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1989

Light Duty Truck


Fuel and Emissions
Including Driveability
GMC
T R U C K

- 4 6 8 LT GRN 014

4 6 7 LT BLU D 16

12V TO ECM IF USING


ECM 1 FUSE

; ^ ,

42 3 W H T D4 EST

4 3 0 PPL/WHT B5 REFERENCE

4 2 4 TAN/BLK D5 BYPASS

B3 GROUND
W
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:

X-8932 10-30 Series R-V-G-P Light Duty Truck Service Manual


X-8929 10 Series S-T Light Duty Truck Service Manual
X-8930 10 Series M-Van Light Duty Truck Service Manual
X-8931 10-30 Series C-K Light Duty Truck Service Manual

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.

NOTICE: No part of this publication may be reproduced, stored in


any retrieval system or transm ited, in any form or by
GMC TRUCK DIVISION any means, including but not lim ited to electronic,
TR U C K S BUS GROUP m echanical, photocopying,recording or otherw ise,
without the prior writen permission of the GMC Truck
General M otors Corporation Division of General Motors Corp. This includes all text,
Pontiac, M ichigan illustrations, tables and charts.
CAUTION:
To reduce the chance of personal injury and/or property damage, the following instructions must be
carefully observed.

Proper service and repair are important to the safety of the service technician and the safe, reliable
operation of all motor vehicles. If part replacement is necessary, the part must be replaced 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.

ACTION SYMBOL USAGE

The general narrative writing style has been replaced in


some procedures w ith action symbols. To improve readability
and to provide em phases w h en needed, the fo llo w in g
symbols are used in the text.

<-- Remove or Disconnect Inspect

-- Install or Connect | | j| | Measure

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

FOR GASOLINE ENGINES COMPUTER C O M M A N D


WITH CONTROL
I
THROTTLE BODY INJECTION FUEL CONTROL
C,K,P,R,V,S,T TRUCK
EVAPORATIVE EMISSION
AND
M -VAN, G-VAN
CONTROL ?
MODELS IGNITION SYSTEM/EST

10/ 1500 - 20/ 2500 - 30/3500 ELECTRONIC SPARK CONTROL


SERIES
AIR MANAGEMENT 8

The Table of Contents on this page indicates the


sections covered in this manual. At the beginning EXHAUST GAS
of each individual section is a Table of Contents RECIRCULATION
9
which gives the page number on which each major
subject begins.
AUTOMATIC TRANSMISSION
CONVERTER CLUTCH OR
W hen reference is made in this m anual to a 10
DOWN-SHIFT CONTROL AND
brand name, number, or specific tool, an equivalent
MANUAL TRANSMISSION
product may be used in place of the recommended
SHIFT LIGHT
item.

All information, illustrations, and specifications POSITIVE CRANKCASE 11


contained in this Manual are based on the latest VENTILATION
product in fo rm a tio n a v a ila b le at th e tim e of
publication approval. The right is reserved to make
changes at any time w ithout notice. THERMOSTATIC AIR CLEANER w

SPECIAL TOOLS AND


SPECIFICATIONS
" I

1988 General Motors Corporation August, 1988 ABBREVIATIONS 14


All rights reserved. Printed in U.S.A.
ALPHABETICAL INDEX
I

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

ALL NEW GENERAL M O TO RS VEHICLES ARE CERTIFIED BY THE U N IT E D STATES


ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE
REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS
CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY
STANDARDS. IN M OST CASES, THESE A D JU STM EN T POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT,
MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO THE ORIGINAL
INTENT OF THE DESIGN.

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

VISUAL/PHYSICAL UNDERHOOD INSPECTION SECTION DESCRIPTION

One of the most important checks that must Section "2"


be done as part of any diagnostic procedures or Driveability Symptoms
finding the cause of an em issions test failure, is a
careful visu al/p h ysical underhood in sp ectio n . The fuel and em issions driveability diagnosis
This can often lead to fixing a problem without further procedures apply to various systems in current GM
steps. Inspect all vacuum hoses for correct routing, vehicles. The procedures assum e th a t the vehicle
pinches, cuts, or disconnects. Be sure to inspect hoses worked right at one time and the problem is due to
th a t are difficult to see beneath the a ir clean er, time, wear, dirt or other causes. S tart with the ECM
compressor, generator, etc. Inspect all the wires in diagnosis in Section "3 and then to Section "2 which
the engine co m p a rtm e n t for co rrect and good references driveability symptoms.
connections, burned or chafed spots, pinched wires, or
contact with sharp edges or hot exhaust manifolds. Section "3"
This visual/physical inspection is very important. It Com puter Command Control
must be done carefully and thoroughly.
This is an electro n ically co n tro lled e x h au st
BASIC ELECTRIC CIRCUITS emission system th a t uses an electro n ic control
module (ECM) to control fuel d eliv ery , ig n ition
You should u n d erstan d the basic th e o ry of tim in g , a ir m a n a g e m e n t a n d e x h a u s t g as
electricity, and know the meaning of voltage, amps, recirculation. It also controls the engagement of the
and ohms. You should understand what happens in a tran sm issio n co n v erter clu tch an d th e m a n u al
circuit with an open or a shorted wire. You should be transmission shift light. This section diagnoses the
able to read and understand a wiring diagram . A system with the use of a "Scan tool.
sh o rt to ground is re fe rre d to as a g round to
distinguish it from a short between wires. Section "4"
Fuel Control System
EMISSIONS
The ECM controls th e air/fuel delivery to the
The exhaust emission control systems used on combustion cham ber by controlling the fuel flow
General Motors engines perform a specific function to through the injector(s). The ECM also controls idle
lower exhaust emissions while maintaining good fuel speed. The in-tank fuel pump is controlled by the
economy and driveability. ECM. When ignition is turned "ON, the pump will
run for 2 seconds for most systems, then stop unless
MAINTENANCE SCHEDULE the engine is cranking or running. On some vehicles,
the fuel pump will run for 20 seconds. The fuel control
R efer to th e G en eral M otors M ain ten an ce system is used on all engines. The ECM may control
Schedule in Section "OB of the Truck Service Manual the A/C clutch of the compressor and m aintain idle
or in the glove box for the maintenance service that speed to improve idle quality.
should be perform ed to re ta in em ission control
performance. Section "5"
Evaporative Emission Control
VEHICLE EMISSION CONTROL INFORMATION
LABEL This system has a canister which stores fuel vapor
from the fuel tank. The fuel vapor is removed from the
The Vehicle Emission Control Information label canister and consumed in the norm al combustion
(F ig u re 1-1) c o n ta in s im p o r ta n t e m is s io n process when the engine is running. This system is
specifications and setting procedures. In the upper used on all engines and is not controlled by the ECM.
left corner is exhaust emission inform ation which
Section "6"
identifies the year, the manufacturing division of the
Ignition/Electronic Spark Tim ing
engine, the displacement in liters of the engine, the
class of vehicle and type of fuel metering. Also there is
This system is controlled by th e ECM which
an illustrated emission component and vacuum hose
regulates ignition timing and is used on all engines.
schem atic. This label is located in the engine
compartment of every General Motors Corporation
vehicle. If the label has been removed, it can be
ordered from the parts division, (GMSPO). Refer to
the Standard Parts Catalog.
GENERAL INFORMATION 1-3

ENGINE ADJUSTMENT
SPECIFICATIONS
ADJUSTMENT
PROCEDURE
LABEL CODE
ENGINE SIZE

***
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC

LABEL PART NUMBER

AREA OF CERTIFICATION

ALWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL


FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS".

EVAPORATIVE EMISSION SYSTEM

EXHAUST EM ISSION SYSTEM


J 3 G 4.3 T 5 TA A 7

CERT YEAR CHECK S U M


J = 1988 DIGIT

D IV IS IO N D ISPLA C EM EN T VEHICLE CLASS AND S TA N DA R DS


1G = CPC Liters - Largest
T = GASOLINE TRUCK CATALYST D ESIGNATOR
2G = BOC if m ore than one
K = DIESEL TRUCK
3G = T&B
FUEL METERING

5 = TBI

7S3236-6E

Figure 1-1 - Vehicle Emission Control Information Label


1-4 GENERAL INFORMATION

Section "7" Section "11"


Electronic Spark Control (ESC) Positive Crankcase V entilation (PCV)

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)

Section "8" The THERMAC system re g u la te s h eated a ir


Air M anagem ent through the air cleaner to provide uniform inlet air
tem perature which gives good d riv eab ility under
This system provides additional oxygen to the various clim atic conditions. T his system is not
exhaust gases to continue the combustion process. Air controlled by the ECM and is used on all engines.
m anagem ent is used only on engine/transm ission
com binations th a t req u ire it to m eet em issio n Section "13"
standards. Special Tools

Section "9" Refer to Section "13 for sp e c ia l tools and


Exhaust Gas Recirculation (EGR) equipment needed to diagnose the fuel control and
emissions systems.
The EGR system uses a valve to feed a small
amount of exhaust gas back into the intake manifold Section "14"
to control formation of NOx. This system is used on all A bbreviations
engines and is controlled by the ECM.
Refer to Section "14 for abbreviations used in this
Section "10" manual.
Torque Converter Clutch (TCC)f Downshift
Control and M anual Transmission Shift Light
Control
COMPONENT LOCATIONS
The TCC is ECM controlled and is used on all
There are m any com ponent system s used to
engines with a THM 700R4 automatic transmission.
control fuel and emissions. Each system is described
This system reduces slippage losses in the torque
in a section which includes general description of the
convertor by coupling the engine flywheel to the
system, diagnosis and on-vehicle service. Component
output shaft of the transmission.
locations for all series vehicles and all engines are
The ECM controls the downshift solenoid in the
illu s tra te d in F ig u re s 1-2 th ro u g h 1-14. The
THM 400 autom atic tran sm issio n for wide-open
"Com ponent L ocation views show all em ission
throttle downshift.
systems that are used for the particular vehicle/engine
The ECM controls the shift light on all engines
combination. Not every vehicle re q u ire s all the
with manual transm ission to indicate the best shift
systems or components shown, only the ones needed to
point for maximum fuel economy on vehicles below
meet emission standards for the area of certification.
8500 GVW.
GENERAL INFORMATION 1-5

' M ' series r p o :LN 8 e n g i n e c o d e :E 2 . 5 L L4

COMPUTER C O M M A N D O ECM INFORMATION r "; EMISSION COMPONENTS


CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic C o n tro l M o d u le (E .C .M .) A M a n ifo ld pressure (M .A .P .) N1 C rankcase v e n t (PCV) v a lv e

C2 ALDL diagn ostic co nn ecto r B E xhaust o x y g e n N 1 5 Fuel v a p o r canister

C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle position (T.P.S.)


C5 ECM harness g ro u n d D C o o lan t te m p e ra tu r e
C6 Fuse p a n el F V ehicle speed (V.S.S.)
C8 Fuel p u m p te s t co nn ecto r G P o w e r S tee rin g Pressure
T M a n ifo ld A ir T e m p e ra tu re (M .A .T .)

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

'S' SERIES r p o :L N 8 ENGINE CODElE 2 . 5 L L4

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 pressure (M .A .P .) N1 C rankcase v e n t v a lv e (PCV)
C2 ALDL diagn ostic co n n ecto r B E xhaust o x y g e n N 1 5 Fuel V a p o r C an ister
C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle position (T.P.S.)
C5 ECM harness g ro u n d D C o o lan t te m p e ra tu r e
C6 Fuse p a n el F V ehicle sp eed (V .S .S .)
C8 Fuel p u m p te s t co n n ecto r G P o w e r S te e rin g Pressure
T M a n ifo ld A ir T e m p e ra tu re (M .A .T .)
ECM CONTROLLED
COMPONENTS
1 Fuel in jecto r
2 Id le air control
3 Fuel Pum 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.)
8 O il Pressure S w itch
12 E xhaust Gas R ecircu lation V acu u m S olenoid
13 A/C re la y 4 -2 2 -8 8
7C

Figure 1-3 - Component Locations - 2.5L (S Series)


GENERAL INFORMATION 1-7

'S / T ' SERIES r p o :LL2 ENGINE CODE:R 2. 8L V6

C2

6mm ^ 11
:N1! i
m FMB
[El

COMPUTER C O M M A N D O ECM INFORMATION : EMISSION COMPONENTS


CONTROL SENSORS (NOT ECM CONTROLLED)
C1 E lectronic 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 B1 E xhaust o x y g e n (F ed e ra l) N9 A ir Pum p

C3 "SERVICE ENGINE S O O N " lig h t B2 E xhaust O x y g e n (C a lifo rn ia ) N 15 Fuel V a p o r C an ister

C5 ECM harness g ro u n d C T h ro ttle position (T.P.S.)

C6 Fuse panel D C o o lan t te m p e ra tu re

C8 Fuel p u m p te s t co nn ecto r F V ehicle speed (V.S.S.)


C9 Elapsed T im er M o d u le J Electronic Spark C on trol Knock (E.S.C.
U EGR vacuu m diagn ostic sw itch

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

Figure 1-4 - Component Locations - 2.8L (ST Series)


1-8 GENERAL INFORMATION

'S /T ' series rp o :L B 4 e n g in e c o d e :Z 4 .3 L V 6

COMPUTER C O M M A ND O e CM 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 N 1 5 Fuel V a p o r C an ister
C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle po sition (T.P.S.)
C5 ECM harness gro u n d D C oo lan t te m p e ra tu re
C6 Fuse p a n e l F V ehicle speed (V.S.S.)
C8 Fuel p u m p te s t co nn ecto r J Electronic Spark C ontrol Knock (E.S.C.)

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

Figure 1-5 - Component Locations - 4.3L (ST Series)


GENERAL INFORMATION 1-9

'C /K ' series r p o ;LB 4 e n g i n e c o d e :Z 4 .3 L V6

COMPUTER C O M M A N D O ECM INFORMATION n EMISSION COMPONENTS


CONTROL SENSORS (NOT ECM CONTROLLED)
C1 E lectronic 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)

C2 ALDL diagn ostic co nn ecto r B E xhaust o x y g e n N9 A ir P um p

C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle po sition (T.P.S.) N 15 Fuel V a p o r C an ister

C5 ECM harness g rou nd D C oo lan t te m p e ra tu r e

C6 Fuse panel F V ehicle speed (V.S.S.)

C8 Fuel pu m p te s t co nn ecto r J Electronic Spark C ontrol Knock (E.S.C.)

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

Figure 1-6 - Component Locations - 4.3L (CK Series)


1-10 GENERAL INFORMATION

' G ' series r p o :LB4 e n g i n e c o d e :Z 4 .3 L V6

COMPUTER C O M M A N D Q 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 diagn ostic co nn ecto r B Exhaust o x yg e n N9 A ir Pum p
C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle position (T.P.S.) N 1 5 Fuel V a p o r C an iste r
C5 ECM harness g ro u n d D C oo lan t te m p e ra tu re
C6 Fuse p a n el F V ehicle speed (V.S.S.)
C8 Fuel p u m p te s t co n n ecto r J Electronic Spark C on trol Knock (E.S.C.)

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

14 Transm ission d o w n s h ift re la y (T H M -4 0 0 o n ly) 7 -8 -8 8

Figure 1-7 - Component Locations - 4.3L (G Series)


GENERAL INFORMATION 1-11

' M ' SERIES r p o :LB4 ENGINE CODE. Z 4 .3 L V 6

COMPUTER C O M M A N D O ECM INFORMATION EMISSION COMPONENTS


CONTROL SENSORS (NOT ECM CONTROLLED)
C1 E lectronic 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)

C2 ALDL diagn ostic co nn ecto r B E xhaust o x y g e n N9 A ir Pum p

C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle p o sitio n (T.P.S.) N 15 Fuel V a p o r C an ister

C5 ECM harness gro u n d D C o o lan t te m p e ra tu r e

C6 Fuse panel F V ehicle speed (V .S .S .)


C8 Fuel pu m p te s t co nn ecto r J Electronic Spark C on trol Knock (E.S.C.)

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

Figure 1-8 - Component Locations - 4.3L (M Series)


1-12 g e n e r a l I n f o r m a t io n

' C / K ' s e rie s rp o :L 05 e n g in e c o d e :H /K 5 .0 / 5 .7 L V 8

COMPUTER C O M M A N D Q ECM INFORMATION ; ' j 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 n n ecto r B E xhaust o x y g e n N2 Fuel M o d u le (5 .7 L H .D . o n ly )
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 iste r
C6 Fuse p a n el F Vehicle speed (V.S.S.)
C8 Fuel p u m p te s t co nn ecto r J Electronic Spark C o n tro l Knock (E.S.C.)

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 )

Figure 1-9 - Component Locations - 5.0L/5.7L (CK Series)


GENERAL INFORMATION 1-13

'G ' s e r i e s rpo:L03/L05 e n g in e c o d e : H/K 5.0/5.7L V8

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)

C2 ALDL diagnostic co nn ecto r B E xhaust o x y g e n N2 Fuel M o d u le (5 .7 L o n ly )

C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle position (T.P.S.) N9 A ir Pum p

C5 ECM harness g rou nd D C o o lan t te m p e ra tu r e N 15 Fuel V a p o r C an ister

C6 Fuse panel F V ehicle speed (V .S .S .)


C8 Fuel pu m p te s t co nn ecto r J Electronic Spark C o n tro l Knock (E.S.C.)

] 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)

Figure 1-10 - Component Locations 5.0L/5.7L (G Series)


1-14 GENERAL INFORMATION

' R / V ' SERIES r p o :L05 e n g i n e c o d e :K 5 .7 L V 8

COMPUTER C O M M A N D O ECM INFORMATION I'"; 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 diagn ostic co nn ecto r B Exhaust o x y g e n N2 Fuel M o d u le (5 .7L H .D . o n ly )
C3 "SERVICE ENGINE S O O N " lig h t C T h ro ttle position (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 J Electronic Spark C on trol Knock (E.S.C.)

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-<

Figure 1-11 - Component Locations - 5.7L (RV Series)


GENERAL INFORMATION 1-15

'P ' SERIES r p o :L05 e n g i n e c o d e :K 5.7 L V 8

A
.A

,T

IiH c T |; N2 j| C3 I C6

C8

LT
-H

COMPUTER C O M M A N D O ECM INFORMATION EMISSION COMPONENTS


3
CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic C o n tro l 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 n n 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 p o 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 15 Fuel V a p o r C an ister

C6 Fuse p anel F V eh icle sp eed (V.S.S.)


C8 Fuel pu m p te s t co n n ecto r J E lectronic Spark C on trol Knock (E.S.C.)

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

Figure 1-12 - Component Locations 5.7L (P Series)


1-16 GENERAL INFORMATION

'C / K & RN ' SERIES rp o :L 19 e n g in e c o d e : N 7 .4 L V 8

.....
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

Figure 1-13 - Component Locations - 7.4L (CK & RV Series)


GENERAL INFORMATION 1-17

'G ' s e r i e s rpo:L19 e n g in e c o d e :N 7.4L V8

COMPUTER C O M M A N D O ECM INFORMATION i 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 diagn ostic co n n 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 p o sitio n (T.P.S.) N9 A ir P um 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 V ehicle sp eed (V .S .S .)


C8 Fuel pu m p te s t co nn ecto r

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

Figure 1-14 - Component Locations 7.4L (G Series)


1-18 GENERAL INFORMATION ------------------------- -----------------------

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

Visually (physically) Check: C heck com p ressio n . See S ectio n " 6 A of


- Vacuum hoses for spits, kinks, and proper appropriate Service Manual.
connections, as shown on Vehicle Em ission Check TCC for proper operation. See Section "10.
Control Information label. Use "Scan tool if available.
- Ignition wires for cracking, hard n ess, and Check for dragging brakes.
proper connections. Suggest owner fill fuel tank and recheck fuel
Check ignition timing. See Emission Control economy.
Information label. Check for exhaust system restriction. See Section
Remove spark plugs. Check for cracks, wear, "3.
im proper gap, burned electrodes or heavy
deposits. Repair or replace, as necessary.

ECM INTERMITTENT CODES OR PERFORMANCE


Problem may or may not turn "ON the "Service Engine Soon light, or store a code.

