
(381) Plug, Bore
(382) Spring, 4-3 Sequence Valve
Transmission/Transaxle Automatic Transmission - 4L60-E 7-253
(383) Valve, 4-3 Sequence (390) Spring, 3-2 Downshift Valve
(384) Valve, 3-4 Relay (391) Valve, 3-2 Control
(385) Valve, 3-4 Shift (392) Spring, 3-2 Control Valve
(386) Spring, 3-4 Shift Valve (394) 3-2 Control Solenoid
(387) Valve, Reverse Abuse (395) Retainer, Bore Plug
(388) Spring, Reverse Abuse Valve (396) TCC PWM Solenoid Valve
(389) Valve, 3-2 Downshift (397) Spring, Regulator Apply
(398) Valve, Isolator

Pump Body Passages

55936
Legend
(1) Suction (intake) (16) Reverse Input
(2) Decrease (26) C.C. Signal
(3) Line (29) 3-4 Clutch
(4) Converter Feed (37) Overrun Clutch
(5) Release (43) Exhaust
(7) To Cooler (45) Vent
(8) Lube from Cooler (46) Seal Drain
(11) Torque Signal (47) Void
7-254 Automatic Transmission - 4L60-E Transmission/Transaxle
Pump Cover Passages

55937
Legend
(1) Suction (intake) (18) Forward Clutch Feed
(2) Decrease (26) C.C. Signal
(3) Line (29) 3-4 Clutch
(4) Converter Feed (37) Overrun Clutch
(5) Release (43) Exhaust
(7) To Cooler (45) Vent
(8) Lube from Cooler (46) Seal Drain
(11) Torque Signal (47) Void
(16) Reverse Input
Transmission/Transaxle Automatic Transmission - 4L60-E 7-255
Pump Cover Passages: Case Side

Legend
(232) Oil Pump Cover Screen (16) Reverse Input (Rev. Cl.)
(237) Check Valve Retainer and Ball Assembly (18) Forward Clutch Feed
(240) Orificed Cup Plug (26) C.C. Signal
(1) Suction (Intake) (29) 3-4 Clutch
(2) Decrease (37) Overrun Clutch
(3) Line (43) Exhaust
(5) Release (45) Vent
(7) To Cooler (46) Seal Drain
(8) Lube from Cooler (47) Void
(11) Torque Signal
7-256 Automatic Transmission - 4L60-E Transmission/Transaxle

Case Fluid Passages (Pump Cover Side)

Legend
(10) Connector, Oil Cooler Pipe (16) Reverse Input
(39) Plug, Pressure (18) Forward Clutch Feed
(3) Line (26) C. C. Signal
(7) To Cooler (29) 3-4 Clutch
(8) Lube from Cooler (37) Overrun Clutch
(11) Torque Signal (45) Vent
Transmission/Transaxle Automatic Transmission - 4L60-E 7-257

10129
Legend
(#1(61)) Checkball (16) Reverse Input (Rev. Cl.)
(#7(40)) 3rd Accum. Retainer and Ball Assembly (17) D4
(#10 Checkball (18) Forward Clutch Feed
(42)) (19) Rear Lube
(44(38)) Accumulator Bleed Plug (20) Accumulator
((92)) TCC Screen (21) Orificed Accumulator
(3) Line (22) Signal A
(9) Actuator Feed Limit (24) 2nd
(10) Filtered Actuator Feed (25) 2nd Clutch
(11) Torque Signal (26) C.C. Signal
(12) PR (27) 3-4 Signal
(13) D4-3-2 (28) 3rd Accumulator
(14) Lo/Reverse (29) 3-4 Clutch
(15) Reverse
7-258 Automatic Transmission - 4L60-E Transmission/Transaxle
(30) 4th Signal (38) D2
(31) Servo Feed (39) Orificed D2
(32) 4th (40) 3-2 Signal
(33) 3-4 Accumulator (41) Lo
(34) D3 (42) Lo/1 st
(35) Overrun (43) Exhaust
(36) Overrun Clutch Feed (44) Orificed Exhaust
(37) Overrun Clutch (47) Void
Transmission/Transaxle Automatic Transmission - 4L60-E 7-259

10128

Legend
(3) Line (28) 3rd Accumulator
(9) Actuator Feed Limit (29) 3-4 Clutch
(10) Filtered Actuator Feed (30) 4th Signal
(11) Torque Signal (31) Servo Feed
(12) PR (32) 4th
(13) D4-3-2 (33) 3-4 Accumulator
(14) Lo/Reverse (34) D3
(15) Reverse (35) Overrun
(16) Reverse Input (Rev. Cl.) (36) Overrun Clutch Feed
(17) D4 (37) Overrun Clutch
(18) Forward Clutch Feed (38) D2
(20) Accumulator (39) Orificed D2
(21) Orificed Accumulator (40) 3-2 Signal
(22) Signal A (41) Lo
(24) 2nd (42) Lo/1st
(25) 2nd Clutch (43) Exhaust
(26) C.C. Signal (44) Orificed Exhaust
(27) 3-4 Signal
7-260 Automatic Transmission - 4L60-E Transmission/Transaxle
Spacer Plate Passages

CZD
38 3$0

n----- W n29$)^nag DD12 m 1 D 411_____ . A

° we1 oO?
4P W_ OQ DK1 B° D34®? § 170 ^ i7HO 1□A' L 1—
10 ;f© p ? 1-™ i8dgi2™8 01214 °
o & 29$ 7 7 38Q0D17 q 12 4* A
<Q9 W 15 41 041 ^ 43/44 © ° /
Os/io 43,44 20014
o iv & Y ^ 1^8 0 024 Q24*5^10/22
27/290 DO© o
O
35a Q 34
T * 0*a 0/23
34 ^ 4 ^ 38139
38J39 O

W l0(49) (& )

° 33 020
Q32 17 W1 9 o 0 O
20Q
O ® 0 0 2 5
Q 25* O® O <520/21
25 A ,
25 □ 020/21
V 03 "0
0021
□ 25 U 9 /1 0 (50 )0
OSD 25 O d :

10126
Legend
(49) Shift Solenoids Screen (16) Reverse Input (Rev. Cl.)
(50) Pressure Control Solenoid Screen (17) D4
(3) Line (17/18) D4
(9) Actuator Feed Limit (18) Forward Clutch Feed
(9/10) Actuator Feed Limit/Filtered Actuator Feed (20) Accumulator
(10) Filtered Actuator Feed (20/21) Accumulator/Orificed Accumulator
(10/22) Filtered Actuator Feed/Signal A (21) Orificed Accumulator
(10/23) Filtered Actuator Feed/Signal B (22) Signal A
(11) Torque Signal (24) 2nd
(12) PR (24/25) 2nd/2nd Clutch
(13) D4-3-2 (25) 2nd Clutch
(14) Lo/Reverse (26) C.C. Signal
(15) Reverse (27) 3-4 Signal
(15/16) Reverse/Reverse Input (Rev. Cl.) (27/29) 3-4 Signal
Transmission/Transaxle Automatic Transmission - 4L60-E 7-261
(28) 3rd Accumulator (36) Overrun Clutch Feed
(29/28) 3-4 Clutch/3rd Accumulator (37) Overrun Clutch
(29) 3-4 Clutch (38) D2
(30) 4th Signal (38/39) D2/Orificed D2
(31) Servo Feed (40) 3-2 Signal
(32) 4th (41) Lo
(33) 3-4 Accumulator (42) Lo/1 st
(34) D3 (43) Exhaust
(35a) Overrun (43/44) Exhaust/Orificed Exhaust
(35) Overrun (44) Orificed Exhaust
(35/36) Overrun/Overrun Clutch Feed (47) Void
(35/39) Overrun/Orificed D2
7-262 Automatic Transmission - 4L60-E TransmissiorVTransaxle
Spacer Plate to Control Valve Body Gasket

10127

Legend
(3) Line (28) 3rd Accumulator
(9) Actuator Feed Limit (29) 3-4 Clutch
(10) Filtered Actuator Feed (30) 4th Signal
(11) Torque Signal (31) Servo Feed
(12) PR (32) 4th
(13) D4-3-2 (33) 3-4 Accumulator
(14) Lo/Reverse (34) D3
(15) Reverse (35) Overrun
(16) Reverse Input (Rev. Cl.) (35/39) Overrun/Orificed D2
(17) D4 (36) Overrun Clutch Feed
(18) Forward Clutch Feed (37) Overrun Clutch
(20) Accumulator (38) D2
(21) Orificed Accumulator (40) 3-2 Signal
(22) Signal A (41) Lo
(23) Signal B (42) Lo/1 st
(24) 2nd (43) Exhaust
(25) 2nd Clutch (44) Orificed Exhaust
(26) C.C. Signal (47) Void
(27) 3-4 Signal
Transmission/Transaxle Automatic Transmission - 4L60-E 7-263
Control Valve Body Passages (Case Side)

10124
Legend
(#2) Checkball (61) (16) Reverse Input (Rev. Cl.)
(#3) Checkball (61) (17) D4
(#4) Checkball (61) (18) Forward Clutch Feed
(#5) Checkball (61) (20) Accumulator
(#6) Checkball (61) (22) Signal A
(#8) Checkball (61) (23) Signal B
(#12) Checkball (61) (24) 2nd
(3) Line (25) 2nd Clutch
(9) Actuator Feed Limit (26) C.C. Signal
(10) Filtered Actuator Feed (27) 3-4 Signal
(11) Torque Signal (28) 3rd Accumulator
(12) PR (29) 3-4 Clutch
(13) D 4-3-2 (30) 4th Signal
(14) Lo/Reverse (31) Servo Feed
(15) Reverse (32) 4th
7-264 Automatic Transmission - 4L60-E Transmission/Transaxle
(33) 3-4 Accumulator (40) 3-2 Signal
(34) D3 (41) Lo
(35) Overrun (42) Lo/1 st
(36) Overrun Clutch Feed (43) Exhaust
(37) Overrun Clutch (47) Void
(38) D2

2-4 Servo Passages

10130
Legend
(11) Case Servo Orificed Plug (28) 3rd Accumulator
(40) 3rd Accum. Retainer and Ball (32) 4th
Assembly (#7) (43) Exhaust
(#7(40)) 3rd Accum. Retainer and Ball (44) Orificed Exhaust
Assembly
(25) 2nd Clutch
Transmission/Transaxle Automatic Transmission - 4L60-E 7-265
1-2 Accumulator Cover Fluid Passages

213852

Legend
(20) Accumulator
(21) Orificed Accumulator
(25) 2nd Clutch
7-266 Automatic Transmission - 4L60-E Transmission/Transaxle

Illustration Tool Number/Description

J 33037
Band Apply Pin Tool

9206

— / t " J 35944
Flushing Tool

9210

J 36850
Transjel® Transmission
Assembly Lubricant

24825

5
J 38417
Plastic Speed
a Sensor Removal and
J Installation Tool

9216
Transmission/Transaxle Automatic Transmission - 4L60-E 7-267

Illustration Tool Number/Description

J 28458
Power Piston Seal Protector
and Diaphragm Retainer
Installer

1010

J 28742-A
Weather Pack Terminal
Remover

5396

J 33095
< 1 ............... —> > =
Control Module Connector
Terminal Remover

5397

J 34142-B
Unpowered Test Lamp

5382

J 35616
Connector Test Adapter Kit

8917
7-268 Automatic Transmission - 4L60-E Transmission/Transaxle

Illustration Tool Number/Description Illustration Tool Number/Description

J 35689-A
J 39200
Metri-pack Terminal
Digital Multimeter (DMM)
Remover

5395 3430

J 35944-A
J 39775
Transmission Oil Cooler and
Jumper Harness
Line Flushing Tool

9210 13538

J 41364-A
J 35944-20
Neutral Position Adjustment
Cooler Flushing Fluid
Tool

15015 102613

J36169-A
Fused Jumper Wire

20896

J 38125-4
Terminal Repair Kit

9081
Transmission/Transaxle Automatic Transmission - 4L80-E 7-269

Automatic Transmission - 4L80-E

Specifications

Temperature vs Resistance
Minimum Nominal Maximum
Temperature Temperature Resistance Resistance Resistance Signal
*F •c Cl Cl Cl volts
-40 -40 90636 100707 110778 5.00
-22 -30 47416 52684 57952 4.78
-4 -20 25809 28677 31545 4.34
14 -10 14558 16176 17794 3.89
32 0 8481 9423 10365 3.45
50 10 5104 5671 6238 3.01
68 20 3164 3515 3867 2.56
86 30 2013 2237 2461 1.80
104 40 1313 1459 1605 1.10
122 50 876 973 1070 3.25
140 60 600 667 734 2.88
158 70 420 467 514 2.56
176 80 299 332 365 2.24
194 90 217 241 265 1.70
212 100 159 177 195 1.42
230 110 119 132 145 1.15
248 120 89.9 99.9 109.9 0.87
266 130 69.1 76.8 84.5 0.60
284 140 53.8 59.8 65.8 0.32
302 150 42.5 47.2 51.9 0.00

Fastener Tightening Specifications (On-Vehicle)

Application N.m Lb Ft Lb in
Accumulator Cover Bolts 11 — 97
Bracket to Frame Bolt 26 19 —
Control Valve Assembly to Case Screws 11 — 97
Converter to Flywheel Bolts 67 49 —

Crossmember to Frame Bolts 77 56 —

Engine Rear Mount to transmission Bolts 44 33 —
Oil Pan to Transmission Case Bolts 24 18 —

Park/Neutral Position Switch Bolts 27 20 —

Parking Pawl Bracket to Case Bolt 24 18 —

Rear Servo Cover to Case Bolt 24 18 —

Shift Lever to Transmission Nut 27 20 —

Swivel to Equalizer Lever Bolt 27 20 —

Solenoids to Valve Body Screw 10 — 89

Speed Sensor to Case 11 — 97
Transmission Case to Engine Stud 47 34 —
7-270 Automatic Transmission - 4L80-E Transmission/Transaxle
Fastener Tightening Specifications (On-Vehicle) (cont’d)
Application N-m Lb Ft Lb In
Transmission Converter Cover Bolts 33 24 —
Transmission Heat Shield Bolts 17 13 —
Transmission Oil Cooler Bracket to Radiator Bolts 10 — 89
Transmission Oil Cooler to Bracket Bolts 6 — 53
Transmission Oil Cooler Line Clip Bolts 12 9 —
Transmission Oil Cooler Line Clip Nuts 8 — 71
Transmission Oil Cooler to Bracket Bolts 10 — 89
Transmission Oil Cooler Line to Oil Cooler Nut 27 20 —
Transmission Oil Cooler Line to Radiator Nut 27 20 —
Transmission Oil Level Indicator Stud 47 34 —
Transmission Oil Level Indicator Tube Nut 25 18 —
Transmission to Engine Brace Bolts (Left and Right Side,
55 41 —
Gasoline)
Transmission to Engine Brace Bolts (Right Side Only, Diesel) 70 51 —

Fastener Tightening Specifications (Overhaul)

Application N.m Lb Ft Lb In
Solenoid to Valve Body 8 — 71
Control Valve Assembly to Case 11 — 97
Oil Test Hole Plug 11 — 97
Flywheel Housing Cover to Transmission 7 — 62
Pump Body to Cover 24 18 —
Pump Assembly to Case 24 18 —
Rear Servo Cover to Case 24 18 —
Pressure Control Solenoid Bracket to Valve Body 8 — 71
Parking Pawl Bracket to Case 24 18 —
Accumulator Housing to Valve Body 11 — 97
Fourth Clutch 23 17 —

Oil Pan to Case 24 18 —

Extension Housing to Case 34 25 —
Manual Shaft to Detent Lever Nut 24 18 —
Speed Sensor and Bracket Assembly to Case 11 — 97
Case Center Support 44 32 —
Flywheel to Converter 44 32 —
Transmission Case to Engine 44 32 —
Cooler Pipe Connector Nut at Case and Radiator 38 28 —
Valve Body to Case/Lube Pipe 11 — 97
Engine Rear Mount to Transmission Bolt 44 32 —
Engine Rear Support Bracket to Frame Nut 44 32 —
Valve Body to Case/PSM 11 — 97
Drain Plug, Oil Pan 34 25 —
Transmission/Transaxle Automatic Transmission - 4L80-E 7-271
Scan Tool Data Value Examples Only the parameters listed below are used in this
(Gas VCM) manual for diagnosing. If a scan tool displays other
parameters, the values are not recommended by
If you have completed the On-Board Diagnostic General Motors for use in diagnosis.
(OBD) system check, if the diagnostics are
functioning properly and if no DTCs display, you may Scan tests are performed under the following driving
use the Typical Scan Values in the table below for conditions:
comparison. These typical values are an average of • Engine idling
display values recorded from normally operating • Upper radiator hose is hot
vehicles. They represent the display from a normally
• Closed throttle
functioning system.
• Transmission is in Park
You should never use a scan tool that displays faulty
data. The problem should be reported to the • Closed Loop
manufacturer. The use of a faulty scan tool can • Accessories OFF
result in misdiagnosis and the unnecessary
replacement of parts.

Scan Tool Data Value Examples (Gas VCM)

Tech 2 Parameter Units Displayed Typical Scan Values
Engine Torque N.m (lb ft) Varies
TP Sensor Volts 0.59V
TP Angle Percent applied 0%
Engine Speed RPM 610 RPM
Transmission ISS RPM 680 RPM
Turbine Speed RPM 680 RPM
Transmission OSS RPM 0
Vehicle Speed km/h (mph) 0
Current Gear 1,2, 3,4 1
1-2 Sol. ON/OFF ON
2-3 Sol. ON/OFF OFF
Gear Ratio Ratio 8.00:1
Speed Ratio Ratio 8.00:1
1-2 Sol. Open/Short to Ground Yes No
1-2 Sol. Shorted/to Voltage Yes/No No
2-3 Sol. Open/Short to Ground Yes/No No
2-3 Sol. Shorted/to Voltage Yes/No No
TFP Switch A/B/C ON/OFF OFF/ON/OFF
ECT 'C( - F) 83*C (181 *F)
Trans. Fluid Temp. *C (*F) Varies
TFT Sensor Volts Varies
IAT Sensor •C(*F) Varies
Transmission Hot Mode ON/OFF OFF
PC Sol. Actual Current amps 0.96 amps
PC Sol. Ref. Current amps 0.96 amps
PC Sol. Duty Cycle Percent On Time 57%/Varies
TCC Brake Switch Open/Closed Closed
TCC Duty Cycle % 0%
TCC Slip Speed RPM -70 Varies
TCC Duty Cycle Open Short Yes/No No
to Ground
7-272 Automatic Transmission - 4L80-E Transmission/Transaxle

Scan Tool Data Value Examples (Gas VCM) (cont’d)

Tech 2 Parameter Units Displayed Typical Scan Values
TCC Duty Cycle Short to Voltage Yes/No No
1-2 Shift Time Seconds Varies
2-3 Shift Time Seconds Varies
3-4 Shift Time Seconds Varies
Adaptable Shift Yes/No No
Engine Run Time HnMin:Sec 00:00:00
Ignition Voltage Volts 13.5-14.5
Cruise ENABLED/DISABLED DISABLED
A/C Clutch ON/OFF OFF
4WD ENABLED/DISABLED DISABLED
4WD Low ENABLED/DISABLED DISABLED
Power Take-Off Yes/No No

Scan Tool Data Value Examples Only the parameters listed below are used in this
(Diesel PCM) manual for diagnosing. If a scan tool displays other
parameters, the values are not recommended by
If you have completed the On-Board Diagnostic General Motors for use in diagnosis.
(OBD) system check, if the diagnostics are
functioning properly and if no DTCs display, you may Scan tests are performed under the following driving
use the Typical Scan Values in the table below for conditions:
comparison. These typical values are an average of • Engine idling
display values recorded from normally operating • Upper radiator hose is hot
vehicles. They represent the display from a normally • Closed throttle
functioning system.
• Transmission is in Park
You should never use a scan tool that displays faulty
data. The problem should be reported to the • Closed Loop
manufacturer. The use of a faulty scan tool can • Accessories OFF
result in misdiagnosis and the unnecessary
replacement of parts.

Scan Tool Data Value Examples (Diesel PCM)

Tech 2 Parameter Units Displayed Typical Scan Values
Engine Torque N-m (lb ft) 29 N-m (19 lb ft)
APP Angle % 0%
Engine Speed RPM 620 RPM
Transmission ISS RPM 700 RPM
Turbine Speed RPM 700 RPM
Transmission OSS RPM 0 RPM
Vehicle Speed km/h (mph) 0 km/h (0 mph)
Current Gear 1, 2, 3, 4 1
1-2 Sol. On/Off On
2-3 Sol. On/Off Off
Gear Ratio Ratio 8.00:1
Speed Ratio Ratio 8.00:1
1-2 Sol. Open/Short to Ground Yes/No No
1-2 Sol. Short to Volts Yes/No No
2-3 Sol. Open/Short to Ground Yes/No No
2-3 Sol. Short to Volts Yes/No No
Transmission^ransaxle Automatic Transmission - 4L80-E 7-273
Scan Tool Data Value Examples (Diesel PCM) (cont’d)
Tech 2 Parameter Units Displayed Typical Scan Values
TFP Sw. A/B/C On/Off Off/On/Off
ECT •C/’ F 83 *C (181 * F) (Varies)
Trans. Fluid Temp. •C/-F 80*C (118*F) (Varies)
TFT Sensor Volts 2.25 Volts (Varies)
IAT *C/' F Varies
Transmission Hot Mode On/Off Off
PC Sol. Actual Current Amps 0.83 amps
PC Sol. Ref. Current Amps 0.83 amps
PC Sol. Duty Cycle % 43%
TCC Brake Switch Open/Closed Open
TCC Duty Cycle % 0%
TCC Slip Speed RPM -80 RPM
TCC Duty Cycle Open/Short to
Yes/No No
Ground
TCC Duty Cycle Short to Volts Yes/No No
1-2 Shift Time Seconds Varies
2-3 Shift Time Seconds Varies
3-4 Shift Time Seconds Varies
Adaptable Shift Yes/No No
Engine Run Time Hour/Minutes/Seconds Varies
Ignition Voltage Volts 13.5-14.5 Volts
Cruise Enabled/Disabled Disabled
A/C Clutch On/Off Off
Power Take Off Yes/No No
4WD Enabled/Disabled Disabled
4WD Low Enabled/Disabled Disabled
7-274 Automatic Transmission - 4L80-E
Transmission Scan Tool Data Definitions
1-2 Shift Time: Displays 0.00-6.38 seconds. This
parameter is the actual time of the last 1-2 shift. The
shift time is based on the gear ratio change after the
commanded 1-2 shift. This value is only accurate if
the Adaptable Shift parameter indicates Yes.
1-2 Sol (Solenoid): Displays ON or OFF. These
parameters are the commanded status of the
1-2 Shift Solenoid Valves. ON represents a
commanded energized state (current is flowing
through the solenoid). OFF represents a
non-commanded state (current is not flowing
through the solenoid).
1-2 Sol. (Solenoid) Open/Shorted to Ground:
Displays Yes or No. This parameter indicates if an
open or a short to ground exists in the feedback
signal from the 1-2 Shift Solenoid Valve to the VCM.
1-2 Sol. (Solenoid) Shorted to Voltage: Displays
Yes or No. This parameter indicates if a short to
B+ exists in the feedback signal from the 1-2 Shift
Solenoid Valve to the VCM.
1 - 2 TAP Cell (4-16): Scan tool displays kPa or psi.
This parameter displays the amount of pressure
varied from a calibrated base line pressure for shifts.
Each TAP Cell is based on a calibrated shift torque
value. Each TAP Cell value is calculated from the
last shift time. This cell pressure is used in addition
to the calibrated base line pressure to adjust the
apply of a clutch or band during the next shift.
2- 3 Shift Time: Displays 0.00-6.38 seconds. This
parameter is the actual time of the last 2-3 shift. The
shift time is based on the gear ratio change after the
commanded 2-3 shift. This value is only accurate if
the Adaptable Shift parameter indicates Yes.
2-3 Sol. (Solenoid): Displays ON or OFF. These
parameters are the commanded status of the
2-3 Shift Solenoid valves. ON represents a
commanded energized state (current is flowing
through the solenoid). OFF represents a
non-commanded state (current is not flowing through
the solenoid).
2-3 Sol. (Solenoid) Open/Shorted to Ground:
Displays Yes or No. This parameter indicates if an
open or a short to ground exists in the feedback
signal from the 2-3 Shift Solenoid Valve to the VCM.
2-3 Sol. (Solenoid) Shorted to Voltage: Displays
Yes or No. This parameter indicates if a short to
B+ exists in the feedback signal from the 2-3 Shift
Solenoid Valve to the VCM.
2 - 3 TAP Cell (4-16): Scan tool displays kPa or psi.
This parameter displays the amount of pressure
varied from a calibrated base line pressure for shifts.
Each TAP Cell is based on a calibrated shift torque
value. Each TAP Cell value is calculated from the
last shift time. This cell pressure is used in addition
to the calibrated base line pressure to adjust the
apply of a clutch or band during the next shift.
3- 4 Shift Time: Displays 0.00-6.38 seconds. This
parameter is the actual time of the last 3-4 shift. The
Transmission/Transaxle
shift time is based on the gear ratio change after the
commanded 3-4 shift. This value is only accurate if
the Adaptable Shift parameter indicates Yes.
3 -4 TAP Cell (4-16): Scan tool displays kPa or psi.
This parameter displays the amount of pressure
varied from a calibrated base line pressure for shifts.
Each TAP Cell is based on a calibrated shift torque
value. Each TAP Cell value is calculated from the
last shift time. This cell pressure is used in addition
to the calibrated base line pressure to adjust the
apply of a clutch or band during the next shift.
4WD: Displays Enabled or Disabled. This parameter
indicates whether the vehicle is currently in a
four-wheel drive mode.
4WD Low: Displays Enabled or Disabled. This
parameter is the signal state of the four-wheel drive
low circuit. Enabled indicates a 0 voltage signal
requesting 4WD Low. Disabled indicates a B+
voltage signal which does not request 4WD Low.
A/C Clutch: Displays ON or OFF. This represents
the commanded state of the A/C clutch control relay.
The clutch should be engaged whenever ON is
displayed. The VCM/PCM will compensate for the
additional engine load that is accompanied with the
A/C clutch engaged.
Adaptable Shift: The scan tool displays Yes or No.
Yes indicates that the proper operating conditions
(i.e. TP Sensor Delta, Engine Torque, Vehicle Speed
Data, Engine Vacuum, Shift Delay, etc.) were all
within the proper operating range during the last shift
and the Shift Time was accurate. This shift
information is then used through the adaptive
function to update the adapt cells. No indicates that
not all of the operating conditions were met in order
to enable this function and that the adapt cells were
not updated.
APP (Accelerator Pedal Position) Angle: Diesel
application: Displays a range of 0-100%. The APP
angle is computed by the PCM from APP voltage.
The APP angle should display 0% at idle and 100%
at wide open throttle (WOT).
Cruise: Displays ENABLED or DISABLED. This
parameter indicates whether the VCM/PCM is
allowing cruise operation. The VCM/PCM has the
ability to disable cruise control under certain
conditions.
Current Gear: Displays 1, 2, 3, or 4. This parameter
indicates the current commanded state of the shift
solenoids.
Current TAP (Transmission Adaptive Pressure):
Displays a Torque Based Cell range of 0-16. This
parameter indicates the current cell used for line
pressure modification (adaptation).
ECT (Engine Coolant Temperature): Displays
-40 * C to 151 * C (-40 * F to 304 * F). This parameter is
the input signal of the engine coolant temperature
sensor. Engine coolant temperature is high when the
signal voltage is low (0 volts), and engine coolant
temperature is low when the signal voltage is
high (5 volts).
TransmissiorVTransaxle
Engine Run Time: Displays a range of
0:00:00-18:12:15 Hr/Min/Sec. This parameter
measures how long the engine has been operating.
When you turn the ignition switch Off, the value
resets to zero.
Engine Speed: Displays 0-8192 RPM. This
parameter indicates the rotational speed of the
engine expressed as revolutions per minute.
Engine Torque: Displays 0-9999 ft/lb. This
parameter is a calculated value based on engine
load, throttle position, Mass Air Flow, and other
engine and transmission inputs. This parameter is
accurate to within 15 ft/lb of actual measured
engine torque.
Gear Ratio: Displays a range of 0.00 to 8.00:1. This
parameter is the actual gear ratio of the current
commanded gear. In the current gear of R, D3, D2,
and D1, it is calculated by dividing the input speed
by the output speed. In the current gear of D4 with
TCC lock up, the gear ratio is calculated by dividing
the turbine speed by the output speed.
Hot Mode: Displays ON or OFF. This parameter
monitors the transmission fluid temperature. Yes
indicates that the transmission fluid temperature has
exceeded 135*C (275 *F).
Ignition Voltage: Displays 0.0-25.5 volts. This
parameter represents the system voltage measured
by the VCM/PCM at its ignition feed.
Latest Shift: Displays 0.00-6.38 seconds. This
parameter is the actual shift time of the last upshift.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
PC (Pressure Control) Sol. Act. (Actual) Current:
Displays 0.00-1.1 amps. This parameter is the actual
current of the pressure control solenoid circuit at the
control module. Zero amp (no current flow) indicates
an actual higher line pressure. A reading of 1.1 amp
(high current flow) indicates an actual lower line
pressure.
PC (Pressure Control) Sol. Duty Cycle: Displays
0%-100%. This parameter is the commanded state
of the pressure control solenoid expressed as a
percentage of energized ON time. A reading of 0%
indicates zero ON time (non energized), or no
current flow. Approximately 60% at idle indicates
maximum ON time (energized), or high current flow.
PC (Pressure Control) Sol. Ref. (Reference)
Current: Displays 0.00-1.1 amps. This parameter is
the commanded current of the pressure control
solenoid circuit at the control module. Zero amp (no
current flow) indicates a commanded higher line
pressure. A reading of 1.1 amp (high current flow)
indicates a commanded lower line pressure.
Speed Ratio: The scan tool displays a range of
0.00:1-8.00:1. This parameter indicates engine
speed divided by transmission output speed.
Standard TAP (Transmission Adaptive Pressure):
Displays Yes or No. The standard TAP is an amount
of pressure that is added to the base line pressure.
If the shift requires standard TAP to achieve the
shift, the scan tool displays Yes. If the shift requires
Automatic Transmission - 4L80-E 7-275
more or less than the standard TAP to achieve the
shift, the scan tool displays No. This reading
indicates that the TAP is out of the standard range.
TCC Brake Switch (PCM Application): Displays
Open or Closed. This parameter indicates the state
of the TCC brake switch circuit input. Open indicates
a zero voltage input (the brake switch is open and
the brake pedal is not applied). Closed indicates a
B+ voltage input (the brake switch is closed when
the brake pedal is applied).
TCC Brake Switch (VCM Application): Displays
Open or Closed. This parameter indicates the state
of the TCC brake switch circuit input. Open indicates
a zero voltage input (the brake switch is open and
the brake pedal is applied). Closed indicates a
B+ voltage input (the brake switch is closed and the
brake pedal is not applied).
TCC Duty Cycle: Displays 0%-100%. This
parameter is the commanded percentage of ON time
of the TCC PWM solenoid. 90% represents an ON
(energized) commanded state. 0% represents an
OFF (non-energized) commanded state.
TCC Duty Cycle Open/Shorted to Ground:
Displays Yes or No. This parameter indicates if an
open or a short to ground exists in the feedback
signal from the TCC PWM Sol. Valve to the VCM.
TCC Duty Shorted to Voltage: Displays Yes or No.
This parameter indicates if a short to B+ exists in
the feedback signal from the TCC PWM Sol. Valve
to the VCM.
TCC (Torque Converter Clutch) Slip Speed:
Displays -4080 to +4079 RPM. This parameter is the
difference between transmission input speed and
engine speed. A negative value indicates that the
engine speed is less than the input speed
(deceleration). A positive value indicates that the
engine speed is greater than the input speed
(acceleration). A value of zero indicates that the engine
speed is equal to the input speed (TCC is applied).
TFP Switch A/B/C: Displays On/Off, On/Off, On/Off.
These parameters are the three inputs from the
Automatic Transmission Fluid Pressure Manual Valve
Position Switch Assembly. ON represents a 0 voltage
signal. OFF represents a B+ voltage signal.
TFT (Transmission Fluid Temperature) Sensor:
Displays 0.00-5.00 volts. When the transmission fluid
is cold, the sensor resistance is high and the VCM
will sense a high signal voltage. As the transmission
fluid temperature warms to normal operating
temperature, the sensor resistance becomes less
and the voltage decreases to about 1.5-2.0 volts.
TP (Throttle Position) Angle: Displays a range of
0%—100%. The TP Angle is computed by the VCM
from TP voltage. The TP Angle should display 0% at
idle and 100% at Wide Open Throttle (WOT).
TP (Throttle Position) Sensor: Scan tool displays
a range of 0.00-5.00 volts. The VCM uses the
TP Sensor in order to determine the amount of
throttle demanded by the driver. Voltage will be
below 1 volt at idle. Voltage will be above 4 volts
at Wide Open Throttle (WOT).
7-276 Automatic Transmission - 4L80-E
Trans. Fluid Temp. (TFT): Displays -40 * C to 151 * C
(-40 * F to 304 * F). This parameter is the input signal
of the transmission fluid temperature sensor.
Transmission fluid temperature is high when the
signal voltage is low (0 volts), and transmission
fluid temperature is low when the signal voltage is
high (5 volts).
Transmission ISS (Input Shaft Speed): Displays
0-8192 RPM. This parameter measures the
rotational speed of the input shaft expressed as
revolutions per minute.
Transmission OSS (Output Shaft Speed): Displays
0-8192 RPM. This parameter indicates the rotational
speed of the transmission output shaft expressed as
Diagnostic Trouble Code (DTC) Identification (Gas)
DTC Description
P0218 Transmission Fluid Overtemperature
P0502 Vehicle Speed Sensor Circuit — Low Input
P0503 Vehicle Speed Sensor Circuit — Intermittent
P0560 System Voltage Malfunction
Automatic Transmission Fluid Temperature
P0711
(TFT) Sensor Circuit Range/Performance
Transmission Fluid Temperature Sensor
P0712
Circuit — Low Input
Transmission Fluid Temperature Sensor
P0713
Circuit — High Input
Transmission/Transaxle
revolutions per minute. On four-wheel drive
applications, the transfer case output shaft speed
is measured.
Turbine Speed: Displays 0-8192 RPM. This
parameter indicates the rotational speed of the
Torque Converter Turbine Shaft expressed as
revolutions per minute. In commanded gears 1, 2,
and 3, the turbine speed equals the input speed. In
commanded gear 4, the turbine speed equals 3/4 of
the input speed.
Vehicle Speed: Displays 0-255 km/h (0-158 mph).
This parameter is the input signal from the
OSS sensor.
DTC Type Default Action
• The VCM freezes shift adapts.
D
• DTC P0218 is stored in the VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
• The VCM commands maximum line
DIB
pressure.
• The VCM defaults a calculated OSS from
the AIT ISS Sensor output.
• DTC P0502 is stored in the VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
• The VCM commands maximum line
DIB
pressure.
• The VCM defaults a calculated OSS from
the A/T ISS Sensor output.
• DTC P0503 is stored in the VCM history.
• The VCM commands an immediate
landing to second gear.
• The VCM freezes shift adapts.
D
• The VCM turns off all transmission
output devices.
• DTC P0560 is stored in VCM history.
• The VCM freezes shift adapts.
• The VCM defaults the TFT to
D
140‘ C(284* F).
• DTC P0711 is stored in the VCM history.
• The VCM freezes shift adapts.
. The VCM defaults TFT to 140 *C (284 • F)
D
for shift scheduling (hot mode pattern).
• DTC P0712 is stored in VCM history.
• The VCM freezes shift adapts.
. The VCM defaults TFT to 140* C (284 *F)
D
for shift scheduling (hot mode pattern).
• DTC P0713 is stored in VCM history.
Transmission/Transaxle, Automatic Transmission - 4L80-E 7-277
Diagnostic Trouble Code (DTC) Identification (Gas) (cont’d)
DTC Description DTC Type Default Action
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
P0716 Input Speed Sensor Circuit — Intermittent DIB
• The VCM commands maximum line
pressure.
• DTC P0716 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
P0717 Input Speed Sensor Circuit — Low Input DIB
• The VCM commands maximum line
pressure.
• DTC P0717 is stored in VCM history.
P0719 Brake Switch Circuit — Low Input D DTC P0719 is stored in VCM history.
P0724 Brake Switch Circuit — High Input D DTC P0724 is stored in VCM history.
• The VCM commands maximum line
pressure.
P0730 Incorrect Gear Ratio D
• The VCM freezes shift adapts.
• DTC P0730 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM inhibits TCC engagement.
P0741 Torque Converter Clutch System Stuck Off DIB
• The VCM inhibits fourth gear
engagement.
• DTC P0741 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM commands maximum line
P0742 Torque Converter Clutch System Stuck On DIB pressure.
• The VCM freezes shift adapts.
• DTC P0742 is be stored in VCM history.
• The VCM disables the PC Sol. Valve.
P0748 Pressure Control Circuit — Electrical D • The VCM freezes shift adapts.
• DTC P0748 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM commands maximum line
pressure.
P0751 1-2 Shift Solenoid Valve — Performance DIB
• The VCM freezes shift adapts.
• 3-2 downshifts above 25 MPH are
inhibited.
• DTC P0751 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
• 3-2 downshifts above 25 MPH are
P0753 1-2 Shift Solenoid Valve Circuit — Electrical D/A
inhibited.
• The VCM commands maximum line
pressure.
• DTC P0753 is stored in VCM history.
7-278 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Trouble Code (DTC) Identification (Gas) (cont’d)
DTC Description DTC Type Default Action
• The VCM illuminates the MIL for
California emissions.
• The VCM commands an immediate
landing to second gear.
P0756 2-3 Shift Solenoid Valve — Performance D/A
• The VCM freezes shift adapts.
• The VCM commands maximum line
pressure.
• DTC P0756 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM commands maximum line
pressure.
P0758 2-3 Shift Solenoid Valve Circuit— Electrical DIA
• The VCM freezes shift adapts.
• The VCM commands an immediate
landing to second gear.
• DTC P0758 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
Automatic Transmission Fluid Pressure • The VCM assumes D4 shift pattern.
P1810 Manual Valve Position Switch Circuit DIB • The VCM commands maximum line
Malfunction pressure.
• The VCM forces TCC apply when fourth
gear is commanded.
• DTC P1810 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM inhibit s TCC engagement.
Torque Converter Clutch Pulse Width
P1860 D/A • The VCM inhibits fourth gear
Modulation Solenoid Valve Circuit-Electrical
engagement.
• The VCM freezes shift adapts.
• DTC P1860 is stored in VCM history.
• The VCM illuminates the MIL for
California emissions.
• The VCM commands maximum line
pressure.
P1870 Transmission Component Slipping DIB • The VCM inhibits TCC engagement.
• The VCM inhibits fourth gear
engagement.
• The VCM freezes shift adapts.
• DTC P1870 is stored in VCM history.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-279
Diagnostic Trouble Code (DTC) Identification (Gas) (cont’d)
DTC Description DTC Type Default Action
• The VCM illuminates the MIL for
California emissions.
• The VCM freezes shift adapts.
• The VCM assumes a 4WD Lo state if
the switch fails when open, or the VCM
Four-Wheel Drive Low Switch Circuit assumes a 4WD High state if the switch
P1875 DIB fails when closed, for a transmission shift
Electrical
pattern.
• The VCM inhibits fourth gear
engagement.
. The VCM freezes shift adapts.
• DTC P1875 is stored in VCM history.
DTC Types:
A - Emission related, will turn on the MIL after the first failure
B - Emission related, will turn on the MIL after two consecutive trips with a failure
C - Non-emission related, will turn on the service lamp after the first failure
D - Non-emission related, no lamps

Diagnostic Trouble Code (DTC) Identification (Diesel)

DTC Description DTC Type Default Action
• The PCM freezes shift adapts.
P0218 Transmission Fluid Overtemperature D
• DTC P0218 is stored in the PCM history.
• The PCM inhibits TCC engagement.
• The PCM freezes shift adapts.
• The PCM turns off the PC Sol. Valve.
P0560 System Voltage Malfunction D
• The PCM commands an immediate
landing into 2nd gear.
• DTC P0560 is stored in PCM history.
• The PCM uses a TFT default value of
Transmission Fluid Temperature Sensor 140*C (284 *F).
P0711 D
Circuit Range/Performance • The PCM freezes shift adapts.
• DTC P0711 is stored in the PCM history.
• The PCM freezes shift adapts.
Transmission Fluid Temperature Sensor • The PCM uses a TFT default value of
P0712 D
Circuit — Low Input 140‘ C (284* F).
• DTC P0712 is stored in PCM history.
• The PCM freezes shift adapts.
Transmission Fluid Temperature Sensor • The PCM uses a TFT default value of
P0713 D
Circuit — High Input 140*C (284 *F).
• DTC P0713 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
P0716 Input Speed Sensor Circuit — Intermittent B • The PCM commands maximum line
pressure.
• DTC P0716 is stored in PCM history.
7-280 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Trouble Code (DTC) Identification (Diesel) (cont’d)
DTC Description DTC Type Default Action
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
P0717 Input Speed Sensor Circuit — Low Input B • The PCM commands maximum line
pressure.
• DTC P0717 is stored in PCM history.
P0719 Brake Switch Circuit — Low Input D • DTC P0719 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
• The PCM commands maximum line
P0722 Output Speed Sensor — Low Input B
pressure.
• The PCM calculates OSS from ISS.
• DTC P0722 is stored in the PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
• The PCM commands maximum line
P0723 Output Speed Sensor Intermittent B
pressure.
• The PCM calculates OSS from ISS.
• DTC P0723 is stored in the PCM history.
• Apply TCC if APP is greater than 0.5%
and the vehicle speed is greater than
P0724 Brake Switch Circuit — High Input D 30 mph.
• DTC P0724 is stored in VCM history.
• The PCM commands maximum line
pressure.
P0730 Incorrect gear ratio D
• The PCM freezes shift adapts.
• DTC P0730 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM inhibits TCC engagement.
• The PCM inhibits fourth gear
P0741 Torque Converter Clutch System Stuck Off B engagement.
• The PCM commands increased line
pressure.
• DTC P0741 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
P0742 Torque Converter Clutch System Stuck On B • The PCM commands maximum line
pressure.
• DTC P0742 is stored in PCM history.
• The PCM freezes shift adapts.
Pressure Control Solenoid Circuit — • The PCM commands maximum line
P0748 D
Electrical pressure by disabling the PC Sol. Valve.
• DTC P0748 is stored in PCM history.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-281
Diagnostic Trouble Code (DTC) Identification (Diesel) (cont’d)
DTC Description DTC Type Default Action
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
P0751 1-2 Shift Solenoid Valve —Performance B • The PCM commands maximum line
pressure.
• DTC P0751 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
• The PCM commands maximum line
P0753 1-2 Shift Solenoid Valve — Electrical A
pressure.
. MIL
• DTC P0753 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM commands an immediate
landing into second gear.
P0756 2-3 Shift Solenoid Valve — Performance A • The PCM freezes shift adapts.
• The PCM commands maximum line
pressure.
• DTC P0756 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM commands an immediate
landing to second gear.
P0758 2-3 Shift Solenoid Valve — Electrical A • The PCM freezes shift adapts.
• The PCM commands maximum line
pressure.
• DTC P0758 is stored in the PCM history
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
• The PCM assumes a D4 shift pattern.
Transmission Fluid Pressure Manual Valve
P1810 Position Switch Assembly — Circuit B • The PCM commands maximum line
Malfunction pressure.
• The PCM commands TCC apply with
4th gear commanded ON.
• DTC P1810 is stored in PCM history.
• The PCM freezes shift adapts.
• The PCM commands maximum line
P1811 Maximum Adapt and Long Shift D
pressure.
• DTC P1811 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM inhibits TCC engagement.
Torque Converter Clutch Pulse Width • The PCM inhibits fourth gear
P1860 A
Modulation Solenoid Circuit — Electrical engagement.
• The PCM freezes shift adapts.
• DTC P1860 is stored in PCM history
7-282 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Trouble Code (DTC) Identification (Diesel) (cont’d)
DTC Description DTC Type Default Action
• The PCM illuminates the MIL.
• The PCM commands maximum line
pressure.
• The PCM inhibits TCC engagement.
P1870 Transmission Component Slipping B
• The PCM inhibits fourth gear
engagement.
• The PCM freezes shift adapts.
• DTC P1870 is stored in PCM history.
• The PCM illuminates the MIL.
• The PCM freezes shift adapts.
• The PCM assumes a 4WD Lo state if
Four-Wheel Drive Low Switch Circuit — the switch fails when open, or the PCM
P1875 B
Electrical assumes a 4WD High state if the switch
fails when closed, for a transmission shift
pattern.
• DTC P1875 is stored in PCM history.
DTC Types:
A - Emission related, will turn on the MIL after the first failure.
B - Emission related, will turn on the MIL after two consecutive trips with a failure.
C - Non-emission related, will turn on the service lamp after the first failure.
D - Non-emission related, no lamps.

Fluid Capacity (On-Vehicle)

Application Liters Gallons
Overhaul 12.8 13.5
Pan Removal 7.3 7.7
Type Recommended Dexron® III T2620

Fluid Capacity (Overhaul)

Liters Quarts
(approximate)
Dry 12.8 13.5
Oil Pan Removal 7.3 7.7
Transmission/Transaxle Automatic Transmission - 4L80-E 7-283
Range Reference
Range Park Reverse Neutral OD D 2 1
Gear N R N 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 1st 2nd
@1-2 Shift
ON ON ON ON OFF OFF ON ON OFF OFF ON OFF ON OFF
Solenoid
@2-3 Shift OFF
OFF OFF OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF
Solenoid
Fourth
— — — — — — A — — — — — — —
Clutch
Overrun
— — — — — — — A A A A A A A
Clutch
Overdrive
H H H H H H OR A A A A A A A
Roller Clutch
Forward
— — — A A A A A A A A A A A
Clutch
Direct Clutch — A — — — A A — — A — — — —
Front Band A — A
Intermediate * * * *
— — — H OR OR H OR H H
Sprag Clutch
Intermediate
— — — — A A A — A A — A — A
Clutch
Lo Roller
— — — H OR OR OR H OR OR H OR H OR
Clutch
Rear Band — A A —
A = Applied
H = Holding
OR = Overrunning
* = Holding but not effective
ON = The solenoid is energized.
OFF = The solenoid is de-energized
@ = The solenoid’s state follows a shift pattern which depends upon vehicle speed and throttle position. The pattern
does not depend upon the selected gear.__________________________________________________________

Gear Ratios Shift Solenoid Valve State and Gear Ratio

Gear Gear Ratio Gear 1-2 SS Valve 2-3 SS Valve Gear Ratio
First 2.48 1 ON OFF 2.48:1
Second 1.48 2 OFF OFF 1.48:1
Third 1.00 3 OFF ON 1.00:1
Fourth 0.75 4 ON ON 0.75:1
Reverse 2.08 R ON OFF 2.08:1
7-284 Automatic Transmission - 4L80-E________________________ TransmissionTTransaxle
Transmission General Specifications
Length (mm) Length (in)
Direct Clutch Piston Travel Specification 3.07-4.72 0.121-0.186
Intermediate Clutch Piston Travel
1.02-2.72 0.040-0.107
Specification
Forward Clutch Piston Travel
3.07-4.72 0.121-0.186
Specification
Overrun Clutch Piston Travel
0.838-2.38 0.033-0.094
Specification

Rear Servo Pin Specification Line Pressure

Refer to the rear servo pin selection chart in order to
determine the correct pin usage. Pressure Control Solenoid Approximate Line
Current (Amp) Pressure (PSi)
0.02 157-177
0.10 151-176
0.20 140-172
0.30 137-162
0.40 121-147
0.50 102-131
0.60 88-113
0.70 63-93
0.80 43-73
0.90 37-61
0.98 35-55

2B391
Transmission/Transaxle Automatic Ttansmission - 4L80-E 7-285
Component Resistance
Resistance at 20*C
Component Wire Color Pass-Thru Pin (68’ F) Circuit Number
1-2 Shift Solenoid Valve Red *E 839A
20-40 O
(1-2 SS Valve) LT Green A 1222
2-3 Shift Solenoid Valve Red *E 839B
20-40 0
(2-3 SS Valve) Yellow B 1223
Pressure Control Purple C 1228
Solenoid Valve 3.5-8 0
(PC Sol. Valve) LT Blue D 1229

TCC Solenoid Valve Red *E 839C

10-15 0
(TCC Sol. Valve) Black S 418
Automatic Transmission Brown L 1227
Fluid Temperature 3333-3689 O
(TFT) Sensor Gray M 452
Automatic Transmission Red/Black »* 1230
Input Shaft Speed ** 1042-2088 0
(AT ISS) Sensor Blue/White 1231
Automatic Transmission Purple/White #** 821
Output Shaft Speed *** 1042-2088 0
(A/T OSS) Sensor LT Green/Black 822
1. * Spliced Internally to Pin E (circuit #839)
2. ** AT ISS Sensor Harness
3 ***fijj o s s Sensor Harness
7-286 Automatic Transmission - 4L80-E Transmission/Transaxle

Diagnostic Information and

Procedures
Functional Test Procedure

Functional Test Procedure

Step Action Value(s) Yes No
Perform the Transmission Fluid Checking Procedure.
1 — —
Is the fluid level correct? Go to Step 2
Check for PCM trouble codes, both current and history. Go to Diagnostic
Are PCM trouble codes present? Trouble
Code (DTC)
Identification
—
(Gas) or
2
Diagnostic
Trouble
Code (DTC)
Identification
(Diesel) Go to Step 3
Perform the Road Test Procedure.
3 —
Was the condition duplicated? Go to Step 4 Go to Step 12
4 Is a harsh or soft shift condition present? — Go to Step 7 Go to Step 5
Is the vehicle’s performance poor? Go to Torque
5 — Converter Clutch
Diagnosis Go to Step 6
Is the engagement into Drive or Reverse delayed or
6 —
missing? Go to Step 7 Go to Step 9
Perform the Line Pressure Check Procedure. Refer to Symptom
7 —
Is the line pressure correct? Go to Step 8 Diagnosis Tables
Inspect the transmission wire harness connectors and the
8 transmission range switch. — Refer to Symptom
Was the problem found and corrected? System OK Diagnosis Tables
Is vibration or noise a concern? Refer to
Flywheel/Torque
9 —
Converter
Vibration Test Go to Step 10
Is the fluid leaking? Refer to Fluid
10 — Leak Diagnosis
and Repair Go to Step 11
Are other transmission conditions present? Refer to Symptom
11 —
Diagnosis Tables Go to Step 12
12 Was the condition corrected? — Exit Table Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-287

Schematic and Routing Diagrams

Automatic Transmission Schematic Icons

Icon Icon Definition
Refer to Electrostatic Discharge (ESD) Sensitive Devices in Section 8A-3 Symbols

>
19384
Refer to On-Board Diagnostics II (OBD II) Circuits in Section 8A-5 Repair Procedures

A
iO B D Ilk
19385
 7-288
Automatic Transmission Controls Schematics (PWR, GND and VSS)

| Hot in Run And Start! iH o tA tA in m esj iHot In Run And S ta ll

p “• “ ’ IP r “ “ ’ Underhood

Automatic Transmission - 4L80-E

■Power ■ Power Power
.Distributionn H8 i GAGES 'Fuse I Distributionn P tl k ECMB 'Fuse-Relay
J Distribution ecm i
Fuse 4 Fuse Fuse l rCenter
'C ell 10
I J7 C 10 A
Block C ellO G12
G 12HV 20 A
C ellO
20 A
l I

0.8 PNK 39 1 ORN 440

_ _ j
Vehicle Speed
Sensor (VSS)
0
Puee'B ga ’ S213
r
i S101 0.8 PNK 439 A
Details 1 0.5 LT GRN/BLK PCM
Cal 11
▼ ^ ------ « P101 C l= BRN
Fuse Block 0.8 ORN 440 0.8 PNK 439 C2=BRN
Ground Details 4WD | 2WD
C3-BLL1
Distribution ► ---------- C el 11
C el 14
0.5 y
♦S215 0.5LTGRN/BLKJ822 PPUWIjr|821 0.5
Vehicle Speed PPL/WHT 821
VSS VSS
Low »«<» Sensor (VSS)
mgn
Adaptor
0.5BLK/WHT 451 0.8 ORN 440 BT822 0.5 AT 0.5 LT
0.5 LT GRN/BLK PPL/WHTJ821 GRN/BLK 822
K C200 I *
C13 D13 C12JL _C11j[C3
Powertrain1* Battery Battery Ignition
1 BLK/WHT 451 Control1 Positive Positive Positive Positive 0.5 LT GRN/BLK
Module (PCM)1 Voltage p + ) Voltage (B + ) Voitege Voltage
C5 J jCIOO
P101 A. ' A/TOSS Signal VSS Instrument
jM p u t Input
£021__
r • SI03 AS C2
0.5 DK 389
I 0.5 BRN 437 0.5DKGRN 389 GRN
▲
Ground 0.5 G4.C200
Distribution
BLK/WHTI 451 0.5DKGRN 389

Transmission/Transaxle
C el 14
1 0.5 BRN 437 S211+

1
TAN/ 551
BLK/ 451
WHTl
«JL
Ground
0.35 PNK 39
9..
Ignition
13JL
A /T OSS
0.5DKGRN 389
15i
VSS
0.5 LT GRN/BLK
7A
VSS
12JL
VSS ’ Vehicle Speed
WHT Positive Signal Output Low High 'Sensor (VSS)
Voltage Input 'Buffer
mG104l
- A

186626
 Transmission/Transaxle
Automatic Transmission Controls Schematics (Brake Switch and Shift Solenoids)

| Hot At All Tlme«l I Hot In Run, Bulb Test And Start]

_ _
IP Fuse
Distribution B8 I . Stop/Haz j Block
Cell 10 P Fusel
C7 > 20 A
D2

E1 J TRANS
Fuse 20
10 A
_ _ _ _ _ _ j
l
PCM
Cl -3 2 BRN
C 2-24B R N
C 3 -3 2 BLU
i

1 ORN 140 \
0
TumSoST
Detals
Cell 11
* S299
1 ORN 140 0.35 PNK 1020 0.35 PNK 1020 0
BSC227
0.8 ORN 140
0.5 PNK
A2»C100
1020 Fuse Block
A
BJL E Cl 22
Details
Cel 11
^ Brake Switch
Assembly Automatic
0.5 RED 830
N.O.TCC Transmission
Stoplamp
Switch
\! 0.5 RED 0SRED OARED 839

I AJL
A
Torque 2 - 3 Shit 1 -2 Shift
Convertor Solenoid Solenoid
Clutch (2 -3 SS) (1 -2 SS)
Al Puise Width Vtove Valve
0.8 WHT 17
Solenoid B
A&C227 (TCCPW MSOq

Automatic Transmission - 4L80-E

Vatve
0.8 WHT 17 0.5 TAN 418 0AYEL 1223 OALTGRN 1222

Exterior
Lights ♦ ------------- -OS220 s
r ------ ---

C el10 B A Cl 22

AAC200 0.5 BRN 418 0.5LTGRN 1222

0.8 WHT 17
0.5 YEL7BLK 1223
P101
B10jC2 C5 C6 ________________________ C4
Powertrain r Stoplamp TCCPWMSOL 2 -3 S S 1 -2 S S
Control1 Switch Valve Valve Valve
Input Control Control Control
A Module1
________________________ _________________ ____ _____________ __________________ ___________ ______ j

7-289
186628
 7-290
Automatic Transmission Controls Schematics (TFP Valve Position Switch and PC Solenoid Valve)

