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TO IGNITION
COIL
Service Manual
(Fuel Injected Gas Engines Only)
FOREWORD
This Service Manual replaces Section 6C and 6E for 2.5L, 2.8L, 4.3L, 5.0L, 5.7L, and 7.4L
gasoline engines w ith throttle body injection and supplements the following shop manuals:
This manual includes the general description of a system, diagnosis and on-vehicle service
procedures for the fuel control and emissions used on light duty truck w ith a throttle body
injection fuel control system.
Wiring diagrams for the above vehicles are also published in a separate "Truck W iring
Diagram" booklet.
This manual should be kept in a handy place for ready reference. If properly used, it w ill
meet the needs of technicians and vehicle owners.
CAUTION:
These vehicle's contain some parts dimensioned in the metric system as well as in the customary
system. Some fasteners are metric and are very close in dimension to fam iliar customary fasteners in the
inch system. It is important to note that, during any vehicle maintenance procedures, replacem ent
fasteners must have the same measurements and strength as those rem oved, w h eth er m etric or
customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength.
Customary bolts use radial lines for this purpose, w hile most customary nuts do not have strength
markings.) Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly
personal injury. Therefore, fasteners removed from the vehicle should be saved for re-use in the same
location whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original. For information and assistance, see your authorized
dealer.
Proper service and repair are important to the safety of the service technician and the safe, reliable
operation of all motor vehicles. If part replacement is necessary, the part must be replaced w ith one of
the same part number or w ith an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended and described in this service manual are effective methods of
performing service and repair. Some of these procedures require the use of tools specially designed for
the purpose.
Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not
recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe
operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected.
It is im portant to note that this manual contains various Cautions and Notices that must be carefully
observed in order to reduce the risk of personal injury during service or repair, or the possibility that
improper service or repair may dam age the vehicle or render it unsafe. It is also im p ortant to
understand that these "Cautions" and "Notices" are not exhaustive, because it is impossible to warn of
all the possible hazardous consequences that might result from failure to follow these instructions.
Disassemble [ ^ T ig h t e n
h- Assemble | 9 | Im portant
m Clean ^ Adjust
1989 TABLE OF CONTENTS SECTION
LIGHT DUTY TRUCK
GENERAL INFORMATION
FUEL AND EMISSIONS
SERVICE MANUAL DRIVEABILITY SYMPTOMS
iii
Noone
knows your
GMtruck
better.
Noone.
Mr. Goodwrench wants you to have the right parts for So keep that great GM feeling with genuine GM parts
your truckwhether you see him for service or whether at participating independent Mr. Goodwrench dealers
you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,
Cadillacs, GMC and Chevy Trucks.
Thats why Mr. Goodwrench wants to have a good
stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and
transmissions to GM Goodwrench Motor Oil that meets
OfNKRAL M OTORS CORPORATION
or exceeds all specifications for General Motors cars
or light trucks. And Mr. Goodwrench has a complete
line of GM chemicals for fine care of your GM vehicle.
Plus accessories to add convenience
or just a little extra style.
F5085
iv
GENERAL INFORMATION 1-1
SECTION 1
GENERAL INFORMATION
CONTENTS
GENERAL ............................................................... 1-1 Positive Crankcase V e n tila tio n (PCV) 1-4
VISUAL/PHYSICAL UNDERHOOD INSPEC____ 1-2 Therm ostatic A ir Cleaner (THERMAC) . . . . 1-4
BASIC ELECTRIC CIRCUITS.................................. 1-2 Special T o o ls ................................................... 1-4
EMISSIONS............................................................ 1-2 A bbreviations ................................................. 1-4
MAINTENANCE SCHEDULE............................... 1-2 COMPONENT LOCATIONS.................................. 1-4
VEHICLE EMISSION CONTROL INFO. LABEL . . 1-2 2 .5 L -M S e r ie s ................................................. 1-5
SECTION DESCRIPTION....................................... 1-2 2.5L - S Series ................................................. 1-6
D rive a b ility S ym ptom s.................................... 1-2 2.8L - ST S e rie s ................................................. 1-7
C om puter Command Control 4.3 L - ST Series................................................... 1-8
(Using "Scan" Tool Diagnosis) ............... 1-2 4.3L-C K S eries................................................. 1-9
Fuel Control S y s te m ....................................... 1-2 4.3L-G Series ................................................. 1-10
Evaporative Emission Control .................... 1-2 4 .3 L -M S e r ie s ................................................. 1-11
Ignition/E lectronic Spark Tim ing ............... 1-2 5.0L75.7L-CK S e rie s ....................................... 1-12
Electronic Spark C o n tro l............................... 1-4 5.0Ly5.7L-G Series ....................................... 1-13
A ir M anagem ent ......................................... 1-4 5.7L- RV S e rie s................................................. 1-14
Exhaust Gas Recirculation ........................... 1-4 5.7L - P Series..................................................... 1-15
Torque Converter Clutch, D ow nshift 7.4L-C K RV S e r ie s ......................................... 1-16
Control and Manual Transmission Shift 7.4L-G Series ......................................... 1-17
Light C o n t r o l.............................................. 1-4
GENERAL
All engines in this m anual have a Computer This section has a brief description of systems
Command Control system, with electronic control used to control fuel and emissions.
module (ECM), to control the throttle body injection Abbreviations that are used in driveability and
(TBI) fuel system. The ECM varies the air/fuel ratio. emissions are listed at the end of the manual.
In addition, the ECM controls the ignition timing W irin g h a rn e s s s e rv ic e in fo rm a tio n , for
system as well as other emission control systems such harnesses used with the ECM, is also provided in
as the exhaust gas recirculation system. the computer command control section.
It is important to review the emission sections Special tools used to diagnose and repair a system
and ECM wiring diagrams for a specific engine to are illustrated at the end of the manual.
determine what is controlled by the ECM and what
systems are non-ECM controlled.
1-2 GENERAL INFORMATION
ENGINE ADJUSTMENT
SPECIFICATIONS
ADJUSTMENT
PROCEDURE
LABEL CODE
ENGINE SIZE
***
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC
AREA OF CERTIFICATION
5 = TBI
7S3236-6E
This system uses a knock sensor in connection The PCV system passes crankcase vapors into the
with the ECM to control spark timing to allow the intake manifold. This system is not controlled by the
engine to have maximum spark advance w ithout ECM and is used on all engines.
spark knock. This improves driveability and fuel
economy and is used on all engines except the 2.5L & Section "12"
7.4L. Thermostatic Air Cleaner (THERMAC)
J ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Id le air control
3 Fuel p u m p re la y
5 Transm ission C o n v e rte r Clutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
8 Oil pressure sw itch
12 E xhaust Gas R ecircu lation V acu um S olenoid
7S3297
13 A/C re la y
6 - 2-86
Figure 1-2 - Component Locations 2.5L (M Series)
1-6 GENERAL INFORMATION
C2
6mm ^ 11
:N1! i
m FMB
[El
ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Idle air control
3 Fuel p u m p rela y
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 E lectronic Spark C on trol m o d u le (E.S.C.)
8 Oil pressure sw itch
9 Electric A ir C on trol so len oid (E.A.C.)
12 E xhaust Gas R ecircu lation V acuum Solenoid
13 A/C R elay
4 -2 2 -8 8
7S3298
ECM CONTROLLED
COMPONENTS
1 Fuel in jector
2 Idle air control
3 Fuel pu m p rela y
5 Transm ission C o n v e rte r Clutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C on trol m o d u le (E.S.C.)
8 O il pressure sw itch
12 E xhaust Gas R ecirculation V acuum S olenoid
8S4329
7 -1 1 -8 8
ECM CONTROLLED
COMPONENTS
1 Fuel in jector
2 Id le air co ntrol
3 Fuel pu m p relay
5 Transm ission C o n v e rte r Clutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C ontrol m o d u le (E.S.C.)
8 O il pressure sw itch
9 Electric A ir C ontrol so len oid (E.A.C.)
12 Exhaust Gas R ecirculation V acu um S olenoid 7S 3 3 0 0
5 -2 1 -8 8
ECM CONTROLLED
COMPONENTS
1 Fuel in jector
2 Idle air control
3 Fuel p u m p re la y
5 Transm ission C o n v e rte r C lutch C on nector
6 E lectronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C o n tro l m o d u le (E.S.C.)
8 Oil pressure sw itch
9 Electric A ir C o n tro l so len oid (E.A .C .)
12 E xhaust Gas R ecircu lation V acu um S olenoid 7S3301
ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Idle a ir co ntrol
3 Fuel p u m p re la y
5 Transm ission C o n v e rte r C lutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C o n tro l m o d u le (E.S.C.)
8 Oil pressure sw itch
7S 3 2 9 9
9 Electric A ir C on trol so len oid (E.A.C.)
5 -2 1 -8 8
12 E xhaust Gas R ecirculation V acu um S olenoid
ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Idle a ir control
3 Fuel pu m p rela y
5 Transm ission C o n v e rte r C lutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C o n tro l m o d u le (E.S.C.)
8 Oil pressure sw itch
9 Electric A ir C on trol s o len o id (E .A .C .)
12 E xhaust Gas R ecircu lation V acu u m S olenoid 7S 3 3 0 3
W '
14 5 -1 9 -8 7
Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly )
C1
N2 7
.....
COMPUTER C O M M A N D O ECM INFORMATION EMISSION COMPONENTS
CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic C ontrol M o d u le (E .C .M .) A M a n ifo ld A b s o lu te Pressure (M .A .P .) N1 C rankcase v e n t v a lv e (PCV)
] ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air co ntrol
3 Fuel pu m p relay
5 Transm ission C o n v e rte r C lutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C on trol m o d u le (E.S.C.)
8 Oil pressure sw itch
9 Electric A ir C on trol so len oid (E.A.C.)
12 Exhaust Gas R ecirculation V acuum S olenoid
14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly)
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air co ntrol
3 Fuel pu m p rela y
5 Transm ission C o n v e rte r Clutch C on nector
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
7 Electronic Spark C on trol m o d u le (E.S.C.)
8 Oil pressure sw itch
9 Electric A ir C on trol so len o id (E.A.C.)
12 Exhaust Gas R ecircuiation V acu um S olenoid 7 -8 -8 8
14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly) 7S 3305-<
A
.A
,T
IiH c T |; N2 j| C3 I C6
C8
LT
-H
ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Idle air co ntrol
3 Fuel p u m p rela y
5 Transm ission C o n v e rte r C lutch C on nector
6 E lectronic S park T im in g D is trib u to r (E.S.T.)
6a R e m o te ig n itio n coil
7 Electronic Spark C o n tro l m o d u le (E.S.C.)
8 O il pressure sw itch
9 Electric A ir C o n tro l s o len o id (E.A .C .)
12 E xhaust Gas R ecircu lation V acu um S olenoid
7 S 3 3 0 7 -6 E
14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly )
4 -1 5 -8 7
.....
COMPUTER C O M M A N D O ECM INFORMATION EMISSION COMPONENTS
CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic C on trol M o d u le (E .C .M .) A M a n ifo ld A b s o lu te Pressure (M .A .P .) N1 C rankcase v e n t v a lv e (PCV)
C2 ALDL d iagn ostic co nn ecto r B E xhaust o x y g e n N2 Fuel M o d u le
C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle po sition (T.P.S.) N9 A ir Pum p
C5 ECM harness g ro u n d D C o o lan t te m p e ra tu r e N 1 5 Fuel V a p o r C an ister
C6 Fuse p anel F Vehicle speed (V.S.S.)
C8 Fuel p u m p te s t co n n ecto r
ECM CONTROLLED
COMPONENTS
1 Fuel in jector
2 Idle air co ntrol
3 Fuel p u m p re la y
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
8 Oil pressure sw itch
9 Electric A ir C on trol so len o id (E.A.C.)
12 Exhaust Gas R ecirculation V acu um S olenoid
14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly )
7S3306
5 -1 9 -8 7
ECM CONTROLLED
COMPONENTS
1 Fuel in jector
2 Id le a ir co ntrol
3 Fuel p u m p re la y
6 Electronic Spark T im in g D is trib u to r (E.S.T.)
6a R em o te ig n itio n coil
8 Oil pressure sw itch
9 Electric A ir C on trol so len o id (E.A.C.)
12 E xhaust Gas R ecircu lation V acu um S olenoid
14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly ) 8S 4 3 3 0 -6 E
4 -1 5 -8 7
V
DRIVEABILITY SYMPTOMS 2-1
S E C T IO N 2
DRIVEABILITY SYMPTOMS
CONTENTS
Before S t a r t in g ............................................................................................................................................................ ..2-1
Poor Fuel E c o n o m y ..................................................................................................................................................... ..2-1
ECM In te rm itte n t Codes or P e rfo rm a n c e ............................................................................................................... ..2-2
Dieseling, R u n -O n ....................................................................................................................................................... ..2-2
Backfire ........................................................................................................................................................................ ..2-3
Rough, Unstable, or Incorrect Idle, S talling .......................................................................................................... ..2-3
Excessive Exhaust Emissions or Odors ......................................................................................................................2-4
Hard S t a r t...................................................................................................................................................................... ..2-4
Surges a n d /o r C h u g g le .............................................................................................................................................. ..2-5
Lack o f Power, Sluggish, or S p o n g y ........................................................................................................................ ..2-5
D e to n a tio n /S p a rk K n o c k ......................................................................................................................................... ..2-5
H esitation, Sag, S tu m b le ..............................................................................................................................................2-6
Cuts Out, Misses .......................................................................................................................................................... ..2-6
B E F O R E S T A R T IN G
Before using this section, you should have Vacuum hoses for splits, kinks, and proper
performed the SYSTEM CHECK in Section "3 connections, as shown on Vehicle E m ission
Diagnosis. Control Information label.
Verify the customer complaint, and locate the Air leaks at throttle body mounting and intake
correct SYMPTOM below. C heck the item s manifold. See Section "4.
indicated under that symptom. Ignition wires for cracking, hardness, proper
If the ENGINE CRANKS BUT WILL NOT routing, and carbon tracking.
RUN, see CHART A-3, in Section "3. W iring for proper connections, pinches, and
Refer to the related Chassis Service Manual for cuts,
corrective action of driveability symptoms that are T h e im p o r ta n c e o f th is s te p c a n n o t be
not fuel or emission related. stressed too stro n g ly - it can lead to co rre c tin g
a problem w ith o u t fu rth e r ch eck s an d can save
C a re fu l V isual C h eck valuable time.
The following symptoms cover several engines.
Several of the following symptom procedures To determine if a particular system or component is
call for a careful visual (physical) check. This check used, refer to the ECM w irin g d ia g ra m s for
should include: application.
P O O R FU E L E C O N O M Y
D efinition: Fuel economy, as m easured by an actual road test, is
noticeably lower than expected. Also, economy is noticeably lower than it
was on this vehicle at one time, as previously shown by an actual road test.
CHECK:
- Engine therm ostat for faulty part (always open) ' Are excessively heavy loads being carried?
or for wrong heat range. See Section "6B of ' U acceleration too much too often?
appropriate Service Manual. ' SuSSest drlver read Im portant Facts of Fuel
- Fuel pressure. See CHART A-6. Economy in Owners Manual.
Check owner's driving habits. * Perform S p te m Check, m Section 3 .
- Is A/C "ON full time (Defroster mode "ON)? * Check air cleaner element (filter) for dirt or being
- Are tires at correct pressure? plugged.
Check for proper calibration of speedometer.
2-2 DRIVEABILITY SYMPTOMS
The ECM code charts, in Section "3, determine Trouble Code was stored for a circuit having a
if there is a fault with a circuit, or, if there is an sensor, except for Codes 44 and 45, substitute a
interm ittent problem. The fault must be present to known good sensor and recheck.
locate the problem. If a fault is interm ittent, use of Loss of code memory: To check, disconnect TPS,
Trouble Code Charts may result in replacement of and idle engine until "Service Engine Soon light
good parts. An interm itent means that a code is comes "ON. Code 22 should be stored, and kept
stored in the ECM memory, but the circuit is OK. in memory when ignition is turned "OFF, for at
Refer to Section "3 for wiring diagrams. least 10 seconds. If not, check for open in CKT
Most interm ittent problems are caused by faulty 440 to the ECM. If CKT 440 has 12 volts to the
electrical connections or w iring. Perform ECM at all times, replace ECM.
careful check of the suspected circuits for:
CHECK:
Poor m ating of the connector halves, or
terminals, not fully seated in the connector - E lectrical system in terferen ce caused by a
body (backed out). defective relay, ECM driven solenoid, or switch.
Improperly formed or damaged term inals. They can cau se a sh a rp e le c tric a l su rg e.
All connector te rm in als, in a problem Normally, the problem will occur when the
circuit, should be carefully reform ed to faulty component is operated.
increase contact tension. - Improper installation of electrical options, such
Poor term inal to wire connection. This as lights, 2-way radios, etc.
requires removing the term inal from the - EST wires should be routed away from spark
connector body as outlined in Section "3. plug w ires, d is tr ib u to r w ires, d is tr ib u to r
If a visual (physical) check does not find the housing, coil, and generator. Wire from CKT 453
cause of the problem, the vehicle can be driven to distributor should have a good contact to
with a voltmeter connected to a suspected circuit ground.
or a "Scan tool may be used. An abnormal - Ignition secondary shorted to ground.
voltage reading, when the problem occurs, - CKTs 419 (SES light) and 451 (Diagnostic Test)
indicates the problem may be in that circuit. If interm ittently shorted to ground.
the wiring and connectors check OK, and a - ECM power grounds. See S ectio n "1 for
location.
- Incorrect or defective CalPak/PROM.
DIESELING, RUN-ON
Definition: Engine continues to run, after key is turned
"OFF, but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.
Check injector(s) for leaking. Apply 12 volts to - Visually check injector and TBI assem bly for
fuel pump "test term inal to turn "ON fuel pump fuel leakage. See Section "4.
and prime fuel system. See CHART A-5 in
Section "3.
DRIVEABILITY SYMPTOMS 2-3
BACKFIRE
Definition: Fuel ignites in intake manifold, or in
exhaust system, making a loud popping noise.
CHECK:
- EGR operation, for being open all the time. See For erratic spark timing
EGR diagnosis in Section "9. Distributor reference.
- Output voltage of ignition coil. See Section "6. For faulty spark plugs and/or plug wires or
- For crossfire between spark plugs (distributor boots.
cap, spark plug wires, and proper routing of plug Faulty AIR check valve.
wires). Perform a compression check - look for sticking
- For interm ittent condition in primary ignition or leaking valves.
system. For proper valve timing.
- Engine timing - See Vehicle Emission Control Broken or worn valve train parts.
Information label.
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING
Definition: The engine runs unevenly at idle. If bad enough, the vehicle may shake.
Also, the idle may vary in rpm (called "hunting). Either condition may be severe enough
to cause stalling. Engine idles at incorrect speed.
Perform careful visual check as described at start - For injector(s) leaking. Check fuel pressure
of this section. CHART A-6.
Perform "System Check in Section "3. - If a sticking throttle shaft or binding linkage
CHECK: casuses a high TPS voltage (open th ro ttle
Motor Mounts for damage, grounding out on the indication), the ECM will not control idle.
frame or mispositioned. Monitor TPS voltage. "Scan and/or Voltmeter
Throttle linkage for sticking or binding. See should read less than 1.25 volts with throttle
Section "4. closed.
Ignition timing. See "Vehicle Emission Control - Vacuum leaks can cause higher than normal
Information label. idle.
ECM ground circuits. See Section "1 for location. - Battery cables and ground straps should be clean
IAC system. See Code 35 in Section "3. Diagnosis and secure. Erratic voltage will cause IAC to
in Section "4. change its position, re s u ltin g in poor idle
Generator output voltage. Repair if less than 9, or quality.
more than 16 volts. - Minimum idle air rate. See Section "4.
P/N switch circuit. See diagnosis in Section "3, or - Check AIR system. See Section "8.
use "Scan tool. - EGR valve: There should be no EGR at idle. See
PCV valve for proper operation, by placing finger Section "9.
over inlet hole in valve end several times. Valve Run a cylinder compression check.
should snap back. If not, replace valve. See Section Inspect oxygen sensor for silicon contamination
" 11 . from fuel, or use of improper RTV sealant. The
E v a p o ra tiv e em issio n co n tro l sy stem . See sensor will have a white, powdery coating, and
diagnosis in Section "5. will result in a high but false signal voltage (rich
A/C signal to ECM term inal "B8. "Scan tool exhaust indication). The ECM will then reduce
should indicate A/C is being requested whenever the am ount of fuel delivered to the engine,
A/C is selected and the pressure cycling switch is causing a severe driveability problem.
closed. See diagnosis in Section "3. Check ignition system: wires, plugs, rotor, etc.
Controlled idle speed. See Section "4. Monitoring block learn will help identify the
MAP sensor - ignition "O N , engine stopped. cause of the problem. If the system is running
Compare MAP voltage with known good vehicle. lean (block learn g reater than 138), refer to
Voltage should be the same 400 mV (.4 volt), "Diagnostic Aids on facing page of Code 44 in
or Section "3. If the system is running rich (block
Start and idle engine. Disconnect sensor electrical learn less than 118), refer to "Diagnostic Aids
connector. If idle improves, substitute a known on facing page of Code 45 in Section "3.
good sensor and recheck. Stalling may be due to an incorrect idle air rate.
A/C refrigerant pressure too high. Check for Refer to Code 35 in Section "3 or "Idle Speed
overcharge or faulty pressure switch. Error in Section "4 for diagnosis.
2-4 DRIVEABILITY SYMPTOMS
- Coolant sensor, which has shifted in value. Spark plugs for correct heat range.
- Correct coolant solution - should be a 50/50 Check EGR system for not opening. See Section
mix of GM #1052753 anti-freeze coolant (or "9.
equiv.) and water. For proper transmission shift points.
CHECK: Check TCC operation. See Section "10.
For incorrect basic engine p arts such as cam,
- Ignition tim ing. See "V ehicle E m ission heads, pistons, etc.
Control Information label. Excessive oil entering combustion chamber.
- For poor fuel quality, proper octane rating. Remove carbon with top engine cleaner.
- For correct PROM. (See Service Bulletins). Follow instructions on can.
- THERMAC for staying closed. See Section On vehicles with 7.4L or 5.7L (over 8500 GVW)
" 12 .
engine and a dual catalytic converter system,
- Fuel system for low pressure. See CHART A-6 check for an exhaust re stric tio n in the re a r
in Section "3. converter area. See Figure 3-17.
SECTION 3
COMPUTER CO M M AND CONTROL
(USING "SCAN" TOOL DIAGNOSIS)
TABLE OF CONTENTS #
GENERAL DESCRIPTION ............................. ..3-2 THROTTLE POSITION SENSOR .................... 3-13
ALDL C o n n e c to r......................................... ..3-2 TPS O u tp u t................................................... 3-13
W irin g Harness and C o n n e c to rs ............ ..3-3 TBI 220 (4 .3 L & V 8 Engine) .................... 3-13
In fo rm a tio n Sensors....................................3-3 TBI 2 2 0 (2 .8L Engine) ............................. 3-13
Electrostatic Discharge Damage ..........3-3 TBI 700 ........................................................ 3-13
ELECTRONIC CONTROL M O D U L E .................3-3 VEHICLE SPEED SENSOR................................ 3-13
Mem-Cal ( L 4 ) ................................................3-4 MAT SENSOR................................................... 3-13
PROM (V6 & V 8 ) ......................................... ..3-4 EGR SYSTEM ................................................... 3-13
CalPak (V6 & V8) .........................................3-5 IDLESPEED........................................................ 3-13
FUEL CONTROL ................................................3-5 ELECTRONIC SPARK T IM IN G ........................ 3-14
INPUT INFORM ATION.................................... ..3-5 ELECTRONIC SPARK C O N T R O L.................... 3-14
C oolant Tem perature S e n s o r................. ..3-5 SYSTEM OVERVOLTAGE ............................. 3-14
MAP S e n s o r................................................ ..3-5 PARK/NEUTRAL SW ITCH................................ 3-14
Oxygen (O 2) S e n s o r ....................................3-5 CRANK SIGNAL................................................ 3-14
T h ro ttle Position S e n s o r.............................3-6 POWER STEERING PRESSURE S W IT C H ____3-14
M a n ifo ld A ir T em perature Sensor . . . . 3-6 DISTRIBUTOR REFERENCE SIGNAL............... 3-14
Vehicle Speed S e n s o r............................... ..3-6 A/C CLUTCH C O NTRO L.................................. 3-14
Knock S e n s o r................................................3-7 A/C "O N " SIGNAL............................................ 3-14
Park/Neutral Switch S ig n a l........................3-7 EXHAUST SYSTEM ......................................... 3-14
Crank S ig n a l................................................ ..3-7 ON-VEHICLE SERVICE......................................... 3-92
D istrib u to r Reference S ig n a l................... ..3-7 WIRE HARNESS................................................ 3-92
Power Steering Pressure Switch Signal . 3-7 CONNECTORS AND TE R M IN A LS ................. 3-92
A/C C ontrol S ig n a l.......................................3-7 M icro-P ack................................................... 3-93
Transmission Gear Position Signal . . . . 3-7 M e tri-P a c k ................................................... 3-93
D IA G N O S IS ............................................................3-7 W eather-Pack ............................................ 3-93
BULB CHECK .....................................................3-7 Compact T h re e ............................................ 3-94
SYSTEM CHECK ................................................3-7 ELECTRONIC CONTROL MODULE ............... 3-94
Diagnostic M o d e .........................................3-8 ECM Connector Term inal Voltages . . . 3-94
Field Service M o d e .................................... ..3-8 ECM Replacement w ith Mem-Cal (2.5L). 3-94
"Scan" T o o l ................................................ ..3-8 ECM W irin g Diagram - 2.5L .................... 3-95
Engine Does Not Start ............................. ..3-8 ECM W irin g Diagram - 2.8L .................... 3-98
Code System ................................................3-9 ECM W irin g Diagram - 4.3L & V8 .......... 3-101
Clearing Codes ......................................... ..3-9 ECM Connector T erm inals- 2.5 L ............ 3-105
ELECTRONIC CONTROL MODULE .................3-9 ECM Connector Term inals - 2.8 L ............ 3-106
ECM Quad Driver (QDR) C h e c k .................3-9 ECM Connector T e rm in a ls14.3L & V8 . . 3-107
PROM ............................................................3-10 If ECM is Being Replaced ........................ 3-108
Mem-Cal ..................................................... ..3-10 Functional C h e c k ....................................... 3-109
C a lP a k ............................................................3-10 ECM Replacement w ith PROM & CalPak
FUEL CONTROL ................................................3-10 ( V 6 & V 8 ) ................................................ 3-109
Fuel In je c to r................................................ ..3-10 PROM .......................................................... 3-109
Pressure Regulator .................................. ..3-10 C a lP a k .......................................................... 3-112
Idle A ir Control ......................................... ..3-10 COOLANT TEMPERATURE SENSOR............ 3-112
Fuel Pump C ir c u it.........................................3-10 M APSENSO R................................................... 3-112
Fuel M o d u le ................................................ ..3-10 OXYGEN SENSOR............................................ 3-114
Fuel M odule C heck.................................... ..3-10 THROTTLE POSITION SENSOR...................... 3-116
Fuel Pump C ircuit (Two Fuel T a nks). . . . 3-11 M ATSENSO R ................................................... 3-117
Fuel Tank Selector Diagnosis KNOCKSENSOR.............................................. 3-117
(Two Fuel Tanks).........................................3-11 VEHICLE SPEED SENSOR................................ 3-117
Checking Fuel Gage (Tw o Fuel Tanks) . . 3-11 PARK/NEUTRAL SW ITCH................................ 3-117
COOLANT TEMPERATURE SENSOR............ ..3-12 POWER STEERING PRESSURE S W IT C H ------ 3-117
MAPSENSOR.....................................................3-12 A/C CONTROL................................................... 3-118
OXYGEN SENSOR........................................... ..3-12 PARTS INFORMATION ....................................... 3-118
3-2 COMPUTER COMMAND CONTROL
GENERAL DESCRIPTION
6 -2 5 -8 7
*7 S 35 37-6 E
C - This term inal, on some air management systems, There are several ways for a person to become
is wired to the ground side of the electric air statically charged. The most common methods of
control valve. It can be used to diagnose the air charging are by friction and by induction. An example
management system. Refer to Section "8. of charging by friction is a person sliding across a car
E - This term inal is the serial d ata line on all seat, in which a charge of as much as 25,000 volts can
engines except 2.5L and is used by a "Scan tool build up. Charging by induction occurs when a person
to read various system data information. with well in su la ted shoes stan d s n ear a highly
F - This term inal is used to diagnose th e TCC charged object and m om entarily touches ground.
system and is wired to the ground side of the TCC Charges of the same polarity are drained off, leaving
solenoid. Refer to Section "10. the person highly charged with the opposite polarity.
G - This term inal is used to diagnose the fuel pump Static charges of eith er type can cause dam age,
circuit on all "CK series. On other engines the therefore, it is im portant to use care when handling
fuel pump test lead is in the engine compartment and testing electronic components.
near the fuel pump relay. Refer to CHART A-5
or A-5A. NOTICE: To p r e v e n t p o s s ib le E l e c t r o s t a t i c
H - This term inal is used to diagnose the brake Discharge damage:
system on "CK trucks. Refer to CK Light Duty Do Not touch the ECM connector pins
Service Manual for additional information. or soldered components on the ECM
M - This term inal is the serial data line for the 2.5L circuit board.
engines and is used by a "Scan tool to read When handling a PROM, CAL-PAK or
various system data information. M EM -CA L, Do N o t to u c h th e
component leads, and Do Not remove
W iring Harness and Connectors integrated circuit from carrier.
Be sure to follow the guidelines listed
A wiring harness electrically connects the ECM to below if s e rv ic in g an y of th e s e
various sensor, solenoid and relays within the system. electronic components.
Many connectors in the engine com partm ent are 1. Do not open the replacement part
environmentally protected because of the systems low package until it is time to install
voltages and current levels. the part.