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

EXCESSIVE EXHAUST EMISSIONS OR ODORS


Definition: Vehicle fails an emission test. May also have excessive "rotten egg smell
(hydrogen sulfide). Excessive odor does not necessarily indicate excessive emissions.
Perform "System Check in Section "3. If the system is running rich, (block learn less
IF TEST SHOWS EXCESSIVE CO AND HC, (or than 118), refer to "Diagnostic Aids on facing
also has excessive odors): page of Code 45 in Section "3.
Check items which cause engine to run RICH. IF TEST SHOWS EXCESSIVE NOx:
Make sure engine is a t n o rm al o p e ra tin g
Check items which cause engine to run LEAN,
temperature.
or to run too hot.
CHECK: - EGR valve for not opening. See "EGR System
- Fuel pressure. See CHART A-6, in Section "3. Check in Section "9.
- Incorrect timing. See "Vehicle Emission Control - Vacuum leaks.
Information label on vehicle. - Remove carbon with top engine cleaner. Follow
- Canister for fuel loading. See Section "5. instructions on can.
- PCV valve for being plugged or stuck, or blocked - Check ig n itio n tim in g for ex cessiv e base
PCV hose. See Section "11. advance. See "V ehicle E m issio n C ontrol
- S p ark p lu g s, p lu g w ire s , a n d ig n itio n Information label on vehicle.
components. - Coolant system and coolant fan for proper
- Check for lead co n tam in atio n of c a ta ly tic operation.
converter (look for removal of fuel filler neck If the system is ru n n in g lean, (block learn
restrictor). greater than 138), refer to "Diagnostic Aids on
- Presence of fuel in crankcase. facing page of Code 44 in Section "3.
- Check for improperly installed fuel cap. See
Section "4.
HARD START
Definition: Engine cranks OK, but does not start for a long
time. Does eventually run, or may start but immediately dies.
CHECK:
For water contaminated fuel. 4. Connect a rad iato r test pump to the line and
Fuel pressure. See Section "3, CHART A-6. apply 103 kPa (15 psi) pressure. If the pressure
TPS for sticking or binding. See Section "4. will hold for 60 seconds, the check valve is OK.
EGR operation. See Section "9. Long cranking time but eventually runs. Refer to
Fuel pump relay - Connect test light between Section "3, CHART A-3, "Engine C ranks but
pump "test term inal and ground (S/T or M Van) Will Not Run.
or between fuel pump connector CKT 120 and Check ignition system for:
ground (C,K,R,V,G,& P). Light should be "ON, Proper output, with J-26792 (ST-125).
for 2 seconds, following ignition "O N . See Worn shaft.
CHART A-5 in Section "3. Bare and shorted wires.
On 7.4L, and some 5.7L engines, a fuel module Pickup coil resistance and connections.
circuit will run the fuel pump for 20 seconds, Loose ignition coil ground.
following ignition "ON. If this circuit is not Moisture in distributor cap.
functioning, this may cause a hot, hard start S p ark p lu g s, w et p lu g s, c ra c k s, w ear,
condition. See Section "3, CHART A-5. improper gap, burned electrodes, or heavy
For a faulty in-tank fuel pump, check valve, deposits.
which would allow the fuel in the lines to drain If engine starts, but then im m ediately stalls,
back to the tank after the engine is stopped. To open d istributor bypass line. If engine then
check for this condition: starts, and runs OK, replace distributor pickup
1. Ignition "OFF. coil.
2. Disconnect fuel line at the filter. See Section H ard start, with engine at norm al operating
"4. temperature. See C rank Signal Diagnosis, in
3. Remove the tank filler cap. See Section "4. Section "3.
Check CKT 423 (EST) for short to ground.
DRIVEABILITY SYMPTOMS 2-5

SURGES AND/OR CHUGGLE


Definition: Engine power variation under steady throttle or
cruise. Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal.
Use a "Scan tool to make sure reading of VSS TCC Operation. See Section "10.
matches vehicle speedometer. See Code 24 in Inspect Oxygen sensor for silicon contamination
Section "3. from fuel, or use of improper RTV sealant. The
CHECK: sensor may have a white, powdery coating and
result in a high but false signal voltage (rich
- For interm ittent EGR at idle. See Section "9. exhaust indication). The ECM will then reduce
- Ignition timing. See "Vehicle Emission Control the am ount of fuel delivered to the engine,
Information label. causing a severe driveability problem.
- Inline fuel filter for d irt or restriction. See
Remove spark plugs. Check for cracks, wear,
CHART A-6 in Section "3.
im proper gap, burned electrodes, or heavy
- Fuel pressure. See CHART A-6 in Section "3.
deposits. Also, check condition of distributor
- Generator output voltage. Repair, if less than 9
cap, rotor, and spark plug wires.
volts or more than 16 volts.

LACK OF POWER, SLUGGISH, OR SPONGY


Definition: Engine delivers less than expected power. Little or
no increase in speed when accelerator pedal is pushed down part way.
Compare custom ers vehicle to sim ilar unit. EGR operation for being open or partly open all
Make sure the customers vehicle has an actual the time. See Section "9.
problem. Generator output voltage. Repair if less than 9
Remove air cleaner and check air filter for dirt, or more than 16 volts.
or for being plugged. Replace as necessary. Engine valve timing and compression.
Refer to Section "12. Engine for proper or worn camshaft.
If there is spray from only one injector, then, Transmission torque converter operation. See
there is a malfunction in the injector assembly, Section "7A.
or in the signal to the injector assembly. The Secondary ignition voltage, using a scope or ST-
malfunction can be isolated, by switching the 125.
injector connectors. If the problem remains with Proper operation of EST. See Section "6.
the original in jecto r, a fte r sw itch in g the Check exhaust system for restriction:
connector, the injector is defective. Replace the 1. W ith e n g in e a t n o rm a l o p e r a t in g
injector. If the problem moves with the injector temperature, connect a vacuum gage to any
connector, the problem is an improper signal in convenient vacuum port on intake manifold.
the injector circuit, see CHART A-3 in Section 2. Run engine at 1000 rpm and record vacuum
"3. reading.
3. Increase rpm slowly to 2500 rpm. Note
CHECK: vacuum reading at steady 2500 rpm.
Ignition timing. See "Vehicle Emission Control 4. If vacuum at 2500 rpm decreases more than
Information label. 3, from reading at 1000 rpm, the exhaust
For restricted fuel filter, contaminated fuel or system should be inspected for restrictions.
improper fuel pressure. See CHART A-6 in 5. Disconnect exhaust pipe from engine and
Section "3. repeat steps 3 & 4. If vacuum still drops,
ECM grounds. Refer to Section "1. more than 3 with exhaust disconnected,
Injector wires for short to ground at Air Cleaner. check valve timing.

DETONATION / SPARK KNOCK


Definition: A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change with throttle opening.
Check for obvious overheating problems. - Restricted air flow to radiator, or restricted
Low coolant. water flow thru radiator.
Loose water pump belt. - Faulty or incorrect therm ostat.
2-6 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.

HESITATION, SAG, STUMBLE


Definition: Momentary lack of response, as the accelerator is
pushed down, can occur at all vehicle speeds. Usually, most severe,
when first trying to make the vehicle move, as from a stop sign.
May cause the engine to stall, if severe enough.
Perform careful visual (physical) check as For correct PROM/Cal-Pak
described at start of Section "2. TPS for binding or sticking.
CHECK: Generator output voltage. Repair if less than 9
or more than 16 volts.
Fuel pressure. See CHART A-6 in Section "3. For open HEI ground, CKT 453. See Section "6.
Water contaminated fuel. Canister purge system for proper operation. See
Ignition timing. See "Vehicle Emission Control Section "5.
Information label. EGR valve operation. See Section "9.
CUTS OUT, MISSES
Definition: Steady pulsation or jerk in g th a t follows engine
speed, usually more pronounced as engine load increases. The
exhaust has a steady spitting sound at idle or low speed.
Check for missing cylinder by: CHECK:
1. Disconnecting IAC motor. S tart engine. - Spark plug wires by connecting ohmmeter to
Remove one spark plug wire at a time, using ends of each wire in question. If meter reads
insulated pliers. over 30,000 ohms, replace wire(s).
2 . If there is an rpm drop on all cylinders
- Ignition coil and secondary voltage using spark
(equal to within 50 rpm), go to "ROUGH, tester J-26792 (ST-125), or equivalent.
U NSTA BLE, OR INCORRECT ID LE, - For restricted fuel filter. Also check fuel tank for
STALLING symptom . Reconnect IAC water. See Section "4 for location.
motor. - For low fuel pressure. See CHART A-6 in
3. If there is no rpm drop on one or more Section "3.
cylinders, or excessive variation in drop, - Check for proper valve timing.
check for spark on the suspected cylinder(s) Perform compression check on q u estio n ab le
with J 26792 (ST-125) Spark Gap Tool or cylinder(s) found above. If compression is low,
equivalent. If no spark, see Ignition Section repair as necessary.
"6. If there is spark, remove spark plug(s) Visually check distributor cap and rotor for
in those cylinders and check for: moisture, dust, cracks, burns, etc. Spray cap and
Cracks plug wires with fine water m ist to check for
Wear shorts.
Improper gap Remove rocker covers. Check for bent pushrods,
Burned electrodes worn rocker arms, broken valve springs, worn
Heavy deposits camshaft lobes.
P e rfo rm c o m p re s s io n ch ec k on
questionable cylinder.
COMPUTER COMMAND CONTROL 3-1

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

The Computer Command Control system has a 11 ______


computer (electronic control module) to control the F E C B A
o o
fuel delivery, ignition timing, some emission control G H M
b! J
systems and engagement of the transmission TE R M IN A L IDENTIFICATION
converter clutch, downshift control or the manual
GROUND [7 ] TCC (|F U 5 E D )
transmission shift light.
The system , th ro u g h the E lectronic Control D IA G N O STIC TE R M IN A L r~]
Module (ECM), m onitors a num ber of engine and H
[71 A.I.R. (IF U SED)
| G I FUEL P U M P (CK)
|------ ,
1------ 1 [ h I BRAKE SENSE
vehicle functions (F igure 3-1) and controls the
SERIAL D A TA (V 6 /V 8 ) SPEED IN PU T (CK)
following operations: SERIAL D A TA (L4)
(SEE SPECIAL TOOLS) M
Fuel control (SEE SPECIAL TO OLS)
Ignition/electronic spark timing *7 S 35 41-6 E
6 -2 -8 7
Electronic spark control
Figure 3-2 - ALDL Connector
Air management
Exhaust gas recirculation This connector has term inals th a t are used to
Torque converter clutch, downshift control or diagnose the system either with jum per wires or a
manual transmission shift light "Scan tool.
The diagnosis in this section is provided when a The following term inals are used:
"Scan tool to interface with the Computer Command A - This term inal provides a ground circuit to other
Control system is available. If a "Scan tool is not terminals.
available, refer to Section "15 for diagnosis. B - This term inal is the "diagnostic term inal for the
ECM. When grounded to "A term in al, the
ALDL Connector "Service Engine Soon light will flash codes (key
(Figure 3-2) "ON and engine "OFF) entering the diagnostic
The Assembly Line D iagnostic Link (ALDL) mode or flashes a field service mode (engine
twelve terminal connector is wired to the ECM and is running) to determine if system is in a "Closed
located under the instrum ent panel in the passenger or "Open Loop operation.
compartment.

* OPERATING C O N D ITIO N S SENSED * SYSTEMS CONTROLLED

A/C " O n " or " O ff"


A ir M a n a g e m e n t
Engine C o o lan t " T e m p e ra tu re "
E xhaust Gas R ecirculation (EGR)
Engine Crank Signal
Electronic Spark T im in g (EST)
E xhaust 0 x y g e n ( 0 2) Sensor
Fuel C on trol
D istrib u to r R efe re n ce
Idle A ir C ontrol (IAC)
C ra n ks h aft Position
Electric Fuel Pum p
Engine S peed (R PM )
Transm ission C o n v e rte r C lutch (TCC),
M a n ifo ld A b s o lu te Pressure (M A P ) ELECTRONIC
D o w n s h ift C ontrol or M a n u a l
Park N e u tra l S w itc h (P /N ) Position (EN G IN E)
Transm ission S h ift Light
System V o lta g e CONTROL
A ir C on ditioning
T h ro ttle P osition (TPS) M O D U LE
D iagnostics
Transm ission G ea r Position (E C M )
"Service Engine S oo n" Light
Vehicle S peed (VSS)
D iagnostic T e rm in a l (A LD L)
Fuel Pum p V o lta g e
D a ta O u tp u t (ALDL)
P o w e r S tee rin g Pressure
Electronic Spark C on trol (ESC)
EGR V acuum
E -C e ll-2 .8 L
Engine Knock (ESC)
M a n ifo ld A ir T e m p e ra tu re (M A T ) * All system s n o t used on all en g in es.

6 -2 5 -8 7

*7 S 35 37-6 E

Figure 3-1 - Computer Command Control System


COMPUTER COMMAND CONTROL 3-3

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

ECM w ill becom e in o p e ra tiv e if its


te m p e ra tu re ex ceed s 185F (85C).
T h ere fo re , it is re c o m m e n d e d th a t
temporary insulation be placed around the
ECM during the time the vehicle is in a
paint oven or other high te m p e ra tu re
processes.
There are two types of ECMs used in light duty
trucks.
A vehicle equipped with a 4 cylinder engine has an
ECM (referred to as GMP4) with two parts for service.
A controller (an ECM without a Mem-Cal) and a Mem-
Cal (Memory and Calibration unit).
All vehicles with a V6 or V8 cylinder engine have

ACCESS COVER
0
M E M /C A L an ECM (referred to as GMCM) with three parts for
6S 25 48-6E service. A controller (an ECM without a PROM), a
Figure 3-3 - Electronic Control Module (L4) PROM with specific program in fo rm atio n for an
engine and vehicle and a C alP ak w ith specific
calibration information.

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.

NOTICE: The ECM m u st be m a in ta in e d a t a m ECM m PROM CARRIER

tem perature below 185F (85C) a t all m PROM (ENGINE CALIBRATOR) d l C A LP AK


4S 1217-6E
times. This most essential if the vehicle is
put through a paint baking process. The Figure 3-5 - PROM and CalPak (V6 & V8)
COMPUTER COMMAND CONTROL 3-5

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

Fuel delivery is controlled by the Computer Command


Control system. The general descrip tio n of fuel
control is in Section "4. This includes the fuel
injector, pressure regulator, idle air control valve and
the fuel pump electrical circuit.

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

2 HARNESS CONNECTOR TO ECM

4 -2 -8 5 3 LOCKING TAB * 5 S 16 40-6 E A

Figure 3-6 - Coolant 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.

Figure 3-11 - Manifold Air Temperature Sensor - L4


Throttle Position Sensor
(Figure 3-9 or 10)
The Throttle Position Sensor (TPS) is connected to Vehicle Speed Sensor
th e th r o ttle s h a ft on th e TBI u n it. It is a
potentiometer with one end connected to 5 volts from The Vehicle Speed Sensor (VSS) located behind
the ECM and the other to ground. A th i r d w ire is the speedometer or on the transm ission on "CK or
connected to the ECM to measure the voltage from the "P series, sends a pulsing voltage signal to the ECM,
TPS. As the th r o ttle v alv e an g le is ch anged which the ECM converts to miles per hour. This
(accelerator pedal moved), the output of the TPS also sensor mainly controls the operation of the TCC
changes. At a closed throttle position, the output of system, shift light, and cruise control.
COMPUTER COMMAND CONTROL 3-7

Knock Sensor Power Steering Pressure Switch Signal

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.

Crank Signal Transmission Gear Position Signal

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

If the diagnostic term inal "B, in ALDL connector, is


grounded with the ignition "ON and the engine
stopped, the system will enter the diagnostic mode.
IG N IT IO N " O N ," ENGINE STOPPED. With the key "ON and the engine "OFF, jumper
IS THE "SERVICE ENGINE S O O N " (SES)
LIGHT FLASHING CODE 12?
ALDL terminals "B to "A. The "Service Engine
Soon light should flash Code 12 to indicate that the
diagnostic system is working. Code 12 consists of "one
YES
flash followed by a pause and then "two flashes. The
NO
code will repeat for a total of three tim es and will
zc H continue to repeat if there are no other codes stored.
IS THE "SERVICE CHECK FOR G R O U N D ED
ENGINE S O O N " (SES) CKT 4 5 1 . SEE W IRING
This procedure can also be done with some "Scan
LIGHT " O N " STEADY? D IA G R A M FOR CHART tools.
A -1 . If Code 12 does not display, refer to CHART A-2.
A flashing Code 12 does not mean an engine problem;
it simply means that the diagnostic mode is working.
YES NO Any other stored codes (Figure 3-16) will begin to
flash after Code 12.
JUMPER ALDL | SEE CHART A-1
TE R M IN A L "B " TO " A " . i IN SECTION " 3 " . i
Field Service M ode
DOES SES LIGHT FLASH
CODE 12?
If the diagnostic term inal "B is grounded with the
engine running, the system will enter the field service
YES NO mode. In this mode, the "Service Engine Soon light
HZ , ^ T T - --------------- will show whether the system is in "Open or "Closed
j SEE CHART A-2 j
DOES "S C A N " DISPLAY Loop and fuel sytem is operating normally.
ECM DATA? i IN SECTION " 3 " . i
I____________ I
"Scan" Tool
YES NO
HZ rrr A "Scan tool is designed to interface with the
DOES ENGINE START? SEE CHART A-2 Computer Command Control system. It supplies a
IN SECTION " 3 " visual reading of most inputs to the ECM and some
outputs. Review the tool in stru c tio n m anual to
understand its operation and limitations.
YES NO
C onnect a " S c a n tool to th e ALDL an d
in cigarette/cigar lighter connector or 12 volts and there
ARE A N Y CODES SEE CHART A-3 J
DISPLAYED? i IN SECTION " 3 " . i should be a visual instruction displayed. If there is no
I____________ I display or tool reads "No DATA or No ALDL with
ignition "ON, refer to CHART A-2.
YES NO With the tool in the code position, the display
window will indicate any code stored in the ECM
REFER TO APPLICABLE CHECK "S C A N " DA TA FOR memory (Figure 3-16). Referring to the applicable
CODE CHART. START TYPICAL VALUES. REPAIR code chart, the tool will "Scan an input to determine
W ITH LOW EST CODE. AS NECESSARY. IF ALL
if a specific circuit is operating properly. If there are
OK, SEE "DRIVEABILITY
S Y M P T O M S " IN SECTION no codes, the system check is completed. Additional
" 2" . information on "Scan tools is in Section "13.
If there are additional driveability symptoms,
refer to Section "2.
If there are additional codes, refer to applicable
code chart.

Engine Does Not Start

8 -3 -8 8 If the engine cranks but will not start, refer to


7S 3 5 3 8 -6 E
CHART A-3 through A-6 to determine if there is a fuel
Figure 3-12 - System Check or ignition problem.
COMPUTER COMMAND CONTROL 3-9

Code System indicates th a t the ECM has failed and m ust be


(Figure 3-16) replaced.
The ECM is equipped with a self-diagnosis system If the ECM has been replaced and the condition
which detects system failure and aids the technician was not corrected, the following information may be
in locating the circuit at fault via a code. the cause:
The ECM is really a computer. It uses sensors to An in c o r r e c t ECM or P R O M /M e m -C al
look at many engine operating conditions. It has a application may cause a malfunction and may
memory and it knows what a certain sensor reading or may not set a code.
should be under certain conditions. These conditions If the connector at the ECM is the possible
are described on the facing page of each code chart. If problem, the term inal may have to be removed
a sensor reading is not what the ECM thinks it should from the connectors in order to properly check
be, the ECM will turn "ON the "Service Engine Soon them.
light on the instrum ent panel, and will store a code in Although the PROM/Mem-Cal rarely fails, it
the memory. The code tells which circuit the trouble operates as part of the ECM, therefore, it could
is in. A circuit consists of a sensor, such as coolant be the cause of the problem.
tem perature, the wiring and connectors to it, and the Although a rare condition, the replacem ent
ECM. ECM may be faulty.
An "interm ittent code is one which does not reset In the case of an interm ittent problem, refer to
itself, and is not present while you are working on the Section "2 and m ake a c a re fu l p h y sical
vehicle. This is often caused by a loose connection. inspection of the system involved.
The facing page of a code chart will contain diagnostic A shorted solenoid, relay coil or harness may
aids to help in detecting interm ittents. cause an ECM to fail and a replacement ECM to
A "hard code is one which is present when you are fail when it is installed. Use a short tester
working on the vehicle and the condition still exists J34636, BT 8405, or eq u iv alen t as a fast,
while working on the vehicle. The chart with the accurate means of checking for a short circuit.
stored code number will lead you to the cause of the Refer to ECM quad driver (QDR) check before
problem. replacing ECM. (Figure 3-18)

Clearing Codes ECM Quad Driver (QDR) Check

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

Engine misfires, surges or stalls. Idle Air Control


"Scan tool is erratic or inoperative.
The diagnosis of idle air control can be found in
The ECM used with an L4 engine has IC circuits Code 35 chart for 2.5L engine and Section "4 for all
that are fault protected, therfore, if a circuit has other engines.
failed, the IC may not be damaged and will keep the If the IAC valve is disconnected or connected with
circuit open until the fault in the circuit has been the engine running, the idle rpm may be wrong. In
corrected. W hen the fau lt has been co rrected , this case, on engines with TBI 220 units, the IAC
reinstall ECM and check circuit. Replace ECM only if valve may be reset by tu rn in g the ignition switch
the circuit is still inoperative. "ON and "OFF one time. On engines using a TBI
700 unit, the idle rpm is reset at a speed above 30 mph
PROM (48 km/hr).
The IAC valve affects only the idle characteristics
A PROM th a t has failed or was in s ta lle d of the engine. If it is open fully, too much air will be
improperly will generally set a Code 51. allowed in the manifold and idle speed will be high. If
it is stuck closed, too little air will be allowed in the
Mem-Cal manifold, and idle speed will be too low. If it is stuck
part way open, the idle may be rough, and will not
A Mem-Cal th a t has failed or was in sta lle d respond to engine load changes.
improperly will set a Code 51.
Fuel Pump Circuit
CalPak
Code 54 indicates a failure in th e fuel pump
A no start and run condition will resu lt if the circuit.
CalPak is not installed in the ECM. A CalPak that is Two types of fuel pump relays are used on light
removed will set a Code 52. duty trucks. The "S,T and "M series use one type
and "C, K, R, V, G and "P series use the other type.
FUEL CONTROL Both relays have the same function, but term inals
arrangem ent is different. Both relays have a term inal
Fuel delivery is controlled by the C om puter to test the fuel pump operation. This is eith er a
Command Control system. separate term inal located near the relay or along the
The diagnosis of fuel control starts with "Engine ECM h arn ess or a t te rm in a l "G in th e ALDL
Cranks But Will Not Run CHART A-3. This chart connector. By applying voltage at this term inal, it can
will test the fuel system and if there is a problem, will be determined if the fuel pump will operate. This
lead you to checking the fuel pump relay circuit, term inal will also prime the fuel line to the TBI unit.
diagnosing the injector circuit or diagnosing the fuel Refer to CHART A-5 or A-5A for diagnosis of fuel
system. pump relay circuit.
An inoperative fuel pump would cause a no start
Fuel Injector condition. A fuel pump which does not provide enough
pressure can result in poor performance.
Testing the fuel injector circuit is in CHART A-3 An inoperative fuel pump relay can result in long
and additional diagnosis in CHART A-4. cranking times, particularity if the engine is cold. The
A fuel injector which does not open may cause a oil pressure switch will turn "ON the fuel pump, as
no-start condition. An injector which is stuck partly soon as oil pressure reaches about 28 kPa (4 psi).
open, could cause loss of pressure after sitting, so long
crank times would be noticed on some engines. Also, Fuel M odule
dieseling could ocur because some fuel could be
delivered to the engine after the key is turned "OFF. On a 7.4L engine or a G Van with a 5.7L engine
and all other 5.7L engines over 8500 GVW, a fuel
Pressure Regulator module will override the ECM two second tim er and
the fuel pump will run for twenty seconds and then
T estin g the p ressu re re g u la to r circ u it is in shut "OFF if the vehicle is not started. This circuit
CHART A-3 and A-4. corrects a hot re s ta rt (vapor lock) d u rin g a high
If the pressure regulator in the TBI supplies ambient condition.
pressure which is too low (below 62 kPa or 9 psi), poor
performance could result. If the pressure is too high, Fuel M odule Check
unpleasant exhaust odor may result.
1. Disconnect the fuel module. (CHART A-5 OR A-
5A)
COMPUTER COMMAND CONTROL 3-11

2. W ith a te st lig h t and ig n itio n "O N , probe


connector term inal "C to ground. Circuit is OK if
light is "ON. There is an open if the light is
"OFF.
3. Probe connector term inals "C to "D w ith test
light. Circuit is OK if light is "ON . There is an
open in ground circuit if light is "OFF.
4. Ignition "OFF. Probe connector term inals "A to
"D with test light. Ignition "ON, te st light
should illum inate for two seconds. There is an
open in the circuit if the light is "OFF.
5. Replace fuel module if there is no twenty second
fuel pump operation.