1 Powertrain
! Control

Automatic Transmission - 4L80-E

Transmission Transmission Transmission TFT 4WD Front ■ Module (PCM)
Range A Range B Range C Sensor Wheel Lock . A
Input Input Input Signal F e e d _________ J iiA

Transmission/Transaxle
186629
 Transmission/Transaxle
Automatic Transmission Controls Schematics (VCM Power and VSS )
|Hot in Run And Start!
r — -
•Power 4 *• Underhood
U M tD U O O»n F " t ECMB D ta tS u tto T ^ T ENG 1 H71ecmi 'Fuse-Relay
IC ell 10 Fuse Q FUie I pantgf
i 012<t %% Ce" 1° L8> 20 A J8T 20A , ' ^ e rn e r
L _ •>
i
Vehicle Speed
1 ORN 440 0.8 PNK 539 1 PNK 439 Sensor ^/SS)
0
r — • S101 r ----- <>S108 r ------ OS161 (5.7L)
I I SI04 (7.41)
I I
i + VCM
2WD
Fuae&odT TSelioSr Fuse Block a - BUI
DetaHe DetaHe Details C 2 - RED
C e lt! C el 11 C el 11 C 3 - cu t
0.5 PPL/ 821 C 4 - BLK
0.5 LT WHT C 5 - BLK
QRN/BLK 822
A B 0.5 PPL/ 821
Vehicle Speed VSS
WHT
Sensor (VSS) High
0.5 LT
A GRN/BLK 822
0.5 PPL/
0.5 LT WHT
GRN/BLK 822

Automatic Transmission - 4L80-E

0.5 LT GRN/BLK

0.8 ORN 440 0.8 PNK 539 0.8 PNK 439

21 C3 4 Cl 18 C4
Battery Ignition Ignition
965- *■ Vehicle
Positive
Low High JControl
j
Positive Posftfce
Voltage (B-t-) Voltage Voltage Module (VCM)
■ >

7-291
52784
 7-292
Automatic Transmission Controls Schematics (TCC and Shift Solenoid Controls)

| h « At AMTimes] IhottnRun, Bulb Test And Start]

Automatic Transmission - 4L80-E

0
0

Transmlssion/Transaxle
(VCM) | I
L _______________________________________________________________________ ________________________________ J

186630
 Transmission/Transaxle
Automatic Transmission Controls Schematics (PC Solenoid Controls and 4WD Indicator)

Automatic Transmission - 4L80-E

7-293
186631
7-294 Automatic Transmission - 4L80-E Transmission/Transaxle

Component Locator
Automatic Transmission Components

Automatic Transmission Components

Connector End Group
Name Location Locator View View No.
Brake Switch Assembly Top of Brake Pedal — — —
l/P Fuse Block Lower LH side of l/P 201-25 Fig. 39 — —
Transfer Case
LH Top of Transfer Case 201-20 Fig. 30 — —
Switch (M30)
Transfer Case
LH Top of Transfer Case 201-23 Fig. 36 — —
Switch (MG5)
Transfer Case
LH Top of Transfer Case 201-21 Fig. 32 — —
Switch (MT1)
Transfer Case
LH Top of Transfer Case 201-22 Fig. 34 — —
Switch (MW3)
Underhood Fuse-Relay
LH rear of Engine Compartment, on Fender 201-4 Fig. 8 — —
Center
Vehicle Control Module Engine Compartment, near EBCM 201-24 Fig. 37 — —
LH rear side of Transmission (LH side of Transfer
Vehicle Speed Sensor 201-19 Fig. 29 — —
Case w/4WD)
C100 LH rear of Engine Compartment at Bulkhead 201-3 Fig. 7 202-0 —

C120 Rear of Engine, near Transmission 201-22 Fig. 34 202-40 —

Behind RH portion of l/P, near Heater Motor, in
C200 201-24 Fig. 38 202-5,6 —
Foam Wrap
C227 Under LH of l/P, near Stoplamp Switch 201-29 Fig. 48 — —
Engine Harness, approximately 11 cm into
S101 — — —
Underhood Fuse-Relay Center Breakout
Engine Harness, approximately 8 cm into Fuel
S104 (VIN M, R, W) — — —
Injector Connector Breakout
Engine Harness, approximately 30 cm from
S104 (VIN J) — — —
Fuse-Relay Center Breakout towards EGR Breakout
Engine Harness, approximately 5 cm from
S106 (VIN W) — — —
EGR Valve Breakout toward Fuel Injector Breakout
Engine Harness, approximately 17 cm from
S106 (VIN M,R) — — —
EGR Valve Breakout toward Fuel Injector Breakout
Engine Harness, approximately 7 cm from
S106 (VIN J) — — —
EGR Valve Breakout toward Underhood Lamp
Engine Harness, approximately 11 cm from Ignition
S108 (VIN M,R,W) — — —
Coil Breakout toward Starter Solenoid
Engine Harness, approximately 5 cm from Backup
S108 (VIN J) — — —
Lamp Switch harness, Breakout toward EGR Valve
Engine Harness, approximately 7 cm from
S152 Underhood Fuse-Relay Center Breakout, — — —
toward VCM
Engine Harness, approximately 8 cm from
S161 (VIN M.R) — — —
EGR Breakout toward Injector harness Breakout
Engine Harness, approximately 30 cm from
S161 (VIN W) EGR Harness Breakout, toward Taillamp Harness — — —
Breakout
l/P Harness, approximately 20 cm right of Heater
S222 — — —
and A/C Control Breakout
Transmission/Transaxle
Automatic Transmission Electronic
Component Views
Legend
(313) 1-2 Shift Solenoid Valve (1-2 SS Valve)
(22Automatic Transmission Output (Shaft)
(right))Speed Sensor (A/T OSS Sensor)
(34)Automatic Transmission Fluid Temperature
Sensor (TFT Sensor)
(40) Automatic Transmission Fluid Pressure
Manual Valve Position Switch (TFP Val.
Position Sw.)
Automatic Transmission - 4L80-E 7-295
71422
(320) Pressure Control Solenoid Valve
(PC Sol. Valve)
(323) Torque Converter Clutch Pulse Width
Modulation Solenoid Valve
(TCC PWM Sol. Valve)
(22 Automatic Transmission Input (Shaft) Speed
(left)) Sensor (A/T ISS Sensor)
(311) 2-3 Shift Solenoid (2-3 SS Valve)
7-296 Automatic Transmission - 4L80-E Transmission/Transaxle

Visual Identification 2-3 Shift Solenoid Valve Connector, Wiring

Harness Side
AT Internal Connector End Views

Automatic Transmission Fluid Pressure

Manual Valve Position Switch Connector,
Wiring Harness Side

[—w<~\ U A B
<= Z D
177158
• 12162205
Connector Part
• Conn 2F M/P 150.2 P2S
Information
• MDGRA
177157 Circuit
• 12162200 Pin Wire Color No. Function
Connector Part Transmission
• Conn 3F M/P 150.2 P2S A 0.8 RED 839A
Information Solenoid Power
• RED
2-3 Shift Solenoid
Circuit B 0.8 YEL 1223
(2-3 SS) Valve Control
Pin Wire Color No. Function
A 0.8 PNK 1224 Range Signal A Input Torque Converter Clutch Pulse Width
B 0.8 DK BLU 1225 Range Signal B Input Modulated (TCC PWM) Solenoid Valve
C 0.8 ORN 1226 Range Signal C Input Connector, Wiring Harness Side

1-2 Shift Solenoid Valve Connector, Wiring

Harness Side

177158
• 12162205
Connector Part
• Conn 2F M/P 150.2 P2S
Information
168428 • MDGRA
• 12162201 Circuit
Connector Part
• Conn 2F M/P 150.2 P2S Pin Wire Color No. Function
Information
• NAT Transmission
A 0.8 RED 839C
Circuit Solenoid Power
Pin Wire Color No. Function Torque Converter
1-2 Shift Solenoid Clutch Pulse Width
A 0.8 LT GRN 1222 B 0.8 BLK 418
(1-2 SS) Valve Control Modulated Solenoid
(TCC PWM Sol.) Valve
Transmission
B 0.8 RED 839B
Solenoid Power
Transmission/Transaxle Automatic Transmission - 4L80-E 7-297
Pressure Control Solenoid Valve Connector, Transmission Fluid Temperature (TFT) Sensor
Wiring Harness Side Connector, Wiring Harness Side

r \
B A

168421 175785
• 12146800 • 12047662
Connector Part Connector Part
• Conn 2F M/P 480 SPL • CONN 2F M/P 150
Information Information
• NAT • BLK
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
Pressure Control Transmission Fluid
A 0.8 PPL 1228 Solenoid (PC Sol.) Valve A 0.8 BRN 1227 Temperature (TFT)
HIGH Control Sensor Signal
PC Sol. Valve B 0.8 GRY 452 TFT Sensor Ground
B 0.8 LT BLU 1229
LOW Control
7-298 Automatic Transmission - 4L80-E
Diagnostic Information and
Procedures
DTC P0218 Transmission Fluid Overtemperature (Gas)
Circuit Description
The flow of transmission fluid starts in the
transmission pan. It is then drawn through the filter
and transmission case into the oil pump assembly.
The oil pump assembly pressurizes the fluid (line
pressure), which becomes the main supply line of
fluid. This fluid is directed to various components
and hydraulic circuits within the transmission. The
pressure regulator valve receives this fluid and
directs it to the converter clutch shift valve. The
converter clutch shift valve directs hot fluid leaving
the torque converter or regulated converter feed
fluid, through the cooler line to the transmission oil
cooler. The transmission oil cooler is located in the
radiator. The vehicle may also be equipped with an
Transmission/Transaxle
199392
auxiliary oil cooler. The cooled fluid (center lube) is
returned to the transmission trough the return cooler
line and into center lube port of the transmission.
The Automatic Transmission Fluid Temperature (TFT)
Sensor, senses the fluid temperature in the
transmission pan.
If the Vehicle Control Module (VCM) detects a high
TFT for a long period of time, then DTC P0218 sets.
DTC P0218 is a type D DTC.
Conditions for Setting the DTC
. No TFT Sensor DTCs P0712 or P0713.
• The TFT is greater than 130*C (266 *F).
• All conditions are met for 410 seconds.
Transmission/Transaxle
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The VCM freezes shift adapts from
being updated.
• DTC P0218 is stored in the VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the VCM.
Diagnostic Aids
• Inspect the cooling system fluid level
and condition.
• Verify the customer’s driving habits, such as
trailer towing, etc. . .
Automatic Transmission - 4L80-E 7-299
• The scan tool Trans. Fluid Temp. (TFT)
should rise steadily during warm-up cycles
then stabilize.
• DTC P0218 may set approximately 600 seconds
after DTC P0711 has set. Follow the diagnostic
table for DTC P0711 before proceeding to the
diagnostic table for DTC P0218. Repairing the
condition that set DTC P0711 will likely
eliminate DTC P0218.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. DTC P0711 may also set a DTC P0218. Go to
the DTC P0711 tables for diagnosis.
4. This step inspects for air restrictions and loss of
transmission fluid flow, causing an extremely
high TFT.

DTC P0218 Transmission Fluid Overtemperature (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
2 —
will erase the stored Failure Records from the VCM.
3. Record the DTC Failure Records then clear the DTC.
4. Perform the transmission fluid checking procedure. Go to 4L80-E
Refer to 4L80-E Transmission Fluid Checking Transmission
Procedure. Fluid Checking
Was the fluid checking procedure performed? Go to Step 3 Procedure
Is DTC P0711 also set? Go to
3 —
Diagnostic Aids Go to Step 4
7-300 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0218 Transmission Fluid Overtemperature (Gas) (cont’d)
Step Action Value(s) Yes No
1. Inspect the engine cooling system for the following
conditions:
• Air flow restrictions
• Air flow blockage
• Debris.
2. Inspect the transmission cooling system for the
following conditions:
4 —
• Air flow restrictions
• Air flow blockage
• Debris
• Damaged cooler lines or hoses.
• Low A/T Fluid Cooler flow. Refer to A/T Oil Cooler
flow test.
Was a condition found? Go to Step 7 Go to Step 5
Perform the line pressure check procedure. Refer to
5 4L80-E Line Pressure Check Procedure. —
Was a condition found? Go to Step 7 Go to Step 6
Inspect the torque converter stator for damage. Refer to Go to System
Torque Converter Clutch Diagnosis. Diagnosis Table
6 —
Was a condition found? Transmission
Go to Step 7 Overheating
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions.
7 —
• Turn the ignition switch to the RUN position.
• The TFT must be less than 129‘ C (265*F) for at
least 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0218. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0218 Transmission Fluid Overtemperature (Diesel)
Circuit Description
The flow of transmission fluid starts in the
transmission pan. It is then drawn through the filter
and transmission case into the oil pump assembly.
The oil pump assembly pressurizes the fluid (line
pressure), which becomes the main supply line of
fluid. This fluid is directed to various components
and hydraulic circuits within the transmission. The
pressure regulator valve receives this fluid and
directs it to the converter clutch shift valve. The
converter clutch shift valve directs hot fluid leaving
the torque converter or regulated converter feed
fluid, through the cooler line to the transmission oil
cooler. The transmission oil cooler is located in the
radiator. The vehicle may also be equipped with an
auxiliary oil cooler. The cooled fluid (center lube) is
returned to the transmission trough the return cooler
line and into center lube port of the transmission.
Automatic Transmission - 4L80-E 7-301
199392
The Automatic Transmission Fluid Temperature (TFT)
Sensor, senses the fluid temperature in the
transmission pan.
If the Powertrain Control Module (PCM) detects a
high TFT for a long period of time, then DTC P0218
sets. DTC P0218 is a type D DTC.
Conditions for Setting the DTC
. No TFT Sensor DTCs P0712 or P0713.
• The TFT is greater than 130' C (266 * F).
• All conditions are met for 410 seconds.
Action Taken When the DTC Sets
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM freezes shift adapts from
being updated.
• DTC P0218 is stored in the PCM history.
7-302 Automatic Transmission - 4L80-E
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the PCM.
Diagnostic Aids
• Inspect the cooling system fluid level
and condition.
• Verify the customer’s driving habits, such as
trailer towing, etc. . .
• The scan tool Trans. Fluid Temp. (TFT)
should rise steadily during warm-up cycles
then stabilize.
Transmission/Transaxle
• DTC P0218 may set approximately 600 seconds
after DTC P0711 has set. Follow the diagnostic
table for DTC P0711 before proceeding to the
diagnostic table for DTC P0218. Repairing
the condition that set DTC P0711 will likely
eliminate DTC P0218.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. DTC P0711 may also set a DTC P0218. Go to
the DTC P0711 table for diagnosis.
4. This step inspects for air restrictions and loss of
transmission fluid flow, causing an extremely
high TFT.

DTC P0218 Transmission Fluid Overtemperature (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to:
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
2 —
will erase the stored Failure Records from the PCM.
3. Record the DTC Failure Records then clear the DTC.
4. Perform the transmission fluid checking procedure. Go to 4L80-E
Refer to 4L80-E Transmission Fluid Checking Transmission
Procedure. Fluid Checking
Was the fluid checking procedure performed? Go to Step 3 Procedure
Is DTC P0711 also set? Go to
3 —
Diagnostic Aids Go to Step 4
1. Inspect the engine cooling system for the following
conditions:
• Air flow restrictions
• Air flow blockage
• Debris.
2. Inspect the transmission cooling system for the
following conditions:
4 —
• Air flow restrictions
• Air flow blockage
• Debris
• Damaged cooler lines or hoses
• Low A/T fluid cooler flow. Refer to A/T oil cooler
flow test.
Was the condition found? Go to Step 7 Go to Step 5
Perform the line pressure check procedure. Refer to
5 4L80-E Line Pressure Check Procedure. —
Was the condition found? Go to Step 7 Go to Step 6
Transmission/Transaxle Automatic Transmission - 4L80-E 7-303
DTC P0218 Transmission Fluid Overtemperature (Diesel) (cont’d)
Step Action Value(s) Yes No
Inspect the torque converter stator for damage. Refer to Go to System
Torque Converter Clutch Diagnosis. Diagnosis Table
6 —
Was the condition found? Transmission
Go to Step 7 Overheating
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions.
7 —
• Turn the ignition switch to the RUN position.
• The TFT must be less than 129'C (264 *F) for at
least 5 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0218. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-304 Automatic Transmission - 4L80-E
DTC P0502 Vehicle Speed Sensor Circuit Low Input (Gas Only)
The Output Shaft Speed Sensor (OSS Sensor),
which is a Permanent Magnet (PM) generator,
provides the vehicle speed information to the Vehicle
Control Module (VCM). The PM generator produces
a pulsing AC voltage as the transmission speed
sensors rotor teeth pass through the sensor’s
magnetic field. The AC voltage level and the number
of pulses increase as the speed of the vehicle
increases. The VCM then converts the pulsing
voltage to a digital signal for vehicle speed. The
vehicle speed is used for engine and transmission
calculations.
If the VCM detects a low vehicle speed and there
is a high engine speed in a drive gear range,
DTC P0502 sets. DTC P0502 is a type D DTC. For
California emissions, DTC P0502 is a type B DTC.
Transmission/Transaxle
• No Mass Air Flow (MAF) sensor DTCs P0101,
P0102 or P0103.
. No MAP DTCs P0106, P0107 or P0108.
• No Throttle Position (TP) Sensor DTCs P0122
or P0123.
• No TFP Val. Position Sw. DTC P1810.
. No ATT ISS Sensor DTC P0716 or P0717.
• The engine torque must be 60 N-m (80 lb ft) to
the following:
• No change in 4WD Lo for at least 2.0 seconds.
- 542 N.m (400 lb ft) 5.7L
- 677 N.m (500 lb ft) 7.4L
• The A/T ISS is greater than 1500 RPM.
• The gear range is not Park or Neutral.
Transmission/Transaxle
• TP angle is greater than 10%.
• The engine is running more than 475 RPM for
7 seconds.
• The OSS is less than 50 RPM for at least
4 seconds.
Action Taken When the DTC Sets
• For California emissions, the VCM illuminates
the Malfunction Indicator Lamp (MIL).
• The VCM commands maximum line pressure.
• The VCM freezes the shift adapts.
• The VCM defaults a calculated output speed
value by using the ISS values.
• DTC P0502 is stored in the VCM history.
Conditions for Clearing the MIL/DTC
• For California emissions, the VCM turns off the
MIL after three consecutive trips without a
failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is cycled OFF long enough in order to power
down the VCM.
Automatic Transmission - 4L80-E 7-305
Diagnostic Aids
• DTC P0502 sets when no vehicle speed is
detected at the start off.
• Inspect the wiring at the VCM, the OSS Sensor
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation.
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• First diagnose and clear any engine DTCs or
TP Sensor codes. Then inspect for any
transmission DTCs that may have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for voltage in the 822 low circuit.
6. This step tests the 5-volt and ground circuit of
the VCM.
11. This step tests the integrity of the OSS Sensor.
13. This step tests the OSS circuit.

DTC P0502 Vehicle Speed Sensor Circuit Low Input (Gas Only)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check{5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
erases the stored Freeze Frame and Failure records
from the VCM.
2 —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
4. Raise and support the drive axle assembly.
5. Place the Transmission in neutral.
6. Observe the transmission OSS on the scan tool,
while rotating a drive wheel.
Ensuring that the drive shaft is rotating, does the Go to
Transmission OSS increase with the drive wheel speed? Diagnostic Aids Go to Step 3
7-306 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0502 Vehicle Speed Sensor Circuit Low Input (Gas Only) (cont'd)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the OSS Sensor harness connector from
the sensor.
3. Turn the ignition switch to the Run position.
3 4. Using the J 39200 DMM on DC volts and J 35616-A 4.0-5.1 volts DC
Connector Test Adapter Kit, measure the voltage
between the OSS Sensor harness connector
terminal A (PPL/WHT) and a good ground.
Is the voltage within the specified value? Go to Step 4 Go to Step 5
With the ignition switch in the RUN position, measure the
voltage between terminal B (GRN/BLK) of the OSS Sensor
4 harness connector and a good ground. 0.2 volts
Is the voltage less than the specified value? Go to Step 6 Go to Step 12
Was the voltage reading in Step 3 greater than the
5 5.1 volts
specified value? Go to Step 12 Go to Step 7
With the ignition switch in the Run position, measure the
voltage between terminals A and B of the OSS Sensor
6 harness connector. 4.0-5.1 volts
Is the voltage within the specified value? Go to Step 10 Go to Step 8
Inspect circuit 821 for high resistance or an open circuit.
Refer to General Electrical Diagnosis Procedures.

7 Important: 4 wheel drive vehicles use an in-line connector —

between the engine harness and the OSS Sensor harness
at the transfer case.
Did you find the condition? Go to Step 18 Go to Step 9
Inspect circuit 822 for an open circuit between the
connector and the VCM.
Important: 4 wheel drive vehicles use an in-line connector
8 —
between the engine harness and the OSS Sensor harness
at the transfer case.
Did you find the condition? Go to Step 18 Go to Step 13
Inspect circuit 821 for a short to ground.
9 —
Did you find the condition? Go to Step 18 Go to Step 13
Using the J 39200 DMM, measure the resistance between
10 terminals A and B of the OSS Sensor. 1042-20880
Is the resistance within the specified value? Go to Step 11 Go to Step 17
1. Place the transmission in Neutral.
2. With the J 39200 DMM on terminals A and B, select
the AC volts.
11 0.5 volts AC
3. Rotate the rear wheels ensuring that the driveshaft
is turning.
Is the voltage greater than the specified value? Go to Step 13 Go to Step 15
1. Inspect circuit 821 for a short to voltage B+. Refer to
General Electrical Diagnosis Procedures.
2. Inspect circuit 822 for a short to voltage B+. Refer to
12 General Electrical Diagnosis Procedures. —
3. Inspect circuits 821 and 822 for a short together.
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 18 Go to Step 14
Transmission/Transaxle Automatic Transmission - 4L80-E 7-307
DTC P0502 Vehicle Speed Sensor Circuit Low Input (Gas Only) (cont’d)
Step Action Value(s) Yes No
1. Reconnect the OSS Sensor connector to the
OSS Sensor.
2. With the ignition OFF disconnect the VCM
connector C1 (blue) from the VCM.
3. Connect the J 39200 DMM to terminals C1-29 and
13 0.5 volts AC —
C1-30.
4. While rotating the rear wheels and ensuring that the
driveshaft is turning, measure the voltage with the
DMM on AC volts.
Is the voltage greater than the specified value? Go to Step 14
1. Inspect the VCM pins for corrosion or poor tension.
2. Inspect the connector C1 terminals for corrosion or
14 —
poor tension.
Did you find the condition? Go to Step 18 Go to Step 16
1. Remove the OSS Sensor.
2. Inspect the Output Shaft Speed Sensor Rotor for
damage or misalignment.
15 —
Refer to Transmission Overhaul Procedure, in Unit
Repair.
Did you find the condition? Go to Step 18 Go to Step 17
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
16 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 18
Replace the OSS Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle
17 — —
Service.
Is the replacement complete? Go to Step 18
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
18 3. Operate the vehicle so that the transmission OSS is —
greater than 500 RPM for 1 second.
4. Select Specific DTC.
Begin the
5. Enter DTC P0502. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-308 Automatic Transmission - 4L80-E
DTC P0503 Vehicle Speed Sensor CKT Intermittent (Gas Only)
Connector
J
OSS OSS
Inline to Low High
Engine
Harness B"
Circuit Description
The Output Shaft Speed Sensor (OSS Sensor), which
is a Permanent Magnet (PM) generator, provides the
vehicle speed information to the Vehicle Control
Module (VCM). The PM generator produces a pulsing
AC voltage as the transmission speed sensors rotor
teeth pass through the sensor’s magnetic field. The
AC voltage level and the number of pulses increase
as the speed of the vehicle increases. The VCM then
converts the pulsing voltage to a digital signal for
vehicle speed. The vehicle speed is used for engine
and transmission calculations.
If the VCM detects a low vehicle speed and there
is a high engine speed in a drive gear range,
DTC P0503 sets. DTC P0503 is a type D DTC. For
California emissions, DTC P0503 is a type B DTC.
Conditions for Setting the DTC
• No TFP Val. Position Sw. DTC P1810.
• No 4WD Low DTC P1875.
Transmission/Transaxle
Vehicle
* Control
1 Module (VCM)
\ A
69022
• Not in 4WD Low.
• No TFP Val. Position Sw. changes for greater
than 10 seconds.
• No 4WD Low Switch change within 2 seconds.
• The gear range is not Park or Neutral.
• No VSS increase greater than 250 RPM within
2 seconds.
• The OSS RPM has dropped greater than
1000 RPM for at least 4 seconds.
Action Taken When the DTC Sets
• For California emissions, the VCM illuminates
the Malfunction Indicator Lamp (MIL).
• The VCM commands maximum line pressure.
• The VCM freezes the shift adapts.
• The VCM defaults a calculated output speed
value by using the ISS values.
• DTC P0503 is stored in the VCM history.
Transmission/Transaxle
Conditions for Clearing the MIL/DTC
• For California emissions, the VCM turns off the
MIL after three consecutive trips without a
failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is cycled OFF long enough in order to power
down the VCM.
Diagnostic Aids
• DTC P0503 sets when the VCM detects an
OSS loss.
• Inspect the wiring at the VCM, the OSS Sensor
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
Automatic Transmission - 4L80-E 7-309
- A chafed wire
- A broken wire inside the insulation.
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• The vehicle may need to be driven to duplicate
the intermittent condition.
• First diagnose and clear any engine DTCs or
TP Sensor codes. Then inspect for any
transmission DTCs that may have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the integrity of the OSS Sensor.
5. This step tests for voltage in the 822 low circuit.
7. This step tests the 5-volt and ground circuit of
the OSS sensor circuit.
13. This step tests the OSS sensor and the circuit.

DTC P0503 Vehicle Speed Sensor CKT Intermittent (Gas Only)

Step Action Value(a) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
erases the stored Freeze Frame and Failure records
from the VCM.
3. Record the DTC Freeze Frame and Failure Records
2 and DTCs. 1000 RPM
4. Raise and support the drive axle assembly.
5. Select scan tool Transmission OSS.
6. Start the engine and place the transmission selector
in D3 range.
7. With the drive wheels rotating, slowly accelerate to
2000 engine RPM and hold. No fault verified
Does the Transmission OSS drop or fluctuate more than at this time. Go
the specified value? Go to Step 3 to Diagnostic Aids
7-310 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0503 Vehicle Speed Sensor CKT Intermittent (Gas Only) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition switch to the OFF position.
2. Disconnect the OSS Sensor harness connector from
the OSS sensor.
3. Using a J 39200 DMM on AC voltage scale, and
J 35616-A Connector Test Adapter Kit, connect
the J 39200 DMM to terminals A and B on the
3 OSS Sensor. —
4. Turn the ignition switch to the Run position and start
the engine.
5. Place the transmission selector in D3 range.
6. With the drive wheels rotating, slowly accelerate to
2000 engine RPM and hold.
Does the DMM voltage drop or fluctuate at 2000 RPM? Go to Step 11 Go to Step 4
1. With the engine OFF, turn the ignition switch to the
RUN position.
2. Using the J 39200 DMM on DC volts, connected to a
4 good ground, measure the voltage at cavity A, 4.0-5.1 volts DC
(circuit 821 PPL/WHT), of the OSS Sensor
connector.
Is the voltage within the specified value and steady? Go to Step 5 Go to Step 6
With the ignition switch in the Run position, measure
the voltage at cavity B, (circuit 822 GRN/BLK), of the
5 OSS Sensor connector. 0.2 volts

Is the voltage less than the specified value? Go to Step 7 Go to Step 12

Is the voltage reading in Step 4 greater than the specified
6 5.1 volts
value? Go to Step 12 Go to Step 8
1. Connect the J 39200 DMM leads to cavity A and
cavity B of the OSS Sensor connector.
7 2. With the ignition switch in the RUN position, record 4.0-5.1 volts DC
the voltage.
Is the voltage within the specified value and steady? Go to Step 13 Go to Step 9
Inspect circuit 821 (PPL/WHT) for high resistance or an
open circuit. Refer to General Electrical Diagnosis
8 Procedures. —
Did you find the condition? Go to Step 18 Go to Step 10
Inspect circuit 822 (GRN/BLK) for high resistance or an
open circuit. Refer to General Electrical Diagnosis
9 Procedures. — —

Did you find the condition? Go to Step 18

Inspect circuit 821 (PPL/WHT) for a short to ground. Refer
10 to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 18 Go to Step 13
Using the J 39200 DMM, measure the resistance between
11 terminals A and B of the OSS Sensor. 1042-2088Q
Is the resistance within the specified value? Go to Step 15 Go to Step 17
Inspect circuits 821 and 822 for a short to B+ voltage or
shorted together.
12 —
Refer to General Electrical Diagnosis Procedures.
Did you find a shorted condition? Go to Step 18 Go to Step 14
Transmission/Transaxle Automatic Transmission - 4L80-E 7-311
DTC P0503 Vehicle Speed Sensor CKT Intermittent (Gas Only) (cont’d)
Step Action Value(s) Yes No
1. Reconnect the OSS Sensor connector to the
OSS Sensor.
2. With the ignition OFF disconnect the C1 (blue)
VCM connector from the VCM.
13
3. Connect the J 39200 DMM to terminals C1-29
0.5 volts AC —
and C1-30.
4. While rotating the rear wheels by hand and ensuring
that the driveshaft is turning, measure the output
voltage with the DMM on AC volts.
Is the voltage greater than the specified value? Go to Step 14
1. Inspect the VCM pins for corrosion or poor tension.
14 2. Inspect the connector terminals for corrosion or
—
poor tension.
Did you find a condition? Go to Step 18 Go to Step 16
1. Remove the OSS Sensor. Refer to Speed Sensor
Replacement.
15 2. Inspect the Output Shaft Speed Sensor Rotor for —
looseness, damage or misalignment.
Did you find the condition? Go to Step 18 Go to Step 17
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
16 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 18
Replace the OSS Sensor.
Refer to VCM Replacement/Programming (5.7L) or
17 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 18
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
18 3. Operate the vehicle so that the transmission OSS is —

greater than 500 RPM with no RPM change greater

than 450 for one second.
Begin the
4. Select Specific DTC. Enter DTC P0503. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-312 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0560 System Voltage Malfunction (Gas)

|HotlnRun AndStart!
n Underhood
ECM11 1Fuse - Relay
H7 k ecm
Fuse * Center
20A l
L __________________________________ ____ ___________________________ ____ _______________________________ J
1 ORN 440 1 PNK 439

r - - +S101 >S161 (5.7L)

I S104 (7.4L)

Fuse Block FuseBlock

Details Details
Cell 11 Cell 11

0.8 ORN 440 0.8 PN 439

2 1 [C 3 18 C4
Battety Ignition 1Vehicle
Positive Positive 1Control
Voltage (B+) Voltage Module (VCM)

40794
Circuit Description • The VCM turns off the PC Sol. Valve.
Circuits 439 is the ignition voltage feed for the • The VCM inhibits the TCC engagement.
Vehicle Control Module (VCM). Circuit 440 is the • The VCM freezes the shift adapts.
battery voltage feed for the VCM. • DTC P0560 is stored in VCM history.
If the VCM detects a low voltage, a high voltage
for a long time, or a high voltage, for a short Conditions for Clearing the DTC
amount of time, then DTC P0560 sets. DTC P0560 • A scan tool can clear the DTC from the VCM
is a type D DTC. history. The VCM clears the DTC from the VCM
Conditions for Setting the DTC history if the vehicle completes 40 warm-up
cycles without a failure reported.
System Voltage Low:
• The VCM cancels the DTC default actions
• The engine speed is greater than 1500 RPM. when the fault no longer exists and the ignition
• One of the following conditions exists for is OFF long enough in order to power down
greater than 15 seconds. the VCM.
- The system voltage is less than 10.5 volts at
a maximum transmission temperature of Diagnostic Aids
152*C (305 *F) or: • Charging the battery with a battery charger and
- The system voltage is less than 6.7 volts at jumpstarting an engine may set this DTC.
a minimum transmission temperature of • If this DTC is set when an accessory is
-40 *C (-40-F). operated, inspect for faulty connections or an
System Voltage High: excessive current draw.
The system voltage is greater than 19 volts for • Inspect for faulty electrical connections at the
10 seconds. starter solenoid.
• Inspect for faulty electrical connections at the
Action Taken When the DTC Sets fusible link.
• The VCM does not illuminate the Malfunction . Inspect for loose or damaged terminals at
Indicator Lamp (MIL). the generator.
• The VCM causes an immediate landing to
second gear.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-313
• Inspect the generator belt condition Test Description
and tension. 4. This step tests the charging system voltage.
• First diagnose and clear any engine DTCs or 5. This step tests the battery voltage input at
TP Sensor codes that are present. Then the VCM.
inspect for any transmission DTCs that may
have reset. 6. This step tests the ignition voltage and battery
voltage inputs at the VCM.

DTC P0560 System Voltage Malfunction (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record Failure Records for reference.
2 The Clear Info function will erase the stored Failure 10 volts
Records from the VCM.
3. Record the DTC Failure Records.
4. Using the J 39200 DMM, measure the battery
voltage across the battery terminals. Go to Battery
Is the voltage higher than the specified value? Go to Step 3 Diagnosis
1. Start the engine.
3 2. Warm the engine to normal operating temperature. — Go to Charging
Is the generator/check engine light ON? System Diagnosis Go to Step 4
1. Turn the headlights and the heater blower motor to
the ON position.
2. Increase the engine speed to 1500 RPM.
4 13-15 volts
3. Observe the J 39200 DMM battery voltage and
record your voltage reading for reference. Go to Charging
Is the J 39200 DMM voltage within the specified range? Go to Step 5 System Diagnosis
1. Increase the engine speed to 1500 RPM.
System Checks
5 2. Observe the scan tool Ignition voltage. 13-15 volts OK Go to
Is the scan tool Ignition Voltage within the specified range. Diagnosis Aids Go to Step 6
1. Turn the ignition switch to the OFF position.
2. Locate terminal C4-18 (circuit 439 PNK) and terminal
C3-21 (circuit 440 ORN) in the VCM connectors. Do
not disconnect the VCM connectors.
3. Connect the J 39200 DMM black lead to ground.
4. Start the engine.
5. Run the engine at 1500 RPM with the headlights
6 and the blower motor ON. 0.5 volts
6. Using the J 39200 DMM and the J 35616-A
Connector Test Adaptor Kit, backprobe terminals
C4-18 and C3-21 to measure the battery voltage and
the ignition voltage input at VCM connectors.
Is there a voltage variance between the voltage measured
at the battery (taken in Step 4) and at terminals C4-18
and C3-21 that is greater than the specified value? Go to Step 7 Go to Step 10
7-314 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0560 System Voltage Malfunction (Gas) (cont’d)

Step Action Value(s) Yes No
Does terminal C4-18 (circuit 439) have the voltage
7 —
variance? Go to Step 8 Go to Step 9
Repair the high resistance condition in circuit 439.
8 Refer to Wiring Repair. — —
Is the repair complete? Go to Step 11
Repair the high resistance condition in circuit 440.
9 Refer to Wiring Repair. — —
Is the repair complete? Go to Step 11
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
10 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 11
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
11 • Start the vehicle. —
• Warm the engine to normal operating temperature.
• Ensure that the scan tool Ignition Voltage is
12-18 volts. Begin the
4. Select Specific DTC. Enter DTC P0560. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0560 System Voltage Malfunction (Diesel)
|Hot A t AJI Times|
Circuit Description
Circuit 439 is the ignition voltage feed for the
Powertrain Control Module (PCM). Circuit 440 is the
battery feed for the PCM.
If the PCM detects either a low system voltage or a
high system voltage for a short time, then DTC P0560
sets. DTC P0560 is a type D DTC.
Conditions for Setting the DTC
System Voltage Low
• The engine speed is greater than 1500 RPM.
• One of the following conditions exists for
greater than 15 seconds:
- The system voltage is less than 10.5 volts at
a maximum transmission temperature of
152*C (305 *F).
- The system voltage is less than 6.7 volts at
a minimum transmission temperature of
-40 *C (-40 *F).
System Voltage High
System voltage is greater than 19 volts for
10 seconds.
Action Taken When the DTC Sets
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
Automatic Transmission - 4L80-E 7-315
|Hot In Run And Start|
201048
• The PCM commands an immediate landing to
second gear.
• The PCM turns off the PC Sol. Valve.
• The PCM inhibits the TCC engagement.
• The PCM freezes the shift adapts.
• DTC P0560 is stored in PCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is OFF
long enough in order to power down the PCM.
Diagnostic Aids
• Charging the battery with a battery charger and
jumpstarting an engine may set DTCs.
• If this DTC is set when an accessory is
operated, inspect for faulty connections or an
excessive current draw.
• Inspect for faulty electrical connections at the
starter solenoid.
• Inspect for faulty electrical connections at the
fusible link.
7-316 Automatic Transmission - 4L80-E Transmission/Transaxle
• Inspect for loose or damaged terminals at Test Description
the generator. 4. This step tests the charging system voltage.
• Inspect the generator belt wear condition 5. This step tests the battery voltage input at
and tension. the PCM.
• First diagnose and clear any engine DTCs that 7. This step tests the ignition voltage inputs at
are present. Then inspect for any transmission the PCM.
DTCs that may have reset.

DTC P0560 System Voltage Malfunction (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Failure Records from the PCM.
3. Record the DTC Failure Records, then clear
2 10.5 volts
the DTC.
4. If any DTCs are present, refer to their applicable
diagnostic tables before continuing.
5. Using the J 39200 DMM, measure the battery
voltage across the battery terminals.
6. Record the battery voltage measurement for future
reference. Go to Charging
Is the voltage higher than the specified value? Go to Step 3 System Diagnosis
1. Start the engine.
2. Allow the engine to warm to normal operating
3 —
temperature. Go to Charging
Is the generator lamp ON? System Diagnosis Go to Step 4
1. Increase the engine speed to greater than
1500 RPM.
4 13-15 volts
2. Observe the scan tool ignition voltage. Go to Charging
Is the ignition voltage within the specified range? Go to Step 5 System Diagnosis
1. Turn the ignition switch OFF.
2. Disconnect the C3 (blue-32) PCM connector
(Additional DTCs will set).
3. With the engine OFF, turn the ignition switch in the
RUN position.
5 4. Measure the battery voltage input at the PCM 0.5 volts
connector terminal C3-C13. Use the J 39200 DMM
and the J 35616-A Connector Test Adaptor Kit.
Is there a voltage variance between the voltage measured
at the battery (taken in Step 2) and at terminal C3-C13
that is greater than the specified value? Go to Step 6 Go to Step 7
Repair the high resistance condition in circuit 440.
6 Refer to Wiring Repairs. — —
Did you repair the circuit? Go to Step 11
Transmission/Transaxle Automatic Transmission - 4L80-E 7-317
DTC P0560 System Voltage Malfunction (Diesel) (cont’d)
Step Action Value(s) Yes No
Measure the ignition voltage input at PCM connector
terminal C3-C11.
7 Is there a voltage variance between the voltage measured 0.5 volts
at the battery (taken in Step 2) and at terminal C3-C11
that is greater than the specified value? Go to Step 8 Go to Step 9
Repair the high resistance condition in circuit 439.
8 Refer to Wiring Repairs. — —
Did you repair the circuit? Go to Step 11
1. Inspect PCM connector terminal C3-C13 for damaged
or backed out connector pins.
2. Inspect PCM connector terminal C3-C11 for damaged
9 or backed out connector pins. —

3. Inspect for weak terminal tension.

Did you find the condition? Go to Step 11 Go to Step 10
Replace the PCM.
10 Refer to PCM Replacement/Programming. — —

Is the replacement complete? Go to Step 11

In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Start the vehicle.
11 —
• Warm the vehicle to normal operating
temperature.
• Using the scan tool, verify that the PCM sees an
ignition voltage between 8.3 and 16.5 volts.
Begin the
4. Select Specific DTC. Enter DTC P0560. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-318 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0711 Fluid Temp Sensor CKT Range/Performance (Gas)

A
iOBDIlk
Automatic
Transmission

Sensor ^ Vehicle
Ground * Control
1Module (VCM)
_ _ _ _ _ j1 >
it A

69025

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Vehicle Control Module
(VCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the VCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The VCM uses this information to control
shift quality and torque converter clutch apply.
The DTC P0711 will set if either of the following
conditions occur:
• The TFT sensor resistance has no change.
• The TFT sensor resistance has an unrealistic
change in a short amount of time (multiple
changes within seconds).
DTC P0711 is a type D DTC.
Conditions for Setting the DTC
• No A/T ISS sensor DTC P0716 or P0717.
• No A/T OSS sensor DTC P0722 or P0723.
• No Engine Coolant Temperature (ECT)
DTCs P0117 or P0118.
• No A/T Component Slipping DTC P1870.
• System voltage is 10.0-16.0 volts.
• The engine is running greater than 475 RPM
for at least 35 seconds.
Transmission/Transaxle
. The TFT is -40* to +21 *C (-40* to +70 *F)
at start up.
• The Engine Coolant Temperature (ECT) is
greater than 85 *C (185*F).
• ECT has changed at least 55 "C (130‘ F) since
start up.
• The vehicle speed is greater than 5 mph for at
least 900 seconds (15 minutes).
• The TCC slip speed is greater than 60 RPM for
at least 800 seconds (13.3 minutes).
• DTC P0711 will set if all of the above
conditions have been met and one of the
following conditions exist:
- The TFT has not changed more than
2.25 *C (4*F), in more than 800 seconds
(13.3 minutes) (No TFT change).
- The TFT has changed more than 20 ’ C
(68 *F) 14 times in 7 seconds (unrealistic
temperature change).
Action Taken When the DTC Sets
• The VCM does not illuminates the Malfunction
Indicator Lamp (MIL).
• The VCM commands increased line pressure.
• The VCM freezes shift adapts.
• The VCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus
5 degrees.
- If the Engine Coolant Temperature (ECT) is
less than 85 *C (185*F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 85*-110-C (185*-230*F) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110 *C (230 *F) then
Default TFT is set to 140*C (284 *F) and
transmission shift pattern is in Hot Mode.
- If ECT and TFT DTCs are both set then
Default TFT is 1 4 0 'C (284 *F).
• DTC P0711 is stored in VCM history.
Automatic Transmission - 4L80-E 7-319
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation.
- Moisture intrusion
- Corrosion
. When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• First diagnose and clear any engine DTCs or
TP Sensor DTCs that are present. Then inspect
for any transmission DTCs that may have reset.
• DTC P0218 may set approximately
600 seconds after DTC P0711 has set.
Follow the diagnostic table for DTC P0711
before proceeding to the diagnostic table for
DTC P0218.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests for proper A/T fluid level and
condition.
3. This step verifies which condition has set
DTC P0711.
5. The 12-volt test lamp is used as a fixed
resistance.
6. This step ensures that the VCM monitors
circuit 1227.
7-320 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0711 Fluid Temp Sensor CKT Range/Performance (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
Perform the NT Fluid Checking Procedure. Go to
Did you perform the fluid checking procedure? Transmission
2 —
Fluid Checking
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the stored Failure Records for
reference. The Clear Info function will erase the
Failure Records from the VCM.
3. Record the DTC Failure Records.
3 —
4. Clear the DTC Freeze Frame and Failure Records.
5. Select TFT on the scan tool.
6. Drive the vehicle and observe the scan tool for one
of the following conditions:
. No TFT change,
. An unrealistic TFT change (The TFT change is Fault is not
greater than 20 *C (36'F) 14 times in 7 seconds). present. Refer to
Did either of the fail conditions occur? Go to Step 4 Diagnostic Aids
4 Did the scan tool display an unrealistic TFT change? — Go to Step 5 Go to Step 6
1. Turn the ignition switch OFF.
2. Disconnect the transmission 20-way connector.
Additional DTCs may set.
3. Using the J 35616-A Connector Test Adapter Kit,
install a 12 volt test lamp between terminals L and M
5 —
of the engine side of the transmission 20-way
connector.
4. Turn the ignition switch to the run position.
Does the scan tool TFT display an unrealistic TFT
change? Go to Step 7 Go to Step 8
1. Record the scan tool TFT display from step 4.
2. Turn the ignition OFF.
3. Disconnect the transmission 20-way connector.
6 —
Additional DTCs may set.
4. Turn the ignition switch to the RUN position.
Is the scan tool TFT the same as in step 4? Go to Step 7 Go to Step 8
Transmission/Transaxle Automatic Transmission - 4L80-E 7-321
DTC P0711 Fluid Temp Sensor CKT Range/Performance (Gas) (cont’d)
Step Action Value(s) Yes No
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
7 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 9
Replace the TFT Sensor.
Refer to A/T Fluid Temperature Sensor Replacement, in
8 — —
On-vehicle Service.
Is the replacement complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
9 • The TFT changes by more than 3 *C (5 ' F) after —
the engine has been running for 35 seconds.
• For a period of at least 11 seconds, the TFT does
not change more than 20 *C (36 *F) within
0.2 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0711. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-322 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0711 Fluid Temp Sensor CKT Range/Performance (Diesel)

"* Automatic
I Transmission

1 Powertrain
I Sensor
I Ground Control
I j Module (PCM)
I
L _ _ _ _ _ _
i A

69016

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Powertrain Control Module
(PCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the PCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The PCM uses this information to control
shift quality and torque converter clutch apply.
The DTC P0711 will set if either of the following
conditions occur:
• The TFT sensor resistance has no change.
• The TFT sensor resistance has an unrealistic
change in a short amount of time (multiple
changes within seconds).
DTC P0711 is a type D DTC.
Conditions for Setting the DTC
• No A/T OSS sensor DTC P0502 or P0503.
. No An ISS sensor DTC P0716 or P0717.
• No Engine Coolant Temperature (ECT)
DTCs P0117 or P0118.
• No A/T Component Slipping DTC P1870.
• System voltage is 10.0-16.0 volts.
• The engine is running greater than 475 RPM
for at least 35 seconds.
Transmission/Transaxle
. The TFT is -40* to +21 "C (-40* to +70 *F)
at start up.
• The Engine Coolant Temperature (ECT) is
greater than 85 *C (185*F).
• ECT has changed at least 5 5 ‘ C (130*F) since
start up.
• The vehicle speed is greater than 5 mph for
at least 900 seconds (15 minutes).
• The TCC slip speed is greater than 60 RPM for
at least 800 seconds (13.3 minutes).
• DTC P0711 will set if all of the above
conditions have been met and one of the
following conditions exist:
- The TFT has not changed more than
2.25‘ C (4*F), in more than 800 seconds
(13.3 minutes) (No TFT change).
- The TFT has changed more than 2 0 ' C
(68 *F) 14 times in 7 seconds (unrealistic
temperature change).
Action Taken When the DTC Sets
• The PCM does not illuminates the Malfunction
Indicator Lamp (MIL).
• The PCM commands increased line pressure.
• The PCM freezes shift adapts.
• The PCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus
5 degrees.
- If the Engine Coolant Temperature (ECT) is
less than 85 * C (185 * F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 85*-110*C (185*-230‘ F) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110 *C (230 *F) then
Default TFT is set to 140*C (284 *F) and
transmission shift pattern is in Hot Mode.
- If ECT and TFT DTCs are both set then
Default TFT is 140‘ C (284*F).
• DTC P0711 is stored in PCM history.
Automatic Transmission - 4L80-E 7-323
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
PCM history. The PCM clears the DTC from
the PCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation.
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• First diagnose and clear any engine DTCs or
APP Sensor DTCs that are present. Then
inspect for any transmission DTCs that may
have reset.
• DTC P0218 may set approximately
600 seconds after DTC P0711 has set. Follow
the diagnostic table for DTC P0711 before
proceeding to the diagnostic table for
DTC P0218.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests for proper A/T fluid level and
condition.
3. This step verifies which condition has set
DTC P0711.
5. The 12-volt test lamp is used as a fixed
resistance.
6. This step ensures that the PCM monitors
circuit 1227.
7-324 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0711 Fluid Temp Sensor CKT Range/Performance (Diesel)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to:
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the A/T Fluid Checking Procedure. Go to
Did you perform the fluid checking procedure? Transmission
2 —
Fluid Checking
Go to Step 3 Procedure
1. install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
Failure Records from the PCM.
3. Record the DTC Failure Records, then clear
3 the DTC. —
4. Select TFT on the scan tool.
5. Drive the vehicle and observe the scan tool for one
of the following conditions:
. No TFT change,
• An unrealistic TFT change (The TFT change is Fault is not
greater than 20’ C (36‘ F) 14 times in 7 seconds). present. Refer to
Did either of the fail conditions occur? Go to Step 4 Diagnostic Aids
Did the scan tool display an unrealistic temperature
4 —
change? Go to Step 5 Go to Step 6
1. Turn the ignition switch OFF.
2. Disconnect the transmission 20-way connector
(multiple DTCs will set).
3. Using the J 35616-A Connector Test Adapter Kit,
install a 12 volt test lamp between terminals L and M
5 —
of the engine side of the transmission 20-way
connector.
4. Turn the ignition switch to the RUN position.
Does the scan tool TFT display an unrealistic temperature
change? Go to Step 7 Go to Step 8
1. Record the scan tool TFT display from step 4.
2. Turn the ignition OFF.
3. Disconnect the transmission 20-way connector. —
6
Additional DTCs may set.
4. Turn the ignition switch to the RUN position.
Is the scan tool TFT the same as in step 4? Go to Step 7 Go to Step 8
Transmission/Transaxle Automatic Transmission - 4L80-E 7-325
DTC P0711 Fluid Temp Sensor CKT Range/Performance (Diesel) (cont’d)
Step Action Value(s) Yes No
Replace the PCM.
7 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 9
Replace the TFT Sensor.
Refer to A/T Fluid Temperature Sensor Replacement, in
8 — —
On-vehicle Service.
Is the replacement complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
9 • The TFT changes by more than 3*C (5'F) after —
the engine has been running for 30 seconds.
• For a period of at least 30 seconds, the TFT does
not change more than 2 0 'C (36*F) within
0.2 seconds. Begin the
4. Select Specific DTC. Enter DTC P0711. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-326 Automatic Transmission - 4L80-E
DTC P0712 Fluid Temperature Sensor CKT Low Input (Gas)
r ----------------
■ Sensor
^ Ground
I
L ______
Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Vehicle Control Module
(VCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the VCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The VCM uses this information to control
shift quality and torque converter clutch apply.
If the VCM detects a continuous short to ground in
the TFT Sensor or signal circuit, then DTC P0712
sets. DTC P0712 is a type D DTC.
Conditions for Setting the DTC
• The ignition is ON.
• The TFT Sensor indicates a voltage of less
than 0.14 volts.
• All conditions met for 15 seconds.
Transmission/Transaxle
"l Automatic
Transmission
Vehicle
1Control
1Module (VCM)
1 >
69025
Action Taken When the DTC Sets
• The VCM does not illuminates the Malfunction
Indicator Lamp (MIL).
• The VCM commands increased line pressure.
• The VCM freezes shift adapts.
• The VCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus
5 degrees.
- If the Engine Coolant Temperature (ECT) is
less than 8 5 ' C (185 * F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 8 5 ’ -110'C (185°-230'F ) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110’ C (230*F) then
Default TFT is set to 140 * C (284 * F) and
transmission shift pattern is in Hot Mode
- If ECT and TFT DTCs are both set then
Default TFT is 140* C (284 *F).
• DTC P0712 is stored in VCM history.
Transmission/Transaxle
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation.
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
Automatic Transmission - 4L80-E 7-327
• Test the TFT Sensor at various temperatures in
order to evaluate the possibility of a skewed
(mis-scaled) sensor. Use the Temperature vs
Resistance table. A skewed sensor may cause
delayed garage shifts or TCC complaints.
• Verify the customer driving habits, trailer towing,
weight, or towing in Overdrive.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests for a short to ground or a
"skewed" sensor by verifying the fault still
exists.
4. This step tests for an internal fault within the
transmission by creating an open.
6. This step inspects circuit 1227 of the
A/T Wiring Harness Assy, for being shorted
to ground.

DTC P0712 Fluid Temperature Sensor CKT Low Input (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the fluid checking procedure?
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
3 reference. The Clear Info function will erase the 0.14 volts
stored Failure Records from the VCM.
3. Record the DTC Failure Records, then clear
the DTC.
Does the scan tool display a TFT Sensor signal voltage Go to
less than the specified value? Go to Step 4 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way harness
connector. Multiple DTCs may set.
4 4.92 volts
3. Turn the ignition switch to the RUN position.
Does the scan tool display a TFT Sensor signal voltage
greater than the specified value? Go to Step 5 Go to Step 9
7-328 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0712 Fluid Temperature Sensor CKT Low Input (Gas) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector
(Automatic Transmission Connector End View). 16kO at 10 *C
(50-F) to 133Q
5 3. Using the J 39200 DMM and the J 35616-A
at 110*C
Connector Test Adapter Kit, measure the resistance (230 *F)
between terminals L and M.
Refer to Electronic Component Description.
Is the resistance within the specified values? Go to Step 6 Go to Step 7
Measure the resistance between terminal L and a good
6 ground on the transmission case. 50 kft Go to
Is the resistance less than the specified value? Go to Step 10 Diagnostic Aids
1. Disconnect the TFT Sensor from the A/T Wiring
Harness.
7 2. Measure the resistance between terminals L and M 50kQ
of the Jumper Harness.
Is the resistance less than the specified value? Go to Step 10 Go to Step 8
Replace the TFT Sensor.
Refer to A/T Fluid Temperature Sensor Replacement, in
8 — —
On-vehicle Service.
Is the replacement complete? Go to Step 13
Inspect circuit 1227 for a short to ground.
9 Refer to General Electrical Diagnosis Procedures. —
Did you find a short to ground condition? Go to Step 13 Go to Step 11
Replace the A/T Wiring Harness Assy.
Refer to Internal Wiring Harness Replacement, in
10 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 13
Inspect the VCM for faulty connections.
11 —
Did you find the condition? Go to Step 13 Go to Step 12
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
12 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 13
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
13 —
3. Be sure the TFT Sensor indicates a voltage greater
than 0.16 volts for 15 seconds. Begin the
4. Select Specific DTC. Enter DTC P0712. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0712 Fluid Temperature Sensor CKT Low Input (Diesel)
Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Powertrain Control Module
(PCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the PCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The PCM uses this information to control
shift quality and torque converter clutch apply.
DTC P0712 is a type D DTC.
Conditions for Setting the DTC
• Ignition is on.
• TFT is less than 0.14 volts.
The above conditions exist for 15.0 seconds.
Automatic Transmission - 4L80-E 7-329
"* Automatic
I Transmission
1 Powertrain
Sensor
Ground Control
| Module (PCM)
69016
Action Taken When the DTC Sets
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM commands increased line pressure.
• The PCM freezes shift adapts.
• The PCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus
5 degrees.
- If the Engine Coolant Temperature (ECT) is
less than 85 * C (185 * F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 85*-110*C (185*-230*F) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110* C (230 *F) then
Default TFT is set to 140*C (284 *F) and
transmission shift pattern is in Hot Mode.
- If ECT and TFT DTCs are both set then
Default TFT is 140* C (284 *F).
• DTC P0712 is stored in PCM history.
7-330 Automatic Transmission - 4L80-E
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Transmission/Transaxle
• First diagnose and clear any engine DTCs or
APP Sensor DTCs that are present. Then
inspect for any transmission DTCs that may
have reset.
• DTC P0218 may set approximately
600 seconds after DTC P0712 has set. Follow
the diagnostic table for DTC P0712 before
proceeding to the diagnostic table for
DTC P0218.

Diagnostic Aids Test Description

• Inspect the wiring at the PCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 3. This step tests for a short to ground or a
- A bent terminal "skewed" sensor by verifying the fault still
exists.
- A backed out terminal
4. This step tests for an internal fault within the
- A damaged terminal transmission by creating an open.
- Poor terminal tension 6. This step inspects circuit 1227 of the
- A chafed wire A/T Wiring Harness Assy, for being shorted
- A broken wire inside the insulation. to ground.
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.