2. A void to u c h in g e l e c t r i c a l
Inform ation Sensors term inals of the part.
3. Before removing the part from its
In addition to the ECM, the Computer Command package, ground the package to a
Control system has the following information sensors: known good ground on the vehicle.
Oxygen sensor 4. A lw ays to u c h a k now n good
Coolant sensor ground before handling the part.
Throttle position sensor T his step sh o u ld be re p e a te d
Manifold absolute pressure sensor before in stallin g the p art if the
Vehicle speed sensor p a rt h as been h a n d le d w h ile
Manifold tem perature sensor sliding across th e s e a t, w hile
Knock sensor s ittin g down from a s ta n d in g
and the following input signals: p o sitio n , or w h ile w a lk in g a
Park/neutral switch signal distance.
Crank signal
Distributor reference signal ELECTRONIC CONTROL MODULE
Power steering pressure switch signal (Figure 3-3 or 3-4)
A/C control signal The Electronic Control Module (ECM) is located in
Transmission gear position signal the passenger compartment and is the control center
of the Computer Command Control system.
Electrostatic Discharge Damage The ECM constantly looks a t the information from
various sensors, and controls the systems th at affect
Electronic components used in control systems are vehicle p erfo rm an ce. The ECM p erfo rm s th e
often designed to carry very low voltage, and are very diagnostic function of the system. It can recognize
susceptible to d am ag e cau sed by e le c tro s ta tic operational problems, alert the driver through the
discharge. It is possible for less than 100 volts of static "Service Engine Soon light, and store a code or codes
electricity to cause dam age to some ele c tro n ic which identify the problem areas to aid the technician
components. By comparison, it takes as much as 4,000 in making repairs. See diagnosis section for more
volts for a person to even feel the zap of a static information.
discharge.
3-4 COMPUTER COMMAND CONTROL
Mem-Cal (L4)
(Figure 3-3)
This assembly contains both the functions of the
PROM and CalPak. Like the PROM, it contains the
calibrations needed for a specific vehicle as well as the
back-up fuel control circuitry required if the rest of the
ECM becomes damaged or faulty.
PROM (V 6 & V 8 )
(Figure 3-5)
Inform ation for specific engine and vehicle is
m ECM m PROM ACCESS COVER program m ed using an in teg rated circu it called a
S ECM HARNESS PROM, (Programmable Read-Only Memory). In the
CONNECTORS TO ECM 4 S 1 1 9 6 -6 E parts book, it is listed as a calibrator. This allows one
model of controller to be used for many different
Figure 3-4 - Electronic Control Module (V6 & V8) vehicles. The PROM is located inside the ECM and
The ECM is designed to process the various input has inform ation on the vehicles w eight, engine,
information (Figure 3-1) and then sends the necessary transmission, axle ratio, and several others. While
electrical responses to control fuel delivery, spark one ECM part number can be used by many vehicle
timing and other emission control systems. The input lines, a PRQM is very specific and m ust be used for the
information has an interrelation to more than one right vehicle. For this reason, it is very im portant to
output, therefore, if the one input failed it could effect check the latest p arts book and Service B u lletin
more than one systems operation. in form ation for the correct p a r t n u m b e r w hen
The ECM has a "learning ability which allows it replacing a PROM.
to make corrections for minor variations in the fuel
system to improve driveability. If the b attery is
disconnected to clear codes, or for re p a ir, th e
"learning process has to begin all over again.
A ch a n g e m ay be n o te d in th e v e h ic le s
performance. To "teach the vehicle, make sure the
engine is at operating tem perature, and drive at part
th ro ttle , w ith m o d e ra te a c c e le ra tio n and idle
conditions, until normal performance returns.
CalPak (V 6 & V 8 )
(Figure 3-5)
A CalPak is used to allow fuel delivery if other
parts of the ECM are damaged. If the C alPak is
missing, it will result in a no start and run condition.
FUEL CONTROL
INPUT INFORMATION
Coolant Tem perature Sensor
(Figure 3-6)
The coolant tem perature sensor is a therm istor (a
resistor which changes value based on temperature) The MAP sensor reading is the opposite of what you
mounted in the engine coolant stream. Low coolant would measure on a vacuum gage. When manifold
tem perature produces a high resistance (100,000 ohms pressure is high, vacuum is low. The MAP sensor is
at -40C/-40F) while high tem perature causes low also psed to m easure barom etric p ressu re under
resistance (70 ohms at 130C/266F). c e rta in co n d itio n s, w hich allo w s th e ECM to
The ECM supplies a 5 volt signal to the coolant automatically adjust for different altitudes.
tem perature sensor through a resistor in the ECM and The ECM sends a 5 volt reference signal to the
measures the voltage. The voltage will be high when MAP sensor. As the manifold pressure changes, the
the engine is cold, and low when the engine is hot. By electrical resistance of the sensor also changes. By
m easuring the voltage, the ECM knows the engine monitoring the sensor output voltage, the ECM knows
coolant tem perature. Engine coolant tem perature the m anifold p ressu re. A h ig h er p ressu re, low
affects most systems the ECM controls. vacuum (high voltage) requires more fuel, while a
lower pressure, higher vacuum (low voltage) requires
less fuel.
The ECM uses the MAP sensor to control fuel
delivery and ignition timing.
r
1 ENGINE C O O LA N T TEMPERATURE SENSOR
MAP Sensor
(Figure 3-7)
The Manifold Absolute P ressure (MAP) sensor
m easu res th e c h an g e s in th e in ta k e m an ifo ld
pressure, which result from engine load and speed
changes, and converts this to a voltage output.
A closed throttle on engine coastdown will produce Oxygen (O 2) Sensor
a relatively low MAP output, while a wide-open (Figure 3-8)
throttle will produce a high output. This high output The exhaust oxygen (O2) sensor is mounted in the
is produced because the pressure inside the manifold exhaust system where it caji monitor the oxygen
is the same as outside the manifold, so 100% of the content of the exhaust gas stream . The oxygen
outside air pressure is measured. content in the exhaust reacts with the oxygen sensor
3-6 COMPUTER COMMAND CONTROL
to produce a voltage output. This voltage ranges from the TPS is low (approximately .5 volt). As the throttle
approximately .1 volt (high oxygen - lean mixture) to valve opens, the output increases so that, at wide-open
.9 volt (low oxygen - rich mixture). throttle, the output voltage should be approximately 5
By monitoring the voltage output of the oxygen volts.
sensor, the ECM w ill know w hat fuel m ix tu re By monitoring the output voltage from the TPS,
command to give to the injector (lean mixture-low the ECM can determine fuel delivery based on throttle
voltage-rich command, rich mixture-high voltage-lean valye angle (driver demand).
command).
M anifold Air Tem perature (M A T) Sensor
(Figure 3-11)
The Manifold Air Temperature (MAT) sensor is a
therm istor (a resistor which changes value based on
tem p eratu re) m ounted on a 2.5L engine in th e
manifold.
Low temperature produces a high resistance (100,000
ohms at -40C/-40F) while high tem perature causes
low resistance (70 ohms at 130C/266F).
The ECM supplies a 5 volt signal to the sensor
through a resistor in the ECM and m easures the
m THROTTLE BODY ASSEMBLY
voltage. The voltage will be high when the manifold
[ T 1 THROTTLE POSITION SENSOR - NON-ADJUSTABLE
air is cold, and low when the air is hot. By measuring
m THROTTLE POSITION SENSOR - NON-ADJUSTABLE
the voltage, the ECM know s th e m an ifo ld a ir
m THROTTLE POSITION SENSOR - ADJUSTABLE
temperature.
m SCREW ASSEMBLY
The MAT sensor signal is used by the ECM to
delay EGR until the manifold air tem perature reaches
m RETAINER 7S3652-6E
about 5C (40F).
Figure 3-9 - Throttle Position Sensor - V6/V8 The ECM uses the signal to slightly retard the
timing during high ambient air temperatures.
Located in the engine block, the knock sensor The power steering pressure switch is used with
re ta rd s ig n itio n tim in g d u rin g a s p a rk knock the 4-cylinder engine and is located near the power
condition to allow the ECM to m aintain maximum steering gear. When steering is to the extreme left or
timing advance under most conditions. right, the switch is closed and this signal will increase
the idle air rate and retard the spark for a stable idle.
Park/Neutral Switch Signal
A/C Control Signal
The Park/N eutral (P/N) switch, located on the
steering column, is used on an automatic transmission This signal indicates that the A/C control switch is
vehicle to indicate to the ECM when the transmission turned "ON and the pressure switch is closed. The
is in park or neutral. This inform ation is used to ECM uses this signal to adjust the idle speed and on
control the operation of the transm ission converter 2.5L, 2.8L, and 4.3L S/T engines, engages the A/C
clutch and idle air control. compressor clutch.
The ECM uses this signal to tell when the vehicle A sw itc h , lo c a te d in s id e th e a u to m a tic
is in the STARTING mode. transmission, opens when the transm ission shifts to
high gear. T his s ig n a l is u sed for d e la y e d
Distributor Reference Signal disengagement of the torque converter clutch. Refer
to Section "10 for specific application.
The distributor sends a signal to the ECM to
indicate engine rpm. See Section "6 for fu rther
information.
DIAGNOSIS
The Computer Command Control system has a SYSTEM CHECK
diagnostic system built into the ECM to indicate a (Figure 3-12)
failed circuit. An amber "Service Engine Soon light S in ce th is is the s ta r tin g p o in t for th e
on the instrum ent panel will illuminate if a problem diagnostic procedures or finding the cause of an
has been detected when the engine and vehicle are em issions test failure, always begin here.
running. This light is also used for a bulb and system The system check is perform ed through the
check.
twelve terminal assembly line diagnostic link (ALDL)
The System Check is the starting point for the
d ia g n o stic p ro ced u res or an e m is s io n s te s t connector (Figure 3-2) under the instrum ent panel in
failure. The diagnostic charts are related to the ECM the passenger compartment.
and will determine if the ECM is working properly. The Computer Command Control System Check
This section diagnoses the fuel system controlled by is a procedure that determines the following:
the ECM and has charts to diagnose a circuit when the 1. Bulb Check - to check SES light circuit and
ECM has displayed a code. that the ECM can complete the circuit.
The system requires an ALDL read-out "Scan 2. D iagnostic Mode - th is in d ic a te s if the
tool, tachom eter, te s t lig h t, o h m m eter, d ig ita l diagnostic code system is working.
voltmeter with 10 megohms impedance (J-34029A), 3. "Scan Data - this determines if the ECM is
vacuum gage and jumper wires for diagnosis. Refer to suppling input and output visual data.
Section "13 for additional information about special
4. Engine S tart - this step is done after it has
tools. If a "Scan tool is not available, refer to Section
"15. been determined that the ECM will display
codes and data.
BULB CHECK 5. Other Codes - Proceed to applicable chart if a
code is displayed. Scanning the d ata for
With the ignition "ON and engine not running, typical value may indicate a problem area if
the lamp should illuminate, which indicates that the they are incorrect. If all systems appear to be
ECM has completed the circuit to turn "ON the light. fu n c tio n in g , rev ie w th e " D r iv e a b ility
If the "Service Engine Soon light is not "ON, Symptoms in Section "2.
refer to CHART A-l for diagnosis. The system check starts with a bulb check. If
When the engine is started, the light will turn there is no "Service Engine Soon light, refer to
"OFF. If the light remains "ON, refer to system
check. CHART A-l.
3-8 COMPUTER COMMAND CONTROL
Diagnostic M ode
When the ECM sets a code, the "Service Engine The ECM uses an integrated circuit (IC) called a
Soon light will come "ON and a code will be stored in quad driver (QDR) in place of separate tran sisto rs
memory. If the problem is interm ittent, the light will toturn "ON or "OFF different circuits controlled by
go out after 10 seconds when the fault goes away. the ECM. Each QDR has four separate outputs that
However, the code will stay in the ECM memory for 50 can independently turn "ON or "OFF four different
starts or until the b attery voltage to the ECM is circuits.
removed. Removing battery voltage for 30 seconds ECM service part number 1227747, used with V6
will clear all stored codes. The ECM B fuse can also be & V8 engines, does not have fa u lt p ro te c tio n ,
used to clear codes on all vehicles except CK which has therefore, a single faulty circuit many times causes all
a fuse link. four QDR outputs to be inoperative or "ON all the
Codes should be cleared after repairs have been time. A failed QDR usually results in either a shorted
completed. Also, some diagnostic charts will tell you or open ECM output. Because of the increased current
to clear the codes before using the chart. This allows flow, two QDR outputs are used to drive the TCC
the ECM to set the code while going through the chart, solenoid.
which will help to find the cause of the problem more Refer to the ECM QDR check procedure (Figure 3-
quickly. 18). This check will not test all ECM functions but it
will determine if a specific circuit has caused a specific
NOTICE: To prevent ECM damage, the key must be QDR to fail in the ECM.
" O F F w h en d is c o n n e c tin g or A faulty circuit is the largest cause of a failed QDR,
reconnecting power to ECM (for example therefore, the check procedure should be used if there
battery cable, ECM pigtail, ECM fuse, is an indication of an ECM replacement, especially if
jum per cables, etc.) the rem oved ECM ex h ib its c h a ra c te ristic s of a
damaged QDR such as:
ELECTRONIC CONTROL MODULE "SES light with no codes stored.
Engine will not start and/or ECM will not flash
The diagnosis of the Electronic Control Module Code 12.
(ECM) starts with the system check. The code system Flickering, interm ittent, or dim "SES light.
indicates a failure of a specific circuit and diagnosis Output, such as TCC circuit, is inoperative or
may indicate replacement of the ECM. A Code 55 "ON at all times.
3-10 COMPUTER COMMAND CONTROL
Figure 3-14 - Selector Valve and M eter Switch Figure 3-15 - Two Fuel Tank W iring
Connector
Jum per term inals "C and "B and the gage MAP SENSOR
should indicate quantity of the left fuel tank.
If there was no indication in either position, Code 33 or Code 34 indicates a failure in the MAP
check for an open circuit from term inal "B to sensor circuit. Also refer to "MAP O utput Check
the fuel gage. M ake sure th a t th e two Diagnosis on page 3-73 to check the MAP sensor if
term inal connector, with one pink wire that is there is no code.
located near the selector valve (Figure 3-15), is
correctly connected. OXYGEN SENSOR
If there was no indication in one position,
check for an open circuit in that position or
faulty sending unit. Code 13 indicates an open in the oxygen sensor
If there is a change indicated between tanks, circuit. Code 44 indicates a shorted oxygen sensor
the circuit is OK. circuit. Code 45 indicates a high voltage in the oxygen
4. Ingition "OFF, connect fuel tank selector valve sensor circuit. If a code is set, the engine will always
and meter switch connector. run in the "Open Loop mode. The oxygen sensor
5. Perform fuel system pressure test (CHART A-6) if voltage o u tp u t can be m easured w ith a d ig ita l
engine would not run in one or eith er selector vo ltm eter having at le a st a 10 m egohm s in p u t
switch positions. impedance. Use of a standard shop type voltmeter will
result in an inaccurate reading.
COOLANT TEMPERATURE SENSOR Normal "Scan voltage varies between 100 mV to
999 mV (.1 and 1.0 volt) while in "Closed Loop. Code
Code 14 or Code 15 indicates a failure in the 13 sets in one minute if voltage remains between .35
coolant tem perature sensor circuit. and .55 volt, but the system will go "Open Loop in
Most "Scan tools display engine tem perature in about 15 seconds.
degrees centigrade. A fter engine is sta rte d , the Using the "Scan, observe the block learn values
tem perature should rise steadily to about 90C then at different rpm and air flow conditions to determine
stabilize when therm ostat opens. when Code 44 or Code 45 may have been set. If the
condition for Code 44 exists, the block learn values
will be around 150. If the condition for Code 45 exists,
the block learn values will be around 115.
COMPUTER COMMAND CONTROL 3-13
THROTTLE POSITION SENSOR 3. If voltage is out of range, rotate TPS until 0.48
.06 volt are obtained.
Code 21 indicates th a t there is a shorted TPS 4. If above voltage lim itation cannot be obtained,
circuit. Code 22 indicates that there is an open in the replace TPS.
TPS circuit. When a code is set, the ECM will use an 5. Remove voltmeter and jum pers, reconnect TPS
artificial value for throttle position and some engine connector to sensor.
performance will return.
A broken TPS can cause interm ittent bursts of TBI 700
fuel from the injector(s) and an unstable idle because
the ECM thinks the throttle is moving. This check should be performed only when throttle
A "Scan tool reads throttle position in volts. body parts have been replaced or after the minimum
Should read about .753 volt (2.5L), .45 volt (2.8L), .60 air flow has been adjusted.
volt (4.3L & V8) with throttle closed and ignition 1. Connect digital voltmeter J34029-A or equivalent,
"ON or at idle. Voltage should increase at a steady from TPS connector term inal "B (dark blue wire)
rate as throttle is moved toward WOT. to te rm in al "C (black w ire). J u m p e rs for
"Scan TPS while depressing accelerator pedal term inal access can be made using te rm in als
with engine stopped and ignition "ON. Display "1214836 and "12014837. A "Scan tool can be
should vary from below 1.25 volts (1250 mV) when used to read the TPS output voltage.
throttle was closed, to over 4.5 volts (4500 mV) when 2. W ith ignition "ON, engine stopped, the TPS
throttle is held at wide open throttle position. voltage should be less than 1.25 volts. If more
than 1.25 volts, replace TPS.
TPS O utput 3. Remove the voltmeter and jumpers, reconnect the
TPS connector to the sensor.
TBI 220 (4.3L and V8 Engine)
VEHICLE SPEED SENSOR
This check should be performed only when throttle
body or TPS has been replaced or, after the minimum The vehicle speed sensor circuit diagnosis is in
air flow has been adjusted. Code 24 chart.
1. C o n n e c t d ig ita l v o ltm e te r J-3 4 0 2 9 -A , or "S can re a d in g sh o u ld closely m atch w ith
equivalent, from TPS connector te rm in al "B speedometer reading, with drive wheels turning.
(dark blue wire) to term inal "A (black wire).
Jum pers for term inal access can be made using M AT SENSOR
term inals "1214836 and "12014837. A "Scan
tool can be used to read TPS output voltage. Code 23 indicates that there is an open in the MAT
2. W ith ignition "ON, and engine stopped, TPS circuit. Code 25 indicates th a t there is a short to
voltage should be less than 1.25 volts. If more ground in the MAT circuit.
than 1.25 volts, check minimum idle speed before A "S can tool read s te m p e ra tu re of th e a ir
replacing TPS. entering the engine and should read close to ambient
3. Remove voltmeter and jumpers and reconnect TPS air tem perature when engine is cold, and rises as
connector to sensor. underhood tem perature increases.
This check should be performed only when throttle Code 32 indicates that there is a failure in the
body parts have been replaced or after the minimum EGR system circuit.
air flow has been adjusted.
1. Connect digital voltmeter J -34029-A or equivalent IDLE SPEED
from TPS connector term inal "B (dark blue wire)
to te rm in a l "A (black wire). J u m p e rs for Code 35 sets when there is a problem with idle air
term inal access can be made using term in als control on a 2.5L engine. Refer to "Diagnosis in
"1214836 and "12014837. A "Scan tool can be Section "4 for idle air control check for other engines.
used to read TPS output voltage. System too lean. (High air/fuel ratio)
2. With ignition "ON, engine stopped, TPS voltage Idle speed may be too high or too low. Engine
should be between .42 and .54 volt. speed may vary up and down, disconnecting IAC
does not help. May set Code 44.
3-14 COMPUTER COMMAND CONTROL
"Scan and/or voltm eter w ill read an oxygen SYSTEM OVER VOLTAGE
sensor output less than 300 mV (.3 volt). Check
for low regulated fuel pressure or water in fuel. A Code 53 sets on a 2.5L engine if there is voltage
lean exhaust with an oxygen sensor output fixed greater than 17.1 volts for two seconds a t ECM
above 800 mV (.8 volt) will be a contam inated term inal "B l. This indicates th at there is a basic
sensor, usually silicone. This may also set a Code generator problem.
45.
System too rich (Low air/fuel ratio) PARK/NEUTRAL SWITCH
Idle speed too low. "Scan counts usually above
80. System obviously rich and may exhibit black Diagnosis of the park/neutral switch is on page 3-
smoke exhaust. 76 of this section.
"Scan tool and/or voltmeter will read an oxygen
sensor signal fixed above 800 mV (.8 volt). CRANK SIGNAL
Code 43 sets if there is an open or short to ground The diagnosis of the A/C "O N sig n al on all
in the ESC circuit. engines other than 2.5L is covered on page 3-90 of this
If the conditions for a Code 43 are present, the section.
"Scan will always display "YES. There should not
be a knock at idle unless an internal engine problem, EXHAUST SYSTEM
or a system problem exists.
Refer to page 3-73 for diagnosis of a restricted
exhaust system.
COMPUTER COMMAND CONTROL 3-15
CODE IDENTIFICATION
The Service Engine Soon light will only be "ON if the malfunction exists under the conditions listed
below. If the malfunction clears, the light will go out and the code will be stored in the ECM. Any codes
stored will be erased if no problem reoccurs within 50 engine starts.
CODE AND CIRCUIT PROBABLE CAUSE CODE AND CIRCUIT PROBABLE CAUSE
Code 13-0 2 Sensor Indicates that the Code 33 - MAP Sensor MAP sensor output to
Open Oxygen Sensor oxygen sensor circuit or Low Vacuum high for 5 seconds or
Circuit sensor was open for one an open signal circuit.
minute while off idle.
Code 14 - Coolant Sensor Sets if the sensor or Code 34 - MAP Sensor Low or no output from
signal line becomes High Vacuum sensor with engine
High Temperature
grounded for 3 seconds. running.
Indication
CHART A-1
NO "SERVICE ENGINE SOON" LIGHT
ALL ENGINES
Circuit Description:
There should always be a steady "Service Engine Soon light when the ignition is "ON and engine stopped.
Battery ignition voltage is supplied to the light bulb. The ECM will control the light and turn it "ON by
providing a ground path through CKT 419.
CHART A-1
NO "SERVICE ENGINE SOON" LIGHT
ALL ENGINES
CLEAR CODES A N D C O N FIR M "CLOSED LOOP " O PERATION A N D N O "SERVICE ENGINE S O O N " LIGHT.
3-18 COMPUTER COMMAND CONTROL
CTEEQ^SgBODl
lEGDj^p] EE] CHEDtjjjJ
I.P. HARNESS CONNECTOR
15 W A Y . (FRONT V IE W ) ECM
12 V
TO OIL PRESS. SW.
JUNCTION
& FUEL P U M P RELAY ORN 4 4 0
BLOCK BATTERY
r - - n
---------- i ORN 4 4 0
FEED
i FUSIBLE LINK
FUSIBLE LINK OR ECM B FUSE
ECM FUSE
DIA GN OSTIC
-
A LD LC O N N E C TO R SERIAL D A TA
o B
M
o -G R O U N D A8
A8
(2 .5L O N L Y )
SERIAL D A TA
(ALL EXCEPT 2.5L)
r ORN 461
r ORN 461 8 -4 -8 8
6 -2 5 -8 7 7 S 3 6 8 6 -6 E
CHART A-2
NO ALDL DATA OR W O N 'T FLASH CODE 12
"SERVICE ENGINE SOON" LIGHT "O N " STEADY
ALL ENGINES
Circuit Description:
There should always be a steady "Service Engine Soon light when the ignition is "ON and engine stopped.
Battery ignition voltage is supplied to the light bulb. The ECM will turn the light "ON by grounding CKT 419.
With the diagnostic term inal grounded, the light should flash a Code 12, followed by any trouble code(s)
stored in memory.
A steady light suggests a short to ground in the light control CKT 419, or an open in diagnostic CKT 451.
Test Description: Numbers below refer to circled 3. This step will check for an open diagnostic CKT
numbers on the diagnostic chart. 451.
1. If there is a problem with the ECM that causes a 4. At this point the "Service Engine Soon light
"Scan tool to not read serial data then the ECM wiring is OK. The problem is a faulty ECM or
should not flash a Code 12. If Code 12 does flash, PROM/Mem-Cal. If Code 12 does not flash, the
be sure that the "Scan tool is working properly on ECM should be replaced u sin g th e o rig in a l
another vehicle. If the "Scan is functioning PROM/Mem-Cal. Replace the PROM/Mem-Cal
properly and CKT 461 is OK, the PROM/Mem-Cal only a fte r try in g an ECM , as a d e fe c tiv e
or ECM m ay be a t fa u lt for th e No ALDL PROM /M em-Cal is an u n lik ely cause of the
symptom. problem.
2. If the light goes "OFF when the ECM connector is
disconnected, then CKT 419 is not shorted to
ground.
COMPUTER COMMAND CONTROL 3-19
3-20 COMPUTER COMMAND CONTROL
4 3 9 PNK/BLK TO ECM
7S 3 7 7 4 -6 E
6 -2 5 -8 7 7 -2 3 -8 6
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
2.5L ENGINE
Circuit Description:
This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank. This chart should be used on engines using the Model 700 throttle body.
Test Description: Numbers below refer to circled Use an injector test light like J34730, BT8329A or
numbers on the diagnostic chart. equivalent, to test injector circuit. A blinking
1. A "Service Engine Soon light "ON is a basic test light indicates the ECM is controlling the injector.
to determ ine if there is a 12 volt supply and 5. This test will determine if there is fuel pressure at
ignition 12 volts to ECM. No ALDL may be due to the injector and that the injector is operating.
an ECM problem and CHART A-2 will diagnose
the ECM. If TPS is over 2.5 volts the engine may Diagnostic Aids:
be in the clear flood mode which will cause
startin g problems. If coolant sensor is below If no trouble is found in the fuel pump circuit or
-30C, the ECM w ill provide fuel for th is ignition system and the cause of a "Engine C ranks
extremely cold tem perature which will severely But Will Not Run has not been found, check for:
flood the engine. Fouled spark plugs
2. Voltage at the spark piug is checked using spark EGR valve stuck open
tester tool ST125 (J26792) or equivalent. No Low fuel pressure. See CHART A-6.
spark indicates a basic ignition problem. W ater or foreign m aterial in the fuel system.
3. While cranking engine there should be no fuel A ground CKT 423 (EST) may cause a "No
spray with injector disconnected. Replace an S tart or a "Start then Stall condition.
injector if it sprays fuel or drips like a leaking Basic engine problem.
water faucet.
COMPUTER COMMAND CONTROL 3-21
YES NO
YES NO
NO YES
3= zm
CONNECT INJECTOR TEST LIGHT FAULTY INJECTOR
TO HARNESS CONNECTOR. SEAL OR INJECTOR
CRANK ENGINE.
DOES TEST LIGHT BLINK?
YES NO
I i - ----------------------- 1
RECONNECT INJECTOR CONNECTOR. I SEE INJECTOR CIRCUIT [
NO
=E=
NO TROUBLE FO U N D . IGN "OFF.
INSTALL FUEL PRESSURE GAGE. REFtR TO FUEL SYSTEM
SEE D IA G N O S TIC AIDS
PRESSURE TEST IN SECTION 4.
ON FACING PAGE. IGN " O N " .
FUEL PRESSURE SH O U LD BE 6 2 -9 0 KPa (9 -1 3 psi)
IS IT?
1
YES NO
m t :
FAULTY INJECTOR I SEE FUEL SYSTEM
i D IA G N O S IS C H ART A -6 i
I__________________ i
7S3775
4 -2 7 -8 7
3-22 COMPUTER COMMAND CONTROL
ECM
IGN 10A
ECM
4 6 8 LTG R N
481 RED
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
ALL ENGINES EXCEPT 2.5L
Circuit Description:
This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank. This chart should be used on engines using the Model 220 throttle body.
Test Description: Numbers below refer to circled 4. Use an injector te s t lig h t lik e B T8320, or
numbers on the diagnostic chart. eq u iv alen t, to te st each in jecto r c irc u it. A
1. A "Service Engine Soon light "ON is a basic test blinking light indicates the ECM is controlling
to determ ine if there is a 12 volt supply and the injectors.
ignition 12 volts to ECM. No ALDL may be due to 5. This test will determine if there is fuel pressure at
an ECM problem and CHART A-2 will diagnose the injectors and that the injectors are operating.
the ECM. If TPS is over 2.5 volts the engine may
be in the clear flood mode which will cause Diagnostic Aids:
s ta rtin g problems. If coolant sensor is below
-30C, th e ECM w ill p ro v id e fuel for th is If no trouble is found in the fuel pump circuit or
extremely cold tem perature which will severely ignition system and the cause of a "Engine C ranks
flood the engine. But Will Not Run has not been found, check for:
2. Voltage at the spark plug is checked using spark Fouled spark plugs
te ster tool ST125 (J26792) or equivalent. No EGR valve stuck open
spark indicates a basic ignition problem. Low fuel pressure. See CHART A-6.
3. While cranking engine there should be no fuel W ater or foreign material in the fuel system.
spray with injectors disconnected. Replace an A grounded CKT 423 (EST) may cause a "No
injector if it sprays fuel or drips like a leaking S tart or a "Start then Stall condition.
water faucet. Basic engine problem.
COMPUTER COMMAND CONTROL 3-23
YES NO
7TT
DISCONNECT ONE SPARK PLUG W IRE. j SEE FUEL P U M P RELAY CIRCUIT
INSTALL A SPARK TESTER (ST 125 OR i CHART A -5 OR A -5A
E Q U IVALENT)
i ____________________________________
CRANK ENGINE A N D CHECK FOR
SPARK.
IS THERE SPARK?
YES NO
n z n r
\-------------------------- 1
RECONNECT SPARK PLUG W IRE.
DISCONNECT INJECTOR CONNECTORS.
| SEE IG N ITIO N SYSTEM
i CHECK IN SECTION 6
J
i
CRANK ENGINE.
IS THERE FUEL SPRAY FR O M ONE OR BOTH INJECTORS?
NO YES
in =
CONNECT INJECTOR TEST LIGHT TO ONE HARNESS CONNECTOR. FAULTY INJECTOR
CRANK ENGINE. SEAL OR INJECTOR
REPEAT TEST ON OTHER CONNECTOR
DOES TEST LIGHT BLINK ON BOTH TESTS?