Fuel Pump Circuit


(Tw o Fuel Tanks)
A quick check can be made by pressing fuel tank
selector switch with the ignition "ON and listening
for movement of the selector valve. Note th a t the m FUEL TANK SELECTOR SWITCH
selector switch is part of the fuel pump relay circuit, f T l FUEL PUMP CONNECTOR
A TAN WIRE TO LEFT FUEL PUMP
therefore, the valve will only operate for two seconds B GRAY WIRE TO RIGHT FUEL PUMP
or twenty if equpped with a fuel module. f T l TAN/WHITE WIRE TO FUEL PUMP RELAY
Refer to CHART A-5A for the diagnosis of the fuel |~ 4 l BLACK GROUND WIRE TO FUEL TANK SELECTOR
pump relay circuit. SWITCH
If the problem is "Engine Cranks But Will Not fTl FUSE PANEL
Run, this diagnosis is used because there is no fuel m BUS BAR GROUND
pump operation and will determine if the electrical
8S4332-6E
system is operating.
The circled num bers on CHART A-5A refer to Figure 3-13 - Fuel Tank Selector Switch
information provided below: 2. Disconnect fuel tank selector valve and m eter
1. This procedure applies direct voltage to run switch connector (Figure 3-14).
the fuel pump. Toggling the fuel tank selector 3. Apply 12 volts to the fuel pump test term inal at
switch will test the operation of each fuel tank the fuel pump relay.
pump. 4. Connect a test light between term inals "E and
2. If neither pump would run, the contacts inside "D on the selector valve connector and move
the relay or fuel tank selector switch may be selector switch from top to bottom positon. Light
inoperative. Check single connector (Figure should be "ON in both positions.
3-13) tan/white wire to the fuel pump relay on If light is "OFF in both positions, check for
the cowl.Check the two term inal connector open in that circuit or faulty switch.
(Figure 3-13) tan and gray wire to the fuel If light is "OFF in one position, check for open
pumps. in th at circuit or a faulty switch.
3. This step checks voltage from the battery and If light is "ON in both positions, check fuel
the ground circuit to the relay. gage circuit.
4. This test determines if there is voltage from 5. Disconnect 12 volts, connect fuel pump connector
the ECM te rm in a l " A l on th e ECM to and check fuel gage.
term inal "D on the relay connector.
5. This completes the fuel pump relay circuit but Checking Fuel Gage
if this diagnosis was used because the engine (Tw o Fuel Tanks)
would not start, then diagnose the oil pressure There should be a different quantity of fuel in the
switch. left and right fuel tanks. Refer to CHART A-5A for
electrical circuit.
Fuel Tank Selector Diagnosis 1. Disconnect fuel tan k selector valve and m eter
(Tw o Fuel Tanks) switch connector. (Figure 3-14)
A quick check can be made by listening for the 2. Ignition "ON.
selector valve operation when pressing fuel tan k 3. Jum per term inals "A and "B on the selector
selector switch and the ignition "ON. valve connector. Fuel gage should indicate
Checking selector valve circuit - CHART A-5A: quantity of the right fuel tank.
1. Disconnect fuel pump connector (Figure 3-13).
3-12 COMPUTER COMMAND CONTROL

rn GROUND WIRE LEFT UNIT


|~ 2 l CAM
I 3 I LEFT FUEL PUMP AND SENDING
UNIT
f~4~l " 0 RING SEAL
m LEFT UNIT CONNECTOR
rn GAGE
REAR LAMP CONNECTOR PINK WIRE FROM FUEL
TO FUEL TANK SELECTOR VALVE AND
I 6 | RIGHT UNIT CONNECTOR METER SWITCH
m GROUND WIRE RIGHT UNIT I 2 | LEFT FUEL PUMP AND SENDING UNIT CONNECTOR
[T ] RIGHT FUEL PUMP AND m LEFT FUEL PUMP AND SENDING UNIT CONNECTOR
SENDING UNIT f~4~j LEFT GROUND WIRE
I 9 I RIGHT FUEL TANK
m FUEL TANK SELECTOR VALVE
AND METER SWITCH
I 5 I RIGHT FUEL PUMP AND SENDING UNIT
CONNECTOR
I 6 I RIGHT GROUND WIRE
flTI SELECTOR VALVE AND
F T ] RIGHT FUEL PUMP AND SENDING UNIT
METER SWITCH CONNECTOR
O H LEFT FUEL TANK 8 S 4 3 3 4 -6 E
8S4333-6E

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.

TBI 220 (2.8L Engine) EGR SYSTEM

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

ELECTRONIC SPARK TIMING The crank signal diagnosis procedure is on page 3-


78 of this section. If there is no crank signal to the
When the system is ru n n in g on the ig n itio n ECM, the engine may be hard to start.
module, that is, no voltage on the bypass line, the
ignition module grounds the EST signal. The ECM POWER STEERING PRESSURE SWITCH
expects to see no voltage on the EST line during this
condition. If it sees a voltage, it sets Code 42 and will The diagnosis of the power steerin g p ressu re
not go into the EST mode. switch is covered on page 3-80 of this section.
When the rpm for EST is reached (about 400 rpm),
and bypass voltage applied, the EST should no longer DISTRIBUTOR REFERENCE SIGNAL
be grounded in the ignition module so the EST voltage
should be varying. The d istributor reference signal is covered in
If the bypass line is open or grounded, the ignition Section "6 of the ignition system and electronic spark
module will not switch to EST mode so the EST control.
voltage will be low and Code 42 will be set.
If the EST line is grounded, the ignition module A/C CLUTCH CONTROL
will switch to EST, but because the line is grounded
there will be no EST signal. A Code 42 will be set. The diagnosis of the A/C clutch control on a 2.5L
Code 42 sets if there is an open or a short to ground engine is covered on page 3-82 of this section and on
in the EST or bypass circuit. 2.8L engine on page 3-86.

ELECTRONIC SPARK CONTROL A/C "O N" 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

Sets if the sensor, Code 35 - IAC IAC error


Code 15 - Coolant Sensor
Low Temperature connections, or wires
Indication open for 3 seconds. Code 42 - EST ECM has seen an open
or grounded EST or
Bypass circuit.
Code 2 1 -TPS TPS voltage greater
than 2.5 volts for 3 Code 43 - ESC Signal to the ECM has
Signal Voltage High
remained low for too
seconds with less than
1200 RPM. long or the system has
failed a functional
A shorted to ground or check.
Code 2 2 -TPS
Signal Voltage Low open signal circuit will
Code 44 Sets if oxygen sensor
set code in 3 seconds.
Lean Exhaust Indication voltage remains below
Sets if the sensor, .2 volts for about 20
Code 23 - MAT
connections, or wires seconds.
Low Temperature
Indication open for 3 seconds.
Code 45 Sets if oxygen sensor
Rich Exhaust Indication voltage remains above
Code 24-V SS No vehicle speed present
during a road load decel. .7 volts for about 1
No Vehicle Speed
minute.
Indication
Code 51 Faulty MEM-CAL,
Code 25 - MAT Sets if the sensor or
High Temperature signal line becomes PROM, or ECM.
Indication grounded for 3 seconds.
Code 52 Fuel CALPAK
missing or faulty.

Code 53 System overvoltage.


Indicates a basic
generator problem.
Code 32 - EGR Vacuum switch shorted
to ground on start up Code 54 - Fuel Pump Sets when the fuel
OR Low voltage pump voltage is less
Switch not closed after than 2 volts when
the ECM has reference pulses are
being received.
commanded EGR for a
specified period of time.
OR Code 55 Faulty ECM
EGR solenoid circuit
open for a specified 6 -2 5 -8 7
period of time. 7S 3 3 37-6 E

Figure 3-16 - ECM Code System


3-16 COMPUTER COMMAND CONTROL

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. If the fuse in holder is blown, refer to facing page If the engine runs OK, check:
of Code 54 for complete circuit. Faulty light bulb.
2. Using a test light connected to 12 volts, probe each CKT 419 open.
of the system ground circuits to be sure a good Gage fuse blown. This will result in no brake
ground is present. See "ECM Terminal End View warning light, oil or generator lights, seat belt
in front of this section for ECM pin locations of reminder, etc.
ground circuits. If the engine cranks but will not run, check:
Continuous battery-fuse or fusible link open.
ECM ignition fuse open.
Battery CKT 440 to ECM open.
Ignition CKT 439 to ECM open.
Poor connection to ECM.
COMPUTER COMMAND CONTROL 3-17

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

. PNK/BLK 4 3 9 IGN FEED


IG N ITIO N
SWITCH r B R N /W H T 4 1 9
BATTERY GAGE FUSE SES LIGHT
r W H T/B LK 451 5-6 V

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

12V 4 3 9 PNK/BLK 4 3 9 RED


TBI U N IT
INJECTOR

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

IF CODE 5 4 IS STORED, USE TH A T CHART FIRST


CHART A-3


IGN " O N " - IF S.E.S. LIGHT IS OFF, SEE CHART A - 1 .
INSTALL "S C A N " TO O L - IF " N O A LD L ", SEE CHART A -2 .
CHECK THE FO LLO W IN G :
ENGINE CRANKS BUT WILL NOT RUN
TPS - IF OVER 2 .5 V A t CLOSED THROTTLE, SEE CODE 21 . 2.5L ENGINE
C O O L A N T - IF BELOW -30C . SEE CODE 15.
IGN. "O F F " FOR 10 SECONDS. IGN " O N " , LISTEN FOR
P U M P TO RUN. DOES IT?

YES NO

DISCONNECT ONE SPARK PLUG W IRE. I SEE FUEL P U M P RELAY


INSTALL A SPARK TESTER (S T -125 OR i CIRCUIT CHART A -5
EQ U IVALENT).
CRANK ENGINE A N D CHECK FOR
SPARK.
IS THERE SPARK?

YES NO

RECONNECT SPARK PLUG W IRE.


DISCONNECT INJECTOR CONNECTOR. \ SEE IG N ITIO N SYSTEM
i CHECK IN SECTION 6
CRANK ENGINE.
IS THERE FUEL SPRAY FR O M INJECTOR?

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 [

CRANK ENGINE. i D IA G N O SIS CHART A -4 i


IS THERE FUEL SPRAY FR O M INJECTOR?

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

482 W H T 481 RED 4 6 7 LT BLU


r
TBI 2 2 0 U N IT
BA
INJECTORS

481 RED

INJ. A 4.3L & V-8 (C, K, G & M SERIES)


12V 7S 3 7 7 7
IGN 1 0 A (7 .5 A M -V A N )
7 -3 0 -8 7 7 -0 7 -8 7

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

IF CODE 54 IS STORED, USE T H A T CHART FIRST

IGN " O N " - IF S.E.S. LIGHT IS OFF, SEE CHART A - 1 .


CHART A-3
INSTALL "SC A N " TO O L - IF "N O A LD L ", SEE CHART A -2 .
CHECK THE FO LLO W IN G :
ENGINE CRANKS BUT WILL NOT RUN
TPS - IF OVER 2 .5 V A T CLOSED THROTTLE, SEE CODE 21. ALL ENGINES EXCEPT2.5L
C O O LA N T - IF BELOW -30C, SEE CODE 15.
IG N . "O FF" FOR 10 SECONDS. IGN. " O N " .
ONE FU E LT A N K :
LISTEN FOR P U M P TO RUN. DOES IT?
T W O FUEL TANKS:
LISTEN FOR P U M P IN EACH TA N K USING SELECTOR
SW ITCH. BOTH PUM PS M U S T RUN.
D O THEY BOTH RUN?

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

NO TROUBLE F O U N D . FAULTY INJECTOR IGN "O FF:.


INSTALL FUEL PRESSURE GAGE, REFER 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?

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

PICK-UP COIL HALL


11) EFFECT
SWITCH

----- 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

482 W H T I 481 RED 4 6 7 LT BLU D 16

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

" 4 3 0 PPL/W HT B5 REFERENCE


JU
~ 4 2 4 TAN/BLK D5 BYPASS

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 .

FUSE LINK (CK)

BATT 4 4 0 ORN ------


12V
OR ECM B
FUSE (RVGP) FUEL PU M P
RELAY
12 V O LT
4 6 5 DK G R N /W H T A1 RELAY
DRIVE
450
BLK/W HT
OIL ~L
PRESS.
SWITCH
120
T A N /W H T B2 FUEL P U M P
SIGNAL
120 T A N /W H T
4 9 0 RED OR 9 2 0 PNK/BLK (CK)
FUEL PU M P
TEST TERM. ------ CK ONLY FUEL PU M P FUSE
OR ALDL (CKG) 20 A (CK O N LY )
FUEL P U M P
(R,V,G & P)

=
(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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. This procedure applies direct voltage to run the An inoperative fuel module may be the cause of a
fuel pump. If the pump runs, it may be a fuel hot stall/no start condition. Check for power and
pump relay circuit problem which the following ground circuit to the fuel module and a complete
step will locate. circuit to the pump from term inal "A. If OK, and
2. This step checks voltage from the battery and the the pump does not run for the specified 20 seconds
ground circuit to the relay. at initial ignition "ON, replace the fuel module.
3. This test determines if there is voltage from the
ECM, term inal "A l, to term inal "D on the relay
connector.
4. This completes the fuel pump relay circuit but if
this diagnosis was used because the engine would
not run then oil pressure switch should also be
diagnosed.
COMPUTER COMMAND CONTROL 3-31

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'

CONNECT A TEST LIGHT BETW EEN REPAIR OPEN


NO YES
HARNESS CONNECTOR TE R M IN A L
C K T S 450 A N D 4 4 0 .
CKT 4 4 0 .
z
REFER TO FUEL
I
N O TROUBLE F O U N D
1
M O D U LE CHECK
1
PROCEDURE.
LIG H T" O N " LIG H T" OFF"

CONNECT TEST LIGHT BETWEEN REPAIR OPEN


TE R M IN A L CKT 4 6 5 A N D G N D . GROUND FUEL M O D U LE IS ON
IG N IT IO N "O FF" FOR 10 CKT 4 5 0 . A L L 7 .4 L ,G V A N W IT H
SECONDS. 5.7L A N D ALL OTHER
IG N IT IO N " O N " . TEST LIGHT 5.7L OVER 8 5 0 0 G V W
S H O U LD LIGHT FOR 2 ENGINES.
SECONDS. DOES IT?

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

....... I ...... ____ L


N O TROUBLE FO U N D FAULTY OIL
PRESSURE SWITCH
8 -4 -8 8
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7 S 3 8 0 5 -6 E
3-32 COMPUTER COMMAND CONTROL

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

FUEL RETURN LINE

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

TBI U N IT THROTTLE BODY MODEL 220 TBI


INJECTORS PRESSURE REGULATOR

FUEL RETURN LINE

T
FLEX HOSE FUEL PRESSURE LINE FU ELC A P

IN -T A N K FUEL PUM P

IN-LINE FUEL FILTER


FUEL PRESSURE
7 S 3 8 0 6 -6 E
8 -4 -8 8 GAGE TEST POINT FU E LTA N K P U M P INLET FILTER
7 -2 9 -8 6

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 13 will set if: Normal "Scan voltage varies between 100 mV to
Engine at normal operating temperature 999 mV (.1 and 1.0 volt) while in "Closed Loop. Code
At least 2 minutes engine time after start. 13 sets in one minute if voltage rem ains between .35
Oxygen sensor signal voltage steady between and .55 volt, but the system will go "Open Loop in
.35 and .55 volt. about 15 seconds. Refer to "ECM Interm ittent Codes
Throttle position sensor signal above 4%. or Performance in Section "2.
All conditions m u st be m et for about 60
seconds.
If the conditions for a Code 13 exist, the
system will not go "Closed Loop.
2. This will determine if the sensor is at fault or the
wiring or ECM is the cause of Code 13.
3 In doing this test, use only a high impedence
digital volt ohm m eter. This test checks the
continuity of CKTs 412 and 413 because if CKT
413 is open the ECM voltage on CKT 412 will be
over .6 volt (600 mV).
COMPUTER COMMAND CONTROL 3-37

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 14 will set if: Check harness routing for a potential short to
S ig n a l v o lta g e in d ic a te s a c o o la n t ground in CKT 410.
te m p e ra tu re above 130C (266F) for 3 "Scan tool displays engine te m p e ra tu re in
seconds. degrees centigrade. After engine is s ta rte d , the
2. This test will determine if CKT 410 is shorted to temperature should rise steadily to about 90C then
ground which will cause the conditions for Code stabilize when therm ostat opens.
14. See "ECM Interm ittent Codes or Performance in
Section "2.
The "Temperature to Resistance Value scale at
the right may be used to test the coolant sensor at
various tem perature levels to evaluate the possibility
of a "slewed (mis-scaled) sensor. A "slewed sensor
could result in poor driveability complaints.
COMPUTER COMMAND CONTROL 3-39

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

210 100 185

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 15 will set if: A "Scan tool reads engine tem perature in degrees
S ig n a l v o lta g e in d i c a te s a c o o la n t centigrade. After engine is started, the tem perature
tem perature less than -44C (-47F) for 3 should rise steadily to about 90C then stabilize when
seconds. therm ostat opens.
2. This test sim u lates a Code 14. If the ECM A faulty connection, or an open in CKT 410 or 452
recognizes the low signal voltage, (high temp.) and will results in a Code 15.
the "Scan reads 130C or above, the ECM and See "ECM Interm ittent Codes on Performance in
wiring are OK. Section "2.
3. This test will determine if CKT 410 is open. There The "Temperature To Resistance Value scale at
should be 5 volts present at sensor connector if the right may be used to test the coolant sensor at
measured with a DVOM. various tem perature levels to evaluate the possibility
of a "slewed (mis-scaled) sensor. A "slewed sensor
could result in poor driveability complaints.
COMPUTER COMMAND CONTROL 3-41

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 21, will set if; A "Scan tool reads thro ttle position in volts.
Engine running Should read about .48 volt (2.8L), .45 to 1.25 volts (on
TPS signal voltage is greater than about 3.5 all others) with throttle closed and ignition on or at
volts idle. Voltage should increase at a steady rate as
All conditions met for 5 seconds. throttle is moved toward WOT.
With throttle closed, the TPS should read less Also some "Scan tools will read throttle angle .0%
than .70 volt. If it doesnt, check adjustment. = closed throttle 100% = WOT.
2. W ith the TPS sensor disconnected, the TPS Refer to Section "2 for "ECM Interm ittent Codes
voltage should go low if the ECM and wiring is or Performance.
OK. "Scan TPS while depressing accelerator pedal
3. Probing CKT 452 with a test light checks the 5 with engine stopped and ignition "ON. D isplay
volts return CKT, because a faulty 5 volts return should vary from below 2.5 volts (2500 mV) when
will cause a Code 21. throttle was closed, to over 4.5 volts (4500 mV) when
throttle is held at wide open throttle position.
COMPUTER COMMAND CONTROL 3-43

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 22, will set if: A "Scan tool reads thro ttle position in volts.
Engine running Should read about .48 volt (2.8L), .45 to 1.25 volts (on
TPS signal voltage is less than about .2 volt for all others) with throttle closed and ignition "ON or at
3 seconds. idle. Voltage should increase at a steady rate as
2. Simulates Code 21: (high voltage) If the ECM throttle is moved toward WOT.
recognizes the high signal voltage the ECM and An open or short to ground in CKTs 416 or 417
wiring are OK. will result in a Code 22.
3. TPS - 2.8L: Refer to "Adjustable TPS Output Refer to Section "2 for "ECM Interm ittent Codes
Check in this section. TPS - except 2.8L: Replace or Performance.
TPS. "Scan TPS while depressing accelerator pedal
4. This simulates a high signal voltage to check for with engine stopped and ignition "ON. D isplay
an open in CKT 417. should vary from below 2.5 volts (2500 mV) when
throttle was closed, to over 4.5 volts (4500 mV) when
throttle is held at wide open throttle position.
COMPUTER COMMAND CONTROL 3-45

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 23 will set if all conditions are met: A "S can tool reads te m p e ra tu re of th e a ir
A signal voltage indicates a m anifold air entering the engine and should read close to ambient
te m p e ra tu re below -30C (-22F) for 12 air tem perature when engine is cold, and rises as
seconds. underhood tem perature increases.
Time since engine start is 1 minute or longer. C arefully check h arn ess and connections for
No VSS (vehicle not moving) possible open CKT 472 or 452.
2. A Code 23 will set, due to an open sensor, wire, or Refer to Section "2 for "ECM Interm ittent Codes
connection. This test will determine if the wiring or Performance.
and ECM are OK. The "Temperature to Resistance Value scale at
3. This will determine if the signal CKT 472 or the 5 the right may be used to test the MAT sensor at
volt return CKT 452 is open. various tem perature levels to evaluate the possibility
of a "slewed (mis-scaled) sensor. A "slewed sensor
could result in poor driveability complaints.
COMPUTER COMMAND CONTROL 3-47

CODE 23
MANIFOLD AIR TEMPERATURE (M A T) SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
2.5L ENGINE

DOES "S C A N " TO O L DISPLAY M A T -30C OR COLDER?