DTC P0712 Fluid Temperature Sensor CKT Low Input (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the Transmission Fluid Checking Procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the fluid checking procedure? Procedure
Go to Step 3
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
3 reference. Using the Clear Info function will erase the 0.13 volts
stored Failure Records from the PCM.
3. Record the DTC Failure Records, then clear
the DTC.
Does the scan tool display a TFT Sensor voltage less than Go to
the specified value? Go to Step 4 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way harness
connector (Multiple DTCs will set).
4 4.92 volts
3. Turn the ignition ON.
Does the scan tool display a TFT Sensor voltage greater
than the specified value? Go to Step 5 Go to Step 9
Transmission/Transaxle Automatic Transmission - 4L80-E 7-331
DTC P0712 Fluid Temperature Sensor CKT Low Input (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector. 16,0000 at
3. Using the J 39200 DMM and the J 35616-A 10*C (50*F) to
5
Connector Test Adapter Kit, measure the resistance 1330 at 110'C
between terminals L and M. (230-F)
Refer to Electronic Component Description.
Is the resistance within specified values? Go to Step 6 Go to Step 7
Measure the resistance between terminal L and a good
6 ground on the transmission case. 50kO Go to
Is the resistance less than the specified value? Go to Step 10 Diagnostic Aids
1. Disconnect the TFT Sensor.
Refer to A/T Fluid Temperature Sensor Replacement.
7 2. Measure the resistance between terminals L and M 50kO
of the Jumper Harness.
Is the resistance less than the specified value? Go to Step 10 Go to Step 8
Replace the TFT Sensor.
8 Refer to A/T Fluid Temperature Sensor Replacement. — —
Is the replacement complete? Go to Step 13
Inspect circuit 1227 for a short to ground.
9 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 13 Go to Step 11
Replace the Automatic Transmission Wiring Harness
Assembly.
10 Refer to Internal Wiring Harness Replacement, in — —
On-vehicle Service.
Is the replacement complete? Go to Step 13
Inspect the PCM for faulty connections.
11 —
Did you find the condition? Go to Step 13 Go to Step 12
Replace the PCM.
12 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 13
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
13 —
3. Be sure the TFT sensor indicates a voltage greater
than 0.16 volts for 10 seconds. Begin the
4. Select Specific DTC. Enter DTC P0712. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-332 Automatic Transmission - 4L80-E
DTC P0713 Fluid Temperature Sensor CKT High Input (Gas)
r —■ — — -
■ Sensor
I Ground
I I
L ____________ ___
Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Vehicle Control Module
(VCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the VCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The VCM uses this information to control
shift quality and torque converter clutch apply.
If the VCM detects a continuous open or short to the
power in the TFT signal circuit or the TFT Sensor,
then DTC P0713 sets. DTC P0713 is a type D DTC.
Conditions for Setting the DTC
1. The TFT Sensor indicates a voltage greater
than 4.94 volts.
2. The ignition is ON.
3. Ail conditions met for 400 seconds.
Transmission/Transaxle
1Automatic
Transmission
Vehicle
I Control
I Module (VCM)
J
69025
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The VCM commands increased line pressure.
• The VCM freezes shift adapts.
• The VCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus 5
degrees.
- If the Engine Coolant Temperature (ECT) is
less than 8 5 ' C (185 * F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 85*-110*C (185*-230*F) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110*C (230*F) then
Default TFT is set to 140*C (284 *F) and
transmission shift pattern is in Hot Mode.
- If ECT and TFT DTCs are both set then
Default TFT is 140* C (284 *F).
• DTC P0713 is stored in VCM history.
Transmission/Transaxle
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the harness for a faulty connection or
an open in circuit 1227.
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• High voltage (B+) in circuit 1227 may also
damage the TFT Sensor.
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
DTC P0713 Fluid Temperature Sensor CKT High Input (Gas)
Step Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
1 —
Perform the transmission fluid checking procedure.
2 Refer to Transmission Fluid Checking Procedure.
Did you perform the fluid checking procedure?
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
3 tool in order to record the Failure Records for
reference. The Clear Info function will erase the
stored Failure Records from the VCM.
3. Record the DTC Failure Records.
Does the scan tool display a TFT Sensor signal voltage
greater than the specified value?
Automatic Transmission - 4L80-E 7-333
• The scan tool displays the transmission fluid
temperature (TFT) in degrees. After the
transmission operates, the temperature rises
steadily to about 100‘ C (212‘ F). The
temperature then stabilizes.
• Test the TFT Sensor at the various
temperatures in order to evaluate the possibility
of a skewed (mis-scaled) sensor. Use the
Temperature vs Resistance table. A skewed
sensor may cause firm shifts or TCC
complaints.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for higher than normal
circuit voltage which may also damage the
TFT Sensor.
6. This step simulates a TFT Sensor DTC P0712.
If the VCM recognizes the low signal voltage
(high temperature), and the scan tool displays
146*C (295 *F) or greater, the VCM and the
wiring are OK.
7. This step verifies a problem in the TFT Sensor
circuit inside the transmission.
8. This step inspects the TFT Sensor and the
Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assy.) for an
open Circuit 470 becomes circuit 452 inside the
transmission.
Value(s) Yes No
Go to Powertrain
OBD System
Check (5.7L) or
Powertrain OBD
System Check
(OBD System
Go to Step 2 Check){7AL)
— —
Go to Step 3
4.92 volts
Go to Diagnostic
Go to Step 4 Aids
7-334 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0713 Fluid Temperature Sensor CKT High Input (Gas) (cont’d)
Step Action Value(s) Yes No
Important: Refer to Test Description for information about
Step 4.
4 5.1 volts
Does the scan tool display a TFT voltage greater than the
specified value? Go to Step 11 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Using the J 39200 DMM and the J 35616-A
5 Connector Test Adapter Kit, measure the voltage 4.9-5.0 Volts
between jumper harness terminal L and a good
ground.
Refer to Electronic Component Description.
5. Turn the ignition switch to the RUN position.
Is the voltage within the specified value? Go to Step 6 Go to Step 10
1. Turn the ignition OFF.
2. Install a J 36169-A Fused Jumper Wire between
terminals L and M on the transmission
20-way connector (Automatic Transmission
6 Connector End View). 0.2 volts

3. Turn the ignition switch to the RUN position.

Is the scan tool TFT Sensor signal voltage less than the
specified value? Go to Step 7 Go to Step 12
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness to the
transmission side of the 20-way connector 16kQ at 10*C
(Automatic Transmission Connector End View). (50-F) to 133Q
7
3. Using the J 39200 DMM, measure the resistance at 110’ C
between terminals L and M. (230 *F)
Refer to Electronic Component Description. Go to
Is the resistance within the specified values? Diagnostic Aids Go to Step 8
1. Remove the transmission oil pan.
Refer to Changing the Fluid and Filter, in On-Vehicle
Service.
8 2. Inspect the A/T Wiring Harness Assy, for an open in —
circuits 1227 and 452. Refer to General Electrical
Diagnosis Procedures.
Did you the open condition? Go to Step 9 Go to Step 15
Replace the A/T Wiring Harness Assy.
Refer to Internal Wiring Harness Replacement, in
9 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
Inspect circuit 1227 for high resistance or an open.
10 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 13
Inspect circuit 1227 for a short to voltage B+.
11 —
Did you find the condition? Go to Step 16 Go to Step 13
Transmission/Transaxle Automatic Transmission - 4L80-E 7-335
DTC P0713 Fluid Temperature Sensor CKT High Input (Gas) (cont’d)
Step Action Value(s) Yes No
Inspect circuit 470 for an open.
12 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 13
Inspect the VCM for faulty or intermittent connections.
13 —
Did you find the condition? Go to Step 16 Go to Step 14
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
14 — —
VCM Replacement/Programming (7.4L).
Is the Replacement complete? Go to Step 16
Replace the TFT Sensor. Refer to A/T Fluid Temperature
15 Sensor Replacement. — —
Is the replacement complete? Go to Step 16
in order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
16 3. Operate the vehicle so that the TFT Sensor indicates —
a voltage less than 4.92 volts for 400 seconds
(6.8 minutes). Begin the
4. Select Specific DTC. Enter DTC P0713. diagnosis again.
Has the test run and passed? System OK Go to Step 1.
7-336 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0713 Fluid Temperature Sensor CKT High Input (Diesel)

■* Automatic
I Transmission

p “ ■*_ “ “ 1 Powertrain
| Sensor
I Ground Control
I Module (PCM)
I

68016

Circuit Description Action Taken When the DTC Sets

The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the 4L80-E Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness Assy).
The TFT Sensor is a resistor, or thermistor, which
changes value based on temperature. The sensor
has a negative-temperature coefficient. This means
that as the temperature increases, the resistance
decreases, and as the temperature decreases the
resistance increases. The Powertrain Control Module
(PCM) supplies a 5-volt reference signal to the
sensor on circuit 1227 and measures the voltage
drop in the circuit. When the transmission fluid is
cold, the sensor resistance is high and the PCM
detects high signal voltage. As the fluid temperature
warms to a normal operating temperature, the
resistance becomes less and the signal voltage
decreases. The PCM uses this information to control
shift quality and torque converter clutch apply.
DTC P0713 is a type D DTC.
Conditions for Setting the DTC
• The ignition is on.
• TFT is greater than 4.94 volts.
The above conditions exist for 400 seconds.
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM commands increased line pressure.
• The PCM freezes shift adapts.
• The PCM determines a TFT default
Transmission Temperature (TFT) using the
following matrix:
- If the Engine Run Time is less than
60 seconds then Default TFT equals the
Intake AIR Temperature (IAT), plus
5 degrees.
- If the Engine Coolant Temperature (ECT) is
less than 85 * C (185 * F) then Default TFT
equals IAT plus 10 degrees.
- If the ECT is 85--110-C (185‘ -230*F) then
Default TFT equals ECT plus 10 degrees.
- If the ECT is greater 110 *C (230 *F) then
Default TFT is set to 140‘ C (284 *F) and
transmission shift pattern is in Hot Mode.
- If ECT and TFT DTCs are both set then
Default TFT is 140-C (284 *F).
• DTC P0713 is stored in PCM history.
Transmission/Transaxle
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
Automatic Transmission - 4L80-E 7-337
• First diagnose and clear any engine DTCs or
TP Sensor DTCs that are present. Then inspect
for any transmission DTCs that may have reset.
• DTC P0218 may set approximately 600
seconds after DTC P0713 has set. Follow the
diagnostic table for DTC P0713 before
proceeding to the diagnostic table for
DTC P0218.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for higher than normal
circuit voltage which may also damage the
TFT Sensor.
6. This step simulates a TFT Sensor DTC P0712.
If the PCM recognizes the low signal voltage
(high temperature), and the scan tool displays
146*C (295 *F) or greater, the PCM and the
wiring are OK.
7. This step verifies a problem in the TFT Sensor
circuit.
8. This step inspects the TFT sensor and the
A/T Wiring Harness Assy, for an open.

DTC P0713 Fluid Temperature Sensor CKT High Input (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the fluid checking procedure?
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
3 reference. Using the Clear Info function will erase the 4.92 volts
stored Failure Records from the PCM.
3. Record the DTC Failure Records, then clear
the DTC.
Does the scan tool display a TFT Sensor signal voltage Go to
greater than the specified value? Go to Step 4 Diagnostic Aids
Important: Refer to Test Description for information about
Step 4.
4 5.1 volts
Does the scan tool display a TFT voltage greater than the
specified value? Go to Step 11 Go to Step 5
7-338 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0713 Fluid Temperature Sensor CKT High Input (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(multiple DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
5 4. Using the J 39200 DMM and the J 35616-A 4.9-5.0 volts
Connector Test Adapter Kit, measure the voltage
between Jumper Harness terminal L and a good
ground.
5. Turn the ignition switch to the RUN position.
Is the voltage within the specified value? Go to Step 6 Go to Step 10
1. Turn the ignition OFF.
2. Install a J 36169-A Fused Jumper Wire between
terminals L and M of the transmission 20-way
6 connector. 0.2 volts
3. Turn the ignition switch to the RUN position.
Is the TFT sensor signal voltage less than the
specified value? Go to Step 7 Go to Step 12
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness to the
transmission side of the 20-way connector. 16kfl at 10*C
(50 *F) to 133Q
7 3. Using the DMM, measure the resistance between at 110*C
terminals L and M. (230 *F)
Refer to Electronic Component Description. Go to
Is the resistance within the specified values? Diagnostic Aids Go to Step 8
1. Remove the transmission oil pan.
Refer to On-Vehicle Service, Transmission Pan
removal.
2. Inspect the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assy.) for an open in
8 —
circuit 1227.
3. Inspect for an open in A/T Wiring Harness Assy,
circuit 452. Refer to General Electrical Diagnosis
Procedures.
Did you find the open condition? Go to Step 9 Go to Step 15
Replace the A/T Wiring Harness Assy.
Refer to Internal Wiring Harness Replacement, in
9 — —
On-vehicle Service.
Is the replacement complete? Go to Step 16
Inspect circuit 1227 for high resistance or an open.
10 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 13
Inspect circuit 1227 for a short to voltage B+.
11 —
Did you find the condition? Go to Step 16 Go to Step 13
Inspect circuit 452 for an open.
12 Refer to General Electrical Diagnosis Procedures. —-
Did you find the condition? Go to Step 16 Go to Step 13
Transmission/Transaxle Automatic Transmission - 4L80-E 7-339
DTC P0713 Fluid Temperature Sensor CKT High Input (Diesel) (cont’d)
Step Action Value(s) Yes No
Inspect the PCM for faulty or intermittent connections.
13 —
Did you find the condition? Go to Step 16 Go to Step 14
Replace the PCM.
14 Refer to PCM Replacement/Programming. — —
Is the Replacement complete? Go to Step 16
Replace the TFT Sensor.
15 Refer to A/T Fluid Temperature Sensor Replacement. — —
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
16 —
3. Operate the vehicle so that the TFT Sensor indicates
a voltage less than 4.92 volts for 10 seconds. Begin the
4. Select Specific DTC. Enter DTC P0713. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-340 Automatic Transmission - 4L80-E
DTC P0716 Input Speed Sensor Circuit Intermittent (Gas)
Circuit Description
The Automatic Transmission Input (Shaft) Speed
(A/T ISS) Sensor provides transmission input speed
to the Vehicle Control Module (VCM). The A/T ISS
Sensor is a Permanent Magnet (PM) generator. The
sensor mounts into the transmission case and
maintains a slight air gap between the sensor and
the Forward Clutch Housing. The PM generator
produces an AC voltage as the Forward Clutch
Housing rotor teeth pass through the sensor’s
magnetic field. The AC voltage level increases as
the turbine shaft speed increases. The VCM converts
the AC voltage into a digital signal. The VCM
determines actual turbine speed using the digital
signal. The VCM uses the input speed to calculate
torque converter slip speed, and gear ratios.
When the VCM detects an unreasonably large
change in the input speed, in a very short period
of time, then DTC P0716 sets. DTC P0716 is a
type D DTC. For California emissions vehicles,
DTC P0716 is a type B DTC.
Conditions for Setting the DTC
• No Throttle Position (TP) Sensor DTCs P0121,
P0122 or P0123.
• No OSS Sensor DTC P0502 or P0503.
• No A/T ISS Sensor DTC P0717.
• No Shift Solenoid DTC P0751 or P0753.
Transmission/Transaxle
• The TP is greater than 10%.
• The vehicle speed is greater than 25 mph.
• The transmission is not in Park or Neutral.
• The engine is running greater than 375 RPM
for more than 7 seconds.
• The input speed varies by 1300 RPM for
greater than 5 seconds.
Action Taken When the DTC Sets
• For California emission vehicles only, the
VCM illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM commands maximum line pressure.
• The VCM freezes shift adapts.
• DTC P0716 is stored in VCM History.
Conditions for Clearing the MIL/DTC
1. For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-341
Diagnostic Aids • When diagnosing for an intermittent short or
• Inspect the wiring at the VCM , the Output open, massage the wiring harness while
Shaft Speed (OSS) Sensor connector and all watching the test equipment for a change.
other circuit connecting points for the following: • First diagnose and clear any engine DTCs or
- A bent terminal TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
- A backed out terminal have reset.
- A damaged terminal
- Poor terminal tension
Test Description
The numbers below refer to the step numbers on the
- A chafed wire
diagnostic table.
- A broken wire inside the insulation
2. This step tests for proper operation to the
- Moisture intrusion A/T ISS Sensor.
- Corrosion 6. This step tests for proper A/T ISS circuit
- The A/T ISS sensor harness being near the operation up to the VCM connections. Remove
DIS components or the ignition wires. the fuel pump relay in order to eliminate a
flooding condition during this step.

DTC P0716 Input Speed Sensor Circuit Intermittent (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
2 Records from the VCM. —
3. Record the DTC Freeze Frame and Failure Records.
4. With the vehicle in Park, start the engine.
5. Raise the drive wheels.
6. Select scan tool Transmission ISS and Engine RPM.
7. Observe the Transmission ISS while slowly
accelerating the engine to 2000 RPM and hold. Go to
Is the scan tool Transmission ISS more than 800 RPM? Diagnostic Aids Go to Step 3
1. Turn the ignition switch to the OFF position.
2. Remove the connector from the A/T ISS sensor.
3. Remove the A/T ISS Sensor from the transmission.
3 4. Using the J 39200 DMM and J 35616 Connector Test 1042-2088Q
Adaptor Kit, measure the resistance of the A/T ISS
Sensor.
Is the sensor resistance within the specified value? Go to Step 4 Go to Step 9
Inspect circuit 1230 (RED/BLK) for an open or a short to
ground.
4 —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition? Go to Step 7 Go to Step 5
Inspect circuit 1231 (BLU/WHT) for an open.
5 Refer to General Electrical Diagnosis Procedures. —
Did you find an open condition? Go to Step 8 Go to Step 6
7-342 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0716 Input Speed Sensor Circuit intermittent (Gas) (cont’d)
Step Action Value(s) Yes No
1. Re-install the A/T ISS Sensor in the transmission.
2. Reconnect the A/T ISS Sensor connector to the
sensor.
3. Disconnect VCM connector C3 (Clear) (additional
DTCs may set).
4. Probe across terminal C3-7 and terminal C3-8 at
6 VCM connector C3 with J 39200 DMM on AC 0.5 volts AC
voltage.
5. Remove the fuel pump relay.
Refer to Automatic Transmission Components (Gas).
6. With the vehicle in Park, crank the engine. Go to
Is the voltage above the specified value? Go to Step 10 Diagnostic Aids
Repair the open or short to ground in circuit 1230.
7 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 12
Repair the open in circuit 1231.
8 Refer to Wiring Repairs. — —
Did you correct the open condition? Go to Step 12
Replace the Input Shaft Speed Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle
9 — —
Service.
Is the replacement complete? Go to Step 12
1. Inspect the VCM pins for corrosion or weak tension.
2. Inspect the C3 connector terminals for corrosion or
10 —
weak tension.
Did you find the condition? Go to Step 12 Go to Step 11
Replace the VCM.
Refer to VCM Repiacement/Programming (5.7L) or
11 — —
VCM Repiacement/Programming (7.4L).
Is the replacement complete? Go to Step 12
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
12 • The engine must be running and Transmission —
ISS must be greater than 500 RPM.
• The VCM must see an input speed change of
less than 200 RPM for 1 second.
Begin the
4. Select Specific DTC. Enter DTC P0716. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/!ransaxle
DTC P0716 Input Speed Sensor Circuit Intermittent (Diesel)
Circuit Description
The Automatic Transmission Input (Shaft) Speed
(A/T ISS) Sensor provides transmission input speed
to the Powertrain Control Module (PCM). The
A/T ISS Sensor is a Permanent Magnet (PM)
generator. The sensor mounts into the transmission
case and maintains a slight air gap between the
sensor and the Forward Clutch Housing. The PM
generator produces an AC voltage as the Forward
Clutch Housing rotor teeth pass through the sensor’s
magnetic field. The AC voltage level increases as
the turbine shaft speed increases. The PCM converts
the AC voltage into a digital signal. The PCM
determines actual turbine speed using the digital
signal. The PCM uses the input speed to calculate
torque converter slip speed, and gear ratios.
When the PCM detects an unrealistically large
change in input speed, then DTC P0716 sets.
DTC P0716 is a type B DTC.
Conditions for Setting the DTC
. No A/T ISS Sensor DTC P0717
. No OSS Sensor DTCs P0722 or P0723
. No Shift Solenoid DTCs P0751 or P0753.
• System voltage is 9.0 volts.
• Engine speed is greater than 475 RPM.
• The APP Angle is greater than 15%.
Automatic Transmission - 4L80-E 7-343
• Transmission Fluid Pressure Manual Valve
Position Switch is not indicating Park or
Neutral.
• The vehicle speed is greater than 32 Km/h
(20 mph).
• The A/T ISS varies by more than 1200 RPM
within 4 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0716 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
7-344 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Aids • You may have to drive the vehicle in order to
• Inspect the wiring at the PCM, the transmission experience a fault.
connector and all other circuit connecting points • First diagnose and clear any engine DTCs that
for the following conditions: are present. Then inspect for any transmission
- A bent terminal DTCs that may have reset.
- A backed out terminal Test Description
- A damaged terminal The numbers below refer to the step numbers on the
- Poor terminal tension diagnostic table.
- A chafed wire 4. This step tests for proper operation of the
- A broken wire inside the insulation A/T ISS Sensor.
- Moisture intrusion 8. This step tests for proper A/T ISS Sensor
circuit operation up to the PCM connections.
- Corrosion You remove the Fuel Sol. Fuse in order to
• When diagnosing for an intermittent short or eliminate a flooding condition during this step.
open, massage the wiring harness while 10. This step tests for a short to ground in the
watching the test equipment for a change. A/T ISS Sensor circuit.

DTC P0716 Input Speed Sensor Circuit Intermittent (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. Turn the ignition to the RUN position with the
engine OFF.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2 —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
4. With the transmission in Park, start the engine.
5. Observe the scan tool, Transmission ISS.
6. Run the engine to 2000 RPM and hold the engine
speed steady. Exit DTC table.
Does the Transmission ISS RPM change by more than No fault at
1200 RPM at steady engine speed? Go to Step 3 this time
1. Turn the ignition to the OFF position.
2. Disconnect the A/T ISS Sensor harness connector
from the A/T ISS Sensor,
3 3. Using the J 35616-A Connector test Adapter Kit, 1042-20880
connect the J 39200 DMM to the A/T ISS Sensor
terminals. Select the OHS scale.
Is the A/T ISS Sensor resistance within the
specified value? Go to Step 4 Go to Step 15
1. With the J 39200 DMM connected to the ISS sensor,
select AC Volts.
2. With the transmission in Park, start the engine. Greater than
4
3. Run the engine to 2000 RPM and hold the engine 10.0 volts AC
speed steady.
Is the DMM voltage steady? Go to Step 5 Go to Step 15
Transmission/Transaxle Automatic Transmission - 4L80-E 7-345
DTC P0716 Input Speed Sensor Circuit Intermittent (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition to the OFF position.
2. Select DC Volts on the J 39200 DMM.
3. Turn the ignition to the RUN position with the
5 engine OFF. 10.5 volts DC
4. Measure the voltage at both A/T ISS Sensor harness
connector terminals A and B to a good ground.
Is either voltage reading greater than the specified value? Go to Step 6 Go to Step 8
1. Inspect circuit 1230 for a short to power.
2. Inspect circuit 1231 for a short to power.
6 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 7 Go to Step 16
Repair the short to power in circuits 1230 and/or 1231.
7 — —
Is the repair complete? Go to Step 18
1. Reconnect the A/T ISS harness connector to the
A/T ISS Sensor.
2. Turn the ignition to the OFF position.
3. Disconnect the PCM C1 (BRN-32 Pin) connector.
4. Connect the J 39200 DMM on AC Volts to the
C1 connector terminals D1 and D11.
8 0.4 volts AC
5. Remove the Fuel Sol. Fuse in the Fuse/Relay
Center.
Refer to Automatic Transmission Components.
6. Turn the ignition to the RUN position and crank the
engine while observing the J 39200 DMM.
Is the voltage greater than the specified value and steady? Go to Step 16 Go to Step 9
With the J 39200 DMM measure the resistance between
9 terminals D1 and D11 of the PCM C1 connector. 1042-2088Q
Is the circuit resistance within the specified value? Go to Step 10 Go to Step 12
1. Measure the resistance from both PCM C1 connector
terminals D1 and D11 to a good ground.
10 2. Measure the resistance from C1 connector 50kQ
terminal C1-D11 to a good ground. Go to
Is either resistance less than the specified value? Go to Step 11 Diagnostic Aids
Inspect circuits 1230 and 1231 for short to ground.
11 Refer to General Electrical Diagnosis Procedures. — —
Did you find and correct the condition? Go to Step 18
Is the resistance reading from Step 9 less than the
12 1042-2088Q
specified value? Go to Step 13 Go to Step 14
Repair circuits 1230 and 1231 for a short together.
13 Refer to Wiring Repairs. — —
Is the repair complete? Go to Step 18
1. Inspect circuit 1230 for high resistance or an open.
2. Inspect circuit 1231 for high resistance or an open.
14 — —
Refer to General Electrical Diagnosis Procedures.
Did you find and correct the condition? Go to Step 18
7-346 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0716 Input Speed Sensor Circuit Intermittent (Diesel) (cont’d)
Step Action Value(8) Yes No
Replace the A/T ISS Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle
15 — —
Service.
Is the replacement complete? Go to Step 18
Inspect the PCM pins and connector terminals for
16 corrosion or weak tension. —
Did you find the condition? Go to Step 18 Go to Step 17
Replace the PCM.
17 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 18
In order to verify your repair, perform the following
procedure:
1. Select DTC.
Important: Failure to clear codes first may cause
poor engine performance and high idle at start up.
2. Select Clear Info.
18 —
3. Operate the vehicle under the following conditions:
• Start and run the engine greater than 475 RPM.
• The PCM must see an A/T ISS change of less
than 500 RPM for 1 second.
Begin the
4. Select Specific DTC. Enter DTC P0716. diagnosis again.
Has the test run and passed? System OK Go to Step 1
TransmissiorVTransaxle
DTC P0717 Input Speed Sensor Circuit Low input (Gas)
Circuit Description
The Automatic Transmission Input (Shaft) Speed
(AIT ISS) Sensor provides transmission input speed
to the Vehicle Control Module (VCM). The A/T ISS
Sensor is a Permanent Magnet (PM) generator. The
sensor mounts into the transmission case and
maintains a slight air gap between the sensor and
the Forward Clutch Housing. The PM generator
produces an AC voltage as the Forward Clutch
Housing rotor teeth pass through the sensor’s
magnetic field. The AC voltage level increases as
the turbine shaft speed increases. The VCM converts
the AC voltage into a digital signal. The VCM
determines actual turbine speed using the digital
signal. The VCM uses the input speed to calculate
torque converter slip speed, and gear ratios.
When the VCM detects a low or no input speed
during high vehicle and high engine speeds, then
DTC P0717 sets. DTC P0717 is a type D DTC. For
California emissions vehicles, DTC P0717 is a type
B DTC.
Conditions for Setting the DTC
. No OSS DTC P0502 or P0503.
• No TFP Val. Position Sw. DTC P1810.
• TFP Val. Position Switch is not Park or Neutral.
Automatic Transmission - 4L80-E 7-347
• The vehicle speed is greater than 12 mph.
• The engine runs greater than 475 RPM for at
least 5 seconds.
• The measured input speed is less than 25 RPM
for at least 5.0 seconds.
Action Taken When the DTC Sets
• For California emissions only, the VCM
illuminates the Malfunction Indicator
Lamp (MIL).
• The VCM defaults the transmission to maximum
line pressure.
• The VCM freezes shift adapts.
• DTC P0717 is stored in VCM history.
Conditions for Clearing the MIL/DTC
1. For California Emissions, the VCM turns OFF
the MIL after three consecutive ignition cycles
without a failure reported.
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
7-348 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Aids • When diagnosing for an intermittent short or
• Inspect the wiring at the VCM , the Output open, massage the wiring harness while
Shaft Speed (OSS) Sensor connector and all watching the test equipment for a change.
other circuit connecting points for the following: • First diagnose and clear any engine DTCs or
- A bent terminal TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
- A backed out terminal have reset.
- A damaged terminal
- Poor terminal tension
Test Description
The numbers below refer to the step numbers on the
- A chafed wire
diagnostic table.
- A broken wire inside the insulation
3. This step tests for proper circuit operation up to
- Moisture intrusion the VCM connections. Remove the fuel pump
- Corrosion relay in order to eliminate a flooding condition
- The A/T ISS sensor harness being near the during this step.
DIS components or the ignition wires. 5. This step tests for proper operation of the Input
Shaft Speed Sensor.

DTC P0717 Input Speed Sensor Circuit Low Input (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(JAL)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
2 erase the stored Freeze Frame and Failure Records —
from the VCM.
3. Record the DTC Freeze Frame and Failure Records.
4. With the vehicle in Park, start the engine and idle
greater than 500 RPM.
5. Select scan tool Transmission ISS and Engine RPM. Go to
Is the Transmission ISS greater than 50 RPM? Diagnostic Aids Go to Step 3
1. Turn the ignition switch to the OFF position.
2. Disconnect VCM connector C3 (Clear) (additional
DTCs may set).
3. Probe across terminal C3-7 and terminal C3-8 at
3 VCM connector with J 39200 DMM on AC voltage. 0.5 volts AC
4. Remove the fuel pump relay.
Refer to Automatic Transmission Components (Gas).
5. With the vehicle in Park, crank the engine.
Is the voltage above the specified value? Go to Step 12 Go to Step 4
1. Turn the ignition switch to the OFF position.
2. Remove the connector from the A/T ISS Sensor.
4 3. Using the J 39200 DMM and J 35616 Connector Test 1042-20880
Adaptor Kit, measure the resistance between
terminal A and terminal B of the A/T ISS Sensor.
Is the sensor’s resistance within the specified value? Go to Step 5 Go to Step 11
Transmission/Transaxle Automatic Transmission - 4L80-E 7-349
DTC P0717 Input Speed Sensor Circuit Low Input (Gas) (cont’d)
Step Action Value(s) Yes No
1. Select AC volts on the J 39200 DMM.
2. With the vehicle in Park, crank the engine.
5 0.5 volts AC
Is the J 39200 DMM voltage greater than the
specified value? Go to Step 7 Go to Step 6
1. Remove the A/T ISS Sensor from the transmission.
2. Inspect the A/T ISS Sensor.
6 3. Inspect the forward clutch housing for damage —
(rotor teeth).
Did you find the condition? Go to Step 14 Go to Step 11
Inspect circuit 1230 (RED/BLK) for an open or short to
ground.
7 —
Refer to General Electrical Diagnosis Procedures.
Did you find a condition? Go to Step 8 Go to Step 9
Repair the open or short to ground in circuit 1230.
8 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 14
Inspect circuit 1231 (BLU/WHT) for an open or short to
ground.
9 —
Refer to General Electrical Diagnosis Procedures. Go to
Did you find a condition? Go to Step 10 Diagnostic Aids
Repair the open or short to ground in circuit 1231.
10 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 14
Replace the Input Shaft Speed Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle —
11 —
Service.
Is the replacement complete? Go to Step 14
1. Inspect the VCM pins for corrosion or weak tension.
2. Inspect the C3 connector terminals for corrosion or —
12
weak tension.
Did you find the condition? Go to Step 14 Go to Step 13
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
13 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 14
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• The vehicle in drive range and the engine must
14 —
be running.
• Vehicle speed greater than 12 MPH.
• The VCM must see an input speed greater than
500 RPM for 1 second. Begin the
4. Select Specific DTC. Enter DTC P0717. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-350 Automatic Transmission - 4L80-E
DTC P0717 Input Speed Sensor Circuit Low Input (Diesel)
Circuit Description
The Automatic Transmission Input (Shaft) Speed
(A/T ISS) Sensor provides transmission input speed
to the Powertrain Control Module (PCM). The
A/T ISS Sensor is a Permanent Magnet (PM)
generator. The sensor mounts into the transmission
case and maintains a slight air gap between the
sensor and the Forward Clutch Housing. The PM
generator produces an AC voltage as the Forward
Clutch Housing rotor teeth pass through the sensor’s
magnetic field. The AC voltage level increases as
the turbine shaft speed increases. The PCM converts
the AC voltage into a digital signal. The PCM
determines actual turbine speed using the digital
signal. The PCM uses the input speed to calculate
torque converter slip speed, and gear ratios.
When the PCM detects a low or no input speed
during high vehicle and high engine speeds, then
DTC P0717 sets. DTC P0717 is a type B DTC.
Conditions for Setting the DTC
. No OSS Sensor DTCs P0722 or P0723.
. No TFP Val. Position Sw. DTC P1810.
• TFP Val. Position Sw. is not in Park or Neutral.
• The vehicle speed is greater than 32 Km/h
(20 mph).
Transmission/Transaxie
• System voltage is 9.0 volts.
• The engine runs greater than 475 RPM
7 seconds.
• The A/T ISS is less than 50 RPM for at least
5 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM defaults the transmission to maximum
line pressure.
• The PCM freezes shift adapts.
• DTC P0717 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-351
Diagnostic Aids • First diagnose and clear any engine DTCs that
• Inspect the wiring at the PCM, the transmission are present. Then inspect for any transmission
connector and all other circuit connecting points DTCs that may have reset. If a DTC P0717
for the following conditions: and a DTC P0730 are both present, diagnose
DTC P0717 first.
- A bent terminal
- A backed out terminal Test Description
- A damaged terminal The numbers below refer to the step numbers on the
diagnostic table.
- Poor terminal tension
2. This step tests for proper operation of the
- A chafed wire
A/T ISS Sensor.
- A broken wire inside the insulation
4. This step tests for proper A/T ISS Sensor and
- Moisture intrusion circuit operation. Remove the Fuel Sol. fuse in
- Corrosion order to eliminate a flooding condition.
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.

DTC P0717 Input Speed Sensor Circuit Low Input (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
2 1042-20880
Important: If a DTC P0730 is also present, refer to
the Diagnostic Aids.
4. Disconnect the wiring harness at the Input Shaft
Speed Sensor.
5. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit, connect the test leads to
the A/T ISS Sensor terminals. Set the J 39200
DMM selector on OHMS.
6. Measure the resistance of the A/T ISS Sensor.
Is the resistance within the specified value? Go to Step 3 Go to Step 9
1. With the leads on the A/T ISS Sensor, select
AC volts on the J 39200 DMM.
3 2. With the selector in park position, start the engine 3.0 volts AC
and idle above 700 RPM.
Is the DMM voltage greater than the specified value? Go to Step 4 Go to Step 9
7-352 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0717 Input Speed Sensor Circuit Low Input (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Reconnect the NT ISS Harness to the sensor.
2. With the ignition in the OFF position, disconnect the
PCM C1 (BRN-32 Pin) connector.
3. Probe across terminals D11 and D1 at the PCM
connector C1 with the J 39200 DMM on AC voltage.
4. Remove the Fuel Sol. Fuse located in the
4 0.4 volts AC
Fuse/Relay Center.
Refer to Automatic Transmission Components.
5. With the vehicle in Park, turn the ignition to the
switch to the Start position in order to crank the
engine.
Is the voltage greater than the specified value? Go to Step 10 Go to Step 5
Inspect circuit 1230 for an open, a short to B+, or a short
to ground.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 7 Go to Step 6
Inspect circuit 1231 for a short to B+, or an open.
6 Refer to General Electrical Diagnosis Procedures. — Refer to
Did you find the condition? Go to Step 8 Diagnostic Aids
Repair the condition in circuit 1230.
7 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 12
Repair the condition in circuit 1231.
8 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 12
Replace the Input Shaft Speed Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle
9 — —
Service.
Is the replacement complete? Go to Step 12
Inspect the PCM pins and the C1 connector terminals.
10 —
Did you find the condition? Go to Step 12 Go to Step 11
Replace the PCM.
11 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 12
In order to verify your repair, perform the following
procedure:
1. Select DTC.
Important: Failure to clear codes before continuing
may cause poor engine performance and high idle at
start up.
2. Select Clear Info.
12 —
3. Operate the vehicle under the following conditions:
. Start and run the engine above 500 RPM.
• Drive the vehicle greater than 12 mph.
. The PCM must see a Trans. ISS greater than
500 RPM for 1 second.
Begin the
4. Select Specific DTC. Enter DTC P0717. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0719 Brake Switch Circuit Low Input (Gas)
Circuit Description
The TCC/Stoplamp switch indicates the brake pedal
status. The normally-closed TCC/Stoplamp switch
supplies a B+ signal on circuit 420 to the Vehicle
Control Module (VCM). The signal voltage circuit
opens when the brakes are applied.
If the VCM detects an open TCC/Stoplamp Switch
circuit during accelerations, then DTC P0719 sets.
DTC P0719 is a type D DTC.
Conditions for Setting the DTC
. No OSS DTC P0502 or DTC P0503.
• The VCM detects an open TCC/Stoplamp
Switch/circuit (0 volts) for 15 minutes.
• The following sequence of events occurs eight
consecutive times:
1. The vehicle speed is less than 8 km/h
(5 mph).
2. Then the vehicle speed is 8-40 km/h
(5-25 mph) for 3.5 seconds.
3. Then the vehicle speed is greater than
40 km/h (25 mph) for 6 seconds.
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
Automatic Transmission - 4L80-E 7-353
201444
• For TCC scheduling, the VCM disregards the
brake switch state if the TP Sensor is greater
than 1% and the vehicle speed is greater than
20 MPH.
• DTC P0719 is stored in VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the
TCC/Stoplamp Switch and ail other circuit
connecting points for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
7-354 Automatic Transmission - 4L80-E
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• Ask about the customer’s driving habits and
any unusual driving conditions he or she might
have, such as stop and go traffic or
expressway driving.
• Inspect the brake switch for proper mounting
and adjustment.
• Inspect for the most current calibration ID and
the latest bulletins.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Transmission/Transaxle
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for TCC/Stoplamp switch voltage
to the VCM connector.
7. This step isolates the TCC/Stoplamp switch as
a source for setting the DTC.
10. This step tests for a short to ground in circuit
441 (ignition voltage) to the TCC/Stoplamp
switch.
12. This step tests for a short to ground in circuit
420, from the TCC/Stoplamp switch to
the VCM.
13. This step isolates the VCM as a source for
causing the fuse to open.

DTC P0719 Brake Switch Circuit Low Input (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. The Clear Info function will erase the
2 stored Failure Records from the VCM. —
3. Record the DTC Failure Records then clear the DTC.
4. Select the TCC Brake Switch on the scan tool.
5. Do not apply the brake pedal.
Does the scan tool TCC Brake Sw. indicate CLOSED, Go to
when the brake pedal is not applied? Diagnostic Aids Go to Step 3
1. Remove the Brake fuse.
2. Inspect the Brake fuse for an open.
3 —
Refer to General Electrical Diagnosis Procedures.
Is the fuse open? Go to Step 10 Go to Step 4
1. Turn the ignition switch to the OFF position.
2. Disconnect the C4 (BLK) connector from the VCM.
3. Connect a 12-volt test lamp to a good ground.
4. Using the J 35616 Connector Test Adaptor Kit and
the 12-volt test lamp, probe terminal C4-10
4 (420 PPL). —
5. Re-install the fuse.
6. Turn the ignition switch to the RUN position.
7. Do not apply the brake pedal.
Is the test lamp on? Go to Step 15 Go to Step 5
Transmission/Transaxle Automatic Transmission - 4L80-E 7-355
DTC P0719 Brake Switch Circuit Low Input (Gas) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition key to the OFF position.
2. Remove the connector from the TCC/Stoplamp
switch.
5 3. Use the J 39200 DMM to measure B+ voltage at 10-13 volts
terminal D (441 BRN) of the brake switch connector.
4. Turn the ignition switch to the RUN position.
Is B+ voltage indicated? Go to Step 7 Go to Step 6
Inspect circuit 441 for an open.
6 Refer to General Electrical Diagnosis Procedures. — —
Did you find and correct an open condition? Go to Step 17
1. Turn the key to the RUN position.
2. Install a fused jumper wire from terminal C
(420 PPL) to terminal D (441 BRN) of the
7 TCC/Stoplamp switch connector. —
3. Probe the VCM connector terminal C4-10 (420 PPL)
with the test lamp.
Is the test lamp on? Go to Step 9 Go to Step 8
Inspect circuit 420 for an open.
8 Refer to General Electrical Diagnosis Procedures. — —

Did you find and correct an open condition? Go to Step 17

Replace the TCC/Stoplamp switch.
9 Refer to Stoplamp Switch Replacement. — —
Is the replacement complete? Go to Step 17
1. Turn the key to the RUN position.
2. Apply and hold the brake pedal.
10 3. Install a new fuse while keeping the brake pedal —
applied.
Does the fuse open with the brake pedal applied? Go to Step 11 Go to Step 12
Inspect circuit 441 for a short to ground. Refer to General
11 Electrical Diagnosis Procedures. — —
Did you find and correct the short to ground condition? Go to Step 17
With the key in the RUN position, release the brake pedal. Go to
12 —
Does the fuse open when the brake pedal is released? Go to Step 13 Diagnostic Aids
1. Disconnect the C4 (BLK) connector from the VCM
(additional DTCs may set).
2. Turn the key to the RUN position.
13 —
3. Install a new fuse.
4. Do not apply the brake pedal.
Does the fuse open? Go to Step 14 Go to Step 15
Inspect circuit 420 for a short to ground. Refer to General
14 Electrical Diagnosis Procedures. — —
Did you find and correct the short to ground condition? Go to Step 17
7-356 Automatic Transmission - 4L80-E Transmlssion/Transaxle
DTC P0719 Brake Switch Circuit Low Input (Gas) (cont’d)
Step Action Value(s) Yes No
Inspect the VCM terminals for corroded or weak
15 connections. —
Did you find a shorted condition? Go to Step 17 Go to Step 16
Replace the VCM. Refer to VCM
16 Replacement/Programming with KS calibration prom. — —
Is the replacement complete? Go to Step 17
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
17 • With the engine OFF, turn the ignition switch to the —
RUN position.
• The brake pedal is not applied.
• Select TCC Brake Sw. on the scan tool.
Does the TCC Brake Sw. indicate Closed when the brake Begin Diagnosis
pedal is not applied, then indicate Open when the brake Repair verified, again, Go to
pedal is applied? exit DTC table Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-357
DTC P0719 Brake Switch Circuit Low Input (Diesel)

| Hot At AIITlmesI

Power
Distribution B8 •) STOPyHAZ
Cell 10 , <T Fusel
20A ■JTCC Stoplamp
L_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ j Switch
1 ORN 140 Assembly
N.O.TCC
Fuse block \ Stoplamp
Details i S299 '• Switch
Cell 11 0.8 ORN 140
1 ORN 140
B , 0,221
0.8 WHT 17
A£C227
0.8 WHT 17
Exterior
Lights ◄---------1i S220
Cell 110
0.8 WHT 17
A$C200
0.8 WHT 17
B1<) .C2
Powertrain J" Stoplamp
Control | Switch
Module | Input
* (PCM) i

201051

Circuit Description Conditions for Clearing the DTC

The normally open TCC/Stoplamp switch indicates • A scan tool can clear the DTC from the PCM
brake pedal status to the Powertrain Control Module history. The PCM clears the DTC from the PCM
(PCM). Applying the brake pedal closes the switch, history if the vehicle completes 40 warm-up
supplying voltage to the PCM. Releasing the brake cycles without a failure reported.
pedal interrupts voltage to the PCM. • The PCM cancels the DTC default actions
If the PCM detects an open TCC/Stoplamp switch when the fault no longer exists and the ignition
(stuck OFF) during decelerations, then DTC P0719 is OFF long enough in order to power down
sets. DTC P0719 is a type D DTC. the PCM.
Conditions for Setting the DTC Diagnostic Aids
. No OSS Sensor DTC P0722 or P0723 • Inspect the wiring at the PCM, the
• The PCM detects an open TCC/Stoplamp TCC/Stoplamp switch connector and all other
switch/circuit (0 volts) and the following circuit connecting points for the following
sequence of events occur ten conditions:
consecutive times: - A bent terminal
1. the vehicle speed is greater than 32 km/h - A backed out terminal
(20 mph) for 6 seconds. - A damaged terminal
2. Then the vehicle speed is 8-32 km/h - Poor terminal tension
(5-20 mph) for 3 seconds.
- A chafed wire
3. Then the vehicle speed is less than
8 km/h (5 mph). - A broken wire inside the insulation
4. DTC P0719 has not passed. - Moisture intrusion
- Corrosion
Action Taken When the DTC Sets • When diagnosing for an intermittent short or
• The PCM does not illuminate the Malfunction open, massage the wiring harness while
Indicator Lamp (MIL). watching the test equipment for a change.
• DTC P0719 is stored in PCM history.
7-358 Automatic Transmission - 4L80-E
• Ask about the customer’s driving habits and
any unusual driving conditions ne or
have, such as stop and go traffic or
expressway driving.
• Inspect the TCC/Stoplamp switch for proper
mounting and adjustment.
• First diagnose and clear any engine DTCs
codes that are present. Then inspect for any
transmission DTCs that may have reset.
Transmission/Transaxle
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step isolates the TCC/Stoplamp Switch as
a source for setting the DTC.
5. This step tests for a short to ground between
the fuse and the TCC/Stoplamp Switch.
7. This step tests for a short to ground in
circuit 17.
8. This step removes the PCM from circuit 17 as
the source of a short to ground.

DTC P0719 Brake Switch Circuit Low Input (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Failure Records from the PCM.
3. Record the DTC Failure Records, then clear
2 —
the DTC.
4. Select the TCC Brake Switch on the scan tool.
5. Disconnect the TCC/Stoplamp Switch connector from
the TCC/Stoplamp switch.
6. Connect a test lamp from cavity B (circuit 140 ORN)
of the TCC/Stoplamp Switch connector to a known
good ground.
is the test lamp ON? Go to Step 3 Go to Step 4
Install a J 36169-A Fused Jumper Wire from terminal B
(circuit 140 ORN) to terminal A (circuit 17 WHT) of the
3 TCC/Stoplamp Switch connector. —
Did the scan tool TCC/Brake Switch status change from
Open to Closed? Go to Step 10 Go to Step 12
1. Remove the Stop/Hazard fuse.
2. Inspect the Stop/Hazard fuse for an open.
4 —
Refer to General Electrical Diagnosis Procedures.
Is the fuse open? Go to Step 5 Go to Step 11
Replace the Stop/Hazard fuse.
5 —
Does the replacement fuse open immediately? Go to Step 6 Go to Step 7
Inspect circuit 140 for a short to ground.
6 Refer to General Electrical Diagnosis Procedures. — —
Did you find and repair the condition? Go to Step 15
1. Reconnect the TCC/Stoplamp Switch connector.
Intermittent short
7 2. Apply the brake pedal. — to ground. Go to
Does the fuse open immediately? Go to Step 8 Diagnostic Aids.
Transmissfon/Transaxfe Automatic Transmission - 4L80-E 7-359
DTC P0719 Brake Switch Circuit Low Input (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Disconnect the C2 (BRN-24 Pin) connector from
the PCM.
8 2. Replace the Stop/Hazard fuse. —
3. Apply the brake pedal.
4. Does the fuse open immediately? Go to Step 9 Go to Step 13
Inspect circuit 17 for a short to ground.
9 Refer to General Electrical Diagnosis Procedures. — —
Did you find and repair the condition? Go to Step 15
Replace the TCC/Stoplamp Switch.
10 Refer to Stoplamp Switch Replacement. — —

Is the replacement complete? Go to Step 15

Inspect circuit 140 for an open.
11 Refer to General Electrical Diagnosis Procedures. — —
Did you find and correct the condition? Go to Step 15
Inspect circuit 17 for an open.
12 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 15 Go to Step 13
Inspect the PCM pins, the connector terminals, and the
13 wiring for corrosion or shorting together. —
Did you find the condition? Go to Step 15 Go to Step 14
Replace the PCM.
14 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 15
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• With the engine OFF, the ignition switch is in the
15 —
RUN position.
• Depress the brake pedal.
• The scan tool TCC Brake Switch status must
indicate Closed (12 volts) for 2 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0719. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-360 Automatic Transmission - 4L80-E
DTC P0722 Output Speed Sensor Circuit Low Input (Diesel Only)
Circuit Description
The speed sensor circuit consists of a magnetic
induction type sensor, which is the Output Shaft
Speed (OSS) Sensor, a Vehicle Speed Sensor (VSS)
Buffer Module, and wiring. Gear teeth pressed onto
the output shaft carrier assembly induce an
alternating voltage into the sensor. This signal
transmits to the VSS Buffer Module. The VSS Buffer
Module compensates for various final drive ratios.
The VSS Buffer Module also converts the AC OSS
Sensor signal into a 40 pulse per revolution (PPR)
5-vo lt DC square wave form signal on circuit 437 to
indicate transmission output speed.
When the Powertrain Control Module (PCM) detects
a low output speed when the vehicle has a high
engine speed in a drive gear range, then
DTC P0722 sets. DTC P0722 is a type B DTC.
Transmission/Transaxle
201054
Conditions for Setting the DTC
. No MAP DTCs P0106, P0107 or P0108.
• No TFP Val. Position Sw. DTC P1810.
• The APP Angle is greater than 10%.
• The engine torque must be 108-642 N.m
(80-475 lb ft).
• Engine speed is greater than 475 RPM for
7 seconds.
• The engine speed is less than 3800 RPM.
• The A/T ISS Sensor speed is greater than
1500 RPM.
• The transmission is not in Park or Neutral.
• System voltage is 9.0-16.0 volts.
• The OSS Sensor speed is less than 200 RPM
for at least 3 seconds.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-361
Action Taken When the DTC Sets • 4WD vehicles use an in-line harness connector
• The PCM Illuminates the Malfunction Indicator between the OSS Sensor harness and the
Lamp (MIL). transfer case extension harness.
• The PCM commands maximum line pressure. • When diagnosing for an intermittent short or
open, massage the wiring harness while
• The PCM freezes shift adapts. watching the test equipment for a change. It
• The PCM defaults to the calculated output may be necessary to drive the vehicle.
speed value using the Input Shaft Speed • Inspect the Speed Sensor wiring for contact
Sensor values. with sharp metal edges.
• DTC P0722 is stored in PCM history.
Test Description
Conditions for Clearing the MIL/DTC The numbers below refer to the step numbers on the
• The PCM turns OFF the MIL after three diagnostic table.
consecutive trips without a failure reported. 2. This step verifies the fault condition.
• A scan tool can clear the DTC from the PCM 3. This step tests sensor integrity.
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up 9. This step verifies power and ground to the
cycles without a failure reported. VSS Buffer Module.
• The PCM cancels the DTC default actions 15. This step verifies the PCM input controlled by
when the fault no longer exists and the ignition the Speed Buffer.
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Inspect the wiring at the PCM, the A/T OSS
and the VSS Buffer Module connectors, and all
other circuit connecting points for the following
conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
7-362 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0722 Output Speed Sensor Circuit Low Input (Diesel Only)
Step Action Value(8) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
1 Check performed? — OBD System
Go to Step 2 Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2 3. Record the DTC Freeze Frame and Failure Records —
and DTCs, then clear the DTC.
4. Raise the drive wheels and support the axle
assembly.
5. Start the engine and place the transmission in
D1 range.
Cannot verify
6. Gradually increase the wheel speed. fault. Exit the
Does the Transmission OSS increase with the drive DTC table and go
wheel speed? to Diagnostic Aids Go to Step 3
1. Turn the ignition OFF.
2. Disconnect the OSS Sensor connector from the
OSS Sensor.
3. Connect a J 39200 DMM on AC Voltage scale
between terminals A and B at the OSS Sensor. 2.0 volts AC at
3
4. Start the engine, and place the transmission in 2000 RPM
D1 range
5. With the wheels turning, slowly accelerate to
2000 engine RPM.
Is the voltage greater than the specified value? Go to Step 4 Go to Step 18
1. Reconnect the OSS Sensor connector to the
OSS Sensor.
2. Disconnect the VSS Buffer harness from the
VSS Buffer.
3. Using the J 39200 DMM measure the voltage
between terminals 7 and 12 of the Speed Buffer 2.0 volts AC at
4
Harness Connector. 2000 RPM
4. Start the engine, and place the transmission in D1.
5. With the wheels turning, slowly accelerate engine
speed to 2000 RPM.
Is the voltage greater than the specified value? Go to Step 7 Go to Step 5
1. Inspect circuit 821 for an open.
2. Inspect circuit 822 for an open.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 16 Go to Step 6
1. Inspect circuit 821 for a short to ground.
2. Inspect circuit 822 for a short to ground.
6 3. Inspect circuits 821 and 822 for a short together. —
Refer to General Electrical Diagnosis Procedures. Refer to
Did you find the condition? Go to Step 16 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L80-E 7-363
DTC P0722 Output Speed Sensor Circuit Low Input (Diesel Only) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition to the OFF position.
2. Measure the voltage between terminal 9 of the
VSS Buffer connector and a good ground with the
7 J 39200 DMM on DC volts. 10.5 volts DC
3. Turn the ignition to the RUN position.
Is the voltage greater than the specified value? Go to Step 9 Go to Step 8
Inspect the ignition feed circuit 39 for high resistance or Go to Step 21
an open.
8 — —
Refer to General Electrical Diagnosis Procedures.
Did you find and correct the condition?
With the key to the RUN position, measure the voltage
9 between terminals 8 and 9 of the VSS Buffer connector. 10.5 volts DC
Is the voltage greater than the specified value? Go to Step 11 Go to Step 10
Inspect the VSS Buffer Module ground circuit 451 for high
resistance or an open.
10 — —
Refer to General Electrical Diagnosis Procedures.
Was the condition found and corrected? Go to Step 21
With the connector off of the Speed Buffer and the key in
the RUN position, measure the voltage between
terminal 13 of the VSS Buffer Harness Connector and a 4.8-5.2 volts
11
good ground. DC
Is the voltage within the specified value? Go to Step 15 Go to Step 12
Is the voltage in Step 11 greater than the specified
12 5.2 volts DC
voltage? Go to Step 14 Go to Step 13
Inspect circuit 437 for continuity or a short to ground.
13 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 21 Go to Step 17
Inspect circuit 437 for a short to power.
14 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 21 Go to Step 17
1. Reconnect the VSS Buffer Harness Connector to the
Speed Buffer Module.
2. With the J 39200 DMM set on DC volts and on a
good ground, back probe terminal 13 of the
VSS Buffer Module. 1.5-3.5 volts
15
DC
3. Start the engine, and place the transmission in D1.
4. With the wheels turning, slowly accelerate the engine
speed to 2000 RPM.
Is the voltage within the specified values? Go to Step 17 Go to Step 19
1. Repair circuit 821.
2. Repair circuit 822.
16 — ■—
Refer to Wiring Repairs.
Did you correct the condition? Go to Step 21
Inspect the PCM for faulty or intermittent connections. Go to Step 21 Go to Step 20
17 —
Did you find the condition?
Replace the OSS Sensor. Refer to Speed Sensor
18 Replacement in On-Vehicle Service. — —
Is the replacement complete? Go to Step 21
Replace the VSS Buffer Module. Refer to Buffer Module
19 Replacement. — —
Is the replacement complete? Go to Step 21
7-364 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0722 Output Speed Sensor Circuit Low Input (Diesel Only) (cont’d)
Step Action Value(s) Yes No
Replace the PCM.
20 Refer to PCM Replacement/Programming. —
Is the replacement complete? Go to Step 21
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
21 • Drive the vehicle under steady acceleration above —
10% APP.
• The PCM must see an output speed greater than
500 RPM for 1 second.
Begin the
4. Select Specific DTC. Enter DTC P0722. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0723 Output Speed Sensor Circuit Intermittent (Diesel Only)
Circuit Description
The speed sensor circuit consists of a magnetic
induction type sensor, which is the Output Shaft
Speed (OSS) Sensor, a Vehicle Speed Sensor (VSS)
Buffer Module, and wiring. Gear teeth pressed onto
the output shaft carrier assembly induce an
alternating voltage into the sensor. This signal
transmits to the VSS Buffer Module. The VSS Buffer
Module compensates for various final drive ratios.
The VSS Buffer Module also converts the alternating
current (AC) OSS signal into a 40 pulse per
revolution (PPR) 5 -vo lt DC square wave form signal
on circuit 437 to indicate transmission output speed.
If the PCM detects an unrealistically large change in
the Output Shaft Speed (OSS) Sensor reading, then
DTC P0723 sets. DTC P0723 is a type B DTC.
Automatic Transmission - 4L80-E 7-365
201054
Conditions for Setting the DTC
• No TFP Val. Position Sw. DTC P1810.
. No 4WD Low DTC P1875.
• No TFP Val. Position Sw. change for greater
than 6 seconds.
• The engine must be running more than
475 RPM for at least 7 seconds.
• System voltage is 9.0-16.0 volts.
• The vehicle is not in 4 Wheel Drive Low.
• No 4WD Low Switch status change for
2 seconds.
• The OSS RPM decrease is greater than
1000 RPM while in a Drive gear for at least
3.5 seconds.
7-366 Automatic Transmission - 4L80-E Transmission/Transaxle
Action Taken When the DTC Sets • It may be necessary to drive the vehicle.
• The PCM illuminates the Malfunction Indicator • When diagnosing for an intermittent short or
Lamp (MIL). open, massage the wiring harness while
• The PCM commands maximum line pressure. watching the test equipment for a change.
• The PCM freezes shift adapts.
Test Description
• The PCM defaults to the calculated output
speed value using the ISS Sensor values. The numbers below refer to the step numbers on the
diagnostic table.
• DTC P0723 is stored in PCM history.
2. This step verifies the fault condition.
Conditions for Clearing the MIL/DTC 4. This step verifies the OSS Sensor and
• The PCM turns OFF the MIL after three circuit output to the VSS Buffer Module.
consecutive trips without a failure reported.
7. This step tests the voltage supply to the
• A scan tool can clear the DTC from the PCM VSS Buffer Module.
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up 9. This step tests the integrity of the ground
cycles without a failure reported. circuit.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Inspect the wiring at the PCM, the A/T OSS,
the VSS Buffer Module connectors and all other
circuit connecting points for the following
conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
Transmission/Transaxle Automatic Transmission - 4L80-E 7-367
DTC P0723 Output Speed Sensor Circuit Intermittent (Diesel Only)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
2 1000 RPM
then clear the DTC.
4. Raise the drive wheels and support the axle
assembly.
5. Start the engine and place the transmission in
D3 range.
6. With the Drive wheels rotating, slowly accelerate to
2000 RPM and hold. No fault verified
Does the Transmission OSS drop or fluctuate more than at this time. Go
the specified value? Go to Step 3 to Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the OSS Sensor connector from the
OSS Sensor.
3. Connect a J 39200 DMM on AC Voltage scale
between terminals A and B on the OSS Sensor.
3 —
4. Start the engine.
5. Place the transmission in D3 range.
6. With the wheels rotating, slowly accelerate to
2000 engine RPM and hold.
Does the voltage drop or fluctuate at 2000 RPM? Go to Step 17 Go to Step 4
1. Turn the ignition OFF.
2. Reconnect the OSS Sensor harness to the sensor.
3. Disconnect the VSS Buffer Module harness
connector from the component.
4. Turn the ignition to the RUN position.
5. Set the J 39200 DMM on AC volts.
Greater than
4 6. Connect the J 39200 DMM between terminals 7 and 2.0 volts AC
12 of the VSS Buffer Module harness connector.
7. Start the engine.
8. Place the transmission in D3 range.
9. With the wheels rotating, slowly accelerate to
2000 engine RPM and hold steady.
Does the voltage drop or fluctuate at 2000 RPM? Go to Step 5 Go to Step 7
Inspect circuit 821 and circuit 822 for an intermittent open.
5 Refer to General Electrical Diagnosis Procedures. —