1
NO
X
RECONNECT INJECTOR CONNECTORS. I SEE INJECTOR CIRCUIT
CRANK ENGINE. i D IA G N O SIS CHART A -4
IS THERE FUEL SPRAY FROM INJECTORS? i___________________________
ONE ONLY NO
i
l |
YES NO
X
FAULTY INJECTORS j SEE FUEL SYSTEM
i D IA G N O S IS CHART A -6
I_______ d________
7S3778
4 -2 7 -8 7
______iHkL.
3-24 COMPUTER COMMAND CONTROL
ECM
4 6 7 BLU ~ | D 16
INJECTOR
----- 4 2 3 W H T D4 EST
TO ECM
4 3 0 PPL/W HT B5 REFERENCE
DIST. HEI
10A M O D U LE
t ECM 1 4 2 4 TAN/BLK D5 BYPASS
IG N ITIO N FUSE
SWITCH 4 5 3 BLK/RED B3 GROUND
<- EST CONNECTOR
S-T SERIES
4 3 9 PNK/BLK
DIST. HEI
423 W H T D4 EST
M O D U LE HIlU
4 3 0 PPL/W HT B5 REFERENCE
IGN
COIL
----- 4 2 4 TAN/BLK D5 BYPASS
4 3 9 PNK/BLK
j 4 5 3 BLK/RED B3 GROUND
M SERIES
8 -4 -8 8
7 -2 0 -8 7 *8 S 4 3 8 1 -6E
CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
2.5L ENGINE
Circuit Description:
This chart should only be used if diagnosis in CHART A-3 indicated an injector circuit prqblem.
Test Description: Numbers below refer to circled 2. This step tests for 12 volts to the injector. It will
numbers on the diagnostic chart. also determine if there is a short to voltage on the
1. This test will determine if the ignition module is ECM side of the circuit.
generating a reference pulse, if the wiring is at 3. This test checks for continuity to the ECM.
fault or if the ECM is at fault. By touching and
removing a test light, connected to 12 volts, to
CKT 430, a reference pulse should be generated.
If injector test light blinks, the ECM and wiring
are OK.
COMPUTER COMMAND CONTROL 3-25
CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
FROM
2.5L ENGINE
CHART A-3
INJECTOR TEST
LIGHT DOES
N O T BLINK
8 -4 -8 8
CLEAR CODES A N D CON FIR M "CLOSED LOOP " OPERATION A N D N O "SERVICE ENGINE S O O N " LIGHT.
7S 39 30-6 E
3-26 COMPUTER COMMAND CONTROL
ECM
4 6 8 LTGRN D 14
TBI 2 2 0 U N IT
INJECTORS
INJ A
OR
ECM 1
12V 4 3 9 PNK/BLK TO ECM IF USING
IGN 10A ECM 1 FUSE
423 W HT D4 EST
f 4 5 3 BLK/RED B3 GROUND
V'V'
TO IG N ITIO N
COIL 5 -1 -8 7
8 -4 -8 8 e8S 4 3 8 2 -6 E
CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
ALL ENGINES EXCEPT 2.5L
Circuit Description:
This chart should ony be used if diagnosis in CHART A-3 indicated an injector circuit problem. If both
injector circuits fail to blink when tested, diagnose one injector circuit at a time.
Test Description: Numbers below refer to circled 2. This step tests for 12 volts to the injector. It will
numbers on the diagnostic chart. also determine if there is a short to voltage on the
1. This test will determine if the ignition module is ECM side of the circuit.
generting a reference pulse, if the wiring is at 3. This test checks for continuity to the ECM.
fault or if the ECM is at fault. By touching and
removing a test light, connected to 12 volts, to
CKT 430, a reference pulse should be generated.
If injector test light blinks, the ECM and wiring
are OK.
COMPUTER COMMAND CONTROL 3-27
CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
FROM ALL ENGINES EXCEPT 2.5L
CHART A-3
INJECTOR TEST
LIGHT DOES
N O T BLINK
8 -4 -8 8
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7 S 3 9 3 1 -6 E
3-28 COMPUTER COMMAND CONTROL
C B A
0 3
RELAY
HARNESS
CONNECTOR
ECM B
4 -2 2 -8 8
7 -3 0 -8 7 7 S 3 8 0 2 -6 E
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
" S , T & M " SERIES
Circuit Description:
When the ignition switch is turned "ON, the ECM will turn "ON the in-tank fuel pump. It will remain
"ON as long as the engine is cranking or running, and the ECM is receiving distributor reference pulses. If
there are no reference pulses, the ECM will shut "OFF the fuel pump within 2 seconds after ignition "ON or
engine stops.
The pump will deliver fuel to the TBI unit where the system pressure is controlled to about 62 to 90 kPa (9 to
13 psi). Excess fuel is then returned to the fuel tank.
Test Description: Numbers below refer to circled 3. Determines if ECM can control the relay.
numbers on the diagnostic chart. 4. The oil pressure switch serves as a backup for the
1. Turns "ON the fuel pump if CKT 120 wiring is fuel pump relay to help prev en t a "no s t a r t
OK. If the pump runs, it maybe a fuel pump relay situation. If the fuel pump relay was found to be
circuit problem, which the following steps will inoperative, the oil pressure switch circuit should
locate. also be tested to determine why it did not operate
2. The next two steps check for power and ground the fuel pump.
circuits to the relay.
COMPUTER COMMAND CONTROL 3-29
3-30 COMPUTER COMMAND CONTROL
ECM
QMD
FUEL P U M P
RELAY C O N N .
=
(IN T A N K )
A 1 0=1
BULKHEAD 15 0
B 10A
FUEL CONNECTOR
C PNK/BLK 39 - r\ r IGN 12V O N ALL 7.4L, G V A N W IT H
M O D U LE
_ E C M /IG N 5.7L, A N D ALL OTHER 5.7L OVER
D - BLK/W HT 4 5 0
E
T 8 5 0 0 G V W ENGINES. 5 -2 1 -8 8
7 -2 0 -8 7 7S 38 0 4 -6 E
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
(ONE FUEL TANK)
"C, K, R, V, G & P " SERIES
Circuit Description:
When the ignition switch is turned "ON, the Electronic Control Module (ECM) will turn "ON the in-tank
fuel pump. It will remain "ON as long as the engine is cranking or running, and the ECM is receiving
distributor reference pulses. If there are no reference pulses, the ECM will shut "OFF the fuel pump within 2
seconds after ignition "ON or engine stops except when a fuel module is used.
The pump will deliver fuel to the TBI unit where the system pressure is controlled to about 62 to 90 kPa (9 to
13 psi). Excess fuel is then returned to the fuel tank.
A fuel module is used on all 7.4L, G van with 5.7L, and all other 5.7L over 8500 GVW engines to correct a
hot restart (vapor lock) during a high ambient condition. It is designed to over-ride the ECM two second pump
operation and will run the fuel pump for twenty seconds at initial ignition "ON.
CHART A-5
FROM CHART A -3
FUEL P U M P DOES N O T RUN
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
APPLY FUSED 12V TO FUEL P U M P TEST TE R M IN A L
(ONE FUEL TANK)
LISTEN FOR IN TA N K FUEL P U M P . DOES IT RUN? "C, K, R, V, G & P" SERIES
NO
X
R EM OVE 12V FR O M TE S TT E R M IN A L
OPEN IN CKT 1 2 0 /9 2 0 , RELAY OR
IG N IT IO N "O FF" FOR TEN SECONDS.
CKT 150 TO THE FUEL P U M P OR
DISCONNECT FUEL M O D U L E *
FAULY PUM P.
IG N IT IO N " O N " . LISTEN FOR IN TA N K FUEL
PU M P . P U M P S H O U LD RUN FOR 2 SECONDS
AFTER IG N ITIO N O N . DOES IT?
NO YES
ZE ~1
DISCONNECT P U M P RELAY. IF N O FUEL M O D U L E , N O TROUBLE F O U N D . IN RELAY
IG N ITIO N " O N " ENGINE STOPPED. CIRCUIT W ITH FUEL M O D U L E :
PROBE RELAY HARNESS-CONNECTOR TER M IN A L IG N ITIO N "O F F ", CONNECT M O D U L E & W A IT TEN
CKT 4 4 0 W IT H A TEST LIGHT TO G R O U N D . SECONDS..
IG N ITIO N " O N " , FUEL P U M P SH O U LD RUN FOR
A B O U T TW E N TY SECONDS..
DOES IT?
LIG H T" O N " LIG H T" OFF'
YES NO
ZE X
FAULTY C O N N EC TIO N AT RELAY TE R M IN A L " D " OR OPEN OR SHORT TO
FAULTY RELAY. CONN EC T FUEL M O D U L E IF G R O U N D IN CKT 4 6 5
R E M O VED . OR FAULTY ECM.
IF ORIGINAL S Y M P T O M W A S "EN G IN E CRANKS BUT W ILL
N O T R U N ", C O N TIN U E TESTING OIL PRESSURE SW ITCH.
ENGINE AT N O R M A L OPERATING TEMPERATURE.
OIL PRESSURE N O R M A L
DISCONNECT FUEL P U M P RELAY. ENGINE SHO U LD
C O N TIN U E TO RUN. DOES IT?
YES NO
n r X
RECONNECT FUEL PU M P OPEN IN CKT 4 4 0 OR 1 2 0 /9 2 0 TO
RELAY. THE OIL PRESSURE SW ITCH OR
IG N IT IO N "O FF ". FAULTY OIL PRESSURE SW ITCH.
PROBE FUEL P U M P TEST
TE R M IN A L W IT H A TEST
LIGHT TO G R O U N D .
N O LIGHT LIGHT
ECM
QMD
FUEL P U M P
RELAY C O N N .
10A
BATT
12 V ------ 4 4 0 ORN
ECM B FUSE
FUEL P U M P
RELAY
12 VOLT
4 6 5 DK G R N /W H T A1 | IRELAY
DRIVE
OIL
PRESSURE 450
SW ITCH 'B LK /W H T
120 B2
c T A N /W H T
FUEL P U M P
SIGNAL
FUEL P U M P TEST
RED
T E R M IN A L
120 T A N /W H T
LEFT
LEFT <-
r H -w
L__________
PM VALVE
LEFT
120
T A N /W H T
t RIGHT
RIGHT
FUEL TA N K SELECTOR SWITCH
FUEL TA N K SELECTOR 150
VALVE & METER SWITCH BLK
BUS
BAR
LEFT FUEL P U M P
A
B
------- 9 2 0 TAN = -
FUEL
C - PNK/BLK 39 B vv F
M O D U LE 9 3 0 P N K /W H T ------it
D B LK /W H T 4 5 0
E 1 SENDING U N IT rb
LEFT TA N K
5.7L
(OVER 8 5 0 0 G V W )
A N D ALL 7.4L
ENGINES
FUEL
A (N O T USED) GAGE
30PNK
20A
IGN
39 PNK/BLK
12 V
GAGE
FUSE RIGHT FUEL P U M P
921 GRA - L Z 0 Z l
931 PNK/BLK
SENDING U N IT 8S 3 9 98-6 E
RIGHT TA N K 6 -1 9 -8 7
CHART A-5A, Fuel Pump Relay Circuit Diagnosis - (Two Fuel Tanks) - "RV" Series
COMPUTER COMMAND CONTROL 3-33
3-34 COMPUTER COMMAND CONTROL
TBI
INJECTOR
THROTTLE BODY MODEL 700 TBI
PRESSURE REGULATOR
i . :i = 3
/
IN-LINE
FUEL FILTER
f
FLEX HOSE FUEL PRESSURE LINE
IN -T A N K P U M P
FUEL PRESSURE
GAGE TEST
FUEL
TA N K
T
FLEX HOSE FUEL PRESSURE LINE FU ELC A P
IN -T A N K FUEL PUM P
CHART A-6
FUEL SYSTEM PRESSURE TEST
ALL ENGINES
Circuit Description:
When the fuel pump is running, fuel is delivered to the injector(s) and then to the regulator where the
system pressure is controlled to about 62 to 90 kPa (9 to 13 psi). Excess fuel is then returned to the fuel tank.
Test Description: Numbers below refer to circled the pump test term inal, fuel pressure should rise
numbers on the diagnostic chart. to 90 to 103 kPa (13 to 15 psi) as the pressure gage
1. Pressure, but less than 62 kPa (9 psi) falls into two outlet hose is gradually pinched.
areas: 3. This test determines if the high fuel pressure is
Regulated pressure but less than 62 kPa (9 psi) - due to a restricted fuel return line or a throttle
Amount of fuel to injector OK but pressure is too body pressure regulator problem.
low. System will be lean running and may set
Code 44. Also, hard starting cold and poor overall Diagnostic Aids:
performance.
Restricted flow causing pressure drop - Normally, If the vehicle is equipped with a fuel module, the
a vehicle with a fuel pressure of less than 62 kPa module must be disconnected before perform ing
(9 psi) at idle will not be driveable. However, if the fuel system pressure test. Refer to Section "4.
the pressure drop occurs only while driving, the Fuel system is under pressure. To avoid fuel
engine could surge and stop when pressure is too spillage, refer to procedures in Section "4 for
low. testing or making repairs requiring disassembly
2. Restricting the outlet side of the gage allows the of fuel lines or fittings.
pump to develop its maximum pressure (dead On V6 or V8 engine, the fuel pressure drops to
head pressure). With battery voltage applied to almost zero psi after pump shuts "OFF.
COMPUTER COMMAND CONTROL 3-35
3-36 COMPUTER COMMAND CONTROL
ECM
2 -2 0 -8 7
7 -3 0 -8 7 4S 07 9 0 -6 E
CODE 13
OXYGEN SENSOR OPEN CIRCUIT
ALL ENGINES
Circuit Description:
The ECM supplies a voltage of about .45 volt between term inals "D7 and "D6. (If measured with a 10
megohm digital voltmeter, this may read as low as .32 volt). The oxygen sensor varies the voltage within a
range of about 1 volt if the exhaust is rich, down through about .10 volt if exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below 315C (600F). An open sensor
circuit or cold sensor causes "Open Loop operation.
CODE 13
OXYGEN SENSOR CIRCUIT
(OPEN CIRCUIT)
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
5 -3 -8 8
7S 30 54-6 E
3-38 COMPUTER COMMAND CONTROL
C O O LAN T TEMPERATURE
SENSOR
7 -2 0 -8 7
CODE 14
COOLANT TEMPERATURE SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)
ALL ENGINES
Circuit Description:
The coolant tem perature sensor is a therm istor that controls the signal voltage to the ECM. The ECM
applies a voltage on CKT 410 to the sensor. When the engine is cold, the sensor (thermistor) resistance is high,
therefore the ECM will see high signal voltage.
As the engine warms, the sensor resistance becomes less and the voltage drops. At normal engine operating
temperature (85C to 95C), the voltage will measure about 1.5 to 2.0 volts.
CODE 14
COOLANT TEMPERATURE SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)
ALL ENGINES
DIAGNOSTIC AID
C O O LA N T SENSOR
TEMPERATURE VS. RESISTANCE VALUES
(A P P R O X IM A TE )
F C OHMS
160 70 45 0
100 38 1,800
70 20 3 ,4 00
40 4 7 ,5 0 0
20 -7 13 ,500
0 -18 2 5 ,0 0 0
-40 -40 10 0 ,7 0 0
5-26-88
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7S3055-6E
3-40 COMPUTER COMMAND CONTROL
C O O LA N T TEMPERATURE
SENSOR
7-20-87
CODE 15
COOLANT TEMPERATURE SENSOR CIRCUIT
(LOWTEMPERATURE INDICATED)
ALL ENGINES
Circuit Description:
The coolant temperature sensor is a thermistor that controls the signal voltage to the ECM. The ECM
applies a voltage on CKT 410 to the sensor. When the engine is cold, the sensor (thermistor) resistance is high,
therefore the ECM will see high signal voltage.
As the engine warms, the sensor resistance becomes less and the voltage drops. At normal engine operating
temperature (85C to 95C), the voltage will measure about 1.5 to 2.0 volts.
CODE 15
COOLANT TEMPERATURE SENSOR CIRCUIT
(LOW TEMPERATURE IN D IC ATED )
ALL ENGINES
DIAGNOSTIC AID
C O O LAN T SENSOR
TEMPERATURE TO RESISTANCE VALUES
(A P P R O X IM A TE )
F C OHMS
21 0 100 185
160 70 450
100 38 1 ,8 00
70 20 3 ,4 0 0
40 4 7 ,5 0 0
20 -7 1 3 ,5 0 0
0 -18 2 5 ,0 0 0
-40 -40 1 0 0 ,7 0 0
5-26-88
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3261-6E
3-42 COMPUTER COMMAND CONTROL
CODE 21
THROTTLE POSITION SENSOR (TPS) CIRCUIT
(SIGNAL VOLTAGE HIGH)
ALL ENGINES
Circuit Description:
The throttle position sensor (TPS) provides a voltage signal that changes relative to the throttle blade
angle. Signal voltage will vary from about .5 volt at idle to about 5 volts at wide open throttle.
The TPS signal is one of the most important inputs used by the ECM for fuel control and for most of the
ECM control outputs.
CODE 21
THROTTLE POSITION SENSOR (TPS) CIRCUIT
(SIGNAL VOLTAGE HIGH)
ALL ENGINES
2 -2 4 -8 7
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7<. , ft>.
3-44 COMPUTER COMMAND CONTROL
CODE 22
THROTTLE POSITION SENSOR (TPS) CIRCUIT
(SIGNAL VOLTAGE LOW)
ALL ENGINES
Circuit Description;
The throttle position sensor (TPS) provides a voltage signal that changes relative to the throttle blade.
Signal voltage will vary from about .5 volt at idle to about 5 volts at wide open throttle.
The TPS signal is one of the most important inputs used by the ECM for fuel control and for most of the
ECM control outputs.
CODE 22
THROTTLE POSITION SENSOR (TPS) CIRCUIT
(SIGNAL VOLTAGE LOW)
ALL ENGINES
6 -2 5 -8 7
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. * 7S 3365-6E
3-46 COMPUTER COMMAND CONTROL
CODE 23
M ANIFOLD AIR TEMPERATURE (M A T) SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
2.5L ENGINE
Circuit Description:
The manifold air tem perature (MAT) sensor is a therm istor that controls the signal voltage to the ECM.
The ECM applies a voltage (4-6 volts) on CKT 472 to the sensor. When the air is cold, the sensor (thermistor)
resistance is high, therefore the ECM will see a high signal voltage. If the air is warm, the sensor resistance is
low therefore the ECM will see a low voltage.
CODE 23
MANIFOLD AIR TEMPERATURE (M A T) SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
2.5L ENGINE
YES NO
DISCONNECT SENSOR.
JUMPER HARNESS TERM INALS TOGETHER.
"S C A N " SH O U LD DISPLAY TEMPERATURE OVER 130C
CODE 23 IS IN TE R M ITTEN T. IF NO
A D D IT IO N A L CODES WERE STORED,
REFER TO "D IA G N O S T IC A ID S " ON
DOES IT? FACING PAGE.
YES NO
JUMPER CKT 4 7 2 TO G R O U N D .
FAULTY C O N N EC TIO N OR SENSOR.
"S C A N " S HOULD DISPLAY TEMP.
OVER 130C.
DOES IT?
YES NO
F C OHMS
21 0 100 185
160 70 450
100 38 1,8 00
70 20 3 ,4 00
40 4 7 ,5 00
20 -7 1 3 ,5 0 0
0 -18 2 5 ,0 0 0
-40 -40 1 0 0 ,7 0 0
2-25-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3285
3-48 COMPUTER COMMAND CONTROL
ECM
P/N SW ITCH
E 4 5 0 BLK/W HT ------
CLOSED IN
4 3 4 ORN/BLK | B10 AAAr-12V
PARK OR NEUTRAL
7S 3693
8 - 8-88 7 -9 -8 6
CODE 24
VSS CIRCUIT FAULT
ALL ENGINES
Circuit Description:
The ECM applies and monitors 12 volts on CKT 437. CKT 437 connects to the vehicle speed sensor (VSS)
which alternately grounds CKT 437 when drive wheels are turning. This pulsing action takes place about 2000
times per mile and the ECM will calculate vehicle speed based on the time between "pulses.
A "Scan tool reading should closely match with speedometer reading with drive wheels turning.
Test Description: Numbers below refer to circled 3. A steady 8-12 volts a t th e ECM co n n ecto r
numbers on the diagnostic chart. indicates CKT 437 is open or a faulty vehicle speed
Code 24 will set if: sensor.
CKT 437 voltage is constant. 4. This is normal voltage which indicates a possible
Engine speed is more than 200 rpm . interm ittent condition.
Vehicle speed signal indicates less than 10
mph (16 km/h) on "Scan tool. Diagnostic Aids:
All conditions must be met for 10 seconds.
These conditions are met d u rin g a road load 1. "S can re a d in g should clo sely m atch w ith
deceleration. speedometer reading, with drive wheels turning.
1. This test monitors the ECM voltage on CKT 437. 2. Check p ark /n eu tral switch diag n o sis c h a rt if
With the wheels turning, the pulsing action will vehicle equipped with automatic transmission.
result in a varying voltage. The variation will be 3. If p ark /n eu tral switch is OK, refer to "ECM
greater at low wheel speeds to an average of 4-6 Interm ittent Codes or Perform ance in Section
volts at about 20 mph (32 km/h).
2. A voltage of less than 1 volt at the ECM connector
indicates th a t the CKT 437 wire is shorted to
ground. Disconnect CKT 437 at the vehicle speed
sensor. If voltage now reads above 10 volts, the
vehicle speed sensor is faulty. If voltage remains
less than 10 volt, then CKT 437 wire is grounded.
If 437 is not grounded, check for a faulty ECM
connector or ECM.
COMPUTER COMMAND CONTROL 3-49
CODE 24
VSS CIRCUIT FAULT
ALL ENGINES
DISREGARD CODE 2 4 IF SET W HILE DRIVE WHEELS ARE N O T TU R N IN G .
7 S 3694
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 0 7 -0 6 -8 7
3-50 COMPUTER COMMAND CONTROL
CODE 25
M ANIFOLD AIR TEMPERATURE (M A T) SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)
2.5L ENGINE
Circuit Description:
The manifold air tem perature (MAT) sensor is a therm istor that controls the signal voltage to the ECM.
The ECM applies a voltage (4-6 volts) on CKT 472 to the sensor. When the air is cold, the sensor (thermistor)
resistance is high, therefore the ECM will see a high signal voltage. As the air warms, the sensor resistance
becomes less, and the voltage drops.
CODE 25
MANIFOLD AIR TEMPERATURE (M A T) SENSOR
CIRCUIT
(HIGH TEMPERATURE INDICATED)
ALL ENGINES
D IA G N O S TIC A ID
M A T SENSOR
TEMPERATURE TO RESISTANCE VALUES
(A P P R O XIM A TE
F C OHMS
21 0 100 185
160 70 450
100 38 1,8 00
70 20 3 ,4 0 0
40 4 7 ,5 0 0
20 -7 1 3 ,500
0 -1 8 2 5 ,0 0 0
-40 -4 0 1 0 0 ,7 0 0
6 -1 7 -8 7
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 31 90-6 E
3-52 COMPUTER COMMAND CONTROL
TO EGR VALVE
7 -1 5 -8 7
7 -3 0 -8 7 7S 3 7 3 7
CODE 32
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
2.5 L & 5 .0 L
4.3L (EXCEPT ST)
5 .7 l (UNDER 8500 GVW )
Circuit Description:
The ECM operates a solenoid to control the exhaust gas recirculation (EGR) valve. This solenoid is
normally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass
to the EGR valve.
The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid thereby sh u ttin g off
vacuum to the EGR valve diaphragm. With the EGR valve closed, fuel integrator counts will be greater than
they were during normal EGR operation. If the change is not within the calibrated window, a Code 32 will be
set.
The ECM will check EGR operation when:
Vehicle speed is above 50 mph.
Engine vacuum is between 40 and 51 kPa.
No change in throttle position while test is being run.
Test Description: Numbers below refer to circled 5. When engine is started , exhaust backpressure
numbers on the diagnostic chart. should cause vacuum to bleed off and valve should
1. By grounding the diagnostic term inal, the EGR fully close.
solenoid should be energized and allow vacuum to
be applied to the EGR valve and the vacuum Diagnostic Aids:
should hold.
2. When the diagnostic term inal is ungrounded, the Before replacing ECM, use an ohmmeter and
vacuum to the EGR valve should bleed off through check the resistance of each ECM controlled
a vent in the solenoid and the valve should close. relay and solenoid coil. Refer to ECM QDR
The gage may or may not bleed off but this does Check procedure, F igure 3-18. See ECM
not indicate a problem. w irin g d ia g ra m for coil te rm . I.D . of
3. This test will determine if the electrical control solenoid(s) and relay(s) to be checked. Replace
part of the system is at fault or if the connector or any solenoid where resistance measures less
solenoid is at fault. than 20 ohms.
4. This system uses a negative backpressure valve
which should hold vacuum with engine "OFF.
COMPUTER COMMAND CONTROL 3-53
NO YES
INSTALL A V A C U U M GAGE IN
V A C U U M LINE A T VALVE.
PLUG V A C U U M HOSE FROM THROTTLE BODY.
REMOVE G R O U N D FR O M D IA G N O S TIC TER M IN A L.
START A N D IDLE ENGINE.
REPEAT TEST.
DOES GAGE IN DICATE V A C U U M ? LIFT UP ON EGR VALVE A N D OBSERVE IDLE.
NO YES IDLE ROUGHENS NO CHANGE
1 1 ......... .........i
OK N O T OK
LIGHT "O N " LIGHT "O FF"
I----- I
CONNECT TEST LIGHT REPAIR OPEN N O TROUBLE FO U N D . OVER 1 0 "
BETWEEN HARNESS IN G R O U N D SEE IN TERM ITTENTS VACUUM
CONNECTOR CKT. IN SECTION "2.
1
TERMINALS " A " & "B ".
G R O U N D D IA G N O S TIC REPLACE
TERMINAL. EGR FILTER.
1 .
...Liz: c:
REPLACE SOLENOID. O PE N C K T 4 3 5 OR
FAULTY ECM. SEE
"D IA G N O STIC A ID S '
ON FACING PAGE.
8 -4 -8 8
CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3 8 4 7 -6 E
3-54 COMPUTER COMMAND CONTROL
ECM
IGN.
TO EGR VALVE
ENGINE t>ECM 1
VACUUM 10AC fu se
&
a 439 PNK/BLK -
CODE 32
EGR SYSTEM
2.8L, 4.3L (ST), 7.4L & 5.7L (OVER 8500 G VW )
Circuit Description:
The ECM operates a solenoid to control the exhaust gas recirculation (EGR) valve. This solenoid is
normally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass
to the EGR valve.
The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid thereby shutting off
vacuum to the EGR valve diaphragm. With the EGR valve closed, fuel integrator counts will be greater than
they were during normal EGR operation. If the change is not within the calibrated window, a Code 32 will be
set.
The ECM will check EGR operation when:
Vehicle speed is above 50 mph.
Engine vacuum is between 40 and 51 kPa.
No change in throttle position while test is being run.
MAP SENSOR
ECM
Af\f\/V-
*
MANIFOLD
416 GRY
432 LTGRN
|C14 h
G E } - MAP SIGNAL
5VREF
ABSOLUTE
PRESSURE ALL CK 455 PPL
(VACUUM)
-E E }
SENSOR
2.5L ENGINE 469 BLK/RED -E D GROUND
4.3LM 455 BLK/RED - O Q
- (GRVST) - ----- 455 PPL
i 02 h 7S 3697-6E
7-31-87 8 - 2-88
CODE 33
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM)
ALL ENGINES
Circuit Description:
The manifold absolute pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The
ECM receives this information as a signal voltage that will vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
wide open throttle.
CODE 33
M AP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM )
ALL ENGINES
7S 3 6 9 8
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
8 -5 -8 8
3-58 COMPUTER COMMAND CONTROL
MAP SENSOR
ECM
\
M A N IF O LD
----- 4 1 6 GRY
- 4 3 2 LTG R N
{ c u }
-nay
-^yyv^ sv ref
- M A P SIGNAL
ABSOLUTE
PRESSURE
(V A C U U M )
ALL CK ------- 4 5 5 PPL
CZHD- SENSOR
2.5L ENGINE 4 6 9 BLK/RED
-O D - GROUND
-4 .3 L M ~ 4 5 5 BLK/RED H 02 h
7 -30-8 7
- (GRVST) - ------ 4 5 5 PPL
-E H - 7 S 3 6 9 7 -6 E
8 - 2-88
CODE 34
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE LOW
(HIGH VACUUM)
ALL ENGINES
Circuit Description:
The manifold absolute pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The
ECM receives this information as a signal voltage that will vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
wide open throttle.
If the MAP sensor fails the ECM will substitute a fixed MAP value and use the throttle position sensor
(TPS) to control fuel delivery.
CODE 34
M AP SENSOR CIRCUIT
SIGNAL VOLTAGE LOW
(HIGH VACUUM )
ALL ENGINES
IG N ITIO N "O FF " FOR 10 SECONDS
START ENGINE A N D IM M E D IA T E L Y NOTE M A P
VALUE ON "S C A N ".
o DOES "SC A N " DISPLAY M A P BELOW .25 VOLTS?
YES NO
IGN ITION "O F F ".
DISCONNECT SENSOR ELECTRICAL CONNECTOR.
CODE 3 4 IS IN TE R M ITTE N T.
IF N O A D D IT IO N A L CODES WERE
JUMPER HARNESS TERM INALS "B " TO "C". STORED, REFER TO D IA G N O S TIC
IGN ITION " O N " . AIDS O N FACING PAGE.
M A P VOLTAGE S H O U LD READ OVER 4 VOLTS.
DOES IT?