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

OPEN SENSOR OPEN CKT 4 7 2 ,


G R O U N D CIRCUIT, FAULTY C O N N EC TIO N
FAULTY C O N NECTION OR FAULTY ECM.
D IA G N O S TIC A ID
OR FAULTY ECM.
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 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

* * VEHICLE SPEED SIGNAL 4- 4 3 7 BRN A 10 -AAAr- 12v

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 25 will set if: A "S can tool reads te m p e ra tu re of th e a ir
Signal voltage in d ic a te s a m anifold a ir entering the engine and should read close to ambient
te m p e ra tu re below 150C (302F) for 2 air tem perature when engine is cold, and rises as
seconds. underhood tem perature increases.
Time since engine start is 1 minute or longer. Check harness routing for possible short to ground
A vehicle speed is present. in CKT 472.
Refer to Section "2 for "ECM Interm ittent Codes
or Performance.
The "Temperature to Resistance Value scale at
the rig h t may be used to test the MAT sensor at
various tem perature levels to evaluate the possibility
of a "slewed (mis-scaled) sensor. A "slewed sensor
could result in poor driveability complaints.
COMPUTER COMMAND CONTROL 3-51

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

IF A N Y OTHER CODES ARE STORED, DIAGNOSE T H E M FIRST.


CODE 32
IF VEHICLE EXHIBITS A R OUGH OR INCORRECT IDLE, REPAIR
IDLE C O M P LA IN T FIRST. SEE SECTION " 2 " . EGR SYSTEM
2 .5 L & 5 .0 L
o
D ISCONNECT EGR S O LEN O ID V A C U U M HOSE 4.3L (EXCEPT ST)
(M A N IF O L D SIDE).
CHECK V A C U U M SOURCE TO SOLENOID (IF N O T OK, 5.7L (UNDER 8500 G VW )
REPAIR).
CHECK V A C U U M HOSE BETWEEN SOLEN O ID A N D VALVE
FOR RESTRICTIONS.
INSTALL A H A N D HELD V A C U U M P U M P W IT H GAGE ON
M A N IF O LD SIDE OF EGR SOLENOID.
IGN ITION " O N " ENGINE STOPPED.
D IA G N O STIC TE R M IN A L GR OU N D ED .
APPLY V A C U U M .
OSBSERVE EGR VALVE.
VALVE S H O U LD M O V E . DOES IT?

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

RECONNECT EGR SOLENOID. REM O VE EGR


CONNECTOR. EGRVALVE
CONNECT V A C U U M GAGE TO VALVE.
PROBE HARNESS
V A C U U M HOSE AT EGR VALVE, CHECK PASSAGES
CONNECTOR TER M IN A L
ENGINE AT N O R M A L FOR BEING
" A " W ITH A TEST LIGHT
OPERATING TEMP. PLUGGED. IF N O T
TO G R O UND.
PUT TR A N S M IS IO N IN GEAR. PLUGGED REPLACE
LIGHTLY ACCELERATE FROM A EGR VALVE.
STOP.
LIGHT "O N " LIGHT "OFF" OBSERVE V A C U U M GAGE,
I I SHOULD BE LESS TH A N 10"
REPAIR OPEN VACUUM .
CONNECT A TEST LIGHT
BETWEEN HARNESS IN CKT 439
CONNECTOR TERMINALS
"A " & "D ".

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 .

LIGHT " O N ' LIGHT "O FF'

...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 -

B ---- 435 GRY {7T


c
D
VENT FILTER CONTROL '
CIRCUITRY !

EVRV SOLENOID ASSY.


8-4-88
8 - 8-88 7S3689-6E

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. W ith the ignition "ON , engine stopped, the Before replacing ECM, use an ohm m eter and
solenoid should not be energized and vacuum check the resistance of each ECM controlled relay
should not pass to the EGR valve. Grounding the and solenoid coil. Refer To ECM QDR check
diagnostic term inal will energize the solenoid and procedure, Figure 3-18.
allow vacuum to pass to valve. See ECM w iring diag ram for coil te rm in a l
2. Checks for plugged EGR passages. If passages are identification of solenoid(s) and relay(s) to be
plugged, the engine may have severe detonation checked.
on acceleration. Replace any solenoid where resistance measures
3. The vehicle must be driven during this test in less than 20 ohms.
order to produce sufficient engine load to operate
the EGR. Lightly accelerating (approximately 1/4
throttle) will produce a large and stable enough
reading to determine if the ECM is commanding
the system "ON.
COMPUTER COMMAND CONTROL 3-55
3-56 COMPUTER COMMAND CONTROL

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 33 will set when: The "Altitude To Voltage scale at the right may
Signal is too high for a time greater than 6 be used to test the MAP sensor at a specific altitude
seconds. level to evaluate the possibility of a "slewed (mis-
Engine misfire or a low unstable idle may set scaled) sensor. A "slewed sensor could result in poor
Code 33. driveability complaints.
Engine Running: Engine misfire or a low unstable idle may set Code
Manifold pressure greater than 75.3 kPa (A/C 33. Disconnect MAP sensor and system will go into
"OFF) 81.2 kPa (A/C "ON) backup mode. If the misfire or idle condition remains,
Throttle angle less than 2% see "Driveability Symptoms in Section "2.
Conditions met for 2 seconds. R efer to "ECM I n t e r m i t t e n t C o d es or
2. With the MAP sensor disconnect the ECM; should Performance in Section "2.
see a low voltage if the ECM and wiring is OK.
COMPUTER COMMAND CONTROL 3-57

CODE 33
M AP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM )
ALL ENGINES

IGNITION "ON" ENGINE STOPPED VOLTAGES


ALTITUDE VOLTAGE RANGE
Meters Feet
Below 305 Below 1,000 3.8 5.5V
305 610 1,000-2,000 3.6 5.3V
610 914 2,000-3,000 3.5 5.1V
914-1219 3,000-4,000 3.3 5.0V
1219-1524 4,000-5,000 3.2 4.8V
1524-1829 5,000-6,000 3.0 4.6V
1829-2133 6,000-7,000 2.9 4.5V
2133-2438 7,000-8,000 2.8 4.3V
2438-2743 8,000-9,000 2.6 4.2V
2743-3048 9,000-10,000 2.5 4.0V

LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE

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.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Code 34 will set when: An interm ittent open in CKTs 416 will result in a
When engine is less than 600 rpm. Code 34.
Manifold pressure reading less than 13 kPa, R efer to "ECM I n te r m i t t e n t C o d es or
conditions met for 1 second Performance in Section "2.
or The "Altitude to Voltage scale at the right may
Engine is greater than 600 rpm. be used to test the MAP sensor at a specific altitude
Throttle angle over 20%. level to evaluate the possibility of a "slewed (mis-
Manifold pressure less than 13 kPa conditions scaled) sensor. A "slewed sensor could result in poor
met for 1 second.. driveability complaints.
2. This tests to see if the sensor is at faulty for the
low voltage or if there is a ECM or wiring problem.
3. This simulates a high signal voltage to check of an
open in CKT 432. if the test light is bright during
this test, CKT 432 is probable shorted to ground.
If "Scan reads over 4 volts at this lest CKT 416
can be checked by m easu rin g the voltage at
terminal "C. (should be 5 volts)
COMPUTER COMMAND CONTROL 3-59

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

IG N ITIO N "O F F ". FAULTY C O N N EC TIO N


REMOVE JUMPER W IRE. OR SENSOR.
PROBE TE R M IN A L "B " (CKT 4 3 2 ) W IT H A
L IG H TTO 12 VOLTS.
IG N ITIO N " O N " .
"SC A N " SH O U LD READ OVER 4 VOLTS.
DOES IT?

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

Below 305 Below 1,000 3.8- -5.5V


305 610 1,000 - 2,000 3.6- -5.3V
610 914 2.000-3,000 3.5- -5.1V
914-1219 3.000-4,000 3.3- -5.0V
1219-1524 4.000-5,000 3.2- -4.8V
1524-1829 5.000-6,000 3.0- -4.6V
1829-2133 6.000-7,000 2.9- -4.5V
2133-2438 7.000-8,000 2.8- -4.3V
2438-2743 8.000-9,000 2.6- -4.2V
2743-3048 9.000-10,000 2.5- -4.0V

LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE


7S 3699
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 0 7 -0 6 -8 7
3-60 COMPUTER COMMAND CONTROL

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

"SC A N " TO O L M U S T BE IN OPEN


M O D E DU R IN G THIS CHECK.
CODE 35
IDLE AIR CONTROL (IAC) SYSTEM
2.5L ENGINE


A/C "O FF " DURING ENTIRE CHECK.
ENGINE AT N O R M A L OPERATING
TEMPERATURE A N D TR A N S M IS S IO N IN DRIVE
(A /T ) OR NEUTRAL (M /T ).
RECORD ENGINE SPEED. IF IDLE IS ERRATIC OR
UNSTABLE, REFER TO FACING PAGE.



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.

RPM SAME AS RECORDED RPM HIGHER TH A N RECORDED IN FIRST STEP.


IN FIRST STEP.
IDLE ENGINE FOR 1 M IN U T E IN
DRIVE (A /T ) OR NEUTRAL (M /T ).
SHIFT TO N EUTRAL (A /T ).
NOTE ENGINE SPEED.

W ILL N O T RETURN TO RPM RETURNS TO RPM RECORDED IN FIRST STEP.


RECORDED IN FIRST STEP.
1
IDLE AIR CONTROL CIRCUIT OK.



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.

IG N ITIO N " O N " , ENGINE STOPPED.


G R O U N D D IA G N O STIC TEST TER M IN A L.
CONNECT A TEST LIGHT BETWEEN EACH IAC
HARNESS CONNECTOR TE R M IN A L A N D G ROUND.

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

CLEAR CODES, CONFIRM "CLOSED LOOP" OPERATION, NO "SERVICE ENGINE SOON' 7 -1 7 -8 7


LIGHT, AND VERIFY CONTROLLED IDLE. 8 S 4 6 5 2 -6 E
3-62 COMPUTER COMMAND CONTROL

PICK-UP COIL HALL EFFECT SWITCH


ECM
I? (2 .5 L S /T TRUCK O N LY )

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

423 W HT -00 EST

4 3 0 PPL/W HT H B5 \ REFERENCE

4 2 4 TAN/BLK - BY-PASS

45 3 BLK/RED T bT T

ALL EXCEPT 2.5L& 2.8L 7 S 3 7 0 0 -6 E


8- 11-86 8 -4 -8 8

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

DISCONNECT FUEL M O D U L E IF EQUIPPED.


ON TW O FUEL TA N K SYSTEM , CHECK P U M P OPERATION IN EACH TA N K .
CODE 54
IGN. "O FF" FOR 10 SECONDS
IGN. " O N " . FUEL PUMP CIRCUIT
LISTEN FOR IN -T A N K FUEL PU M P.
P U M P SHO U LD RUN AFTER IGN. " O N ' (LO W VOLTAGE)
DOES IT?

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 ".

LIGHT LIGHT YES NO LIGHT "O N * LIG H T "O FF '


"O N " "O FF"

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 ".

LIGHT "O N * LIGHT "O FF '


I I
FAULTY CO N N EC TIO N A T RELAY TE R M IN A L " D " OR CKT 4 6 5 OPEN. SHORTED TO
FAULTY RELAY. CONNECT M O D U LE IF R E M O V ED . G R O U N D , OR FAULTY ECM.
C O N TIN U E TEST IF ORIG IN A L S Y M P T O M W A S "ENGINE
CRANKS BUT W ILL N O T R U N "
ENGINE AT N O R M A L OPERATING TEMPERATURE.
OIL PRESSURE N O R M A L. START ENGINE.
DISCONNECT FUEL P U M P RELAY. ENGINE S H O U LD
C O N TIN U E TO RUN. DOES IT?

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 .

LIGHT "O FF' LIGHT " O N "

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

(EXCEPT 2.5L ENGINE)

CHECK T H A T ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE

P R O M , CLEAR M E M O R Y , A N D RECHECK. IF CODE 51 REAPPEARS, REPLACE ECM.

CODE 52
FUEL CALPAK MISSING

(EXCEPT 2.5L ENGINE)

CHECK FOR M ISSIN G CALPAK A N D TH A T ALL PIN ARE FULLY INSERTED IN THE

S O C K ET- IF OK, REPLACE ECM.

CODE 53
SYSTEM OVER VOLTAGE
(2.5L ENGINE)

THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM .

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

EXCEPT 2.5L ENGINE

BE SURE ECM GR O U N D S ARE OK A N D TH A T M E M -C A L IS PROPERLY

LATCHED. IF OK REPLACE ELECTRONIC CONTROL M O D U LE (EC M ).

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

RESTRICTED EXHAUST SYSTEM CHECK


ALL ENGINES

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:

CHECK AT A. I. R. PIPE: OR CHECK AT 0 2 SENSOR:


1. Remove the ru b b er hose a t the ex h au st 1. Carefully remove O2 sensor.
manifold A.I.R. pipe check valve. Remove 2. In stall B orroughs e x h au st b ack p ressu re
check valve. tester (BT 8515 or BT 8603) or equivalent in
2. Connect a fuel pump pressure gauge to a hose place of O2 sensor (see illustration).
and nipple from a P ropane E n rich m en t 3. After com pleting test described below, be
Device (J 26911) (see illustration). sure to coat threads of O2 sensor with anti-
3. Insert the nipple into the exhaust manifold seize compound P/N 5613695 or equivalent
A.I.R. pipe. prior to re-installation.

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

Figure 3-17 - Exhaust System Check


3-74 COMPUTER COMMAND CONTROL

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

MAP OUTPUT CHECK


ALL ENGINES
Circuit Description:
The manifold absolute pressure (MAP) sensor measures manifold pressure (vacuum) and sends th at signal
to the ECM. The MAP sensor is mainly used for fuel calculation, when the ECM is running in the throttle body
backup mode. The MAP sensor is also used to determine the barometric pressure and to help calculate fuel
delivery.

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

MAP OUTPUT CHECK


ALL ENGINES

ALTITUDE VOLTAGE RANGE


Meters Feet

Below 305 Below 1,0 0 0 3.8- -5.5V


305- -6 1 0 1,000- 2,000 3.6- -5.3V
610- -9 1 4 2,000- 3.000 3 .5 - -5.1V
914- -1219 3.000- 4.000 3.3- -5.0V
1219- -1524 4.0 0 0 - 5.000 3.2-- -4 8 V
1524- -1829 5.000- 6.000 3 .0 - -4.6V
1829- -2133 . -
6 000 7.000 2.9- -4.5V
2133- -2438
2438- -2743
2743- -3048
. -
7.000- 8.000
8 000 9.000
9 ,0 0 0 - 10.000
2 . 8 - -4.3V
2 . 6 - -4.2V
2.5- -4.0V

LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE

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

PARK/NEUTRAL SWITCH DIAGNOSIS


ALL ENGINES
EXCEPT "P" SERIES
(AUTO TRANSMISSION ONLY)
Circuit Description:
The park/neutral switch contacts are closed to ground in park or neutral and open in drive ranges.
The ECM supplies ignition voltage, through a current limiting resistor, to CKT 434 and senses a closed
switch, when the voltage on CKT 434 drops to less than one volt.
The ECM uses the P/N signal as one of the inputs to control:
Idle Air Control
VSS Diagnostics
EGR

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Checks for a closed switch to ground in park If CKT 434 indicates P/N (grounded), while in
position. Different makes of "Scan tools will read drive range, the EGR would be inoperative, resulting
P/N differently. Refer to operators m anual for in possible detonation.
type of display used for a specific tool. If CKT 434 always indicates drive (open), a drop in
2. Checks for an open switch in drive or reverse the idle may exist when the gear selector is moved into
range. drive range.
3. Be sure "S can in d icates d riv e, even w hile
wiggling shifter to test for an in term itten t or
misadjusted switch in drive range.
COMPUTER COMMAND CONTROL 3-77

PARK/NEUTRAL SWITCH DIAGNOSIS


ALL ENGINES
EXCEPT "P" SERIES
(AUTO TRANSMISSION ONLY)

W IT H TR A N S A XLE/TR A N SM ISS IO N IN PARK, "S C A N '


TO O L S H O U LD IN D IC A TE PARK OR NEUTRAL.
DOES IT?

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.

YES YES ric


X I I
FAULTY P/N SW ITCH C O N N EC TIO N CKT 4 3 4 SHORTED OPEN G R O U N D CKT 4 3 4 OPEN
OR TO G R O U N D CKT 4 5 0 . OR
P/N SWITCH MISADJUSTED OR FAULTY ECM CONNECTION
OR FAULTY ECM. OR
FAULTY. ECM.

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

CRANK SIGNAL DIAGNOSIS


ALL ENGINES

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 )

POWER STEERING (P/S) PRESSURE SWITCH CHECK


2.5L ENGINE
Circuit Description:
The power steering pressure switch is normally open to ground, and CKT 495 will be near battery voltage.
Turning the steering wheel increases power steering oil pressure and its load on an idling engine. The
pressure switch will close before the load can cause an idle problem.
Closing the switch causes CKT 495 to read less than 1 volt. The ECM will increase the idle air rate and
retard the timing.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. Checks for ECM signal voltage on CKT 495 and A pressure switch that will not close, or an open
confirms that ground CKT 450 is OK. CKT 495 or 450, may cause the engine to stop when
2. Maximum resistance, or infinity, indicates an power steering loads are high.
open switch. A switch th at will not open, or a CKT 450 or 495,
3. Less than 1 ohm indicates that the switch is closed shorted to ground, will cause tim ing to retard at idle,
when the power steering pressure is high. Switch and may affect idle quality.
is OK.
COMPUTER COMMAND CONTROL 3-81

POWER STEERING (P/S)


PRESSURE SWITCH CHECK
2.5L ENGINE

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

A/C CLUTCH CONTROL DIAGNOSIS


(Page 1 of 2)
2.5L ENGINE
Circuit Description:
ECM control of the A/C clutch improves idle quality and performance by;
Delaying clutch apply until the idle air rate is increased.
Releasing clutch when idle speed is too low.
Releasing clutch at wide open throttle.
Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
Turning on air conditioning supplies CKT 459 battery voltage to the clutch control relay and term inal "B8.
After a time delay of about 1/2 second the ECM will ground term inal "A4, CKT 458, and close the control relay.
A/C compressor clutch will engage.

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

A/C CLUTCH CONTROL DIAGNOSIS


(Page 2 of 2)
2.5L ENGINE
Circuit Description:
ECM control of the A/C clutch improves idle quality and performance by;
Delaying clutch apply until the idle air rate is increased.
Releasing clutch when idle speed is too low.
Releasing clutch at wide open throttle.
Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
Turning on air conditioning supplies CKT 459 battery voltage to the clutch control relay and term inal "B8.
After a time delay of about 1/2 second, the ECM will ground termirial "A4, CKT 458, and close the control
relay. A/C compressor clutch will engage.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
3. Checks for faulty cycling switch. Before replacing ECM, use ohmmeter and check
Solenoids and relays are turned "ON or "OFF by resistance of each ECM controlled relay or solenoid
the ECM, using internal electronic switches called coil. See ECM w iring diagram for coil te rm in a l
"drivers. Each driver is part of a group of four, identification for solenoids(s) and relay (s) to be
called Quad-Drivers. Failure of one driver can checked.
damage any other driver in the set. Replace any relay or solenoid th at measures less
Solenoid and relay coil resistance must measure than 20 ohms.
more than 20 ohms. Less resistance will cause
early failure of the ECM "driver. U sing an
ohmmeter, check the coil resistance of the A/C
relay before replacing the ECM.
COMPUTER COMMAND CONTROL 3-85

A/C CLUTCH CONTROL


DIAGNOSIS
(Page 2 of 2)
FROM A/C CLUTCH
2.5L ENGINE
CONTROL D IA G N O S IS
CHART (1 OF 2 )

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

A/C CLUTCH CONTROL DIAGNOSIS


(Page 1 of 2)
2.8L ENGINE & 4.3L (S /T )
Circuit Description:
ECM control of the A/C clutch improves idle quality and performance by:
Delaying clutch apply until the idle air rate is increased.
Releasing clutch when idle speed is too low.
Releasing clutch at wide open throttle.
Smooths cycling of the compressor by providing additional fuel a t the instant clutch is applied.
Turning on air conditioning supplies CKT 59 battery voltage to the clutch control relay and term inal "B8 of
the ECM connector. After a time delay of about 1/2 second the ECM will ground term inal "A2 of the ECM
connector, CKT 459, and close the control relay. A/C compressor clutch will engage.