Did you find the condition? Go to Step 12 Go to Step 6

7-368 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0723 Output Speed Sensor Circuit Intermittent (Diesel Only) (cont’d)
Step Action Value(s) Yes No
Inspect circuit 821 and circuit 822 for an intermittent short
together or a short to ground. Refer to General Electrical
6 Diagnosis Procedures. — —
Did you find the condition? Go to Step 12
1. With the engine OFF, turn the ignition switch to the
RUN position.
7 2. Select DC volts, and measure ignition voltage at 10.5 volts DC
terminal 9 of the VSS Buffer Module harness.
Is the voltage greater than the specified value? Go to Step 9 Go to Step 8
Repair the intermittent open or high resistance in circuit 39.
8 Refer to Wiring Repairs. — —
Is the repair complete? Go to Step 21
1. Connect the J 39200 DMM between terminals 8 and
9 of the VSS Buffer Module harness connector. Set
9 the J 39200 DMM on DC volts. 10.5 volts DC
2. Turn the ignition to the Run position.
Is the voltage greater than the specified value? Go to Step 11 Go to Step 10
Repair the open or high resistance in circuit 451 (ground).
10 Refer to Wiring Repairs. — —
Is the repair complete? Go to Step 21
1. With the engine OFF, turn the ignition to the RUN
position.
4.8-5.2 volts
11 2. Using the J 39200 DMM, measure the voltage at the
DC
VSS Buffer connector terminal 13
Is the voltage steady and within the specified value? Go to Step 13 Go to Step 14
Repair the short in circuit 821 and circuit 822.
12 Refer to Wiring Repairs. — —
Did you correct the condition? Go to Step 21
1. Turn the ignition to the OFF position.
2. Reconnect the VSS Buffer Module harness to the
VSS Buffer Module.
3. Set the J 39200 DMM on the DC volts scale.
4. Back probe terminal 13 of the VSS Buffer Harness
connector with the J 39200 DMM. 1.5-3.5 volts
13
DC
5. Start the engine.
6. Place the transmission in a D3 range.
7. With the wheels rotating, slowly accelerate the
engine to 2000 RPM and hold.
Is the voltage reading steady within the specified value? Go to Step 19 Go to Step 18
Is the voltage from step 11 greater than the
14 5.2 Volts DC
specified value? Go to Step 15 Go to Step 16
Inspect for a short to power in circuit 437. Refer to
15 General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 21 Go to Step 20
Inspect circuit 437 for continuity or short to ground. Go to Step 21 Go to Step 19
16 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition?
Transmission/Transaxle Automatic Transmission - 4L80-E 7-369
DTC P0723 Output Speed Sensor Circuit Intermittent (Diesel Only) (cont’d)
Step Action Value(s) Yes No
Replace the OSS Sensor.
Refer to Speed Sensor Replacement, in On-Vehicle
17 — —
Service.
Is the replacement complete? Go to Step 21
Replace the VSS Buffer Module.
18 — —
Is the replacement complete? Go to Step 21
Inspect the PCM terminals and connector for improper
19 tension or corrosion. —
Did you find the condition? Go to Step 21 Go to Step 20
Replace the PCM.
20 Refer to PCM Repiacement/Programming. — —
Is the replacement complete? Go to Step 19
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
21 • Drive the vehicle in D3. —
• The PCM must see a Transmission OSS greater
than 500 RPM and no change greater than
450 RPM for 1 second.
Begin the
4. Select Specific DTC. Enter DTC P0723. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-370 Automatic Transmission - 4L80-E
DTC P0724 Brake Switch Circuit High Input (Gas)
Circuit Description
The TCC/Stoplamp Switch indicates the brake pedal
status. The normally closed brake switch supplies a
B+ signal on circuit 420 to the Vehicle Control
Module (VCM). The signal voltage circuit opens
when the brakes are applied.
If the VCM detects a closed TCC/Stoplamp switch
during decelerations, then DTC P0724 sets.
DTC P0724 is a type D DTC.
Conditions for Setting the DTC
. No OSS DTC P0502.
• The VCM detects a closed TCC/Stoplamp
Switch/circuit (12 volts) for 2 seconds during
decelerations.
• The following sequence of events occurs
10 consecutive times:
1. The vehicle speed is greater than
32 km/h (20 mph) for 6 seconds.
2. Then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds.
3. Then the vehicle speed is less than
8 km/h (5 mph).
Action Taken When the DTC Sets
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• DTC P0724 is stored in VCM history.
Transmission/Transaxle
201444
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the
TCC/Stoplamp Switch connector and all other
circuit connecting points for the following
conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-371
• Ask about the customer’s driving habits and Test Description
any unusual driving conditions he or she might The numbers below refer to the step numbers on the
have, such as stop and go traffic or diagnostic table.
expressway driving.
3. This step isolates the TCC/Stoplamp switch as
• Inspect the brake switch for proper mounting a source for setting the DTC.
and adjustment.
• Inspect for the most current calibration ID and
the latest bulletins.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.

DTC P0724 Brake Switch Circuit High Input (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. The Clear Info function will erase the
stored Failure Records from the VCM.
2 3. Record the DTC Failure Records. —
4. Select TCC Brake Switch on the scan tool.
5. Do not apply the brake pedal.
6. With the brake pedal not applied, note the TCC
brake switch status.
7. Apply the brake pedal.
Did the TCC/Brake Switch status change from Closed Go to
to Open? Diagnostic Aids Go to Step 3
1. Turn the ignition switch to the OFF position.
2. Disconnect the TCC/Stoplamp switch connector from
the brake switch.
3 —
3. Turn the key to the RUN position.
Did the TCC/Brake Switch status change from Closed
to Open? Go to Step 4 Go to Step 5
Replace the Stoplamp Switch.
4 Refer to Stoplamp Switch Replacement. — —
Is the replacement complete? Go to Step 7
Inspect circuit 420 for a short to B+. Refer to General
5 Electrical Diagnosis Procedures. —
Did you find a short to B+ condition? Go to Step 7 Go to Step 6
7-372 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0724 Brake Switch Circuit High Input (Gas) (cont’d)
Step Action Value(s) Yes No
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
6 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 7
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
7 3. Operate the vehicle brake pedal so that for a total of —
2 consecutive times, the VCM sees the brake switch
Closed and then Open, for greater than two seconds. Begin the
Does the scan tool TCC Brake Switch status change from diagnosis again.
Closed to Open? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-373
DTC P0724 Brake Switch Circuit High Input (Diesel)

|Hot At All Times|

Power
Distribution B8 *s STOP/HA2 BA
Cell 10 ^
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Powertrain J" Stoplamp I
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Circuit Description
The normally open TCC/Stoplamp Switch indicates
brake pedal status to the Powertrain Control Module
(PCM). Applying the brake pedal closes the switch,
supplying voltage to the PCM. Releasing the brake
pedal interrupts voltage to the PCM.
If the PCM detects a closed TCC/Stoplamp Switch
(Stuck ON) during accelerations, then DTC P0724
sets. DTC P0724 is a type D DTC.
Conditions for Setting the DTC
. No OSS Sensor DTCs P0722 or P0723
• The PCM detects a closed TCC/Stoplamp
Switch or circuit, and the following sequence of
events occur eight consecutive times:
1. The vehicle speed is less than 8 km/h
(5 mph).
2. The vehicle speed is 8-32 km/h
(5-20 mph) for 3.1 seconds.
3. The vehicle speed is greater than
32 km/h (20 mph) for 7 seconds.
201051
• DTC P0724 has not passed.
• The TCC/Stoplamp Switch is closed for
900 seconds (15 minutes).
Action Taken When the DTC Sets
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• For TCC scheduling, the PCM disregards the
TCC/Stoplamp Switch state if the APP Sensor
is greater than 0.5% and the vehicle speed is
greater than 40 Km/h (25 mph).
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
7-374 Automatic Transmission - 4L80-E Transmission/Transaxle
Diagnostic Aids • Ask about the customer’s driving habits and
any unusual driving conditions he or she might
• Inspect the wiring at the PCM, the
have, such as stop and go traffic or
TCC/Stoplamp Switch connector and all other
expressway driving.
circuit connecting points for the following
conditions: • Inspect the brake switch for proper mounting
and adjustment.
- A bent terminal
• First diagnose and clear any engine DTCs that
- A backed out terminal are present. Then inspect for any transmission
- A damaged terminal DTCs that may have reset.
- Poor terminal tension Test Description
- A chafed wire The numbers below refer to the step numbers on the
- A broken wire inside the insulation diagnostic table.
- Moisture intrusion 2. This step isolates the TCC/Stoplamp Switch as
- Corrosion a source for setting the DTC.
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.

DTC P0724 Brake Switch Circuit High Input (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
2 stored Failure Records from the PCM. —
3. Record the DTC Failure Records, then clear
the DTC.
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the TCC Stoplamp Switch connector.
Did the scan tool TCC/Brake Switch status change from
Closed to Open? Go to Step 3 Go to Step 4
Replace the TCC/Stoplamp Switch.
3 Refer to TCC/Stoplamp Switch Replacement. — —
Is the replacement complete? Go to Step 6
Inspect circuit 17 for a short to B+.
4 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 6 Go to Step 5
Replace the PCM.
5 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 6
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
6 —
3. Select TCC Brake Switch on the scan tool, and
depress the brake pedal. Begin the
Does the TCC Brake Switch state change, when the pedal diagnosis again.
is depressed? System OK Go to Step 1
Transmission/Transaxle________________________ Automatic Transmission - 4L80-E 7-375
DTC P0730 Incorrect Gear Ratio (Gas)

O/D Interm. Lo
Fourth Overrun Roller FWD Direct Front Sprag Interm. Roller Rear
Range Gear 1-2 Sol 2-3 Sol Clutch Clutch Clutch Clutch Clutch Band Clutch Clutch Clutch Band
1st On Off — — H A — — * — H —
2nd Off Off — — H A — — H A O —
Overdrive
3rd Off On — — H A A — O A O —
4th On On A — O A A — O A O —
A = Applied
H = Holding
* = Holding but not effective
O = Overrunning_________

Circuit Description Action Taken When the DTC Sets

The Vehicle Control Module (VCM) calculates the
gear ratio based on the Automatic Transmission
Input Shaft Speed (A/T ISS) and Output Shaft Speed
(OSS) Sensor readings. The VCM compares the
known transmission gear ratio to the calculated ratio
for the selected gear ranges.
If the VCM detects an unknown transmission gear
ratio, then DTC P0730 sets. DTC P0730 is a
type D DTC.
Conditions for Setting the DTC
The following conditions are met for 10 seconds.
• No Manifold Absolute Pressure (MAP)
DTCs P0106, P0107, or P0108.
• No Throttle Position (TP) DTCs P0121, P0122,
or P0123.
• No OSS DTCs P0502 or PO503.
. No ATT ISS DTCs P0716 or P0717.
. No TFP Val. Position Sw. DTC P1810.
. No 4WD Low DTC P1875.
• The Vehicle Speed is greater than
7 km/h (4 mph).
• The TP Angle is greater than 15%.
• The TFT is greater than 20 *C (68 *F).
• 30 seconds must have elapsed since the last
gear range change.
• The engine torque is 110 N-m (80 lb ft) to the
following:
- 542 N.m (400 lb ft) 5.7L
- 677 N-m (500 lb ft) 7.4L
• The engine is running greater than 475 RPM
for 5 seconds.
• The Gear Ratio is one of the following:
- Greater than 2.50 or less than 2.42
- Greater than 1.50 or less than 1.44
- Greater than 1.03 or less than 0.25
- Greater than 2.12 or less than 2.04
• The VCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The VCM commands maximum line pressure.
• The VCM freezes shift adapts.
• DTC P0730 is stored in VCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• A false or incorrect A/T OSS or A/T ISS signal
can set DTC P0730.
• DTC P1870 detects an incorrect gear ratio in
fourth gear with TCC applied.
• Inspect for any improperly installed after-market
equipment.
• Sticking or contamination of shift valves may
cause intermittent incorrect gear ratios.
• Refer to the Shift Solenoid Valve State and
Gear Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
actual selected range. A faulty TFP Val.
Position Sw. could set DTC P1810.
4. This step tests for proper ratios in each
commanded gear state.
7-376 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0730 Incorrect Gear Ratio (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Is the procedure complete? Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. The Clear Info function will erase the
stored Failure Records from the VCM.
3 —
3. Record the DTC Failure Records.
4. Record the DTCs.
5. Start the engine.
6. Apply the parking brake, and select each Go to DTC P1810
transmission range: D1, D2, D3, D4, N, R, and P. TFP Val. Position
Does the scan tool TFP Switch A/B/C display match each Switch in this
selected gear range? (Refer to the Range Signal table). Go to Step 4 section
1. Drive the vehicle in D3 with greater than 15% TP.
2. Drive the vehicle above 7 mph for greater than
2 seconds in each specified gear range. Rev 2.04-2.12
3. Use the scan tool snapshot mode to record the 1st 2.42-2.50
4
transmission gear ratio for each commanded gear 2nd 1.44-1.50
range: Reverse, 1st, 2nd, and 3rd. 3rd 0.25-1.03
Are the commanded gear ratios within the values for each Refer to
specified gear range? Diagnostic Aids Go to Step 5
1. Connect the J 21867 Pressure Gauge to the
transmission line pressure tap.
2. Perform the line pressure test.
5 —
Refer to the Line Pressure Check Procedure.
Is the line pressure within specifications for each selected
gear range? Go to Step 6 Go to Step 8
1. Remove the transmission oil pan.
Go to
Refer to Changing the Fluid and Filter, in On-Vehicle
Transmission
6 Service. — Overhaul
2. Inspect the oil pan and the fluid for contamination. Procedure, in Unit
Did you find excessive contamination? Repair Go to Step 7
Inspect the transmission for the following problems: Go to
• Sticking shift valves Transmission
7 — Overhaul
• Stuck apply pistons
Procedure, in Unit
Did you find the condition? Go to Step 10 Repair
Transmission/Transaxle Automatic Transmission - 4L80-E 7-377
DTC P0730 Incorrect Gear Ratio (Gas) (cont’d)
Step Action Value(8) Yes No
Is the system line pressure low only in the specific gear Go to System
which indicated an incorrect gear ratio? Diagnosis Table;
8 —
Low Line
Go to Step 9 Pressure
Inspect for fluid pressure loss in the following areas:
• 1-2 SS Valve seal
• 2-3 SS Valve seal
• Valve body passages
9 — Go to
• Valve body gaskets
Transmission
• Band apply pistons and seals
Overhaul
• Clutch apply pistons and seals. Procedure, in Unit
Did you find the condition? Go to Step 10 Repair
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
10 • Key ON, the engine is running.
—
• Drive the vehicle in Reverse, 1st, 2nd, and
3rd gear.
• The VCM must see a valid gear ratio range
versus the commanded gear ratio.
Begin the
4. Select Specific DTC. Enter DTC P0730. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-378 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0730 Incorrect Gear Ratio (Diesel)

O/D Interm. Lo
Fourth Overrun Roller FWD Direct Front Sprag Interm. Roller Rear
Range Gear 1-2 Sol 2-3 Sol Clutch Clutch Clutch Clutch Clutch Band Clutch Clutch Clutch Band
1st On Off — — H A — — # — H —
2nd Off Off — — H A — — H A O —
Overdrive
3rd Off On — — H A A — O A O —
4th On On A — O A A — O A O —
A = Applied
H = Holding
* = Holding but not effective
O = Overrunning_________

Circuit Description Action Taken When the DTC Sets

The Powertrain Control Module (PCM) calculates a
ratio based on the Automatic Transmission Input
Shaft Speed (A/T ISS) Sensor and Output Shaft
Speed (OSS) Sensor readings. The PCM compares
the known transmission gear ratio to the calculated
ratio, for the selected gear range.
If the PCM detects an incorrect gear ratio, then
DTC P0730 sets. DTC P0730 is a type D DTC.
Conditions for Setting the DTC
The following conditions are met for 7 seconds.
. No MAP DTCs P0106, P0107, P0108.
. No An ISS Sensor DTCs P0716 or P0717.
. No OSS Sensor DTCs P0722 or P0723.
• No TFP Val. Position Sw. DTC P1810.
• No Four Wheel Drive Low DTC 1875.
• The Vehicle Speed is greater than
6.4 km/h (5 mph).
• The APP Angle is greater than 25%.
• The TFT is greater than 20 *C (68 *F).
• System voltage is 9.0-16.0 volts.
• 10 seconds must have elapsed since the last
gear range change.
• The engine speed is greater than 475 RPM for
at least 7 seconds.
• The engine speed is less than 3750 RPM.
• The engine torque is 100-642 N-m
(80-475 lb ft).
• The Gear Ratio is one of the following:
- Greater than 2.52 or less than 2.42
- Greater than 1.50 or less than 1.45
- Greater than 1.02 or less than 0.98
- Greater than 0.77 or less than 0.73
- Greater than 2.12 or less than 2.04
- Greater than 2.72 or less than 2.67
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0730 is stored in PCM history.
Conditions for Clearing the DTC
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Sticking or contaminated shift valves may cause
an undefined gear ratio.
• Refer to the Shift Solenoid Valve State and
Gear Ratio table.
• First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
DTCs that may have reset. If a DTC P0717
Input Speed Sensor Circuit No Signal and a
DTC P0730 are both present, diagnose
DTC P0717 first.
• DTC P1870 detects an incorrect gear ratio in
fourth gear with TCC applied.
• A faulty 4WD FRT axle switch circuit may cause
a DTC P0730 to set.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
actual selected range. A faulty TFP Val.
Position Sw. could set DTC P0730.
4. This step tests for proper ratios in each
commanded gear state.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-379
DTC P0730 Incorrect Gear Ratio (Diesel)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Is the procedure complete?
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
stored Failure Records from the PCM.
3 —
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTCs.
Refer to
4. Start the engine.
DTC P1810 TFP
5. Apply the parking brake, and select each Valve Position Sw
transmission range: D1, D2, D3, D4, N, R, and P. CKT Malfunction
Does the scan tool TFP Switch A/B/C display match each (Diesel), in this
selected gear range? (Refer to the Range Signal table). Go to Step 4 section
1. Drive the vehicle in Reverse and D4.
2. Hold the vehicle speed above 8 km/h (65 mph) for
greater than 2 seconds in the specified gear range. Rev-2.04-2.12
1st-2.52-2.42
4 3. Use the scan tool snapshot mode in order to record 2nd-1.45-1.50
the transmission gear ratio for each commanded 3rd-0.98-1.02
gear range: Reverse, 1st, 2nd, 3rd and 4th. 4th-0.73-0.77
Are the gear ratios within the parameters for each Refer to
specified gear range? Diagnostic Aids Go to Step 5
1. Connect the J 21867 Pressure Gauge to the
transmission line pressure tap.
2. Perform the Line Pressure Checking Procedure.
5 —
Refer to Line Pressure Check Procedure.
Is the line pressure within specifications for each selected
gear range? Go to Step 6 Go to Step 8
1. Remove the transmission oil pan.
Go to
Refer to Changing the Fluid and Filter, in On-Vehicle
Transmission
6 Service. — Overhaul
2. Inspect the oil pan and the fluid for contamination. Procedure, in Unit
Did you find excessive contamination? Repair. Go to Step 7
Inspect the transmission for the following problems: Go to
• Sticking shift valves Transmission
7 — Overhaul
• Stuck apply pistons
Procedure, in Unit
Did you find the condition? Go to Step 10 Repair.
7-380 Automatic Transmission - 4L80-E Transmission/!ransaxle
DTC P0730 Incorrect Gear Ratio (Diesel) (cont’d)
Step Action Value(s) Yes No
Js the system line pressure low only in the specific gear Go to System
which indicated an incorrect gear ratio? Diagnosis Table;
8 —
Low Line
Go to Step 9 Pressure
Inspect for fluid pressure loss in the following areas:
• 1-2 SS Valve seal
• 2-3 SS Valve seal
• Valve body passages
9 —
Go to
. Valve body gaskets
Transmission
• Band apply pistons and seals
Overhaul
• Clutch apply pistons and seals. Procedure, in Unit
Did you find the condition? Go to Step 10 Repair.
in order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Start, the engine. —
10
• Drive the vehicle in Reverse, 1st, 2nd, 3rd and
4th gear.
• The PCM must see a valid gear ratio versus the
commanded gear ratio for 7 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0730. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P0741 TCC System Stuck Off (Gas)
Automatic
Transmission
Circuit Description
Important: DTC P0741 inspects for high Torque
Converter Clutch (TCC) slip in 2nd and 3rd gear
only. The transmission must be in hot mode or
experiencing a wide open throttle maneuver in order
for the TCC to be commanded ON in 2nd and
3rd gear.
The Vehicle Control Module (VCM) energizes the
Torque Converter Clutch Pulse Width Modulated
Solenoid Valve (TCC PWM Sol. Valve) by grounding
circuit 418. This blocks the exhaust for TCC signal
fluid and allows filtered 2 -3 drive fluid to feed the
TCC signal circuit. When the vehicle’s operating
conditions are appropriate for TCC application, the
VCM begins the TCC duty cycle to approximately
30%. This allows TCC signal fluid pressure to move
the converter clutch shift valve into the apply position
and direct regulated apply fluid to the torque
converter. The VCM then increases (ramps) the duty
cycle to approximately 60%, where regulated apply
fluid pressure, applies the converter clutch. The
vehicle application determines the TCC apply rate.
Once the TCC applies, the duty cycle immediately
increases to approximately 70% to achieve full apply
pressure, in the regulated apply fluid circuit.
Automatic Transmission - 4L80-E 7-381
7 Vehicle
Control
, Module (VCM)
i >
1
|Hot In Run, BulbTest AndStart]
7 IP Fuse
Block
-►l/P Cluster
69046
The TCC PWM Sol. Valve is de-energized by the
VCM opening circuit 418. This action allows the TCC
signal fluid to exhaust through the solenoid and
blocks filtered 2 -3 drive fluid from entering the TCC
signal circuit. The loss of fluid pressure in the TCC
signal circuit releases the TCC.
If the VCM detects high TCC slip when the TCC is
commanded ON, then DTC P0741 sets. DTC P0741
is a type D DTC. For California emissions vehicles
DTC P0741 is a type B DTC.
Conditions for Setting the DTC
• No Throttle Position (TP) Sensor DTCs P0121,
P0122, or P0123.
. No OSS DTC P0502, or P0503.
• No A/T ISS Sensor DTCs P0716 or P0717.
. No TCC DTCs P0742 or P1860.
• No TFP Val. Position Sw. DTC P1810.
• The engine must be running greater than
475 RPM for at least 7 seconds.
• The gear ratio must indicate 2nd, 3rd, or
4th gear.
• The Throttle Position is 10-100%.
• The TFP Val. Position Sw. must be in D4, D3,
or D2 and has not changed in 5 seconds.
7-382 Automatic Transmission - 4L80-E
• Gear ratio is equal to 2nd, 3rd or 4th.
• The transmission fluid temperature (TFT) is
+20* to +150‘ C (68* to +302 *F).
• TCC duty cycle greater than 70%.
• The TCC Slip Speed is greater than 140 RPM,
for 3 seconds.
• All conditions must be met for a total of
5 occurrences.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) for California emissions vehicles.
• The VCM inhibits the TCC.
• The VCM increases line pressure.
• The VCM inhibits 4th gear.
• DTC P0741 is stored in VCM history.
Conditions for Clearing the DTC
1. For California emissions, the VCM turns OFF
the MIL after three consecutive trips without a
failure reported.
Transmission/Transaxle
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Residue or contamination may cause shift
valves to stick intermittently.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests for excessive TCC slip when
TCC is commanded on.
3. This step inspects for possible causes of no
TCC apply.

DTC P0741 TCC System Stuck Off (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
2 from the VCM. 140 RPM
2. Drive the vehicle in D3.
3. Record the data using snapshot mode.
Is the TCC slip speed snapshot data greater than the
specified value when the TCC Duty Cycle is commanded Go to
greater than 70% for greater than 3 seconds? Go to Step 3 Diagnostic Aids
Inspect the TCC PWM Sol. Valve for being mechanically
Stuck OFF.
3 —
Refer to Torque Converter Clutch Diagnosis.
Did you find the condition? Go to Step 5 Go to Step 4
Transmission/Transaxle Automatic Transmission - 4L80-E 7-383
DTC P0741 TCC System Stuck Off (Gas) (cont’d)
Step Action Value(s) Yes No
1. Inspect the TCC PWM sol. valve for a damaged
exhaust orifice.
2. Inspect for the converter regulated apply valve being
stuck in the off (release) position.
3. Inspect the converter clutch shift valve for a stuck
condition.
4 4. Inspect for a misaligned or damaged valve body — —

gasket.
5. Inspect for a restricted apply or release passage.
6. Inspect for the Torque Converter for being
mechanically stuck OFF.
7. Refer to system Diagnosis No TCC Apply.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Drive the vehicle in D3 with steady acceleration
5 and TP over 12%. —
• TCC duty cycle is greater than 70%.
• The VCM must see a TCC slip of less than
20 RPM for 3 seconds.
• Select Specific DTC.
Begin the
4. Enter DTC P0741. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-384 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0741 TCC System Stuck Off (Diesel)

r _ — _ _ —
Automatic ■JPowertrain
1
Transmission Control
J TCC PWM Module (PCM)
' Solenoid
1 Control l >
C5YC3
|Hot In Run, Bulb Test And Start)
SP101 IIP Fuse
TR A N S I Block

.8 BRN 418 Fuse 2 0

10 A
t

-►i/P Cluster
.35 PNK 1020

A2» C100

Circuit Description
Important: DTC P0741 inspects for high Torque
Converter Clutch (TCC) slip in 2nd and 3rd gear
only. The transmission must be in hot mode or
experiencing a wide open throttle maneuver in order
for the TCC to be commanded ON in 2nd and
3rd gear.
The Powertrain Control Module (PCM) energizes the
Torque Converter Clutch Pulse Width Modulated
Solenoid Valve (TCC PWM Sol. Valve) by grounding
circuit 418. This blocks the exhaust for TCC signal
fluid and allows filtered 2 -3 drive fluid to feed the
TCC signal circuit. When the vehicle’s operating
conditions are appropriate for TCC application, the
PCM begins the TCC duty cycle to approximately
30%. This allows TCC signal fluid pressure to move
the converter clutch shift valve into the apply position
and direct regulated apply fluid to the torque
converter. The PCM then increases (ramps) the duty
cycle to approximately 60%, where regulated apply
fluid pressure, applies the converter clutch. The
vehicle application determines the TCC apply rate.
Once the TCC applies, the duty cycle immediately
increases to approximately 70% to achieve full apply
pressure, in the regulated apply fluid circuit.
201056
The TCC PWM Sol. Valve is de-energized by the
PCM opening circuit 418. This action allows the
TCC signal fluid to exhaust through the solenoid
and blocks filtered 2 -3 drive fluid from entering the
TCC signal circuit. The loss of fluid pressure in the
TCC signal circuit releases the TCC.
If the PCM detects high TCC slip when the TCC is
commanded ON, then DTC P0741 sets. DTC P0741
is a type B DTC.
Conditions for Setting the DTC
1. No A/T ISS Sensor DTCs P0716 or P0717.
2. No OSS DTC P0722, or P0723.
3. No TCC Stuck ON DTC P0742.
4. No TCC PWM Sol. Valve DTC P1860.
5. No TFP Val. Position Sw. DTC P1810.
6. The TCC PWM Soi. Valve is commanded in
2nd or 3rd gear for greater than 0.6 seconds.
7. The engine must be running greater than
475 RPM for at least 7 seconds.
8. The TCC Duty Cycle is greater than 70% for
1.0 second.
9. The gear ratio must indicate 2nd or 3rd gear.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-385
10. The APP Angle is 15-99% . Diagnostic Aids
11. The TFP Val. Position Sw. must be in D4, D3, • Residue or contamination may cause shift
or D2 and has not changed state within valves to stick intermittently.
3 seconds.
• First diagnose and clear any engine DTCs or
12. The TFT must be 20 to +15CTC (68-302 *F).
TP Sensor codes that are present. Then
13. The TCC slip speed is greater than 175 RPM inspect for any transmission DTCs that may
for 4 seconds.
have reset.
14. All conditions must be met for a total of
4 occurrences. Test Description
Action Taken When the DTC Sets The numbers below refer to the step numbers on the
• The PCM illuminates the Malfunction Indicator diagnostic table.
Lamp (MIL). 2. This step tests for excessive TCC slip when
• The PCM inhibits the TCC. TCC is commanded on.
• The PCM increases line pressure. 3. This step inspects for possible causes of no
• The PCM inhibits 4th gear. TCC apply.
• DTC P0741 is stored in PCM history.
Conditions for Clearing the DTC
• For California emissions, the PCM turns OFF
the MIL after three consecutive trips without a
failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.

DTC P0741 TCC System Stuck Off (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2. Record the Freeze Frame and Failure records, then
2 175 RPM
clear the DTC.
3. Drive the vehicle in D3 with the TCC
commanded ON.
4. Record the data using snapshot mode.
Is the TCC slip speed greater than the specified value
when the TCC PWM Sol. Valve is commanded ON Go to
(greater than 70%)? Go to Step 3 Diagnostic Aids
Inspect the TCC PWM Sol. Valve for being mechanically
stuck OFF.
3 Refer to Torque Converter Clutch Diagnosis in this —
section.
Did you find the condition? Go to Step 5 Go to Step 4
7-386 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0741 TCC System Stuck Off (Diesel) (cont’d)

Step Action Value(s) Yes No
1. Inspect for the Torque Converter for being
mechanically stuck OFF
2. Inspect the TCC for a damaged exhaust orifice.
3. Inspect the Torque Converter for possible damage.
4. inspect for the converter apply shift valve for being
4 stuck in the off (release) position. — —
5. Inspect for a misaligned or damaged valve body
gasket.
6. Inspect for a restricted apply or release passage.
7. Refer to On-Vehicle Service.
Did you find and correct the condition? Go to Step 5
in order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
5 • Drive the vehicle in D4 with steady acceleration —
and the APP Angle over 15%.
• The PCM must see a TCC slip of less than
175 RPM for 3 seconds.
Begin the
4. Select Specific DTC . Enter DTC P0741. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-387

DTC P0742 Torque Converter Clutch System Stuck On (Gas)

Automatic Vehicle
Transmission Control
,Module(VCM)

A
| Hot In Run, Bulb Test And Start]

7 IP Fuse
Block

-►l/P Cluster

69046

Circuit Description Conditions for Setting the DTC

The Vehicle Control Module (VCM) energizes the
Torque Converter Clutch Pulse Width Modulated
Solenoid Valve (TCC PWM Sol. Valve) by grounding
circuit 418. This blocks the exhaust for TCC signal
fluid and allows filtered 2 -3 drive fluid to feed the
TCC signal circuit. When the vehicle’s operating
conditions are appropriate for TCC application, the
VCM begins the TCC duty cycle to approximately
30%. This allows TCC signal fluid pressure to move
the converter clutch shift valve into the apply position
and direct regulated apply fluid to the torque
converter. The VCM then increases (ramps) the duty
cycle to approximately 60%, where regulated apply
fluid pressure, applies the converter clutch. The
vehicle application determines the TCC apply rate.
Once the TCC applies, the duty cycle immediately
increases to approximately 70% to achieve full apply
pressure, in the regulated apply fluid circuit.
The TCC PWM Sol. Valve is de-energized by the
VCM opening circuit 418. This action allows the TCC
signal fluid to exhaust through the solenoid and
blocks filtered 2 -3 drive fluid from entering the TCC
signal circuit. The loss of fluid pressure in the
TCC signal circuit releases the TCC.
If the VCM detects low TCC slip when the TCC is
commanded OFF, then DTC P0742 sets. DTC P0742
is a type D DTC. For California emissions vehicles
DTC P0742 is a type B DTC.
• No Manifold Absolute Air (MAP) Sensor
DTCs P0106, P0107, or P0108.
• No Throttle Position (TP) Sensor DTCs P0121,
P0122 or P0123.
. No OSS DTCs P0502 or P0503.
. No A/T ISS Sensor DTCs P0716 or P0717.
. No TCC DTCs P0741 or P1860.
• No TFP Valve Position Sw. DTC P1810.
• Engine speed is 900-4700 RPM.
• The engine torque must be 75 N-m (60 lb ft) to:
- 375 N-m (300 lb ft) 4.3L
- 500 N-m (400 lb ft) 5.7L
- 625 N-m (500 lb ft) 7.4L
• No TFP Val. Position Sw. change within
5.0 seconds.
• The TFP Val. Position Sw. must indicate D4, for
at least 10 seconds.
• The commanded gear must be 2nd, 3rd, or 4th.
• Engine speed is 900-4700 RPM.
• The Throttle Position is 12%.-100%.
• Vehicle speed is 7-75 MPH.
• The TCC slip speed must be -10 to +10 RPM
for at least 4.0 seconds.
• All conditions met for 7 occurrences
(7.4L, 4 occurrences).
7-388 Automatic Transmission - 4L80-E Transmission/Transaxle

Action Taken When the DTC Sets Diagnostic Aids

• The VCM illuminates the Malfunction Indicator
Lamp (MIL) for California emissions vehicles.
• The VCM commands maximum line pressure.
• The VCM freezes shift adapts.
• DTC P0742 is stored in VCM history.
Conditions for Clearing the DTC
• The VCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
• If the TCC is mechanically stuck On with the
parking brake applied and any gear range
selected, the TCC fluid mechanically applies the
TCC. TCC fluid mechanically applying the TCC
can cause an engine stall.
• A stuck TP Sensor may set a DTC P0742.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the mechanical state of the
TCC. When the VCM commands the TCC
solenoid OFF, the slip speed should increase.

DTC P0742 Torque Converter Clutch System Stuck On (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will 0.2-0.9 volts at
2 erase the stored Freeze Frame and/or the Failure 0% to 4.5 volts
Records from the VCM. at 100%
3. Record the DTC Freeze Frame and Failure Records.
4. Select scan tool TP Angle and TP Sensor.
5. Apply the accelerator pedal. Go to
Are the TP Sensor values within the specified range? Go to Step 3 Diagnostic Aids
Drive the vehicle in the D4 drive range in fourth gear
under steady acceleration with a TP Sensor angle greater
3 than 12%. —
Does the scan tool display a TCC Slip Speed of -10 to Go to
+10 RPM while the displayed TCC Duty Cycle is 0%? Go to Step 4 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L80-E 7-389
DTC P0742 Torque Converter Clutch System Stuck On (Gas) (cont’d)
Step Action Value(s) Yes No
The TCC is mechanically stuck ON.
Perform the following inspections:
1. Inspect the exhaust orifice in the TCC PWM Sol.
Valve for any clogging.
2. Inspect the converter clutch apply valve for the
possibility of being stuck in the apply position.
4 — —
3. Inspect the valve body gasket for misalignment or
damage.
4. Inspect for a restricted release or apply passage.
5. Inspect for restricted transmission cooler line.
6. Refer to TCC Stuck On.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
5 • Operate the vehicle in D4 with the TCC Duty —
Cycle 0% and throttle above 12%.
• Ensure that the TCC slip speed is greater than
175 RPM for 6 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0742. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-390 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0742 Torque Converter Clutch System Stuck On (Diesel)

Automatic Powertrain
Transmission ! Control
tcc pwm Module (PCM)
Solenoid 1 *
Control
is&
I &

A
[Hot InRun, BulbTest AndStart1
P101 ---------'' IP Fuse
TRANS | BlOCk

-►l/P Cluster

Circuit Description
The Powertrain Control Module (PCM) energizes the
Torque Converter Clutch Pulse Width Modulated
Solenoid Valve (TCC PWM Sol. Valve) by grounding
circuit 418. This blocks the exhaust for TCC signal
fluid and allows filtered 2 -3 drive fluid to feed the
TCC signal circuit. When the vehicle’s operating
conditions are appropriate for TCC application, the
PCM begins the TCC duty cycle to approximately
30%. This allows TCC signal fluid pressure to move
the converter clutch shift valve into the apply position
and direct regulated apply fluid to the torque
converter. The PCM then increases (ramps) the duty
cycle to approximately 60%, where regulated apply
fluid pressure, applies the converter clutch. The
vehicle application determines the TCC apply rate.
Once the TCC applies, the duty cycle immediately
increases to approximately 70% to achieve full apply
pressure, in the regulated apply fluid circuit.
The TCC PWM Sol. Valve is de-energized by the
PCM opening circuit 418. This action allows the TCC
signal fluid to exhaust through the solenoid and
blocks filtered 2 -3 drive fluid from entering the TCC
signal circuit. The loss of fluid pressure in the
TCC signal circuit releases the TCC.
If the PCM detects low TCC slip when the TCC is
commanded OFF, then DTC P0742 sets. DTC P0742
is a type B DTC.
201056
Conditions for Setting the DTC
The following conditions occur once per TCC cycle
two consecutive times:
. No MAP Sensor DTCs P0106, P0107,
or P0108
. No ArT ISS Sensor DTCs P0716 or P0717
• No TCC stuck on DTC P0741.
. No OSS Sensor DTCs P0722 or P0723.
• No TFP Valve Position Sw. DTC P1810
. No TCC PWM Sol. Valve DTC P1860.
• The engine speed is less than 3300 RPM.
• The engine must run more than 475 RPM for
greater than 7 seconds.
• System voltage is 9.0-16.0 volts.
• The engine torque must be 176-645 N-m
(130-475 lb ft).
• The gear range is D4.
• The commanded gear must be 2nd, 3rd, or 4th.
• The APP Angle must be greater than 15%.
• The TCC slip speed must be -10 to +10 RPM
for at least 3 seconds.
• All conditions met for 4 occurrences.
Transmission/Transaxle
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0742 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the
PCM history. The PCM clears the DTC from
the PCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Automatic Transmission - 4L80-E 7-391
Diagnostic Aids
• If the TCC is mechanically stuck On with the
parking brake applied and any gear range
selected, the TCC fluid mechanically applies the
TCC. TCC fluid mechanically applying the TCC
can cause an engine stall.
• A stuck or skewed APP Sensor may set
DTC P0742.
• First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
DTCs that may have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the mechanical state of the
TCC. When the PCM commands the TCC
solenoid OFF, the slip speed should increase.

DTC P0742 Torque Converter Clutch System Stuck On (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the 0% at Closed
scan tool in order to record the Freeze Frame and Throttle
Failure Records for reference. Using the Clear Info
2 100% at
function will erase the stored Freeze Frame and
Failure Records from the PCM. Wide Open
Throttle (WOT)
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
4. Verify the APP Sensor Operation. Use the scan tool. Refer to
Are the APP Angle values within the specified range? Go to Step 3 Diagnostic Aids
Drive the vehicle in the D4 drive range in fourth gear
under steady acceleration with a APP Angle greater
3 than 15%. —
Does the scan tool display a TCC Slip Speed of -10 to Go to
+10 RPM while the displayed TCC Duty Cycle is 0%? Go to Step 4 Diagnostic Aids
7-392 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0742 Torque Converter Clutch System Stuck On (Diesel) (cont’d)
Step Action Value(s) Yes No
The TCC is mechanically stuck ON.
Perform the following inspections:
1. Inspect the exhaust orifice in the TCC PWM Sol.
Valve for any clogging.
2. Inspect the converter clutch shift valve for the
possibility of being stuck in the apply position.
4 — —
3. Inspect the valve body gasket for misalignment or
damage.
4. Inspect for a restricted release or apply passage.
5. Inspect for a restricted transmission cooler line.
6. Refer to system diagnosis TCC Stuck On.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
5 • Operate the vehicle in D4 with the TCC duty —
cycle 0% and APP Angle above 15%.
• Ensure that the TCC slip speed is 175-1500 RPM
for 3 seconds.
Begin the
4. Select Specific DTC. Enter DTC P0742. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-393

DTC P0748 Pressure Control Solenoid CKT Electrical (Gas)

Automatic
Transmission

Pressure
Control Solenoid
(PCSOL) Valve

10.5LTBLU 1229 05PPL 1228

L ___ _
D

0.5 LT BLU/WHT 1229

0.5
RED/BLK 1228
16.A._ _rA C3
r ———
___
____
_
■* Vehicle
PCSOL PCSOL
ValveLow ValveHigh * Control
1Module (VCM)
1 A
40805
Circuit Description Action Taken When the DTC Sets
The Pressure Control Solenoid Valve (PC Sol. Valve) • The VCM does not illum inate the Malfunction
is a Vehicle Control Module (VCM) controlled device Indicator Lamp (MIL).
that regulates the transmission line pressure. The • The VCM disables the PC Sol. Valve, defaulting
VCM compares Throttle Position (TP) Sensor the transmission to maximum line pressure.
voltage, engine RPM, and other inputs in order to
• The VCM freezes shift adapts.
determine the appropriate line pressure for a given
load. The VCM regulates the pressure by applying a • DTC P0748 is stored in VCM history.
varying amperage to the PC Sol. Valve. The applied
amperage varies from 0.1 amps for maximum line Conditions for Clearing the DTC
pressure to 1.1 amps for minimum line pressure. The • A scan tool can clear the DTC from the VCM
VCM monitors the applied amperage. history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
If the VCM detects a PC duty cycle that exceeds
cycles without a failure reported.
95% or less than 1.9%, then DTC P0748 sets.
DTC P0748 is a type D DTC. • The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
Conditions for Setting the DTC is OFF long enough in order to power down
• The system voltage is greater than 10 volts at the VCM.
-4 0 ‘ C TFT or 12.5 volts at 150* C TFT.
• The engine must be running more than
475 RPM for at least 7 seconds.
• The PC duty cycle exceeds 95% or is less
than 1.9%.
• All conditions met for 200 milliseconds
(0.2 seconds).
7-394 Automatic Transmission - 4L80-E Transmission/Transaxle

Diagnostic Aids Test Description

• Inspect the wiring at the VCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 2. This step tests the ability of the VCM to
- A bent terminal command the PC Sol. Valve.
- A backed out terminal 3. This step tests the PC Sol. Valve and the A/T
wiring harness Assy, for incorrect resistance.
- A damaged terminal
6. This step tests the PC Sol. Valve and the
- Poor terminal tension internal wiring harness for a short to ground.
- A chafed wire 8. When performing this step refer to Product
- A broken wire inside the insulation Service Bulletin #9474L80E-07 for PC Sol.
- Moisture intrusion Valve Application.
9. This step tests the entire PC Sol. Valve circuit
- Corrosion
up to the VCM for continuity.
• When diagnosing for an intermittent short or
10. This step tests for a short to ground in circuits
open, massage the wiring harness while
1228 and 1229, of the engine harness.
watching the test equipment for a change.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Inspect for improperly wired after-market
equipment.

DTC P0748 Pressure Control Solenoid CKT Electrical (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the
scan tool in order to record the Failure Records
for reference. The Clear Info function will erase
the stored Failure Records from the VCM.
2 3. Record the DTC Failure Records. 0.16 amp
4. With the transmission in Park, start the engine.
5. Using the transmission output control function on the
scan tool, apply 0.1-1.0 amps while observing the
PC Ref. Current and the PC Act. Current.
Is the PC Act. Current reading always within the specified
value of the PC Ref. Current? (Refer to the Line Pressure Go to
specification table.) Diagnostic Aids Go to Step 3
Transmission/Transaxle Automatic Transmission - 4L80-E 7-395
DTC P0748 Pressure Control Solenoid CKT Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector
3 3—7Q
(Automatic Transmission Connector End View).
4. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit, measure the resistance
between terminals C and D.
Is the resistance within the specified value? Go to Step 6 Go to Step 4
1. Disconnect the Automatic Transmission Wiring
Harness Assembly at the PC Sol. Valve.
4 3-7£3
2. Measure the resistance of the PC Sol. Valve.
Is the resistance within the specified range? Go to Step 5 Go to Step 8
Replace the Automatic Transmission Wiring Harness
Assembly.
5 Refer to Internal Wiring Harness Replacement, in — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
Measure the resistance from terminal C on the jumper
6 harness, to the transmission case. 9£2
Is the resistance less than the specified value? Go to Step 7 Go to Step 9
1. Inspect the Automatic Transmission Wiring Harness
Assembly (circuits 1228 and 1229) for a short to
ground condition.
Refer to General Electrical Diagnosis Procedures.
7 —
2. Replace the harness if necessary.
Refer to Internal Wiring Harness Replacement, in
On-Vehicle Service.
Did you find a shorted condition? Go to Step 16 Go to Step 8
Replace the PC Sol. Valve.
Refer to Pressure Regulator Valve Replacement, in
On-Vehicle Service.
8 — —
Important: Refer to the Test Description for information on
component replacement.
Is the replacement complete? Go to Step 16
1. Disconnect the J 39775 Jumper Harness from
the transmission side of the 20-way connector
(Automatic Transmission Connector End View).
2. Reconnect the transmission 20-way connector.
9 3-7£2
3. Disconnect the C3 (grey/clear) VCM connector.
4. Measure the resistance between terminals C3-6
and C3-16.
Is the resistance within the specified range? Go to Step 10 Go to Step 11
1. Connect the J 39200 DMM to terminal C3-6 and to a
good ground.
10 7£2
2. Measure the resistance.
Is the resistance greater than the specified value? Go to Step 15 Go to Step 14
7-396 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0748 Pressure Control Solenoid CKT Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
Is the resistance in step 9 greater than the
11 70
specified value? Go to Step 12 Go to Step 13
1. Inspect circuit 1228 for an open.
Refer to General Electrical Diagnosis Procedures.
2. Inspect circuit 1229 for an open.
12 Refer to General Electrical Diagnosis Procedures. — —
3. Repair the circuits if necessary. Refer to Wiring
Repairs.
Did you find and repair the open condition? Go to Step 16
Inspect circuits 1228 and 1229 for a shorted together
condition.
13 — —
Refer to General Electrical Diagnosis Procedures.
Did you find and repair the condition? Go to Step 16
1. Inspect circuit 1228 for a short to ground.
Refer to General Electrical Diagnosis Procedures.
2. Inspect circuit 1229 for a short to ground.
14 Refer to General Electrical Diagnosis Procedures. — —
3. Repair the circuits if necessary. Refer to Wiring
Repairs.
Did you find and repair the shorted to ground condition? Go to Step 16
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
15 VCM Replacement/Programming (7.4L) with KS — —
Calibration Prom.
Is the replacement complete? Go to Step 13
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
16 3. Ensure the following conditions are met: —
• The engine is running.
• The PC Duty Cycle is 2-95%. Begin the
4. Select Specific DTC. Enter DTC P0748. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-397

DTC P0748 Pressure Control Solenoid CKT Electrical (Diesel)

Automatic
Transmission
r ————————— ——n

'' Powertrain
PCSOL PCSOL.
ValveLow ValveHigh 1Control
I Module (PCM)
I 1 >
L.

40783
Circuit Description Action Taken When the DTC Sets
The Pressure Control Solenoid Valve (PC Sol. Valve) • The PCM does not illuminate the Malfunction
is a Powertrain Control Module (PCM) controlled Indicator Lamp (MIL).
device that regulates the transmission line pressure. • The PCM disables the PC Sol. Valve, defaulting
The PCM compares the Accelerator Pedal Position the transmission to maximum line pressure.
(APP) Sensor voltage, engine RPM, and other inputs
• The PCM freezes shift adapts.
in order to determine the appropriate line pressure
for a given load. The PCM regulates the pressure by • DTC P0748 is stored in PCM history.
applying a varying amperage to the PC Sol. Valve.
The applied amperage varies from 0.1 amps for
Conditions for Clearing the DTC
maximum line pressure to 1.1 amps for minimum line • A scan tool can clear the DTC from the PCM
pressure. The PCM monitors the circuit amperage. history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
If the PCM detects a PC duty cycle that exceeds
cycles without a failure reported.
95% or is less than 1.9%, then DTC P0748 sets.
DTC P0748 is a type D DTC. • The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
Conditions for Setting the DTC is OFF long enough in order to power down
• The system voltage is 9.0-16.0 volts. the PCM.
• The engine must be running greater than
475 RPM for at least 7 seconds.
• The PC duty cycle exceeds 95% or is less
than 1.9%.
• All conditions met for 200 milliseconds
(0.2 seconds).
7-398 Automatic Transmission - 4L80-E Transmission/Transaxle

Diagnostic Aids Test Description

• Inspect the wiring at the PCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 2. This step tests the ability of the PCM to
- A bent terminal command the PC Sol. Valve.
- A backed out terminal 3. This step tests the PC Sol. Valve and the
- A damaged terminal Automatic Transmission Wiring Harness
Assembly for incorrect resistance.
- Poor terminal tension
6. This step tests the PC Sol. valve and the
- A chafed wire
internal wiring harness for a short to ground.
- A broken wire inside the insulation
8. When performing this step refer to Product
- Moisture intrusion Service Bulletin #9474L80E-07 for PC Sol.
- Corrosion Valve Application.
• When diagnosing for an intermittent short or 9. This step tests the entire PC Sol. valve circuit
open, massage the wiring harness while for proper resistance.
watching the test equipment for a change. 10. This step tests for a short to ground in circuits
• Inspect for any transmission DTCs that may 1228 and 1229 of the engine harness.
have reset.