NO YES
YES NO
I IE
C K T 4 1 6 OPEN OR C K T 4 1 6 SHORTED CKT 4 3 2 OPEN
TO G R O U N D OR CKT 4 1 6 SHORTED TO OR
SENSOR G R O U N D OR FAULTY ECM CKT 4 3 2 SHORTED TO G R O U N D
OR
IGNITION "ON" ENGINE STOPPED VOLTAGES CKT 4 3 2 SHORTED TO SENSOR G R O U N D
OR
ALTITUDE VOLTAGE RANGE FAULTY ECM
Meters Feet
CODE 35
IDLE AIR CONTROL (IAC) SYSTEM
2.5L ENGINE
Circuit Description:
Code 35 will set when the closed throttle engine speed is 100 rpm above or below the correct engine idle
speed for 45 seconds. Review "General Description in Section "4.
Test Description: Numbers below refer to circled If idle is too high, stop engine. Ignition "ON.
numbers on the diagnostic chart. Ground diagnostic terminal. Wait a few seconds for
1. Continue with test even if engine will not idle. If IAC to seat, then disconnect IAC. Start engine. If idle
idle is too low, "Scan will display 80 or more speed is above 800 50 rpm, locate and correct
counts, or steps. If idle is high, it will display "0 vacuum leak.
counts. System too lean. (High air/fuel ratio)
Occasionally, an erratic or unstable idle may occur. Idle speed may be too high or too low. Engine speed
Engine speed may vary 200 rpm or more up and may vary up and down, disconnecting IAC does not
down. Disconnect IAC. If th e co n d itio n is help. May set Code 44.
unchanged, the IAC is not faulty, there is a system "Scan and/or Voltmeter will read an oxygen sensor
problem. Proceed to paragraph three below. output less than 300 mV (.3 volt). Check for low
2. When the engine was stopped, the IAC valve regulated fuel pressure or water in fuel. A lean
retracted (more air) to a fixed "park position for exhaust with an oxygen sensor output fixed above
increased air flow and idle speed during the next 800 mV (.8 volt) will be a contam inated sensor,
engine start. A "Scan will display 100 or more usually silicone. This may also set a Code 45.
counts. System too rich (Low air/fuel ratio)
3. Be sure to disconnect the IAC valve prior to this Idle speed too low. "Scan counts usually above 80.
test. The test light will confirm the ECM signals by System obviously rich and may exhibit black smoke
a steady or flashing light on all circuits. exhaust.
4. There is a remote possibility that one of the circuits "Scan tool and/or voltmeter will read an oxygen
is shorted to voltage which would have been sensor signal fixed above 800 mV (.8 volt).
indicated by a steady light. Disconnect ECM and Check:
turn the ignition "ON and probe term inals to High fuel pressure
check for this condition. Injector leaking or sticking.
Throttle body.
Diagnostic Aids: Remove IAC and inspect bore for foreign material
or evidence of IAC valve dragging the bore.
A slow unstable idle may be caused by a system A/C Compressor or relay failure.
problem that cannot be overcome by the IAC. "Scan See if A/C diagnosis circuit if shorted to ground. If
counts will be above 60 counts if too low and "0 counts the relay is faulty, an idle problem may exist.
if too high. Refer to "Rough, U n stab le, In co rrect Idle or
Stalling in "Driveability Sym ptom s in Section
COMPUTER COMMAND CONTROL 3-61
IG N ITIO N "O FF" FOR 10 SECONDS.
START ENGINE A N D IM M E D IA T E L Y
OBSERVE RPM IN NEUTRAL.
IG N IT IO N "O FF".
DISCONNECT IAC VALVE HARNESS.
REFER TO "D IA G N O S T IC A ID S "
ON FACING PAGE.
NO LIGHTS, ONE OR
MORE CIRCUITS.
LIG H T STEADY
OR FLASHING ALL
CIRCUITS
I
CHECK FOR OPEN OR SHORT TO
G R O U N D IN CIRCUIT W IT H NO FAULTY IAC
LIGHT. ARE ALL CIRCUITS OK? C O N N EC TIO N OR IAC
V A LV E, OR PLUGGED
PASSAGE. IF LIGHT
YES NO APPEARS TO BE STEADY,
~~l~ REFER TO TEST, S TE P 4
CHECK RESISTANCE ACROSS IAC COILS. SHO U LD BE REPAIR W IR IN G A N D ON FACING PAGE.
MORE TH A N 20 O H M S BETWEEN IAC TERMINALS RECHECK.
OPPOSITE HARNESS CONNECTOR TERM INALS " A " TO
"B " A N D "C " TO " D " .
OK
IE N O T OK
FAULTY ECM
C O N NECTION OR ECM.
REPLACE IAC VALVE A N D RETEST.
IDLE N O T OK
REPLACE ECM
E 0
423 W H T D4 EST
IG N ITIO N
EXCEPT 2.5 L S /T TRUCK 4 3 0 PPL/W HT - B5 REFERENCE
M OD U LE
4 2 4 TAN/BLK D5 BYPASS
PRIM. IGN. COIL
4 5 3 BLK/RED B3 GROUND
EST CONNECTOR
IGN
2.5L&2.8L
ECM
DISTRIBUTOR
D ISTRIBUTOR 4 TERM.
C ONNECTOR
4 3 0 PPL/W HT H B5 \ REFERENCE
4 2 4 TAN/BLK - BY-PASS
45 3 BLK/RED T bT T
CODE 42
ELECTRONIC SPARK TIM ING (EST)
ALL ENGINES
Circuit Description
Refer to page 3-9 for EST and Code 42.
Test Description: Numbers below refer to circled Selecting the 10-20,000 ohm s p o sitio n w ill
numbers on the diagnostic chart. indicate above 5000 ohms. The im portant thing is
1. Code 42 means the ECM has seen an open or short that the module "switched.
to ground in the EST or bypass circuits. This test 4. The module did not switch and this step checks for:
confirms Code 42 and that the fault causing the EST CKT 423 shorted to ground.
code is present. Bypass CKT 424 open.
2. Checks for a normal EST ground path through the Faulty ignition module connection or module.
ignition module. An EST CKT 423 shorted to 5. Confirms that Code 42 is a faulty ECM and not an
ground will also read less th a n 500 ohm s; interm ittent in CKTs 423 or 424.
however, this will be checked later.
Diagnostic Aids:
3. As the test light voltage touches CKT 424, the
module should switch causing the ohm m eter to The "Scan tool does not have any ability to help
"overrange if the meter is in the 100-200 ohms diagnose a Code 42 problem.
position. Refer to Section "2 for "ECM Interm ittent Code
or Performance.
COMPUTER COMMAND CONTROL 3-63
3-64 COMPUTER COMMAND CONTROL
ECM 1
ESC
MODULE
7
7 -2 1 -8 7
CODE 43
ELECTRONIC SPARK CONTROL (ESC) CIRCUIT
ALL ENGINES EXCEPT 2.5L AND 7.4L
Circuit Description:
Electronic spark control is accomplished with a module that sends a voltage signal to the ECM. As the
knock sensor detects engine knock, the voltage from the ESC module to the ECM drops, and this signals the
ECM to retard timing. The ECM will retard the timing when knock is detected and rpm is above about 900
rpm.
Code 43 means the ECM has been low voltage at CKT 485 term inal "B7 for longer than 5 seconds with the
engine running or the system has failed the functional check.
This system performs a functional check once per start-up to check the ESC system. To perform this test,
the ECM will advance the spark when coolant is above 95C and at a high load condition (near W.O.T.). The
ECM then checks the signal at "B7 to see if a knock is detected. The functional check is performed once per
start-up and if knock is detected when coolant is below 95C (194F), the test has passed and the functional
check will not be run. If the functional check fails, the "Service Engine Soon light will remain "ON until
ignition is turned "OFF or until a knock signal is detected.
Test Description: Numbers below refer to circled 5. If CKT 496 is routed to close to secondary ignition
numbers on the diagnostic chart. wires, the ESC module may see the interference as
1. If the conditions for a Code 43 are present, the a knock signal.
"Scan will always display "YES. There should 6. This checks the ground circuit to the module. An
not be a knock at idle unless an internal engine open ground will cause the voltage on CKT 485 to
problem, or a system problem exists. be about 12 volts which would cause the Code 43
2. T his te s t w ill d e te rm in e if th e sy ste m is functional test to fail.
functioning at this time. Usually a knock signal 7. Connecting CKT 496 with a test light to 12 volts
can be generated by tapping on the right exhaust should g en erate a knock sig n al. T h is w ill
manifold. If no knock signal is generated, try d eterm ine if th e ESC m odule is o p e ra tin g
tapping on block close to the area of the sensor. correctly.
3. Because Code 43 sets when the signal voltage on
CKT 485 remains low, this test should cause the Diagnostic Aids:
signal on CKT 485 to go high. The 12 volts signal
should be seen by the ECM as "no knock if the Code 43 can be caused by a faulty connection at
ECM and wiring are OK. the knock sensor at the ESC module or at the ECM.
4. This test will determ ine if the knock signal is Also check CKT 485 for possible open or short to
being detected on CKT 496 or if the ESC module is ground.
at fault. Refer to Section "2 for "ECM Interm ittent Codes
or Performance.
COMPUTER COMMAND CONTROL 3-65
CODE 43
ENGINE IDLING . ELECTRONIC SPARK CONTROL
"S C A N " SET ON KNOCK SIGNAL. (ESC) CIRCUIT
IS THERE A KNOCK SIGNAL INDICATED?
ALL ENGINES EXCEPT
2.5L AND 7.4L
YES NO
HZ m
DISCONNECT ESC M O D U L E . ENGINE IDLING.
ENGINE IDLING. TAP ENGINE BLOCK IN AREA OF KNOCK SENSOR.
PROBE HARNESS TE R M IN A L "C " (CKT IS A KNOCK SIGNAL IN D IC A TE D W H ILE TAPPING
4 8 5 ) W IT H A TEST LIGHT CONNECTED ON ENGINE?
TO 12 VOLTS.
AFTER 5 SECONDS, DOES "SC A N "
DISPLAY A KNOCK SIGNAL? NO YES
z c
1
DISCONNECT ESC M O D U L E .
PROBE HARNESS TE R M IN A L
CODE 4 3 IS IN TE R M IT TE N T. IF
N O A D D IT IO N A L CODES WERE
NO YES
" D " (CKT 4 8 6 ) W IT H A TEST STORED, REFER TO " D IA G N O S
~r~ IE L IG H T T O 12 V. TIC A ID S ON FACING PAGE.
IG N ITIO N " O N " . CKT 4 8 5 OPEN,
PROBE TE R M IN A L SHORTED TO
"B " (CKT 4 3 9 ) G R O U N D , OR LIGHT "O N * LIGHT "OFF*
W ITH A TEST LIGHT FAULTY ECM.
TO G R O U N D .
RECONNECT ESC M O D U L E .
DISCONNECT KNOCK SENSOR.
REPAIR OPEN
G R O U N D CKT 4 8 6 .
ENGINE IDLING.
M O M E N T A R ILY TO UC H KNOCK
SENSOR HARNESS (CKT 4 9 6 ) W IT H
A TEST L IG H T T O 12V.
EACH TIM E THE TEST LIGHT
CONTACTS CKT 4 9 6 , A KNOCK
SIGNAL S H O U LD BE GENERATED.
IS A KNOCK SIGNAL IN D IC A TE D
W IT H "SC A N "?
YES NO
IE
FAULTY CONNECTION A T SENSOR CKT 4 9 6 O PEN, SHORTED TO
OR FAULTY KNOCK SENSOR. G R O U N D , FAULTY C O N N EC
TIO N A T ESC M O D U L E , OR
FAULTY ESC M O D U L E .
LIGH T "O N * LIGHT "O F F '
T........... X
REMOVE CKT 4 9 6 FROM CONNECTOR.
RECONNECT ESC M O D U L E .
OPEN CKT 4 3 9
ENGINE IDLING .
IS THERE A KNOCK SIGNAL INDICATED?
YES NO
nr m
FAULTY CONNECTION
OR ESC M O D U L E .
IF AN AUDIBLE KNOCK CAN BE HEARD,
REPAIR INTERNAL ENGINE PROBLEM. IF OK,
CHECK FOR R O U TIN G OF WIRE FR O M KNOCK
SENSOR TO ESC M O D U L E FOR PICKING UP
FALSE KNOCK SIGNALS FR O M A N ADJACENT
W IRE. REROUTE AS NECESSARY. IF RO U TIN G
IS CORRECT, REPLACE KNOCK SENSOR.
2 -1 2 -8 7
7S 3 2 9 2 -6 E
3-66 COMPUTER COMMAND CONTROL
ECM
8 -5 -8 8 4S 07 90-6 E
CODE 44
LEAN EXHAUST INDICATED
ALL ENGINES
Circuit Description:
The ECM supplies a voltage of about .45 volt between terminals "D6 and "D7. (If measured with a 10 meg
ohm digital voltmeter, this may read as low as .32 volt.) The oxygen sensor varies the voltage within a range of
about 1 volt if the exhaust is rich, down through about .10 volt if exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below about 315C (600F). An open
sensor circuit or cold sensor causes "Open Loop operation.
Test Description: Numbers below refer to circled Fuel C o n tam in atio n . W ater, even in sm all
numbers on the diagnostic chart. amounts, near the in-tank fuel pump inlet, can be
1. Code 44 is set when the oxygen sensor signal delivered to the injectors. The water causes a lean
voltage on CKT 412: exhaust and can set a Code 44.
Remains below .2 volt for 20 seconds. Fuel Pressure. System will be lean if pressure is
And the system is operating in "Closed Loop. too low. It may be necessary to m onitor fuel
pressure while driving the vehicle at various road
Diagnostic Aids: speeds an/or loads to confirm. See Fuel System
diagnosis.
Using the "Scan, observe the block learn values AIR System. Be sure air is not being directed to
at different rpm and air flow conditions. The "Scan the exhaust ports while in "Closed Loop. If the
also displays the block cells, so the block learn values block learn value goes down while squeezing air
can be checked in each of the cells to determine when hose to left side of exhaust ports, refer to Section 8.
the Code 44 may have been set. If the conditions for If the above are OK, it is a faulty oxygen sensor.
Code 44 exists, the block learn values will be around CKT 413. If CKT 413 is open, the voltage at
150. term inal "D7 will be over one volt. This may also
Oxygen Sensor W ire. Sensor p ig tail may be cause Code 13 to set.
m isp o sitio n ed and c o n ta c tin g th e e x h a u s t If all check OK, the oxygen sensor is faulty.
manifold.
Check for interm ittent ground in wire between
connector and sensor.
COMPUTER COMMAND CONTROL 3-67
CODE 44
LEAN EXHAUST INDICATED
ALL ENGINES
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
3-68 COMPUTER COMMAND CONTROL
ECM
0 2 SENSOR
D7
SIGNAL
D6 0 2 GROUND
~ CIRCUIT
2 -2 0 -8 7
8 -5 -8 8 4S 07 9 0 -6 E
CODE 45
RICH EXHAUST INDICATED
ALL ENGINES
Circuit Description:
The ECM supplies a voltage of about .45 volt between term inals "D6 and "D7. (If measured with a 10
meg ohm digital voltmeter, this may read as low as .32 volt.) The oxygen sensor varies the voltage within a
range of about 1 volt if the exhaust is rich, down through about .10 volt if exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below about 315 C (600F). An open
sensor circuit or cold sensor causes "Open Loop operation.
Test Description: Numbers below refer to circled HEI S h ield in g . An open g ro u n d CKT 453
numbers on the diagnostic chart. (ignition system reference low) may result in EMI,
1. Code 45 is set when the oxygen sensor signal or induced electrical "noise. The ECM looks at
voltage or CKT 412: this "noise as reference pulses. The additional
Remains above .7 volt for 50 seconds, and in pulses result in a higher than actual engine speed
"Closed Loop. signal.The ECM then delivers too m uch fuel,
Engine time after start is 1 minute or more. causing system to go rich. Engine tachometer will
Throttle angle greater than 2%. (about .2 volt also show higher than actual engine speed which
above idle voltage) can help in diagnosing this problem.
Canister Purge. Check for fuel saturation. If full
Diagnostic Aids: of fuel, check canister control and hoses. See
Evaporative Emission Control in Section 5.
Using the "Scan, observe the block learn values MAP Sensor. An output th at causes the ECM to
at different rpm and air flow conditions to determine sensor a higher than normal manifold pressure
when the Code 45 may have been set. If the conditions (low vacuum) can cause the system to go rich.
for Code 45 exists, the block learn values will be Disconnecting the MAP sensor will allow the
around 115. ECM to set a fixed value for the MAP sensor.
Fuel Pressure. System will go rich if pressure is Substitute a different MAP sensor if the rich
too high. The ECM can compensate for some condition is gone while the sensor is disconnected.
increase. However, if it gets too high, a Code 45 Pressure R eg u lato r. Check for le ak in g fuel
may be set. pressure regulator diaphragm by checking for
See Fuel System diagnosis chart. presence of liquid fuel in the vacuum line to the
Leaking Injector. regulator.
Check for fuel contaminated oil. Check for le a k in g fuel p re s s u re re g u la to r
diaphragm by checking vacuum line to regulator
for fuel.
TPS. An interm ittent TPS output will cause the
system to go rich, due to a false indication of the
engine accelerating.
COMPUTER COMMAND CONTROL 3-69
CODE 45
RICH EXHAUST INDICATED
ALL ENGINES
J s?
4^
*
< r< r
Ao< r
CLEAR CODES A N D C O N FIR M "CLOSED LO O P" OPERAT
3-70 COMPUTER COMMAND CONTROL
CODE 54
FUEL PUMP CIRCUIT
(LOW VOLTAGE)
Circuit Description
The status of the fuel pump CKT 120 is monitored by the ECM at term inal "B2 and is used to compensate
fuel delivery based on system voltage. This signal is also used to store a code if the fuel pump relay is defective
or fuel pump voltage is lost while the engine is running. There should be about 12 volts on CKT 120 for at least
2 seconds after the ignition is turned, or any time reference pulses are being received by the ECM.
Code 54 will set if the voltage at terminal "B2 is less than 2 volts for 1.5 seconds since the last reference
pulse was received. This code is designed to detect a faulty relay, causing extended crank time, and the code will
help the diagnosis of an engine that "Cranks But Will Not Run.
Tf a fault is detected during start-up, the "Service Engine Soon light will stay "ON until the ignition is
w
COMPUTER COMMAND CONTROL 3-71
1
NO YES
zc m
IGN. "O FF ".
CLEAR CODES.
USING A FUSED JUMPER W IRE. CONNECT
START A N D RUN ENGINE FOR 30
FUEL PU M P TEST C O N N . TO FIXED 12
SECONDS OR U N TIL CODE 5 4 SETS.
VOLTS.
DOES CODE SET?
DOES P U M P RUN?
YES NO YES NO
1 1 m z t
IGN. "O FF ". DISCONNECT FUEL P U M P BACK PROBE ECM TERM. CODE 5 4 IS INTER
DISCONNECT FUEL RELAY. B2 W IT H A TEST LIGHT M IT T E N T . REFER TO
P U M P RELAY. USING THE FUSED TO G R O U N D . D IA G N O S TIC A ID S ON
PROBE CKT 4 4 0 W IT H A JUMPER W IRE, CONNECT IGN. "O FF" FOR 10 SEC. FACING PAGE.
TEST LIGHT TO CKT 120 TO 12 VOLTS. NOTE LIGHT AFTER IGN.
GROUND. DOES P U M P RUN? "O N ".
1 ....
CONNECT TEST REPAIR FAULTY OPEN CKT 120, FAULTY CO N N EC TIO N OPEN CKT
LIGHT BETWEEN OPEN IN RELAY FAULTY IN -T A N K A T ECM OR FAULTY 12 0 TO ECM.
CKTS 4 4 0 & 4 5 0 C K T 44 0 P U M P OR FAULTY ECM.
PUMP GROUND.
1
LIGHT "O FF"
I
CONNECT TEST LIGHT BETWEEN REPAIR OPEN CKT 4 5 0
HARNESS CKT. 4 6 5 A N D G N D .
IGN. "O FF " FOR 10 SECONDS.
NOTE TEST LIGHT AFTER IGN.
"O N ".
YES NO
IE m
RECONNECT FUEL P U M P RELAY. FAULTY OIL
IG N IT IO N "O FF ". PRESSURE SWITCH
PROBE FU E L P U M P T E S T
TE R M IN A L W IT H A TEST LIGHT
TO G R O U N D .
I
FUEL P U M P FAULTY OIL 7S 3 7 9 4
CIRCUIT OK PRESSURE SW ITCH
6 -1 7 -8 7
3-72 COMPUTER COMMAND CONTROL
CODE 51 CODE 51
CODE 52
FAULTY MEM-CAL
CODE 53
CODE 55 (2.5L ENGINE)
OR
PROM PROBLEM
CHECK T H A T ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE
CODE 52
FUEL CALPAK MISSING
CHECK FOR M ISSIN G CALPAK A N D TH A T ALL PIN ARE FULLY INSERTED IN THE
CODE 53
SYSTEM OVER VOLTAGE
(2.5L ENGINE)
CODE 53 W ILL SET IF VOLTAGE A T ECM TER M IN A L B1 IS GREATER TH A N 17.1 VOLTS FOR 2 SECONDS .
CHECK A N D REPAIR CHARGING SYSTEM .
CODE 55
FAULTY ECM
ALL ENGINES
CLEAR CODES A N D C O N FIR M "CLOSED LO O P" OPERATION A N D N O "SERVICE ENGINE S O O N " LIGHT. 8 -4 -8 8
7S 37 84-6 E
COMPUTER COMMAND CONTROL 3-73
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. Either of
the following procedures may be used for diagnosis, depending upon engine or tool used:
DIAGNOSIS:
1. With the engine idling at normal operating tem perature, observe the exhaust system backpressure
reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi).
2. Increase engine speed to 2000 rpm and observe gage. Reading should not exceed 20.7 kPa (3 psi).
3. If the backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
4. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure.
5. 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.
4 -2 6 -8 8
7S 33 40-6 E
MAP SENSOR
ECM
- o
(D
i
4 1 6 GRY |c i h 5V R EF
*
4 3 2 LTG R N - M A P SIGNAL
M A N IF O LD - E i>
ABSOLUTE
PRESSURE
(V A C U U M )
ALLC K 4 5 5 PPL
-E U SENSOR
2.5L ENGINE 4 6 9 BLK/RED
G E J GROUND
4.3L M ~ 4 5 5 BLK/RED I 02 h
- (GRVST) ~ ------ 4 5 5 PPL
7S 3 6 9 7
8 - 8-88 8 - 2-88
Test Description*. Numbers below refer to circled 2. Applying 34 kPa (10 hg) vacuum to the MAP
numbers on the diagnostic chart. sensor should cause the voltage to be 1.2 - 2.3 volts
1. Checks MAP sensor output voltage to the ECM. less than the voltage at Step 1. Upon applying
This voltage, without engine running, represents vacuum to the sensor, the change in voltage
a barometer reading to the ECM. should be instantaneous. A slow voltage change
indicates a faulty sensor.
3. Check vacuum hose to sensor for leak in g or
restriction. Be sure no other vacuum devices are
connected to the MAP hose.
COMPUTER COMMAND CONTROL 3-75
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 1 2 -1 -8 7
7 S 3 1 6 2 -6 E
3-76 COMPUTER COMMAND CONTROL
YES NO
m nz
SHIFT TR A N S A XLE/TR A N SM ISS IO N IN TO DRIVE. DISCONNECT PARK/NEUTRAL SW ITCH CONNECTOR.
"S C A N " TO O L S H O U LD DISPLAY A CHANGE TO JUMPER HARNESS CONN EC TO R TERM IN A LS " A " A N D
INDICATE DRIVE. "B " (CKT 4 3 4 TO 4 5 0 ).
DOES IT? "S C A N " TO O L S H O U LD INDICATE PARK OR NEUTRAL.
DOES IT?
NO YES NO YES
m
DISCONNECT P/N SW ITC H . N O TROUBLE JUMPER HARNESS CONNECTOR FAULTY P/N SW ITCH
THIS SH O U LD CAUSE F O U N D . P/N TE R M IN A L " A " (CKT 4 3 4 ) TO CO N N EC TIO N
"S C A N " TO O L TO DISPLAY CIRCUIT OK. ENGINE G R O U N D . OR
DRIVE RANGE. "S C A N " TO O L SH O U LD INDICATE P/N SW ITCH M IS A D JU S TE D
DOES IT? PARK OR NEUTRAL. OR
DOES IT? FAULTY.
1 2 -2 -8 7
7 S 3 1 6 1 -6 E
3-78 COMPUTER COMMAND CONTROL
ALL ENGINES
Circuit Description:
Crank signal is a 12 volts signal to the ECM during cranking to allow enrichment and cancel diagnostics
until engine is running or 12 volts is no longer on circuit.
Test Description: Numbers below refer to circled 2. Checks to determine if source of open fuse or fuse
numbers on the diagnostic chart. link was a faulty ECM.
1. Checks for normal (cranking) voltage to term inal
"C9 of ECM. Test light should be "ON during
cranking and then go "O F F when engine is
running.
COMPUTER COMMAND CONTROL 3-79
7S 3 7 0 9 -6 E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 6-22-87
3-80 COMPUTER COMMAND CONTROL
ECM
4 5 0 (G N D )
HARNESS CONNECTOR
7 -2 0 -8 7 (E N D V IE W )
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON LIGHT.
7S 3 7 0 7
6 -2 3 -8 7
3-82 COMPUTER COMMAND CONTROL
Test Description: Numbers below refer to circled 2. This and following tests check for fau lty A/C
numbers on the diagnostic chart. control relay.
1. Checks for low refrigerant as cause for no A/C.
COMPUTER COMMAND CONTROL 3-83
3-84 COMPUTER COMMAND CONTROL
A/C CONTROL
HTR A/C
PANEL SWITCH A/C PRESSURE
FUSE
25 A CYCLING SW ITCH
IG N IT IO N
I__________ I
A/C CLUTCH
459 DKGRN B8
SIGNAL
A .C .
Cl u t c h
control
- 39 PNK/BLK
RELAY
k in - 4 5 8 BLU
59 CLUTCH
DKGRN GAGES
S'FUSE CONTROL
i BLK^ 4, f 20A
0 0
LH IG N IT IO N 1
RELAY
HARNESS
CONNECTOR
7 -2 0 -8 7
7 -2 0 -8 7 A/C COMPRESSOR CLUTCH 7S 38 45-6 E
7S 38 50-6 E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 0 7 -0 6 -8 7
3-86 COMPUTER COMMAND CONTROL
A/C CONTROL
HTR A/C
PANEL SWITCH A/C PRESSURE
FUSE
25A CYCLING SW ITCH ECM
IG N ITIO N
I__________ l
A/C CLUTCH
59 D K G R N B8
A. C. S IGNAL
CLUTCH
CONTROL CLUTCH
- 39 PNK/BLK
RELAY CONTROL
tlD- 459
D K G R N /W H T
95 9
G R N /W H T GAGES
BLK FUSE
j: 20 A
I
IG N IT IO N 1
RELAY
HARNESS
CONNECTOR
7 -2 0 -8 7
7 -2 0 -8 7 A/C COMPRESSOR CLUTCH 7S 38 48-6 E
Test Description: Numbers below refer to circled 2. This and following tests check for faulty A/C
numbers on the diagnostic chart. control relay.
1. Checks for low refrigerant as cause for no A/C.
COMPUTER COMMAND CONTROL 3-87
3-88 COMPUTER COMMAND CONTROL
A/C CONTROL
HTR A/C
PANEL SWITCH A/C PRESSURE
FUSE
25A CYCLING SWITCH ECM
IG N ITIO N
i__________ i
A/C CLUTCH
59 D K G R N B8
SIGNAL
A .C .
CLUTCH
CONTROL CLUTCH
- 39 PNK/BLK
RELAY C O N TROL
HID- 459
DK G R N /W H T
959
G R N /W H T GAGES
FUSE
l BLK^ 4, 20A
7T7T7
IG N IT IO N 1
RELAY
HARNESS
CONNECTOR i
7 -2 0 -8 7
7 -3 0 -8 7 A/C COMPRESSOR CLUTCH 7 S 3 8 4 8 -6 E
7 S 3 8 5 1 -6 E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 5 -2 7 -8 7
3-90 COMPUTER COMMAND CONTROL
YES NO
m
REFER TO LIST BELOW OF THE ECM TER M IN A LS W H IC H L4 ENGINE ECM IS FAULT PROTECTED.
ARE Q DR OUTPU TS. CORRECT FAULTY CIRCUIT, REINSTALL ECM
USIN G THE 2 0 0 K O H M SCALE ON D V M * , M EASURE A N D CHECK CIRCUIT. REPLACE ECM ON LY
RESISTANCE BETW EEN THE ECM CASE A N D EACH ECM IF CIRCUIT IS STILL INOPERATIVE.
TE R M IN A L LISTED, BLACK (N EG .) LEAD TO CASE A N D
RED (P O S .) LEAD TO ECM TER M IN A L.
B+
ALL TE R M IN A LS LISTED SHO U LD HAVE RESISTANCE OF
P i
50K O H M S OR M O R E .
__ ECM
D O THEY? [_ jm n n r u i
SO LE N O ID
B
YES
JT O FIGURE 1
NO
zr m
DVM
A5 SES LIGHT
USE DVM J-34029-A OR EQUIVALENT
2
A7 TCC SO LEN O ID , D O W N S H IF T
ON-VEHICLE SERVICE
WIRE HARNESS
The ECM harness electrically connects the ECM te rm in al p air, it is possible to dam age c e rta in
to the various solenoids, switches, and sensors in components. Always use ju m p er w ires betw een
vehicle engine and passenger compartment. connectors, for circu it checking. NEVER probe
Wire harnesses should be replaced with proper through the W eather-Pack seals. Use tachom eter
p art num ber harnesses. W hen signal w ires are adapter J35812, or equivalent, which provides an easy
sp liced , into a h a r n e s s , use w ire w ith h ig h hook up of the tach. lead. The connector test adapter
tem perature insulation only. kit J35616, or equivalent, contains an assortment of
With the low current and voltage levels found in flexible connectors, used to probe term inals during
the system, it is important that the best possible bond diagnosis. Fuse remover and test tool BT 8616, or
at all wire splices be made by soldering the splices, as equivalent, is used for removing a fuse and to adapt
shown in Figure 3-19. fuse holder, with a meter, for diagnosis.