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

A/C CLUTCH CONTROL DIAGNOSIS


(Page 2 of 2)
2.8L ENGINE & 4.3L (S /T )
Circuit Description:
ECM control of the A/C clutch improves idle quality and performance by;
Delaying clutch apply until the idle air rate is increased.
Releasing clutch when idle speed is too low.
Releasing clutch at wide open throttle.
Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
Turning on air conditioning supplies CKT 59 battery voltage to the clutch control relay and term inal "B8 of
the ECM connector. After a time delay of about 1/2 second the ECM will ground term inal "A2 of the ECM
connector, CKT 459, and close the control relay. A/C compressor clutch will engage.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
3. Checks for faulty cycling switch. Before replacing ECM, use ohmmeter and check
Solenoids and relays are turned "ON or "OFF by resistance of each ECM controlled relay or solenoid
the ECM, using internal electronic switches called coil. Refer to ECM QDR Check (Figure 3-18). See
"drivers. Each driver is part of a group of four, ECM wiring diagram for coil term inal identification
called Quad-Drivers. Failure of one driver can for solenoid(s) and relay(s) to be checked.
damage any other driver in the set. Replace any relay or solenoid th a t measures less
Solenoid and relay coil resistance must measure than 20 ohms.
more than 20 ohms, less resistance will cause
early failure of the ECM "driver. U sing an
ohmmeter, check the coil resistance of the A/C
relay before replacing the ECM.
COMPUTER COMMAND CONTROL 3-89

A/C CLUTCH CONTROL


DIAGNOSIS
(Page 2 of 2)
FR O M A/C CLUTCH
2.8L ENGINE & 4 .3 L (S /T )
C O N TROL D IA G N O S IS
CHART (1 o f 2 )

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

4.3L AND V8 ENGINE


Circuit And Test Description:
Turning "ON the air conditioning supplies CKT 59 battery voltage to the A/C compressor clutch and to
term inal "B8 of the ECM connector to increase idle air rate and m aintain idle speed.
The ECM does not control the A/C compressor clutch, therefore, if A/C does not function, refer to the A/C
section of the service manual for diagnosis of the system.
If A/C is operating properly and idle speed dips too low when the A/C compressor turns "ON or flares too
high when the A/C compressor turns "OFF, check for an open CKT 59 to the ECM. If circuits are OK, it is a
faulty ECM connector term inal "B8 or ECM.
COMPUTER COMMAND CONTROL 3-91

ECM QDRCHECK PROCEDURE


V6 OR V8 ENGINE
USE THIS CHECK PROCEDURE ONLY AFTER OTHER
D IA G N O S TIC CHARTS IN THE SERVICE M A N U A L HAVE
D E TE R M IN E D T H A T THERE W A S AN ECM FAILURE.
REM O VE THE ECM FR O M THE VEHICLE.
IDEN TIFY THE SERVICE NUM BER OF THE ECM IN THE
VEHICLE.
IS THE ECM SERVICE PART NUMBER 1 2 2 7 7 4 7 ?

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

THE PRIOR TEST HAS D E TE R M IN ED T H A T A Q DR IN THE KEY " O N " , ENGINE N O T R U N N IN G .


ECM HAS BEEN D A M A G E D . IT IS M O S T IM P O R T A N T TO USE A FUSED A M M E T E R CAPABLE OF M E A S U R IN G
LOCATE A N D REPAIR THE CIRCUIT OR C O M P O N E N T TH A T A T LEAST 2 A M P S (J -340 29-A OR EQ U IV A LE N T).
CAUSED THE D A M A G E . FAILURE TO D O SO W ILL RESULT CONNECT ONE LEAD OF THE A M M E T E R TO
IN A N O TH E R FAILURE OF THE NEW LY REPLACED ECM. CHASSIS G R O U N D .
A N Y TE R M IN A L W IT H LESS TH A N 50K O H M S RESISTANCE CONNECT THE R E M A IN IN G LEAD TO EACH CIRCUIT
IS C O N NECTED TO A DEFECTIVE QDR. THE ECM W H IC H W A S CHECKED ABOVE. (FIGURE 1)
TE R M IN A L W IT H THE LO W EST RESISTANCE W A S MEASURE SU STA IN ED CURRENT FLO W TH R O U G H
C O N NECTED TO THE VEHICLE CIRCUIT M O S T LIKELY TO EACH CIRCUIT FOR 2 M IN U T E S EACH (IN M O S T
HAVE CAU SED THE QDR FAILURE. CASES, THE TCC SOLEN O ID C A N N O T BE EASILY
TESTED FOR CURRENT D R A W ).
NOTE AM PERA G E.
DISC O N NEC T THE C O M P O N E N T IN TH A T VEHICLE
CIRCUIT A N D CHECK FOR A SHORT TO VO LTA G E. IF
THE CIRCUIT IS N O T SHORTED TO VO LTA G E, REPLACE
THE C O M P O N E N T IN T H A T CIRCUIT A N D THE ECM.

IF A CIRCUIT(S) HAS MORE IF N O CIRCUIT HAS


TH A N 0 .7 5 A M P S CURRENT MORE TH A N 0 .7 5
E C M # 1227747
DRAW . A M P S CURRENT
DRAW.
ECM
QDR O U TP U T CIRCUIT T
NUM B ER TE R M IN A L CHECK FOR A SHORT TO REPLACE ECM
VOLTAGE IN EXCESSIVE
A2 A/C RELAY (2 .8L )
CURRENT D R A W CIRCUIT.
A3 N O T USED IF N O SHORT TO
1 VO LTA G E, REPLACE
C1 N O T USED RELATED SO LE N O ID OR
RELAY.
C2 EAC SOLEN O ID

A4 EGR OR EVRV SOLEN O ID

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

A7 RELAY OR SHIFT LIGHT


8 -5 -8 8
8S -4 335-6E

Figure 3-18 - ECM QDR Check Procedure (V6 or V8)


3-92 COMPUTER COMMAND CONTROL

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

TWISTED/SHIELDED CABLE TWISTED LEADS


DRAIN WIRE

OUTER JACKET

M Y LA R

1. REMOVE OUTER JACKET. 1. LOCATE D A M A G E D WIRE.


2. U N W R A P A L U M IN U M /M Y L A R TAPE. DO NOT 2. REMOVE IN S U LA TIO N AS REQUIRED.
REMOVE M Y LA R .

SPLICE & SOLDER


3. U N TW IST CONDUCTORS. STRIP IN S U LA TIO N AS 3. SPLICE TW O WIRE TOGETHER USING SPLICE


NECESSSARY. CLIPS A N D ROSIN CORE SOLDER.

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

Figure 3-19 - W ire Harness Repair


COMPUTER COMMAND CONTROL 3-93

Micro-Pack To remove a terminal:


1. Slide the seal back on the wire.
Refer to Figure 3-20 and repair procedure for 2. In s e rt tool (3) BT-8518, or J3 5 6 8 9 , or
replacement of a Micro-Pack terminal. equivalent, as shown in insert "A and "B, to
release the term inal locking tab (2).
Metri-Pack 3. Push the wire and terminal out through the
connector.
Some connectors use term inals called Metri-Pack If reusing the term inal, reshape the locking tang (2).
Series 150. (Figure 3-21). These may used a t the
coolant sensor, as well as TBI units. W eather-Pack
They are also called "Pull-To-Seat term inals,
because, to install a term inal on a wire, the wire is A W eather-Pack connector can be identified by a
first inserted through the seal (5) and connector (4). rubber seal, at the re a r of the connector. This
The term inal is then crimped on the wire and the connector, which is used in the engine compartment,
term inal pulled back into the connector to seat it in protects against moisture and dirt, which could create
oxidation and deposits on the te rm in a ls. T his
protection is im portant, because of the very low
voltage and cu rren t levels found in the electronic
system.
Repair of a Weather-Pack term inal is shown in
Figure 3-22. Use tool J28742, or BT8234-A to remove
the pin and sleeve terminals.
If removal is attempted with an ordinary pick,
there is a good chance that the term inal will be bent,
or deformed. Unlike standard blade type term inals,
these term inals cannot be straightened once they are
bent.
Make certain th a t the connectors are properly
seated and all of the sealing rings in place, when
connecting leads. The hinge type flap provides a
back u p , or seco n d ary locking fe a tu re for th e
connector. They are used to improve the connector
reliability by retaining the term inals, if the small
term inal lock tangs are not positioned properly.
Figure 3-20 - Micro-Pack Connector W eather-Pack connections cannot be replaced
with standard connections. Instructions are provided
with W eather-Pack connector and term inal packages.

1. M ETRI-PACK SERIES 3. TO O L J3 5689 OR B T-8446


1 5 0 FEMALE TE R M IN A L 4. CONNECTOR BODY
2. LO CKING TA N G 5. SEAL
4 -1 8 -8 6
*7 S 3 2 1 3 -6 E

Figure 3-21 - Metri-Pack Series 150 Terminal Removal


3-94 COMPUTER COMMAND CONTROL

1. OPEN SECONDARY LOCK HINGE ON CONNECTOR Im portant


FEMALE r s _______ .MALE When replacing a production ECM with a service
C O N N E C T O R ^ _ ^ ^ L-:T ,V > i ^C O N NECTO R
co n tro ller, tra n s fe r the b ro a d c a st code and
production ECM part number to the controller
label. Do not record information on the access
^SECONDARY, cover.
LOCK HINGE
2. REMOVE TERMINAL USING TOOL
NOTICE: The ig n itio n m u st be " O F F , w hen
PUSH TO
RELEASE disconnecting or reconnecting the ECM
connector, to prevent internal damage to
TERMINAL TOOL J-28742/BT8234-A the ECM.
3. CUT WIRE IMMEDIATELY BEHIND CABLE SEAL
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
'WIRE
Discharge damage to the ECM, Do Not
(C ^ ^ S E A L ' touch the connector pins or so ld ered
4. REPLACE TERMINAL components on the circuit board.
A. SLIP NEW SEAL ONTO WIRE.
B. STRIP 5 m m (.2") OF INSULATION FROM WIRE.
C. CRIMP TERMINAL OVER WIRE AND SEAL ECM Connector Terminal Voltages

SEAL Refer to Figure 3-33 through 3-35, for voltage


charts to aid in diagnosis.
5. PUSH TERMINAL AND CONNECTOR AND
ENGAGE LOCKING TANGS. ECM Replacement - w ith Mem-Cal (2.5L)
6. CLOSE SECONDARY LOCK HINGE
(Figures 3 -36,3-37 and 3-44)
7S 35 42-6 E
Remove or Disconnect
Figure 3-22 - Weather-Pack Terminal Repair
1. Negative battery cable.
Compact Three 2. Connectors from ECM.
3. ECM mounting hardware.
The Compact Three connector, which looks similar 4. ECM from passenger compartment.
to a W eather-Pack connector, is not sealed and is used 5. ECM access cover (Figure 3-3).
where resistance to the environment is not required. 6. Mem-Cal removal (Figure 3-38).
This type of connector, most likely, is used at the air
control solenoid. Use the standard method, when Im portant
repairing a terminal. Do not use the Weather-Pack Replacement ECM is supplied without a Mem-Cal,
term inal tool J28742, or BT8234-A, as these will so care should be used when removing it from the
damage the term inals. defective ECM, because it will be reused in the
new ECM.
ELECTRONIC CONTROL MODULE
Using two fingers, push both retaining clips back
Replacement of the Electronic Control Module away from the Mem-Cal. At the same time, grasp it at
(ECM) consists of a service controller, w ithout a both ends and lift it up out of the socket. Do not
PROM/Calpak, or Mem-Cal. remove the cover of the Mem-Cal. Use of unapproved
If the diagnostic procedures required the ECM to Mem-Cal removal methods may cause damage to the
be replaced, the ECM, PROM, Calpak, and Mem-Cal Mem-Cal or socket.
should be checked for the correct part number. If they
are, remove the PROM and Calpak, or Mem-Cal, and Inspect (Figure 3-39)
install them in the service controller. The service
For alig n m en t notches of the M em-Cal and
controller will not contain a PROM/Calpak, or Mem-
carefully set it aside. Do not open the Mem-Cal.
Cal.
COMPUTER COMMAND CONTROL 3-95

Figure 3-23 - ECM W iring Diagram - 2.5L (1 of 3)


3-96 COMPUTER COMMAND CONTROL

ECM

Figure 3-24 - ECM Wiring Diagram - 2.5L (2 of 3)


COMPUTER COMMAND CONTROL 3-97

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

VEHICLE 2 4 PIN A-B


BUFFER BRN 4 3 7 ----- A 1 0 SPEED C ONNECTOR
SENSOR
VEHICLE SPEED SENSOR

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

A4 A/C RELAY CONTROL

7S3267
5 -2 7 -8 7

Figure 3-25 - ECM Wiring Diagram - 2.5L (3 of 3)


3-98 COMPUTER COMMAND CONTROL

ECM

if

* 6S 26 78-6E
5 -2 7 -8 7

Figure 3-26 - ECM W iring Diagram - 2.8L (1 of 3)


COMPUTER COMMAND CONTROL 3-99

________ ECM

A ------- LT B LU /W H T 441
p r r m _ C5 IAC COIL " A " HI

IAC B LT BLU/BLK 4 4 2 - C6 IAC COIL " A " LO

VALVE _ C LT G R N /W H T 4 4 3 C4 IAC COIL "B " HI


ju u u u ------- LT GRN/BLK 4 4 4 C3 IAC COIL "B " LO
D

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

PPL/W HT 4 3 0 B5 REFERENCE HIGH

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

A1 FUEL PUM P RELAY ::H Q r r :


DK G R N /W H T 4 6 5
DRIVE (1 2 V )
BLK/W HT
32 PIN C-D
r 1 CONNECTOR
ENGGND
3 A C | B |
FUEL
PUMP r m s
RELAY
M l
L -j
TO
FUEL T A N /W H T 120 B2 FUEL PU M P SIGNAL
PUMP

OIL
FUEL P U M P
press,
a TEST
SW ITCH 8 -4 -8 8
C ONNECTOR
6S 26 79-6 E

Figure 3-27 - ECM W iring Diagram - 2.8L (2 of 3)


3-100 COMPUTER COMMAND CONTROL

ECM

GAGE SERVICE ENGINE SOON


IGN PNK/BLK 39 B R N /W H T 4 1 9 A5 LIGHT CONTROL
12V
S ES LA M P
20 A

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.

BRN 4 3 6 C2 EAC SOLEN O ID


EAC S O LEN O ID
ECM 1
IGN
PNK/BLK 4 3 9 A6
12V
10 A

2 4 PIN A-B
CONNECTOR
BUFFER BRN 4 3 7 A 10 VSS SIGNAL

VEHICLE SPEED SENSOR

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

Figure 3-28 - ECM W iring Diagram - 2.8L (3 of 3)


COMPUTER COMMAND CONTROL 3-101

ECM

ORN ~D O RN/GRN 461 - A8 SERIAL DATA

ALDL B | ------------------------------ W H T/B LK 451 - A9 D IAGNOSTIC TEST

BLK/W HT 450 - A 12 SYSTEM GND / bi\


4 5 0 (5 5 1 RV)
D1 SYSTEM GND
|b l k / w h t
ENGINE GR O U N D S X L

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 ~=

PPL 4 1 2 D7 OXYGEN SENSOR


SIGNAL

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 )

A PPL 4 5 5 A11 M A P GROUND


M A P SENSOR (V 8 & 4 .3 L C K )
B
LT GRN 4 3 2 C11 M A P SIGNAL

C
H

A A
C GRY416 - C14 + 5V REFERENCE

D K B LU 417 C13 TPS SIGNAL


TPS B
| h v ^
A
BLK 4 5 2 A11 SEN SO R G R O U N D
(4.3L & V8 R V M G P)
^dU D 1.
BLK 45 2 D2 SENSOR G R O U N D
CO O LAN T
(4.3L & V8 CK)
TEMPERATURE
SENSOR
YEL 4 1 0 C10 C O O LAN T TEMP.
SIGNAL

A/C

IGN 3 LTG R N 6 6 DK G R N /W H T 59 B8 A/C SIGNAL


- 32 PIN C-D
PRESSURE CYCLING CONNECTOR
SW ITCH

A/C COMPRESSOR 7S3198


8 - 2-88

Figure 3-29 - ECM Wiring Diagram - 4.3L & V8 (1 of 4)


3-102 COMPUTER COMMAND CONTROL

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

ORN 44Q C 16 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

T A N /W H T 120 i B2 FUEL PU M P SIGNAL

FUEL P U M P


TEST CONNECTOR

SWITCH 24 PIN A-B


CONNECTOR
FUEL PUMP RELAY CIRCUIT (M )

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

TERM . (RV G P) ENGGND


FUEL
PUMP
FUEL P U M P RELAY
20 A (CK)

PNK/BLK 9 2 0 (CK) OR T A N /W H T 120 1

T A N /W H T 120 B2 FUEL PU M P SIGNAL

REFER TO CHART A -5 A FOR


32 PIN C-D
T W O FUEL TA N K SYSTEM
CONNECTOR

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

FUEL PUMP RELAY CIRCUIT (CK RV G P) 7S3199


7 -7 -8 7

Figure 30 - ECM Wiring Diagram - 4.3L & V8 (2 of 4)


COMPUTER COMMAND CONTROL 3-103

Figure 3-31 - ECM W iring Diagram - 4.3L & V8 (3 of 4)


3-104 COMPUTER COMMAND CONTROL

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

GRN 4 6 8 C15 INJECTOR


DRIVER (5 .7 L P )

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

PNK/BLK 4 3 9 A6 12V IGN

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

Figure 32 - ECM W iring Diagram - 4.3L & V8 (4 of 4)


COMPUTER COMMAND CONTROL 3-105

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION


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 in closed loop (for "Engine Run" column)

VOL TAGE VOLTAGE

KEY ENG. WIRE WIRE KEY ENG.


" O N : RUN. C IR C U IT P IN COLO R COLOR PIN CIRCUIT QN" RUN
B ATT.12.VOLTS 12 14

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

N O T I SEABLE IAC "B " LO Q BLK


LT GRN/
N O T I SEABLE IAC "B ' HI C4 WHT WHT 4 ESTCONTROL 0 1,0
LT BLU/ TAN/
N O T I SEABLE IAC " A " HI C5 WHT BLK D5 ESTBYPASS 0 4 .7 5
LT BLU/
N O T I SEABLE IAC " A " LO BLK TAN D6 G RND (0 ;) 0 0

NOT USED C7 PPL 07 0 2 SENSOR SIGNAL Q <3>


BLU/
12.3 P/S SW ITCH eg YEL OH NOT USED

0 0 CRANK SIGNAL C9 PPL/W HT BLK n>q GR OU N D o___ 0


C O O LA N T
1.9 1.7 TEMP. S IG N A L ____ C1Q YEL Rl K mn GROUND n n ___
4.7 2.0 M A P SIGNAL Cl 1 LTGRN m i NOT U S FD

1.3 _ 1 I M A T SIGNAL C12 TAN D 12 NO TUSED

,73 V .73 V TPS SIGNAL C13 DK BLU m i NOT U S FD


5 VOLT
5 5 REFERENCE C 14 GRY 32 PIN C-D 14 NOT USED
C O NNECTOR
N O TUSED C15 015 N O TU S E D

12 14 BATTERY 12 VOLTS C16 ORN BLU D 16 INJECTOR A 12 14

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

Figure 3-33 - ECM Connector Terminal End View - 2.5L


3-106 COMPUTER COMMAND CONTROL

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION


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 temperature Engine idling in closed loop (for "Engine Run" column)

VOl.TAGE VOLTAGE

KEY ENG. WIRE WIRE KEY ENG.


"ON : RUN .......... C I R C U I T PIN {C O L O R COLOR PIN CIRCUIT ON" RUN
3K G R N / ORN B1 BATT.12.VOLTS 12 14
o 14 FUEL P U M P RELAY A1 W HT
A/C CLUTCH TAN/
12 14 CONTRO! A? OK RRN W HT 02 ... FUEL P U M P SIGN AI n 14
BLK/
MOT IISFD A1 RED B3 EST REF LOW 0 0
B4 N O T USED
12 14 E G RCONTROL A4 GRY
"SERVICE ENGINE BRN/ ppiy EST
0 14 S O O N "C O N T R O L A5 WHT W HT B5 REFERENCE HI 0 1.6
PNK7'
12 _ 14 IGN ECM FUSE Afj BLK NOT USED
SHIFT LIGHT OR TAN/ BLK B7 ESC SIGNAL 9 9
12 14 TCC CONTROL A7 BLK
ORN/ B8 A/C SIGNAL 0 0 /1 2
2-5 2 5 SERIAL D A TA A$ GRN H K tlR N
W HT/
5 5 DIAG. TERM. A9 BLK B9 N O T USED
SPEED 2 4 PIN A-B ORN/ PARK/NEUTRAL
SENSOR SIGNAL A ig BRN CONNECTOR BLK B10 SW .SIGNAL 0 0
0 0 M AP GROUND A11 PPL B11 N O T USED
BLK/
0 0 SYSTEM G R O U N D A 12 W HT B12

TAN/
N O T USED C1 WHT D1 SYSTEM GR OU N D 0 0

12 14 EACSOL. C2 BRN BLK D2 5V RETURN 0 0


LT GRN/ /D l\
N O T I SEABLE IAC "B " LO Q BLK D3 N O T USED
LT GRN/ BACK V IE W
N O T I SEABLE IAC "B" Hi _ C4 W HT W HT D4 EST CONTROL 0 1.0
LT BLU/ CONNECTOR TA N /
N O T I SEABLE IAC " A " HI C5 WHT BLK D5 ESTBYPASS 0 4 .7 5
LT BLU/
N OT I SEABLE IAC " A " LO C6 BLK TAN D6 G R N 'D .(0 7) 0 0

NOT USED C
7 PPL D7 0 2 SENSOR SIGNAL 0

N O T USED C3 D8 N O T USED

0 0 CRANK SIGNAL C9 PPL/W HT D9 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

4.9 2.0 M A P SIGNAL C1 1 LT GRN D11 N O T USED


ELAPSED DK BLU/
.4 .4 TIM E R M O D U LE C12 WHT D 12 N O T USED

45 V 45 V TPS SIGNAL C 1 ,i DK BLU D 13 N O T USED


5 V O LT
REFERENCE C l 4 GRY 32 PIN C-D LT GRN D 14 INJECTOR B 12 14
5 ..... ... 5________
CONNECTOR
N O T USED C15 D 15 N O T USED

12 14 BATTERY 12 VOLTS C16 ORN BLU D 16 INJECTOR A 12 14

1 Varies fro m .60 to b a tte ry vo lta g e


ENGINE 2.8L LL2
5 M easured b e tw e e n te rm in a ls C 1 3 and D2 ( ,05V)
d e p en d in g on p o sitio n o f d rive wheels. 6 12 V in gear
2 Varies w ith te m p e ra tu re . 7
VEHICLE S/T TRUCK
0 V w ith A/C " o n "
3 Varies, (toggles) 8 12 V w ith A/C " o n "
4 12V First t w o seconds. 9 12 V w h e n cold
7 -7 -8 7
6 S 2 8 1 9 -6 E

Figure 3-34 - ECM Connector Terminal End View - 2.8L


COMPUTER COMMAND CONTROL 3-107

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

KEY ENG. WIRE WIRE KEY ENG.