DTC P0748 Pressure Control Solenoid CKT Electrical (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Failure Records for
reference. Using the Clear Info function will erase the
stored Failure Records from the PCM.
2 3. Record the DTC Failure Records, then clear 0.16
the DTC.
4. With the engine running, put the transmission
in Park.
5. Using the scan tool transmission output control
function, apply 0.1-1.0 amps while observing the
PC Ref. Current and the PC Act. Current.
Is the PC Act. Current reading always within the specified Go to
value of the PC Ref. Current? Diagnostic Aids Go to Step 3
TransmissiorVTransaxle Automatic Transmission - 4L80-E 7-399
DTC P0748 Pressure Control Solenoid CKT Electrical (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way conne ctor
(additional DTC’s may set).
3. Install the J 39775 Jumper Harness on th<►
3 transmission side of the 20-way connector 3 -7 ft
4. Measure the resistance between terminals C and D.
Use the J 39200 DMM and the J 35616-A Connector
Test Adapter Kit.
Is the resistance within the specified value? Go to Step 6 Go to Step 4
1. Disconnect the Automatic Transmission W ring
Harness Assembly at the PC Sol. Valve.
4 3 -7 ft
2. Measure the resistance of the PC Sol. Va ve.
Is the resistance within the specified range? Go to Step 5 Go to Step 8
Replace the Automatic Transmission Wiring Har less
Assembly.
5 Refer to Internal Wiring Harness Replacement, i n — —
On-vehicle Service.
Is the replacement complete? Go to Step 16
Measure the resistance from terminal C in the ji imper
6 harness to the transmission case. 9ft
Is the resistance less than the specified value? Go to Step 7 Go to Step 9
1. Inspect the Automatic Transmission Wiring Harness
Assembly (circuits 1228 and 1229), for a : short to
ground condition.
7 Refer to Electrical Diagnosis. —
2. Replace the harness if necessary.
Did you find the condition? Go to Step 16 Go to Step 8
Important: Refer to test description Step 8 for i nformation
on component replacement.
Replace the PC Sol. Valve.
8 — —
Refer to Pressure Regulator Replacement, in 0 l-Vehicle
Service.
Is the replacement complete? Go to Step 16
1. Disconnect the J 39775 Jumper Harness 1rom the
transmission side of the 20-way connectoi .
2. Reconnect the transmission 20-way connc ctor.
9 3. Disconnect the C1 (32 Pin/Brown) PCM c innector. 3-7 ft
4. Measure the resistance between terminals C1-C7
and C1-C15.
Is the resistance within the specified range? Go to Step 10 Go to Step 11
Measure the resistance between terminal C1-C1 and a
10 good ground. 7 ft
Is the resistance greater than the specified vain 3? Go to Step 15 Go to Step 14
7-400 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P0748 Pressure Control Solenoid CKT Electrical (Diesel) (cont’d)

Step Action Value(s) Yes No
Is the resistance in step 9 greater than the
11 7Q
specified value? Go to Step 12 Go to Step 13
1. Inspect circuit 1228 and circuit 1229 for an open.
Refer to General Electrical Diagnosis Procedures.
12 2. Repair the circuits if necessary. —
Refer to Wiring Repairs.
Did you find and repair the open condition? Go to Step 16 Go to Step 12
1. Inspect circuits 1228 and 1229 for a shorted
condition. Refer to General Electrical Diagnosis
Procedures.
13 — —
2. Repair the circuits if necessary. Refer to Wiring
Repairs.
Did you find and repair a shorted condition? Go to Step 16
Inspect circuit 1228 and circuit 1229 for a short to ground.
14 Refer to General Electrical Diagnosis Procedures. — —
Did you find and repair the shorted to ground condition? Go to Step 16
Replace the PCM.
15 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
16 3. Ensure the following conditions are met: —
• The engine is running.
• The PC sol. duty cycle is 2-95%.
Begin the
4. Select Specific DTC. Enter DTC P0748. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow action on the 1-2 and the 3-4 shift
valves. The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve
(2-3 SS Valve) in order to allow four different shifting
combinations.
When the Vehicle Control Module (VCM) detects a
2 -2 -3 -3 gear ratio or a 1 -1 -4 -4 gear ratio, then
DTC P0751 sets. DTC P0751 is a type D DTC.
For California emissions vehicles DTC P0751 is
a type B DTC.
Conditions for Setting the DTC
. No MAF DTCs P0101, P0102 or P0103.
• No MAP Sensor DTCs P0106, P0107,
or P0108.
. No TP Sensor DTCs P0121, P0122, or P0123.
• No OSS DTCs P0502 or P0503.
. No An ISS Sensor DTCs P0716 or P0717.
. No 1-2 SS Valve DTC P0753.
. No 2-3 SS Valve DTC P0758.
• No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
. No 4WD Low DTC P1875.
Automatic Transmission - 4L80-E 7-401
40795
• Not in 4WD Low.
• The engine must be running more than
475 RPM for 7 seconds.
• The vehicle speed is greater than
3 km/h (2.0 mph).
• The TP Sensor is greater than 10%.
• The Engine Torque is 80 N.m (60 lb ft) to
the following:
- 540 N.m (400 lb ft) 5.7L
- 675 N.m (500 lb ft) 7.4L.
• The transmission fluid temperature (TFT) is
greater than 20 * C (68 * F).
• All the above conditions are met and one of the
following conditions occur:
Stuck Off (after two occurrences)
- When the 1-2 SS Valve is stuck OFF, first
gear is commanded and the ratio is equal to
second gear for greater than 2.0 seconds,
and 4th gear is commanded with the TCC
locked and the ratio equals 3rd gear for
greater than 3 seconds.
Stuck On (after five occurrences)
- When the 1-2 SS Valve is stuck ON, second
gear is commanded and the ratio is equal to
first gear for greater than 3 seconds.
7-402 Automatic Transmission - 4L80-E Transmission/Transaxle

Action Taken When the DTC Sets Diagnostic Aids

• The VCM illuminates the Malfunction Indicator • Verify that the transmission meets the
Lamp (MIL) for California emissions vehicles. specifications in the Shift Speed table.
• The VCM commands maximum line pressure. • Other internal transmission failures can cause
• The VCM inhibits 3 -2 downshifts above more than one shift to occur.
25 mph. • First diagnose and clear any engine DTCs or
• The VCM freezes shift adapts. TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
• DTC P0751 is stored in VCM history.
have reset.
Conditions for Clearing the DTC • Refer to Shift Solenoid Valve State and Gear
• For California emissions only, the VCM turns Ratio table.
OFF the MIL after three consecutive trips
Test Description
without a failure reported.
The numbers below refer to the step numbers on the
• A scan tool can clear the DTC from the VCM
diagnostic table.
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up 2. This step tests the function of the TFP Val.
cycles without a failure reported. Position Sw.
• The VCM cancels the DTC default actions 3. This step tests whether the scan tool
when the fault no longer exists and the ignition commanded all the shifts, or whether all the
is OFF long enough in order to power down shift solenoids responded correctly but all of the
the VCM. correct shifts did not occur.

DTC P0751 1-2 Shift Solenoid Valve Performance (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
2 —
3. Record the DTC Freeze Frame and Failure Records.
4. Select TFP Sw. A/B/C on the scan tool.
5. With the engine operating, apply the brake pedal,
and select each transmission range: D1, D2, D3, D4,
N, R, and P. Go to DTC P1810
Does each selected transmission range match the scan TFP Valve
tool TFP Switch display? (Refer to the Range Position Sw CKT
Signal table.) Go to Step 3 Malfunction (Gas)
1. Raise and support the drive axle assembly.
2. Start the engine.
3. With the transmission in D4 range, use the scan tool
3 in order to command first, second, third, and fourth —
gears while accelerating the vehicle.
Did you detect a 2-2-3-3 or 1-1-4-4 shift pattern only? Go to
(You may need to road test the vehicle). Go to Step 4 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L80-E 7-403
DTC P0751 1-2 Shift Solenoid Valve Performance (Gas) (cont’d)
Step Action Value(s) Yes No
1. Inspect the shift solenoid/hydraulic circuit for a
1-2 SS Valve internal malfunction.
2. Inspect the shift solenoid/hydraulic circuit for a stuck
1-2 shift valve.
4 3. Inspect the shift solenoid/hydraulic circuit for
—
damaged seals on one or both of the shift solenoids.
The shift solenoids can leak oil into the second gear
clutch pack.
4. Refer to the diagnosis tables. Go to
Did you find and correct the condition? Go to Step 5 Diagnostic Aids
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions
(If traffic and road conditions permit):
5 • Accelerate the vehicle with the TP angle greater —

than 12% up to 55 mph.

• The VCM must see the proper ratio for each
commanded gear for greater than one second in
D1, D2, D3, and D4 (wait for the TCC Lock-up in
4th gear). Begin the
4. Select Specific DTC. Enter DTC P0751. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-404 Automatic Transmission - 4L80-E
Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow action on the 1-2 and the 3-4 shift
valves. The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve
(2-3 SS Valve) to allow four different shifting
combinations.
When the Powertrain Control Module (PCM) detects
2 -2 -3 -3 or a 1 -1 -4 -4 gear ratio, then DTC P0751
sets. DTC P0751 is a type B DTC.
Conditions for Setting the DTC
. No MAP Sensor DTCs P0106, P0107,
or P0108
• No OSS DTCs P0722 or P0723
. No AfT ISS Sensor DTCs P0716 or P0717
. No TCC DTCs P0741 or P0742.
. No 1-2 SS Valve DTC P0753
. No 2-3 SS Valve DTC P0758
. No TFP Val. Position Sw. DTC P1810
• No Four Wheel Drive DTC P1875.
• No Four Wheel Drive DTC P1875
• The engine must be running greater than
475 RPM for at least 7 seconds.
Transmission/Transaxle
40795
• The vehicle speed is greater than
3.2 km/h (2 mph).
• The APP Angle is greater than 10%.
• System voltage is 9.0-16.0 volts.
• The Engine Torque is 108-644 N-m
(80-475 lb ft).
• Vehicle is not in four wheel drive low.
• The transmission fluid temperature is
greater than 20 * C (68 * F) and less than
130*C (255 *F).
• The engine speed is less than 3750 RPM.
• Not in Four Wheel Drive Low.
• All the above conditions are met and one of the
following conditions occur:
Stuck Off (for two occurrences)
• First gear is commanded and the gear ratio
is equal to second gear for greater than
1.5 seconds.
• Fourth gear is commanded (with TCC locked)
and the gear ratio equals third gear for
greater than 3 seconds.
Stuck On (for five occurrences)
Second gear is commanded and the gear
ratio equals first gear for greater than
2.2 seconds.
Transmission/Transaxle
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0751 is stored in the PCM history.
Conditions for Clearing the MILVDTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Automatic Transmission - 4L80-E 7-405
Diagnostic Aids
• Verify that the transmission meets the
specifications in the Shift Speed table.
• Other internal transmission failures may cause
similar shift patterns.
• First diagnose and clear any engine DTCs or
APP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to Shift Solenoid Valve State and Gear
Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the function of the TFP Val.
Position Sw.
3. This step tests whether the scan tool
commanded all the shifts, or whether all the
shift solenoids responded correctly but all the
shifts did not occur.

DTC P0751 1-2 Shift Solenoid Valve Performance (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTC.
4. Select TFP Sw. A/B/C on the scan tool.
5. With the engine operating, apply the brake pedal,
and select each transmission range: D1, D2, D3, D4, Go to DTC P1810
N, R, and P. TFP Valve
Does each selected transmission range match the scan Position Sw CKT
tool TFP Switch A/B/C display? (Refer to the Range Malfunction
Signal table.) Go to Step 3 (Diesel)
1. Raise and support the drive axle assembly.
2. Start the engine.
3. With the transmission in D4 range, use the scan tool
3 in order to command first, second, third, and fourth —
gears while accelerating the vehicle.
Did you detect a 2-2-3-3 or 1-1 -4-4 shift pattern only? Go to
(You may need to road test the vehicle). Go to Step 4 Diagnostic Aids
7-406 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0751 1-2 Shift Solenoid Valve Performance (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Inspect the shift solenoid/hydraulic circuit for a
1-2 SS valve internal malfunction.
2. Inspect the shift solenoid/hydraulic circuit for
4 damaged seals on one or both of the shift solenoids. — —
3. Refer to the diagnosis tables.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions
(If traffic and road conditions permit):
• Place the transmission in D4.
5 —

• Hold the throttle greater than 10%, and accelerate

to 55 mph.
• The PCM must see the proper gear ratio for each
commanded gear for greater than one second in
D1, D2, D3, and D4 with TCC locked.
Begin the
4. Select Specific DTC. Enter DTC P0751. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-407

DTC P0753 1-2 Shift Solenoid Circuit Electrical (Gas)

| Hot In Run, BulbTast And Start |

■; IP Fuse
| Block Transmission
TRANS
Fuse20 l
10A

X 0.5 PNK 1020

0.35 PNK 1020
SP101 0.35 PNK 1020
A 2 i:C100
FuseBlock
Details
Cell 11

0.5 LT GRN 1222

C2
Vehicle J" 1-2SS I
Control Valve
I
Control
Module | I
> (VCM) i I

20 1 4 5 1

Circuit Description • The above conditions are met, and either of

The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls the following conditions occur for 4.3 out of
the fluid flow action on the 1-2 and the 3-4 shift 5 seconds.
valves. The 1-2 SS Valve is a normally-open exhaust - The VCM commands the solenoid on, and
valve that is used with the 2-3 Shift Solenoid Valve the voltage input remains high (B+).
(2-3 SS Valve) to allow for four different shifting - The VCM commands the solenoid off and
combinations. The 1-2 SS Valve attaches to the the voltage input remains low.
control valve body within the transmission. The
ignition voltage goes directly to the 1-2 SS Valve. Action Taken When the DTC Sets
The VCM controls the 1-2 SS Valve by providing the • The VCM illuminates the Malfunction Indicator
ground path through circuit 1222. Lamp (MIL) for California Emissions vehicles.
When the Vehicle Control Module (VCM) detects a • The VCM commands maximum line pressure.
continuous open or short in the 1-2 SS Valve
• The VCM freezes shift adapts.
circuit or the 1-2 SS Valve, then DTC P0753 sets.
DTC P0753 is a type D DTC. For California • The VCM inhibits 3 -2 downshifts above
emissions vehicles, DTC P0753 is a type A DTC. 25 MPH.
• DTC P0753 is stored in VCM history.
Conditions for Setting the DTC
• The system voltage is 10-16 volts. Conditions for Clearing the DTC
• The ignition is ON. 1. For California emissions, the VCM turns OFF
the MIL after three consecutive trips without a
• The engine runs more than 475 RPM for
failure reported.
greater than 7 seconds.
7-408 Automatic Transmission - 4L80-E
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
Transmission/Transaxle
• An open ignition feed on circuit 1020 can cause
multiple DTCs to set.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to Shift Solenoid Valve State and Gear
Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests the function of the 1-2 SS Valve
and the internal wiring harness.
5. This step tests the power to the 1-2 SS Valve
from the ignition through the fuse.
7. This step tests the ability of the VCM and the
wiring to control the ground circuit.
10. This step measures the resistance of the
Automatic Transmission Wiring Harness
Assembly and the 1-2 SS Valve.

DTC P0753 1-2 Shift Solenoid Circuit Electrical (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check(5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
2 tool in order to record the Freeze Frame and Failure —
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
3. Record the DTC Freeze Frame and Failure Records.
Were DTCs P0753, P0758, or P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the trans. fuse.
2. If you find an open fuse, inspect the following
components for a short to ground:
• Circuit 1020
• The 3 solenoids
3 • The Automatic Transmission Wiring Harness —
Assembly
3. Repair the circuit, the solenoid, and replace the
harness if necessary.
Refer to Wiring Repairs.
Did you find and correct the condition? Go to Step 16 Go to Step 4
Transmission/Transaxle Automatic Transmission - 4L80-E 7-409
DTC P0753 1-2 Shift Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
Using the transmission output control function on the scan
tool, command the 1-2 SS Valve ON and OFF three times
4 while listening to the bottom of the transmission pan —
(use a stethoscope if needed). Go to
Does the solenoid click when commanded? Diagnostic Aids Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
Additional DTCs will set.
3. Install the J 39775 Jumper Harness on the engine
harness connector.
5 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a 12 volt test lamp from the J 39775
Jumper Harness cavity E to ground.
Is the test lamp on? Go to Step 7 Go to Step 6
Repair the open or high resistance in ignition feed
circuit 1020 to the 1-2 SS Valve.
6 — —
Refer to Wiring Repairs.
Did you find and correct the condition? Go to Step 16
1. Install a 12 volt test lamp between cavities E and A
of the J 39775 Jumper Harness.
2. Using the transmission output control function,
7 command the 1-2 SS Valve On and Off three times. —
Does the test lamp illuminate when you command the shift
solenoid ON and turn off when you command the shift
solenoid OFF? Go to Step 10 Go to Step 8
Inspect circuit 1222 for an open or short to ground.
8 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 9
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or —
9 —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 16
1. Turn the ignition OFF.
2. Install J 39775 Jumper Harness on the transmission
20-way connector (Automatic Transmission Connector
End View).
10 19-310
3. With the J 39200 DMM and the J 35616-A Connector
Test Adapter K it, measure the resistance between
terminals A and E.
Is the resistance within the specified values? Go to Step 12 Go to Step 11
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 1-2 SS Valve.
11 19-310
2. Measure the resistance of the 1-2 SS Valve.
Is the resistance within the specified values? Go to Step 14 Go to Step 15
7-410 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0753 1-2 Shift Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
1. Measure the resistance between terminal A and
ground. Use the J 39200 DMM.
12 2. Measure the resistance between terminal E and 250kQ
ground. Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 1-2 SS Valve.
13 2. Measure the resistance from the component’s 250kO
terminals to ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Replace the Automatic Transmission Wiring Harness
Assembly.
14 Refer to Internal Wiring Harness Replacement, in — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
Replace the 1-2 SS Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters 1-2 Sol. and 1-2 Sol.
Open/Shorted to GRND, and 1-2 Sol. Shorted to
Voltage.
16 4. Operate the vehicle under the following conditions: —
• The VCM commands the 1-2 SS Valve On, and
the 1-2 Sol. Shorted to Voltage is No.
• The VCM commands the 1-2 SS Valve OFF, and
the 1-2 Sol. Open/Shorted to GRND is No.
• All conditions met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P0753. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-411

DTC P0753 1-2 Shift Solenoid Circuit Electrical (Diesel)

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Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and the 3-4 shift
valves. The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve
(2-3 SS Valve) in order to allow four different shifting
combinations. The 1-2 SS Valve attaches to the
control valve body within the transmission. The
ignition voltage goes directly to the 1-2 SS Valve.
The Powertrain Control Module (PCM) controls the
1-2 SS Valve by providing the ground path through
circuit 1222.
If the PCM detects a continuous open or short to
ground in the 1-2 SS Valve circuit or the 1-2 SS
Valve, then DTC P0753 sets. DTC P0753 is a
type A DTC.
Conditions for Setting the DTC
• The engine runs more than 475 RPM for
greater than 7 seconds.
• System voltage is 9.0-16.0 volts.
40790
• The PCM detects either of the following fail
conditions for 4.3 out of 5 seconds.
- The PCM commands the Solenoid ON and
the voltage input remains high (B+).
- The PCM commands the Solenoid OFF and
the voltage input remains low (0 volts).
Action Taken When the DTC Sets
• The PGM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0753 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
7-412 Automatic Transmission - 4L80-E Transmission/Transaxle
D iagnostic Aids • First diagnose and clear any engine DTCs that
• Inspect the wiring at the PCM, the transmission are present. Then inspect for any transmission
DTCs that may have reset.
connector and all other connecting points for
the following conditions: • Refer to Shift Solenoid Valve State and Gear
Ratio table.
- A bent terminal
- A backed out terminal Test Description
- A damaged terminal The numbers below refer to the step numbers on the
diagnostic table.
- Poor terminal tension
4. This step tests the function of the 1-2 SS Valve
- A chafed wire and the Automatic Transmission Wiring Harness
- A broken wire inside the insulation Assembly.
- Moisture intrusion 5. This step tests the power to the 1-2 SS Valve
- Corrosion from the ignition through the fuse.
• When diagnosing for an intermittent short or 7. This step tests the ability of the PCM and the
open, massage the wiring harness while wiring to control the ground circuit.
watching the test equipment for a change. 10. This step measures the resistance of the
Automatic Transmission Wiring Harness
• An open ignition feed circuit can cause multiple
Assembly and the 1-2 SS Valve.
DTCs to set.

DTC P0753 1-2 S hift Solenoid C ircuit E lectrical (D iesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
2 Records for reference. Using the Clear Info function —
will erase the stored Freeze Frame and Failure
Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
Are DTCs P0758 or P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the trans. fuse for an open.
2. If you found an open fuse, inspect circuit 1020, the
3 three solenoids, and the Automatic Transmission
—
Wiring Harness Assembly for a short to ground.
Refer to General Electrical Diagnosis Procedures.
Did you find and correct the condition? Go to Step 16 Go to Step 5
Using the transmission output control function on the scan
tool, command the 1-2 SS Valve ON and OFF three times
4 while listening to the bottom of the transmission pan —
(use a stethoscope if needed). Go to
Does the solenoid click when commanded? Diagnostic Aids Go to Step 5
Transmission/Transaxle Automatic Transmission - 4L80-E 7-413
DTC P0753 1-2 S hift Solenoid C ircuit Electrical (D iesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
5 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from the J 39775 Jumper
Harness cavity E to a good ground.
Is the test lamp on? Go to Step 7 Go to Step 6
Repair the open or short to ground in ignition feed
circuit 1020 to the 1-2 SS Valve.
6 — —
Refer to Wiring Repairs.
Did you find and correct the condition? Go to Step 16
1. Install a test lamp between cavity E and cavity A of
the J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the 1-2 SS Valve On and Off
7 —
three times.
Does the test lamp illuminate when the shift solenoid is
commanded ON and turn off when the shift solenoid is
commanded OFF? Go to Step 10 Go to Step 8
Inspect circuit 1222 for an open or short to ground.
8 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 9
Replace the PCM.
9 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 16
1. Turn the ignition OFF.
2. Install J 39775 Jumper Harness on the transmission
20-way connector.
10 3. With the J 39200 DMM and the J 35616-A Connector 19-31 £2
Test Adapter Kit, measure the resistance between
terminals A and E.
Is the resistance within the specified value? Go to Step 12 Go to Step 11
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 1-2 SS Valve.
11 19-31Q
2. Measure the resistance of the 1-2 SS Valve.
Is the resistance within the specified values? Go to Step 14 Go to Step 15
Measure the resistance between terminals A and E and a
12 good ground. 250k£2 Go to
Are both reading greater than the specified value? Diagnostic Aids Go to Step 13
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 1-2 SS Valve.
13 2. Measure the resistance from the 1-2 SS Valve 250kQ
terminals to a good ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
7-414 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0753 1-2 Shift Solenoid Circuit Electrical (Diesel) (cont’d)
Step Action Value(s) Yes No
Replace the Automatic Transmission Wiring Harness
Assembly.
14 Refer to Internal Wiring Harness Replacement, in —
On-vehicle Service.
Is the replacement complete? Go to Step 16
Replace the 1-2 SS Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters 1-2 Sol. and 1-2 Sol.
Open/Shorted to GRND, and 1-2 Sol. Shorted to
Voltage.
16 4. Operate the vehicle under the following conditions: —
• The PCM commands the 1-2 SS Valve On, and
the 1-2 Sol. Shorted to Voltage is No.
• The PCM commands the 1-2 SS Valve OFF, and
the 1-2 Sol. Open/Shorted to GRND is No.
• All conditions are met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P0753. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
fluid flow acting on the 2-3 shift valves. The 2-3 SS
Valve is a normally-open exhaust valve used with the
1-2 Shift Solenoid Valve (1-2 SS Valve) in order to
allow for four different shift combinations.
If the VCM detects a non first gear ratio while first
gear is commanded, or a first gear ratio while
fourth gear is commanded, then DTC P0756 sets.
DTC P0756 is a type D DTC. For California
emissions vehicles, DTC P0756 is a type A DTC.
Conditions for Setting the DTC
• No MAF DTCs P0101, P0102 or P0103.
. No MAP DTCs P0106, P0107, or P0108.
. No TP Sensor DTCs P0121, P0122, or P0123.
• No OSS DTCs P0502 or P0503.
. No A/T ISS Sensor DTCs P0716 or P0717.
• No 4WD Low DTC P1875.
• Not in 4WD Low.
• No TFP Val. Position Sw. DTC P1810.
• No shift solenoid electrical DTCs P0753
or P0758.
• The engine runs more than 475 RPM for
7 seconds.
• The vehicle speed is greater than
4 km/h (2.0 mph).
Automatic Transmission - 4L80-E 7-415
40795
• The TP Angle is greater than 8%.
• The transmission fluid temperature (TFT) is
greater than 20 *C (68 °F).
• The engine torque is 108 N-m (80 lb ft) to the
following:
- 540 N-m (400 lb ft) 5.7L
- 675 N-m (500 lb ft) 7.4L.
• All of the above conditions are met and either
of the two following conditions occur:
Stuck On (for 7 occurrences)
- When the 2-3 SS Valve is stuck on, the
commanded gear equals 1st and the ratio
equals 4th for greater than 2 seconds, and
the commanded gear equals 2nd and the
ratio equals 3rd for greater than 3 seconds.
Stuck Off (for 7 occurrences)
- When the 2-3 SS Valve is stuck off, the
commanded gear equals 3rd and the ratio
equals 2nd for greater than 4 seconds.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) for California emissions vehicles.
• The transmission immediately lands to
2nd gear.
• The VCM commands maximum line pressure.
• The VCM freezes shift adapts.
• DTC P0756 is stored in VCM history.
7-416 Automatic Transmission - 4L80-E
Conditions for Clearing the MIL7DTC
• For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Verify that the transmission meets the
specifications in the Shift Speed table.
• Other internal transmission failures may cause
more than one shift to occur.
Transmission/Transaxle
• The customer may complain of an engine
over-rev condition or neutral condition in
4th gear.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to Shift Solenoid Valve State and Gear
Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the function of the TFP Val.
Position Sw.
3. This step tests for a selected gear ratio versus
a ratio not obtainable under normal operating
conditions.

DTC P0756 2-3 Shift Solenoid Valve Performance (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
2 —
3. Record the DTC Freeze Frame and Failure Records.
4. Select TFP Sw. A/B/C on the scan tool.
5. With the engine running, apply the brake pedal and
select each transmission range: D1, D2, D3, D4, N,
R, and P. Go to DTC P1810
Does each selected transmission range match the scan TFP Valve
tool TFP Switch A/B/C display? (Refer to the Range Position Sw CKT
Signal table.) Go to Step 3 Malfunction (Gas)
1. Raise and support the drive axle assembly.
2. Start the engine.
3. With the transmission in the D4 range, use the scan
3 tool in order to command 1st, 2nd, 3rd, and —
4th gears while accelerating the vehicle.
Was 1st gear commanded and not achieved, or 4th gear
commanded and another gear occurred? (You may need Go to
to road test the vehicle). Go to Step 4 Diagnostic Aids
Transmission/Transaxle Automatic Transmission - 4L80-E 7-417
DTC P0756 2-3 Shift Solenoid Valve Performance (Gas) (cont’d)
Step Action Value(s) Yes No
1. Inspect the shift solenoid/hydraulic for an internal
malfunction at one or both of the shift solenoids.
2. Inspect the shift solenoid/hydraulic for damaged
4 seals on one or both of the shift solenoids. — —
3. Refer to the diagnosis tables.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions
only if traffic conditions permit:
5 • The VCM must see the proper gear ratio for each —

gear for greater than one second in D1, D2, D3,

and D4.
• Accelerate the vehicle with the TP angle greater
than 8% (4.3L, 12.5%) up to 55 mph. The TCC
must be locked in fourth gear. Begin the
4. Select Specific DTC. Enter DTC P0756. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-418 Automatic Transmission - 4L80-E
Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
fluid flow acting on the 2-3 shift valve. The 2-3 SS
Valve is a normally-open exhaust valve that is used
with the 1-2 Shift Solenoid Valve (1-2 SS Valve) to
allow four different shift combinations.
When the Powertrain Control Module (PCM) detects
a non first gear ratio while first gear is commanded
or a first gear ratio while fourth gear is commanded,
then DTC P0756 sets. DTC P0756 is a type A DTC.
Conditions for Setting the DTC
. No TFT Sensor DTCs P0712 or P0713
• No A/T ISS Sensor DTCs P0716 or P0717
. No OSS Sensor DTCs P0722 or P0723
• No shift solenoid electrical DTCs P0753
or P0758
• No TFP Val. Position Sw. DTC P1810
. No 4WD Lo DTC P1875
• System voltage is 9.0-16.0 volts.
• Not in 4WD Low
• The vehicle speed is greater than
3.2 km/h (2 mph).
• The APP angle is greater than 10%.
• The Transmission Fluid Temperature (TFT) is
2 0 *-1 3 0 ‘ C (6 8 ’ -2 6 6*F ).
Transmission/Transaxle
40795
• The engine torque is 100-644 N-m
(80-475 lb ft).
• The engine speed is 475-3750 RPM for at
least 7 seconds.
• All of the above conditions are met and either
of the two following conditions occur:
Stuck On (after 2 occurrences)
- First gear is commanded and the ratio
equals 4th gear for greater than
2.75 seconds.
- Second gear is commanded and the gear
ratio equals 3rd for greater than
2.75 seconds.
Stuck Off (after 7 Occurrences)
- Third gear is commanded and the gear ratio
equals 2nd for greater than 3.25 seconds..
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands 2nd gear.
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0756 is stored in PCM history.
TransmissiorVTransaxle
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Diagnostic Aids
• Verify that the transmission meets the
specifications in the Shift Speed table.
• Other internal transmission failures may cause
similar shift patterns.
Automatic Transmission - 4L80-E 7-419
• The customer may complain of an engine
over-rev condition or neutral condition in
4th gear.
• First diagnose and clear any engine DTCs or
APP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to Shift Solenoid Valve State and Gear
Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the function of the TFP Val.
Position Sw.
3. This step tests for a selected gear ratio versus
a ratio not obtainable under normal driving
conditions.

DTC P0756 2-3 Shift Solenoid Valve Performance (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTC.
4. Select TFP Sw. A/B/C on the scan tool.
5. With the engine running, apply the brake pedal and
select each transmission range: D1, D2, D3, D4, N, Go to DTC P1810
R, and P. TFP Valve
Does each selected transmission range match the scan Position Sw
tool TFP Switch A/B/C display? (Refer to the Range CKT Malfunction
Signal table.) Go to Step 3 (Diesel)
1. Raise and support the drive axle assembly.
2. Start the engine.
3. With the transmission in the D4 range, use the scan
3 tool in order to command 1st, 2nd, 3rd, and —

4th gears while accelerating the vehicle.

Was 1st gear commanded and not achieved, or 4th gear
commanded and another gear occurred? (You may need Go to
to road test the vehicle). Go to Step 4 Diagnostic Aids
7-420 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0756 2-3 Shift Solenoid Valve Performance (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Inspect the shift solenoid/hydraulic for an internal
malfunction at one or both of the shift solenoids.
2. Inspect the shift solenoid/hydraulic for damaged
4 seals on one or both of the shift solenoids. — —
3. Refer to the diagnosis tables.
Did you find and correct the condition? Go to Step 5
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions
only if traffic conditions permit:
5 • The PCM must see the proper gear ratio for each —

commanded gear for greater than one second in

D1, D2, D3, and D4 with TCC locked.
• Accelerate the vehicle with the TP greater than
10% to 55 mph.
Begin the
4. Select Specific DTC. Enter DTC P0756. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-421

DTC P0758 2-3 Shift Solenoid Circuit Electrical (Gas)

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Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
fluid acting on the 2-3 shift valve. The 2-3 SS Valve
is a normally-open exhaust valve used with the
1- 2 Shift Solenoid Valve (1-2 SS Valve) in order to
allow four different shifting combinations. The 2-3 SS
Valve attaches to the control valve body within the
transmission. The ignition voltage goes directly to the
2- 3 SS Valve. The Vehicle Control Module (VCM)
controls the 2-3 SS Valve by providing the ground
path through circuit 1223.
If the VCM detects a continuous open or short in the
2-3 SS Valve circuit or the 2-3 SS Valve, then
DTC P0758 sets. DTC P0758 is a type D DTC. For
California emissions vehicles, DTC P0758 is a
type A DTC.
Conditions for Setting the DTC
• The system voltage is 10-16 volts.
• The engine is running more than 475 RPM for
more than 7 seconds.
201454
• The above conditions are met and either of the
following conditions occur for 4.3 out of
5 seconds.
- The VCM commands the 2-3 SS Valve On,
and the voltage input remains high (B+).
- The VCM commands the 2-3 SS Valve Off,
and the voltage input remains low (0 volts).
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) for California emission vehicles.
• The VCM commands an immediate landing to
second gear.
• The VCM commands maximum line pressure.
• The VCM freezes shift adapts form being
updated.
• DTC P0758 is stored in VCM history.
Conditions for Clearing the DTC
1. For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
7-422 Automatic Transmission - 4L80-E
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• Inspect the wiring at the VCM, the transmission
connector and ail other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
Transmission/Transaxle
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to Shift Solenoid Valve State and Gear
Ratio table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests the function of the 2-3 SS Valve
and the internal wiring harness.
5. This step tests the power to the 2-3 SS Valve
from the ignition through the fuse.
7. This step tests the ability of the VCM and the
wiring to control the ground circuit.
10. This step measures the resistance of the
Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assy.) and the
2-3 SS valve.

DTC P0758 2-3 Shift Solenoid Circuit Electrical (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
2 tool in order to record the Freeze Frame and Failure —
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
3. Record the DTC Freeze Frame and Failure Records.
Were DTCs P0753, or P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the trans. fuse.
2. If you find an open fuse, inspect the following
components for a short to ground.
• Circuit 1020
• The 3 solenoids.
3 • The Automatic Transmission Wiring Harness —

Assembly
3. Repair the circuit, the solenoid, or replace the
harness if necessary.
Refer to Wiring Repairs.
Did you find and correct the condition? Go to Step 16 Go to Step 4
Transmission/Transaxle Automatic Transmission - 4L80-E 7-423
DTC P0758 2-3 Shift Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
Using the scan tool Output Control Function, command the
2-3 SS Valve ON and OFF three times while listening to
4 the bottom of the transmission pan (use a stethoscope if —
needed). Go to
Does the solenoid click when commanded? Diagnostic Aids Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
harness connector.
5 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a 12 volt test lamp from the J 39775
Jumper Harness cavity E to ground.
Is the test lamp on? Go to Step 7 Go to Step 6
Repair the open or high resistance in ignition feed
circuit 1020 to the 2-3 SS Valve.
6 — —
Refer to Wiring Systems.
Did you find and correct the condition? Go to Step 16
1. Install the test lamp between cavities E and B of the
J 39775 Jumper Harness.
2. Using the transmission output control function,
7 command the 2-3 SS Valve On and Off three times. —
Does the test lamp illuminate when you command the shift
solenoid ON and turn off when you command the shift
solenoid OFF? Go to Step 10 Go to Step 8
Inspect circuit 1223 for an open or short to ground.
8 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 16 Go to Step 9
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
9 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 16
1. Turn the ignition OFF.
2. Install J 39775 Jumper Harness on the transmission
20-way connector (Automatic Transmission Connector
End View).
10 19-310
3. With the J 39200 DMM and the J 35616-A Connector
Test Adapter K it, measure the resistance between
terminals B and E.
Is the resistance within the specified values? Go to Step 12 Go to Step 11
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 2-3 SS Valve.
11 19-310
2. Measure the resistance of the 2-3 SS Valve.
Is the resistance within the specified values? Go to Step 14 Go to Step 15
7-424 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0758 2-3 Shift Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
1. Measure the resistance between terminal B and a
good ground. Use the J 39200 DMM.
12 2. Measure the resistance between terminal E and a 250kO
good ground. Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 2-3 SS Valve.
13 2. Measure the resistance from the component’s 250k&
terminals to ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Replace the Automatic Transmission Wiring Harness
Assembly.
14 Refer to Internal Wiring Harness Replacement, in — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
Replace the 2-3 SS Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters, 2-3 Sol., and 2-3 Sol.
Open/Shorted to GRND, and 2-3 Sol. Shorted to
Voltage.
16 4. Operate the vehicle under the following conditions: —
• The VCM commands the 2-3 SS Valve On, and
the 2-3 Sol. Shorted to Voltage is No.
• The VCM commands the 2-3 SS Valve OFF, and
the 2-3 Sol. Open/Shorted to GRND is No.
• All conditions met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P0758. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-425

DTC P0758 2-3 Shift Solenoid Circuit Electrical (Diesel)

|Hot In Run, BulbTeat AndStart|
"! IP Fuse
D2^ TRANS ; Block
Fuse20 I
E1 10A
E

0.35 PNK 1020

Automatic f
Transmission T CCPWMSOL
Valve
Control
—
0.5RED 638 1-2 Shift
-► Solenoid
valve
A
0.5RED 839
A2iC100
A
0.35 PNK 1020 2-3 Shift
Solenoid
TO CSTR - INST (2-3 SS)
Valve
B
0.5 PNK 1020
0.5YEL 1223

B
0.5 YEL/BLK 1223
SP101
C6 C3
Powertrain r 2-3 SS
Control1 Valve
Module1 Control
> (PCM) I

Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valve. The
2-3 SS Valve is a normally-open exhaust valve used
with the 1-2 Shift Solenoid Valve (1 -2 SS Valve) in
order to allow four different shifting combinations.
The 2-3 SS Valve attaches to the control valve body
within the transmission. The ignition voltage goes
directly to the 2-3 SS Valve. The Powertrain Control
Module (PCM) controls the 2-3 SS Valve by
providing the ground path through circuit 1223.
If the PCM detects a continuous open or short to
ground in the 2-3 SS Valve circuit or the 2-3 SS
Valve, then DTC P0758 sets. DTC P0758 is a
type A DTC.
Conditions for Setting the DTC
• The engine is running greater than 475 RPM
for greater than 7 seconds.
• The system voltage is 10-16.0 volts.
• The PCM detects either of the following fail
conditions for 4.3 out of 5 seconds.
- The PCM commands the solenoid ON and
voltage input remains high (B+).
- The PCM commands the solenoid OFF and
voltage input remains low (0 volts).
40789
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands an immediate landing to
second gear.
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
• DTC P0758 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
7*426 Automatic Transmission - 4L80-E Transmission/Transaxle

Diagnostic Aids • First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
• Inspect the wiring at the PCM, the transmission
DTCs that may have reset.
connector and all other circuit connecting points
for the following conditions: • Refer to Shift Solenoid Valve State and Gear
Ratio table.
- A bent terminal
- A backed out terminal Test Description
- A damaged terminal The numbers below refer to the step numbers on the
diagnostic table.
- Poor terminal tension
4. This step tests the function of the 2-3 SS Valve
- A chafed wire and the Automatic Transmission Wiring Harness
- A broken wire inside the insulation Assembly.
- Moisture intrusion 5. This step tests the power to the 2-3 SS Valve
- Corrosion from the ignition through the fuse.
• When diagnosing for an intermittent short or 7. This step tests the ability of the PCM and the
wiring to control the ground circuit.
open, massage the wiring harness while
watching the test equipment for a change. 10. This step measures the resistance of the
Automatic Transmission Wiring Harness
• An open ignition feed circuit can cause multiple Assembly and the 2-3 SS Valve.
DTCs to set.

DTC P0758 2-3 Shift Solenoid Circuit Electrical (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
2 Records for reference. Using the Clear Info function —

will erase the stored Freeze Frame and Failure

Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC.
Are DTCs P0753, or P1860 also set? Go to Step 3 Go to Step 4
1. Inspect the Trans, fuse for an open.
2. If you found an open fuse, inspect circuit 1020, the
3 three solenoids, and the Automatic Transmission —
Wiring Harness Assembly for a short to ground.
Refer to Wiring Repairs.
Did you find and correct the condition? Go to Step 16 Go to Step 5
Using the transmission output control function on the scan
tool command the 2-3 SS Valve ON and OFF three times
4 while listening to the bottom of the transmission pan (use —
a stethoscope if needed). Go to
Does the solenoid click when commanded? Diagnostic Aids Go to Step 5
Transmission/Transaxle Automatic Transmission - 4L80-E 7-427
DTC P0758 2-3 Shift Solenoid Circuit Electrical (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
5 —
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to a good ground.
Is the test lamp on? Go to Step 7 Go to Step 6
Repair the open or high resistance in ignition feed
circuit 1020 to the 2-3 SS Valve.
6 Refer to Wiring Repairs. — —
Did you find and correct an open or high resistance
condition? Go to Step 16
1. Install a test lamp between cavity E and cavity B of
the J 39775 Jumper Harness.
2. Using the transmission output control function on the
7 scan tool, command the 2-3 SS Valve On and Off
—
three times.
Does the test lamp illuminate when the shift solenoid is
commanded ON and turn off when the shift solenoid is
commanded OFF? Go to Step 10 Go to Step 8
Inspect circuit 1223 for an open or short to ground.
8 Refer to General Electrical Diagnosis Procedures. —
Did you find an open or short to ground condition? Go to Step 16 Go to Step 9
Replace the PCM.
9 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 16
1. Turn the ignition OFF.
2. Install the J 39775 Jumper Harness on the
transmission 20-way connector.
10 3. With the J 39200 DMM and the J 35616-A Connector 19-310
Test Adapter Kit, measure the resistance between
terminals B and E.
Is the resistance within the specified value? Go to Step 12 Go to Step 11
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 2-3 SS Valve.
11 19-310
2. Measure the resistance of the 2-3 SS Valve.
Is the resistance within the specified values? Go to Step 14 Go to Step 15
Measure the resistance between terminals B and E to a
12 good ground. 250kO Go to
Are both reading greater than the specified value? Diagnostic Aids Go to Step 13
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the 2-3 SS Valve.
13 2. Measure the resistance from the 2-3 SS Valve 250kO
terminals to a good ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
7-428 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P0758 2-3 Shift Solenoid Circuit Electrical (Diesel) (cont’d)
Step Action Value(s) Yes No
Replace the Automatic Transmission Wiring Harness
Assembly.
14 Refer to Internal Wiring Harness Replacement, in — —
On-vehicle Service.
Is the replacement complete? Go to Step 16
Replace the 2-3 SS Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement complete? Go to Step 16
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters, 2-3 Sol., 2-3 Sol.
Open/Shorted to GRND and 2-3 Sol. Shorted to
Voltage.
16 4. Operate the vehicle under the following conditions: —
• The PCM commands the 2-3 SS Valve On, and
the 2-3 Sol. Shorted to Voltage is No.
• The PCM commands the 2-3 SS Valve OFF, and
the 2-3 Sol. Open/Shorted to GRND is No.
• All conditions are met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P0758. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-429
DTC P1810 TFP Valve Position Sw CKT Malfunction (Gas)

’ Vehicle
Control
Transmission Transmission Transmission | Module (VCM)
RangeA RangeB RangeC
Input Input Input
23 f ------ 22' f --------- 11 C3 (GRY)
0.5 PNK 1224 0.5 RED 1226

0.5 DK BLU 1225

r — — —N.-a5------------ R. P. £103
7 Automatic
1 0.5PNK1224 0.5 DKBLU 1225 0.5ORN 1226 Transmission
1 aJ bJ d \ _____________
Automatic
Transmission
Fluid Pressure
REV D3 D4 (TFP) Manual
J Switch Switch Switch ValvePosition
Switch

/
LO
Switch
X D2
Switch

69034
Circuit Description Conditions for Setting the DTC
The Automatic Transmission Fluid Pressure Manual DTC P1810 sets if any of the following conditions
Valve Position Switch (TFP Val. Position Sw.) occur:
consists of five normally-open pressure switches. The Condition 1
Vehicle Control Module (VCM) supplies battery
voltage to each range signal. By grounding one or • The system voltage is 10-16.0 volts.
more of these circuits through various combinations • The engine is more than 475 RPM for at least
of the pressure switches, the VCM detects what 7 seconds.
manual valve position has been selected and • The VCM detects an illegal TFP Val. Position
compares the actual voltage combination of the Sw. combination for greater than 60 seconds.
switches to a TFP Val. Position Sw. combination Condition 2
table stored in memory.
• The system voltage is 10-16 volts.
The TFP Val. Position Sw. assembly cannot
. No OSS DTC P0502 or P0503.
distinguish between Park and Neutral because the
monitored valve body pressures are identical in both • The engine speed is less than 50 RPM for
cases. With the ignition On and the engine Off, 0.3 seconds, 50-550 RPM for greater than
D2 is indicated. When the transmission 20-way 0.02 seconds and then greater than 550 RPM
connector is disconnected, the ground potential for and the vehicle speed is less than 4 km/h
the three range signals to the VCM is removed, and (2.5 mph).
with the ignition On, D2 is indicated. • The VCM detects the gear range as D2 before
If the VCM detects an invalid state of the TFP Val. and after start up.
Position Sw. circuit by deciphering the TFP Val. • The condition exists for greater than 7 seconds.
Position Sw. inputs, then DTC P1810 sets. The VCM looks for a condition change only at
DTC P1810 is a type D DTC. For California start-up.
emissions vehicles DTC P1810 is a type B DTC.
7-430 Automatic Transmission - 4L80-E
Condition 3
. No MAP DTCs P0106, P0107 or P0108.
. No TP Sensor DTCs P0121, P0122, or P0123.
. No OSS DTCs P0502 or P0503.
• No A/T ISS Sensor DTCs P0716 or P0717.
. No 1-2 SS Valve DTCs P0751 or P0753.
. No 2-3 SS Valve DTCs P0756 or P0758.
• The vehicle speed is greater than 8 km/h
(5 mph).
• The TP Sensor is:
108-540 N-m (80-400 lb ft) 5.7L.
108-675 N-m (80-500 lb ft) 7.4L.
• The engine torque is greater than
100 N-m (80 lb ft).
• The engine is running more than 475 RPM for
more than 7 seconds.
• The TFP Val. Position Sw. indicates the
following:
- P/N when the ratio indicates less than 1.05:1
for greater than 15 seconds.
- Reverse when the ratio indicates D4, D3, D2,
and D1 for greater than 5 seconds.
- D4, D3, D2, and D1 when the ratio indicates
reverse for greater than 7 seconds.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp for California Emission Vehicles.
• The VCM commands maximum line pressure.
• The VCM assumes D4 for the PRNDL shift
pattern.
• The VCM freezes shift adapts.
• The VCM commands the TCC on in
commanded fourth gear.
• DTC P1810 is stored in VCM history.
Conditions for Clearing the DTC
• For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
• A scan tool can clear the DTC from the
VCM history. The VCM clears the DTC from
the VCM history if the vehicle completes 40
warm-up cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Transmission/Transaxle
Diagnostic Aids
• Refer to the accompanying table for the normal
range signals and the illegal combinations.
• Inspect the wiring at the VCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• DTC P1810 can be falsely set during a fluid fill
procedure. After refilling the fluid, cycle key
down then start and run the vehicle for
20 seconds. Key down and allow the VCM to
power down, and then restart the vehicle.
• DTC P1810 can be set falsely by low pump
pressure or a stuck pressure regulator.
• DTC P1810 can be set by a rolled forward
clutch piston seal. It may allow the VCM to see
a 2.08:1 ratio (reverse) when the manual valve
position is indicated as D4.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
• Refer to the Range Signal table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
manual valve that is actually selected.
4. This step tests the voltage from the VCM to the
transmission 20-way connector.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-431
DTC P1810 TFP Valve Position Sw CKT Malfunction (Gas)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
1. Inspect for proper adjustment of the transmission Go to
linkage from the select lever to the manual valve. Transmission
2 —
2. Inspect the fluid. Fluid Checking
Did you perform the inspections? Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
3 —
3. Record the DTC Freeze Frame and Failure Records.
4. While the engine idles at normal operating
temperature, apply the parking brake.
5. Select each transmission range: D1, D2, D3, D4, N,
R, and P.
Does each selected transmission range match the scan
tool TFP Switch A/B/C display? (Refer to the Range Go to
Signal table.) Diagnostic Aids Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the transmission 20-way connector.
4 4. With the engine OFF, turn the ignition to the RUN —
position.
5. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit check the voltage at the
harness connector terminals N, R, and P.
Is B+ displayed on all three circuits? Go to Step 6 Go to Step 5
Inspect the circuits that did not indicate B+ in Step 4 for
an open or short to ground.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find an open or shorted to ground condition? Go to Step 9 Go to Step 7
Verify that circuits 1224, 1225, and 1226 are not shorted
together. Use a J 36169-A Fused Jumper Wire in order to
ground each circuit while monitoring the scan tool
6 TFP Switch display. —
Go to TFP Valve
When a range signal circuit is grounded, are any of the Position Switch
other range signal circuits affected? Go to Step 8 Resistance Check
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
7 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 9
7-432 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1810 TFP Valve Position Sw CKT Malfunction (Gas) (cont'd)
Step Action Value(s) Yes No
Repair the affected wiring as needed.
8 Refer to Wiring Repairs. — —
Is the repair complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Turn the ignition switch to the RUN position for at
least 2 seconds.
9 —
• Start the vehicle.
• Idle the vehicle in Park above 600 RPM for
7 seconds.
• Drive the vehicle in D4 with the throttle at least
10% and the TCC locked for 60 seconds.
Begin the
4. Select Specific DTC. Enter DTC P1810. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-433

DTC P1810 TFP Valve Position Sw CKT Malfunction (Diesel)

1 Powertrain
Control
Transmission Transmission Transmission Module (PCM)
RangeA RangeB RangeC
Input Input Input 1
*
B6 B5 B4 C2 A
ioeonk
0.8 PNK 1224 0.8 RED 1226
S P101

0.8 DK BLU 1225

t Automatic
0.5 PNK 1224 0.5DKBLU 1225 0.5ORN 1226 Transmission
A B, _____ CA Automatic
Transmission

I REV
;3 D4
FluidPressure

X
D3 (TFP) Manual
Switch Switch Switch ValvePosition
Switch

LO D2
/ Switch • Switch

69036
Circuit Description Conditions for Setting the DTC
The Automatic Transmission Fluid Pressure Manual DTC P1810 sets if either of the following conditions
Valve Position Switch (TFP Val. Position Sw.) occur:
consists of five normally-open pressure switches. The Condition 1
Powertrain Control Module (PCM) supplies battery
voltage to each range signal. By grounding one or • System voltage is 9.0-16.0 volts.
more of these circuits through various combinations • The engine is running greater than 475 RPM
of the pressure switches, the PCM detects what for greater than 7 seconds.
manual valve position has been selected and • The PCM detects an illegal TFP Val. Position
compares the actual voltage combination of the Sw. combination for greater than 25 seconds.
switches to a TFP Val. Position Sw. combination Condition 2
chart stored in memory.
• The system voltage is 9.0-16.0 volts.
The TFP Val. Position Sw. cannot distinguish
. No OSS Sensor DTCs P0722 or P0723.
between Park and Neutral because the monitored
valve body pressures are identical in both cases. • The engine speed is less than 50 RPM for
With the ignition On and the engine Off, D2 is 1.5 seconds, 50-525 RPM for greater than
indicated. When the transmission 20-way connector 0.1 seconds and then the engine speed is
is disconnected, the ground potential for the three greater than 575 RPM and the vehicle speed is
range signals to the PCM is removed, and with the less than 4 km/h (2.5 mph).
ignition On, D2 is indicated. • Vehicle speed is less than 4 Km/h (2.5 mph).
If the PCM detects an invalid state of the TFP Val. • The PCM detects the gear range as D2 before
Position Sw. circuit by deciphering the TFP Val. and after start up.
Position Sw. inputs, then DTC P1810 sets. • The condition exists for greater than
DTC P1810 is a type B DTC. 7.5 seconds. The PCM looks for a condition
change only at start-up.
7-434 Automatic Transmission - 4L80-E
Condition 3
. No MAP DTCs P0106, P0107 or P0108.
• No A/T ISS Sensor DTCs P0716 or P0717.
. No OSS DTCs P0722 or P0723.
. No 1-2 SS Valve DTCs P0751 or P0753.
. No 2-3 SS Valve DTCs P0756 or P0758.
• The engine speed is less than 3750 RPM.
• System voltage is 9.0-16.0 volts.
• The vehicle speed is greater than
8 km/h (5 mph).
• The APP Angle is greater than 12%.
• The engine torque is 100-644 N-m
(80-475 lb ft).
• The engine is running for more than 7 seconds.
• The TFP Val. Position Sw. indicates the
following:
- P/N when the ratio indicates less than 1.05:1
for greater than 15 seconds.
- Reverse, when the ratio is not 2.04-2.12 for
greater than 15 seconds.
- D4, D3, D2, or D1 when the ratio indicates
reverse (2.04-2.12) for greater than
5 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM assumes D4 for the PRNDL shift
pattern.
• The PCM freezes shift adapts.
• DTC P1810 is stored in PCM history.
Conditions for Clearing the MIL/DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Transmission/Transaxle
Diagnostic Aids
• Refer to the accompanying chart for the normal
range signals and the illegal combinations.
• Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.
• DTC P1810 can be falsely set during a fluid fill
procedure. After refilling the fluid, cycle key
down then start and run the vehicle for
20 seconds. Key down and allow the PCM to
power down, and then restart the vehicle.
• DTC P1810 can be set falsely by low pump
pressure or a stuck pressure regulator.
• DTC P1810 can be set by a rolled forward
clutch piston seal. It may allow the PCM to see
a 2.08:1 ratio (reverse) when the manual valve
position is indicated as D4.
• First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
DTCs that may have reset.
• Refer to the Range Signal table.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
manual valve that is actually selected.
4. This step tests the voltage from the PCM to the
transmission 20-way connector.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-435
DTC P1810 TFP Valve Position Sw CKT Malfunction (Diesel)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Inspect for proper adjustment of the transmission
Go to
linkage from the select lever to the manual valve. Transmission
2 —
2. Inspect the fluid. Fluid Checking
Did you perform the inspections? Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
3 3. Record the DTC Freeze Frame and Failure —
Records, then clear the DTC.
4. While the engine idles at normal operating
temperature, apply the parking brake.
5. Select each transmission range: D1, D2, D3, D4,
N, R, and P.
Does each selected transmission range match the scan
tool TFP Switch A/B/C display? (Refer to the Range Go to
Signal table.) Diagnostic Aids Go to Step 4
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the transmission 20-way connector.
4 4. With the engine OFF, turn the ignition to the —
RUN position.
5. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit, check the voltage at the
harness connector terminals N, R, and P.
Do all three circuits display B+? Go to Step 6 Go to Step 5
Inspect the circuits that did not indicate B+ in Step 4 for
an open or short to ground condition.
5 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 8 Go to Step 7
To verify that circuits 1224, 1225, and 1226 are not
shorted together, use a fused jumper to ground on each Refer to
6 circuit while monitoring the scan tool TFP Switch display. — TFP Valve
When a range signal circuit is grounded, are any of the Position Switch
other range signal circuits affected? Go to Step 8 Resistance Check
Replace the PCM.
7 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 9
7-436 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1810 TFP Valve Position Sw CKT Malfunction (Diesel) (cont’d)
Step Action Value(8) Yes No
Repair the affected wiring as needed.
8 Refer to Wiring Systems. — —
Is the repair complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Turn the ignition switch to the RUN position for at
least 2 seconds.
9 —
• Start the vehicle.
• Idle the vehicle in Park above 600 RPM for
8.5 seconds.
• Drive the vehicle in D4 with throttle more than
12% and obtain TCC lock up.
Begin the
4. Select Specific DTC. Enter DTC P1810. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle Automatic Transmission - 4L80-E 7-437
DTC P1811 Maximum Adapt and Long Shift (Diesel Only)

O/D Interm. Lo
Fourth Overrun Roller FWD Direct Front Sprag Interm. Roller Rear
Range Gear 1-2 Sol 2-3 Sol Clutch Clutch Clutch Clutch Clutch Band Clutch Clutch Clutch Band
1st On Off — — H A — — * — H —

2nd Off Off — — H A — — H A 0 —

Overdrive
3rd Off On — — H A A — 0 A 0 —
4th On On A — 0 A A — 0 A 0 —
A = Applied
H = Holding
* = Holding but not effective
O = Overrunning_________