M olded on c o n n e c to rs r e q u ir e c o m p le te When diagnosing, open circuits are often difficult
replacement of the connector. This means splicing a to locate by sight, because oxidation, or term inal mis
new connector assembly into the harness. alignm ent are hidden by the connectors. M erely
Refer to Figures 3-22 through 3-33, for w iring wiggling a connector on a sensor, or in the w iring
diagrams. harness, may correct the open circuit condition. This
Replacement connectors and term inals are listed should always be considered, when an open circuit, or
in Group 8.965, of the Standard Parts Catalog. failed sensor is indicated. Interm ittent problems may,
also, be caused by oxidized or loose connections.
CONNECTORS AND TERMINALS Before making a connector repair, be certain of the
type of connector. Weather-Pack and Compact Three
Use care, when probing a connector or replacing connectors look similar, but are serviced differently.
term inals in them. It is possible to short between
opposite terminals. If this happens, to the wrong
OUTER JACKET
M Y LA R
D RAIN WIRE
I MSCZZZ3
4 SPLICE WIRES USING SPLIC SLIPS A N D ROSIN CORE 4. COVER SPLICE W ITH TAPE TO INSULATE
SOLDER. W R AP EACH SPLICE TO INSULATE. FROM OTHER WIRES.
5. W R AP W ITH M Y LA R A N D DRAIN (U N IN S U LA TE D ) WIRE. 5. RETWIST AS BEFORE A N D TAPE W ITH
ELECTRICAL TAPE A N D H O LD IN PLACE.
I
TAPE OVER W H O LE BUNDLE TO SECURE AS BEFORE.
4 S 0 5 7 0 -6 E
ECM
ECM
GAGE
IGN A5 SERVICE ENGINE SOON
PNK/BLK 3 9 B R N /W H T 4 1 9
12V LIGHT CONTROL
20 A SES LA M P
BRAKE SW ITCH
N.C. a
- PPL 4 2 0 J
A U T O M A T IC
TRANS. TCC
SO LE N O ID
TAN/BLK 4 2 2 A2 TCC CONTROL (A /T )
ALDL
CONN. /^ K Z b i\
A U T O M A T IC TR A N S M IS S IO N BACK V I^ W
m TAN/BLK 4 5 6 A2
SHIFT LIGHT
(M /T )
V 0FJ
CONNECTOR
M A N U A L TR A N S.
SHIFT LA M P
M A N U A L TR A N S M IS S IO N
r B L K 15 7 - D 10 GR OU N D
D9 GR OU N D
A A
B LK /W H T 4 5 0
P/N
PARK
SW ITCH
ORN/BLK 4 3 4 _
t B10 NEUTRAL
SWITCH (A /T )
(12 V)
P/S
SW ITCH POWER
N .O . BLU/ORN 4 9 5 STEERING
r . C8
PRESSURE
SWITCH
IGN. 3
25 A 32 P IN C -D
PRESSURE CYCLING DK G R N /W H T 4 5 9 CONNECTOR
B8 A/C SIGNAL
SWITCH
GAGE 20 A
7S3267
5 -2 7 -8 7
ECM
if
* 6S 26 78-6E
5 -2 7 -8 7
________ ECM
A ------- LT B LU /W H T 441
p r r m _ C5 IAC COIL " A " HI
ECM 1
IGN A6 IGN
PNK/BLK 439
12V 1QA \ 481
\R E D IN J.1
D 16 INJECTOR
v - r LT BLU 467 DRIVER
482 in j 2
D 14 INJECTOR
PICK-UP COIL
WHT ^ LT GRN --------4 6 8 DRIVER
2 4 PIN A-B
C ONNECTOR
BLK/RED 4 5 3 - B3 REFERENCE LO W
T A N /B L K 4 2 4 ~ D5 BYPASS
D4 EST
W H T 423 i
ECM B
12 V ioa
------------- ORN 4 4 0 B1 12V
- a n .-
------------- ORN 4 4 0 C16 12V
OIL
FUEL P U M P
press,
a TEST
SW ITCH 8 -4 -8 8
C ONNECTOR
6S 26 79-6 E
ECM
BRAKE SWITCH
n -R
- PPL 4 2 0
A U T O M A T IC
TRANS. TCC
SOLEN O ID
TAN/BLK 4 2 2 A7 A/T TCC CONTROL
ALDL
CONN. B
MANUAL
& TAN/BLK 4 5 6 A7 TRANS.
SHIFT LA M P
M A N U A L TR A N S.
SHIFT LA M P
ALDL
CONN.
2 4 PIN A-B
CONNECTOR
BUFFER BRN 4 3 7 A 10 VSS SIGNAL
A A
BLK /W H T 4 5 0
A
P/N
PARK
SWITCH I B
ORN/BLK 4 3 4 B10 NEUTRAL
SWITCH (A /T )
KNOCK
SENSOR
(H I
ESC SENSOR IN PU T E 4 9 6 DK BLU
ELECTRONIC
ESC G R O U N D D 4 8 6 BRN
SPARK KNOCK
CONTROL SPARK RETARD C 4 8 5 BLK B7 RETARD
MODULE SIGNAL (ESC) 32 PIN C-D
12 V IGN. B CONNECTOR
A
PNK/BLK 4 3 9 A6 12V IGN
ECM 1
IGN B GRY 4 3 5 EGR
A4
12V CONTROL
EVRV S O LEN O ID
10 A
___ BLK/W HT
6S2680
7 -7 -8 7
ECM
N .O . <2>
CRANK FUSE
IGN SW .
'------------ ------------------------ PPL/W HT 8 0 6 - C9 CRANK SIGNAL
START
VIAN. TRANS. 5A PPL 9 0 6 (P)
CLUTCH START
SW ITCH
START SOLEN O ID ~=
2 4 PIN A-B
OXYGEN SENSOR
CONNECTOR
TA N 4 1 3 - D6 O XYG EN SENSOR
ENGINE G N D GROUND
PPL 4 5 5 M A P GROUND
D2
(4 .3 L & V 8 R V M G P )
C
H
A A
C GRY416 - C14 + 5V REFERENCE
A/C
ECM
LT B LU /W H T 441 -
i' T r m _ C5 IAC COIL A " HI
IAC
VALVE ra i r
_
ju u u u
LT BLU/BLK
LT GRN/BLK 4 4 4
442
LT G R N /W H T 4 4 3
-
C4
-
C6
C3
IAC COIL " A " LO
IAC COIL "B " HI
IAC COIL "B " LO
ECM B
ORN 4 4 0 B1 12V
DK G R N /W H T 4 6 5 A1 FUEL P U M P RELAY
DRIVE (1 2 V )
E N G .G N D
FUEL P U M P
TEST CONNECTOR
FUSE LINK (C K)
ECM
BATT
RED 2C ORN 4 4 0 B1 12V
12 v JU NCTIO N BLOCK OR ECM B
FUSE (RV G P)
OIL PRESS. SW ITCH ( * %
------- ORN 4 4 0 C16 12V
CLOSES AT 4 PSI
DK G R N /W H T 4 6 5 A1 FUEL P U M P RELAY
DRIVE (1 2 V )
Eh
ALDL (CK)
RED 4 9 0 BLK/W HT
FUEL A
PUMP
B
FUEL 20A
V- PNK/BLK 39 IGN 12 V
M O D U LE
BLK/W HT D
ALL 7.4 L A N D
rr SO M E 5.7L
ECM
INJ A 10A
ig n _ J c k g m ) _ _ RFO _INJ. 1
- r r r r L <- r BLU 4 6 7 D 16 INJECTOR
DRIVER
12 v ECM 110A
(R V P ) BLU 4 6 7 D 15 INJECTOR
DRIVER (5.7L P)
482 INJ. 2,
whT INJECTOR
G R N 468 D 14
r DRIVER
ECM/IGN
IGN .
- + s \S - 439 A /\/Y V Y \i GRY 4 3 5 A4 EGR SOLENOID
12V 4 .3 L & 5 .0 L
EGR SOLEN O ID
10 A
B GRY 4 3 5
A4 EVRV SOLENOID
EVRV SOLEN O ID 5 .7 L & 7 .4 L
BLK/W HT
C ALDL
_ A A ^ V W \_ B _
BRN 4 3 6 C2 EAC SOLENOID
EAC SOLEN O ID
12 V IGN. B
ELECTRONIC
ESC G R O U N D L) 4 8 6 BRN OR BLK/RED --------TO ENGINE GRD.
SPARK KNOCK
CONTROL SPARK RETARD C 4 5 7 YEL/BLK OR YEL/RED OR BLK ----------------- B7 RETARD 2 4 PIN A-B
M O D U LE SIGNAL (ESC) CONNECTOR
A
(EXCEPT P)
ESC SENSOR IN PU T E 4 9 6 DK BLU
A A
KNOCK
SENSOR
PICK-UP COIL m
W H T 423 D4 -EST
PPL/W HT 4 3 0 32 PIN C-D
B5 REFERENCE
W i i SET T IM IN G CONNECTOR
CONNECTOR
! I TACH - TAN/BLK 4 2 4 D5 BY-PASS
LEAD
BLK/RED 4 5 3 B3 -REF. LO W
PRIM ARY COIL
7S3200
8 - 2-88
DKGRN/ ORN B1
o 14 FUEL P U M P RELAY A1 WHT BACK VIE*
1? 14
SHIFT LIGHT (M T )
T
CCrO NT RO I (AT) A?
TA N /
Rl K
\ F l.
CONNECTOR
TAN/
W HT B2 FUEL PUMP SIGNAL 0 14
BLK/
1? 14 EGR SO! FNOID A\ GRY RED 83 EST REF LO W 0 0
B4 NOTUSED
12 14 A/C RELAY
"SERVICE ENGINE
A4 BLU
BRN/
PPL/ EST .5ST
W HT B5 REFERENCE HI 0 1 .6 M
0 14 S O O N "C O N T R O L A5 W HT
PNK/
12 14 IGN ECM FUSE Aj BLK B6 N O TU S E D
B7 NOTUSED
NO TUSED A7
DKGRN/
2-5 2 SERIAL D A TA A3 ORN W HT B8 A/C SIGNAL 0 0
W HT/
DiAG . TERM. B9 NOTUSED
5 5 A9 BLK
SPEED 2 4 PIN A-B ORN/ PARK/NEUTRAL
12 SENSOR SIGNAL A1Q BRN CONNECTOR BLK B10 SW .SIGNAL p , 0 ____
MAT&
0 0 TPS G R O U N D A11 BLK B11 NOTUSED
BLK/
S YSTEM G R O U N D A 12 WHT B12 NO TUSED
0 0
BLK//
NOTUSED ci WHT 01 .....SYSTEM GR OU N D 0 0
BLK/
NOTUSED C2
LT GRN/ A A RED D2
D3
5V RETURN
NOTUSED
0 0
1 Varies fro m .60 to b a tte ry v o lta g e d e p e n d in g on p o sitio n o f d rive w heels. ENGINE 2.5L
2 Varies w ith te m p e ra tu re .
3 Varies. VEHICLE S/T TRUCK M VAN
4 12V First tw o seconds.
5 M easured b e tw e e n te rm in a ls C13 and A 1 1 ( 05V). 8 -4 -8 8
6 A/C "O FF." 7S3264
VOl.TAGE VOLTAGE
TAN/
N O T USED C1 WHT D1 SYSTEM GR OU N D 0 0
NOT USED C
7 PPL D7 0 2 SENSOR SIGNAL 0
N O T USED C3 D8 N O T USED
JL 2. 1 . 7 ....
C O O LA N T
TEMP. SIGNAL C 10 YEL D 10 N O T USED
T B I F U E L IN J E C T IO N E C M C O N N E C T O R ID E N T IF IC A T IO N
This ECM voltage chart is for use w ith a digital voltm eter to further aid in diagnosis. The voltages
you get may vary due to low battery charge or other reasons, but they should be very close.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
Engine at operating tem perature Engine idling (for "Engine Run" column)
Diagnostic terminal not grounded ALDL tool not installed
VOL.TAGE VOLT AGE
~WK.......
0 0 SYSTEM G R O U N D A 12 W HT B12
BLK/
N OTUSED C1 W HT D1 SYSTEM G R O U N D 0 0
BLK/RED
12 14 EACSO L. C2 BRN A A PPL D2 SENSOR G R O U N D 0 0
/K. 1 \ /L M \
LT GRN/
N O T I SEABLE IAC " B " LO BLK D3 N O TUSED
C3
LTG RN/ BA CK V IE W
OF 7 W HT D4 ESTCO N TR O L 0 i p
N O T I SEABLE IAC "B " HI C4 W HT
LT BLU/ COIn NECTOR TAN/
N O T I SEABLE IAC " A " HI C5 W HT BLK D5 ESTBYPASS 0 4 .7 5
LT BLU/
N O T I SEABLE IAC " A " LO C6 BLK TAN D6 G N D ( 0 7) 0 0
---n n ---
12 14 HI GEAR SW ITCH C7 LT BLU PPL D7 O 2 SENSOR SIGNAL
N O TUSED
N OTUSED Of D8
0 0 CRANK SIGNAL C9 PPL/W HT
D9 N O TUSED
C O O LA N T
(? ) 1.9 1.7 TEM P. SIGNAL n o YEL D 10 NOTUSED ____ _
---D U -ZZ
4.9 2.0 M A P SIGNAL C11 LTG R N D11 .. NOT USED..................
BLU D 16 INJECTOR A 12 14
12 14 BATTERY 12 VOLTS C16 ORN
Remove or Disconnect
1. New ECM from its packaging and check the
m RETAINER service number to make sure it is the same as the
[T 1 INSTRUMENT PANEL defective ECM.
m ELECTRONIC CONTROL MODULE 2. Access cover.
6S 2886-6E
Im portant
Press only on the ends of the Mem-Cal.
Small notches in the Mem-Cal must be aligned
with the sm a|l notches in the Mem-Cal socket.
Press on the ends of the M em-Cal, u n til the
retaining clips snap into the ends of the Mem-Cal.
Do not press on the middle of the Mem-Cal, only
the ends.
Figure 3-37 - Electronic Control Module (M ) Figure 3-39 - Mem/Cal Unit Installation
COMPUTER COMMAND CONTROL 3-109
Functional Check
(Figures 3-36 and 3-37; 3-40 through 3-43) I 3 [ ELECTRONIC CONTROL MODULE
r~4~| BRACKET
H I SEAT RISER
Remove or Disconnect
7S 37 65-6 E
1. Negative battery cable or ECM B fuse Figure 3-41 - Electronic Control Module (G)
2. Connectors from the ECM.
3. ECM. Refer to Figure 3-39 for servicing the ECM.
PROM
ACCESS COVER
PROM j
Im p o rta n t
Figure 4
| ? | Important
Press only on the ends of the MEM-CAL.
h
Figure 5
JL
Important
ffl Replacement Electronic Control Module (ECM) Is Figure 6
supplied without a Memory-Calibration unit (MEM-
CAL) so care should be taken when removing the Installing MEM-CAL with 'solid* clips
MEM-CAL from the defective ECM as it will be
reused in the new ECM. Press on the ends of the MEM-CAL until the
retaining clips snap into the ends of the M EM -CAL
Press the clips into the side of the MEM-CAL until
Using two fingers, push both retaining clips back they snap into place. Listen for the click. Do not
away from the MEM-CAL at the same time. Grasp press on the middle of the M EM -CAL only on the
the MEM-CAL at both ends and lift up out of the ends.
MEM-CAL socket. Do not remove the cover of the
MEM-CAL Use of unapproved MEM-CAL removal
methods will cause damage to the MEM-CAL or
MEM-CAL socket.
I Inspect Figure 7
| 9 j important
Do not press on the ends of the MEM-CAL until the
For alignment notches of the MEM-CAL and clips snap into place because the clips may be
carefully set aside Do not open the MEM-CAL damaged.
rib 3
Figure 3
0
-| Remove or Disconnect (Figure 1)
L* Inspect
Figure S
8 S 4 6 9 7 -6 E
m D A S H A N D TOE P A N E L
m BRACKET
Figure 3-45 - Electronic Control Module (P) Figure 3-46 - Coolant Sensor
CALPAK
NOTICE: To p re v e n t p o s s ib le E l e c t r o s t a t i c
Discharge damage to the PROM, CalPak
or Mem-Cal, Do Not touch the component
leads, and Do Not rem ove in te g ra te d
circuit from carrier.
-- Remove or Disconnect
1. Negative battery cable.
2. Drain cooling system below level of sensor. m PORT " J "
3. Electrical connector releasing locking tab. m HARNESS ASSEMBLY
4. Coolant sensor. |T 1 RETAINER
IT] MAP SENSOR
+- Install or Connect m BRACKET
7S 37 54-6 E
1. Sensor in engine.
Figure 3-47 - MAP Sensor - 2.5L (ST)
2. Electrical connector.
3. Refill coolant system.
4. Negative battery cable.
rn port"j"
f T l HARNESS ASSEMBLY
fTl BRACKET
fTl MAP SENSOR
I 5 I RETAINER
7 S 3 7 5 3 -6 E
Q j Install or Connect
1. Bolts or snap sensor on bracket.
2. Electrical connector.
3. Vacuum harness.
4. Negative battery cable.
5.0L/5.7L (CKRVP)
3-114 COMPUTER COMMAND CONTROL
PH EXHAUST MANIFOLD
m ELECTRICAL CONNECTOR
H T ] OXYGEN SENSOR
[ T ] GASKET 7 S 3 7 4 3 -6 E
Im portant
A special anti-seize compound is used on the
oxygen sensor threads. The compound consists of
a liquid graphite and glass bead. The graphite
1 1 j PORT "F" will tend to burn away, but the glass beads will
~2~1 HARNESS ASSEMBLY remain, making the sensor easier to remove.
~3~| MAP SENSOR
m BRACKET New, or service sensors will already have the
7 S 3 7 5 2 -6 E
compound applied to the threads. If a sensor is
Figure 3-53 - MAP Sensor 5.0L/5.7L (G) removed from an engine, and if for any reason it is to
OXYGEN SENSOR be reinstalled, the th read s m u st have an ti-seize
(Figure 3-54 through 3-60) compound applied before reinstallation.
1. Coat threads of oxygen sensor with anti-seize
NOTICE: The oxygen sensor uses a perm anently com pound P/N 3613695, or e q u iv a le n t, if
attached p ig ta il and connector. This necessary.
pigtail should not be removed from the 2. Sensor, and torque to 41 N*m (30 ft. lbs.).
oxygen sensor. Damage or removal of the 3. Electrical connector.
pigtail or connector could affect proper 4. Negative battery cable.
operation of the oxygen sensor.
COMPUTER COMMAND CONTROL 3-115
f T l OXYGEN SENSOR
| 2 | EXHAUST PIPE rn EXHAUST MANIFOLD
|~2~| OXYGEN SENSOR
6S 2888-6E 7S 3745-6E
Figure 3-55 - Oxygen Sensor - 2.8L (ST) & 4.3L Figure 3-58 - Oxygen Sensor - 5.0L/5.7L (RVPG under
Except (G) & 5.7L (CK) over 8600 GVW 8600 GVW)
Figure 3-56 - Oxygen Sensor - 5.7L (RVP over Figure 3-59 - Oxygen Sensor - 7.4L (CK)
8600 GVW)
Figure 3-61 - Throttle Position Sensor - TBI 700 Figure 3-62 - TPS Configurations - TBI 220
THROTTLE POSITION SENSOR
Replacement - TBI 700 Remove or Disconnect
(Figure 3-61) 1. A ir clean er, ad ap ter, and g ask ets. D iscard
gaskets.
NOTICE: The TPS is an electrical component and 2. Electrical connector releasing locking tab.
must not be soaked in any liquid cleaner 3. Two TPS a tta c h in g screw a s s e m b lie s and
or solvent, as damage may result. retainers (if applicable).
4. TPS from throttle body assembly.
Remove or Disconnect
1. Ait* cleaner and gasket. Discard gasket. NOTICE: The TPS is an electrical component and
2. Electrical connector releasing locking tab. must not be soaked in any liquid cleaner,
3. Two TPS attaching screw assemblies. or solvent, as damage may result.
4. TPS from throttle body assembly.
-+ Install or Connect
-H- Install or Connect
1. TPS on throttle body assembly, while lining up
1. With throttle valve closed, install TPS on throttle TPS lever with TPS drive lever on throttle body.
shaft. Rotate counter-clockwise, to align mounting 2. Two TPS a tta c h in g screw a s s e m b lie s an d
holes. retainers (if applicable).
2. Two TPS attaching screw assemblies.
ft Adjust - (2.8L V-6 engines only)
Tighten
Follow "A d ju stab le TPS O u tp u t C h eck
Screw assemblies to 2.0 N*m (18.0 in. lbs.). procedure below.
3. Electrical connector.
4. Air cleaner and new gasket.
Screw assemblies to 2.0 N-m (18.0 in. lbs.).
Replacement - TBI 220 3. Electrical connector.
(Figure 3-62) 4. Air cleaner, adapter, and new gaskets.
Im portant ADJUSTABLE TPS OUTPUT CHECK - TBI 220
On 2.8L (V-6) engines, the TPS is adjustable and is 2.8L Engines Only
supplied with attaching screw retainers. On all This check should be perform ed, only, when
other engines, it is n o n -ad ju stab le w ith o u t throttle body parts have been replaced, or after the
retainers. In addition, on 2.8L (V-6) and 7.4L (V- minimum idle speed has been adjusted.
8) engines, the TPS has a horizontal electrical
connector; on all other engines, the connector is
vertical.
COMPUTER COMMAND CONTROL 3-117
Install or Connect
1. MAT sensor.
2. Electrical connector.
3. Negative battery cable.
KNOCK SENSOR
m ELECTRICAL CONNECTOR
fTI OIL PRESSURE RELAY
I T I A C RELAY
f T I RELAY BRACKET
IT I BULKHEAD CONNECTOR
I 6 | FUEL PUMP RELAY 6 S 2 8 8 5 -6 E
P H OUTLET PIPE
I 2 | POWER STEERING GEAR
m INLET PIPE
I~T1 POWER STEERING PRESSURE SWITCH
EE] ELECTRICAL CONNECTOR 6S 2 7 0 8 -6 E
A/C CONTROL
SECTION 4
GENERAL DESCRIPTION
(MAP) sensor, and crank signal, then determines the
proper air/fuel ratio for starting. This ranges from
PURPOSE
1:5:1 at -36C (-33F) to 14.7:1, a t 94C (201F)
running temperature.
The fuel control system is controlled by an The ECM controls the amount of fuel delivered in
electronic control module (ECM) located in the the starting mode by changing how long the injector is
passenger com partm ent. The ECM is the control turned "ON and "OFF. This is done by "pulsing the
center of the computer command control system found injector for very short times.
in Section "3 which provides additional information
about fuel control and deliver.
Clear Flood M ode
The basic function of the fuel control system is to
control fuel delivery to the engine. Fuel is delivered to
the engine by a throttle body injection (TBI) unit. If the engine floods, clear it by pushing the
The main control sensor is the oxygen (O2) sensor, accelerator pedal down all the way. The ECM then
which is located in the exhaust manifold. The O2 pulses the injector at a 20:1 air/fuel ratio, and holds
sensor tells the ECM the am ount of oxygen in the this injector rate as long as the throttle stays wide
exhaust gas, and the ECM changes the air/fuel ratio to open, and the engine is below 600 rpm. If the throttle
the engine by controlling the fuel injector. A 14.7:1 position becomes less than 80%, the ECM returns to
air/fuel ratio is req u ired for efficient c a ta ly tic the starting mode.
converter operation. Because the constant measuring
and adjusting of the air/fuel ratio, the fuel injection Run M ode
system is called a "Closed Loop system (Figure 4-1).
The Run mode has two conditions called "Open
MODES OF OPERATION Loop and "Closed Loop.
Closed Loop
Acceleration M ode
Deceleration M ode
ECM can cut off fuel completely for short periods. m FUEL FILTER
TBI UNIT
W hen b a tte ry voltage is low, the ECM can Figure 4-2 - Fuel Control System
com pensate for a w eak sp ark d eliv ered by th e A p ressu re re g u la to r in the TBI keeps fuel
distributor by: available to the injectors at a co n stan t p ressu re
Increasing injector on time of fuel delivered between 62 and 90 kpa (9 and 13 psi). Fuel in excess of
Increasing the idle rpm injector needs is retu rn e d to the fuel ta n k by a
Increasing ignition dwell time
separate line.
The ECM controls the injectors that are located in
Fuel C utoff M ode the fuel meter body assembly of the TBI. The injectors
deliver fuel in one of several modes, described above.
No fuel is delivered by the injectors when the In order to properly control the fuel supply, the
ignition is "OFF. This prevents dieseling. Also, fuel fuel pump is operated by the ECM through the fuel
is not delivered if no reference pulses are seen from pump relay and oil pressure switch (see "Fuel Pump
the d istrib u to r, w hich m eans the engine is not Electrical Circuit).
running. Fuel cutoff also occurs at high engine rpm,
to protect internal engine components from damage.
MODEL 220 TBI UNIT
Pressure Regulator
Vacuum Ports All engine idle speeds are controlled by the ECM
through the idle air control (IAC) valve mounted on
The throttle body portion of both TBI units may the throttle body (Figures 4-7 or 4-8). The ECM sends
contain ports located above, or below the th ro ttle voltage pulses to the IAC motor windings causing the
valve. These ports generate the vacuum signals for IAC motor shaft and pintle to move "IN or "OUT a
the exhaust gas recirculation (EGR) valve, MAP given distance (number of steps) for each pulse, (called
sensor, and the canister purger purge system. counts).
Fuel Injector(s)
[T ]T H R O T T L E BODY ASSEMBLY
|~A~~| FUEL FROM PUMP
f j ~ | INJECTOR ELECTRICAL TERMINALS
fc ~ | CONSTANT BLEED - (SOME MODELS)
(~P~| PRESSURE REGULATOR DIAPHRAGM ASSEMBLY
fT~| FUEL INJECTOR [ a ] FUEL INLET [ 7 ] FUEL METER COVER & BODY ASSEMBLIES
| 2 1 FUEL METER ASSEMBLY [ ] FUEL OUTLET |~2~1 THROTTLE BODY ASSEMBLY
|~3~1 PURGE FILTER [~3~1 IDLE AIR CONTROL VALVE ASSEMBLY
|~4~1 INLET FILTER |~A~| FILTERED AIR INLET
[~5~| THROTTLE BODY ASSEMBLY |~j~| PINTLE
[~6~] PRESSURE REGULATOR COVER ASSEMBLY [~C~| THROTTLE VALVE
|~7~| PRESSURE REGULATOR SPRING
[~D~j VACUUM PORTS - FOR ENGINE OR EMISSION
(~8~[ PRESSURE REGULATOR DIAPHRAGM CONTROLS
ASSEMBLY
8P 03 30-S Y 8P 03 1 9 -S Y
Figure 4-6 - TBI 700 Unit Operation Figure 4-7 - Idle Air Control System (TBI 220 Unit)
8P 0 9 33-A S 8 P 0 3 2 1 -SY
Figure 4-9 - Idle Air Control (IAC) Valve (TBI 220) Figure 4-11 - Throttle Position Sensor (TBI 220)
TPS SIGNAL
[ 7 ] TERMINAL PINS
0 m
[~2~| BALL BEARING ASSEMBLY
+ 5V
[~3~~1 STATOR ASSEMBLY
[~4~| ROTOR ASSEMBLY
[~5~| SPRING ECM
[~6~1 PINTLE
[ T J l EAD SCREW
Figure 4-10 - Idle Air Control (IAC) Valve (TBI 700) Figure 4-12 - Throttle Position Sensor (TBI 700)
FUEL CONTROL 4-7
IN -T A N K P U M P .
IN-LINE /
FUEL FILTER FUEL PRESSURE LINEE
/
s= ^.
^
FUEL T ------
TA N K I FILTER R STRAINER _ A
8 S 4 3 3 1 -6 E
4 -8 -8 7
If it is stuck closed, too little air will be allowed in Oil Pressure Switch
the manifold, and idle speed will be too low. If it is
stuck part way open, the idle may be rough, and will Refer to fuel pump relay circuit check in Section
not respond to engine load changes. "3, for oil pressure switch diagnosis.
The minimum air rate is set at the factory with a
stop screw. The stop screw should not be adjusted Fuel M odule
unless a replacement throttle body assembly (that has
not been preset at the factory) is installed or the Refer to the diagnosis section in Section "3 for
minimum air rate does not meet specifications. fuel module check.
An incorrect readjustm ent with a high minimum
air rate will cause the IAC valve pintle to constantly Fuel Filter
bottom on its seat and may result in early IAC valve
failure. A minimum air rate that is too low may result The diagnosis of the fuel filte r is covered in
in a no-start condition in cold weather, a stall after Section "3, as part of the fuel system diagnosis.
start or a stall during deceleration, because of poor A plugged fuel filter may cause a restricted fuel
air/fu el d istrib u tio n th ro u g h the th r o ttle bore. delivery, or a no start condition.
Throttle valve sticking may also occur.
Vacuum leaks will cause the IAC valve pintle to Fuel Pipes and Hoses
be "stepped closer to the seat or to be closed against
its seat in an attem p t to m aintain controlled idle The diagnosis of gasoline odor may be a condition
speed. of a leaking fuel feed, or return pipe or hose. Fuel
pipes that are pinched, plugged, or mis-routed may
Throttle Position Sensor (TPS) cause restricted fuel delivery.
443 b n a 441
AIR o o 444
FLO W
o o ECM
IAC CONNECTOR
IAC COIL " A " HI
LT B LU /W H T 441 C5
N 8 S 3 9 9 7 -6 E
8 -3 -8 8 1 -2 9 -8 7
IG N IT IO N "O FF ."
DISCONNECT IAC VALVE HARNESS.