"ON ' RUN CIRCUIT PIN COLOR
DKGRN/
A A COLOR
ORN
PIN
B1
CIRCUIT
B A TT.12.VO LTS
ON" RUN
12 14
0 14 FUEL P U M P RELAY A1 W HT bACK V IE W
TAN/
NOT IKFn A? co)yNECyr o R WHT.____ B2 K f.U ELEUME-SIClNAI a
ft: BLK/
NOT 1I^Fn A3 'h i RED B3 EST REF LO W o o
c B4 NOTUSED
12 14 E G R C O N TR O L A4 GRY c
c 1 PPI7 EST
"SERVICE ENGINE BRN/
0 14 S O O N "C O N T R O L A5 W HT c WHT B5 REFERENCE HI 0 1.6
....w ........ c
12 14 IGN - ECM FUSE Aft BLK c Bf, NOTUSED
SHIFT LIGHT OR TA N / c BLK B7 ESC SIGNAL 9 9
(t) 12 14 TCC CONTROL A7 BLK c <U_ktD
DKGRN B8 A/C SIGNAL 0 0
2 -5 2-5 SERIAL D A TA A8 ORN c
W HT/

5 5 D IA G . TERM . A9 BLK 89 __NQJLLLSJLL.........
SPEED 24 PIN A-B ORN/ PARK/NEUTRAL
0) SENSOR SIGNAL A1Q BRN CONNECTOR .BLK........ B10 <;w SIGNAI _J1_ __ ,_a
PPL OR
0 0 SENSOR G R O U N D A11 BLK B11 NOTUSED

~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..................

NOTUSED C12 D 12 N O TUSED

.6 V .6 V TPS SIGNAL rn DK BLU 013 ....NOTUSED .. ....... ..................


5 VO LT
32 PIN C-D GRN D 14 ....iN J ttT Q R .B ................ 12 14
5 5 REFERENCE C14 GRY
CONNECTOR
N O TUSED C15 D 15 N O TUSED

BLU D 16 INJECTOR A 12 14
12 14 BATTERY 12 VOLTS C16 ORN

1 Varies fro m .60 t o b a tte ry v o lta g e d e p e n d in g on po sitio n o f d rive w heels.


2 Varies w ith te m p e ra tu re ENGINE 4.3L, 5.0L, 5.7L, 7.4L
3 Varies.
4 12v First t w o seconds on 4.3L & 5.0L (1 2v firs t 20 seconds on 5 .7 L & 7 .4 L ). VEHICLE CKRVGPM
5 M easured b e tw e e n te rm in a ls C13 and A 1 1 ( ,05V).
6 Used on 4.3L, 5.0L o r 5.7L e n g in e. W ire co lo r m ay also be yel/black o r y e llo w /re d .
7 Also d o w n s h ift c o n tro l on THM 400.
8 R e fe rto w irin g d ia g ra m fo rte r m in a ls A 1 1 o r D2 sensor g ro u n d . 8 -2 -8 8
9 A/C "O FF" 7S 3 5 8 2

Figure 3-35 - ECM Connector Terminal End View - 4.3L & V8


3-108 COMPUTER COMMAND CONTROL

IF ECM IS BEING REPLACED:

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

Figure 3-36 - Electronic Control Module (ST) -- Install or Connect


1. Mem-Cal in Mem-Cal socket.

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.

~ T ] RIGHT HAND PLENUM SIDE PANEL


~2~| HOUSING ASSEMBLY
~3~| SEAL
~4~1 ELECTRONIC CONTROL MODULE
~5~1 RETAINER

Figure 3-37 - Electronic Control Module (M ) Figure 3-39 - Mem/Cal Unit Installation
COMPUTER COMMAND CONTROL 3-109

2. Access cover on ECM.


3. ECM in passenger compartment.
4. Connectors to ECM.

Functional Check

1. Turn ignition "ON.


2. Enter diagnostics.
A. Code 12 should flash four times (if no other
codes are present). This indicates the Mem- J
Cal is installed properly, and the ECM is
functioning.
B. If trouble Code 51 occurs, or if the "Service
Engine Soon light is "ON constantly with no
codes, the Mem-Cal is not fully seated or is
defective.
If not fully seated, press firmly on the ends
of the Mem-Cal.
If it is necessary to remove the Mem-Cal,
follow the previous removal instructions.

ECM Replacement - W ith PROM & CALPAK fTl ECM HOUSING


(V6 & V8) m RETAINER

(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.

-4- Install or Connect


1. ECM into vehicle.
2. Connector to the ECM.
3. Negative battery cable or ECM B fuse.
4. Perform System Check.

PROM

Refer to Figure 3-43, for removal and installation


fTl ELECTRONIC CONTROL MODULE
of a PROM.
f T l FUEL MODULE
HT1 ELECTRONIC CONNECTOR 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
8S 4 6 1 3 -6 E Discharge damage to the PROM, CalPak
Figure 3-40 - Electronic Control Module (CK) or Mem-Cal, Do Not touch the component
leads, and Do Not rem ove in te g ra te d
circuit from carrier.
3-110 COMPUTER COMMAND CONTROL

1. R em o ve ECM access cover.

ACCESS COVER

PROM j

2. R em ove PR O M using th e ro c k e r-ty p e PR O M re m o v a l to o l


s h o w n . E ngage on e en d o f th e PR O M carrier w ith th e hook
e n d o f th e to o l. Press on th e v e rtic a l bar en d o f th e to o l and
rock th e e n g a g e d en d o f th e PR O M c a rrie r up as f a r as
possible. E ngage th e o p p o site en d o f th e PROM ca rrier in
th e sam e m a n n e r an d rock th is en d up as fa r as possible.
R e p e a t th is process u n til th e PR OM ca rrier an d PR O M are
fr e e o f th e PR O M so cket. The PR O M c a rrier w ith PR O M in it
should lift o ff o f th e PR O M socket easily.
6. If a service c o n tro lle r is being in s ta lle d , check th e s e rv ic e
n u m b e r on th e co n tro lle r to m a k e sure it is th e sa m e as th e
re m o v e d ECM. R em ove access cover.

7. In stall PR O M an d CALPAK (if used). If a service P R O M or


CALPAK is b e in g in stalled , m a k e sure th e y h a v e th e sam e
p a rt n u m b e r as th e re m o v e d PR O M o r CALPAK.

3. Inspect re fe re n c e en d o f th e PR O M ca rrier an d c a re fu lly set


Im p o rta n t (B efo re in stallin g P R O M )
aside. D o n o t re m o v e PR O M fro m th e ca rrier to co nfirm
PR O M correctness. N otch in P R O M r e fe r e n c e d to s m a ll
notch in c a rrier an d th e
A N Y TIM E THE PR O M IS IN S TA LL E D B A C K W A R D S A N D THE
IG N IT IO N SW ITCH TURNED O N , THE PR O M IS DESTR O YED .

Im p o rta n t

D O N O T press on PR OM or CALPAK - O N LY CARRIER.

S m all notch o f ca rrier m ust be a lig n e d w it h sm all no tch in


socket. Press on PROM or CALPAK c a rrier u n til it is fir m ly
4 . R em o ve CALPAK (if used) using re m o v a l to o l s h o w n . Grasp se a te d in th e socket. D o n o t press on P R O M or CALPAK, o n ly
th e CALPAK ca rrier o f th e n a rr o w en d s o n ly . G e n tly rock carrier
th e ca rrier fro m en d to en d w h ile a p p ly in g a firm u p w a rd
fo rc e. 8. In stall ECM access cover.
5. Inspect re fe re n c e en d o f th e CALPAK ca rrie r an d c a re fu lly 9. In s ta ll ECM in p a s s e n g e r c o m p a r tm e n t a n d p e r f o r m a
set aside. D o n o t re m o v e CALPAK fro m c a rrier to co nfirm " D IA G N O S T IC C IR C U IT CHECK" to c o n firm p ro p e r
CALPAK correctness. N otch in CALPAK re fe re n c e to sam ll in s ta lla tio n .
no tch in c a rrier an d th e
8 - 10-88
6 S 2 5 1 1 -6 E

Figure 3-43 - Servicing ECM - Except 2.5L


COMPUTER COMMAND CONTROL 3-111

E3 Remove or Disconnect (Figures 1 and 2)


Inspect
1. ECM access cover
Type of glips used on the MEM-CAL sockets
| 9 j Important
DO NOT remove any of the other screws. There are two types of clips used on the MEM-CAL
sockets. A 'so lid ' type is used on the early produc
tion models and a 'h o llo w ' type is used on later
production models. See Figure 3.

Hollow Typ* Solid Typ

Figure 4

| ? | Important
Press only on the ends of the MEM-CAL.

Small notches in the MEM-CAL must be aligned


with the small notches in the MEM-CAL socket.

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

Retaining clips have snapped into place

Installing MEM-CAL with 'h o llo w ' clips.

Press down on the ends of the MEM-CAL until the


clips are against the side of the MEM-CAL Press
inward on the clips until they snap into place.
Listen for the click.

| 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

1. New Electronic Control Module (ECM) from its


packaging and check the service number to make Retaining clips have snapped into place
sure it is the same as the defective ECM.

2. Access cover Install or Connect (Figure 1)



1. Access cover on ECM
E3 Install or Connect (Figures 4, S, 6, 7 and 8) 2. ECM in passenger compartment and perform
1. MEM-CAL in MEM-CAL socket System Check" to confirm proper installation

8 S 4 6 9 7 -6 E

Figure 3-44 - Servicing ECM - 2.5L


3-112 COMPUTER COMMAND CONTROL

m D A S H A N D TOE P A N E L
m BRACKET

m R E TA IN E R P n COOLANT TEMPERATURE SENSOR


m E LE C TR O N IC C O N T R O L M O D U L E I 2 | INLET MANIFOLD
7 S 3 8 1 5 -6 E

Figure 3-45 - Electronic Control Module (P) Figure 3-46 - Coolant Sensor

CALPAK

Refer to Figure 3-43, for removal and installation


of a 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.

COOLANT TEMPERATURE SENSOR


(Figure 3-46)

NOTICE: C are m ust be ta k e n , w hen h a n d lin g


coolant sensor. Damage to coolant sensor
will affect proper operation of the fuel
control system.

-- 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.

MAP SENSOR Remove or Disconnect


(Figures 3-47 through 3-53) 1. Negative battery cable.
Other than checking for loose hoses and electrical 2. Vacuum harness assembly.
co nnections, th e only serv ice p o ssib le is u n it 3. Electrical connector releasing locking tab.
replacement, if diagnosis shows sensor to be faulty. 4. Bolts or release lock tabs and remove sensor.
COMPUTER COMMAND CONTROL 3-113

Figure 3-50 - MAP Sensor - 4.3L (S/T)

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

Figure B-49 - MAP Sensor - 2.5L (M)

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

Figure 3-54 - Oxygen Sensor - 2.5L (STM)

Take care when handling the oxygen sensor. The


in-line electrical connector and louvered end must be
kept free of grease, dirt, or other contaminants. Also,
avoid using cleaning solvents of any type. Do not drop
rn port"F" or roughly handle the oxygen sensor.
[~2~l HARNESS ASSEMBLY
m MAP SENSOR
Remove or Disconnect
[~4~| BRACKET E
7S 37 49-6E The oxygen sensor may be difficult to remove,
Figure 3-52 - MAP Sensor - 7.4L (CKRVG) when engine tem perature is below 48C (120F).
Excessive force may dam age th re a d s in ex h au st
manifold or exhaust pipe.
1. Negative battery cable.
2. Electrical connector releasing locking tab.
3. Carefully back out oxygen sensor.

+4- Install or Connect

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)

fTl EXHAUST MANIFOLD


f T l EXHAUST MANIFOLD
m OXYGEN SENSOR
f T ] OXYGEN SENSOR 9S 5626-6E 7S 3747-6E

Figure 3-56 - Oxygen Sensor - 5.7L (RVP over Figure 3-59 - Oxygen Sensor - 7.4L (CK)
8600 GVW)

FTl EXHAUST MANIFOLD


f T l OXYGEN SENSOR
7S3748-6E
Figure 3-57 - Oxygen Sensor - 4.3L (G) & Figure 3-60 - Oxygen Sensor - 7.4L (RVG)
5.0175.7L (CK under 8600 GVW)
3-116 COMPUTER COMMAND CONTROL

[ T 1 THROTTLE BODY ASSEMBLY


m THROTTLE POSITION SENSOR - NON-ADJUSTABLE
I 3 I THROTTLE POSITION SENSOR - NON-ADJUSTABLE
f~H THROTTLE B O D Y ASSEMBLY IT] THROTTLE POSITION SENSOR - ADJUSTABLE
|~2~1 THROTTLE POSITION SENSOR I 5 1 SCREW ASSEMBLY
m SCREW ASSEMBLY m RETAINER
7S 3415-6E 7 S 3 6 5 2 -6 E

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

1. C o n n ect d ig ita l v o ltm e te r J 3 4 0 2 9 -A , or


equivalent, from TPS connector, center term inal
"B to outside term inal "A, (jumpers for term inal
access can be made using term inals 1214836 and
12014837). ALDL scanner can be used to read
TPS output voltage.
2. With ignition "ON, engine stopped, TPS voltage
should be less than 1.25 volts.
3. If voltage is more than 1.25 volts, rotate TPS until
0.48 + .06 volt are obtained.
4. If above voltage lim itation cannot be obtained,
replace TPS.
5. Remove voltmeter and jum pers, reconnect TPS
connector to sensor. fT l M A N IF O L D A IR TE M P E R A T U R E (M A T ) SEN S O R
(A P PLY SEALER TO T H R E A D S O N LY )
[~2~1 EN G IN E IN TA K E M A N IF O L D
M A T SENSOR
7S 3 5 4 4 -6 E
(Figure 3-63)
Figure 3-63 - MAT Sensor - 2.5L
Remove or Disconnect
E3
1. Negative battery cable.
2. Electrical connector releasing locking tab.
3. MAT sensor.

Install or Connect
1. MAT sensor.
2. Electrical connector.
3. Negative battery cable.

KNOCK SENSOR

Refer to Section "7, "Electronic Spark Control,


for replacement of the knock sensor. f T l INSTRUMENT PANEL CLUSTER
{~2~| VEHICLE SPEED SENSOR
VEHICLE SPEED SENSOR | T 1 VSS BUFFER
(Figure 3-64) [~ 4 l ELECTRICAL CONNECTOR 6S 28 93-6 E
Refer to Section "8C, in Service M anual, for
Figure 3-64 - Vehicle Speed Sensor, Typical
vehicle speed sensor service, which is p art of the Except Electronic Instrument Panel & P
speedometer and instrum ent cluster.
--] Install and Connect
PARK/NEUTRAL SWITCH
1. Align actuator on switch, with hole in shift tube.
The park/neutral switch is located on the steering 2 . Position rearw ard portion of the switch (connector
column. side) to fit into cutout in lower jacket.
3. Push down on front of switch to engage the two
A djustm ent tangs.
4. Move gear selection to " p a rk and sw itch is
1. Move the switch housing all the way toward "low adjusted.
gear position. 5. Electrical connectors.
2. Move gear selector to "park position. The main
housing an d h o u sin g back sh o u ld r a tc h e t, POWER STEERING PRESSURE SWITCH
providing proper switch adjustment. (Figures 3-65 and 3-66)
The switch is located in the inlet pipe of the power
Remove or Disconnect steering gear.
1. Place gear selector in "neutral. Remove or Disconnect
2. Electrical connectors.
3. Spread tangs on housing and pull switch. 1. Electrical connector releasing locking tab.
2. Power steering pressure switch.
3-118 COMPUTER COMMAND CONTROL

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

Figure 3-67 - A/C Clutch Control Relay - (S/T)

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

Figure 3-65 - Power Steering Pressure Switch (M )

m A/C CLUTCH CONTROL RELAY 6S 28 57-6 E

Figure 3-68 - A/C Clutch Control Relay - (M )

A/C CONTROL

n ~ l OUTLET PIPE Refer to Figure 3-67 and 3-68, for replacement of


m POW ER STEERING GEAR the A/C clutch control relay on S/T Truck and M Van.
m INLET PIPE
POW ER STEERING PARTS INFORMATION
EI PRESSURE SW ITCH

9S 5 6 2 7 -6 E PART NAME GROUP


Figure 3-66 - Power Steering Pressure Switch (ST)
Controller, E C M ...............................................3.670
Calibrator, P R O M .......................................... ..3.670
+ 4- Install and Connect Sensor, Coolant Temp........................................3.670
1. Power steering pressure switch. Sensor, Exhaust O x y g e n .................................3.670
2. Electrical connector. Sensor, M A P ................................................... ..3.670
Sensor, Throttle Position: P art of
Sensor Kit, Throttle Position.......................... 3.440
Switch, Neu. St. & Backing L P ..................... ..2.698
FUEL CONTROL 4-1

SECTION 4

FUEL CONTROL SYSTEM


TBI MODEL 220 - V6 OR V8 ENGINE
TBI MODEL 7 0 0 -L 4 ENGINE
CONTENTS
Fuel Pressure Relief P r o c e d u re ............... 4-12
GENERAL DESCRIPTION .................................. 4-2
Fuel System Pressure T e s t...........................4-15
PURPOSE.......................................................... 4-2
Thread Locking C o m p o u n d ...................... 4-15
MODES OF OPERATION ................................ 4-2
MODEL 220 AND 700 TBI U N ITS................... 4-15
S tarting M o d e ..............................................4-2
C ontrolled Idle Speed C h e c k ....................4-17
Clear Flood M o d e ....................................... ..4-2
M inim um Idle A ir Rate C h e c k ................. 4-17
Run M o d e ................................................... ..4-2
TBI 220 COMPONENT SERVICE FUEL
Open L o o p ................................................... ..4-2
METER COVER ASSEMBLY-TBI 220 ------ --4-18
Closed L o o p ...................................................4-2
FUEL INJECTOR ASSEMBLY-TBI 220 ------ --4-19
A cceleration M o d e .......................................4-3
FUEL METER BODY ASSEMBLY -
D eceleration M ode .................................. ..4-3
TBI 2 2 0 ................................................................ 4-21
B attery C orrection M o d e ...........................4-3
THROTTLE POSITION SENSOR
Fuel C u to ff M o d e ....................................... ..4-3
(TPS)-TBI 220 ...................................................4-21
FUEL CONTROL OPERATION ...........................4-3
IDLE AIR CONTROL (IAC) VALVE -
MODEL 220 TBI U N I T .......................................4-3
TBI 2 2 0 ............................................................... ..4-22
MODEL 700 TBI U N I T .......................................4-3
THROTTLE BODY ASSEMBLY - TBI 220 ------ --4-23
Vacuum Ports............................................... ..4-4
TBI 700 COMPONENT SERVICE ................. 4-24
Fuel In je c to r(s )............................................ ..4-4
FUEL INJECTOR ASSEMBLY- TBI 700 ---------4-24
Pressure R e g u la to r.......................................4-4
PRESSURE REGULATOR ASSEMBLY .......... 4-25
Idle A ir Control S y s te m ............................. ..4-4
FUEL METER ASSEM BLY..................................4-26
TPS (T h ro ttle Position Sensor) .................4-6
THROTTLE POSITION SENSOR...................... 4-26
FUEL PUMP CIRCUIT....................................... ..4-7
IDLE AIR CONTROL (IAC) V A L V E ................. 4-27
FUEL FILTER........................................................4-7
TUBE MODULE ASSEM BLY........................... ..4-28
In-Line F ilte r...................................................4-7
THROTTLE BODY ASSEMBLY ...................... ..4-28
In-Tank F ilt e r .............................................. ..4-7
FUEL PUMP........................................................4-29
FUEL AND VAPOR PIPES..................................4-7
FUEL PUMP R E LA Y ......................................... ..4-29
FUEL T A N K ..........................................................4-7
FUEL M O D U L E ...................................................4-31
Filler N e c k ................................................... ..4-7
OIL PRESSURE S W IT C H .................................. ..4-31
Fuel Filler Cap ............................................ ..4-7
FUEL FILTER..................................................... ..4-32
ACCELERATOR C O N TR O L............................. ..4-8
In-Line Filter R e p la ce m e n t...................... 4-32
EVAPORATIVE EMISSION C O N T R O L.......... 4-8
In-Tank filte r R e p la ce m e n t...................... 4-32
DIAGNOSIS ........................................................ ..4-8
AUXILIARY FUELTANK C O N T R O L.............4-34
FUEL CONTROL .............................................. ..4-8
Selector Valve and M e te r Switch .......... 4-34
Fuel In je c to rs .............................................. ..4-8
FUEL HOSE AND PIPE ASSEMBLIES...............4-34
Pressure R egulator .................................. ..4-8
M a te ria l..........................................................4-34
Idle A ir C ontrol ......................................... ..4-8
Fuel Line R e p a ir......................................... ..4-34
T h ro ttle Position Sensor (TPS) .................4-9
FUELTANK..........................................................4-35
D rive a b ility S y m p to m s ............................. ..4-9
D raining ..................................................... ..4-35
FUEL PUMP CIRCUIT....................................... ..4-9
R e p la c e m e n t.............................................. 4-35
Fuel Pump R e la y......................................... ..4-9
P u r g in g ..........................................................4-35
Oil Pressure S w itc h .......................................4-9
FUEL SYSTEM CLEANING................................4-37
Fuel M o du le .............................................. ..4-9
In-Line Fuel F ilt e r ....................................... ..4-40
Fuel F ilte r........................................................4-9
Leak T e s t ..................................................... ..4-40
Fuel Pipes and Hoses ..................................4-9
ACCELERATOR CO NTRO L............................. 4-40
Fuel T a n k ........................................................4-9
Accelerator C ontrol C a b le .........................4-40
ACCELERATOR CONTROL ........................... ..4-9
A ccelerator Pedal .......................................4-41
EVAPORATIVE EMISSION CONTROL ____4-9
PARTS INFORMATION .....................................4-43
ON-VEHICLE SERVICE .......................................4-12
SPECIFICATIONS .............................................. 4-44
GENERAL SERVICE M A N U A L ...........................4-12
4-2 FUEL CONTROL

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.