Circuit Description Conditions for Clearing the DTC

The Powertrain Control Module (PCM) compares the
measured gear ratio to the known actual value. This
allows the PCM to determine the actual gear range
of the transmission. When an upshift is commanded,
the PCM measures the interval during which the
gear ratio leaves the current range and changes to
reflect the commanded upshift. This interval is
expressed on the scan tool as Shift Time. When this
interval has exceeded a predetermined limit, the
PCM utilizes the shift adapts in order to attempt to
Diagnostic Aids
shorten the shift time.
If the PCM detects that the maximum allowable shift
time has been exceeded, and that the upshift adapts
have reached their upper limit, then DTC P1811
sets. DTC P1811 is a type D DTC.
Conditions for Setting the DTC
• The engine must be running at greater than
475 RPM for more than 7 seconds.
• One of the following conditions exists, with the
adapt cells at the maximum pressure allowed
for 5 consecutive occurrences of one shift.
- The 1-2 or the 2-3 upshifts are greater than
1.25 seconds.
Test Description
- The 3-4 upshifts are greater than
6.37 seconds.
Action Taken When the DTC Sets
• The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
• The PCM freezes shift adapts.
• The PCM commands maximum line pressure.
• DTC P1811 is stored in PCM history.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
. DTC P1811 can be caused by a faulty
turbocharger or wastegate assembly. If no other
symptoms are present, check the turbocharger
system for proper operation.
• Ask the customer about overloading the vehicle,
exceeding the trailer-towing limit, or towing in
Overdrive.
• If, after several unsuccessful attempts to gain
accurate shift times, and an adapt can be
made, reset adapts and operate the vehicle, in
order to assure proper shifting.
• While driving the vehicle, inspect for loss of
power, misfire, or other engine-related driving
problems.
2. This step tests for low fluid level, which can
cause delayed shifts.
3. This step compares the indicated range signal
from the Range Signal table to the Automatic
Transmission Fluid Pressure Manual Valve
Position Switch (TFP Val. Position Sw.) selected
gear range.
5. This step tests for low line pressure, which can
cause delayed and long shifts.
7-438 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1811 Maximum Adapt and Long Shift (Diesel Only)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Have you performed the transmission fluid checking Go to
procedure? Transmission
2 —
Fluid Checking
Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Failure Records from the PCM.
3. Record the DTC Freeze Frame, then clear the DTC.
3 Important: If any other engine or transmission DTCs —
are set, refer to their respective diagnostic
tables first.
4. Select TFP Sw. A/B/C on the scan tool.
5. Start the engine and apply the brake pedal.
6. Select each gear range: D1, D2, D3, D4, N, R, Go to DTC P1810
and P. TFP Valve
Does each selected transmission range match the TFP Position Sw
Sw. A/B/C display on the scan tool? (Refer to the Range CKT Malfunction
Signal table.) Go to Step 4 (Diesel)
1. Drive the vehicle in D4 in order to obtain a 1-2, a
2-3, and a 3-4 shift time. Use the scan tool snapshot 1-2 or 2-3
mode in order to record the shift times. upshifts:
4 2. Using the scan tool, review the shift time information 1.25 seconds
for 1-2, 2-3, and 3-4 shift times. 3-4 upshifts:
Were all of the shift times greater than the 6.37 seconds.
specified value? Go to Step 5 Go to Step 8
Perform the line pressure test. Go to Symptom
Refer to Line Pressure Check Procedure. Diagnosis table,
5 —
Low Line
Is the line pressure within specifications? Go to Step 6 Pressure
1. Remove the transmission oil pan.
Refer to Changing the Fluid and Filter, in On-Vehicle Go to
Service. Transmission
6 —
2. Inspect the pan and the fluid for contamination. Overhaul
Is there excessive contamination in the transmission Procedure, in
oil pan? Unit Repair. Go to Step 7
Inspect the transmission for fluid pressure loss in one of
the following areas:
• Valve Body Gasket
7 • Forward Clutch Seals — —
• Turbine Shaft Seals
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find and correct the condition? Go to Step 15
Transmission/Transaxle Automatic Transmission - 4L80-E 7-439
DTC P1811 Maximum Adapt and Long Shift (Diesel Only) (cont’d)
Step Action Value(s) Yes No
Select the 1-2, 2-3, and the 3-4 Transmission Adaptive
Pressure (TAP) cells on the scan tool.
8 16.0 PSI
Were any of the upshift TAP cells greater than the Go to
specified value? Go to Step 9 Diagnostic Aids
9 Did the 3-4 shift time exceed the specified value? 6.37 seconds Go to Step 12 Go to Step 10
10 Did the 2-3 shift time exceed the specified value? 1.25 seconds Go to Step 13 Go to Step 11
11 Did the 1-2 shift time exceed the specified value? 1.25 seconds Go to Step 14 —
Inspect the following 3-4 shift circuit components:
• 4th Gear Clutch Plates
• 4th Gear Clutch Seals
12 — —
• A sticking 3-4 Shift Valve
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find and correct the condition? Go to Step 15
Inspect the following 2-3 shift circuit components:
• Turbine Shaft Seals
• Forward Clutch Plates
• Forward Clutch Seals
• Direct Clutch Plates
13 — —
• Direct Clutch Seals
• Center Support Seals
• Improperly tightened Center Support Bolt
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find and correct the condition? Go to Step 15
Inspect the following 1-2 shift circuit components:
• Low Roller Clutch
• Intermediate Clutch Plates
• Intermediate Clutch Seals
14 • Intermediate Sprag Clutch — —
• Overdrive Roller Clutch
• Improperly tightened Center Support Bolt
Refer to Transmission Overhaul Procedure, in Unit Repair.
Did you find and correct the condition? Go to Step 15
In order to verify your repair, perform the following
procedure:
1. Select DTC.
1-2 and 2-3
2. Select Clear Info. upshifts
15 3. Drive the vehicle in D4 range. 1.25 seconds
4. Operate the vehicle through several 1,2,3,4 usphifts. 3-4 upshifts
6.37 seconds
5. Review the scan tool 1-2, 2-3 and 3-4 shift times. Begin the
Are the 1-2, 2-3, or 3-4 shift times less than the diagnosis again.
specified value? System OK Go to Step 1
7-440 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P1860 TCC PWM Solenoid Circuit Electrical (Gas)

|Hot InRun, BulbTest AndStart|

1 1P Fuse
[ Block Transmission
TRANS
Fuse20 i
'
20A A

0.5 PNK 1020

0.35 PNK 1020

£P101 0.35 PNK 1020
A2: :C100
FuseBlock
Details
Cell 11

Vehicle | TCC PWM

Control i Solenoid
Valve
Module i Control
A (VCM)I

201459
Circuit Description • Commanded gear is first.
The Torque Converter Clutch Width Modulation • All of the above conditions are met and either
Solenoid Valve (TCC PWM Solenoid Valve) controls of the following conditions occur for 5 seconds.
fluid acting on the converter clutch valve, which then - The VCM commands the TCC PWM Sol.
controls TCC apply and release. The TCC PWM Sol. Valve to OFF (0%) and the voltage input
Valve attaches to the control valve body within the remains low (zero volts).
transmission. Ignition voltage goes directly to the - The VCM commands the TCC PWM Sol.
TCC PWM Sol. Valve. The Vehicle Control Modulator
Valve to ON (100%) and the voltage input
(VCM) controls the TCC PWM Sol. Valve by remains high (B+).
providing a ground path on circuit 418. The current
flows through the TCC PWM Sol. Valve coil Action Taken When the DTC Sets
according to the duty cycle (percentage of ON time).
• The VCM illuminates the Malfunction Indicator
The TCC PWM Sol. Valve provides a smooth
Lamp for California emission vehicles.
engagement of the torque converter clutch by
operating on a duty cycle percent of ON time. • The VCM inhibits TCC engagement.
If the VCM detects a continuous open or short in the • The VCM inhibits 4th gear.
TCC PWM Sol. Valve circuit or the TCC PWM Sol. • The VCM freezes shift adapts from being
Valve, then DTC P1860 sets. DTC P1860 is a type updated.
D DTC. For California emission vehicles DTC P1860 • DTC P1860 is stored in VCM history.
is a type A DTC.
Conditions for Clearing the DTC
Conditions for Setting the DTC
1. For California emissions vehicles, the VCM
• The system voltage is 10-16.0 volts. turns OFF the MIL after three consecutive trips
• The engine is running greater than 475 RPM. without a failure reported.
. No shift solenoid DTCs P0751, P0753, P0756,
or P0758.
Transmission/!"ransaxle Automatic Transmission - 4L80-E 7-441
2. A scan tool can clear the DTC from the VCM • When diagnosing for an intermittent short or
history. The VCM clears the DTC from the VCM open, massage the wiring harness while
history if the vehicle completes 40 warm-up watching the test equipment for a change.
cycles without a failure reported. • First diagnose and clear any engine DTCs or
3. The VCM cancels the DTC default actions TP Sensor codes that are present. Then
when the fault no longer exists and the ignition inspect for any transmission DTCs that may
is OFF long enough in order to power down have reset.
the VCM. Test Description
Diagnostic Aids The numbers below refer to the step numbers on the
diagnostic table.
• Inspect the wiring at the VCM, the transmission
4. This step tests for voltage to the TCC PWM
connector and all other circuit connecting points
Sol. Valve circuit at the 20-way connector.
for the following conditions:
6. This step tests the ability of the VCM and
- A bent terminal wiring to control the ground circuit.
- A backed out terminal 8. This step tests the resistance of the TCC PWM
- A damaged terminal Sol. Valve and the internal wiring harness.
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

DTC P1860 TCC PWM Solenoid Circuit Electrical (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
2 erase the stored Freeze Frame and Failure Records —
from the VCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTCs.
4. If DTCs P0753 or P0758 are also set, inspect the
trans. fuse.
Is the fuse open? Go to Step 3 Go to Step 4
Inspect the following components for a short to ground.
• Circuit 1020
• The 3 solenoids
3 • The Automatic Transmission Wiring Harness —
Assembly
Refer to General Electrical Diagnosis Procedures. Go to
Did you find and correct the condition? Go to Step 17 Diagnostic Aids
7-442 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1860 TCC PWM Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
harness connector.
4 —
4. With the engine off, turn the ignition to the RUN
position.
5. Connect a test lamp from the J 39775 Jumper
Harness cavity E to ground.
Is the test lamp ON? Go to Step 6 Go to Step 5
Repair the open or high resistance in ignition voltage feed
circuit 1020 to the TCC PWM Sol. Valve.
5 — —
Refer to Wiring Repairs.
Is the repair complete? Go to Step 17
1. Install the test lamp from cavities E to S of the
J 39775 Jumper Harness.
2. Command the TCC PWM Sol. Valve ON and OFF
6 three times. —
Does the test lamp turn ON when you command the TCC
PWM Sol. Valve ON, and does the lamp turn OFF when
you command the TCC PWM Sol. Valve OFF? Go to Step 8 Go to Step 7
1. Inspect circuit 418 for an open or short to ground.
Refer to General Electrical Diagnosis Procedures.
7 2. Repair the circuit if necessary. Refer to Wiring —
Repairs.
Did you find the condition? Go to Step 17 Go to Step 9
1. Install the J 39775 Jumper Harness on the
transmission 20-way connector (Automatic
Transmission Connector End View).
8 2. Using the J 39200 DMM and the J35616-A 10-15Q
Connector Test Adapter Kit, measure the resistance
between terminals E and S.
Is the resistance within the specified values? Go to Step 11 Go to Step 10
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
9 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 17
1. Disconnect the Automatic Transmission Wiring
Harness Assembly at the TCC PWM Sol. Valve.
10 10-15Q
2. Measure the resistance of the TCC PWM Sol. Valve.
Is the resistance within the specified values? Go to Step 12 Go to Step 15
1. Measure the resistance between terminal E and
ground.
11 2. Measure the resistance between terminal S and 250k£2
ground. Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
Inspect the A/T Wiring Harness Assembly for an open
circuit.
12 — —-
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 16
Transmission/Transaxle Automatic Transmission - 4L80-E 7-443
DTC P1860 TCC PWM Solenoid Circuit Electrical (Gas) (cont’d)
Step Action Value(s) Yes No
1. Disconnect the Automatic Transmission Wiring
Harness Assembly at the TCC PWM Sol. Valve.
13 2. Measure the resistance between each of the 250kO
component terminals and ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Inspect the Automatic Transmission Wiring Harness
Assembly for a short to ground.
14 — ■ —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 16
Replace the TCC PWM Sol. Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement Complete? Go to Step 17
Replace the Automatic Transmission Wiring Harness
Assembly.
16 Refer to Internal Wiring Harness Replacement, in — —
On-Vehicle Service.
Is the replacement Complete? Go to Step 17
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters, TCC Duty Cycle, TCC Duty
Cycle Open/Shorted to Ground and TCC Duty Cycle
Shorted to Voltage.
4. Operate the vehicle under the following conditions:
17 —
• The TCC PWM Sol. Valve is commanded ON and
TCC Duty Cycle Shorted to Voltage is No.
• The TCC PWM Sol. Valve is commanded OFF
and TCC Duty Cycle Open/Shorted to Ground
is No.
• Each condition is met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P1860. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-444 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P1860 TCC PWM Solenoid Circuit Electrical (Diesel)

|H o t In R un, Bulb Test And S ta rt!

■J IP Fuse
D2 ^ TRANS Block
Fuse 2 0
E1 10 A E/
Automatic T 0 .5 R E D 8 3 8
Transmission 1-2 Shift 2-3 Shift
Solenoid •<- -► Solenoid
0.35 PNK 1020 Valve Valve
0.5RED
A2iC100
A
0.35 PNK 1020 Torque
Converter
Instrument Clutch
Cluster PulseWidth
Modulation
Solenoid
0.5 PNK 1020 (TCCPWMSOL.)
Valve

0 .8 BLK 418

s
0.5 BRN 418
£P101
C5 C3
Powertrain r TCCPWMSOL.
Control1 Valve
Module1 Control
> (PCM) I
L

69021

Circuit Description
The Torque Converter Clutch Pulse Width Modulation
Solenoid Valve (TCC PWM Sol. Valve) controls fluid
acting on the converter clutch valve, which then
controls TCC apply and release. The TCC PWM Sol.
Valve attaches to the control valve body within the
transmission. Ignition voltage goes directly to the
TCC PWM Sol. Valve. The Powertrain Control
Module (PCM) controls the TCC PWM Sol. Valve by
providing a ground path on circuit 418. The current
flows through the TCC PWM Sol. Valve coil
according to the duty cycle (percentage of ON and
OFF time). The TCC PWM Sol. Valve provides a
smooth engagement of the torque converter clutch
by operating on a duty cycle percent of ON time.
If the PCM detects a continuous open or short to
ground in the TCC PWM Sol. Valve circuit or the
TCC PWM Sol. Valve, then DTC P1860 sets.
DTC P1860 is a type A DTC.
Conditions for Setting the DTC
• System voltage is 9.0-16.0 volts.
• The engine is running more than 475 RPM for
greater than 7 seconds.
• Commanded gear is 1st.
• All of the above conditions are met, and one of
the following conditions occur for 4.3 seconds
out of 5 seconds.
- The PCM commands the solenoid OFF, and
the voltage input remains low (zero volts).
- The PCM commands the solenoid to ON
(100%) and the voltage input remains
high (B+).
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM inhibits TCC engagement.
• The PCM inhibits 4th gear.
• DTC P1860 is stored in PCM history.
Conditions for Clearing the MILVDTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-445
Diagnostic Aids Test Description
• Inspect the wiring at the PCM, the transmission The numbers below refer to the step numbers on the
connector and all other circuit connecting points diagnostic table.
for the following conditions: 4. This step tests for voltage to the TCC PWM
- A bent terminal Sol. Valve.
- A backed out terminal 6. This step tests the ability of the PCM and
wiring to control the TCC PWM Sol. valve
- A damaged terminal ground circuit.
- Poor terminal tension 8. This step tests the resistance of the TCC PWM
- A chafed wire Sol. Valve and the Automatic Transmission
- A broken wire inside the insulation Wiring Harness Assembly.
- Moisture intrusion 12. If the Automatic Transmission Wiring Harness
Assembly is open, do not repair the wiring
- Corrosion harness. You must replace the Automatic
• When diagnosing for an intermittent short or Transmission Wiring Harness Assembly.
open, massage the wiring harness while
watching the test equipment for a change.
• An open in the ignition feed circuit 1020, will
cause multiple DTCs to set.
• First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
DTCs that may have reset.

DTC P1860 TCC PWM Solenoid Circuit Electrical (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
2 will erase the stored Freeze Frame and Failure —
Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTCs.
4. If DTCs P0753, or P0758, are also set, inspect
the fuse.
Is the fuse open? Go to Step 3 Go to Step 4
Inspect circuit 1020, the three solenoids, and the
Automatic Transmission Wiring Harness Assembly for a
3 short to ground. —
Refer to General Electrical Diagnosis Procedures. Refer to
Did you find and correct the shorted condition? Go to Step 17 Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4 —
4. With the engine off, turn the ignition to the RUN
position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to a good ground.
Is the test lamp ON? Go to Step 6 Go to Step 5
7-446 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P1860 TCC PWM Solenoid C ircuit E lectrical (D iesel) (cont’d)

Step Action Value(s) Yes No
Repair the open or high resistance in ignition feed
circuit 1020 to the TCC PWM Sol. Valve.
5 — —
Refer to Wiring Repairs.
Is the repair complete? Go to Step 17
1. Install the test lamp from cavity E to cavity S of the
J 39775 Jumper Harness.
2. Use the scan tool output control function in order to
command the TCC PWM Sol. Valve ON and OFF —
6
three times.
Does the test lamp illuminate when you command the
TCC PWM Sol. Valve ON, and does the lamp turn OFF
when you command the TCC PWM Sol. Valve OFF? Go to Step 8 Go to Step 7
1. Inspect circuit 418 for an open or short to ground.
Refer to General Electrical Diagnosis Procedures.
7 2. Repair the circuit if necessary. Refer to Wiring —
Repairs.
Did you find an open or short to ground condition? Go to Step 17 Go to Step 9
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Measure the resistance between terminals E and S. 10-15S2
8
Use the J 39200 DMM and the J 35616-A Connector
Test Adapter Kit.
Is the resistance within the specified value? Go to Step 11 Go to Step 10
Replace the PCM.
9 Refer to PCM Replacement/Programming. — —
Is the replacement complete? Go to Step 17
1. Disconnect the Automatic Transmission Wiring
Harness Assembly at the TCC PWM Sol. Valve.
10 10-15ft
2. Measure the resistance of the TCC PWM Sol. Valve.
Is the resistance within the specified value? Go to Step 12 Go to Step 15
1. Measure the resistance between terminal E and
ground.
11 2. Measure the resistance between terminal S and a 250kfl
good ground. Go to
Are both readings greater than the specified value? Diagnostic Aids Go to Step 13
Inspect the Automatic Transmission Wiring Harness
Assembly for an open circuit.
12 — —
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition? Go to Step 16
1. Disconnect the Automatic Transmission Wiring
Harness Assembly at the TCC PWM Sol. Valve.
13 2. Measure the resistance between each of the 250kQ
component terminals and a good ground.
Are both readings greater than the specified value? Go to Step 14 Go to Step 15
Inspect the Automatic Transmission Wiring Harness
Assembly for a short to ground.
14 — —
Refer to Wiring Systems.
Did you find a short to ground condition? Go to Step 16
Transmission/Transaxle Automatic Transmission - 4L80-E 7-447
DTC P1860 TCC PWM Solenoid C ircuit E lectrical (D iesel) (cont’d)
Step Action Value(s) Yes No
Replace the TCC PWM Sol. Valve.
Refer to Control Valve Body Removal and Disassembly, in
15 — —
On-Vehicle Service.
Is the replacement Complete? Go to Step 17
Replace the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assy).
16 Refer to Internal Wiring Harness Replacement, in — —
On-vehicle Service.
is the replacement complete? Go to Step 17
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Select the parameters, TCC Duty Cycle, TCC Duty
Cycle Open/Shorted to Ground and TCC Duty Cycle
Shorted to Voltage.
4. Operate the vehicle under the following conditions:
17 —
• The TCC PWM Sol. Valve is commanded ON and
TCC Duty Cycle Shorted to Voltage is No.
• The TCC PWM Sol. Valve is commanded OFF
and TCC Duty Cycle Open/Shorted to Ground
is No.
• Each condition is met for 5 seconds.
Begin the
5. Select Specific DTC. Enter DTC P1860. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-448 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P1870 Transmission Component Slipping (Gas)

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199389

C ircuit Description If the VCM detects an excessive TCC slip speed in

The Vehicle Control Module (VCM) monitors the
engine speed, and the transmission output shaft
speed. The VCM calculates turbine shaft speed and
Torque Converter Clutch (TCC) slip speed by using
inputs from the transmission Input Shaft Speed (ISS)
Sensor, Transmission Output Shaft Speed (OSS)
Sensor and other transmission components. The
forward clutch housing is used as the ISS Sensor
rotor. Whenever the TCC is engaged, engine speed
and turbine speed will closely match, indicating low
TCC slip speed. In D3 with the TCC engaged,
calculated transmission component slip can only
occur in the torque converter. In D4 Overdrive with
the TCC engaged, transmission component slip can
occur in the TCC or the fourth clutch assembly.
D4 Overdrive, when the TCC should be engaged,
then DTC P1870 sets. DTC P1870 is a type D DTC,
For California emissions vehicles, DTC P1870 is a
type B DTC.
C onditions fo r Setting the DTC
The following conditions occur 3 times for
10 seconds:
. No MAP DTCs P0101, P0102 or P0103.
. No MAF DTCs P0106, P0107 or P0108.
• No engine speed DTCs P0335, P0336, P0337,
or P0338.
• No TP Sensor DTCs P0121, P0122, or P0123.
. No OSS DTC P0502.
Transmission/Transaxle
. No ATT 1SS sensor DTCs P0716 or P0717.
. No TCC PWM Sol. Valve DTCs P0741, P0742
or P1860.
. No 1-2 SS Valve DTCs P0751 or P0753.
• No 2-3 SS Valve DTCs P0756 or P0758.
• No TFP Val. Position Sw. DTCs P1810.
• The engine speed is greater than 475 RPM for
7 seconds and not in fuel cutoff mode.
• The TP Sensor is 7-80%.
• Engine speed is 1250-5500 RPM.
• The engine vacuum is 0-105 kPa.
. The TFT is 20* to 130‘ C (68*-266-F).
. Vehicle speed is 56.3-177 Kp/h (35-110 MPH)
• TFP Val. Position Sw. indicates D4.
• Speed ratio is 1.30-0.70 for 5.7L and 7.4L, or
1.69-0.70 for 4.3L.
• The engine torque is 100 N-m (80 lb ft) to the
following:
- 94.8-542 N-m (70-400 lb ft) 5.7L
- 108.4-677.5 N.m (80-500 lb ft) 7.4L.
• The TCC is commanded ON for 5 seconds
or more.
• TCC duty cycle is greater than 95%.
• The VCM detects a slip speed of:
120-550 RPM. 5.7L
110-550 RPM. 7.4L
Action Taken When the MIL/DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL) for California emissions vehicles.
• The VCM commands maximum line capacity.
• The VCM inhibits the TCC engagement.
• The VCM inhibits 4th gear if in hot mode.
• The VCM freezes shift adapts.
• DTC 1870 is stored in VCM History.
Conditions for Clearing the DTC
• For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
Automatic Transmission - 4L80-E 7-449
• A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Diagnostic Aids
• A TFP Val. Position Sw. malfunction can set
DTC P1870.
• A mechanical failure of the shift solenoids or
TCC PWM Sol. Valve can set DTC P1870.
• Internal transmission failures can result in a
DTC P1870.
• Sticking or contaminated shift valves may cause
intermittent slipping in D4.
• First diagnose and clear any engine DTCs or
TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
have reset.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
actual selected range. A faulty TFP Valve
Position Switch can set a DTC P1870.
4. This step tests for excessive TCC slip speed
while in a commanded TCC lock-up state and
in fourth gear; and confirms that the fault is
present.
5. This step tests for excessive TCC slip speed
while in a commanded TCC lock-up state and
in third gear.
6. This step tests for a sticking TCC shift valve.
8. This step tests for proper transmission line
pressure.
7-450 Automatic Transmission - 4L80-E Transmission/!ransaxle

DTC P1870 Transmission Component Slipping (Gas)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to Powertrain
Check performed? OBD System
Check (5.7L) or
1 — Powertrain OBD
System Check
(OBD System
Go to Step 2 Check)(7AL)
Perform the Transmission Fluid Checking Procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 — Fluid Checking
Did you perform the procedure? Go to Step 3 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
from the VCM.
3 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTCs.
4. With the engine idling and at normal operating
temperature, apply the brake pedal.
5. Select each transmission range: D1, D2, D3, D4, N,
R, and P. Go to DTC P1810
Does each selected transmission range match the scan TFP Valve
tool TFP Switch A/B/C display? (Refer to the Range Position Sw CKT
Signal table.) Go to Step 4 Malfunction (Gas)
Drive the vehicle under the following conditions:
. The TFT is 20*-130*C (50--266*F)
• The transmission is in D4.
120 RPM (5.7L)
4 • The TCC is duty cycle is greater than 80%.
110 RPM (7.4L)
• The TP angle is 10-80%.
At any time is the TCC Slip Speed greater than the Go to
specified value for 10 seconds? Go to Step 5 Diagnostic Aids
Drive the vehicle under the following conditions:
• The transmission is in D3.
• Command the TCC ON with the scan tool. 120 RPM (5.7L)
5
• The TP angle is 10-80%. 110 RPM (7.4L)
At any time is the TCC Slip Speed greater than the
specified value for 10 seconds? Go to Step 7 Go to Step 6
Repeat the procedure in step 4. Drive the vehicle under
the following conditions:
• The transmission is in D4. 120 RPM (5.7L)
6
• The TCC duty cycle is greater than 80%. 110 RPM (7.4L)
• The TP angle is 10-80%.
Is the TCC slip speed greater than the specified value? Go to Step 8 Go to Step 11
Transmission/Transaxle Automatic Transmission - 4L80-E 7-451
DTC P1870 Transmission Component Slipping (Gas) (cont’d)
Step Action Value(s) Yes No
Refer to the System Diagnosis table: Slipping TCC.
7 — —
Did you find and correct the condition? Go to Step 12
1. Connect the J 21867 Pressure Gauge to the
Go to the
transmission line pressure tap.
applicable System
8 2. Perform the Line Pressure Check. — Diagnosis Table:
Refer to Line Pressure Check Procedure. Low Line
Is the line pressure within specifications? Go to Step 9 Pressure
1. Remove the transmission oil pan.
Refer to Changing the Fluid and Filter, in
Go to
On-Vehicle Service.
9 — Transmission
2. Inspect for contaminated fluid and excessive Overhaul
material in the pan. Procedure, in
Is the fluid or the pan contaminated? Unit Repair Go to Step 10
1. Inspect the 1-2 SS Valve for contamination
or damaged seals.
10 2. Inspect the 2-3 SS Valve for contamination —
or damaged seals.
Did you find the condition? Go to Step 12 Go to Step 11
Inspect the following components for contamination
or sticking. Go to
Transmission
11 • The 2-3 shift valve — Overhaul
• The 3-4 shift valve Procedure, in
Did you find the condition? Go to Step 12 Unit Repair
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Ensure that TFT is 20 *-130 ’ C (50 *-266' F).
12 • Drive the vehicle in 4th gear, with the TCC —
commanded ON.
• The TP Angle is 7-80%.
• The VCM must see a slip of -20 to +20 RPM for
greater than 10 seconds. Begin the
4. Select Specific DTC. Enter DTC P1870. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-452 Automatic Transmission - 4L80-E Transmission/Transaxle

DTC P1870 Transmission Component Slipping (Diesel)

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199389

Circuit Description If the PCM detects an excessive TCC slip speed in

The Powertrain Control Module (PCM) monitors the
engine speed, and the transmission output shaft
speed. The PCM calculates turbine shaft speed and
Torque Converter Clutch (TCC) slip speed by using
inputs from the transmission Input Shaft Speed (ISS)
Sensor, Transmission Output Shaft Speed (OSS)
Sensor and other transmission components. The
forward clutch housing is used as the ISS Sensor
rotor. Whenever the TCC is engaged, engine speed
and turbine speed will closely match, indicating low
TCC slip speed. In D3 with the TCC engaged,
calculated transmission component slip can only
occur in the torque converter. In D4 Overdrive with
the TCC engaged, transmission component slip can
occur in the TCC or the fourth clutch assembly.
D4 Overdrive, when the TCC should be engaged,
then DTC P1870 sets. DTC P1870 is a type D DTC.
For California emissions vehicles, DTC P1870 is a
type B DTC.
Conditions for Setting the DTC
. No MAP DTCs P0106, P0107 or P0108.
• No Engine Speed DTC P0335
• No ATT ISS Sensor DTCs P0716 or P0717
• No OSS Sensor DTCs P0722 or P0723
. No TCC PWM Sol. Valve DTCs P0741, P0742,
or P1860
. No 1-2 SS Valve DTCs P0751 or P0753
. No 2-3 SS Valve DTCs P0756 or P0758
Transmission/Transaxle
. No TFP Val. Position Sw. DTCs P1810
• The gear range is D4.
• The APP Angle is 12-80%.
. The TFT is +20* to +130'C (68*-266*F).
• The engine speed is 1200-3750 RPM.
• System voltage is 9.0-16.0 volts.
• The vehicle speed is 48-176 km/h
(30-110 mph).
• The engine torque is 75-352 N-m (60-265 lb ft).
The above conditions are met, with 4th gear
commanded and the TCC ON and one of the
following conditions occur:
Condition 1 (after 3 Occurrences)
The PCM detects a slip speed of 120-525 RPM
for greater than 5.0 seconds.
Condition 2 (in the following sequence for one
Occurrence)
1. The PCM detects a TCC Slip Speed of
110-500 RPM for 10 seconds.
• The PCM commands maximum line pressure.
• The PCM freezes shift adapts.
2. The PCM detects a TCC Slip Speed of
110-500 RPM for 10 seconds.
• The PCM commands the TCC OFF for
1.5 seconds.
• The PCM commands the TCC ON.
3. The PCM detects a TCC Slip Speed of
110-500 RPM for 10 seconds.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM commands maximum line pressure.
• The PCM inhibits the TCC engagement.
• The PCM inhibits 4th gear if in hot mode.
• The PCM freezes shift adapts.
• DTC P1870 is stored in PCM History.
Conditions for Clearing the MIL7DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
Automatic Transmission - 4L80-E 7-453
Diagnostic Aids
• A TFP Val. Position Sw. malfunction can set
DTC P1870.
• A mechanical failure of the shift solenoids or
TCC PWM Sol. Valve can set DTC P1870.
• Internal transmission failures can result in a
DTC P1870.
• Sticking shift valves or contamination may
cause intermittent slipping in D4.
• First diagnose and clear any engine DTCs that
are present. Then inspect for any transmission
DTCs that may have reset.
. DTC P1860 TCC PWM Solenoid Circuit
Electrical can cause a DTC 1870 to set.
Diagnose the electrical codes first.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
actual selected range. A faulty TFP Valve
Position Switch can set a DTC P1870.
4. This step tests for excessive TCC slip speed
while in a commanded TCC lock-up state and
in fourth gear; and confirms that the fault is
present.
5. This step tests for excessive TCC slip speed
while in a commanded TCC lock-up state and
in third gear.
6. This step tests for a sticking TCC shift valve.
8. This step tests for proper transmission line
pressure.
7-454 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1870 Transmission Component Slipping (Diesel)
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
Perform the Transmission Fluid Checking Procedure. Go to
Refer to Transmission Fluid Checking Procedure. Transmission
2 —
Fluid Checking
Did you perform the procedure? Procedure
Go to Step 3
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
3 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTC.
4. With the engine idling and at normal operating
temperature, apply the brake pedal.
5. Select each transmission range: D1, D2, D3, D4, N, Go to DTC P1810
R, and P. TFP Valve
Does each selected transmission range match the scan Position Sw
tool TFP Switch A/B/C display? (Refer to the Range CKT Malfunction
Signal table.) Go to Step 4 (Diesel)
Drive the vehicle under the following conditions:
. The TFT is +20 *-130 • C (68 *-266 * F)
• The transmission is in D4.
4 • The TCC is duty cycle is greater than 70%. 120 RPM
• The APP angle is 12-80%.
At any time is the TCC Slip Speed greater than the Go to
specified value for 6 seconds? Go to Step 5 Diagnostic Aids
Drive the vehicle under the following conditions:
• The transmission is in D3.
• Command the TCC ON with the scan tool.
5 110 RPM
• The APP angle is 12-80%.
At any time is the TCC Slip Speed greater than the
specified value for 6 seconds? Go to Step 7 Go to Step 6
Repeat the procedure in step 4. Drive the vehicle under
the following conditions:
• The transmission is in D4.
6 120 RPM
• The TCC duty cycle is greater than 70%.
• The APP angle is 12-80%.
Is the TCC slip speed greater than the specified value? Go to Step 8 Go to Step 11
Refer to the System Diagnosis table: Slipping TCC.
7 — —
Did you find and correct the condition? Go to Step 12
Transmission/Transaxle Automatic Transmission - 4L80-E 7-455
DTC P1870 Transmission Component Slipping (Diesel) (cont’d)
Step Action Value(s) Yes No
1. Connect the J 21867 Pressure Gauge to the
Go to the
transmission line pressure tap.
applicable System
8 2. Perform the Line Pressure Check. — Diagnosis Table:
Refer to Line Pressure Check Procedure. Low Line
Is the line pressure within specifications? Go to Step 9 Pressure
1. Remove the transmission oil pan.
Refer to Changing the Fluid and Filter, in
Go to
On-Vehicle Service.
9 — Transmission
2. Inspect for contaminated fluid and excessive Overhaul
material in the pan. Procedure, in
Is the fluid or the pan contaminated? Unit Repair Go to Step 10
1. Inspect the 1-2 SS Valve for contamination
or damaged seals.
10 2. Inspect the 2-3 SS Valve for contamination —
or damaged seals.
Did you find the condition? Go to Step 12 Go to Step 11
Inspect the following components for contamination
or sticking. Go to
Transmission
11 • The 2-3 shift valve — Overhaul
• The 3-4 shift valve Procedure, in
Did you find the condition? Go to Step 12 Unit Repair
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
. Ensure that TFT is 20 *-130' C (68 *-266 * F).
12 • Drive the vehicle in 4th gear, with the TCC —
commanded ON.
. The APP Angle is 12-80%.
• The PCM must see a slip of -20 to +20 RPM for
greater than 7 seconds. Begin the
4. Select Specific DTC. Enter DTC P1870. diagnosis again.
Has the test run and passed? System OK Go to Step 1
7-456 Automatic Transmission - 4L80-E
DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Gas)
Ignition Voltage
1 4WDLow
I Signal
I l----
C120
0.8 GRY/BLK 1694
Circuit Description
The 4WD low circuit consists of the Vehicle Control
Module (VCM), transfer case switch and the circuit
wiring. The transfer case switch is used to control the
4WD Low signal on circuit 1694. When the operator
moves the 4WD selector lever to 4WD Low, the
transfer case switch closes, and the 4WD Low signal
voltage on circuit 1694 changes from B+ voltage to
zero volts. The VCM then compensates for transfer
case gear reduction in the transmission Output Shaft
Speed (OSS) Sensor readings. The VCM uses the
transmission OSS Sensor signal in order to adjust shift
points, line pressure and Torque Converter Clutch
(TCC) scheduling.
If the VCM detects a continuous open or short to
ground in the 4WD Low signal circuit, then
DTC P1875 sets. DTC P1875 is a type D DTC. For
California emissions vehicles DTC P1875 is a
type B DTC.
Conditions for Setting the DTC
. No MAP DTCs P0106, P0107 or P0108.
. No TP Sensor DTCs P0121, P0122 or P0123.
. No OSS DTCs P0502 or P0503.
. No A/T ISS DTCs P0716 or P0717.
. No 1-2 SS Valve DTCs P0751 or P0753.
. No 2-3 SS Valve DTCs P0756 or P0758.
• No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. DTC P1860.
• The engine is running at least 475 RPM for
7 seconds.
• The TFP Val. Position Sw. is D4.
• The TP Sensor is 10-100%.
. The TFT is 20-125 °C (68-248 *F).
Transmission/Transaxle
Vehicle
1 Control
1 Module (VCM)
' A
iiA
A
A OBDIIL
B
* "* Transfer
/r 1Case
| - t j Switch
201463
• Engine torque is 67 N-m (50 lb ft):
540 N-m (400 lb ft) 5.7L
675 N-m (500 lb ft) 7.4L
• Vehicle speed is greater than 1.5 mph.
• All of the above conditions are met and one of
the following conditions occur:
- Four wheel drive low circuit is closed
(grounded) for more than 1.5 seconds with
a transfer case ratio of 0.95-1.05:1, for
5 occurrences.
- The four wheel drive low circuit is open for
1 second with a transfer case ratio of
2.68-2.76:1 in any two gears for
4 occurrences.
Action Taken When the DTC Sets
• The VCM illuminates the Malfunction Indicator
Lamp (MIL), for California emissions vehicles.
• The VCM assumes a 4WD Low state for
transmission shift patterns when stuck OFF.
• The VCM assumes a non 4WD Low state for
transmission shift patterns, when stuck ON.
• The VCM freezes shift adapts from being
updated.
• DTC 1875 is stored in VCM History.
Conditions for Clearing the DTC
1. For California emissions vehicles, the VCM
turns OFF the MIL after three consecutive trips
without a failure reported.
2. A scan tool can clear the DTC from the VCM
history. The VCM clears the DTC from the VCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
3. The VCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the VCM.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-457
Diagnostic Aids • First diagnose and clear any engine DTCs or
• Inspect the wiring for poor electrical connections TP Sensor codes that are present. Then
inspect for any transmission DTCs that may
at the VCM. Inspect the wiring for poor
have reset.
electrical connections at the transmission
20-way connector. Look for the following • Low pump pressure and a slipping trans can
problems: cause DTC P1875 to set.
- A bent terminal • Transfer case gear ratio is calculated by
dividing the A/T ISS by the OSS.
- A backed out terminal
- A damaged terminal Test Description
- Poor terminal tension The numbers below refer to the step numbers on the
diagnostic table.
- A chafed wire
3. This step tests for a short to ground in
- A broken wire inside the insulation circuit 1694.
- Moisture intrusion 4. This step tests for an open in circuit 1694 or a
- Corrosion faulty transfer case switch.
• When diagnosing for an intermittent short or
open, massage the wiring harness while
watching the test equipment for a change.

DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Gas)

Step Action Valuefs) Yes No
Go to Powertrain
OBD System
Check(5.7L) or
1 — Powertrain OBD
System Check
Was the Powertrain On-Board Diagnostic (OBD) System (OBD System
Check performed? Go to Step 2 Check) (7.4L)
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. The Clear Info function will
erase the stored Freeze Frame and Failure Records
2 from the VCM. —
3. Record the DTC Freeze Frame and Failure Records.
4. Place the transmission in Neutral.
5. Select 4WD HIGH then 4WD LOW on the transfer
case selector lever.
Does the 4WD Low on the scan tool display Disabled
when 4WD HI is selected, then Enabled when 4WD Low is Go to
selected? Diagnostic Aids Go to Step 3
1. Turn the ignition switch OFF.
2. Disconnect the transfer case switch connector.
3 —
3. Turn the ignition switch to the Run position.
Does the 4WD Low on the scan tool indicate Enabled? Go to Step 6 Go to Step 4
1. Ground terminal B of the transfer case switch
connector to a known good ground.
4 2. Ensure that the scan tool displays 4WD Low. —
Does 4WD Low on the scan tool indicate Enabled when
circuit 1694 is grounded? Go to Step 5 Go to Step 7
7-458 Automatic Transmission - 4L80-E Transmission/Transaxle
DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Gas) (cont’d)
Step Action Value(8) Yes No
Replace the transfer case switch.
5 Refer to Transfer Case Switch Replacement. — —
Is the replacement complete? Go to Step 9
1. Inspect circuit 1694 for a short to ground.
2. Repair the circuit if necessary.
6 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 9 Go to Step 8
1. Inspect circuit 1694 for an open.
2. Repair the circuit if necessary.
7 —
Refer to General Electrical Diagnosis Procedures.
Did you find the condition? Go to Step 9 Go to Step 8
Replace the VCM.
Refer to VCM Replacement/Programming (5.7L) or
8 — —
VCM Replacement/Programming (7.4L).
Is the replacement complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Select 4WD LO on the 4WD selector and drive
9 the vehicle. The transfer case gear ratio must be —
2.68-2.76 for 1 second in 4th gear with the TCC
locked.
• Select 4WD High on the selector and drive the
vehicle. The gear ratio must be 0.95-1.05 for
0.5 second in any one gear.
Begin the
4. Select Specific DTC. Enter DTC P1875. diagnosis again.
Has the test run and passed? System OK Go to Step 1
Transmission/Transaxle
DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Diesel)
IgnitionVoltage
4WDLow
Signal
__ I
D2YC1
0.5 GRY/BLK 1694
A t C120
0.8 GRY/BLK 1694
A
Transfer
Case
Switch
&
Circuit Description
The 4 Wheel Drive (4WD) Low circuit consists of the
Powertrain Control Module (PCM), transfer case
switch and the circuit wiring. The transfer case
switch is used to control the 4WD Low signal on
circuit 1694. When the operator moves the 4WD
selector lever to 4WD Low, the transfer case switch
closes, and the 4WD Low signal voltage on 1694
changes from B+ voltage to zero volts. The PCM
then compensates for transfer case gear reduction in
the transmission Output Shaft Speed (OSS) Sensor
readings. The PCM uses the transmission
OSS Sensor signal in order to adjust shift points,
line pressure and Torque Converter Clutch (TCC)
scheduling.
If the PCM detects a continuous open or short to
ground in the 4WD Low signal circuit , then
DTC P1875 sets. DTC P1875 is a type B DTC.
Conditions for Setting the DTC
. No ISS Sensor DTCs P0716 or P0717.
• No OSS Sensor DTCs P0722 or P0723.
. No TCC PWM Sol. Valve DTC P0742.
. No 1-2 SS Valve DTCs P0753 or P0751.
• No 2-3 SS Valve DTCs P0758 or P0756.
• No TFP Val. Position Sw. DTC P1810.
. No TCC PWM Sol. Valve DTC P1860.
• The gear range is D4.
• The APP Angle is 9-99%.
. The engine is running greater than 475 RPM
for more than 7 seconds.
Automatic Transmission - 4L80-E 7-459
n Powertrain
1Control
1Module (PCM)
! >
1A &
A
iO B D H k
. The TFT is 2 0 ‘ -1 3 0 *C (6 8 '-2 4 8 "F).
• All of the above conditions are met and one of
the following fail conditions exist:
- Four wheel drive low circuit is closed
(grounded) for greater than 5 seconds in any
one gear, and the transfer case ratio is
0.95-1.05:1 for 2 occurrences.
- Four wheel drive low circuit is open for
1.5 seconds in two different commanded
gears, and the transfer case ratio is
2.65-2.75:1 for the first occurrence.
Action Taken When the DTC Sets
• The PCM illuminates the Malfunction Indicator
Lamp (MIL).
• The PCM freezes shift adapts from being
updated.
• When stuck ON (closed), the PCM assumes a
non 4WD low state for a transmission shift
pattern.
• When stuck OFF (open), the PCM assumes a
4WD low state for a transmission shift pattern.
• DTC P1875 is stored in PCM history.
Conditions for Clearing the MIL7DTC
• The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
• A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the PCM
history if the vehicle completes 40 warm-up
cycles without a failure reported.
• The PCM cancels the DTC default actions
when the fault no longer exists and the ignition
is OFF long enough in order to power down
the PCM.
7-460 Automatic Transmission - 4L80-E Transmission/Transaxle

Diagnostic Aids • When diagnosing for an intermittent short or

open, massage the wiring harness while
• Inspect the wiring for poor electrical connections
watching the test equipment for a change.
at the PCM. Inspect the wiring for poor
electrical connections at the transmission • A faulty FRT axle actuator may cause a
transfer case connector. Look for the following delayed or a No upshift condition in 4WD LOW.
problems: Test Description
- A bent terminal The numbers below refer to the step numbers on the
- A backed out terminal diagnostic table.
- A damaged terminal 3. This step tests for an open in circuit 1694 or a
- Poor terminal tension faulty transfer case switch.
4. This step tests for a short to ground in
- A chafed wire
circuit 1694.
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Diesel)

Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to
1 Check performed? — Powertrain OBD
Go to Step 2 System Check
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan
tool in order to record the Freeze Frame and Failure
Records for reference. Using the Clear Info function
will erase the stored Freeze Frame and Failure
Records from the PCM.
2 3. Record the DTC Freeze Frame and Failure Records, —
then clear the DTC.
4. Place the transmission in Neutral.
5. Select 4WD HIGH then 4WD LOW on the transfer
case selector lever. (The drive wheels may have to
be rotated).
Does the 4WD LOW on the scan tool display Disabled
when 4WD HIGH is selected and Enabled when Go to
4WD LOW is selected? Go to Step* 3 Diagnostic Aids
1. Turn the ignition switch OFF.
2. Disconnect the C1 PCM connector.
3. Connect the J 39200 DMM to a good ground and to
C1-D2 connector terminal (1694-GRY/BLK).
3 4. Select Ohms on the J 39200 DMM. 0-20 Q
5. Select 4WD LOW with the shift lever while observing
the J 39200 DMM, (the drive wheels may have to be
rotated).
is the J 39200 DMM reading within the specified value
when 4WD LOW is selected. Go to Step 4 Go to Step 5
Transmission/Transaxle Automatic Transmission - 4L80-E 7-461
DTC P1875 4 Wheel Drive Low Switch CKT Malfunction (Diesel) (cont’d)
Step Action Value(s) Yes No
Select 4WD High with the shift lever, (the drive wheels
may have to be rotated).
4 50k Cl
Is the J 39200 DMM reading greater than specified value
when 4WD High is selected? Go to Step 8 Go to Step 6
Inspect or repair circuit 1694 for an open.
5 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 9 Go to Step 7
Inspect and repair circuit 1694 for a short to ground.
6 Refer to General Electrical Diagnosis Procedures. —
Did you find the condition? Go to Step 9 Go to Step 7
Replace the transfer case switch.
7 Refer to Transfer Case Switch Replacement. — —
Is the replacement complete? Go to Step 9
Replace the PCM.
8 Refer to PCM Replacement/Programming. — — -
Is the replacement complete? Go to Step 9
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
• Select 4WD LOW on the 4WD transfer case
selector lever and drive the vehicle. The gear ratio
must be 2.65-2.75 for 1 second in any gear.
9 • Select 4WD HIGH on the 4WD transfer case 4WD High
selector lever and drive the vehicle. The gear ratio
must be 0.95-1.05 for 1 second, in any gear.
4. Select Specific DTC. Enter DTC P1875.
Has the test run and passed?
Important: After the repair has been made, a harsh shift
condition may exist. This condition is caused by the steady Begin the
state adapts. To clear the steady state adapt cells, select diagnosis again.
clear taps. System OK Go to Step 1
7-462 Automatic Transmission - 4L80-E Transmission/!ransaxle
Transmission Fluid Checking Procedure
Step Action Value(s) Yes No
DEFINITION: Diagnose transmission fluid conditions by color
Check the fluid color.
1 —
Is the fluid color red? Go to Step 2 Go to Step 11
2 Is the fluid level satisfactory? — Go to Step 21 Go to Step 3
Check the fluid.
3 —
Is the fluid foamy? Go to Step 8 Go to Step 4
Check the fluid level. The proper fluid level should be in
4 the middle of the X-hatch. —
Is the level high? Go to Step 9 Go to Step 5
Fluid will be low.
5 Add fluid to the proper fluid level. — —

Is the fluid level satisfactory? Go to Step 6

Check for external leaks. Refer to Fluid Leak Diagnosis
6 and Repair. —
Did you find any leaks? Go to Step 7 Go to Step 21
Correct the leak condition.
7 — —
Did you correct the leak condition? Go to Step 21
8 Is the fluid level too high? — Go to Step 9 Go to Step 10
Remove excess fluid to the proper fluid level. Refer to
9 Fluid Changing Procedure in On-Vehicle service section. — —
Is the fluid level satisfactory? Go to Step 21
Check for contaminants in the fluid.
Drain the fluid to determine the source of the
10
contamination.
— —
Did you drain the fluid? Go to Step 15
11 Is the fluid color non-transparent pink? — Go to Step 12 Go to Step 13
Replace the cooler.
12 — —
Is the replacement complete? Go to Step 15
The fluid color should be light brown. Transmission fluid
may turn dark with normal use. This does not always
13 indicate oxidation or contamination. — —
Is the fluid color light brown? Go to Step 14
Drain the fluid to determine if the fluid is contaminated.
A very small amount of material in the bottom pan is a
14 normal condition, but large pieces of metal or other —
material in the bottom pan require a transmission overhaul.
Was the fluid contaminated? Go to Step 15 Go to Step 18
Overhaul the transmission. Refer to the Unit Repair
15 Section. — —
Is the overhaul complete? Go to Step 16
Clear TRANS ADAPT.
16 — —
Are the reset procedures complete? Go to Step 17
Add new fluid.
17 — —
Is the procedure complete? Go to Step 20
Change the fluid and the filter.
18 — —
Is this procedure complete? Go to Step 19
19 Are the reset procedures complete? — Go to Step 20 —

20 Is the fluid level satisfactory? If not, correct as needed. — Go to Step 21 —

Perform the Functional Test Procedure.
21 — —
Is the Functional Test completed? System OK
Transmission/Transaxle Automatic Transmission - 4L80-E 7-463
Transmission Fluid Checking Procedure Caution: Keep the brakes applied at a ll
1. Start the engine and operate the vehicle for times in order to prevent unexpected
15 minutes or until the transmission fluid vehicle motion.
reaches an operating temperature of 2. Start the engine and set the parking brake
82 *-93 * C (1 8 0 '-2 0 0 'F ). 3. Check for diagnostic trouble codes, including
2. Park the vehicle on a level surface. the diagnostic code for a pressure control
solenoid.
3. With your foot on the brake, move the shift
lever through each gear range. Pause for about 4. Repair the vehicle if necessary. Include the
three seconds in each range, ending in Park. following areas:
4. Apply the parking brake and let the engine idle • Inspect the fluid level
for three minutes. • Inspect the manual linkage at the
5. Remove the transmission fluid level indicator, transmission
wipe the indicator clean, and reinsert the • Install or connect the scan tool
indicator. Give the indicator a full twist to close. • Install or connect the oil pressure gage at
6. Wait three seconds and remove the indicator. the line pressure tap
7. Read both sides of the indicator. The fluid must 5. Put the gear selector in Park and set the
be within the hot cross-hatched area using the parking brake.
lowest level reading. 6. Start the engine and allow the engine to
warm up at idle.
Line Pressure Check Procedure 7. Access the Override Pressure Control Solenoid
test on the scan tool.
8. Increase the Pressure Control Solenoid Current
in 0.1-amp increments. Read the corresponding
line pressure on the pressure gage. Allow the
pressure to stabilize for 5 seconds after each
current charge.
9. Compare your data to the Drive-Park-Neutral
Line Pressure.
If your pressure readings differ greatly from the line
pressure chart, refer to the Diagnosis Charts.
The scan tool is only able to control the pressure
control solenoid in Park and Neutral with the vehicle
stopped at idle. This protects the clutches from
extremely high or low pressures in Drive or Reverse
ranges.