REFER TO "D IA G N O S T IC A ID S "
ON FACING PAGE.
N O LIGHTS, ONE OR
M ORE CIRCUITS.
LIGHT STEADY
OR FLASHING ALL
CIRCUITS
N O T OK
FAULTY ECM
X
C O N N EC TIO N OR ECM.
REPLACE IAC VA LVE, RESET
VALVE USING PROCEDURE ON
FACING PAGE A N D RETEST.
CLEAR CODES, CONFIRM "CLOSED LOOP" OPERATION, NO "SERVICE ENGINE SOON' 8-4-88
LIGHT, AND VERIFY CONTROLLED IDLE SPEED IS CORRECT. 8S 4652-6E
4-12 FUEL CONTROL
1 G a s k e t -A ir C leaner
5 O -R ing - Fuel Line In le t N u t
6 O -R ing - Fuel Line O u tle t N u t
10 G a s k e t-F la n g e
20 Fuel M e te r A ssem bly
22 S crew - Fuel M e te r Body
A tta c h in g
25 G a s k e t-F u e l M e te r Body to
T h ro ttle B ody
35 S crew - In jecto r R eta in e r
36 R e ta in e r - In jecto r
40 Fuel In jector
42 O -R ing - Fuel In je c to r-U p p e r
43 O -rin g - Fuel In jector -L o w e r
60 Pressure R eg u lato r C over
A ssem bly
61 S crew - Pressure R eg u lato r
A tta c h in g
65 S eat - Spring
66 Spring - Pressure R eg u lato r
70 Pressure R eg u lato r D ia p h ra g m
A ssem bly
90 N u t - Fuel In le t
91 S e a l-F u e l N u t
96 N u t - F u e l O u tle t
200 T h ro ttle B ody A ssem bly
205 Plug - Idle S top Screw
207 S crew & W a s h e r A ssem bly -
Id le Stop
208 Spring - Id le S top Screw
230 Sensor - T h ro ttle Position
(TPS)
23 2 S crew 8i W a s h e r A ssem b ly
TPS A tta c h in g
250 ld l$ A ir C o n tro l V a lv e (IA C V )
251 S crew - IACV A tta c h in g
255 O -R ing - IACV
270 Tu b e M o d u le A ssem bly
271 S crew A ssem b ly
Tu b e M o d u le Assy.
275 G a s k e t -T u b e M o d u le Assy.
S cre w A s s e m b ly Fuel M e te r
C over A tta c h in g Long
S cre w A s s e m b ly Fuel M ete r
C over A tta c h in g S h o rt
3 Fuel M e te r C o ve r A sse m b ly
4 G asket Fuel M e te r C over
5 G asket Fuel M e te r O u tle t
6 Seal P ressure R e g u la tor
7 Pressure R e g u la to r
8 In je cto r Fuel
9 F ilter Fuel In je c to r In le t
10 O -rin g Fuel In je c to r
Lower
11 O -rin g Fuel In je c to r
U pper
12 W a sh e r Fuel In je c to r
13 S cre w A s s e m b ly Fuel M ete r
B ody T h ro ttle B ody
A tta c h in g
14 Fuel M e te r B o d y A s s e m b ly
15 G asket T h ro ttle B ody to
Fuel M e te r B ody
16 G asket A ir C leaner
17 O -Ring Fuel R eturn Line
18 N u t Fuel O u tle t
19 O -Ring Fuel In le t Line
20 N u t Fuel In le t
21 G asket Fuel O u tle t N ut
22 G a s k e t Fuel In le t N u t
23 S cre w A s s e m c ly TPS
A tta c h in g
24 R etainer TPS A tta c h in g
S cre w
25 S e n so r T h ro ttle P o sitio n
(TPS)
26 Plug Idle S to p S cre w
27 S cre w A s s e m b ly Idle S to p
28 S p rin g Id le S to p S cre w
29 T h ro ttle B o d y A s s e m b ly
30 G asket Flange
31 Valve A s s e m b ly Idle A ir
C o n tro l (IAC)
32 G asket Idle A ir C o n tro l
V alve A s s e m b ly
33 O-Ring IACV
34 S cre w A s s e m b ly
IACV A tta c h in g
7S 36 58-6 E
Figure 4-15 - Model 220 TBI Parts Identification (V-6 and V-8 Engine)
FUEL CONTROL 4-15
A fuel system pressure test is part of several of the Service repair kits are supplied with a small vial
Diagnostic Charts and Symptom checks. To perform of thread locking compound with directions for use. If
this test, follow this procedure: m aterial is not available, use Loctite 262, or GM part
number 10522624, or equivalent.
1. Turn engine "OFF and relieve fuel p ressu re
following above procedure. NOTICE: In precoating screws, do not use a higher
2. Plug THERMAC vacuum port if required on TBI. s tr e n g th lo c k in g c o m p o u n d th a n
3. Uncouple fuel supply flexible hose in engine recommended, since to do so could make
com partm ent. In s ta ll fuel p ressu re gage J- removing the screw extremely difficult, or
29658A/BT8205 and adapter J-2968A-85 between result in damaging the screw head.
steel line and flexible hose.
4. Tighten gage in line to ensure no leaks occur MODEL 220 AND 700 TBI UNITS
during testing. Replacement (Figures 4-16 through 4-20)
5. Connect negative battery terminal.
6. Start engine and observe fuel pressure reading. It Remove or Disconnect
should be 62-90 kPa (9-13 psi). If not, refer to
1. THERMAC hose from engine fitting (ST Series).
CHART A-6 in Section "3 diagnosis.
2. Air cleaner, adapter, and gaskets. Discard gasket.
7. Relieve fuel pressure.
3. E lectrical connectors - idle air control valve,
8. Remove fuel pressure gage.
throttle position sensor, and fuel injectors. (On
9. Install new O-ring on fuel feed line.
TBI 220 units, squeeze plastic tabs on injectors
10. Reinstall fuel line.
and pull straight up.)
11. Reconnect negative battery terminal.
4. Grommet with wires from throttle body.
12. Start engine and check for fuel leaks.
5. Throttle linkage, return springs(s), transm ission
13. Remove plug from vacuum port if installed, and
control cable, and cru ise control (w h erev er
install air cleaner with new gasket.
applicable).
6. Vacuum hoses, noting positions of hoses.
Cleaning and mS* Inspection
7. Inlet and outlet fuel line nuts, using back-up
All TBI component parts, with the exception of wrench J-29698-A or BT-8251-A.
those noted below, should be cleaned in a cold
im m ersion clean er such as C arbon X (X-55) or CAUTION: R efer to "Fuel P r e ss u r e R e lie f
equivalent. P r o c e d u r e (a b o v e ), b efo re
disconnecting fuel lines.
NOTICE: The throttle position sensor (TPS), idle air
control (IAC) valve, pressure regulator 8. Fuel line O-rings from nuts and discard.
diaphragm assem bly, fuel injectors or 9. TBI mounting hardware.
oth er com ponents co n tain in g ru b b e r, 10. TBI unit from intake manifold.
should NOT be placed in a solvent or
cleaner bath. A chemical reaction will NOTICE: To prevent damage to the throttle valve, it
cause these p a rts to sw ell, h ard en or is essential that the unit be placed on a
distort. Do not soak the throttle body with holding fixture, before performing service.
the above parts attached. If the throttle
body assem bly requires cleaning, soak 11. TBI flange (Manifold mounting) gasket.
time in the cleaner should be kept to a
m inimum . Some models have hidden NOTICE: Stuff the manifold opening with a rag, to
throttle shaft dust seals th a t could lose p re v e n t m a te ria l from e n te rin g th e
their effectiveness by extended soaking. e n g in e, an d rem ove th e old g a s k e t
m aterial from surface of intake manifold.
1. Clean all metal parts thoroughly and blow dry
with shop air. Be sure th a t all fuel and air 1? Inspect
passages are free of dirt or burrs. Vlanifold bore for loose parts and foreign m aterial.
2. Inspect mating casting surfaces for damage that Intake manifold sealing surface for cleanliness.
could affect gasket sealing.
4-16 FUEL CONTROL
Figure 4-16 - Replacing TBI 700 Unit - 2.5L Engine Figure 4-18 - Replacing TBI 220 Unit - 4.3L Engine
m TBI UNIT
|~2~| NUT-TIGHTEN TO 25 N m (18 FT. LBS.)
fTI TBI UNIT
fTI
FTI
GASKET
ENGINE INTAKE MANIFOLD
m GASKET
6S 27 97-6 E fTI ENGINE INLET MANIFOLD 7 S 3 5 4 7 -6 E
Figure 4-17 - Replacing TBI 220 Unit - 2.8L Engine figure 4-19 - Replacing TBI 220 Unit - 5.0L/5.7L
Engine
FUEL CONTROL 4-17
n ~ 1 FU E L INJECTOR
5. Fuel meter cover gasket and discard.
I 2 j IN L E T F IL T E R
6. Upper (large) O-rings and steel backup washers
|~3~1 LOWER " O RING
from top of fuel injector cavity and discard.
fT l UPPER " O " RING
[ 5 | WASHER
[ 6 | FU E L METER BODY ASSEMBLY t? Inspect
Fuel injector filte r for evidence of d irt and
5 S 1 6 9 8 -6 E
contamination. If present, check for presence of
Figure 4-23 - Model TBI 220 Fuel Injector Parts dirt in fuel lines and fuel tank.
4. Electrical connectors to fuel injectors.
5. With engine "OFF, and ignition "ON, check for Im portant
leaks around gasket and fuel line couplings.
The TBI unit installed on a 4.3L V6 engine in a C
FUEL INJECTOR ASSEMBLY - TBI 220 or K series tru ck has two D IFFER EN T fuel
(Figures 4-23 to 4-27) injectors (with two D IFFER EN T flow rates).
Injectors having part number 5235134 (color coded
Each fuel injector (see Figure 4-23) is serviced as Orange and Green) should be installed on the
a complete assembly only. th ro ttle lever side. Those w ith p a rt num ber
5235342 (Pink and Brown) go on the TPS side
NOTICE: Use care in removing the fuel injectors to (Figure 4-25).
prevent damage to the electrical connector
terminals* the injector filter, and the fuel Be sure to replace the injector with one having an
nozzle. The fuel injector is serviced as a identical part number. Injectors from other models
complete assem bly only. Also, since the can also fit in TBI model 220, but are calibrated for
injectors are e lectrical com ponents, they different flow rates. (See Figure 4-26 for part number
should not be immersed in any type of liquid location).
solvent or cleaner as damage may occur.
|+ 4-| Install or Connect
1 . L u b ric a te new low er (sm all) O -rin g s w ith
|<-+| Remove or Disconnect automatic transm ission fluid and push on nozzle
1 . Electrical connectors to fuel injectors. (Squeeze end of injector until it presses against injector fuel
plastic tabs and pull straight up.) filter.
2. Fuel m eter cover assem bly, follow ing above 2. Steel injector backup washer in counterbore of fuel
procedure. meter body.
3. With fuel meter cover gasket in place to prevent 3. L u b ric a te new u p p e r (la rg e ) O -rin g w ith
damage to casting, use a screwdriver and fulcrum automatic transm ission fluid and install directly
to carefully lift out each injector (Figure 4-24). over the backup washer. Be sure O-ring is seated
4. Lower (small) O-rings from nozzle of injectors and properly and is flush with top of fuel meter body
discard. surface.
4-20 FUEL CONTROL
7S3653-6E
| 9 | Im portant
Be sure to install the injectors in th eir proper
location. The Orange and Green color coded
injector (part number 5235134) should be installed
P H FUEL INJECTOR on the throttle lever side. The Pink and Brown
[ T ] FUEL METER BODY 4S0099-6E color coded one (part number 5235342) goes on the
Figure 4-27 - Installing Fuel Injector - TBI 220 TPS side (Figure 4-25).
FUEL CONTROL 4-21
Figure 4-29 - TBI Model 220 TPS Configuration Figure 4-31 - Flange Mounted Type IAC Valve
Im portant
All IAC valves on TBI Model 220 units (except
those on the 7.4L engine) are thread-mounted and
have a dual taper, 10 mm diameter, pintle. On the
7.4L engine, the IAC valve is flange-mounted and
has a 12mm diameter, dual taper pintle. Any
replacement of an IAC valve must have the correct
part number, with the appropriate pintle taper
and diameter for proper seating of the valve in the
throttle body.
[~A~| DISTANCE OF PINTLE EXTENSION
|<-+| Remove or Disconnect
[ ] DIAMETER AND SHAPE OF PINTLE
1. Electrical connector.
[~C~1 IAC VALVE GASKET
2. IAC valve.
9 P 1 0 5 8 -A S
On thread mounted units, use a 32 mm ( H )
Figure 4-30 - Thread M o un ted Type IAC Valve wrench (Figure 4-30).
On flange-m ounted u n its, rem ove screw
4. Check for TPS output as follows: assemblies (Figure 4-31)
Connect ALDL scanner to read TPS output 3. IAC valve gasket or O-ring and discard.
voltage.
With ignition "ON and engine stopped, TPS IJJjl Clean
voltage should be less than 1.25 volts. If more Thread mounted valve - Old gasket m aterial from
than 1.25 volts, replace TPS. surface of throttle body assembly to insure proper
seal of new gasket.
IDLE AIR CONTROL (IAC) VALVE-TBI 220 Flange-mounted valve - IAC valve surfaces on
(Figures 4-30 and 4-31) throttle body to assure proper seal of new o-ring
and contact of IAC valve flange.
NOTICE: The IAC valve is an electrical component
and m ust not be soaked in any liquid
cleaner or solvent. O therw ise damage
could result.
FUEL CONTROL 4-23
Im portant
No physical adjustment of the IAC valve assembly
is required after installation. The IAC valve
pintle is reset by turning the ignition "ON for ten
seconds and then "OFF. The ECM then resets the
p in tle to the co rrect p o sitio n. P ro p e r idle
regulation should result.
^ Tighten
Thread-mounted IAC valve assembly to 18.0 N-m
(13.0 lb. ft.) with 32 mm (1 - ) wrench.
Flange-mounted attaching screw assemblies to 3.2
N-m (28.0 lbs. in.)
J. Electrical connector to IAC valve.
J. Start engine and allow engine to reach operating
temperature.
-+ Remove or Disconnect
1 . TBI unit, as described above.
2 . Fuel meter body-to-throttle body attaching screw
assemblies.
NOTICE: If the IAC valve was rem oved d u rin g 3. Fuel meter body assembly.
serv ice , it o p e ra tio n m ay be te s te d 4. Throttle body-to-fuel m eter body g ask et and
electrically with the IAC/ISC Motor Tester discard.
(J-37027 or BT-8256K). However, if the
valve pintle is extended electrically, it Disassemble
must also be retracted electrically. Before
in sta llin g a IAC valve, m e a su re th e TPS from old throttle body, according to previous
distance betw een the tip of the valve instructions, for reuse on new throttle body. (The
pintle and the m ounting surface.If the IAC valve does not have to be removed, since a
dimension is greater than 28 mm (1.10 new one comes with replacement throttle body.)
inches), it must be reduced to prevent
damage to the valve. This may be done Assemble
electrically using an IAC/ISC motor tester TPS onto replacem ent th ro ttle body assembly,
(J-37027 or BT-8256K) or m anually by according to previous instructions.
exerting firm pressure, as shown in Figure
4-32 or 4-33, with a slight side-to-side [-+[ Install or Connect
movement on valve pintle to retract it. 1. New throttle body-to-fuel meter body gasket.
2. Fuel m eter body assem bly on th ro ttle body
assembly.
4-24 FUEL CONTROL
L* Inspect
Fuel injector filter for evidence of d irt and
contamination. If present, check for presence
of dirt in fuel lines and fuel tank.
| ~ n FUEL METER BODY
|~2~| FUEL INJECTOR 9 | Im portant
f~A~l SCREWDRIVER Be sure to replace the injector with an identical
m FULCRUM part. Injectors from other models can fit in the
Model 700 TBI, but are calibrated for different
7 S 3 4 1 9 -6 E flow rates. (See Figure 4-36 for p art num ber
location.)
Figure 4-35 - Removing TBI 700 Fuel Injector
FUEL CONTROL 4-25
L Inspect
Pressure regulator seat in fuel m eter body
cavity for pitting, nicks, or irre g u la ritie s.
(Use magnifying glass if necessary.) If any of
above is present, the whole fuel body casting
must be replaced.
-+ Install or Connect
fTI PRESSURE REGULATOR COVER
1 . Vew pressure regulator diaphragm assem bly,
fT I SCREW ASSEMBLY
making sure it is seated in groove in fuel meter
fTI SPRING - SEAT
body.
2. R egulator sp rin g seat and sp rin g into cover
|j0 SPRING
fTI DIAPHRAGM
assembly.
[T ] FUEL METER ASSEMBLY 7 S 3 4 2 1 -6 E
3. Cover assembly over diaphragm, while aligning
mounting holes.
Figure 4-37 - TBI 700 Pressure Regulator
Im portant
Be sure the electrical connector end on the
injector is p arallel to casting support rib and
facing in the general direction of the cut-out in the
fuel meter body for the wire grommet.
5. With engine "OFF and ignition "ON, check for THROTTLE POSITION SENSOR
fuel leaks. (Figure 4-39)
^ 0
Attaching screws to 6.0 N-m (53 lb. in.).
4. Throttle body injection unit mounting hardware. [T| FUEL METER ASSEMBLY
[ T ] THROTTLE BODY ASSEMBLY
[~3~| THROTTLE POSITION SENSOR
Q Tighten
[~4~1 TPS ATTACHING SCREW &
Mounting hardware to 17 N-m (12 lb. ft.). WASHER ASSEMBLY 8P 0 9 1 6 -A S
Im portant
On TBI Model 700, the IAC valve is flange-
mounted, with dual taper, 10 mm diameter pintle.
If replacement is necessary, only an IAC valve
identified with the correct part number (having
the appropriate pintle shape and diameter) should
be used.
Remove or Disconnect
A DISTANCE OF PINTLE EXTENSION 1 . Electrical connector from IAC valve.
B DIAMETER OF PINTLE 2. Screw assemblies and IAC valve.
C IACV O-RING 3. IAC valve O-ring and discard.
D IACV ATTACHING SCREW ASSEMBLY
7 S 3 4 2 2 -6 E
IJJI Clean
IAC valve seating surfaces on throttle body to
Figure 4-40 - Flange-Mount IAC Valve - TBI 700
assure proper seal of new O-ring and contact of
IAC valve flange.
-<- Im portant
Screw assemblies to 2.0 N-m (18.01b. in.) No physical a d ju stm e n t of th e IAC valve
assembly is required after installation. The IAC
3. Electrical connector to TPS. valve pintle is reset by the ECM. W hen the
4. Check for TPS output as follows: vehicle is operated at normal engine tem perature
Connect ALDL scanner to read TPS output at approximately 30 mph (48 km/hr.), the ECM
voltage. causes the valve pintle to seat in the throttle body.
With ignition "ON and engine stopped, TPS The ECM then has a rest procedure to set the
voltage should be less than 1.25 volts. If more correct pintle position. Proper idle regulation
than 1.25 volts, replace TPS. should result.
IDLE AIR CONTROL (IAC) VALVE Install or Connect
(Figure 4-40)
l. Lubricate new O-ring with transm ission fluid and
NOTICE: The IAC valve is an electrical component install on IAC valve.
and m ust not be soaked in any liquid 2. IAC valve to throttle body.
cleaner or solvent. O therw ise dam age
could result.
4-28 FUEL CONTROL
^ Tighten
Screw assem blies to 3.0 N-m (28.0 lb.
in.).
Remove or Disconnect
r n IDLE AIR CONTROL VALVE
1 . Tube module assembly attaching screws. f T l IDLE STOP SCREW PLUG
2. Tube module assembly. fTl SCREW AND WASHER ASSY.
3. Tube module assembly gasket and discard. [~4~| SPRING
H r ! THROTTLE LEVER
IJJJI Clean | ~ n THROTTLE BORE
Old gasket m aterial from surface of throttle f T l THROTTLE BODY ASSEMBLY
body assembly to insure proper seal of new m THROTTLE POSITION SENSOR
gasket. I T l GASKET
[~To~| TUBE MODULE ASSY.
7S 37 15-6 E
-M-l Install or Connect
Figure 4-43 - Throttle Body Assembly
1. New tube module assembly gasket.
2 . Tube module assembly.
3. Tube module assembly attaching screws.
FUEL CONTROL 4-29
Disassemble
* Assemble
1 TPS, IAC valve, and tube module assembly
onto replacem ent th ro ttle body assem bly,
according to previous instructions.
[ ^ T ig h t e n
Screws to 6.0 N-m (53 lb. in.)
Remove or Disconnect
1. F u e l pu m p a t t a c h i n g h o se fo r s ig n s of 1. Protective cover (CK).
deterioration. 2. Retainer, if installed.
2. Rubber sound insulation a t the bottom of the 3. Electrical connector.
pump. 4. Relay by depressing bracket clip at rear of relay,
or removing bolts from retaining bracket.
|7 + | Install or Connect
1 . Fuel pump assembly into the attaching hose.
4-30 FUEL CONTROL
f~2~|
T1
n
c j
fTI E LE C TR IC A L C O N N E C T O R
f~2~| O IL PR ES S U RE R E LA Y
[~3~| A C R E LA Y 1 1 I R E TA IN E R [_ 4 j BRACKET
[~4~1 R E LA Y B R A C K E T l~2~1 FU EL P U M P R E LA Y [T ] E LE C TR IC A L
FT] BU LKHEAD CO NNECTOR [~3~1 P L E N U M P A N E L CONNECTOR
I 6 | FU EL P U M P R E LA Y 6S 28 85-6 E 7 S 3 7 5 9 -6E
Figure 4-45 - Fuel Pump Relay (ST) Figure 4-48 - Fuel Pump Relay (RV)
[T 1 E LE C TR IC A L C O N N E C T O R [T ] PLEN UM PANEL
f~2~l FU E L P U M P R E LA Y [T ] BRACKET
[~3~| R E TA IN E R
7S 37 57-6 E
7 S 3 7 5 6 -6 E 7 S 3 7 5 8 -6 E
Figure 4-47 - Fuel Pump Relay (CK) Figure 4-50 - Fuel Pump Relay (P)
FUEL CONTROL 4-31
FUEL MODULE
(Figures 4-51 through 4-53)
Remove or Disconnect
1. Fuel module housing.
2. Open housing cover.
3. Fuel module board.
+- Install or connect
1 . Fuel module board.
2. Close cover.
3. Fuel module housing.
m SEAT riser
m fu el m o d u l e
[~3~| e l e c t r o n ic c o n t r o l m o d u l e
fTl ALDL CONNECTOR
7 S 3 7 8 6 -6 E
Remove or Disconnect
1. Electrical connector.
2. Oil pressure switch using wrench J-28687-A or
BT-8220 if required.
fT l BRAKE PEDAL BRACKET
fT l fu el MODULE 7 S 3 7 9 0 -6 E +- Install or connect
Figure 4-51 - Fuel Module (RV) 1. Oil pressure switch.
2. E le c t r ic a l co n n e cto r.
Install or connect
1. Clamp to filter.
2. Clamp bolt.
fTI OIL PRESSURE/FUEL P U M P SWITCH ASSEMBLY 3. Fuel feed nuts.
9S 5266-6E
4. Fuel filler cap.
Remove or Disconnect
On 2.5L engine, relieve fuel system pressure.
1. Fuel filler cap.
2. Fuel feed nuts.
3. Clamp bolt.
4. Filter and clamp.
5. Clamp from filter.
FUEL CONTROL 4-33
rn cup
rn LEFT FRAME SIDE MEMBER
fTl FRONT FUEL FEED HOSE-TIGHTEN NUT TO
26 N-m (20 FT. LBS.)
n IN-LINE FUEL FILTER
|~ 5 l REAR FUEL FEED HOSE-TIGHTEN NUT TO
26 N-m (20 FT. LBS.) 7S 36 50-6 E
QH REAR FUEL FEED PIPE-TIGHTEN NUT F T l BOLT TIGHTEN TO 18 N-m (12 LBS. FT.)
TO 26 N-m (20 FT. LBS.)
[ T 1 FUEL TANK SELECTOR VALVE
n n IN-LINE FUEL FILTER
|~A~l FUEL FEED
IT1 BRACKET
f l f ] FUEL RETURN
[~4~1 VAPOR PIPE
[~C1 RH FUEL RETURN PINK
i 5 [ FUEL RETURN PIPE
H o i RH FUEL FEED ORANGE
m INTERMEDIATE FUEL FEED PIPE-TIGHTEN
NUT TO 26 N-m (20 FT. LBS.) fTl LH FUEL RETURN BLUE
m RIGHT FRAME SIDE MEMBER 7S 36 48-6 E r n LH FUEL FEED YELLOW 7S 3 8 43-6 E
Figure 4-63 - Fuel Filter (G) Figure 4-64 - Selector Valve - (RV)
JjB* Inspect
Fuel tank for any remaining fuel.
m FUEL TANK
NUT TIGHTEN TO 45 N-m (33 FT. LBS.)
a BOLT TIGHTEN TO 35 N-m (26 FT. LBS.)
m STRAP
LEI NUT TIGHTEN TO 7 N-m (5 FT. LBS.)
E BRACKET 7S3821 -6E
|+ + | Remove or Disconnect
1. Negative battery cable.
2. Engine harness connector on the distributor.
H ave a d ry c h e m ic a l ( C la s s B) f ir e
extinguisher near the work area.
3. Fuel system pressure (2.5L engine only)
4. Fuel from the fuel tank. fTl V E N T TUBE
5. Fuel tank. n n FILLER NECK
6. Fuel gage sending and pump unit. I 3 I H O U S IN G
7. Purge fuel tank. [T ] FU E L FILLER C A P 7S 38 28-6 E
fT I INSULATOR
m LOWER SHIELD
n n strap
f ~ 4 ~ 1 FUEL TANK REAR STRAP
INSTALLATION SEQUENCE FRONT STRAP
ITI BOLT TIGHTEN TO 35 N m BOLT TIGHTEN TO 12 N m (10 FT. LBS.)
(26 FT. LBS.)
FUEL TANK , OOA cc
FTI BOLT TIGHTEN TO 3.4 N m 7 S 3 8 3 0 -6 E
(30 IN. LBS.) SHIELD
m NUT TIGHTEN TO 35 N m
(26 FT. LBS.) 7 Figure 4-77 - Fuel Tank - CK (except Chassis Cab)
Figure 4-79 - Fuel Tank - RV U tility & Suburban Figure 4-81 - Fuel Tank - P (32)
4-40 FUEL CONTROL
Leak Test
f T l RETAINER m ROD
f T l SPRING m RETAINER
m SUPPORT m PLATE
[~4~| CABLE [T ] PEDAL 7 S 3 7 8 7 -6 E
Figure 4-83 - Control Cable - 2.8L Figure 4-85 - Control Cable - 2.5L
-- Install or Connect
1 . Retainer to dash panel.
2 . Retainer to accelerator pedal rod or connect cable
in rod slot.
3. Retainer to support bracket.
4. Retainer to throttle lever stud or connect cable to
pulley.
Accelerator Pedal
(Figures 4-86 through 4-92)
The accelerato r pedal controls the th r o ttle ,
fTl RETAINER through a cable. There are not linkage adjustment.
fT l LUBRICANT The throttle cable must be replaced with an identical
fTl THROTTLE LEVER STUD replacement part.
m SPRING All linkages and cables must be checked, to assure
m CABLE free movement with no rubbing, chafing, or binding.
m SUPPORT 7 S 3 7 9 1 -6 E
The throttle must operate freely, without binding,
between full closed and wide open throttle.
Figure 4-84 - Control Cable - 4.3L & V-8
4-42 FUEL CONTROL
P H RETAINER m ROD
f T I SPRING [ T | RETAINER
f T I SUPPORT I 7 | PLATE
7 S 3 7 8 7 -6 E
fTI CABLE ITI PEDAL
PARTS INFORMATION
PART NAME GROUP
Cover, w/Regulator, Fuel Meter:
fTI PIN [T] CABLE P art of Meter Kit, F u e l............................... 3.734
[~2~| SPRING GO REINFORCEMENT Injector, Fuel: P art of
ITI ROD \T] PEDAL Pump, Fuel (In Tank) ................................... 3.774
Relay, Fuel Pump ............................................. 3.990
rH RETAINER 7S 3835-6E
Switch, Oil Press................................................. 1.800
Figure 4-90 - Accelerator Pedal - G
Throttle Body Injection U nit ........................ 3.725
Valve Asm, Idle Air Control: P art of
Control Kit, Idle Air V alv e........................3.820
4-44 FUEL CONTROL
SECTION 5
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)
CONTENTS
GENERAL DESCRIPTION.......................................5-1 V apor Canister (A ltitu d e ) ......................5-3
PURPOSE.......................................................... ..5-1 Tank Pressure C ontrol V a lv e ......................5-3
O PERATION........................................................5-1 Therm ostatic Vacuum S w itc h ................. ..5-3
Evaporative System 2.5L & 2.8 L .............5-1 ON-VEHICLE SERVICE......................................... ..5-3
Evaporative System - Except VAPOR CANISTER............................................5-3
A ltitu d e 4 . 3 L & V 8 ..................................5-2 VAPOR CANISTER H O S E S ............................. ..5-4
Evaporative S ystem -A ltitude 4.3L & V8 . 5-2 VAPOR P IP E ........................................................5-4
Tank Pressure C ontrol Valve ................. ..5-3 V apor Pipe Repair .......................................5-4
D IA G N O S IS .............. ........................................... ..5-3 FUEL C A P .......................................................... ..5-6
RESULTS OF INCORRECT O P E R A T IO N ____5-3 THERMOSTATIC VACUUM SW ITCH.............5-6
VISUAL CHECK OF CANISTER........................ 5-3 PARTS INFORMATION ....................................... ..5-6
FUNCTIONAL TESTS....................................... ..5-3
GENERAL DESCRIPTION
PURPOSE
OPERATION
Evaporative System
2.5L, 2.8L & 4.3L (ST) (Figure 5-5)
Fuel vapors from the fuel tank are purged and
flow into the vapor canister tube labeled "fuel tank
and are absorbed by the carbon. The canister (Figure
5-1) is purged when the engine is running above idle
speed. A timed vacuum source is applied to the vapor
canister tube labeled "canister purge to draw fresh
air through the bottom of the canister. The air mixes
with vapor and the mixture is drawn into the intake
manifold to be consumed in the normal combustion
process.