The ECM monitors voltages from several sensors Open Loop


to determine how much fuel to give the engine. The
fuel is delivered under one of several conditions called When the engine is first started, and it is above
"modes. All the modes are controlled by the ECM. 400 rpm, the system goes into "Open Loop operation.
In "Open Loop, the ECM ignores the signal from the
Starting M ode O2 sensor, and calculates the air/fuel ratio based on
in p u ts from the coolant te m p e ra tu re and MAP
sensors.
When the key is first turned "ON, the ECM turns
The system stays in "Open Loop u n til the
on the fuel pump relay for two seconds, and the fuel
following conditions are met:
pump builds up pressure to the TBI unit. The ECM
1. The O2 sensor has v ary in g v o ltag e o u tp u t,
checks the coolant te m p eratu re sensor, th ro ttle
showing th at it is hot enough to operate properly.
position sensor (TPS), manifold absolute pressure
(This depends on tem perature.)
2. The coolant te m p e ra tu re se n so r is above a
specified temperature.
3. A specific am ount of tim e has elapsed afte r
starting the engine.
The 7.4L engine is designed to operate "Open
Loop at idle. The system will go to "Closed Loop
when the rpm is increased and all conditions above are
met.

Closed Loop

The specific values for the above conditions vary


w ith d iffe re n t en g in es, an d a re s to re d in th e
programmable read only memory (PROM). When
these conditions are m et, th e system s goes into
"Closed Loop operation. In "Closed Loop, the ECM
calculates the air/fuel ratio (injector on-time) based on
the signal from the O2 sensor. This allows the air/fuel
ratio to stay very close to 14.7:1.
FUEL CONTROL 4-3

Acceleration M ode

The ECM looks a t rap id changes in th ro ttle


position and manifold pressure, and provides extra
fuel.

Deceleration M ode

When deceleration occurs, the fuel remaining in


the intake manifold can cause excessive emissions and
backfiring. Again, the ECM looks at changes in rn FUEL PUMP AND
1------1 SENDING UNIT
throttle position and manifold pressure and reduces
the amount of fuel. When deceleration is very fast, the S FUEL SUPPLY LINE

ECM can cut off fuel completely for short periods. m FUEL FILTER
TBI UNIT

Battery Voltage Correction M ode S FUEL RETURN LINE

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

FUEL CONTROL Model 220, used on V6 and V8 engines (Figure 4-


OPERATION 3), consists of three major casting assemblies:
Fuel meter cover with:
Pressure regulator
The fuel control system (Figure 4-2) consists of the Fuel meter body with:
following components: Fuel injectors
Throttle body injection (TBI) unit Throttle body with:
Fuel pump Idle air control (IAC) valve
Fuel pump relay Throttle position sensor (TPS)
Fuel tank
Accelerator control MODEL 700 TBI UNIT
Fuel lines
Fuel filters Model 700, used on the L4 engine (Figure 4-4), is
Evaporative emission control system made up of two major casting assemblies:
The fuel control system has an electric fuel pump, Fuel meter assembly with:
located in the fuel tank on the gage sending unit. It Pressure regulator
pumps fuel to the th ro ttle body through the fuel Fuel injector
supply line, then through an in-line fuel filter. The Throttle body with:
pump is designed to provide pressurized fuel at about Idle air control (IAC)
125 kPa (18 psi). On vehicles with two fuel tanks, Throttle position sensor (TPS)
there is an electric fuel pump and gage sending unit in
each fuel tank.
4-4 FUEL CONTROL

Pressure Regulator

The pressure regulator (see Figure 4-5 and 4-6) is


a diaphragm -operated re lie f valve w ith injector
pressure on one side and air cleaner pressure on the
other. The function of the regulator is to m aintain a
constant pressure at the injectors at all tim es, by
DEb3 controlling the flow in the return line (by means of a
calibrated bypass).
|~T| FUEL INJECTORS The pressure regulator on a TBI 220 u n it is
[~2~| THROTTLE BODY ASSEMBLY
serviced as part of the fuel meter cover and should not
be disassembled.
|~3l THROTTLE POSITION SENSOR (TPS)
The pressure regulator on a TBI 700 u n it is
[~4~| IDLE AIR CONTROL (IAC) VALVE ASSEMBLY serviced as part of the fuel meter assembly and can be
[~5~1 FUEL METER BODY ASSEMBLY disassembled.
[~6~1 FUEL METER COVER ASSEMBLY 8P Q922-AS
Idle Air Control System
Figure 4-3 - Model 220 TBI Unit

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)

The fuel injectors (F igure 4-5 and 4-6) are


solenoid-operated device, controlled by the ECM. The
ECM turns on the solenoid, which lifts a norm ally
closed ball valve off a seat. Fuel, under pressure, is
injected in a conical spray pattern at the walls of the
throttle body bore above the throttle valve.
The fuel which is not used by the injectors passes
through the pressure regulator before being returned
to the fuel tank.

r~3~| FUEL INJECTOR INLET FILTER

[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

f T l FUEL METER ASSEMBLY fj~1PRESSURE REGULATOR SPRING

fTl PRESSURE REGULATOR COVER ASSEMBLY f~F~] FUEL RETURN TO TANK

m FUEL INJECTOR ASSEMBLY [~G~| THROTTLE VALVE

f T l THROTTLE POSITION SENSOR (TPS)


I 5 | THROTTLE BODY ASSEMBLY 8P 0 3 2 0 -S Y

I 6 I TUBE MODULE ASSEMBLY


Figure 4-5 - TBI 220 Unit Operation
fTl IDLE AIR CONTROL (IAC) VALVE
8S 4 6 9 8 -6 E

Figure 4-4 - Model 700 TBI Unit


FUEL CONTROL 4-5

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)

This movement controls airflow around the throttle


plate, which in turn, controls engine idle speed, either
cold or hot. IAC valve pintle position counts can be
seen using a "Scan tool. 0 counts corresponds to fully
closed passage, while 140 counts or more (depending
on the application) corresponds to full flow.
Actual or "controlled idle speed is obtained by the
ECM positioning the IAC valve pintle. Resulting
idle speed is generated from the total idle air flow
(IAC/passage + PCV + throttle valve + vacuum
leaks).
Controlled idle speed is alw ays specified for
normal operating conditions. Normal operating
condition is coolant tem perature in o p eratin g
range, the A/C is "OFF, manual transm ission is
in neutral or automatic transm ission in drive with
proper Park/N eutral switch adjustment. A high or [~T~~| FUEL METER ASSEMBLY
low coolant tem perature, or A/C clutch engaged l~2~l THROTTLE BODY ASSEMBLY [~E~| ELECTRICAL
may signal the ECM to change the IAC counts. [~3~[ IDLE AIR CONTROL VALVE INPUT SIGNAL
The minimum idle air rate is set at the factory
[~A~| FILTERED AIR INLET
with a stop screw. This setting allows enough air
flow by the throttle valves to cause the IAC valve [ ] PINTLE
pintle to be positioned a calibrated num ber of [~C~l VACUUM PORTS FOR ENGINE
OR EMISSION CONTROLS
steps (counts) from the se a t d u rin g n o rm al
controlled idle operation. The IAC counts will be |~D~| THROTTLE VALVE
higher than normal on an engine with less than 8 P 0 3 1 8 -S Y

500 miles, or an engine operating at high altitude


or an engine with an accessory load such as the Figure 4-8 - Idle Air Control SYstem (TBI 700 Unit)
alternator, A/C, power steering or hydra-boost
brakes activated.
4-6 FUEL CONTROL

Th ro ttle Position Sensor (TPS) As the th ro ttle valve ro ta te s in response to


movement of the accelerator pedal, the throttle shaft
The throttle position sensor (TPS), is mounted on tran sfers this rotation movement to the TPS. A
the side of the throttle body opposite the throttle lever potentiom eter (variable resistor) w ithin the TPS
assembly. Its function is to sense the current throttle assembly changes its resistance (and voltage drop) in
valve position and relay that information to the ECM proportion to throttle movement.
(see F igure 4-11 and 4-12). T h ro ttle p o sitio n By applying a reference voltage (5.0 volts) to the
information allows the ECM to generate the required TPS input, a varying voltage (reflecting th ro ttle
injector control signals (base pulse). position) is available at the TPS output. For example,
If the TPS senses a wide open throttle, a voltage approximately 2.5 volts results from a 50% throttle
signal indicating this condition is sent to the ECM. valve opening (depending on TPS calibration). The
The ECM then increases the injector base pulse width, voltage output from the TPS assembly is routed to the
perm itting increased fuel flow. ECM for use in determining throttle position.

|T] THROTTLE VALVE


f i~ | TERMINAL PINS f~2~1 ENGINE CONTROL MODULE (ECM)
[~2~1 BALL BEARING ASSEMBLY r~3~] THROTTLE POSITION A
SENSOR (TPS)
[~~3~1 STATOR ASSEMBLY
[ T ] ROTOR ASSEMBLY
|~5~] SPRING
[~6~] PINTLE
[ 7 ] LEAD SCREW

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

|T~| THROTTLE BODY

[~Tl THROTTLE POSITION SENSOR (TPS)

[~3~l THROTTLE VALVE


9P 1059-A S 8P 0 3 1 6 -S Y

Figure 4-10 - Idle Air Control (IAC) Valve (TBI 700) Figure 4-12 - Throttle Position Sensor (TBI 700)
FUEL CONTROL 4-7

FUEL PUMP CIRCUIT allow fuel p ressu re to b leed o ff


b e fo r e s e r v ic in g f u e l s y s t e m
com ponents. (See "Fuel S ystem
The fuel pump is a turbine type, low pressure
Pressure R elief Procedure.)
electric pump, mounted in the fuel tank. Fuel is
pumped at a positive pressure (above 62 kPa or 9 psi)
from the fuel pump through the in-line filter to the The in-line filter is located in the fuel feed line. It
pressure regulator in the TBI unit (see Figure 4-13). prevents dirt from entering the TBI unit.
Excess fuel is returned to the fuel tank through the
fuel return line. In-Tank Filter
The fuel pump is attached to the fuel gage sender
assembly. A fuel strainer is attached to the fuel pump A woven plastic filter is located on the lower end of
inlet line and prevents dirt particles from entering the the fuel pickup tube in the fuel tank. The filter
fuel line and tends to separate water from the fuel. prevents dirt from entering the fuel line and, also,
On vehicles with two fuel ta n k s, th e re is an stops w ater, unless the filter becomes completely
electric fuel pump and gage sending unit in each tank. submerged in water. This filter is self-cleaning and
Vapor lock problems are reduced when using an normally requires no maintenance. Fuel stoppage, at
electric pump because the fuel is pushed from the tank this point, indicates that the fuel tank contains an
under p ressu re ra th e r th a n being pulled under abnorm al am ount of sedim ent or w ater; the tan k
vacuum, a condition that produces vapor. should, therefore, be thoroughly cleaned.
When the key is first turned "ON w ithout the
engine running, the ECM tu rn s a fuel pump relay FUEL AND VAPOR PIPES
"ON for two seconds. This builds up the fuel pressure
quickly. If the engine is not started w ithin two
The fuel feed and return pipes and hoses extended
seconds, the ECM shuts the fuel pump "OFF and
from the fuel pump and sender to the TBI unit. They
waits until the engine starts. As soon as the engine is
are secured with clamps and are routed along the
cranked, the ECM turns the relay "ON and runs the
frame side member.
fuel pump.
The vapor pipe and hoses extend from fuel pump
On the 5.7L engine in the G van and all other 5.7L
and sender unit to the evaporative emission control
or 7.4L engines in vehicles over 8500 GVW, a fuel
vapor canister.
module will override the ECM and the fuel pump will
run for approxim ately tw enty seconds. The fuel
module corrects a hot restart (vapor lock) during a FUELTANK
high ambient condition.
When the engine is cranking or running, the ECM The fuel tank, at the rear of the underbody, is held
receives distributor reference pulses which in tu rn in place by two metal straps. Anti-squeak pieces are
energize the fuel injectors. used on top of the tank to reduce rattles.
As a backup system to the fuel pump relay, the
fuel pump can also be turned on by an oil pressure Filler Neck
switch. When the engine oil pressure reaches about
28 kPa (4psi), through cranking and the fuel pump To help prevent refueling with leaded gasoline,
relay does not complete the circuit, the oil pressure the fuel filler neck on a gasoline engine vehicle has a
switch will close to complete the circuit to run the fuel built-in restrictor and deflector. The opening in the
pump. restrictor will only admit the smaller unleaded gas
An inoperative fuel pump relay can result in long nozzle spout, which must be fully inserted to bypass
cranking times, particularly if the engine is cold. The the deflector. Attempted refueling with a leaded gas
oil pressure switch will turn on the fuel pump as soon nozzle, or failure to fully in sert the unleaded gas
as oil pressure reaches about 28 kPa (4 psi). nozzle, will result in gasoline splashing back out of the
filler neck.
FUEL FILTER
Fuel Filler Cap
In-line Filter
The fuel tank filler neck is equipped with a screw-
type cap. The threaded part of the cap requires
CAUTION: To r e d u c e th e risk o f fir e and
personal injury, it is necessary to
4-8 FUEL CONTROL

TBI TBI U N IT THROTTLE BODY


INJECTOR PRESSURE REGULATOR

FUEL RETURN LINE

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

Figure 4-13 - TBI Fuel Supply System (Typical)

several turns counterclockwise to remove. The long Fuel Injectors


threaded area was designed to allow any remaining
fuel tank pressure to escape, while the cap was being Testing the fuel injector circuit is in CHART A-3
removed. A built-in torque-limiting device prevents and additional diagnosis in CHART A-4 in Section
overtightening. To install, tu rn the cap clockwise "3.
until a clicking noise is hear. This signals that the A fuel injector which does not open may cause a
correct torque has been reached and the cap is fully no-start condition. An injector which is stuck partly
seated. open, could cause loss of pressure after sitting, so long
crank times would be noticed on some engines. Also,
ACCELERATOR CONTROL dieseling could occur because some fuel could be
delivered to the engine after the key is turned "OFF.
The accelerator control system is a control cable
type, attached to a accelerator pedal assembly. Pressure Regulator

EVAPORATIVE EMISSION CONTROL T estin g the p ressu re re g u la to r c irc u it is in


CHART A-3 and A-4, in Section "3.
The system transfers fuel vapors from the fuel If the pressure regulator in the TBI supplies
tank into a vapor canister and then vapors are purged pressure which is too low (below 62 kPa or 9 psi), poor
into the intake manifold air flow and consumed in performance could result. If the pressure is too high,
combustion. Refer to Section "5, for ad d itio n al excess emissions and unpleasant exhaust odor may
information, diagnosis, and on-vehicle service. result.

DIAGNOSIS Idle Air Control

FUEL CONTROL The diagnosis of idle air control can be found in


Code 35, Section "3, for the 2.5L engine and in this
The diagnosis of fuel control and the TBI unit is in section for all other engines.
Section "3, because the computer command control If the IAC valve is disconnected or connected with
system controls fuel delivery. This system has a built the engine running, the idle rpm may be wrong. In
in diagnostic system in the ECM to indicate a failed this case, on engines with TBI 220 units, the IAC
circuit. This section will explain the system check and valve may be reset by turning the engine "OFF for
the codes related to fuel control. ten seconds and then re-startin g the engine. On
The fuel control can be the reason that the engine engines using a TBI 700 unit, the idle rpm is reset at a
cranks, but will not run and the diagnosis is, also, in speed above 30 mph (48 km/hr).
Section "3. If diagnosis indicates that the engine will The IAC valve affects only the idle characteristics
not run because there is a fuel delivery problem, the of the engine. If it is open fully, too much air will be
diagnosis of the fuel system is, also, included in allowed to the manifold and idle speed will be high.
Section "3.
FUEL CONTROL 4-9

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.

Refer to Section "3 for diagnosis of the throttle Fuel Tank


position sensor.
The diagnosis of gasoline odor may be a condition
Driveability Symptoms of leaking fuel tank, filler neck, or filler cap.
A defective filler cap, a plugged or pinched vapor
Refer to Section "2, for additional fuel control pipe can cause a collapsed fuel tank.
diagnosis. Loose m ounting straps, or foreign m aterial in
tank, may be the cause of a rattle at the fuel tank.
FUEL PUMP CIRCUIT
ACCELERATOR CONTROL
Refer to system diagnosis in Section "3, for fuel
pump diagnosis. Check for correct cable routing, or binding, and
An inoperative fuel pump would cause a no start correct as necessary.
condition. A fuel pump which does not provide enough
pressure can result in poor performance. (See "Fuel EVAPORATIVE EMISSION CONTROL
System Pressure Test procedure).
R efer to S ection "5 , for d ia g n o sis of th e
Fuel Pump Relay Evaporative Emission Control System.

Refer to fuel pump relay circuit check in Section


"3, for fuel pump relay diagnosis.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold. The
oil pressure switch will turn on the fuel pump as soon
as oil pressure reaches about 28 kPa (4psi).
4-10 FUEL CONTROL

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

C6 IAC COIL " A " LO


LT BLU/BLK 4 4 2 -

C4 IAC COIL "B " HI


LT G R N /W H T 4 4 3 -

LT GRN/BLK 4 4 4 ~ C3 IAC COIL "B " LO

N 8 S 3 9 9 7 -6 E
8 -3 -8 8 1 -2 9 -8 7

IDLE AIR CONTROL (IAC) SYSTEM CHECK


ALL ENGINES EXCEPT 2.5L
Circuit Description:
The ECM controls idle rpm with the IAC valve. To increase idle rpm, the ECM moves the IAC valve away
from its seat, allowing more air to pass by the throttle plate. To decrease rpm, it moves the IAC valve toward
its seat, reducing air flow by the throttle plate. A "Scan tool will read the ECM commands to the IAC valve in
counts. The higher the counts, the more air allowed (higher idle). The lower the counts, the less air allowed
(lower idle).
Test Description: Numbers below refer to circled Diagnostic Aids:
numbers on the diagnostic chart.
1. Continue with test, even if engine will not idle. If A rough or unstable idle may be caused by a
idle is to low, "Scan will display 80 or more system problem that cannot be overcome by the
counts, or steps. If idle is high, it will display "0" IAC. "Scan counts will be above 60 counts, if
counts. Occasionally, an erratic or unstable idle engine speed is too low, or "0 counts, if engine
may occur. Engine speed may vary 200 rpm, or speed is too high.
more, up and down. Disconnect IAC. If the If IAC valve pintle position counts are low or zero,
condition is unchanged, the IAC is not at fault. check for vacuum leaks at vacuum fitting, tees
2. When the engine was stopped, the IAC valve and hoses, the th ro ttle body and the in tak e
retracted (more air) to a fixed "park position for manifold.
increased air flow and idle speed during the next If IAC valve pintle position counts are high, look
engine start. A "Scan will display 100 or more for carbon build-up in the IAC valve air inlet
counts. When performing this test, immediately* passage or evidence of tam pering with stop screw.
note rpm on start up, because, on a warm engine, Also check for low engine power or excessive
the rpm will decrease rapidly. accessory loads.
3. Be sure to disconnect the IAC valve prior to this System too lean (High Air/Fuel Ratio)
test. The test light will confirm the ECM signals Idle speed may be too high or too low. Engine
by a steady or flashing light on all circuits. speed may vary up and down, disconnecting IAC
4. There is a rem ote possibility th a t one of the does not help.
circuits is shorted to voltage, which would have System too rich (Low Air/Fuel Ratio)
been indicated by a steady light. Disconnect ECM Idle speed too low. "Scan counts usually above
and turn the ignition "ON and probe term inals to 80. System obviously rich and may exhibit black
check for this condition. exhaust smoke.
Check:
IAC VALVE RESET PROCEDURE High fuel pressure
Injector leaking or sticking
Throttle body - Remove IAC and inspect bore for
Ignition "OFF for 10 seconds
foreign m a te ria l or ev id en ce of IAC valve
S tart and run engine for 5 seconds
dragging the bore. (Repair as required)
Ignition "OFF for 10 seconds
A/C C om pressor or relay failu re - See A/C
diagnosis if circuit is shorted to ground. If the
relay is faulty, idle problem may exist.
Refer to "Rough, U nstab le, In co rrect Idle or
Stalling, in Section "2.
FUEL CONTROL 4-11

"S C A N " TO O L M U S T BE IN OPEN


M O D E D U R IN G THIS CHECK.
IDLE AIR CONTROL (IAC)
SYSTEM CHECK
O A/C "O F F " D U R IN G ENTIRE CHECK. ALL ENGINES EXCEPT 2.5L
ENGINE A T N O R M A L OPERATING
TEMPERATURE A N D TR A N S M IS S IO N IN DRIVE
(A /T ) OR NEUTRAL (M /T ).
RECORD ENGINE SPEED. NOTE: IF A REPAIR HAS BEEN
M A D E REFER TO THE IAC
RESET PROCEDURE ON
THE FACING PAGE
BEFORE RETESTING.
IG N IT IO N "O F F " FOR 10 SECONDS.
START ENGINE A N D IM M E D IA T E L Y
OBSERVE RPM IN NEUTRAL.