Road Test Procedure

• Perform the road test using the Scan Tool.
40720 • Perform this test only when traffic and road
conditions permit.
Line pressures are calibrated for two sets of gear
ranges-Drive-Park-Neutral, and Reverse. This allows • Observe all traffic safety regulations.
the transmission line pressure to be appropriate for Conduct the test according to the following steps:
different pressure needs in different gear ranges: 1. Start the engine.
2. Depress the brake pedal.
Gear Range Line Pressure Range 3. Move the gear selector between the following
Drive, Park, or Neutral 35-171 psi positions:
Reverse 67-324 psi Important: Transmission shifts should be immediate
and not harsh.
Before performing a line pressure check, verify that • Park to Reverse
the pressure control solenoid for the transmission is
• Reverse to Neutral
receiving the correct electrical signal from the vehicle
computer: • Neutral to D4
Use the scan tool in order to see if any transmission
1. Install a scan tool.
malfunction codes have been set. If so, refer to
Notice: The transmission may experience Functional Test Procedure. After repairing the
harsh, soft or mushy shifts for up to vehicle, perform the road test and verify that no
two days later. codes have been set again.
7-464 Automatic Transmission - 4L80-E
If no codes have been set and the condition
remains, refer to the Diagnostic Tables.
If the transmission is not performing well and no
trouble codes have been set, check for an
intermittent condition. Check all electrical connections
for damage or a loose fit. Some scan tools have a
snapshot test which can help to catch an intermittent
condition that does not occur long enough in order
to set a code.
If the condition is suspected to originate in the
torque converter, refer to Torque Converter Clutch
Diagnosis.
Electrical/Garage Shift Test
Perform this test before a road test in order to make
sure that electronic control inputs are connected and
operating. If you do not check the inputs before
operating the transmission, you could misdiagnose a
simple electrical condition as a major transmission
condition.
A scan tool provides valuable information. Use the
scan tool on the Hydra-Matic 4L80-E transmission for
accurate diagnosis.
1. Move the gear selector to Park (P) and set the
parking brake
2. Connect the scan tool to the DLC terminal
3. Start the engine
4. Connect power to the scan tool
5. Verify that the following signals are present on
the scan tool:
• Transmission Input(Shaft) Speed Sensor
(A/T ISS)
• Transmission Output(Shaft) Speed Sensor
(ATT OSS)
• Automatic Transmission Fluid Pressure
Manual Valve (TFP Val.) Position Switch
. Vehicle speed (MILES/HOUR)
• Current Gear
• Reference Transmission Pressure Control
Solenoid Amperage (REF CURRENT)
• Actual Transmission Pressure Control
Solenoid Amperage (ACT CURRENT)
• Engine Coolant Temperature (ECT)
• Automatic Transmission Fluid Temperature
(TFT) Sensor
• TP Angle
. TCC Duty Cycle (TCC DC)
• System Voltage
• TCC Brake Switch
6. Monitor the TCC BRAKE signal with the scan
tool while tapping the brake pedal with your
foot. The brake switch signal should be:
VCM
CLOSED - when the brake pedal is
released
OPEN - when the brake pedal is
depressed
Transmission/Transaxle
PCM
OPEN - when the brake pedal is released
CLOSED - when the brake pedal is
depressed
7. Monitor the Automatic Transmission Fluid
Pressure Manual Valve Position Switch
(TFP Switch) signal by moving the gear selector
through all of the ranges. Verify that the TFP
Switch state matches the gear range which is
indicated on the instrument panel or on the
console. Gear selections should be immediate
and not harsh.
8. Move the gear selector to Neutral and monitor
the Throttle Position Angle while increasing and
decreasing engine RPM with the accelerator
pedal. The Throttle Position Angle should
increase with the engine RPM.
Upshift Control and Torque Converter Clutch
(TCC) Apply
The vehicle computer calculates the upshift points
based primarily upon two inputs:
• Throttle Position Angle
• Vehicle speed
When the VCM/PCM indicates that a shift should
occur, an electrical signal is sent to the shift solenoids,
which in turn move the valves to perform the upshift.
The shift speed charts refer to THROTTLE
POSITION ANGLE instead of MIN THROTTLE or
WOT in order to make shift speed measurement
more uniform and accurate. Monitor THROTTLE
POSITION ANGLE by using the scan tool.
Some scan tools have been programmed in order to
measure and record shift point information. Check
the instruction manual in order to see if this test is
available.
With gear selector in D4, perform the following steps:
1. Refer to Shift Speed and choose a throttle
position of either 15% or 20%.
2. Monitor the throttle position with the scan tool.
3. Accelerate to the chosen throttle position. Hold
the throttle steady.
Important: Shift speeds may vary due to slight
hydraulic delays in responding to electronic controls.
A change from the original equipment tire size also
affects shift speeds.
4. As the transmission upshifts, note the shift
speed for each of the following gears:
• 2nd gear
• 3rd gear
• 4th gear
5. The Torque Converter Clutch (TCC) should apply
in Third or Fourth gear. The TCC will not apply
unless the engine coolant has reached a
minimum operating temperature of approximately
54 "C (130 ° F). Note when the TCC applies. If
you do not notice the apply by an RPM drop,
refer to Torque Converter Clutch Diagnosis.
6. Repeat steps 1-5 using several different
throttle angles.
Transmission/Transaxle
Part Throttle Detent Downshift
At vehicle speeds of 64-88 km/h (40-55 mph) in
Fourth gear, quickly increase the throttle angle. Verify
the following results:
• The TCC releases.
• The transmission downshifts to 3rd gear
immediately.
• The 1-2 Shift Solenoid valve turns OFF.
Full Throttle Detent Downshift
At vehicle speeds of 64-88 km/h (40-55 mph) in
Fourth gear, quickly increase the throttle angle to its
maximum position. Verify the following results:
• The TCC releases.
• The transmission downshifts to 2nd gear
immediately.
• The 1-2 and 2-3 Shift Solenoid valves
turn OFF.
Manual Downshifts
The shift solenoid valves do not control the initial
downshift during manual downshifts. All manual
downshifts are hydraulic. The solenoid states will
change during, or shortly after, a manual downshift is
selected.
1. At vehicle speeds of 64-88 km/h (40-55 mph)
in Fourth gear, release the accelerator pedal
while moving the gear selector to D3. Observe
the following results:
• The TCC releases
• The transmission downshifts to Third gear
immediately
• The engine slows the vehicle down
2. Move the gear selector back to D4 and
accelerate to 64-72 km/h (40-45 mph). Release
the accelerator while moving the gear selector
to D2 and observe the following results:
• The TCC releases
• The transmission immediately downshifts to
Second gear
• The engine slows the vehicle down
3. Move the gear selector back to D4 and
accelerate to 48 km/h (30 mph). Release the
accelerator pedal while moving the gear
selector to D1 and observe the following
results:
• The TCC releases
• The transmission immediately downshifts to
First gear immediately
• The engine slows the vehicle down
Automatic Transmission - 4L80-E 7-465
Coasting Downshifts
1. With the gear selector in D4, accelerate to
Fourth gear with the TCC applied.
2. Release the accelerator pedal and lightly apply
the brakes. Observe the following results:
• The TCC releases.
• Downshifts occur at speeds shown on the
Shift Speed Chart. Refer to Shift Speed.
Manual Gear Range Selection
The shift solenoids control the upshifts in the manual
gear ranges.
Perform the following tests by accelerating at
10-15 degrees TPS.
Manual Third (D3)
With the vehicle stopped, move the gear selector to
D3 and accelerate in order to observe the following
conditions:
• The 1-2 shift
• The 2 -3 shift
• The TCC does not apply
Manual Second (D2)
• With the vehicle stopped, move the gear
selector to D2 and accelerate in order to
observe the 1-2 shift.
• Accelerate to 56 km/h (35 mph) and observe
the following conditions:
- The 2 -3 shift does not occur.
- The TCC does not apply.
Manual First (D1)
With the vehicle stopped, move the gear selector to
D1. Accelerate to 32 km/h (20 mph) and observe the
following conditions:
• No upshifts occur.
• The TCC does not apply.
Reverse (R)
With the vehicle stopped, move the gear selector to
R and slowly accelerate in order to observe that the
1-2 Shift Solenoid valve is ON.
Torque Converter Clutch Diagnosis
The Torque Converter Clutch (TCC) is applied by
fluid pressure, which is controlled by a PWM
solenoid valve. This solenoid valve is located inside
of the automatic transmission assembly. The solenoid
valve energizes or de-energizes by making or
breaking an electrical circuit through a combination
of switches and sensors.
Torque Converter Stator
The torque converter stator roller clutch can have
two different malfunctions.
• The stator assembly freewheels in both
directions.
. The stator assembly remains locked up at
all times.
7-466 Automatic Transmission - 4L80-E
Poor Acceleration at Low Speed
If the stator is freewheeling at all times, the car
tends to have poor acceleration from a standstill. At
speeds above 50-55 km/h (30-35 mph), the car may
act normally. For poor acceleration, you should first
determine that the exhaust system is not blocked,
and the transmission is in First gear when
starting out.
If the engine freely accelerates to high RPM in
Neutral, you can assume that the engine and the
exhaust system are normal. Check for poor
performance in Drive and Reverse to help determine
if the stator is freewheeling at all times.
Poor Acceleration at High Speed
If the stator is locked up at all times, performance is
normal when accelerating from a standstill. Engine
RPM and car speed are limited or restricted at high
speeds. Visual examination of the converter may
reveal a blue color from overheating.
If the converter has been removed, you can check
the stator roller clutch by inserting a finger into the
splined inner race of the roller clutch and trying to
turn the race in both directions. You should be able
to freely turn the inner race clockwise, but you
should have difficulty in moving the inner race
counterclockwise or you may be unable to move the
race at all.
Noise
Im portant: Do not confuse this noise with pump
whine noise, which is usually noticeable in Park,
Neutral, and all other gear ranges. Pump whine will
vary with line pressure.
You may notice a torque converter whine when the
vehicle is stopped and the transmission is in Drive or
Reverse. This noise will increase as you increase
the engine RPM. The noise will stop when the
vehicle is moving or when you apply the torque
converter clutch, because both halves of the
converter are turning at the same speed.
Perform a stall test to make sure the noise is
actually coming from the converter:
1. Place your foot on the brake.
2. Put the gear selector in Drive.
Notice: You may damage the transmission if
you depress the accelerator for more than
six seconds.
3. Depress the accelerator to approximately
1200 RPM for no more than six seconds.
A torque converter noise will increase under
this load.
Transmission/Transaxle
Torque Converter Evaluation and
Diagnosis
Replace the torque converter under any of the
following conditions:
• External leaks appear in the hub weld area.
• The converter hub is scored or damaged.
• The converter pilot is broken, damaged, or fits
poorly into the crankshaft.
• You discover steel particles after flushing the
cooler and the cooler lines.
• The pump is damaged, or you discover steel
particles in the converter.
• The vehicle has TCC shudder and/or no TCC
apply. Replace the torque converter only after
all hydraulic and electrical diagnoses have been
made. The converter clutch material may be
glazed.
• The converter has an imbalance which cannot
be corrected. Refer to Flywheel/Torque
Converter Vibration Test
• The converter is contaminated with engine
coolant which contains antifreeze.
• An internal failure occurs in the stator roller
clutch.
• You notice excessive end play.
• Overheating produces heavy debris in the
clutch.
• You discover steel particles or clutch lining
material in the fluid filter or on the magnet,
when no internal parts in the unit are worn or
damaged. This condition indicates that lining
material came from the converter.
Do not replace the torque converter if you discover
any of the following symptoms:
• The oil has an odor or the oil is discolored,
even though metal or clutch facing particles are
not present.
• The threads in one or more of the converter
bolt holds are damaged. Correct the condition
with a new thread inset.
• Transmission failure did not display evidence of
damaged or worn internal parts, steel particles
or clutch plate lining material in the unit and
inside the fluid filter.
The vehicle has been exposed to high mileage
only. An exception may exist where the lining of
the torque converter clutch dampener plate has
seen excess wear by vehicles operated in
heavy and/or constant traffic, such as taxi,
delivery, or police use.
Transmission/Transaxle
Torque Converter Clutch Shudder
The key to diagnosing Torque Converter Clutch
(TCC) shudder is to note when it happens and under
what conditions.
TCC shudder which is caused by the transmission
should only occur during the apply or the release of
the converter clutch. Shudder should never occur
after the TCC plate is fully applied.
If the shudder occurs while the TCC is applying, the
problem can be within the transmission or the torque
converter. Something is causing one of the following
conditions to occur:
• Something is not allowing the clutch to become
fully engaged.
• Something is not allowing the clutch to release.
• The clutch is releasing and applying at the
same time.
One of the following conditions may be causing the
problem to occur:
• Leaking turbine shaft seals
• A restricted release orifice
• A distorted clutch or housing surface due to
long converter bolts
• Defective friction material on the TCC plate
If Shudder Occurs After TCC has Applied
If shudder occurs after the TCC has applied, most of
the time there is nothing wrong with the
transmission!
As mentioned above, the TCC is not likely to slip
after the TCC has been applied. Engine problems
may go unnoticed under light throttle and load, but
they become noticeable after the TCC apply when
going up a hill or accelerating. This is due to the
mechanical coupling between the engine and the
transmission.
Once TCC is applied, there is no torque converter
(fluid coupling) assistance. Engine or driveline
vibrations could be unnoticeable before TCC
engagement.
Inspect the following components in order to avoid
misdiagnosis of TCC shudder. An inspection will also
avoid the unnecessary disassembly of a transmission
or the unnecessary replacement of a converter.
• Spark plugs - Inspect for cracks, high
resistance or a broken insulator.
• Plug wires - Look in each end. If there is red
dust (ozone) or a black substance (carbon)
present, then the wires are bad. Also look for a
white discoloration of the wire. This indicates
arcing during hard acceleration.
• Coil - Look for a black discoloration on the
bottom of the coil. This indicates arcing while
the engine is misfiring.
Automatic Transmission - 4L80-E 7-467
• Fuel injector - The filter may be plugged.
• Vacuum leak - The engine will not get a correct
amount of fuel. The mixture may run rich or lean
depending on where the leak occurs.
• EGR valve - The valve may let in too much or
too little unburnable exhaust gas and could
cause the engine to run rich or lean.
• MAP/MAF sensor - Like a vacuum leak, the
engine will not get the correct amount of fuel
for proper engine operation.
• Carbon on the intake valves - Carbon restricts
the proper flow of air/fuel mixture into the
cylinders.
• Flat cam - Valves do not open enough to let
the proper fuel/air mixture into the cylinders.
• Oxygen sensor - This sensor may command
the engine too rich or too lean for too long.
• Fuel pressure - This may be too low.
• Engine mounts - Vibration of the mounts can
be multiplied by TCC engagement.
• Axle joints - Check for vibration.
• TP Sensor - The TCC apply and release
depends on the TP Sensor in many engines. If
the TP Sensor is out of specification, TCC may
remain applied during initial engine loading.
• Cylinder balance - Bad piston rings or poorly
sealing valves can cause low power in a
cylinder.
• Fuel contamination - This causes poor engine
performance.
Flywheel/Torque Converter Vibration Test
1. Start the engine.
2. With the engine at idle speed and the
transmission in Park or Neutral, observe the
vibration.
3. Turn the key off.
Removal Procedure
1. Remove the bolts attaching the flexplate shield.
2. Remove the bolts attaching the flexplate to the
torque converter.
3. Rotate the torque converter 120 degrees.
Installation Procedure
1. Install the flexplate to the torque converter.
Secure with the attaching bolts.
Tighten
Tighten the bolts to 44 N-m (33 lb ft).
Refer to Fastener Notice.
2. Install the flexplate shield. Secure with
attaching bolts.
Tighten
Tighten the bolts to 7 N-m (60 lb in).
Start the engine and check for vibration. Repeat the
procedure until you obtain the best possible balance.
7-468 Automatic Transmission - 4L80-E Transmission/Transaxle

TFP Valve Position Switch Resistance

Check
Important: Whenever the transmission 20-way
connector is disconnected and the engine is running,
multiple DTCs will set. Clear any DTC codes after
finishing the procedure.

TFP Valve Position Switch Resistance Check

Step Action Value(s) Yes No
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
2. Using the J 39200 DVOM and the J 35616
1 50 kQ
Connector Test Adapter Kit, measure the resistance
from terminal N to the transmission case.
Is the resistance greater than the value indicated? Go to Step 3 Go to Step 2
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the TFP Val. Position Sw.
2 2. Measure the resistance from terminal A of the 50 kQ
TFP Val. Position Sw. to the switch housing.
Is the resistance greater than the value indicated? Go to Step 15 Go to Step 16
Measure the resistance from terminal R to the
3 transmission case. 50 kQ
Is the resistance greater than the indicated value? Go to Step 5 Go to Step 4
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the TFP Val. Position Sw.
4 2. Measure the resistance from terminal B of the 50 ka
TFP Val. Position Sw. to the switch housing.
Is the resistance greater than the value indicated? Go to Step 15 Go to Step 16
Measure the resistance from terminal P to the
5 transmission case. 50 kQ
Is the resistance greater than the value indicated? Go to Step 7 Go to Step 6
1. Disconnect the Automatic Transmission Wiring
Harness Assembly from the TFP Val. Position Sw.
6 2. Measure the resistance from terminal C of the 50 kQ
TFP Val. Position Sw. to the switch housing.
Is the resistance greater than the value indicated? Go to Step 15 Go to Step 16
1. Start the engine, and let the engine idle.
2. Set the parking brake.
7 3. Place the gear selector in Drive (D4).
200Q
4. Measure the resistance from terminal R to the
transmission case.
Is the resistance less than the indicated value? Go to Step 8 Go to Step 14
1. Place the gear selector in Drive (D4).
8 2. Measure the resistance from terminal P to the
200Q
transmission case.
Is the resistance less than the value indicated? Go to Step 9 Go to Step 14
Transmission/Transaxle Automatic Transmission - 4L80-E 7-469
TFP Valve Position Switch Resistance Check (cont’d)
Step Action Value(s) Yes No
1. Place the selector in Low (D1).
2. Measure the resistance from terminal N to the
9 2000
transmission case.
Is the resistance less than the value indicated? Go to Step 10 Go to Step 14
1. Place the gear selector in Low (D1).
2. Measure the resistance from terminal P to the
10 50 kO
transmission case.
Is the resistance greater than the value indicated? Go to Step 11 Go to Step 16
1. Place the gear selector in Reverse (R).
11 2. Measure the resistance from terminal N to the 2000
transmission case.
is the resistance less than the value indicated? Go to Step 12 Go to Step 16
1. Place the transmission in Reverse (R).
2. Measure the resistance from terminal P to the
12 50 kO
transmission case.
Is the resistance greater than the value indicated? Go to step 13 Go to Step 16
1. Place the gear selector in Manual Third (D3).
2. Measure the resistance from terminal R to the
13 50 kO
transmission case. No problem
Is the resistance greater than the value indicated? found. Exit table. Go to Step 16
1. Disconnect the Automatic Transmission Wiring
Harness from the TFP Val. Position Sw.
2. Inspect circuits 1224, 1225, and 1226 of the
14 —
Automatic Transmission Wiring Harness Assembly for
an open circuit.
Did you find a problem? Go to Step 15 Go to Step 16
Replace the Automatic Transmission Wiring Harness
Assembly. Refer to 4L80-E Automatic Transmission
15 On-Vehicle Service. — —
Verify repair and
Is the replacement complete? go to Step 1
1. Replace the TFP Val. Position Sw.
2. Refer to 4L80-E Automatic Transmission On-Vehicle
Service.
16 — —
3. Inspect the Automatic Transmission Wiring Harness
Assembly. Verify repair and
Is the replacement of the TFP Val. Position Sw. complete? go to Step 1
7-470 Automatic Transmission - 4L80-E Transmission/Transaxle
Automatic Transmission Wiring Harness
Check
Important: The Automatic Transmission Wiring
Harness Assembly Check cannot be used for
checking the Automatic Transmission Fluid Pressure
Manual Valve Position Switch (TFP Val. Position Sw.)
circuit. Refer to Automatic Transmission Fluid
Pressure Manual Valve Position Switch Resistance
Check for those circuits.

Automatic Transmission Wiring Harness Check

Step Action Value(s) Yes No
1. Install the J 39775 on the transmission 20-way
connector. 19-240 @
2. Using the J 39200 DVOM and a J Connector Test 20 *C (68 * F)
1 Adapter Kit J 35616, measure the resistance 24-310 @
between terminals A and E (1-2 Shift 100 *C
Solenoid Valve). (212* F)
Is the resistance within the values indicated? Go to Step 3 Go to Step 2
1. Disconnect the 1-2 Shift Solenoid Valve (1-2 SS
19-240 @
Valve) from the Automatic Transmission Wiring
20'C (68*F)
Harness Assembly (A/T Wiring Harness Assy.).
2 24-310 @
2. Using the DVOM, measure the resistance of the
100-C
1-2 SS Valve.
(212* F)
Is the resistance within the values indicated? Go to Step 12 Go to Step 14
19-240 @
20'C (68-F)
3 Measure the resistance between terminals B and E 24-310 @
(2-3 Shift Solenoid Valve). 100‘ C
Is the resistance within the values indicated? (212 *F) Go to Step 5 Go to Step 4
1. Disconnect the 2-3 Shift Solenoid Valve (2-3 SS 19-240 @
Valve) from the A/T Wiring Harness Assy. 20*C (68*F)
4 2. Using the DVOM, measure the resistance of the 24-310 @
2-3 SS Valve. 100‘ C
Is the resistance within the values indicated? (212-F) Go to Step 12 Go to Step 14
Measure the resistance between terminals S and E 10-110 @
(Torque Converter Clutch Pulse Width Modulation 20 *C (68*F)
5 Solenoid Valve). 13-150 @
Is the resistance within the values indicated? 100‘ C (212*F) Go to Step 7 Go to Step 6
1. Disconnect the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve) 10-110 @
from the A/T Wiring Harness Assy. 20*C (68*F)
6
2. Using the DVOM, measure the resistance of the 13-150 @
TCC PWM Sol. Valve. 100-C (212-F)
Is the resistance within the values indicated? Go to Step 12 Go to Step 14
Transmission/Transaxle Automatic Transmission - 4L80-E 7-471
Automatic Transmission Wiring Harness Check (cont’d)
Step Action Value(s) Yes No
3- 50 @ 20'C
Measure the resistance between terminals C and D (68-F)
7 (Pressure Control Solenoid Valve). 4- 70 9 100 *C
Is the resistance within the values indicated? (212* F) Go to Step 9 Go to Step 8
1. Disconnect the Pressure Control Solenoid Valve
(PC Sol. Valve) from the A/T Wiring Harness Assy. 3 - 50 @ 20’ C
(68 *F)
8 2. Using the DVOM, measure the resistance of the
PC Sol. Valve. 4- 70 @ 100* C
(212* F)
Is the resistance within the values indicated? Go to Step 12 Go to Step 14
3333-36890 @
Measure the resistance between terminals L and M 20*C (68*F)
9 (Transmission Fluid Temperature Sensor). 167-1890 @
Is the resistance within the values indicated? 100 *C (212* F) Go to Step 10 Go to Step 12
Measure the resistance from terminals A, B, C, D, E, L,
M„ N, P, R and S of the A/T Wiring Harness Assy, at the
10 transmission 20-way connector to the transmission case. 250kO
Is the resistance measured greater than the value No problem
indicated? found. Exit table Go to Step 11
1. Disconnect the A/T Wiring Harness Assy, from all the
components.
2. Measure the resistance from all the components
11 250kO
terminals to the transmission case.
Is the resistance measured greater than the value
indicated? Go to Step 12 Go to Step 14
Inspect for high resistance or a shorted condition:
• Inspect the A/T Wiring Harness Assy, for poor
electrical connections at the transmission 20-way
connector and at the component connectors.
• Look for possible bent, backed out, deformed, or
damaged terminals.
12 • Inspect for weak terminal tension. —
• Inspect for chafed wire that could short to bare metal
or other wiring.
• If diagnosing for a possible intermittent condition,
move or massage the A/T Wiring Harness Assy,
while observing the test equipment for a change. Verify the repair
Was high resistance or a shorted condition found? and go to Step 1 Go to Step 13
Replace the A/T Wiring Harness Assy. Verify the repair
13 — —
Is the replacement complete? and go to step 1
Replace the faulty component. Verify the repair
14 — —
Is the replacement complete? go to step 1
7-472 Automatic Transmission - 4L80-E
Clutch Plate Diagnosis
Composition Plates
Dry the plates and inspect the plates for the
following conditions:
• Pitting
• Flaking
• Wear
. Glazing
• Cracking
• Charring
• Chips or metal particles embedded in the lining
Replace a composition plate which shows any of
these conditions.
Steel Plates
im portant: If the clutch shows evidence of extreme
heat or burning, replace the springs.
Wipe the plates dry and check the plates for heat
discoloration. If the surfaces are smooth, even if
color smear is indicated, you can reuse the plate. If
the plate is discolored with heat spots or if the
surface is scuffed, replace the plate.
Causes of Burned Clutch Plates
The following conditions can result in a burned
clutch plate:
• Incorrect usage of clutch plates
• Engine coolant in the transmission fluid
• A cracked clutch piston
• Damaged or missing seals
• Low line pressure
• Valve problems
- The valve body face is not flat
- Porosity between channels
- The valve bushing clips are improperly
installed
- The checks balls are misplaced
• The Teflon® seal rings are worn or damaged
Engine Coolant in Transmission
Notice: Antifreeze will deteriorate the Viton O-ring
seals and the glue used to bond the clutch material
to the pressure plate. Both conditions may cause
transaxle damage.
Perform the following steps if the transmission oil
cooler has developed a leak, allowing engine coolant
to enter the transmission:
1. Because the coolant will attack the seal
material causing leakage, disassemble the
transmission and replace all rubber type seals.
2. Because the facing material may become
separated from the steel center portion, replace
the composition-faced clutch plate assemblies.
3. Replace all nylon parts including washers.
4. Replace the torque converter.
Transmission/Transaxle
5. Thoroughly clean and rebuild the transmission,
using new gaskets and oil filter.
6. Flush the cooler lines after you have properly
repaired or replaced the transmission cooler.
AT Oil Cooler Flow Test
Oil Cooler Flushing Procedure
Tools Required
• J 35944-A Oil Cooler and Line Flusher
• J 35944-20 Flushing Solution
1. Remove the fill cap on the J 35944-A and fill
with 0.6 liter (20 oz.) of the J 35944-20.
Do not overfill.
Follow the manufacturer’s suggested
procedures for handling the solution.
2. Install the cap on the J 35944-A and pressurize
it to 550-700 kPa (80-100 psi).
3. Connect the J 35944-A to the transaxle end of
the oil cooler pipe that feeds the bottom fitting
of the oil cooler.
4. Connect the discharge hose to the top oil
cooler pipe.
5. Clip the discharge hose to the oil drain
container.
6. With the water valve on the J 35944-A in the
OFF position, connect the water supply to
the tool.
7. Turn on the water supply.
N o t i c e : If water does not flow through the oil
cooler (system is completely plugged), do not
continue the flushing procedure, or damage to
the tool or components could result. Turn the
water OFF immediately. Inspect the pipes and
the cooler for restrictions. Replace the oil
pipe(s) and/or the oil cooler.
8. Flush the transaxle fluid by opening the water
valve to the ON position for 10 seconds.
9. Close the water valve and clip the discharge
hose to a 5 gallon pail.
10. Cover the pail with a shop towel in order to
prevent splash.
11. Turn the water valve to the ON position and
depress the trigger in order to mix the flushing
solution into the water flow.
12. Use the bale clip provided in order to hold the
trigger down.
13. Flush the cooler with water and the solution for
2 minutes. During this flush, attach an air
supply to the air valve located on the tool for
3 to 5 seconds every 15 to 20 seconds. This
will create a surging action to ensure complete
cleaning.
14. Release the trigger and turn off the water valve.
15. Disconnect both hoses from the oil cooler pipes
in order to perform an initial flush.
16. Reconnect the hoses to the pipes opposite the
initial flush to do a backflush.
Transmission/Transaxle
17. Turn the water valve to the ON position and
depress the trigger in order to mix the flushing
solution into the water flow.
18. Use the bale clip provided in order to hold the
trigger down.
19. Flush the cooler with water and the solution for
2 minutes. During this flush, attach an air
supply to the air valve located on the tool for
3 to 5 seconds every 15 to 20 seconds. This
will create a surging action to ensure complete
cleaning.
20. Release the trigger. Rinse with water for one
minute.
21. Turn off the water valve.
22. Attach the air supply to the air valve.
23. Dry the system with air until no moisture is
seen leaving the discharge hose.
24. Connect the cooler feed pipe to the transaxle.
The cooler feed is the TOP connector at the
transaxle.
25. Clip the discharge hose to the oil drain
container.
26. After filling the transaxle with fluid, start the
engine.
27. Run the engine for 30 seconds to remove the
residual moisture from the oil cooler.
At least two quarts of the fluid should flow
during the 30 second period.
If the fluid flow is sufficient, check it by
disconnecting the feed line at the cooler and
observing the flow with the engine running.
28. Check for the following conditions:
• Insufficient Flow - Inspect the transmission
for causes.
• Sufficient Flow - Inspect the cooler pipes,
fittings and repeat the cooler flushing
procedure. If the flow is still insufficient,
replace the cooler.
29. Remove the discharge hose and reconnect the
cooler pipes.
Adjust the fluid level.
Fluid Leak Diagnosis and Repair
Methods for Locating Leaks
You can generally locate and repair the cause of
most external leaks with the transmission in the
vehicle. Use any one of the following methods for
locating leaks:
General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 15 miles or until
you have reached normal operating
temperatures.
4. Park the vehicle over clean paper or cardboard.
5. Shut the engine off and look for fluid spots on
the paper.
6. Make necessary repairs.
Automatic Transmission - 4L80-E 7-473
Powder Method
1. Thoroughly clean the suspected leak area with
a solvent.
2. Apply an aerosol type powder such as foot
powder to the suspected leak area.
3. Operate the vehicle for about 15 miles or until
you have reached normal operating
temperatures.
4. Shut the engine off.
5. Inspect the suspected leak area and trace the
leak path through the powder to find the
source.
6. Make necessary repairs.
Dye and Black Light Method
1. Follow the manufacturer’s recommendation for
the amount of dye to be used.
2. Find the leak with a black light.
3. Make the necessary repairs.
Repairing the Leak
Once you have found the leak point, you must next
determine the source of the leak. A new gasket will
not repair the leak if the sealing flange is bent. You
must also repair the bent flange. Before you attempt
to repair a leak, check the following conditions:
Gaskets
• The fluid level or pressure is too high
• Plugged vent or drain-back holes
• Improperly torqued fasteners or threads that are
dirty or damaged
• Warped flanges or sealing surface
• Scratches, burrs, or other damage to the
sealing surface
• A damaged or worn gasket
• Cracking or porosity of the component
• Improper sealant
• Porosity
Seals
• The fluid level or pressure is too high
• Plugged vent or drain-back holes
• Scratches, burrs, nicks, or other damage to the
seal bore
• A damaged or worn seal
• Improper installation
• Cracks in the component
• A scratched or nicked shaft surface
• A loose or worn bearing, which causes excess
seal wear
Possible Points of Oil Leaks
• Oil may leak from the transmission bottom oil
pan or side cover for the following reasons:
- The attaching bolts are not torqued correctly.
- The gasket is damaged or improperly
installed.
- The oil pan or the mounting face is not flat.
7-474 Automatic Transmission - 4L80-E Transmission/!"ransaxle
• Oil may leak from the case for the following Case Porosity Repair Procedure
reasons: 1. Shut off the engine and thoroughly clean the
- The multi-lip seal on the filler tube is area to be repaired with a cleaning solvent.
damaged or missing. Air dry.
- The filler tube bracket is misaligned. Caution: Epoxy adhesive may cause skin
- The speed sensor seal is damaged. Irritations and eye damage. Read and follow
- The manual shaft seal is damaged. a ll Inform ation on the container label as
provided by the manufacturer.
- The connector fittings on the oil cooler are
loose or damaged. 2. Using instructions from the manufacturer, mix a
sufficient amount of epoxy, GM P/N 1052533 or
- The propeller shaft oil seal is worn or
equivalent, in order to make the repair.
damaged.
3. While the transmission case is still hot, apply
- The plug from the line pressure pipe
the epoxy. You can use a clean, dry soldering
is loose.
acid brush to clean the area and also to apply
- The casting is porous. the epoxy cement. Make certain that the area
• Oil may leak from the converter end for the to be repaired is fully covered.
following reasons: 4. Allow the epoxy cement to cure for three hours
- The converter seal is damaged. before starting the engine.
• The seal lip is cut (check the converter 5. Repeat the fluid leak diagnosis procedures.
hub for damage).
• The bushing has been moved forward and
is damaged.
• A garter spring is missing from the seal.
- The converter is leaking from a weld area.
- A casting is porous in the case or the pump.
• Fluid may come out from the vent pipe or the
fill tube under the following conditions:
- Overfilled
- If the fluid appears milky, water or coolant
may be in the fluid.
- The case is porous.
- The fluid level indicator registers incorrectly.
- A vent is plugged.
- The drain back holes are plugged.
- The oil pump is misaligned to the case
gasket, if equipped.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-475
Electronic Component Malfunctions
Component/System Can Effect
• Throttle Position Sensor (TP Sensor) • Erratic shift pattern
• Accelerator Pedal Position Sensor • High or low line pressure
• Rough engine
Engine Speed Sensor TCC apply at the wrong time, or no apply
Automatic Transmission Input(Shaft) Speed Sensor Assembly No TCC Apply
Automatic Transmission Output(Shaft) Speed Sensor • Erratic shift pattern
Assembly (Vehicle Speed Sensor) • TCC apply at the wrong time
Pressure Control Solenoid Valve • High or low line pressure
• Harsh or soft shift quality
Torque Converter Clutch Pulse Width Modulation (TCC PWM) • TCC apply at the wrong time
Solenoid Valve • TCC apply is harsh or soft
Automatic Transmission Fluid Pressure Manual Valve Position • TCC will not apply
Switch Assembly • Will not shift into fourth gear
• Harsh shift quality
• High line pressure
Automatic Transmission Fluid Temperature Sensor Assembly TCC control (on or off)
Engine Temperature Sensor No TCC apply
Shift Solenoid Valves Erratic gear applications:
• Wrong gear
• Only two gears
• Does not shift
Four Wheel Drive Low Switch Erratic shift pattern
Cruise Engaged • Delays in shifting into fourth gear
• Delays in applying TCC
Torque Converter Clutch (TCC) Brake Switch TCC does not apply
7-476 Automatic Transmission - 4L80-E Transmission/Transaxle

Transmission Component Fluid Leak

Diagnosis
Possible Fluid Leak Points

105898
Legend
(3) Bolt and Seal Assembly, Pump to Case (24) Plug, Oil Test Hole
(5) Seal, Oil Pump to Case (27) Bolt, Oil Pan to Case
(8) Connector, Transmission Oil Cooler Pipe (29) Seal, Transmission Oil Pan
(9) Pipe, Vent (34) Harness Assembly, Electrical Wiring
(15) Seal, Extension to Case (201) Seal, Torque Converter Oil
(20) Seal, Prop Shaft Front Slip Yoke Oil (707) Seal Assembly, Manual Shaft
(22) Sensor Assembly, A/T Input Speed and
Output Speed
Transmission/Transaxle Automatic Transmission - 4L80-E 7-477
High Line Pressure
Checks Cause
Pressure Regulator Valve (231) Valve is stuck at high torque signal due to an undersized
bore or sediment
Reverse Boost Valve (228) Valve is stuck at high torque signal due to an undersized
bore or sediment
Retainer Pin (211) Pin is broken
Orificed Plug (210) Plug is blocked
Pressure Control Solenoid Valve (320) • Valve has failed Off
• Loose connector
VCM/PCM Loose connector
Check the VCM/PCM for current DTC(s)

Forward Motion in Neutral

Checks Cause
Manual Valve (319) Valve is mispositioned or stuck
Forward Clutch Springs (607) Jammed
Forward clutch Piston (606) Jammed
Forward Clutch Plates (610, 611) Seized or jammed
Forward Clutch Housing (602) The hole is plugged
Hub (613) The holes are plugged

Inadequate Lubrication at Low Line or Heavy Loads

Checks Cause
Converter Limit Valve (214) Valve is stuck closed by sediment or by a collapsed
valve bore
Retainer Pin (211) Broken

inadequate Lubrication
Checks Cause
Pressure Regulator Valve (231) Valve is stuck in a high demand position
Pump Body (206) Cross channel leakage
Gasket (6) Damaged
Oil Transfer Hole Cup Plug Plug is leaking

Engine Stall in Neutral

Checks Cause
TCC System TCC is stuck On or TCC is dragging
7-478 Automatic Transmission - 4L80-E Transmission/Transaxle
Loss of Power
Checks Cause
Transmission • Low oil
• Not starting in first gear
TCC System TCC is stuck On, or TCC is dragging
Torque Converter (1) Debris is in the converter
Stator Shaft (235) Shaft is broken
Turbine Shaft (502) The bushing is worn
Main Shaft (662) The bushing is worn
Output Shaft (671) The bushing is worn
Bearing (668) The bearing is worn

No Torque in Reverse and Third

Checks Cause
Forward Clutch Hub (613) The hub is broken
Snap Ring (616a) The ring is not seated
Forward Clutch Housing (602) The housing is broken

Transmission Overheats
Checks Cause
TCC Circuit Blockage during apply or release
TCC Valve Spring (224) The spring is broken
Pump Cover (206) Cross channel leakage
Pressure Regulator Valve (231) The valve is stuck in a high demand position
Oil Cooler The cooler or the cooler lines are blocked
Gasket (6) The gasket is damaged
Retainer Pin (211) The pin is broken
Turbine Shaft O-ring (2) The O-ring is damaged
Turbine Shaft Seals (503) The seals are damaged
Stator Shaft Bushing (233) The bushing is worn or damaged
Oil Transfer Hole Cup Plug The plug is leaking
Fluid The fluid level is low
Radiator Air flow is restricted

Transmission Overheats at WOT

Checks Cause
Converter Limit Valve Bypass Orificed Cup Plug The plug is blocked, therefore the converter limit valve is
stuck closed
Transmission/Transaxle Automatic Transmission - 4L80-E 7-479
Low Line Pressure
Checks Cause
Pump (203) Cross channel air leak at body to cover, or cross channel air
leak at body to case gasket
Pressure Regulator Valve (231) Valve is stuck at a low torque signal, due to an undersized
bore or to sediment.
Reverse Boost Valve (228) Valve is stuck at a low torque signal, due to an undersized
bore or to sediment.
Pump Valve Bores Excessive valve clearance due to wear.
Spring (230) The spring is broken
Retainer Pin (211) The pin is broken
Valve Body (301) • Cross channel leaks
• Cross valve land leaks
Gasket/Spacer Plate Plate is damaged or missing
Pressure Control Solenoid Valve (320) • Valve is stuck On
• Broken clip causes leakage
• Wire is pinched to ground
• A screen is missing
VCM/PCM Failed
Check the VCM/PCM for current DTC(s)

Engine Starts in Gear

Checks Cause
Manual Valve (319) • Valve is not engaged to the detent lever
• Valve is stuck in the wrong position
Neutral Safety Switch The switch is not working

Shift Lever indicates Wrong Gear

Checks Cause
Manual Valve (319) Not engaged to detent lever
Detent Pin (711) Misaligned or broken
Manual Shaft (708) The flats are not parallel
Indicator Linkage Misadjusted

No Gear Selection
Checks Cause
Detent Lever (711) The nut is loose or missing
Manual Valve (319) The valve is stuck
Spacer Plate (46) The holes are blocked
Valve Body/Case (301, 7) The channels are blocked
7-480 Automatic Transmission - 4L80-E Transmission/Transaxle

Loss of Drive
Checks Cause
Torque Converter (1) • Broken lug or failed lug welds
• Sheared lug bolts
• Worn turbine shaft splines
• Low oil
• Pump hub is cracked, scored, or broken
• Internal failure
• Failure of the closure weld
• The cover is cracked at a lug weld
Pump (203) • The pump is seized
• The pump gears are broken
Case Extension Seal (20) The seal is missing, damaged, or displaced
Orifice Plate The plate is missing or leaking around the edge
Gasket (6) Damaged
Oil Transfer Hole Cup Plug The plug is leaking or missing
Seals (503) The seals are damaged or missing
Housing (504) The housing is broken
Roller Clutch (512) The clutch is worn, broken, or locked
Carrier (514) Broken
Pinions (518) • Broken free from the pilot
• Spalled pins or pinions
• Plugged pinion pin holes
• Worn thrust washers
• Lack of lube
Bearing (513) The bearing is broken
Roller Clutch (644) • Clutch is worn, broken, or locked
• Lack of lube
Turbine Shaft (502) The shaft or the splines are broken
(Forward Clutch Components)
Seals (603, 604, 605) Nicked or cut
Checkball Leaking
Piston (606) Cracked or jammed
Housing (602) Cracked
Friction Plates (611) The plates are burned or the splines are worn
Reaction Plates (610) The plates are worn or the splines are worn
Spring Assembly (607) Jammed
Driving Hub (615) Broken
Retainer Ring (616) The ring is not seated
Driven Hub (613) The gear teeth are worn
(Rear Gear set)
Pinions (655) Broken or spalled
Pinion Pins (656) Broken or spalled
Transmission/Transaxle Automatic Transmission - 4L80-E 7-481

Loss of Drive (cont’d)

Checks Cause
Needle Bearings (654) Broken or spalled
Sun Gear (649) Broken or spalled
Pinion Thrust Washers (652) Worn
Rear Internal Gear (666) Broken or spalled
Front Internal Gear (661) Broken or spalled
Turbine Shaft Ball Seal Ineffective
Main Shaft (662) The shaft or the splines are broken
Fluid Pressure Too low

No Park
Checks Cause
Detent Lever (711) • Incomplete travel
• Lever is misaligned
Actuator Rod (710) The rabbit ears are bent, disconnected, or broken
Detent Spring (41) Mispositioned
Parking Pawl (703) Broken
Pawl Shaft (702) Broken
Park Bracket (713) Bent or broken
Bolt (714) Loose or broken
Front Internal Gear (661) The splines are broken
Manual Shaft (708) The flats are not parallel

Remains in Park
Checks Cause
Actuator Rod Assembly (710) Stretched

Difficult to Shift Out of Park

Checks Cause
Pawl Return Spring (705) Weak or broken
Vehicle Parked on a hill

Does Not Stay in Park

Checks Cause
Detent Spring (41) Weak or broken
7-482 Automatic Transmission - 4L80-E Transmission/Transaxle
No Reverse
Checks Cause
Case (7) The rear band anchor pin is broken or the pin is not
positioned
Center Support (640) Leaking at the case, or the support is broken
Center Support Seal (639) Leaking
Center Support Bolt (25) • The bolt is loose or broken
• The feed hole is blocked
Rear Band (657) Broken, worn, or not anchored
Rear Band Apply Pin (73) The pin is too short, or the pin is binding in the case
Piston (65) Binding in the case
Seal (66) Leaking, damaged, or worn
Gasket (63) Damaged or displaced
Cover (62) Damaged
Bolts (61) Broken, loose, or missing
Checkball Missing
Fluid Pressure Too low
(Direct Clutch Components)
Reaction Plates (618) The splines are worn
Friction Plates (611) The splines or the friction are worn
Spring Assembly (607) Jammed
Housing (623) Cracked
Piston (619) Leaking
Seal (620, 621, 622) Leaking
Ball Check Leaking

No First Gear - D1
Checks Cause
(Refer to No First Gear - D4)
Housing (504) Broken
Case (7) The rear band anchor pin is broken or the pin is not
positioned
Detent Lever (711) Misaligned

No Second Gear - D1
Checks Cause
(Refer to No Second Gear - D4)

No Overrun Braking - D1
Checks Cause
(Refer to No Overrun Braking - D3)
Check the VCM/PCM for current DTC(s)
Automatic Transmission Fluid Pressure Manual Valve Position • Pinched wire
Switch Assembly • Loose connector
« Loose bolt causing leakage
. No signal to the VCM/PCM
Transmission/Transaxle Automatic Transmission - 4L80-E 7-483
No Engine Braking - D1
Checks Cause
Rear Band (657) Damaged, worn, or not anchored
Rear Band Apply Pin (73) The pin is too short or is binding in the case
Piston (65) The piston is binding in the case
Seal (66) Worn or damaged
Cover (62) Damaged
Gasket (63) Damaged or missing
Bolt (61) Loose, broken, or missing
Checkball • Missing
• Damaged
• Not sealing
• Incorrect size
Fluid Pressure Too low
Output Shaft (671) The shaft or the splines are broken
Main Shaft (662) The shaft or the splines are broken
Thrust Washer (218) Worn or damaged
Bushing (234) Worn or damaged

No First Gear - D2
Checks Cause
(Refer to No First Gear - D4)
Front Band (628) Stuck On

No Second Gear - D2
Checks Cause
(Refer to No Second Gear - D4)
Case (7) • The front band anchor pin is broken or the pin is not
properly positioned
• The intermediate clutch feed cup plug is missing or the
plug is not seated.

No Overrun Braking - D2
Checks Cause
(Refer to No Overrun Braking - D3)

No Engine Braking - D2
Checks Cause
Bushing (234} Worn or damaged
Thrust Washer (218) Worn or damaged
Rear Gear set Spalled or broken
Reaction Drum and Carrier (651) Broken
Main Shaft (662) The shaft or the splines are broken
Output Shaft (671) The shaft or the splines are broken
Sun Gear Shaft (649) The shaft or the splines are broken
7-484 Automatic Transmission - 4L80-E Transmission/Transaxle

No Second Gear Engine Braking - D2

Checks Cause
Fluid Pressure Too low
Direct Clutch Housing (623) • The internal diameter of the splines are worn
• The outer band surface is worn
Front Band (628) Broken, worn, or not anchored
Apply Pin (55) Too short or binding in the case
Apply Clip (56) Broken or missing
Piston (58) Cracked, broken, or binding
Seal (57) Damaged or worn
Case (7) Cracked or damaged
Spacer Plate (46) Damaged
Gasket (48) Torn or pinched
Valve Body Bolts (35) Loose, broken, or missing

No First Gear - D3
Checks Cause
(Refer to No First Gear - D4)
Front Band (628) Stuck On

No Second Gear - D3
Checks Cause
(Refer to No Second Gear - 04}

No Third Gear - D3
Checks Cause
(Refer to No Third Gear - D4)
Front Band (628) Stuck On

No Overrun Braking - D3
Checks Cause
Clutch Plates (508, 509) The splines or the plate are worn
Thrust Washer (218) Damaged or worn
Output Shaft (671) The shaft or the splines are broken
Seals Cut or nicked
Checkball Leaking
Piston (505) Jammed, cracked, or damaged
Housing (504) Cracked or damaged
Sun Gear (650) Worn
Spring Assembly (506) Jammed
Oil Feed Plugged
Transmission/Transaxle Automatic Transmission - 4L80-E 7-485
No Engine Braking - D3
Checks Cause
Main Shaft (662) The shaft or the splines are broken
Bushing (234) Damaged or worn

No First Gear - D4
Checks Cause
Low Roller Assembly (644) • Assembly is not attached
• Broken race
Center Support (640) Broken support or broken splines
Case (7) Check damage near the center support
Retainer Rings (633, 643) Rings are not seated

First Gear Only - D4

Checks Cause
Sun Gear Shaft (649) Broken shaft or broken splines
A/T Output Speed Sensor Assembly (22) Reads zero
A/T Input Speed Sensor Assembly (22) Reads zero

First and Second Gear Only - D4

Checks Cause
2-3 Solenoid (311) • Stuck Off
• Loose connector
• No voltage to the solenoid
• Solenoid O-ring failure
• No PCM signal to the solenoid
2-3 Shift Valve (312) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

Second Gear Only - D4

_____________________ Checks Cause
Check the VCM/PCM for current DTCs
7-486 Automatic Transmission - 4L80-E Transmission/Transaxle
Second and Third Gear Only - D4
Checks Cause
1-2 Solenoid (313) • Stuck Off
• Loose connector
• No voltage to the solenoid
• Solenoid O-ring failure
• No PCM signal to the solenoid
1-2 Shift Valve (314) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

First and Fourth Gear Only - D4

Checks Cause
1-2 Solenoid (313) • Stuck Off
• Pinched wire to ground
1-2 Shift Valve (314) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

Third and Fourth Gear Only - D4

Checks Cause
2-3 Solenoid (311) • Stuck Off
• Pinched wire to ground
2-3 Shift Valve (312) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

No Second Gear - D4
Checks Cause
Case (7) The intermediate clutch feed cup plug is missing or the cup
plug is not seated
Intermediate Clutch Components
Backing Plate (630) Broken
Retainer Ring (633) Missing or not seated
Friction Plates (631) Worn
Outer Race (625) Worn Splines
Center Support (640) The support is cracked or the feed hole is blocked
Center Support Bolt (25) • The bolt is broken or loose
• The oil hole is blocked
Seals (637, 638) Worn
Piston (636) Cracked or jammed
Springs (635) Jammed
Transmission Fluid • Improper fluid
• Additive package
Transmission/Transaxle Automatic Transmission - 4L80-E 7-487
No Second Gear - D4 (cont’d)
Checks Cause
Intermediate Sprag (624) • The outer race splines are worn
• The outer race is broken
• The splines or the inner race is worn
Direct Clutch Housing (623) Broken
Retainer Ring (627) Missing or not seated

No Third Gear - D4
Checks Cause
(Direct Clutch Components)
Seal (620, 621, 622) Leaking
Ball Check Leaking
Piston (619) Cracked or jammed
Housing (623) Cracked
Reaction Plates (618) Worn splines
Friction Plates (611) Worn splines or worn friction
Spring Assembly (607) Jammed
Center Support Seal (639) The seal is leaking at the case
Center Support (640) The support is broken or leaking at the case
Center Support Bolt (25) • Loose or broken
• Blocked hole
2-3 Solenoid (311) • Stuck Off
• Pinched wire
• O-ring failure
• No voltage to the solenoid
VCM/PCM No signal to the solenoid
2-3 Shift Valve (312) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

No Fourth Gear - D4
Checks Cause
(Fourth Clutch Components)
Seals (527, 631) Nicked or cut
Cup Plug (530) Missing
Bolt (26) Loose, broken, or missing
Piston (528) Jammed
Spring Assembly Jammed
Retainer Ring (523) Not seated
Friction Plates (525) Worn or burned
Reaction Plates (526) Worn splices
Housing (529) Damaged or cracked
7-488 Automatic Transmission - 4L80-E Transmission/Transaxle
No Fourth Gear - D4 (cont’d)
Checks Cause
(Overrun Clutch Components)
Housing (504) Broken
Reaction Plates (508) Worn splines
Sun Gear (650) Worn
2-3 Solenoid (311) • Stuck Off
• Pinched wire
• O-ring failure
• No voltage to the solenoid
VCM/PCM No signal to the solenoid
2-3 Shift Valve (312) Stuck
Quad Driver Module Failed
Check the VCM/PCM for current DTCs

No TCC Apply
Checks Cause
TCC Shift Solenoid Valve (323) • Stuck Off
• O-ring failed
• No voltage to the solenoid
• Poor connection
Quad Driver Module Failed
VCM/PCM No signal to the solenoid
Brake Switch • The contact is corroded
• Poor connection
• Pinched wire
• Misadjusted
• No supply voltage
TCC Valve (223) The valve is stuck Off due to sediment or to an
undersized bore
Retainer Pin (211) Broken
Torque Converter (1) Ballooning
Turbine Shaft (502) Plugged oil holes
Turbine Shaft Seals (501) Ineffective
Pump Body Bushing (202) Worn
O-ring (2) Heat set
Oil Transfer Hole Cup Plug Leaking
Regulated Apply Valve (324) Stuck
TCC Valve Release Exhaust Orificed Cup Plug Blocked
Check VCM/PCM for the current DTCs
(Refer to Incorrect TCC Apply or Release)
Transmission/Transaxle Automatic Transmission - 4L80-E 7-489
Soft TCC Apply
Checks Cause
Turbine Shaft Seals (501) Ineffective
Pump Body Bushing (202) Worn
O-ring (2) Heat set
Oil Transfer Hole Cup Plug Leaking
TCC Solenoid (323) Malfunction
Fluid Low pressure

Slipping TCC
Checks Cause
TCC Valve Release Exhaust Orificed Cup Plug Blocked
Turbine Shaft Seal Cut

TCC Stuck On
Checks Cause
Gasket (6) Damaged
TCC Shift Solenoid Valve (323) • Stuck On
• Pinched wire to ground
TCC Apply Valve (324) Stuck
Quad Driver Module Failed
Check VCM/PCM for current DTCs
(Refer to Incorrect TCC Apply or Release)

Incorrect TCC Apply or Release

Checks Cause
A/T Output(Shaft) Speed Sensor Assembly (22) • Poor connection
• Pinched wire
• A broken coil wire
• Incorrect air gap
• Inadequate signal
Throttle Position Sensor • Poor connection
• Pinched wire
• Incorrect resistance
VCM/PCM Failed
Automatic Transmission Fluid Pressure Manual Valve Position • Poor Connection
Switch (40) • No signal to the VCM/PCM
• Pinched wire
A/T Fluid Temperature Sensor Assembly (332) • Poor Connection
• No signal to the VCM/PCM
• Incorrect Resistance
• Pinched wire
Engine Coolant (Gas only) No signal to the VCM/PCM
A/T Fluid Temperature Sensor Assembly (Diesel only) No signal to the PCM
7-490 Automatic Transmission - 4L80-E Transmission/Transaxle

Incorrect TCC Apply or Release (cont’d)

Checks Cause
Brake Switch • Poor connection
• Pinched wire
• No voltage supply
• Misadjusted
Engine Ignition Module Loss of signal or intermittent
Engine Tachometer (Diesel only) Loss of signal or intermittent
Check the VCM/PCM for current DTCs
(only 2WD)
Digital Ratio Adapter (DRAC) • Malfunction
• Incorrect

Converter Ballooning
Checks Cause
Converter Limit Valve (214) Stuck open due to sediment or undersized bore
At High Speeds: Converter Limit Valve Feedback Orificed Blocked
Cup Plug

No Torque Multiplication
Checks Cause
Stator Shaft (235) Broken or detached from the pump cover

Fluid Foaming
Checks Cause
Fluid • Contaminated antifreeze
• Overfilled transmission
Engine Overheated
Filter (31) Cracked or not seated
Seal (32) Damaged or not seated
Vehicle Overloaded

Noise
Checks Cause
Torque Converter (1) • Loose lug bolts
• Out of balance
• Internal failure
Transmission/Engine Misaligned
Case Extension (19) Output shaft support bushing is worn
Transmission/Transaxle Automatic Transmission - 4L80-E 7-491
Engine Stall
Checks Cause
Forward Clutch Housing (602) A seized bearing, if the holes are plugged
(Fourth Clutch Components)
Plates (525, 526) Seized or jammed
Piston (528) Jammed
Spring Assembly (532) Jammed
(Overrun Clutch Components)
Plates (508, 509) Seized or jammed
Piston (505) Jammed
Spring Assembly (506) Jammed

Vibration
Checks Cause
Torque Converter (1) • Out of balance
• Internal failure
Transmission/Engine Misaligned
Case. Extension (19) Output shaft support bushing is worn
Turbine Shaft (502) Worn surface of the stator shaft bushing
Main Shaft (662) Worn Bushing
Output Shaft (671) Worn Bushing
Bearing (668) Worn

Oil Out the Vent Tube

Checks Cause
Pump Cover (206) Cross channel leakage can pressurize the vent area
Fluid • Foaming and filling the pump vent ports
• Transmission is overfilled
Transmission Overheated

No Torque in Second Gear

Checks Cause
Intermediate Sprag (624) • Worn
• Excessive eccentricity
• The sprag is rolled over or the sprag is damaged
7-492 Automatic Transmission - 4L80-E Transmission/Transaxle
Second Gear Starts
Checks Cause
Intermediate Clutch Plates (631, 632) Seized
Direct Clutch Lube Feed Blocked
Center Support Springs (635) Jammed
Center Support Piston (636) Jammed
1-2 Shift Solenoid Valve (313) • Stuck Off
• O-ring failed
• No voltage to the solenoid
• Poor connection
VCM/PCM No VCM/PCM signal to the solenoid
Quad Driver Module Failed
1-2 Shift Valve (314) Stuck
Check the VCM/PCM for current DTCs

Third Gear Starts

Checks Cause
Forward Clutch Components
Driving Hub (615) Plugged holes
Plates (610, 611) Seized
Direct Clutch Components
Plates (611, 618) Seized
Piston (619) Jammed
Spring Assembly (607) Jammed
Lube Feed Hole Blocked

Fourth Gear Starts

Checks Cause
2-3 Shift Solenoid Valve • Stuck On
• Pinched wire to ground
Check the VCM/PCM for current DTCs

Erratic Shift Quality

Checks Cause
Gasket (6) Damaged
Oil Transfer Hole Cup Plug Leaking
Oil Seal Rings (219) Damaged

Transmission Slips
Checks Cause
Fluid Level Too high or too low
Transmission/Transaxle Automatic Transmission - 4L80-E 7-493
Transmission Seized
Checks Cause
(Rear Lube Components)
Cooler Circuit Blocked or leaking
Spacer Plate/Gasket A hole is missing
Lube Pipe (39) • Poor seal
• Damaged
• Missing clips
Valve Body (301) Loose, broken, or missing bolts
Inline Filter Blocked
Output Shaft Seal (20) • Missing or damaged
• Lube holes are missing or the holes are blocked.
Main Shaft (662) Lube holes are missing or the holes are blocked
Center Support (640) • Lube holes are missing or the holes are blocked
• Not held
Apply Pin (55) • Too long
• Binding in the case
Piston (58) Binding in the case
Snap Ring (642) Not seated.
Sun Gear Shaft (649) • Bearing surface is worn
• Blocked lube hole
Rear Gear set The bearing surface is worn
Main Shaft (662) The lube holes are plugged
(In 2nd, 3rd, and 4th)
Rear Band (657) Locked On
Rear Servo Pin (73) Too long or binding in the case
Piston (65) Binding in the case

Case Extension Bearing/Seal Failed

Checks Cause
Orifice Plate The hole is blocked or the hole is missing
Case Extension (19) The lube passages are blocked or missing

Inaccurate Shift Points

Checks Cause
A/T Output(Shaft) Speed Sensor Assembly (22) • Pinched or broken wire
• Loose connector
• Incorrect air gap
• Inadequate signal
• Damaged coil
• Damaged rotor teeth
• Loose connection
Throttle Position Sensor • Pinched or damaged wire
• Incorrect resistance
• Loose connector
• VCM/PCM malfunction
7-494 Automatic Transmission - 4L80-E Transmission/Transaxle
Inaccurate Shift Points (cont’d)
Checks Cause
A/T Fluid Pressure Manual Valve Position Switch • Loose connector
Assembly (40) • Loose bolts causing leakage
• A pinched wire
• No signal to the PCM/VCM
Axle Ratio Ratio is incorrect or ratio has been changed from its
original value
Tire Size Tire size is incorrect or the size has been changed from its
original value
Check VCM/PCM for current DTCs
(only 2WD)
Digital Ratio Adapter (DRAC) • Incorrect
• Malfunction

Harsh Shifts
Checks Cause
Line Pressure • Too high
• Too low
Pressure Control Solenoid Valve (320) • Failed Off
• Loose connector
VCM/PCM Loose connector
Accumulator Piston • Leaking
• Stuck
Accumulator Spring Incorrect
Checkballs Missing
Calibration PROM Incorrect
Check the VCM/PCM for current DTCs

Harsh Shift D to R
Checks Cause
Direct Lube Exhaust Blocked
Forward Clutch Spring (607) Not acting
Retainer Ring (616) Not seated
Checkball Plugged

Harsh Shift 3 to 4
Checks Cause
Spring Assembly (532) Not compressing evenly
Air Bleed Plugged
Bolt (26) The oil feed hole is plugged
Transmission/Transaxle Automatic Transmission - 4L80-E 7-495
Harsh Shift 4 to 3
Checks Cause
Retainer Ring (533) Not seated
Spring Assembly (532) Not acting
Bolt (26) The oil feed hole is plugged
Cup Plug (530) Plugged
Direct Lube Exhaust Blocked

Harsh Shift D4 to D3, D2, or D1

Checks Cause
Spring Assembly (506) Not functioning
Checkball Plugged
Snap Ring (511) Not seated

Soft Shifts
Checks Cause
Line Pressure Too low
Pressure Control Solenoid Valve (320) • Stuck On
• A broken clip is causing leakage
• Pinched wire to ground
VCM/PCM Failed
Accumulator Piston • Leaking
• Stuck
Accumulator Spring Incorrect
Calibration PROM Incorrect
Check the VCM/PCM for current DTCs

Soft Shift into R

Checks Cause
Direct Clutch Oil Feed Plugged
Direct Lube Exhaust Blocked

Soft Shift R to D
Checks Cause
Direct Clutch Spring (607) Not Acting
Retainer Ring (616) Not engaged or missing
Ball Check Plugged

Soft Shift 2 to 1
Checks Cause
Center Support Springs (635) Not acting
Retainer Ring (634) Not seated
Center Support (640) Blocked air bleed
7-496 Automatic Transmission - 4L80-E Transmission/Transaxle
Soft Shift 2 to 3
Checks Cause
Direct Clutch Oil Feed Plugged
Direct Lube Exhaust Blocked

Soft Shift 3 to 2
Checks Cause
Direct Spring Assembly (607) Not acting
Retainer Ring (608) Not engaged or missing
Ball Check Plugged

Soft Shift D3 to D2
Checks Cause
Ball Check Missing
Orifices Incorrect sizes

Delayed Shift 1 to 2
Checks Cause
A/T Output(Shaft) Speed Sensor Assembly (22) • A pinched or broken wire
• A loose connector
• An incorrect air gap
• An inadequate signal
• Coil damage
A/T Input (Shaft) Speed Sensor Assembly (22) • A pinched or damaged wire
• Coil damage
• An inadequate signal
A/T Fluid Pressure Manual Valve Position Switch • A loose connector
Assembly (40) • A pinched wire
• No signal to the VCM/PCM
• Loose bolts causing leakage
Calibration PROM Incorrect
Check the VCM/PCM for current DTCs
(only 2WD)
Digital Ratio Adapter (DRAC) • Malfunction
• Loose connector

No D2 to D1
Checks Cause
Rear Band (657) Broken, worn, or not anchored
Detent Lever (711) Incomplete travel

No D3 to D2
Checks Cause
Front Band (628) Broken, worn, or not anchored
Transmission/Transaxle Automatic Transmission - 4L80-E 7-497
Oil Pan Fluid Leak
Checks Cause
Oil Pan (28) The pan is damaged or the pan is not flat
Gasket (29) Damaged
Case (7) Porosity or cracked
Bolt (27) • The flange is inside out
• High or low torque

Fill Tube Fluid Leak

Checks Cause
Seal • Cut or nicked
• Missing
Case (7) Porosity
Fill Tube • Damaged at the case end
• Not seated in the case
Brackets Out of position, causing tension on the fill tube

Electrical Connector Fluid Leak

Checks Cause
Electrical Connector Damaged, or not seated
O-ring Seal • Cut or nicked
• Missing
Case (7) Porosity or cracked

Cooler Connector Fluid Leaks

Checks Cause
Cooler Connectors (8) • Stripped threads
• Damaged flare
• High or low torque
Case (7) • Stripped threads
• Porosity
• Debris in the threads

Case Extension Fluid Leak

Checks Cause
Case Extension (19) Porosity or cracked
Case (7) Porosity or cracked
Seal (15) • Cut or nicked
• Missing
Bolt (21) • Low torque
• Missing
7-498 Automatic Transmission - 4L80-E Transmission/Transaxle
Manual Shaft Fluid Leak
Checks Cause
Seal (707) • Cut or nicked
• Not seated
Linkage Misadjusted

Pump Body Seal Fluid Leak

Checks Cause
Seal (201) • Cut, nicked, or worn
• Missing garter spring
Torque Converter (1) Damaged hub
Bolt Low Torque

Vehicle Speed Sensor Fluid Leak

Checks Cause
Seal Cut, missing, or nicked
Vehicle Speed Sensor Assembly (22) • Damaged
• Not seated
• Damaged bracket
Bolt (23) • Low torque
• Missing
• Damaged threads
Case (7) Porosity or cracked

Output Shaft Seal Fluid Leak

Checks Cause
Seal (20) Cut or nicked
Case (7) Porosity or cracked

Line Pressure Plug Fluid Leak

Checks Cause
Plug (24) • Stripped threads
• Low or high torque
Case (7) • Porosity or cracked
• Damaged threads
Transmission/Transaxle Automatic Transmission - 4L80-E 7-499

Repair Instructions
Shift Cable Adjustment PR N ® 3 2 1
1. Position the steering column transmission shift
lever to PARK (P).
2. Apply the parking brake.
3. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.