2.8L Only
(Figure 5-6)
This system has a therm ostatic vacuum switch
(TVS) installed in the intake manifold coolant passage Figure 5-1 - Vapor C an ister-2.5Lf 2.8L &4.3L (ST)
to sense engine coolant temperature. This TVS has
two ports and is located between the canister and the
5-2 EVAPORATIVE EMISSION CONTROL
Figure 5-2 - Vapor Canister - 4.3L & V8 Figure 5-3 - Vapor Canister - 4.3L & V8 - Altitude
Except Altitude
TBI unit. When the engine is below 46C (115F), the Evaporative System - A ltitud e
TVS is closed preventing purge of the canister. When 4 .3 L & V 8 (Figure 5-8)
engine tem perature is above 46C (115F), the TVS Fuel vapors from the fuel tank are purged and
opens, allowing purge of the canister. flow into the vapor canister tube labeled "fuel tank
and are absorbed by the carbon. When the canister
Evaporative System - Except A ltitud e (Figure 5-3) is purging, fresh air is drawn in through
4 .3 L & V 8 (Figure 5-7) the air inlet, at the top of the canister. This air flows
Fuel vapors from the fuel tank are purged and to the bottom of the canister and forces the vapors out
flow into the vapor canister tube labeled "fuel tan k the purge line.
and are absorbed by the carbon. The canister (Figure The purge valve is an integral part of the canister.
5-2) is purged when the engine is running above idle When the engine is running, full manifold vacuum is
speed. A timed vacuum source is applied to the vapor supplied to the top tube of the purge valve (control
canister tube labeled "canister purge to draw fresh vacuum signal) which lifts the valve diaphragm and
air through the air inlet, at the top of the canister. opens the valve. The lower tube on the purge valve is
This air flows through a tube to the bottom of the connected to a timed port above the TBI throttle valve.
canister and forces the vapors out the purge line. The The rate of purge is controlled through this port by
canister used on the 4.3L M application functions as throttle valve location (throttle opening).
described above, but has a 5/16 diam eter "fuel tank
tube. All other applications have a canister with a 1/4'
diameter "fuel tank tube.
EVAPORATIVE EMISSION CONTROL 5-3
FUNCTIONAL TESTS
a
r
r?
I [ 2 ^
Figure 5-5 - Evaporative Emissions Control System Schematic - 2.5L & 4.3L (ST)
El Install or Connect
Do not use copper or alum inum tu bing to
replace steel tubing. Those m aterials do not
have satisfactory d u ra b ility to w ith stand
1. Canister and bracket screw. normal vehicle vibrations.
2. Hoses to canister. Do not use rubber hose within 4" (100mm) of
any part of the exhaust system or within 10"
VAPOR CANISTER HOSES (254mm) of the catalytic converter. Hose
inside d iam eter m ust m atch steel tu bing
Refer to Vehicle Emission Control Inform ation outside diameter.
label for routing of canister hoses. When replacing 1. In repairable areas, cut a piece of fuel hose 4"
h o ses, use hose i d e n tif i e d w ith th e w ord (100mm) longer than portion of the line removed.
"Fluoroelastomer. If more than a 6 inch (152 mm) length of pipe is
removed, use a combination of steel tubing and
VAPOR PIPE hose so that hose lengths will not be more than 10
inches (254mm).
The vapor pipe is secured to the underbody with 2. Cut ends of pipe remaining on vehicle square with
clamp and screw assem blies. Flexible hoses are a tube cutter. Using the first step of a double
connected at the fuel tank and the fuel vapor canister. flaring tool, form a bead on the end of both pipe
The pipe should be inspected occasionally for leaks, sections. If pipe is too corroded to withstand bead
kinks, or dents and repaired as required. operation w ithout dam age, the pipe should be
replaced. If a new section of pipe is used, form a
Vapor Pipe Repair bead on both ends of it also.
3. Use screw type hose clamp, part number 2494772
R epair vapor pipe in sections u sin g b razed or equivalent. Slide clamps onto pipe and push
seamless steel tubing meeting GM Specification 123M hose 2" (51mm) onto each portion of fuel pipe.
or its equivalent or hose identified with the words Tighten clamps on each side of repair.
"Fluoroelastomer. Hose not so marked could cause
early failure or failure to meet emission standard.
EVAPORATIVE EMISSION CONTROL 5-5
0
E ll
1=1
d
2 I
Figure 5-7 - Evaporative Emissions Control System Schematic - 4.3L & V8 - Except Altitude
5-6 EVAPORATIVE EMISSION CONTROL
Figure 5-8 - Evaporative Emissions Control System Schematic - 4.3L & V8 - Altitude
FUEL CAP
INSTALL OR RECONNECT
If a fuel tank filler cap requires replacement, use 1 . T herm ostatic vacuum sw itch usin g seale r on
only a cap with the same features. Failure to use the threads
correct cap can result in a m alfunctioning of the 2. Vacuum hoses
system. 3. Refill cooling system
THERMOSTATIC VACUUM SWITCH
PARTS INFORMATION
SECTION 6
IGNITION SYSTEM/EST
CONTENTS
GENERAL DESCRIPTION.....................................6-1 EST PERFORMANCE CHECK .........................6-3
PURPOSE.......................................................... .6-1 2.5L E n g in e ..................................................6-3
OPERATION..................................................... .6-1 Except 2.5L Engine .................................. .6-3
A ll engines except 2.5L S/T Truck .......... 6-1 ON-VEHICLE SERVICE......................................... .6-3
S/T Truck w ith 2 .5 L .................................. 6-2 IGNITION SYSTEM ...........................................6-3
Hall Effect Switch .................................... 6-2 SETTING TIMING ............................................ .6-3
D IA G N O S IS.......................................................... .6-2 EST SYSTEM ................................................... ..6-8
EST SYSTEM ....................................................6-2 Hall Effect Switch T e s t ............................. .6-8
Results o f Incorrect EST O peration . . . 6-2 PARTS INFORMATION ....................................... .6-8
CODE 4 2 ............................................................ .6-3
GENERAL DESCRIPTION
PURPOSE
OPERATION
TERMINAL B - Bypass
At about 400 rpm, the ECM applies 5 volts to this
circuit to switch spark tim ing control from the
module to the ECM. An open or grounded bypass
circuit will set a Code 42 and the engine will run
at base timing, plus a small amount of advance
built into the module.
TERMINAL C - Distributor Reference Hi
This provides the ECM with rpm and crankshaft
position information.
TERMINAL D - EST
This circuit triggers the module. The ECM does
not know what the actual timing is, but it does
know when it gets the reference signal. It then
advances or retards the spark from th at point.
Therefore, if the base timing is set incorrectly, the
engine spark curve will be incorrect.
CODE 42
ECM
PICK-UP COIL HALL EFFECT SWITCH
TT (2.5L S/T TRUCK O N LY )
A B C
0
B +
423 W HT - D4 EST
IG N ITIO N
EXCEPT 2.5L S/T TRUCK- 4 3 0 PPL/W HT - B5 REFERENCE
M O D U LE
4 2 4 TAN/BLK - D5 BYPASS
PRIM. IGN. COIL
4 5 3 BLK/RED - B3 GROUND
g ---nrrtn--
EST CONNECTOR
7S 36 43-6 E
8 -3 -8 7 IGN 8 -4 -8 8
O
ta c h o m e te r is co nn ected to th e Tach te rm ., disco nnect it b e fo re
p ro c eed in g w it h th e te s t).
IGNITION SYSTEM
Check spark a t plug w ith spark te s te r J-26792 or e q u iv a le n t (S T -125 )
w h ile cran kin g (if no spark on on e w ir e , check a second w ir e ) A fe w
CHECK
sparks and th e n n o th in g is considered no spark.
(REMOTE COIL)
I 2.5L & 2.8L TRUCK
No Spark Spark
.1 _ ~1----
D isconnect 4 te rm , d is trib u to r Check fu e l,s p a rk plugs, etc.
co nn ecto r and check fo r spark. See S ection 2 sy m p to m s. TEST LIGHT
T O D .C .
N o spark Spark POW ER SUPPLY
X (1 .5 to 8V )
1 ..........
Check fo r spark a t coil w ire w ith te s te r w h ile cran king . Replace pick-up coil
(L eave spark te s te r conn ected to coil w ire fo r Steps 3-6).
No Spark Spark
I mz
Disconnect d is trib u to r 2 te rm . "C / + " connector.
Ig nitio n sw itch " o n " . Engine stopped.
Check volts a t " + " and "C" te rm 's, of dist. harn. conn.
Inspect cap fo r w a t e r , cracks,
etc. If OK, replace ro to r.
Both te rm 's. 10 volts or m ore Both te rm 's , under 10 volts U n d er 10 vo lts "C " te rm , o n ly
1 1
I
C onnect te st lig h t fro m tach. te rm , to ground. R epair op en tach. lea d or Replace m o d u le an d check fo r
Crank en gin e and ob serve lig ht. conn and re p e a t te s t # 4 . spark fro m coil as in S tep 6.
L. .
I
N o Spark
F
If no m odu le te s te r (J 24642) is a v ailab le; If m o d u le te s te r (J24642) Is ro ta tin g pole piece
Replace ign. coil an d re p e a t Step 5. is a v a ila b le : te s t m odu le still m a g n e tize d ?
I
No Spark Spark OK No
E Z r I I
Ign. coil re m o v e d is OK, System OK Check coil w ire Replace Check pick-u p coil Replace po le piece
reinstall coil an d check coil fro m cap to coil. If m o d u le or conns. (Coil an d s h a ft assy.
w ire fro m dist. cap. if OK, OK, replace coil. resistance should
replace dist. m odu le. be 5 0 0 -1 5 0 0 ohm s
an d n o t g ro u n d e d .)
7-8-88
7S3659-6E
6-6 IGNITION SYSTEM/EST
6 CYL 8 CYL
PICK-UP
COIL
DISTRIBUTOR 4 TE R M IN A L
CONNECTOR
nn
ECM
%
TO
DISTRIBUTOR
CAP TO fL + c ___________g b r e I _L
IGNITION
SWITCH
uu ULJUU
A B AB C D
IG N COIL ' B D4
GRY 423 W H T EST
CONN
4 3 0 PPL/W HT B5 REFERENCE
TACH LEAD
5-9 -8 8
6 -2 5 -8 7
5S 1784-6E
Test Description: Numbers below refer to circled 5. Applying a voltage (1.5 to 8 volts) to module
numbers on the diagnostic chart. terminal "P should turn the module "ON and the
1. Two wires are checked, to ensure that an open is "tach term inal voltage should drop to about 7-9
not present in a spark plug wire. volts. This test will d eterm in e w h eth er the
1A. If spark occurs with EST connector disconnected, module or coil is faulty or if the pick-up coil is not
pick-up coil output is too low for EST operation. generating the proper signal to turn the module
2. A spark indicates the problem m ust be the "ON. This test can be performed by using a DC
distributor cap or rotor. battery with a rating of 1.5 to 8 volts. The use of
3. Normally, there should be battery voltage at the the test light is mainly to allow the "P term inal to
"C and " + te rm in als. Low voltage would be probed more easily. Some digital multi-meters
indicate an open or a high resistance circuit from can also be used to trigger the module by selecting
the distributor to the coil or ignition switch. If "C ohms, usually the diode position. In this position
term inal voltage was low, b ut " + term in al the meter may have a voltage across its term inals
voltage is 10 volts or more, circu it from "C which can be used to trigger the module. The
terminal to ignition coil or ignition coil primary voltage in the ohms position can be checked by
winding is open. u sin g a second m e ter or by c h e c k in g th e
4. Checks for a shorted module or grounded circuit m anufacturers specification of the tool being
from the ignition coil to th e m odule. The used.
distributor module should be turned "OFF, so 6. This should turn "OFF the module and cause a
normal voltage should be about 12 volts. spark. If no spark occurs, the fault is most likely
If the module is turned "ON, the voltage would be in the ignition coil because most module problems
low, but above 1 volt. This could cause the would have been found before this point in the
ignition coil to fail from excessive heat. procedure. A module te ster could d eterm in e
With an open ignition coil prim ary winding, a which is at fault.
small amount of voltage will leak through the
module from the "Bat. to the "tach terminal.
IGNITION SYSTEM/EST 6-7
"L
TO D.C.
N o spark Spark POW ER SUPPLY
I-------- mz (1 .5 to 8V )
N o Spark Spark
nzzzn n r
Both te rm 's . 10 vo lts or m ore Both te rm 's , u n d e r 10 vo lts U n d e r 10 vo lts "C " te rm , o n ly
I ......................................
R econnect dist. 2 te rm . conn.
W ith ign. " O N " , check v o lta g e fro m tach. te rm ,
to gn cf (te rm , m a y be ta p e d back in harness).
Repair w ir e fro m m o d u le " + " te rm ,
to "B " te rm , o f black Ign. coil
co nnector or p rim a ry ckt. to ign. sw .
Check fo r o p en or g n d . in ckt.
fro m "C" te rm , to ign. coil. If Ckt.
is OK, fa u lt is. ign. coil or conn..
L _ -----_
Light on stead y Light Spark N o Spark
blinks
I
Disconnect d is trib u to r 4 te rm , connector.
R em ove dist. cap.
D isconnect p ick-u p coil co nn ecto r fro m m o d u le.
Syster
OK
Replace ign. coil,
it to o is fa u lty
L
V o lta g e drops N o d ro p in v o lta g e
I X
No Spark Spark
X Z
Is ro ta tin g p o le piece
If no m odu le te s te r (J 2464 2) is a v a ila b le ; If m odu le te s te r (J 2 4 6 4 2 ) still m a g n e tiz e d ?
R eplace ign. coil and re p e a t S tep 5. is a v a ila b le : te s t m o d u le
Yes No
N o Spark Spark H Z nz
T~~Z JlZ Check p ick-u p coil
conns. Check p ick-u p
R eplace pole
piece and
Ign. coil re m o v e d is OK, S ystem OK Check coil w ir e R eplace
coil (Coil resistance s h a ft assy.
rein s tall coil an d check coil fro m cap to coil. If m o d u le
O K, replace coil. should be 5 0 0 -1 5 0 0
w ir e fro m dist. cap. if OK,
o h m s an d n o t
rep la ce dist. m o d u le.
g ro u n d e d ). 4-21-88
7S3660
6-8 IGNITION SYSTEM/EST
EST SYSTEM
SECTION 7
GENERAL DESCRIPTION When the knock sensor detects spark knock, the
module turns "OFF the circuit to the ECM. The ECM
PURPOSE then retards EST to reduce spark knock.
Remove or Disconnect
1. Negative battery cable.
2. Wiring harness connector from ESC knock sensor.
3. ESC knock sensor from engine block.
ECM 1
ESC
MODULE
ZZ3
,J
...... J
7 -3 0 -8 7
7 S 3 7 1 1 -6 E
7 -8 -8 6
7-4 ELECTRONIC SPARK CONTROL
m ESC MODULE
l~2~1 ELECTRICAL CONNECTOR 7S3713-6E
SECTION 8
AIR MANAGEMENT SYSTEM
CONTENTS
f \
GENfeftAL DESCRIPTION.................................... ..8-1 ON-VEHICLE SERVICE ....................................... ..8-3
PURPOSE.......................................................... ..8-1 DRIVE B E L T ..................................................... ..8-3
AIR O PERATION.............................................. ..8-1 PUMP CENTRIFUGAL FILTER FAN ............... ..8-3
D IA G N O S IS .......................................................... ..8-2 AIR PUMP.......................................................... ..8-6
AIR SYSTEM ..................................................... ..8-2 AIR CONTROL V A L V E .......................................8-6
A ir P u m p ..................................................... ..8-3 CHECK VALVE ...................................................8-6
Check V a lv e ................................................ ..8-3 AIR INJECTION PIPE ASSEMBLY ................. ..8-6
Hoses And P ip e s ......................................... ..8-3 PARTS INFORMATION ....................................... ..8-10
AIR MANAGEMENT CHECK C H A R T............ ..8-5
GENERAL DESCRIPTION
PURPOSE
rn airpump
IT] EAC VALVE
l~3~] AIR TO AIR CLEANER
I T ! AIR TO EAC VALVE
D O AIR TO EXHAUST PORTS
[HI MANIFOLD VACUUM SIGNAL
f T l AIR INJECTION PIPES (7.4L SHOWN. 4.3L, 5.0L
AND 5.7L HAVE ONE INLET PIPE AT THE FRONT OF
EACH MANIFOLD)
m ECM
l~9~l EAC SOLENOID
HO] CHECK VALVES 6 S 2 7 1 4 -6 E
DIAGNOSIS
AIR SYSTEM
NOTICE: Do Not oil air pump. Inspect drive belt for wear, cracks or deterioration
and replace if required. When installing new belt,
Replace pump if there is excessive noise. it must be seated and fully secured in grooves of
A/C com pressor, a ir pum p, g e n e ra to r, and
Air Pump crankshaft pulleys.
The air pump is a positive displacement vane type PUMP CENTRIFUGAL FILTER FAN
which is perm anently lubricated and req u ires no
periodic maintenance. The centrifugal filter fan should not be cleaned,
Accelerate engine to approximately 1500 rpm and either with compressed air or solvents.
observe air flow from hose. If air flow increases as
engine is accelerated, pump is operating satisfactorily. CAUTION: C e n tr ifu g a l fa n s h o u ld n o t b e
If air flow does not increase or is not present, proceed rem oved from pum p u n le s s it is
as follows: dam aged, as rem oval w ill d estroy
the fan.
Inspect
Before starting replacement note the following:
1. For proper drive belt tension.
Do not allow any filter fragments to enter the air
2. For a leaky pressure relief valve. Air may be heard
pump intake hole.
leaking with the pump running.
Do not remove filter fan by inserting a screwdriver
Check Valve between pump and filter fan. Air dam age to
sealing lip pump will result.
Do not remove metal drive hub from filter fan.
It is seldom possible to remove the filter fan
1. A check valve should be inspected whenever the without destroying it.
hose is disconnected from it or whenever check
valve failure is suspected (A pump th a t had |+ + | Remove or Disconnect
become inoperative and had shown indications of
(Figure 8-5)
having exhaust gases in the pump would indicate
check valve failure). 1. Air pump.
2. Remove the check valve.
2. Pump pulley.
3. Blow th ro u g h th e check valve to w ard the
3. Insert needle nose pliers and pull filter fan from
exhaust manifold side. Air should pass freely.
pump hub.
T urn the valve around and attem p t to blow
through the valve toward the air pump side. No
-n - Install or Connect
air should pass through the valve.
4. Replace valve which does not operate properly. 1. New filter fan on pump hub.
2. Spacer and pump pulley ag ain st c en trifu g al
Hoses and Pipes filter fan.
3. Pump pulley bolts and tighten equal to torque
Inspect spec, in Figure 8-6. This will com press the
centrifugal filter fan onto the pump hole. Do not
l. Hose or pipe for deterioration or holes. drive filter fan on with a hammer. A slight
2. All hoses or pipe co n n ectio n s, and clam p amount of interference with the housing bore is
tightness. normal. After a new filter fan has been installed,
3. Hose or pipe routing. Interference may cause it may squeal upon initial operation or until O.D.
wear. sealing lip has worn in. This may require a short
4. If a leak is suspected on the pressure side of the period of pump operation a t various engine
system, or if a hose or pipe has been disconnected speeds.
on the pressure side, the connections should be 4. Air pump.
checked for leaks with a soapy water solution.
With the pump running, bubbles will form if a
leak exists.
8-4 AIR MANAGEMENT
SO LE N O ID C O NNECTOR
ELECTRIC
AIR CONTROL
TO AIR SOLENOID
CLEANER
A B
FULL
M A N IF O L D <X
VACUUM CHECK VALVE CHECK
(2.8L, 4.3L & V -8 ) VALVE
W W | TT TT
(4 .3 L & V -8 )
TO TO
EXHAUST EXHAUST
PORTS PORTS
ECM
PNK/BLK
r?
4 3 6 BRN
IG N ITIO N
GAGE
FUSE IP.
CONNECTOR
A LD LC O N N E C TO R
7 -2 3 -8 7
7 -2 3 -8 7 * 7 S 3 6 1 2 -6 E
Test Description: Numbers below refer to circled 3. Checks for an open control circuit. Grounding
numbers on the diagnostic chart. diagnostic term inal will energize the solenoid, if
1 . This is a system performance test. When vehicle ECM and circuits are normal. In this step, if test
goes to "Closed Loop, air will switch from the light is "ON, circuits are normal and fault is in
ports and divert to the air cleaner. valve connections or valve.
2. Tests for a grounded electric d iv ert circu it. 4. Checks for voltage from battery through a fuse to
Normal system light will be "OFF. the solenoid.
AIR MANAGEMENT 8-5
7-27-87
*6S 2839-6EB
8-6 AIR MANAGEMENT
Remove or Disconnect
1. Battery ground cable.
2. Electrical connector on control valve.
3. Manifold vacuum signal hose.
4. Air inlet and outlet hoses from valve.
5. Control valve.
f T l AIR PUMP
f~2~| PULLEY BOLT
-+ Install or Connect
TIGHTEN TO 1. Control valve.
10 N-m
(90 IN. LBS.) 2. Air inlet and outlet hoses to valve.
f~3~| PULLEY 3. Manifold vacuum signal hose.
fTl FILTER FAN 4. Electrical connector on control valve.
5. Battery ground cable.
6. Check system operation (See Air M anagem ent
Check chart).
5S 1616-6E
|T 1 BRACKET [ T ] BOLT - TO RQ UE TO 2 5 N -m (1 8 FT. LBS.) Q J ] N U T - TORQUE TO 30 N-m (22 FT. LBS.) 7S 3 6 1 5-6E
NOTE: ON SOME VEHICLES THE EAC VALVE IS MOUNTED ON THE PUMP ADAPTER
7S 34 12-6 E
ALL SERIES
Q H AIR p u m p [ T ] d ive r te r v a l v e or e a c v a l v e
m ADAPTER AND SEAL - TIGHTEN SCREWS TO 10 (88
N-m IN. LBS.) []F] AIR CLEANER
fTl AIR INJECTION PIPE TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) [T] BOLT - TIGHTEN TO 10 N-m (88 IN. LBS.)
fTl CHECK VALVE - TIGHTEN TO 25 N-m (18 FT. LBS.) [ F ] NUT - TIGHTEN TO 34 N-m (25 FT. LBS.)
7 S 3 4 1 3 -6 E
PARTS INFORMATION
SECTION 9
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
CONTENTS
GENERAL DESCRIPTION.......................................9-1 SYSTEM C H E C K .............................................. ..9-3
PURPOSE ...................................... . ............... ..9-1 ON-VEHICLE SERVICE .........................................9-3
OPERATION ................................................... ..9-1 EGR VALVE ..................................................... ..9-3
EGR CONTROL .............................................. ..9-1 EGR M a n ifo ld P a ssa g e ............................. ..9-3
TYPES OF EGR V A L V E S .................................. ..9-2 SYSTEM HOSES .............................................. ..9-8
Port EGR Valve ......................................... ..9-2 EGR SOLENOID .............................................. ..9-10
Negative Backpressure EGR Valve . . . . 9-2 EGR FILTER CLEANING/REPLACEMENT . . . 9-10
EGR VALVE IDENTIFICATION ......................9-2 EGR VACUUM SO LENO ID ............................. ..9-10
D IA G N O S IS .......................................................... .. 9-3 PARTS INFORMATION ....................................... ..9-10
RESULTS OF INCORRECT OPERATION ____9-3
GENERAL DESCRIPTION
PURPOSE
OPERATION
DIAGNOSIS
ON-VEHICLE SERVICE
EGR VALVE
Remove or Disconnect
1. Air cleaner.
2. EGR valve vacuum tube at valve. (Figure 9-5
to 9-10).
3. Bolts or nuts.
4. EGR v alv e an d g a s k e t fro m m a n ifo ld
(Figures 9-11 to 9-15). Discard gasket.
Im portant
Do Not wash EGR valve in solvents or degreaser -
permanent damage to valve diaphragm may result.
Also, sand blasting of the valve is not recommended
since this can affect the operation of the valve.
Inspect
If EGR passage indicates excessive build-up of [T1 EGR VALVE [T] BOLTTIGHTEN
deposits, the passage should be cleaned. Care should [T1 VACUUM HARNESS ,------ TO 2 N m (18 IN. LBS.)
HARNESS CONNECTOR
be taken to en su re th a t all loose p a rtic le s are |~3~1 EGR SOLENOID ^
completely removed to prevent them from clogging the [~4~| MANIFOLD VACUUM
EGR valve or from being ingested into the engine. (PORT-J) 7S 34 59-6E
TO EGR VALVE
ECM
2.5L
ONLY
EXCEPT
2.5L
7-15-87
7-31-87 7S3737
Figure 9-8 - EGR & Solenoid Figure 9-9 - EGR & Solenoid
(5.0L & 5.71 under 8500 GVW) (4.3L (ST) & 5.7L over 8500 GVW)
IJJI Clean
1. With a wire wheel, buff the exhaust deposits from
the mounting surface and around the valve.
2. Look for exhaust deposits in the valve o utlet.
Remove deposit build-up with a screwdriver.
3. Clean mounting surfaces of intake manifold and
valve assembly.
+ i- Install or Connect
1. New EGR gasket.
2. EGR valve to manifold.
m EGR VALVE [ T ] MANIFOLD VACUUM
3. Bolts or nuts.
4. Vacuum tube to valve. [ T ] VACUUM HARNESS j-^ -j HARNESS CONNECTOR
5. Air cleaner. fTI EGR SOLENOID 1----- 1
7 S 3 4 6 2 -6 E
fTI EGR V A L V E
m GASKET
Figure 9-11 - EGR Valve (2.5L) Figure 9-14 - EGR Valve (5.0L & 5.7L)
m EGR V A LV E
m EGR V A L V E
fT I GASKET
fTI GASKET
m N U T T IG H T E N T O 20 N m (15 LB S . FT.) 3 4 5 g _6E
[~3~l B O LT -T IG H T E N T O 25 N m (18 FT. LB S .) 6S 2899-6E
f T I EGR V A L V E
ITI GASKET
m STUD
fTI N U T -T IG H T E N TO 20 N -m (15 FT. LB S .) 7S 3456-6E
Install or Connect 1. Solenoid. See Figures 9-5 thru 9-10 for torque
specification.
1. Filter, if required. 2. Vacuum hoses
2. Solenoid. Tighten bolts to 24 N-m (17 ft. lbs). 3. Electrical connector.
3. Vacuum hoses. 4. Negative battery cable.
4. Electrical connector.
5. Air cleaner, if removed.
6. Negative battery cable.
fTl EGR C O N T R O L S O L E N O ID A S S E M B L Y
m E LE C TR IC A L C O N N E C T O R
HT] V A C U U M C O N N E C T O R FR O M S O U R C E
fT l V A C U U M C O N N E C T O R T O EGR V A L V E
|~ 5 l VENT
------ 1 7S 3793-6E
PARTS INFORMATION
SECTION 10
TORQUE CONVERTER
CLUTCH (TCC)
(ELECTRICAL DIAGNOSIS)
2.5L ENGINES
9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S3858-6E
10-4 TRANSMISSION CONTROLS
ECM
tTc IGN.
PPL GAGE
FUSE
F B 4 2 2 TAN/BLK A7
TCC
ALDL X
TRANS
CONNECTOR
A D C B 4 4 6 LT BLU C7 -JUh
L - /IT U
4TH
GEAR
SIGNAL
4TH GEAR
SWITCH 8 -4 -8 8
TCC SOLENOID
7 -3 1 -8 7 7S 38 59-6 E
I
E N G IN E AT N O R M A L OPERATING TEMPERATURE A N D "CLOSED LO O P".
C O N N E C T TEST LIGHT FR O M TCC TEST P O IN T, ALDL TERM "F" TO G R O U N D .
RAISE DRIVE W HEELS.
S T A R T A N D IDLE ENGINE IN PARK. DO N O T DEPRESS BRAKE PEDAL.
N O T E LIGHT.
8 -4 -8 8
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3860-6E
10-6 TRANSMISSION CONTROLS
9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7S3862-6E
10-8 TRANSMISSION CONTROLS
ECM
IGN/GAGE
FUSE
IG N IT IO N ----------- ---------------------- PNK/BLK 39
20 A
&
SHIFT LIGHT
I.P. CONNECTOR
------- --------
ECM
IG N /G A G E
FUSE I.P. CONNECTOR
IG N IT IO N ----------- ---------------------- PNK/BLK 39 ------- --------
20 A SHIFT LIGHT
ECM
E C M /IG N
FUSE I.P. CONNECTOR
IG N IT IO N ----------- ---------------------- PNK/BLK 43 9 SSL ------------ ------------------TAN/BLK 4 5 6
10 A SHIFT LIGHT
8 -1 9 -8 6
7 -3 1 -8 7 7 S 3 8 6 3 -6 E
Test Description: Numbers below refer to circled 2. This should turn "ON the shift light.
numbers on the diagnostic chart. 3. This checks for an open in the shift light circuit, or
1. This should not turn "ON the shift light. If the a faulty ECM.
light is "ON, there is a short to ground in CKT
456 wiring, or a fault in the ECM.
TRANSMISSION CONTROLS 10-9
MANUAL TRANSMISSION
SHIFT LIGHT CHECK
VEHICLES BELOW 8500 G V W ONLY
8-19-86
7S 3864-6EA
10-10 TRANSMISSION CONTROLS
DIAGNOSIS
TCC SYSTEM
SHIFT LIGHT SYSTEM Figure 10-3 - Downshift Control Relay (except CK)
D ow nshift Control Relay
If the manual transmission shift light does not (Figures 10-2 and 10-3)
illuminate, or is "ON all the time, while driving the
vehicle, refer to "Manual Transmission Shift Light Remove or Disconnect
Check chart.
l. harness connector
2. detaining bolt(s).
ON-VEHICLE SERVICE
-4- Install or Connect
TCC SYSTEM
1. Retaining bolt(s).
2. Harness connector.
Refer to Section "3, for repair of wiring.
Refer to Section "3, for replacement of the ECM. SHIFT LIGHT SYSTEM
For replacem ent of the TCC solenoid, vehicle
speed sensor, or brake sw itch, re fe r to the Refer to Section "3, for repair of wiring.
appropriate series Service Manual, as listed in the Refer to Section "3, for replacement of the ECM.
"Forward.
SECTION 11
POSITIVE CRANKCASE VENTILATION (PCV)
CONTENTS
GENERAL DESCRIPTION..................................... 11-1 FUNCTIONAL C H E C K ..................................... 11-2
D IA G N O S IS .......................................................... 11-1 ON-VEHICLE SERVICE.......................................... 11-2
RESULTS OF INCORRECT O P E R A TIO N ____11-1 PARTS INFORMATION ........................................... 11-2
CLEAN AIR
m PCV VALVE
H AIR CLEANER
m CRANKCASE
VENT HOSE
H PCV VALVE
HOSE 4 S 0 0 6 7 -6 E
Figure 11-1 - PCV Flow(L-4) Figure 11-2 - PCV Flow (V6 and V8)
11-2 POSITIVE CRANKCASE VENTILATION
FUNCTIONAL CHECK
PARTS INFORMATION
PART NAME GROUP
m CHECK VALVE
4S 00 68-6E
VIEW A
IS36 29-6 E
fT I PCV VALVE
m GROMMET
H T l TUBE ASSEMBLY
fTI TBI UNIT - PORT "C "
F T I AIR CLEANER FITTING
n n MAP SENSOR
7S 36 30-6 E
SECTION 12
THERMOSTATIC AIR CLEANER (THERMAC)
CONTENTS
GENERAL DESCRIPTION.......................................12-1 TEMPERATURE SENSOR CHECK.................... ..12-3
PURPOSE.......................................................... ..12-1 ON-VEHICLE SERVICE............................................ 12-3
O PERATIO N..................................................... ..12-1 AIR CLEANER E L E M E N T ................................ .. 12-3
D IA G N O S IS .......................................................... ..12-1 AIR CLEANER...................................................... 12-4
RESULTS OF INCORRECT O P E R A T IO N ____12-1 VACUUM DIAPHRAGM M O T O R ....................12-4
THERMAC AIR CLEANER W AX PELLET A C T U A T O R ................................ 12-4
FUNCTIONAL CHECK ..................................12-3 SENSOR............................................................. .. 12-4
VACUUM MOTOR FUNCTIONAL CHECK . . 12-3 PARTS INFORMATION ....................................... .. 12-5
GENERAL DESCRIPTION
PURPOSE
OPERATION
p n V A C U U M D IA P H R A G M
'------ 1 M O T O R
TEMPERATURE SENSOR
fTl V A C U U M HOSE (TO
fTl SNORKEL
1------ 1 M A N IF O L D V A C U U M )
m H E AT STOVE DUCT I [~2~| WAX PELLET ACTUATOR
S SNORKEL F T l PISTON
LIN KAG E j m CALIBRATED SPRING
m AIR BLEED VALVE m HOT AIR INLET
AIR CLEANER A SM . [~6~| REGULATING DAMPER
ASSEMBLY
fT l D AM P ER DOOR
[~7~| COLD AIR INLET
1------ 1 4S 06 48-6E 7 S 3 8 1 1 -6 E
Figure 12-2 - THERMAC Air Cleaner - S/T Series Figure 12-3 - THERMAC Operation
All Except S/T Series
fTl V A C U U M D IA P H R A G M M O T O R
m D IA P H R A G M SPRING
m TEMPERATURE SENSOR
CD V A C U U M HOSES
CD D IA P H R A G M
r a HEAT STOVE
f~8~1 H O T A IR (E X H AU S T M A N IF O L D )
m D A M P ER DOOR
rm SNORKEL
| ip
4S 00 73-6 E
Refer to Figures "12-8 to 12-13 for repair or All Except S/T Series
replacement of air cleaner. (Figure 12-6)
l. Air cleaner.
2. Vacuum hose from motor. -- Install or Connect
3. Drill out the two spot welds initially with a 1.6mm 1. Actuator.
(1/16 ) drill, then enlarge as required to remove 2. Spring.
the retaining strap. Do not damage the snorkel 3. Rivet.
tube. 4. Air cleaner.
4. Motor retaining strap.
5. Lift up motor, cocking it to one side to unhook the SENSOR
motor linkage at the control damper assembly.
S/T Series
|+7| Install or Connect (Figure 12-7)
-m
~r
m SPOT WELDS
m MOTOR ASM. FTl W A X PELLET A C T U A T O R [T] SNORKEL
PARTS INFORMATION
Air C le a n e r..........................................................3.402
Element (Paper)................................................. ..3.410
Nut, A /C l............................................................ ..3.403
m AIR CLEANER
------ A S S E M B LY
ITI SUPPORT
r | - j B 0 LT-TIGHTEN TO
Seal, Air C le a n e r.................................................3.403 [T1 N UT-TIG HTEN TO ------- 50 N m (37 FT. LBS.)
Sensor, A /C l..........................................................3.415 ----- 2 N-m (18 IN. LBS.) B 0LT-TIGHTEN TO
I 3 I SEAL 30 N-m (22 FT. LBS.)
Motor, A/Cl Vac D iap h ..................................... ..3.415
[~4~l ADAPTER 7 S 3 7 0 1 -6 E
Tube, Eng Air Heat Stove...................................3.417
Stove, Eng Air H e a t.......................................... ..3.417
Figure 12-9 - Air Cleaner (2.5L - M Series)
Figure 12-8 - Air Cleaner (2.5L - S/T Series) Figure 12-10 - Air Cleaner (2.8L - S/T Series)
12-6 THERMOSTATIC AIR CLEANER
Figure 12-12 - Air Cleaner (4.3L - ST Series) Figure 1 2 -1 4 -A irC lean er(7.4L- All)
SPECIAL TOOLS 13-1
SECTION 13
SPECIAL TOOLS
CONTENTS
GENERAL................................................................. 13-1 IAC (Idle A ir C o n tro l).................................. 13-3
"SCAN" TOOL ............ ..................................... .. 13-1 Injector Pulse W id t h .................................. ..13-3
"SCAN" TOOL M O D E S .................................. .. 13-1 In te g ra to r and Block L e a rn ...................... .13-3
Norm al (Open) M ode ............................. .. 13-1 Knock R e ta rd .............................................. .13-3
ALDL M ode ................................................ 13-2 Knock Signal .............................................. .13-3
Factory Test M o d e .................................... .. 13-2 MAT S e n s o r...................................................13-3
"SCAN" TOOL LIMITATIONS AND USE____13-2 MAP S e n s o r..................................................13-3
In te rm itte n t C o n d itio n s ............................. 13-2 M o d e ..............................................................13-3
"SCAN" TOOL POSITIONS............................. .. 13-2 M P H ............................................................... ..13-3
A/C C lu tch ..................................................... 13-2 Oxygen (O 2) S e n s o r.................................. .13-4
A/C R e q u e st................................................ .. 13-2 Park/Neutral S w itc h .................................. ..13-4
B attery V oltage ......................................... 13-2 Power Steering Pressure S w it c h ...............13-4
Closed Loop/Open L o o p ............................. 13-2 PROM I D ........................................................13-4
Block Learn M em ory (BLM) C e ll...............13-2 R P M ............................................................... ..13-4
C odes............................................................ .. 13-3 S hift L i g h t ................................................... ..13-4
C oolant T e m p e ra tu re ............................... .. 13-3 T h ro ttle A n g le ..............................................13-4
Desired RPM................................................ .. 13-3 T h ro ttle Position Sensor (TPS) ............... ..13-4
EGR (D uty C ycle)......................................... .. 13-3 Torque C onvertor Clutch (T C C ).................13-4
EGR P o s itio n ................................................ .. 13-3 Specifications C h a r t.................................. ..13-8
4th G e a r....................................................... ...13-3
"Scan tools are programmed so that the system will The "Scan tool is also a useful and quick way of
go directly into the special mode if the "open mode is comparing operating param eters of a poorly operating
not available. engine with a known good one. For example; A sensor
may shift in value but not set a code. Comparing with
ALDL (1 0Kf or Special) M ode a known good vehicle may uncover the problem.
(n o t used on all engines) The "Scan tool has the ability to save tim e in
diagnosis and prevent the replacement of good parts.
In this mode, all information incorporated into a The key to using the "Scan tool successfully for
specific engine and ECM is obtainable. However, in diagnosis lies in the technicians ability to understand
this mode the system operating characteristics are the system he is trying to diagnose as well as an
modified as follows. u n d erstan d in g of the "S can tools lim ita tio n s.
"Closed Loop timers in ECM are bypassed T herefore, th e tech n ician should read th e tool
EST (spark) is advanced operating manual to become fam iliar with the tool.
IAC will control engine idle to 1000 rpm 50 The following information will describe most of the
rpm (On 5.0L engine the control engine idle is "Scan tool positions and how they can be helpful in
850 rpm 50 rpm. diagnosis.
P/N restrict functions will be disabled
"SCAN" TOOL POSITIONS
Factory Test (Back-up or 3.9 K) M ode
The following positions may not be applicable to
When in this mode, the ECM is operating on the all engines:
fuel back-up logic and calibrated by the Calpak/Mem-
Cal. The Calpak/Mem-Cal is used to control the fuel A/C Clutch
delivery if the ECM fails. This mode verifies that the
back-up feature is OK. The param eters that can be Displays "ON when the ECM has commanded the
read on a "Scan tool in this mode are not of much use A/C clutch "ON.
for service.
A/C Request
"SCAN" TOOL LIMITATIONS AND USE
Displays the state of the A/C signal line to the
The "Scan tool allows a quick check of sensors ECM. Should read "YES whenever the A/C is
and switches which are inputs to the ECM. However, requested.
on some applications the data update rate makes the
tool not as effective as a voltmeter when trying to Battery Voltage
detect an interm ittent which lasts for a very short
time. However, the "Scan tool allows manipulation This displays the battery voltage detected at the
of wiring harnesses or components under the hood ECM ignition input.
while observing the "Scan readout. This helps in
locating interm ittents with the engine not running. Closed Loop/Open Loop
In term itten t Conditions This position will indicate w hether the engine
control system is operating in "Open or "Closed
The "Scan tool is helpful in cases of interm ittent Loop. Most systems go "Closed Loop after a certain
operation. The tool can be plugged in and observed amount of run time, when coolant tem perature is high
while driving the vehicle under the condition where enough, and the oxygen sensor becomes active.
the light comes "ON m om entarily, or the engine
driveability is poor m om entarily. If the problem Block Learn M ultiplier (BLM) Cell - or -
seems to be related to certain areas th a t can be Block Learn M em ory (BLM)
checked on the "S can tool, then those are the
positions that should be checked while driving the T h e re a re up to s ix te e n d if f e r e n t c e lls ,
vehicle. If there does not seem to be any correlation corresponding to ranges of rpm and engine load
between the problem and any specific circuit, the (indicated by MAP signal), and other conditions, such
"Scan tool can be checked on each position, watching as A/C or P/N switch "ON or "OFF, etc. The ECM
for a period of time to see if there is any change in the learns how much adjustment is needed in each cell,
readings that indicates interm ittent operation. and retains it in memory, so that the adjustment will
immediately be made when the engine operates in
that cell (or rpm/load range). This p aram eter will
display what cell the ECM is currently using for the
fuel calculation.
SPECIAL TOOLS 13-3
Normal readings for these positions are around Displays vehicle speed. Useful in Checking TCC
128, if higher, it indicates that the ECM is adding fuel lock up speed or speedometer accuracy.
to the base fuel calculation because the system is lean,
and if the numbers are below 128 the ECM is taking
out fuel from the base calculation because the system
is rich.
13-4 SPECIAL TOOLS
----------------------------------------- 7 3 5
In this position, information is used for assembly Torque Coinvertor Clutch (TCC)
verification only. PROM ID is useful only when the
vehicle is equipped with the original ECM and PROM In this position, the tool will indicate when the
or Mem-Cal. Refer to "Parts Information for correct TCC has been commanded by the ECM to turn "ON.
PROM. This does not necessarily mean that the clutch was
engaged but only that the ECM grounded the circuit
internally. The best way to determine if the clutch
has engaged is to monitor engine RPM when the TCC
comes "ON.
SPECIAL TOOLS 13-5
i------------------------------
TACHOMETER
Use inductive trigg er signal pickup type to check RPM.
eSo
j 29533a /B T 8 127
J 3 3 0 3 1 /B T 8 1 3 0
-------^y B T8320
V | o O J 3 4 7 3 0 -2 A /
V ------y B T8329A
CIRCUIT TESTER
U sed to check all relays an d so len o id s be fo re co nn ecting th e m
to a n e w E C M . M e a s u re s th e circuit resistance and indicates
pass o r fail via g re e n or red LED. A m b e r LED indicates cu rren t
po larity . Can also be used as a n o n -p o w e re d co n tin u ity checker.
^ ^ ^ ^ ^ ^ ^ ^ J 3 4 6 3 6 /B T 8 4 0 5
J2 8 6 8 7 -B /B T 8 2 2 0
J 3 5 6 8 9 /B T 8 4 4 6
J 2 8 7 4 2 -A /B T 8 2 3 4 -A
J 3 3 0 9 5 /B T 8 2 3 4 -A
7 S 3 5 3 5 -6 E
i
SPARK TESTER
S5>
Use to check a va ila b le se co n da ry ig n itio n v o lta g e . A lso called an ST125.
J26792 BT7220-1
J29698-A/BT8251
J 3 3 179-20
J29658-B/BT8205
J34020
J36608(C K)/J24187
VYv N\ J S il
^ ^P
J24642-F/BT7220
7S 3 5 3 6 -6 E
SPECIFICATIONS
SPECIFICATION LOCATION OF INFORMATION
Engine Code 8th digit of VIN number. See Section "OA. Also Owners
Manual, Section "7.
SECTION 14
A bbreviations used in this m anual are listed COOLANT TEMPERATURE SENSOR - Device th a t
below in alphabetical order with an explanation of the senses the engine coolant tem perature, and passes
abbreviation. There are some variations in the use of that information to the electronic control module.
periods and in capitalization (as mph, m.p.h., Mph,
CONV. - CATALYTIC CONVERTER - C ontaining
and MPH) for abbreviations used in this section but
platinum and palladium to speed up conversion of HC
all types are acceptable.
and CO.
A/F - AIR/FUEL (A/F RATIO) - The amount of air-to-
CO - CARBON MONOXIDE - One of the pollutants
fuel for combustion of fuel. Ideal ration is 14.7 parts of
found in engine exhaust.
air to 1 part of fuel.
CURRENT OR AMPERAGE - The rate of flow of
AIR - AIR INJECTOR REACTION SYSTEM - Air flow
electrons is sim ilar to gallons of w ater per m inute
from pump is directed into engine exhaust manifold
flowing in a w ater pipe.
and/or converter to reduce exhaust emissions.
DIAGNOSTIC CODE - P air of num bers obtained
ALDL - ASSEMBLY LINE DIAGNOSTIC LINK - Used
from flash in g "Service E n g in e Soon lig h t, or
at assembly to evaluate Computer Command Control
displaying on a "Scan tool. This code can be used to
and for service to flash the "Service Engine Soon
determine the system malfunction.
light if there are trouble codes. Also used by "Scan
tools to obtain ECM serial data. DIAGNOSTIC TERM. - Grounding term inal "B of
ALDL connector will flash or display a code. When
ANALOG SIGNAL - An electrical signal that varies
grounded with the engine running will en ter the
in voltage within a given parameter.
"Field Service Mode.
Bat + - Battery Positive Terminal (12 Volts)
DIGITAL SIGNAL - An electrical signal th a t is
BLOCK LEARN - ECM memory th a t adjusts the either "ON or "OFF with no in between.
air/fuel ratio on a semipermanent basis.
DIODE - An electrical device th at restricts current
CAPACITOR - An electrical device used to store a flow in one direction.
temporary charge.
DRIVER - An electrical device, usually a power
CALPAK - A device used with fuel injection to transistor, th at operates like a switch; that is, it turns
allow fuel delivery in the event of a PROM or ECM something "ON or "OFF.
malfunction.
DVM (10 M e g .) - D igital V o ltm eter w ith 10
CALIBRATOR - (PROM) - An electronic component Million ohms resistance - used for m easurem ent in
which can be specifically programmed to meet engine electronic systems.
operating requirements for each vehicle model. It
EAC - ELECTRIC AIR CONTROL - Used on AIR
plugs into the Engine Control Module (ECM).
system to direct air flow to Air Switching valve or
CCC - COMPUTER COMMAND CONTROL - has an atmosphere.
electronic control module to control air/fu el and
ECM - ELECTRONIC ENGINE CONTROL MODULE -
emission systems.
A m etal case (located in passenger com partm ent)
CCP - CONTROLLED CANISTER PURGE - ECM containing electronic circuitry w hich ele c tric a lly
controlled solenoid valve th a t p erm its m anifold controls and monitors air/fuel and emission systems
vacuum to purge the evaporative emissions from the on Computer Command Control, and turns "ON the
charcoal canister. "Service Engine Soon light when a m alfunction
occurs in the system.
CID - CUBIC INCH DISPLACEMENT - Used to
describe engine size. ECU - ENGINE CALIBRATION UNIT - An electronic
component which can be specifically programmed to
C/LOOP - CLOSED LOOP - Designed with feedback
the design of each vehicle model to control the M/C
inform ation to the ECM to m aintain an optimum
solenoid. The ECU plugs into the electronic control
air/fuel ratio (14.7:1), output.
module (ECM). The ECU is usually called a PROM.
14-2 ABBREVIATIONS
EFI - ELECTRONIC FUEL INJECTION - Computer IDEAL MIXTURE - The air/fuel ratio which provides
Command Control using throttle body fuel injection. the best performance, while m aintaining m axim um
conversion of exhaust emissions, typically 14.7/1.
EGR - EXHAUST GAS RECIRCULATION - Method of
reducing NOx emission levels. IGN - IGNITION - Refers to ignition switch and
lock.
EECS - EVAPORATIVE EMISSIONS CONTROL
SYSTEM - Used to prevent gasoline vapors in the fuel INPUTS - Inform ation from sources (such as,
tank from entering the atmosphere. coolant tem perature sensors, exhaust oxygen sensor,
etc.) th a t te ll th e ECM how th e sy ste m s a re
EMI OR NOISE - An unwanted signal interfering
performing.
with another needed signal; like an electrical razor
upsets a television picture, or driving under high INTERMITTENT - O ccurs now and then; not
voltage power lines upsets the AM radio in a vehicle. continuously. In e le c tric a l c irc u its , re fe rs to
occasional open, short, or ground.
ENERGIZE/DE-ENERGIZE - When current is passed
through a coil (energized) such as a solenoid, a plunger I.P. - INSTRUMENT PANEL - Contains instrum ent
is pulled or pushed. When the voltage to the solenoid gages and indicator lights to indicate performance of
is turned off, (de-energized), a spring raises or lowers the vehicle.
the plunger.
KM/H - KILOMETER PER HOUR - A metric unit
ESC - ELECTRONIC SPARK CONTROL - Used to measuring distance (1000 meters) in one hour.
sense detonation and retard spark advance when
L - LITER - A metric unit of capacity.
detonation occurs.
LOW - Operates the same as ground and may, or
EST - ELECTRONIC SPARK T IM IN G - ECM
may not, be connected to chassis ground.
controlled timing of ignition spark.
L4 - FOUR CYLINDER IN-LINE ENGINE
EVRV - ELECTRONIC VACUUM REGULATOR VALVE
- Controls EGR vacuum. MALFUNCTION - A probl em th a t causes th e
system to operate incorrectly. Typical malfunctions
FED - FEDERAL - Vehicle/Engine available in all
are; wiring harness opens or shorts, failed sensors, or
states except California.
circuit components.
FI - FUEL INJECTION - Computer Command Control
MAP - MANIFOLD ABSOLUTE PRESSURE SENSOR -
using throttle body fuel injection.
Reads pressure changes in in tak e m anifold w ith
GROUND - A wire shorted to ground. A common reference to zero pressure. It puts out a voltage which
return path for an electrical circuit. A reference point is h ig h est when the p re ssu re is h ig h e st. The
from which voltage measurements may be made. maximum voltage is between 4-5 volts.
HC - HYDROCARBONS - One of the pollutants MAT - MANIFOLD AIR TEMPERATURE SENSOR -
found in engine exhaust. Hydrogen and carbon in Measures tem perature of air in the intake manifold.
gasoline.
MEM-CAL - Contains specific calibrations to meet
HIGH - A voltage more than ground or 0, like the the requirements of a specific engine..
output wire of an oxygen sensor is called __ voltage
MODE - A particular state of operation.
high, as compared to the ground, which is called
voltage low. In digital signals, high is "ON and low is MPH - MILES PER HOUR - A u n it m e asu rin g
"OFF. distance (5280 feet) in one hour.
HIGH IM PEDANCE VOLTMETER - H as h ig h N.C. - NORMALLY CLOSED - State of relay contacts
opposition to the flow of electrical current. Good for or solenoid plunger when no voltage is applied.
reading circuits with low current flow, such as found
Nm - NEWTON METERS (TORQUE) - A m etric
in electronic systems.
unit which measures force.
HEI - HIGH ENERGY IGNITION - A distributor that
N.O. - NORMALLY OPEN - State of relay contacts
uses an electronic module and pick-up coil in place of
or solenoid plunger when no voltage is applied.
contact points.
NOx - NITROGEN, OXIDES OF - One of the
Hg - MERCURY - A calibration material used as a
pollutants found in engine exhaust. N itrogen th a t
standard for vacuum measurement.
combines with oxygen to form oxdes of nitrogen.
IAC - IDLE AIR CONTROL - Installed in the throttle
body of a fuel injected system and controlled by the
ECM to regulate idle speed.
ABBREVIATIONS - 14-3
O 2 - OXYGEN (SENSOR) - Monitors the oxygen TACH - TACHOMETER - A device for indicating
content of the exhaust system and generates a voltage speed for rotation.
signal to the ECM. TBI - THROTTLE BODY INJECTION (U N IT ) - Is
0 LOOP - OPEN LOOP - Describes ECM fuel controlled by the ECM to supply precise air/fu el
control without use of oxygen sensor information. mixture into the intake manifold.
OUTPUT - Functions, typically solenoids, that are TCC - TRANSMISSION / TRANSAXLE CONVERTER
controlled by the ECM. CLUTCH - ECM controlled solenoid in transm ission
which positively couples the tra n sm issio n to the
OXYGEN SENSOR, EXHAUST - Device th at detects
engine.
the amount of oxygen (O2) in the exhaust stream.
THERMAC - THERM OSTATIC AIR CLEANER -
POSITIVE CRANKCASE VENTILATION - Prevent
Provides preheated air to intake manifold to provide
fumes in crankcase from passing into atmosphere. better driveability when engine is cold.
P/N - PARK/NEUTRAL - Refers to switch used to
TPS - THROTTLE POSITION SENSOR - Device that
indicate to the ECM the position of the autom atic tells the ECM the throttle position.
transmission.
TVS - THERMAL VA C U U M SWITCH - Used to
PORT - EXHAUST OR INTAKE PORT
control vacuum in relationship to engine tem perature.
PROM - PROGRAMABLE READ ONLY MEMORY-
V - VOLT - A m easurem ent of electrical pressure.
an electronic term used to describe the engine
calibration unit. VOLTAGE - The pressure of force pushing the
current in a circuit; like pressure in a water pipe.
PULSE WIDTH MODULATED - A device operated by
a digital signal that is controlled by the time duration V-6 - SIX CYLINDER ENGINE - Arranged in a "V.
the device is turned "ON or "OFF. V-8 - EIGHT CYLINDER ENGINE - A rranged in a
QUAD DRIVER - A "chip device that is capable of "V".
operating four separate outputs. Some have digital
V A C U U M - N e g a tiv e p r e s s u r e ; le ss th a n
and some have pulse width modulated outputs.
atmospheric pressure.
RESISTANCE - The ability of a circuit to lim it
V A C U U M , M A N IF O L D - V acuum so u rc e in
current flow; like a restriction in a water pipe.
manifold below throttle plate.
RPM - REVOLUTIONS PER MINUTE - A measure of
VACUUM , PORTED - A vacuum source above
rotational speed. (atmospheric side ) of closed throttle plate.
SELF-DIAGNOSTIC CODE - The ECM can detect
VIN - VEHICLE IDENTIFICATION NUMBER - Appears
malfunctions in the system. If a malfunction occurs,
on a plate attached to the windshield pillar.
the ECM turns "ON the "Service Engine Soon light.
A diagnostic code can be obtained from the ECM VSS - VEHICLE SPEED SENSOR - Sensor which
through the "Service Engine Soon light. This code sends vehicle speed information to the ECM.
will indicate the area of the malfunction. WASTEGATE - A means of controlling the amount
SES - SERVICE ENGINE SOON LIGHT - Lights when of boost available for a turbo charged engine.
a malfunction occurs in Computer Command Control
WOT - WIDE OPEN THROTTLE - Refers to the
system. throttle valve or accelerator pedal when fully open or
depressed.
14-4 ABBREVIATIONS
6 -1 2 -8 7
8S 4 3 4 9 -6 E
INDEX
A Chart A-4:
Injector Circuit Diagnosis - 2 .5 L .................... 3-24
A b b r e v ia tio n ..........................................................14-1 Injector Circuit Diagnosis-except 2.5L . . . 3-26
A cceleration M o d e .............................................. ..4-3 Chart A-5:
Accelerator Control Cable ..................................4-40 Fuel Pump Relay C irc u it-S T M ...................... 3-28
A ccelerator P e d a l...................................................4-41 Fuel Pump Relay Circuit - CKRVGP............... 3-30
A/C Control Chart A-6:
General D e s c rip tio n .........................................3-7 Fuel System Pressure T e s t............................. 3-34
D iag no sis.......................................................... ..3-14 Check Valve D iagnosis....................................... 8-3
S ervice............................................................... ..3-118 Circuit T e s te r........................................................ 13-6
A c tio n Symbol U s a g e ......................................... ..ii Clear Flood M o d e ................................................. 4-2
A irC le a n e r...............................................................12-1 Clearing Trouble Codes ..................................... 3-9
A ir Cleaner E le m e n t..............................................12-3 Closed Loop S ystem ............................................ 4-2
A ir C o nd ition ing Electrical System D iagnosis. 3-83 Code System ........................................................ 3-9
AIR Control V a lv e ...................................................8-6 Code 1 3 .................................................................. 3-36
A ir Filter Elem ent R e p la c e m e n t...................... ..12-3 Code 1 4 ................................................................. 3-38
AIR Filter F a n ..........................................................8-3 Code 1 5 .................................................................. 3-40
AIR Hoses and P ip e s ..............................................8-3 Code 2 1 ................................................................. 3-42
A ir Injection R e a ctio n ......................................... ..8-1 Code 2 2 ................................................................. 3-44
A ir M anagem ent System .................................. ..8-1 Code 2 3 ................................................................. 3-46
D iag no sis.......................................................... .8-2 Code 2 4 ................................................................. 3-48
A ir Pump D ia g n o s is ..............................................8-2 Code 2 5 ................................................................. 3-50
AIR System - 2.8 L ..................................................8-1 Code 32 - 2.5L, 4.3L, 5.0L, & 5.7L
AIR System - 4 . 3 L & V 8 ....................................... .8-1 (Under 8500 GVW) ....................................... 3-52
ALDL C o n n e c to r................................................... .3-2 Code 32 - 2.8L, 4.3L (ST) 7.4L & 5.7L
A u to m a tic T ransm ission.................................... ..10-1 (Over 8500 G V W )............................................ 3-54
A u xilia ry Fuel Tank Control ............................. ..4-34 Code 3 3 .................................................................. 3-56
Code 3 4 .................................................................. 3-58
B Code 3 5 .................................................................. 3-60
Code 4 2 .................................................................. 3-62
B a c k fire ................................................................. .2-3 Code 4 3 .................................................................. 3-64
Basic Electrical C irc u its ........................................1-2 Code 4 4 .................................................................. 3-66
Battery V oltage C orrection M o d e .....................4-3 Code 4 5 .................................................................. 3-68
Before S tarting ................................................... .2-1 Code 5 4 .................................................................. 3-70
Bulb C h eck............................................................ .3-7 Codes 51, 52, 53, 55 ............................................ 3-72
Compact Three Service....................................... 3-94
C Component Locations ....................................... 1-4
Component Systems ......................................... 1-4
CALPAK Computer Command C o n tro l........................... 3-1
General D e s c rip tio n ....................................... .3-5 Connector and Terminal S ervice...................... 3-92
D ia gn osis.......................................................... .3-10 Connector Test Adapter K i t ...................... .. 13-5
S e rvice ............................................................... .3-109 Coolant Sensor
C a u tio n ................................................................. .ii General Description....................................... 3-5
Chart A -1 : Diagnosis.......................................................... 3-12
No "Service Engine Soon" L i g h t ................. .3-16 Service............................................................... 3-112
Chart A-2: Crankcase Vent Filter ....................................... 11-2
No ALDL Data or W o n 't Flash Code 12 or Crank Signal.......................................................... 3-7
"Service Engine Soon" Light on Steady . . 3-18 Crank Signal Diagnosis....................................... 3-14
Chart A-3: Cut Out, Misses ................................................... 2-6
Engine Crank But W o n 't Run - 2 .5 L ...............3-20
Engine Crank But W o n 't Run -Except 2.5L . . 3-22
INDEX
i *
I I
I g m c I
H TRUCK B
I I
G M C .TRUCK
X
$
?
S s
1$Slf
- ____