102215
4. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until it reaches the full mechanical
stop position.

5. Slide the black retaining clip forward on the

range select lever cable end. This will allow the
white lock button to be pushed out.

102234
7-500 Automatic Transmission - 4L80-E Transmission/Transaxle
6. Push the white lock button on the range select
lever cable end out. This will free the metal
core adjust body which is inside the cable end.
Do not push the white lock button
completely out.
7. Inspect the metal core adjust body on the cable
end for dirt or debris that may restrict the
travel. Remove any debris by washing the
cable end, the metal core adjust body, and the
white lock button with soap and water. If the
travel of the metal core adjust body remains
restricted after the cleaning, replace the cable
assembly. Refer to Shift Cable Replacement.
8. Remove the safety stands.
9. Lower the vehicle.
10. Ensure that the parking brake is applied.
11. Turn ON the ignition switch.

12. Move the transmission shift lever from PARK

(P) to 1 and back to PARK (P) ten times.

13. Place the steering column transmission shift

lever in the Park (P) position.
PRN0321 14. Turn the ignition switch to the OFF position.
15. Raise the vehicle. Support the vehicle with
safety stands.

102215
Transmission/Transaxle Automatic Transmission - 4L80-E 7-501
16. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until it reaches the mechanical stop
position.

17. Push in the white lock button in order to secure

the core adjuster body inside the range select
lever cable end.

18. Slide the black retainer clip rearward over the

cable end until it covers the white lock button.
Lock the clip over the cable end.
19. Remove the safety stands.
20. Lower the vehicle.
21. Turn ON the ignition switch.
22. Ensure that all the transmission shift light
positions (P, R, N, D, 3, 2, 1) engaged and
illuminate. If you cannot perform this task,
repeat the cable adjustment procedures.
C a u t io n : W it h th e s e le c t o r le v e r in th e P A R K
p o s itio n , th e p a r k in g p a w l s h o u ld fr e e ly
engage w ith in th e r e a r r e a c t io n in t e r n a l g e a r
lu g s o r o u t p u t r in g h e a r lu g s a n d p r e v e n t
th e v e h ic le f r o m r o llin g , w h ic h c o u ld c a u s e
p e r s o n a l in ju r y .

23. Position the steering column transmission shift

lever to PARK (P). The shift position light
should illuminate. If you cannot perform this
task, repeat the cable adjust procedures.
7-502 Automatic Transmission - 4L80-E Transmission/Transaxle
24. Ensure that the engine starts in PARK (P) and
in NEUTRAL (N) positions only. If the engine
does not start in PARK (P) and in NEUTRAL
(N), the Park/Neutral Position Switch may need
adjustment. Refer to Park/Neutral Back Up
Switch Adjustment.
25. Turn the ignition switch to LOCK.
26. Ensure that the ignition key can only be
removed with the transmission shift lever in the
PARK (P) position.
27. Start the engine and check the vehicle
transmission shifting. The range select lever
cable is properly adjusted if the steering column
shift light positions are the same as the
transmission engagements.
28. Release the parking brake.
Shift Cable Replacement
Removal Procedure
PRN0321
1. Position the steering column transmission shift
lever to PARK (P).
2. Apply the parking brake.
3. Remove the front seat. Refer to Seats.
4. Remove the door sill trim plate. Refer to Door
Sill Plate Replacement in Interior Trim.
5. Remove the hinge pillar trim panel. Refer to
Hinge Pillar Trim Panel Replacement in
Interior Trim.
6. Remove the carpet and the carpet retainers on
the driver’s side to expose the range select
lever cable.
7. Remove the steering column filler panel from
the steering column.

102215
8. Disconnect the range select lever cable from
the steering column shift control.

102218
Transmission/Transaxle Automatic Transmission - 4L80-E 7-503
9. Disconnect the range select lever cable from
the retainers on the cab floor pan.
10. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.

11. Remove the cable retainer from the

transmission mounted bracket. Squeeze the
cable retainer while pulling the cable towards
the rear of the vehicle.
12. Disconnect the cable end from the transmission
range select lever ball stud.
13. Position the transmission range select lever to
PARK (P). Rotate the range select lever
clockwise until the lever reaches the full
clockwise stop position.

14. Remove the range select lever cable from

under the fuel line and from the rear
transmission bracket.
15. Note the routing of the range select lever cable
on the vehicle before removal.
16. Remove the safety stands.
17. Lower the vehicle.
18. Remove the range select lever cable grommet
from the floor panel.
19. Remove the range select lever cable from the
vehicle.

102222
7-504 Automatic Transmission - 4L80-E Transmission/Transaxle
Installation Procedure
1. Position the steering column transmission shift
PR N ® 3 2 1 lever to PARK (P).

102215
2. Ensure that the transmission is in the
mechanical park position. Position the
transmission range select lever to PARK (P).
Rotate the range select lever clockwise until the
lever reaches the full clockwise stop position.
3. Install the range select lever cable to the
vehicle. Route the cable in the original location
noted during removal.

4. Install the range select lever cable grommet to

the floor panel.
5. Install the range select lever cable retainers on
the cab floor pan.

102220
Transmission/Transaxle Automatic Transmission - 4L80-E 7-505
6. Install the range select lever cable end to the
steering column shift control.
7. Install the steering column filler panel to the
steering column.
8. Install the carpet and the carpet retainers on
the driver’s side.
9. Install the door sill trim plate. Refer to Door Sill
Plate Replacement in Interior Trim.
10. Install the hinge pillar trim panel. Refer to Hinge
Pillar Trim Panel Replacement in Interior Trim.
11. Install the front seat. Refer to Seats.
12. Make sure that the steering column
transmission shift lever is in Park (P).
13. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
in General Information.

14. Route the range select lever cable under the

fuel lines.
15. Connect the range select lever cable to the rear
transmission bracket.
16. Install the range select lever cable retainer to
the transmission cable bracket.

17. Remove the black shipping clip from the new

range select lever cable. Discard the clip.
18. Install the range select lever cable end to the
transmission range select lever. Push the cable
end onto the transmission range select lever
stud ball.
19. Adjust the range select lever cable. Refer to
Shift Cable Adjustment.
7-506 Automatic Transmission - 4L80-E Transmission/Transaxle

Park/Neutral Back Up Switch Replacement

Removal Procedure
1. Apply the parking brake.
2. Shift the transmission into neutral.
3. Disconnect the negative battery cable.
4. Remove the nut securing the transmission
control lever to the manual shaft.
5. Remove the transmission control lever from the
manual shaft.
6. Disconnect the wiring harness connector from
the park/neutral position switch.
7. Remove two bolts securing the park/neutral
position switch to the transmission.
8. Remove the park/neutral position switch from
the manual shaft.

Installation Procedure
Tools Required
J 41364-A
1. Position the J 41364-A onto the park/neutral
position switch. Ensure that the two slots on the
switch where the manual shaft is inserted are
lined up with the lower two tabs on the tool.
2. Rotate the tool until the upper locator pin on
the tool is lined up with the slot on the top of
the switch.

3. If the park/neutral position switch did not slide

off the manual shaft, file the outer edge of the
manual shaft in order to remove any burrs.
4. Install the switch to the transmission manual
shaft by aligning the switch hub flats with the
manual shaft flats.
5. Slide the switch onto the transmission manual
shaft until the switch mounting bracket contacts
the mounting bosses on the transmission.
6. Install the switch to the transmission with
two bolts.
Tighten
Tighten the bolts securing the switch to
28 N.m (21 lb ft).
7. Remove the J 41364-A from the switch.
8. Install the wiring harness connectors to the
switch.

32650
Transmission/Transaxle Automatic Transmission - 4L80-E 7-507
9. Install the transmission control lever to the
manual shaft with the nut.
Tighten
Tighten the control lever nut to
28 N.m (21 lb ft).
10. Lower the vehicle.
11. Connect the negative battery cable. Refer to
Battery.
12. Inspect the switch for proper operation. The
engine must start in the Park or Neutral
positions only. If adjustment is required, loosen
the switch retaining bolts and rotate the switch
slightly, then tighten the bolts and check the
switch for proper operation.

Park/Neutral Back Up Switch Adjustment

Adjustment Procedure
• Check the switch for proper operation.
• The engine must be in the P (Park) or
N (Neutral) positions only. If adjustment is
required, loosen the switch retaining bolts and
rotate the switch slightly.
• Tighten the bolts and check the switch for
proper operation.
• Repeat the switch adjustment procedure until
the engine starts when the shift lever is
positioned in park and neutral.

AT Fluid/Filter Changing
Removal Procedure
1. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.
2. Remove the oil pan bolts from the front and the
sides only. Loosen the rear oil pan bolts about
four turns.
Notice: Pry the oil pan down carefully in order
to prevent damage to the transmission case or
the oil pan sealing surfaces.
3. Place a drain pan under the transmission
oil pan.
3.1. Lightly tap the oil pan loose with a
rubber mallet or pry down in order to
allow the fluid to drain.
3.2. Inspect the fluid color. Refer to
Transmission Fluid Checking Procedure.
4. Remove the remaining oil pan bolts, the oil
pan, the gasket, and the magnet.
7-508 Automatic Transmission - 4L80-E Transmission/Transaxle
5. Remove the oil filter and the multi-lip seal. The
seal may be stuck in the pump.
6. Inspect the filter: Pry open the filter and look
inside for the following evidence of root cause
diagnosis:
• Clutch Material
• Bronze slivers indicating bushing wear
• Steel particles
7. Clean the transmission case and the oil pan
gasket surfaces with solvent. Air dry the
transmission case.
8. Remove all traces of old gasket material.

Installation Procedure
Tools Required
J 36850 Transjel® Transmission Assembly Lubricant
1. Lubricate lightly a new oil filter neck seal
assembly. Use J 36850 or equivalent.
2. Install the following parts:
2.1. A new oil filter neck seal assembly
2.2. A new oil filter assembly

3. Install the following parts:

3.1. A new transmission oil pan gasket
3.2. The magnet into the oil pan
3.3. The oil pan
3.4. The oil pan retainer bolts
Tighten
• 4L80E—Tighten the bolts to
24 N.m (18 lb ft).
• 4L60E—Tighten the bolts to
11 N.m (97 lb in).
Notice: Refer to Fastener Notice in
Cautions and Notices.
4. Remove the safety stands.
5. Lower the vehicle.
6. Add new automatic transmission fluid. Refer to
Fluid Capacity and to Transmission Fluid
Checking Procedure.
7. Check the oil pan seal for leaks.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-509

Oil Pan Replacement

Removal Procedure
1. Remove the transmission. Refer to
Transmission Replacement in Automatic
Transmission.
2. Drain the engine oil.
3. Remove the exhaust crossover pipe (4)
retaining bolts from the left exhaust manifold (5)
flange and the exhaust manifold rear pipe (2).
4. Remove the exhaust crossover pipe (4).

5. Remove the oil pan bolts.

6. Remove the oil pan.
7. Do not remove the gasket from the oil pan
groove unless replacement is required. The
gasket is reusable unless damaged.

Installation Procedure
1. If required, install a new oil seal by starting the
seal into the pan groove and working the seal
into the groove in both directions. Once the
seal is exposed to oil, it will expand and no
longer stay in the groove without wrinkles. If
this condition exists, replace the oil seal with a
new seal.
2. Position the oil pan on the crankcase.

62343
7-510 Automatic Transmission - 4L80-E Transmission/Transaxle
3. Install the oil pan bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in) in
sequence shown.
Notice: Refer to Fastener Notice in Cautions
and Notices.

53647
4. Install the exhaust crossover pipe (4).
5. Install the exhaust crossover retaining bolts into
the left exhaust manifold (5) flange and the
exhaust manifold rear pipe (5).
Tighten
Tighten the exhaust crossover retaining bolts to
30 N.m (22 lb ft).
6. Install the transmission assembly. Refer to
Transmission Replacement in Automatic
Transmission.
7. Refill the engine oil. Oil capacity is 6.65 liters
(7 quarts) without a filter change and 7.1 liters
(7.5 quarts) with an oil filter change.

Filler Tube and Seal Replacement

Removal Procedure
1. Remove the engine air cleaner. Refer Engine
Controls.
2. Remove the transmission fluid level indicator
from the fluid fill tube.

102516
Transmission/Transaxle Automatic Transmission - 4L80-E 7-511
3. For the gasoline engine, remove the stud
securing the transmission fluid fill tube bracket
to the transmission.

4. For the diesel engine, remove the transmission

fluid fill tube bracket and ground wire to the
transmission.
5. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.
6. Remove any dirt from the transmission where
the fluid fill tube enters the transmission case.
7. Remove the transmission fluid fill tube from the
transmission. Pull the tube upward from the
transmission.

8. Remove the transmission fill tube seal.

9. Clean the metal parts using solvent. Do not
allow the solvent to enter the transmission.
10. Air dry the parts.

102526
7-512 Automatic Transmission - 4L80-E Transmission/Transaxle
Installation Procedure
1. Install a new oil level indicator tube seal into
the transmission case.

2. Install the oil level indicator tube into the seal

3. For the gasoline engine, install the stud that
secures the oil level indicator tube bracket to
the transmission.
Tighten
Tighten the stud to 47 N-m (35 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.

4. For the diesel engine, install the bolt and nut

that secures the oil level indicator tube bracket
and ground wire to the transmission.
Tighten
Tighten the bolt and the nut to
25 N-m (18 1b ft).
5. Remove the safety stands.
6. Lower the vehicle.
7. Install the air cleaner. Refer to Engine Controls.

102528
Transmission/Transaxle Automatic Transmission - 4L80-E 7-513
8. Install the oil level indicator.
9. Check the transmission fluid level. Refer to
Fluid Capacity (On-Vehicle) and to Transmission
Fluid Checking Procedure.

Vehicle Speed Sensor Replacement

Removal Procedure
1. Disconnect the negative battery cable.
C a u tio n : R e f e r t o 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 to n s a n d N o tic e s .

2. Raise the vehicle. Support the vehicle. Refer to

General Vehicle Lifting and Jacking in General
Information.
3. Disconnect the electrical connectors from both
of the vehicle speed sensors.
4. Remove the vehicle speed sensors from the
transmission case.
5. Inspect the speed sensors for damage.

Installation Procedure
1. Install the vehicle speed sensors into the
transmission case.
Tighten
Tighten the speed sensor bolt to
11 N-m (97 lb in).
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. Connect the electrical connectors to both
vehicle speed sensors.
3. Remove the safety stands.
4. Lower the vehicle.
5. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the bolt to 15 N-m (11 lb ft).

102535
7-514 Automatic Transmission - 4L80-E
Park Lock Pawl and Actuator Replacement
Removal Procedure
Refer to the following transmission component
locator graphic as needed:
Park Lock Pawl And Actuator Assembly
1. Remove the manual shift shaft nut.
2. Remove the manual shaft retaining pin.
3. Remove the inside detent lever.
4. Remove the parking lock actuator assembly.
5. Remove the bolt and the parking lock bracket.
6. Remove the stud and the parking pawl return
spring.
7. Remove the parking pawl shaft hole plug.
Use a modified screw extractor.
8. Remove the following parts:
8.1. The parking lock pawl shaft retainer
8.2. The parking lock pawl shaft
8.3. The parking lock pawl
9. Remove the manual shift shaft.
10. Remove the manual shift shaft seal assembly.
11. Remove the vehicle speed sensors and the
bracket assemblies.
1. Inspect the parking lock pawl for the following
conditions:
• Cracks
• Burrs
• Damage
2. Inspect the parking lock pawl shaft for the
following conditions:
• Damage
• Freeness of fit
3. Inspect the parking pawl return spring for the
following conditions:
• Distortion
• Damage
Transmission/Transaxle
4. Inspect the inside detent lever and the parking
lock actuator assembly for the following
conditions:
• Cracks
• Damage
5. Inspect the manual shift shaft for damaged flats
or damaged threads.
Installation Procedure
Refer to the following transmission component
locator graphic as needed:
Park Lock Pawl And Actuator Assembly
1. Install the parking lock pawl shaft.
2. Install the parking lock pawl.
3. Apply Loctite® sealer or the equivalent to a
new parking pawl shaft hole plug.
4. Install the new parking pawl shaft hole plug.
Use a 7.937 mm (0.312 in) diameter rod in
order to install the plug.
5. Install the parking lock pawl shaft retainer.
6. Install the parking pawl return spring stud.
7. install the parking pawl return spring.
8. Install the inside detent lever to the parking lock
actuator assembly.
9. Install the parking lock actuator assembly over
the parking lock pawl.
10. Install the manual shift shaft seal assembly and
the manual shift shaft.
11. Install the manual shift shaft nut.
12. Install the manual shaft retaining pin.
13. Remove two bolts and the parking lock bracket.
Tighten
Tighten the bolts to 24 N.m (18 lb ft).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.
Transmission/Transaxle Automatic Transmission - 4L80-E 7-515

Pressure Regulator Replacement

Removal Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
C a u tio n : R e fe r to B a t t e r y D is c o n n e c t C a u tio n

2. Raise the vehicle. Refer to Vehicle Lifting and

Jacking in General Information.
3. Support the vehicle with safety stands.
4. Remove the transmission oil pan and the
transmission oil filter. Refer to AT Fluid/Filter
Changing
5. Remove the reverse boost valve bushing
retainer ring.
6. Remove the following parts:
(Refer to Pressure Regulator Valve and
TCC Valve.)
6.1. The reverse boost valve bushing
6.2. The reverse boost valve
6.3. The pressure regulator spring retainer
6.4. The pressure regulator spring
6.5. The pressure regulator valve
6.6. The reverse boost valve bushing
Installation Procedure
Tools Required
J 36850
1. Install the pressure regulator valve. Refer to
Special Tools. Retain the pressure regulator
valve in position with J 36850
2. Pre-assemble the following parts: Refer to
Pressure Regulator Valve and TCC Valve
2.1. The reverse boost valve bushing
2.2. A new reverse boost valve
2.3. A new pressure regulator spring retainer
2.4. The added isolator pressure regulator
spring
2.5. The pressure regulator spring
3. Install the pre-assembled parts into the
pump bore.
4. Install the reverse boost valve bushing retainer 102558
ring while holding the reverse boost valve
bushing in place. Ensure the retainer ring is in
the groove.
5. Install the transmission oil pan and the
transmission oil filter. Refer to AT Fluid/Filter
Changing
6. Remove the safety stands.
7. Lower the vehicle.
8. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).
7-516 Automatic Transmission - 4L80-E Transmission/Transaxle

TCC Valve and Spring Replacement

Removal Procedure
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
Caution: Refer to Battery Disconnect Caution
2. Raise the vehicle. Refer to Vehicle Lifting and
Jacking in General Information.
3. Support the vehicle with safety stands.
4. Remove the transmission oil pan and the
transmission oil filter. Refer to A T F l u i d / F i l t e r
C h a n g in g

5. Remove the wiring harness (if needed)

6. Remove the valve bore plug retainer ring.
7. Remove the following parts:
(Refer to P r e s s u r e R e g u l a t o r V a lv e a n d
102558
TCC V a lv e . )

7.1. The valve bore plug

7.2. The TCC valve
7.3. The TCC valve spring
Installation Procedure
1. install the following parts: Refer to P re s s u re
R e g u l a t o r V a lv e a n d T C C V a lv e

1.1. The TCC valve spring

1.2. The TCC valve
1.3. The valve bore plug
2. Install the valve bore plug retainer ring.
3. Install the wiring harness, if removed
4. Install the transmission oil pan and the
transmission oil filter. Refer to A T F l u i d / F i l t e r
C h a n g in g

5. Remove the safety stands.

6. Lower the vehicle.
7. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
102558
Tighten the terminal bolt to 15 N-m (11 lb ft).
Transmission/Transaxle Automatic Transmission - 4L80-E 7-517
Accumulator Housing Replacement
Removal Procedure
1. Remove the 3rd and 4th clutch accumulator
housing bolts (53).
2. Remove the 3rd and 4th clutch accumulator
housing (51).
3. Remove the accumulator housing gasket (47).
The accumulator housing gasket may be stuck
to the spacer plate (46).
4. Remove the 3rd clutch accumulator piston
spring (50).
5. Remove the 4th clutch accumulator piston
spring (49).
6. Remove the control valve body spacer
plate (46).
7. Remove the control valve assembly to spacer
plate gasket (45) from the spacer plate (46).
40608

Installation Procedure
Tools Required
J 25025-5 Guide Pin
1. Install the J 25025 into the control valve body
bolt hole where the manual shaft detent roller
and spring assembly is mounted.
2. Install the control valve body gasket (45).
3. Install the control valve body spacer plate (46).

40634

4. Install the third and fourth clutch accumulator

housing gasket (47).
5. Install the third clutch accumulator piston spring
(50). This spring is the longer of the two
springs.
6. Install the fourth clutch accumulator piston
spring (49).
7. Install the third and fourth clutch accumulator
housing assembly (51) onto the control valve
body assembly (44).
8. Install the six accumulator housing bolts (53).
Start the bolts finger tight and work towards the
opposite end.

40635
7-518 Automatic Transmission - 4L80-E Transmission/Transaxle
Notice: Refer to Fastener Notice in Cautions and
Notices.
9. Tighten the accumulator housing bolts
sequentially.
Tighten
Tighten the accumulator housing bolts
sequentially to 11 N-m (97 lb in).
10. Remove the J 25025-5.

Accumulator and 2-1 Manual Servo

Replacement
Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to
Vehicle Lifting and Jacking in General
Information.
2. Drain the engine oil.
3. Remove the oil pan bolts, the oil pan and
gasket. Refer to Oil Pan Replacement
4. Remove the oil filter and seal. Refer to Oil
Filter and Seal Replacement
5. Remove the accumulator attaching bolts.

97335
6. Remove the accumulator assembly.

97365
Transmission/Transaxle Automatic Transmission - 4L80-E 7-519
7. Remove the 2-1 manual servo piston
cover bolts.

97336
8. Remove the 2-1 manual servo piston assembly
and the filter.
9. Remove the seal.
10. Disassemble and inspect the accumulator and
the 2-1 manual servo assemblies. Refer to
2-1 Manual Band Servo Disassemble

Installation Procedure
Important: The seal must be installed as shown. If it
is not installed, or is installed in the wrong location,
the transmission will operate only in reverse.
1. Install the 2-1 manual servo piston
assembly seal.
2. Install the 2-1 manual servo piston assembly
and the filter.

97366
7-520 Automatic Transmission - 4L80-E Transmission/Transaxle
3. Install the 2-1 manual servo piston cover bolts.

4. Install the accumulator assembly.

5. Install the accumulator assembly

attaching bolts.
Tighten
Tighten the accumulator bolts and the 2-1
manual servo bolts to 27 N-m (20 lb ft).
Notice: Refer to Fastener Notice
6. Install the new oil filter seal and the oil filter.
Refer to Oil Filter and Seal Replacement
7. Install the oil pan gasket, the oil pan and the oil
pan bolts. Refer to Oil Pan Replacement
8. Lower the vehicle.
9. Fill the transmission to the proper level. Refer
to AT Fluid/Filter Changing
10. Inspect the oil pan gasket for leaks.

97335
Transmission/Transaxle Automatic Transmission - 4L80-E 7-521

Reverse Servo Replacement

Removal Procedure
1. Remove the rear servo assembly from the
transmission case.
Refer to Rear Servo Assembly Remove/lnstall
as needed.
2. Check the pins. Refer to Low and Reverse
Band Servo Pin Check.
3. Disassemble the rear servo accumulator. Refer
to Low and Reverse Band Servo Accumulator
Assemble.
Installation Procedure
Refer to the following transmission component
locator graphic as needed:
Rear Servo Assembly Remove/lnstall
1. Assemble the rear servo accumulator, if
needed. Refer to Low/Reverse Band Servo
Accumulator Installation.
2. Install the rear accumulator spring in the case
bore.
3. Install the following parts:
3.1. A new gasket
3.2. The cover
3.3. The six bolts using a 10-mm socket.
Tighten
Tighten the bolts to 24 N.m (18 lb ft).

Forward Servo Replacement

Removal Procedure
1. Remove the following parts:
1.1. The front servo piston assembly
1.2. The through
1.3. The retainer
1.4. The spring
2. Remove six rear servo bolts using a
10 mm socket.
3. Remove the servo cover and the gasket.

102586
7-522 Automatic Transmission - 4L80-E Transmission/Transaxle
Inspection Procedure
1. Inspect the front servo piston for porosity or
damage.
2. Inspect the seal and seal ring groove for
damage.
3. Inspect the piston pin for wear.
4. Inspect the spring for distortion.
5. Inspect the servo bore for wear or scoring.
6. Clean the all the components.
Installation Procedure
1. Install a new seal onto the piston.
2. Install the front servo piston spring and the
retainer.
3. Install the following parts:
3.1. The ring
3.2. The piston pin
3.3. The piston (Ensure the tapered end of
the piston pin contacts the band.)
4. Install the front servo assembly into the case,

Oil Cooler Line Replacement

Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to
General Vehicle Lifting and Jacking in General
Information.
2. For the7.4L Engine, remove the retainer clips
and the brackets that secure the transmission
cooler lines to the engine.

106947
Transmission/Transaxle Automatic Transmission - 4L80-E 7-523
3. For vehicles with the GVW 15,000 lb chassis,
remove the retainer clips and brackets that
secure the transmission cooler lines to the
engine.

4. For vehicles with the Turbo Diesel GVW

15,000 lb chassis, remove the retainer clips and
brackets that secure the transmission cooler
lines to the engine.

5. For vehicles with the 7.4L Engine and the

Heavy Duty chassis, remove the retainer clips
and brackets that secure the transmission
cooler lines to the engine.

106950
7-524 Automatic Transmission - 4L80-E Transmission/Transaxle
6. For the 5.7L Engine, remove the retainer clips
and brackets that secure the transmission
cooler lines to the engine.

7. For vehicles with the 7.4L Engine and the GVW

15,000 lb chassis, remove the retainer clips and
brackets that secure the transmission cooler
lines to the engine.

8. For vehicles with the Turbo Diesel with Heavy

Duty chassis, remove the retainer clips and
brackets that secure the transmission cooler
lines to the engine.

106953
Transmission/!ransaxle Automatic Transmission - 4L80-E 7-525
9. For vehicles with the Turbo Diesel with Light
Duty chassis, remove the retainer clips and
brackets that secure the transimission cooler
lines to the engine.

10. Disconnect the oil cooler pipe from the

connector at the radiator.
Important: Perform the following procedures
when removing the retaining ring and cooler
line from the quick connect fitting on the
transmission.
11. Pull the plastic cap back from the quick connect
fitting and down along the cooler line about
two inches.

12. Using a bent-tip screwdriver, pull on one of the

open ends of the retaining ring in order to
rotate the retaining ring around the quick
connect fitting until the retaining ring is out of
position and can be completely removed.

104737
7-526 Automatic Transmission - 4L80-E Transmission/Transaxle
13. Remove the retaining ring from the quick
connect fitting.
14. Discard the retaining ring.

15. Pull the cooler line straight out from the quick
connect fitting.
16. Remove the retaining ring (E-clips) securing the
cooler line to the quick connect in order to
remove the remaining cooler lines from the
remaining quick connect fittings.
17. Remove the cooler lines from the vehicle.

Installation Procedure
1. Install the transmission oil cooler line to the
vehicle.
Important:
• Do not reuse any of the existing retaining
rings that were removed from the existing
quick connect fittings. All retaining rings
being installed must be new.
• Ensure the following procedures are
performed when installing the new
retaining rings onto the fittings.
2. Install a new retaining ring (E-clip) into the
quick connect fitting using the following
procedure:
3. Hook one of the open ends of the retaining ring
in one of the slots in the quick connect fitting.

104743
Transmission/Transaxle Automatic Transmission - 4L80-E 7-527
4. Rotate the retaining ring around the fitting until
the retaining ring is positioned with all three
ears through the three slots on the fitting.

5. Do not install the new retaining ring onto the

fitting by pushing the retaining ring.

6. Ensure that the three retaining ring ears are

seen from inside the fitting and that the
retaining ring moves freely in the fitting slots.
7. Install the new retaining ring (E-clip) into the
remaining quick connect fittings.

104664
7-528 Automatic Transmission - 4L80-E Transmission/Transaxle
Notice: Ensure that the cooler line being installed
has a plastic cap on each end that connects to a
quick connect fitting. If no plastic cap exists, or the
plastic cap is damaged, obtain a new plastic cap
and position on to the cooler line prior to the cooler
line installation.
8. Install the cooler lines to the vehicle.

9. Install the cooler line into the quick connect

fitting.
10. Insert the cooler line end into the quick connect
fitting until a click is either heard or felt.

104752
11. Do not use the plastic cap on the cooler line in
order to install the cooler line into the fitting.
12. Pull back sharply on the cooler line in order to
ensure that the cooler line is fastened into the
quick connect fitting.

104750
Transmission/Transaxle Automatic Transmission - 4L80-E 7-529
13. Position (snap) the plastic cap onto the fitting.
Do not manually depress the retaining ring
when installing the plastic cap onto the quick
connect fitting.
14. Ensure that the plastic cap is fully seated
against the fitting.

104753
15. Ensure that no gap is present between the cap
and the fitting.

104754
16. Ensure that the yellow identification band on
the tube is hidden within the quick connect
fitting. A hidden yellow identification band
indicates proper joint seating.

104753
7-530 Automatic Transmission - 4L80-E Transmission/Transaxle
17. Do not install the cooler line end into the fitting
incorrectly.
18. If you cannot position the plastic cap against
the fitting, remove the retaining ring from the
quick connect fitting per Step 5 of the cooler
line removal procedure. Check the retaining ring
and the tube end in order to ensure neither is
bent. Replace the cooler line or the retaining
ring if necessary, and reinstall per Step 2 of the
cooler line installation procedure.
19. Install the cooler line into the quick connect
fitting again in order to install the remaining
cooler lines into the remaining quick connect
fittings.
20. Install the engine or transmission cooler lines to
the engine and transmission clips and brackets
as applicable. Refer to Cooling and Radiator,
4L60-E Automatic Transmission On-vehicle
Service, or 4L80-E Automatic Transmission
On-vehicle Service.
21. For vehicles with the Turbo Diesel with Light
Duty chassis, install the retainer clips and
brackets that secure the transimission cooler
lines to the engine.

22. For vehicles with the Turbo Diesel with Heavy

Duty chassis, install the retainer clips and
brackets that secure the transmission cooler
lines to the engine.

106953
Transmission/Transaxle Automatic Transmission - 4L80-E 7-531
23. For vehicles with the 7.4L Engine and the GVW
15,000 lb chassis, install the retainer clips and
brackets that secure the transmission cooler
lines to the engine.

24. For the 5.7L Engine, install the retainer clips

and brackets that secure the transmission
cooler lines to the engine.

25. For vehicles with the 7.4L Engine and the

Heavy Duty chassis, install the retainer clips
and brackets that secure the transmission
cooler lines to the engine.

106950
7-532 Automatic Transmission - 4L80-E Transmission/Transaxle
26. For vehicles with the Turbo Diesel GVW
15,000 lb chassis, install the retainer clips
and brackets that secure the transmission
cooler lines to the engine.

27. For vehicles with the GVW 15,000 lb chassis,

install the retainer clips and brackets that
secure the transmission cooler lines to the
engine.

28. For the7.4L Engine, install the retainer clips and

the brackets that secure the transmission cooler
lines to the engine.
29. Install the flair nuts securing the oil cooler lines
to the radiator or the auxiliary oil cooler if
equipped.
Tighten
Tighten the flair nuts to 45 N-m (33 lb ft).

106947
Transmission/Transaxle Automatic Transmission - 4L80-E 7-533

Transmission Oil Cooler Replacement

Removal Procedure
1. Disconnect the oil cooler line from the oil
cooler. Refer to Oil Cooler Line Replacement.
2. Remove the four bolts securing the auxiliary oil
cooler brackets to the radiator support.
3. Remove the four bolts and the nuts securing
the auxiliary oil cooler to the two brackets.

106045
Installation Procedure
1. Install the four bolts and the nuts securing the
auxiliary oil cooler to the two brackets.
Tighten
Tighten the bolts to 6 N.m (53 lb in).
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the four bolts securing the oil cooler
brackets to the radiator support.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
3. Connect the oil cooler line to the oil cooler.
Refer to Oil Cooler Line Replacement

Heat Shield Replacement

Removal Procedure
1. Remove the two bolts securing the transmission
heat shield to the transmission.
2. Remove the transmission heat shield from the
transmission.

102545
7-534 Automatic Transmission - 4L80-E Transmission/Transaxle
Installation Procedure
1. Install the transmission heat shield from the
transmission.
2. Install the two bolts securing the transmission
heat shield to the transmission.
Tighten
Tighten the bolts to 17 N-m (13 lb ft).
N o t i c e : Refer to Fastener Notice in Cautions
and Notices.

Vent Hose
Removal Procedure
1. Remove the vent hose bolt and the clamp.
2. Remove the strap securing the vent hose to the
transmission and the wiring harness.
3. Remove the vent hose from the
transmission vent.

Installation Procedure
1. Install the vent hose to the transmission.
2. Install the strap securing the vent hose to the
transmission and the wiring harness.
3. Install the bolt and the clamp.
Tighten
Tighten the bolt securing the clip and the vent
hose to the transmission to 10 N-m (89 lb in).
N o tic e : Refer to Fastener Notice

102339
Transmission/Transaxle Automatic Transmission - 4L80-E 7-535

Control Valve Body Replacement

Removal Procedure
1. Remove the transmission fluid pressure (TFP)
manual valve position switch bolts (76) and the
TFP valve position switch (40).
Important: The five O-rings should remain
attached to the TFP valve position switch (40).

2. Remove the control valve assembly bolts (35).

3. Remove the fluid level indicator stop bracket.
4. Remove the lube oil pipe retainer (37) and
the clamp.
5. Remove the lube oil pipe (39).
6. Remove the manual shaft detent spring
assembly (41).
7. Remove the control valve assembly (44) which
includes the following:
• The accumulator housing assembly (51)
• The control valve assembly to the spacer
plate gasket
• The spacer plate
• The accumulator gasket

54542
8. Remove the manual valve (319) from the
control valve body to prevent any damage.
9. Inspect the manual valve for nicks and burrs.

28384
7-536 Automatic Transmission - 4L80-E Transmission/Transaxle
10. Remove the spacer plate to case gasket (48)
from the case. The gasket may stick to the
spacer plate.
11. Remove the PWM screen (75) from the case
passages.
12. Inspect the PWM screen for debris and
damage.

Important: Do not use a magnet in order to remove

the checkballs. Using a magnet to remove the
checkballs may magnetize the checkballs, causing
metal particles to stick.
13. Remove the eight checkballs (nine checkballs
for some models).

Installation Procedure
Tools Required
• J 25025-5 Guide Pin
. J 36850 TRANSJEL™
Notice: Use Transjel™ J 36850 or equivalent during
assembly in order to retain checkballs or to lubricate
components. Greases other than the recommended
assembly lube will change the transmission fluid
characteristics and will cause undersirable shift
conditions or filter clogging.
1. Install the 8 checkballs (9 some models) into
the case passages:
• The #2 checkball is only used on RCP, RDP,
ZJP and ZLP models
• Use J 36850 or equivalent in order to hold
the checkballs in place
40637 2. Install the PWM screen into the case (75).
Transmission/Transaxle Automatic Transmission - 4L80-E 7-537
3. Install the manual valve (319) into the control
valve body.

40638

4. Install the J 25025-5 into the

transmission case.
5. Install the control valve body gasket (48).
6. Install the control valve body assembly (44).
Attach the manual valve to the detent lever
while installing the control valve body assembly.

40639

7. Install the transmission fluid pressure manual

valve position switch (40). ,
8. Install the transmission fluid pressure manual
valve position switch bolts (76) finger tight.

40640
7-538 Automatic Transmission - 4L80-E Transmission/Transaxle
9. Tighten the bolts in sequence to
11 N-m (97 lb in).
40
10. Remove the J 25025-5.

40641

11. Install the manual shaft detent roller and spring

assembly (41) and bolts (35).
12. Install the two wiring harness clips (33) and
bolts (35).
13. Install the wiring harness clip (33) and
bolts (35).
14. Install the lube oil pipe (39) with the short end
into the control valve body.
15. Install the lube oil pipe retainer (37) and the
bolt (35).

Notice: Tighten the control valve assembly bolts in a

spiral pattern starting from the center. If the bolts are
tightened in a random pattern, the valve bores may
become distorted, which can inhibit valve operation.
Notice: Refer to Fastener Notice in Cautions and
Notices.
16. Install the remaining control valve body bolts.
Tighten
Tighten the bolts sequentially to
11 N-m (97 lb in).

54712
Transmission/Transaxle Automatic Transmission - 4L80-E 7-539

Transmission Replacement
Removal Procedure
Tools Required
J 21366
1. Disconnect the battery negative cable assembly
from the battery negative terminal.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
2. Raise the vehicle. Support the vehicle with
safety stands. Refer to General Vehicle Lifting
and Jacking in General Information.
3. Disconnect the range selector cable from the
transmission bracket. Refer to Shift Cable
Replacement
4. Disconnect the range selector cable from the
transmission range selector lever. Refer to Shift
Cable Replacement
5. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft Replacement (Rear Drive) in
Propeller Shaft.
6. Support the transmission with a
transmission jack.
7. For the 4WD vehicles, remove the transfer
case. Refer to Transfer Case Replacement in
Transfer Case.
8. Gasoline Engine: Remove the following
components:
8.1. Two bolts
8.2. Two washers
8.3. One nut
8.4. The transmission to engine brace
9. Diesel Engine: Remove the following
components:
9.1. Two bolts
9.2. Two washers
9.3. The transmission to engine brace
10. Remove the nut and washer securing the
transmission mount to the crossmember.
11. Remove the two bolts and washers securing
the mount to the transmission.
12. Remove the bolts securing the crossmember to
the frame.
13. Remove the exhaust pipe from the exhaust
manifolds. Remove the muffler assembly from
the exhaust pipe, if required. Refer to Exhaust
System.

102332
7-540 Automatic Transmission - 4L80-E Transmission/Transaxle
14. Five liter and 4.3L Gasoline Engine-Remove
the six bolts securing the converter cover to the
transmission.
15. Mark the flywheel and the torque converter
alignment.

4
16. Diesel Engine and 7.4L/5.7L Engines-Remove
the four bolts securing the converter cover to
the transmission.
17. Mark the flywheel and the torque converter
alignment.

102335

18. Remove the bolts that attach the torque

converter to the engine flywheel.

102211
Transmission/Transaxle Automatic Transmission - 4L80-E 7-541
19. Remove the transmission vent hose.
20. Disconnect the wiring harness connectors from
the vehicle speed sensors and from the park
neutral position switch.
21. Remove all vehicle electrical harness wires,
harness clips, tubes, and brackets that may
interfere with the removal of the transmission.
22. Remove the fluid fill tube and the fill tube seal
from the transmission. Refer to Filler Tube and
Seal Replacement
23. Plug the fluid fill tube opening in the
transmission.
24. Disconnect the transmission oil cooler pipes
from the transmission. Refer to Oil Cooler Line
Replacement
25. Plug the transmission oil cooler pipe connectors
in the transmission case.
26. Install the J 21366 in order to keep the torque
converter from sliding off of the transmission 102339
turbine shaft.
27. Support the engine with a suitable jack stand
before removing the transmission from the
engine.
28. Remove the six studs securing the transmission
to the engine.
29. Pull the transmission straight back from the
engine.
30. Lower the transmission using the
transmission jack.
31. Flush the transmission oil cooler and the pipes
whenever you remove the transmission for
overhaul, or replacement of the torque
converter, the pump, or the transmission case.
Refer to AT Oil Cooler Flushing.
32. Clean the transmission case using a solvent
dampened cloth. Do not allow solvent to enter
the transmission.
33. Air dry the transmission.
34. Clean all hardware and the flywheel cover
using solvent. Air dry all the parts.
35. Inspect all of the components for wear and
damage.
36. Inspect all the seals and the fittings for signs
of wear.
37. Inspect the torque converter for stripped or
broken weld nuts.
38. Inspect the transmission case for cracks.
39. Clean the transmission case using a solvent
dampened cloth.
40. Do not allow solvent to enter the transmission.
Air dry.
41. Inspect all the components for wear and
damage.
42. Inspect all the seals and the fittings for signs
of wear.
43. Inspect the torque converter for stripped or
broken weld nuts.
44. Inspect the transmission case for cracks.
7*542 Automatic Transmission - 4L80-E Transmission/Transaxle
Installation Procedure
Tools Required
J 21366
Important: The torque converter and the flywheel
must be aligned and must rotate freely.
Install the brackets, the clips, and the harnesses to
the original locations.
Do not install the oil level indicator tube.
1. Install the J 21366 in order to keep the torque
converter from sliding off of the transmission
turbine shaft.
2. Install the six studs that are securing the
transmission to the engine in the following way:
2.1. Raise the transmission into place and
remove the J 21366.
2.2. Support the transmission with a
transmission jack.
2.3. Slide the transmission straight onto the
locating pins while lining up the marks on
the flywheel and the torque converter.
3. Tighten the six studs.
Tighten
Tighten the studs to 47 N-m (34 lb ft).
Notice: Refer to Fastener Notice in Cautions
and Notices.
4. Install the transmission vent hose.
5. Connect the wiring harness connectors to the
vehicle speed sensors and to the park neutral
position switch.
6. Install all of the vehicle electrical harness wires,
harness clips, tubes, and brackets removed
before transmission removal.
7. Remove the two plugs from the transmission
case cooler pipe connectors.
8. Install the transmission cooler pipes. Refer to
Oil Cooler Line Replacement.
9. Install the transmission fluid fill tube and the fill
tube seal. Refer to Filler Tube and Seal
Replacement.

102339
Transmission/Transaxle Automatic Transmission - 4L80-E 7-543
10. Install the three bolts securing the torque
converter to the engine flywheel.
Tighten
10.1. Tighten the bolts finger tight in order to
insure proper converter seating.
10.2. Tighten the bolts to 67 N.m (49 lb ft).

11. For the 6.5 liter diesel engine and the 7.4L/5.7L
gasoline engines, Install the bolts securing the
converter cover to the transmission.
Tighten
Tighten the converter cover bolts to
33 N.m (24 lb ft).

102335

12. For the 5.0L gasoline engine, install the bolts

securing the converter cover to the
transmission.
Tighten
Tighten the converter cover bolts to
33 N.m (24 lb ft).
13. Install the exhaust pipe from the exhaust
manifolds and the muffler assembly from the
exhaust pipe if required. Refer to Exhaust
System.
14. Install the bolts securing the crossmember to
the frame.
Tighten
Tighten the bolts to 77 N-m (56 lb ft).
15. Install the two bolts and washers securing the
mount to the transmission.
Tighten
Tighten the bolts to 47 N.m (35 lb ft).
7-544 Automatic Transmission - 4L80-E Transmission/Transaxle
16. Install the nut and the washer securing the
transmission mount to the crossmember.
Tighten
Tighten the bolts to 52 N-m (38 lb ft).
17. For a gasoline engine, install the two bolts, the
two washers, and a nut securing the brace to
the engine and the transmission.
Tighten
Tighten the bolts to 55 N.m (41 lb ft).

18. For a diesel engine, install the two bolts, the

two washers, and a nut securing the brace to
the engine and the transmission.
Tighten
Tighten the bolts to 70 N.m (51 lb ft).
19. For a 4WD vehicle, install the transfer case to
the transmission. Refer to Transfer Case in
Transfer Case.
20. Remove the transmission jack and the engine
support stands.
21. Install the rear propeller shaft. Refer to Rear
Propeller Shaft Replacement (Rear Drive) in
Propeller Shaft.
22. Install the transmission range select cable to
the transmission range select lever and the
bracket. Refer to Shift Cable Replacement
23. Remove the safety stands.
24. Lower the vehicle.
25. Fill with new transmission fluid. Refer to Fluid
Capacity (On-Vehicle) and to Transmission Fluid
Checking Procedure.
26. Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N.m (11 lb ft).
Transmission/Transaxle
AT Oil Cooler Flushing
O il Cooler Flushing
Tools Required
• J 35944-A Cooler Flushing Tool
• J 35944-20 Biodegradable Flushing Solution
Notice: Whenever you remove the transmission for
service, you must perform the automatic transmission
oil cooler flushing procedure in order to remove the
existing fluid which may be contaminated. This will
prevent contamination of the new fluid. You must
perform the flushing procedure after the installation
of the overhauled or replacement transmission.
Notice: Only use J 35944-20 Cooler Flushing Fluid
with the J 35944-A Oil Cooler and Line Flusher. Use
of any other fluid can result in damage to the tool,
damage to the automatic transmission oil cooler
components, or improper flushing of the cooler. Do
not reconnect the oil cooler pipes after you reinstall
the overhauled or service replacement transmission
in the vehicle.
1. Remove the fill cap on J 35944-A.
2. Fill the can with 0.6 liter ( 20-21 ounces) of
J 35944-20.
3. Follow the manufacturer’s suggested
procedures for proper handling of the solution.
Notice: Shop air supply must be equipped with
a water/oil filter and not exceed 825 kPa
(120 psi), or personal injury may result.
4. Secure the fill cap, and pressurize the flusher
can with shop air to 550-700 kPa (80-100 psi).
5. Connect the discharge hose to the transmission
end of the air cooler pipe that goes to the top
fitting at the radiator.
6. Clip the discharge hose to the oil drain
container.
7. Mount the flushing tool to the undercarriage of
the vehicle with the hook provided.
8. Connect the hose from the flushing tool to the
remaining oil cooler pipe.
9. With the water valve on the tool in the OFF
position, connect the water hose from the water
supply to the tool.
10. Turn ON the water supply at the faucet.
Automatic Transmission - 4L80-E 7-545
Initial Flushing
Notice: If water does not flow through the oil cooler
(system is completely plugged), do not continue the
flushing procedure, or damage to the tool or
components could result. Turn the water OFF
immediately. Inspect the pipes and the cooler for
restrictions. Replace the oil pipe(s) and/or the oil
cooler.
1. Switch the water valve on the tool to the ON
position. Allow the water to flow through the oil
cooler for 10 seconds in order to remove the
transmission fluid in the system.
2. Switch the water valve on the tool to the OFF
position. Clip the discharge hose onto a
5-gallon pail with a lid. If there is no lid, place
a shop towel over the end of the hose in order
to prevent splash. The discharge will foam
vigorously when you introduce solution into the
water stream.
3. Switch the water valve on the tool to the ON
position. Depress the trigger that mixes the
flushing solution into the water flow. Use the
bale clip on the handle in order to hold down
the trigger.
4. Flush the oil cooler with water and solution for
2 minutes. During the flush, attach the air
supply to the air valve on the tool for 3 to
5 seconds after every 15 to 20 second interval
in order to create a surging action.
5. Release the trigger. Switch the water valve on
the tool to the OFF position.
6. Disconnect both hoses from the oil
cooler pipes.
Backflush
• Connect the hoses to the oil cooler pipes
opposite from the initial flush in order to
perform a backflush.
• Switch the water valve on the tool to the ON
position. Depress the trigger in order to mix the
flushing solution with the water flow. Use the
bale clip on the handle to hold down the
trigger.
• Flush the oil cooler with water and solution for
2 minutes. During this flush, attach the air
supply to the air valve on the tool for 3 to
5 seconds after each 15 to 20 second interval
in order to create a surging action.
• Release the trigger. Allow water only to rinse
the oil cooler for 1 minute.
7-546 Automatic Transmission - 4L80-E
• Switch the water valve on the tool to the OFF
position.
• Turn the water supply OFF at the faucet.
• Attach the air supply to the air valve on the
tool. Dry out the system with air for at least
2 minutes. Dry out the system longer than
2 minutes, if moisture from the oil cooler line
discharge hose is visible. If available, use an
air chuck clip to secure the air chuck onto the
air valve for ease of operation.
Important: The top fitting at the transmissions
the cooler return. The bottom fitting at the
transmission is the cooler feed.
• Connect the cooler feed pipe to the
transmission.
. If not already connected, attach the discharge
hose to the cooler return pipe. Place the hose
into an appropriate drain container.
• After filling the transmission with DEXRON®’ lll
automatic transmission fluid, or equivalent, start
the engine. Run the engine for 30 seconds.
This removes any residual moisture from the oil
cooler and the cooler pipes, protects all the
components from corrosion, and checks the
flow rate through the cooler.
You should get a minimum of 1.9 liters
(2 quarts) of transmission fluid during this
30 second run. If the flow of fluid is insufficient,
disconnect the oil cooler feed line at the
radiator and restart the engine.
Depending on the flow rate, do the following
inspections:
• Insufficient Feed Flow — Inspect the
transmission for the cause.
• Sufficient Feed Flow — Inspect the oil cooler
pipes and the fittings for restrictions or leaks.
Repeat the oil cooler flushing procedure.
Repeat the check of fluid flow out of the
return line. If the flow is still restricted,
replace the transmission oil cooler. Refer to
Oil Cooler Line Replacement.
Transmission/Transaxle
• Remove the discharge hose.
• Reconnect the cooler return pipe to the
transmission.
• Refill the unit to the proper fluid level. Refer to
Transmission Fluid Checking Procedure.
Tool Cleaning Procedure
1. Clean the tool with every third use.
2. Disconnect the water supply hose from the tool.
3. Bleed air pressure from the can, remove the fill
cap, return any unused solution to the container
and rinse the can out with water. Do not store
the tool with the solution in the tank.
4. Remove the screen from the plumbing and
wash it with water.
5. Use the cleaning pin in order to remove any
material in the solution orifice. The orifice is
located in the plumbing below the screen.
6. Reconnect the plumbing and fill the can half
with water. Secure the fill cap and pressurize
the can to 550-700 kPa (80-100 psi).
7. Aim the tool into the 18.92 **[litre]** (5 gallon)
pail or floor drain and depress the trigger. Allow
the water from the can to flow through the
solution orifice for 30 seconds in order to
ensure proper cleaning.
8. Bleed air pressure from can, remove the fill
cap, and empty the can.
9. Reconnect the fill cap to the flushing tool.
Transmission/Transaxle
Description and Operation
General Service Information
How to Use This Section
This section provides the following information:
• General diagnosis information on transmissions
• A detailed description of the Hydra-matic
transmission operation
• Procedures for diagnosing the Hydra-matic
transmission
When you diagnose any condition of the Hydra-matic
transmission, begin with the Functional Test
Procedure. This procedure indicates the proper path
of diagnosing the transmission by describing the
basic checks. This procedure will then refer you to
the locations of specific checks. After you have
determined the cause of a condition, refer to
On-Vehicle Service for repair procedures. If the faulty
component is not serviceable without removing the
transmission from the vehicle, refer to Unit Repair for
repair information.
Basic Knowledge
Notice: Do not, under any circumstances, attempt to
diagnose a powertrain condition without basic
knowledge of this powertrain. If you perform
diagnostic procedures without this basic knowledge,
you may incorrectly diagnose the condition or
damage the powertrain components.
You must be familiar with some basic electronics in
order to use this section of the service manual. You
should also be able to use the following special
tools:
• A Digital Multimeter (DMM)
. A circuit tester
• Jumper wires or leads
• A line pressure gage set
The Functional Test Procedures verify the correct
operation of electronic components in the
transmission. These procedures will eliminate the
Automatic Transmission - 4L80-E 7-547
Abbreviations and Their Meanings
Throttle Positions
Minimum Throttle: The least amount of throttle
opening required for an upshift.
Light Throttle: Approximately 1/4 of accelerator
pedal travel.
Medium Throttle: Approximately 1/2 of accelerator
pedal travel.
Heavy Throttle: Approximately 3/4 of accelerator
pedal travel.
Wide Open Throttle (WOT): Full travel of the
accelerator pedal.
Full Throttle Detent Downshift: A quick apply of
the accelerator pedal to its full travel, forcing a
downshift.
Zero Throttle Coastdown: A full release of the
accelerator pedal while the car is in motion and in
drive range.
Engine Braking: A condition where the engine is
used to slow the car by manually downshifting during
a zero throttle coastdown.
Shift Conditions
Bump: A sudden and forceful apply of a clutch or
a band.
Chuggle: A bucking or jerking. This condition may
be most noticeable when the converter clutch is
engaged. It is similar to the feel of towing a trailer.
Delayed: A condition where a shift is expected but
does not occur for a period of time. This could be
described as a clutch or band engagement that does
not occur as quickly as expected during a part
throttle or wide open throttle apply of the accelerator,
or during manual downshifting to a lower range. This
term is also defined as LATE or EXTENDED.
Double Bump (Double Feel): Two sudden and
forceful applies of a clutch or a band.
Early: A condition where the shift occurs before the
car has reached proper speed. This condition tends