RPM SAM E AS RECORDED RPM HIGHER TH A N RECORDED IN FIRST STEP.


IN FIRST STEP.
IDLE ENGINE FOR 1 M IN U T E IN
DRIVE (A /T ) OR NEUTRAL (M /T ).
NOTE ENGINE SPEED.

W ILL N O T RETURN TO RPM RETURNS TO RPM RECORDED IN FIRST STEP.


RECORDED IN FIRST STEP.

IDLE AIR CONTROL CIRCUIT OK.



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.

IG N ITIO N " O N ," ENGINE STOPPED.


G R O U N D D IA G N O S TIC TEST TER M IN A L.
CONNECT A TEST LIGHT TO G R O U N D A N D TO UC H
EACH IAC HARNESS CONNECTOR TER M IN A L.

N O LIGHTS, ONE OR
M ORE CIRCUITS.
LIGHT STEADY
OR FLASHING ALL
CIRCUITS

CHECK FOR OPEN OR SHORT TO 1


G R O U N D IN CIRCUIT W IT H NO FAULTY IAC
LIGHT. ARE ALL CIRCUITS OK? CON N EC TIO N OR IAC
VA LVE, OR PLUGGED
PASSAGE. IF LIGHT
YES NO APPEARS TO BE STEADY,
REFER TO TEST,STEP 4
CHECK RESISTANCE ACROSS IAC COILS. REPAIR W IR IN G A N D O N FACING PAGE.
S H O U LD BE MORE TH A N 2 0 O H M S BETWEEN RECHECK.
IAC TER M IN A LS " A " & "B " A N D "C " & " D " .

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

ON-VEHICLE SERVICE Refer to the disassembled views (Figure 4-14 and


4-15) for id e n tific a tio n of p a r ts d u rin g r e p a ir
GENERAL SERVICE MANUAL procedures. Service repair of individual components is
performed without removing the TBI unit from the
CAUTION: engine. If removed, it is essential that care is taken to
prevent damage to the th ro ttle valve or sealin g
To prevent personal injury or dam age to the surface while performing any service.
vehicle as the result of an a ccid en tal start, Whenever service is performed on a TBI or any of
d is c o n n e c t and r e c o n n e c t th e n e g a t iv e its components, first remove the air cleaner, adapter
battery ca b le b efo re and after s e r v ic e is (if applicable), and air cleaner gaskets. Discard the
p erform ed (ex ce p t for th o se te sts w h e r e gaskets and replace them w ith new ones before
battery voltage is required). replacing the air cleaner after service is complete.
To m inim ize the risk of fire, and person al When disconnecting the fuel lines, be sure to use a
injury, disconnect negative battery cable and b ack u p w rench (J-2 9 6 9 8 -A , or B T 8251-A , or
r eliev e th e fu el sy stem p r e s s u r e (w h e re equivalent) to keep the TBI nuts from turning.
applicable) before servicing the fuel system .
(S ee "Fuel P r e s s u r e R e lie f P r o c e d u r e , Fuel Pressure Relief Procedure
below.)
A lso, catch any fu el th a t le a k s ou t w hen The TBI Model 200 for V6 and V8 engines contains a
disconnecting the fuel lines by covering the constant bleed feature in the pressure regulator that
fittings with a shop cloth. Place the cloth in relieves pressure.
an a p p r o v e d c o n t a in e r w h e n w o r k is However, on L4 engines, the TBI Model 700 does
complete. not contain a co n stan t bleed featu re to reliev e
pressure.
The following is general information required when
working on the fuel system: TBI MODEL 700
Always keep a dry chem ical (C lass B) fire 1. Place transm ission selector in park (neutral on
extinguisher near the work area. manual transmissions), set parking brake, and
Fuel pipe fittings re q u ire new O -rings when block drive wheels.
assembling. 2. Loosen fuel filler cap to relieve tank pressure.
All fuel pipe must meet the GM Specification 124- 3. Disconnect three term inal electrical connector at
M, or its equivalent. fuel tank.
All fuel hose must meet GM Specification 6163-M 4. S tart engine and allow to run a few seconds until
or its equivalent. it stops from lack of fuel.
Do not replace fuel pipe with fuel hose. 5. Engage starter for three seconds to dissipate fuel
Always allow fuel pressure to bleed off before pressure in lines. Fuel connections are now safe
servicing any fuel system components. for servicing.
Do not do any repairs on the fuel system until you 6. Disconnect negative battery term inal to avoid
have read the in stru c tio n s and checked the possible fuel discharge if an accidental attem pt is
pictures relating to that repair. made to start the engine.
Observe all Notices and Cautions. 7. After service, reconnect connector at fuel tank,
tighten fuel filler cap and re in s ta ll neg ative
All gasoline engines are designed to use only battery cable.
unleaded gasoline to m aintain proper emission control
system operation. Its use will also minimize spark TBI MODEL 220
plug fouling and extend engine oil life. Using leaded 1. Disconnect negative battery term in al to avoid
gasoline can damage the emission control system and possible fuel discharge if an accidental attem pt is
could result in loss of emission w arranty coverage. made to start the engine.
All vehicles covered in the manual are equipped 2. Loosen fuel filler cap to relieve ta n k vapor
with and evaporative emission system. The purpose of pressure.
the system is to minimize the escape of fuel vapors to 3. The internal constant bleed feature of TBI Model
the atmosphere. Information on this system will be 220 relieves fuel pump system pressure when the
found in Section "5. engine is turned "OFF. Therefore, no fu rth er
The TBI unit repair procedures cover component pressure relief procedure is required.
replacement with the unit on the vehicle. However,
throttle body replacement requires that the complete
unit be removed from the engine.
FUEL CONTROL 4-13

MODEL 700 TBI

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.

Figure 4-14 - Model 700 TBI Parts Identification (L-4 Engine)


4-14 FUEL CONTROL

Model 220 TBI

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

Fuel System Pressure test Thread Locking Com pound

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

m STUD - TIGHTEN TO 17 (12


Nm FT. LBS.)
|~2~l TBI UNIT
fTI GASKET
f T ] ENGINE INTAKE MANIFOLD
7S 35 46-6 E 6S 27 99-6 E

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

9. Check to see if a cc elera to r pedal is free, by


depressing pedal to the floor and releasing, while
engine is "OFF.
10. With engine "OFF, and ignition "ON, check for
leaks around fuel line nuts.
11. Air cleaner, adapter, and new gaskets.
12. Start engine and check again for fuel leaks.
Controlled Idle Speed Check
Before performing this check, there should be no
codes displayed, idle a ir control system has been
checked and ignition timing correct.
1. Set parking brake and block drive wheels.
2. Connect a "Scan tool to the ALDL connector with
tool in Open Mode.
3. S tart engine and bring it to norm al operating
temperature.
4. Check for correct state of Park/N eutral switch on
"Scan tool.
5. Check specifications c h art a t the end of th is
section for controlled idle speed and IAC valve
pintle position (counts).
IT] BOLT - TIGHTEN TO 16 N m (12 FT. LBS.
6. If within specifications, the idle speed is being
ITI TBI U NIT
correctly controlled by the ECM.
[~3~1 GASKET
7. If not w ithin specifications, refer to "Rough,
Rl HEATER
7 S 3 5 4 3 -6 E Unstable or Incorrect Idle, Stalling in Section "2
and review information at the beginning of this
Figure 4-20 - Replacing TBI 220 Unit - 7.4L Engine
check.

+ 4- Install or Connect M inim um Idle Air Rate Check


1. New TBI flange (Manifold mounting) gasket.
2 . TBI with mounting hardware. Check controlled idle speed and perform idle air
control system check first.
Set parking brake and block drive wheels.
S tart engine and bring it to norm al operating
Hardware on 2.5L engine, 17.0 N-m
tem perature (85-100C). Turn engine "OFF.
(12.5 lb. ft.).
Remove air cleaner, adapter and gaskets. On ST
Hardware on 2.8L engine, 25.0 N m
Series vehicle, leave THERMAC hose connected.
(18.01b.ft.).
Hardware on 41.;3L, 5.0L, 5.7L, and 7.4L Check that the throttle lever is not being bound by
engines, 16.0 N-m (12.0 lb. ft.). the throttle, TV or cruise control cables.
New O-rings on fuel line nuts. With IAC valve connected, ground the diagnostic
3.
term inal (ALDL connector).
4. Fuel line inlet and outlet nuts by hand.
6. Turn "ON ignition, do not start engine. Wait at
least 10 seconds (this allows IAC valve pintle to
extend and seat in throttle body).
Fuel line nut to 26.0 N-m (20.0 lb. ft). (Use 7. With ignition "ON, engine stopped, test term inal
back-up wrench to prevent TBI n u ts from still grounded, disconnect IAC valve electrical
turning,) connector. (This disables IAC valve in seated
5. Vacuum hoses and bracket. position). Remove gro u n d from d ia g n o stic
6 . Throttle linkage, return springs(s), transm ission terminal.
control cable, and cru ise control (w h erev er 8 Connect a "Scan tool to the ALDL connector and
applicable). place in open mode. If a tool is not available
Grommet, with wire harness, to throttle body. connect a tachometer to the engine.
Electrical connectors, making sure connectors are 9. S tart engine. With transmission in neutral, allow
fully seated and latched. engine rpm to stabilize.
10. Check rpm against specifications at the end of this
section. Disregard IAC counts on "Scan tool with
the IAC disconnected. If the engine has less than
4-18 FUEL CONTROL

500 miles or is checked at altitudes above 1500


feet, the idle rpm with a seated IAC valve should
be lower than valves above.
11. If th e m in im u m id le a ir r a te is w ith in
specifications, no further check is required.
12. If the m inim um idle a ir ra te is n o t w ith in
specifications, perform the following procedures:
13. If present, remove stop screw plug by piercing it
with an awl, then applying leverage (see Figure 4-
21). The screw is covered to d is c o u ra g e
unauthorized adjustments.
14 With engine at norm al operating tem perature
(85-100C), adjust stop screw to obtain nominal
rpm per specifications with seated IAC valve.
|~T| IDLE STOP SCREW ASSEMBLY
15. Turn ignition "O FF and reconnect IAC valve
electrical connector. \~2 ~\ IDLE STOP SCREW PLUG
8P 0 9 2 0 -A S
16. Disconnect "Scan tool or tachometer.
17. Use silicon sealant or equivalent to cover stop Figure 4-21 - Removing Stop Screw Plug
screw hole.
18. Install air cleaner, adapter and gasket.

TBI 220 COMPONENT SERVICE


FUEL METER COVER ASSEMBLY-TBI 220
(Figure 4-22)
The fuel meter cover assembly contains the fuel
pressure regulator assembly. The regulator has been
adjusted at the factory and should only be serviced as
a complete present assembly.

CAUTION: DO NOT rem ove the four screw s


securing the pressure regulator to
the fu el m eter co v er. The fu el
pressure regulator includes a large
spring under heavy com pression
w h ich , if a c c id e n ta lly re le a se d ,
c o u ld c a u s e p e r s o n a l in ju r y .
D isassem bly might also result in a
fuel leak betw een the diaphragm f T l A T T A C H IN G SCREW-LONG
and the regulator container. HH A T T A C H IN G SCREW-SHORT
fT l F U E L METER COVER ASSEM BLY
Remove or Disconnect f T l COVER G ASKET

Electrical connectors to fuel injectors. (Squeeze j 5 | O U T LE T G ASKET


I 6 | DUST SE AL
plastic tabs and pull straight up.)
2. Long and short fuel meter cover screw assemblies. fTl FU E L M ETER BODY ASSEM BLY
5 S 1 7 0 0 -6 E
3. Fuel meter cover assembly.
Figure 4-22 - Replacing Model 220 Fuel M eter Cover
NOTICE: DO NOT immerse the fuel meter cover
(with pressure regulator) in cleaner,
-<- Install or Connect
as damage to the regulator diaphragm
and gasket could occur. New pressure regulator seal, fuel m eter outlet
4. Fuel meter outlet gasket and pressure regulator passage gasket, and cover gasket.
seal. Discard gaskets and seal. 2 . Fuel meter cover assembly.
3. A ttach in g screw assem blies, precoated w ith
Inspect appropriate locking compound to threads. (Short
screws are next to injectors.)
For dirt, foreign m aterial and casting warpage.
Tighten
Screw assemblies to 3.0 N m (28.0 lb. in.).
FUEL CONTROL 4-19

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

NOTICE: Backup washers and O-rings must be


installed before injectors, or improper
seating of large O-ring could cause
fuel to leak.

4. Injector, aligning raised lug on each injector base


with notch in fuel meter body cavity. Push down
on injector until it is fully seated in fuel m eter
body (Figure 4-27). (E lectrical te rm in a ls of
injector should be parallel with throttle shaft).

f T l TBI MODEL NUMBER


fT l THROTTLE POSITION SENSOR
l~3~1 THROTTLE LEVER
[T 1 INJECTOR P/N 5235134 (ORANGE/GREEN)
fTl INJECTOR P/N 5235342 (PINK/BROWN)

Figure 4-25 - Fuel Injector Color Code Locations


TBI 220 (4.3L Engine C/K Series)

m TOP VIEW OF INJECTOR [c ] BUILD DATE


f~A~l PART IDENTIFICATION NUMBER D - YEAR
[~Bl VENDOR INDENTIFICATION p - MONTH

7S3653-6E

Figure 4-26 - Fuel Injector Port Number Lacation


n ~ | ATTACHING SCREW ASSEMBLY
TBI 220
m FUEL METER BODY ASSEMBLY
fTl GASKET
fTl OUTLET NUT GASKET
fTl OUTLET NUT
[ 6 I OUTLET " 0 RING
fTl INLET "O " RING
fTl INLET NUT
INLET NUT GASKET 7S 3654-6E

Figure 4-28 - Fuel Meter Body Assembly - TBI 220

| 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

5. Fuel meter cover gasket.


6. Fuel Meter cover, following above procedure. 1^1 Tighten
7. Electrical connectors to fuel injectors. Fuel lines to 23N-m (17 lb. ft.).
8. With engine "OFF and ignition "ON, check for
fuel leaks. 6. Injectors, with new upper and lower O-rings in
fuel meter body assembly.
FUEL METER BODY ASSEMBLY-TBI 220 7. Fuel meter cover gasket, fuel meter outlet gasket,
(Figure 4-28) and pressure regulator seal.
8 . Fuel meter cover assembly.
U-+I Remove or Disconnect 9. Long and short fuel meter cover attaching screw
assem b lies, coated w ith a p p ro p ria te th re a d
1. Electrical connections to fuel injectors. (Squeeze
locking compound.
plastic tabs and pull straight up.)
2 . F uel m e te r cover assem b ly , (See p rev io u s
procedure).
3. Fuel m eter cover assem bly, following above Screw assemblies to 3.0 N-m (27.0 lb. in.)
procedure.
4. Fuel injectors, following above procedure. 10. Electrical connectors to fuel injectors.
5. Fuel inlet and return lines. Discard O-rings. 11. With engine "OFF, and ignition "ON, check for
6. Fuel inlet and outlet nuts and gaskets from the leaks around fuel meter body, gasket and around
fuel meter body assembly. Discard gaskets. fuel line nuts.

?| Im portant THROTTLE POSITION SENSOR (TPS)-TBI 220


(Figure 4-29)
Note locations of nuts, for proper reassembly later.
Inlet nut has a larger passage than outlet nut.
Im portant
7. Fuel meter body to throttle body attaching screw On 2.8L 9V-6) engines, the TPS is adjustable, and
assemblies. is supplied with attaching screw retainers. On all
8. Fuel m eter body assem bly from th ro ttle body oth er engines, it is no n -ad ju stable, w ith o u t
assembly. retainers. In addition, on 2.8L (V-6) and 7.4 (V8)
9. T hrottle body to fuel m eter body g ask et and engines, the TPS has a ho rizontal electrical
discard. connector; w hereas, on all other engines, the
connector is a vertical one. Since these TPS
|++| Install or Connect configurations can be mounted interchangeable,
be sure to order the correct one for your engine
1. New thro ttle body to fuel m eter body gasket.
with the identical part number of the one being
Match cut-out portions in gasket with openings in
replaced.
throttle body.
2 . Fuel m eter body assem bly on th ro ttle body
Remove or Disconnect
assembly.
Fuel meter body-to-throttle body attaching screw 1. Electrical connector.
assemblies, precoated with appropriate locking 2 . Two TPS a tta c h in g screw a s s e m b lie s an d
compound. retainers, (if applicable).
3. TPS from throttle body assembly.
^ Tighten
NOTICE: The TPS is an electrical component and
Screw assemblies to 4.0 N-m (30.0 lb. in.)
must not be soaked in any liquid cleaner
4. Fuel inlet and outlet nuts with new gaskets to fuel
or solvent, as damage may result.
meter body assembly.
-4- Install or Connect
Inlet nut to 40.0N-m (30.0 lb. ft). 1 . TPS on throttle body assembly, while lining up
Outlet nut to 29.0 N-m (21.0 lb. ft). TPS lever with TPS drive lever on throttle body.
2. Two TPS attaching screw assemblies.
5. Fuel inlet and return lines and new O-rings. (Use
back-up wrench J-29698-A or BT-8251-A to keep ^ Tighten
TBI nuts from turning.) Screw assemblies to 2.0 N-m (18.0 lb. in).
3. Electrical connector.
4-22 FUEL CONTROL

m THROTTLE BODY ASSEMBLY


f T l THROTTLE POSITION SENSOR - NON-ADJUSTABLE A DISTANCE OF PINTLE EXTENSION
fTl THROTTLE POSITION SENSOR - NON-ADJUSTABLE B DIAMETER OF PINTLE
l~ 4 l THROTTLE POSITION SENSOR - ADJUSTABLE C IACV O-RING
I 5 I SCREW ASSEMBLY D IACV ATTACHING SCREW ASSEMBLY
fTl RETAINER
7 S 3 6 5 2 -6 E 7 S 3 4 2 2 -6 E

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.

-4- Install or Connect


1 . IAC valve into throttle body as follows:
Thread-m ounted valve - In stall w ith new
gasket.
Flange-m ounted valve - In stall w ith new
lubricated O -ring, using a tta c h in g screw
assemblies.

NOTICE: New IAC valves have been reset at the


factory and should be in sta lle d in the
th ro ttle body in an "as is condition,
without any adjustment.

^ 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.

THROTTLE BODY ASSEMBLY-TBI 220

-+ 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

3. F u el m e te r b o d y -th ro ttle a tta c h in g screw


assemblies that above been coated w ith locking
compound.

Attaching screw assemblies to 4.0 N-m (3.50


lb.in.)
\r y z
4. TBI unit onto intake manifold, as previously
described. [ 7 ] FUEL INJECTOR (TOP VIEW )
[ a ] PART NUMBER
[ ] BUILD DATE CODE [ F ] DAY
[ c ] MONTH [ I ] YEAR
1-9 (JAN -SEPT)
0 ,N ,D (OCT,NOV,DEC)
8P 0 9 1 3 -A S

Figure 4-36 - Fuel Injector Part Number Location


TBI 700

TBI 700 COMPONENT SERVICE

FUEL INJECTOR ASSEMBLY-TBI 700


(Figures 4-34 through 4-36)

The fuel injector (see Figure 4-34) is serviced only


as a complete assembly.

NOTICE: Use care in rem oving injector, to


p rev en t dam age to th e e le c tric a l
connector on top of the injector, and
fTl SCREW ASSEMBLY
nozzle. Also, because the fuel injector
m RETAINER
is an electrical component, it should
m FUEL METER ASSEMBLY
not be immersed in any type of liquid
[~4~| LOWER " 0 " RING
solvent or cleaner, as damage may
I 5 | UPPER "O " RING
occur.
f~6~| INJECTOR 7 S 3 4 1 6 -6 E
Remove or Disconnect
Figure 4-34 - Fuel Injection Parts (TBI 700) 1 . Electrical connector to fuel injector.
2 Injector retainer screw and retainer.
.

3. Using a fulcrum, place a screwdriver blade under


ridge opposite connector end and carefully pry
injector out (see Figure 4-35).
4. Remove upper and lower O-rings from injector and
in fuel injector cavity and discard.

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

CAUTION: The p r e ssu r e r e g u la to r


Install or Connect contains a large sp rin g under
0 heavy com pression. U se care
1 . Lubricate new upper and low er O -rings w ith when rem oving the screw s to
automatic transm ission fluid and place them on
prevent personal injury.
injector. (Make sure upper O-ring is in groove and
lower one is flush up against filter.)
2. Pressure regulator cover assembly.
2 . Injector assembly, pushing it straig h t into fuel
3. Pressure regulator spring.
injector cavity.
4. Spring seat.
5. Pressure regulator diaphragm assembly.

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.

3. Injector retainer, using appropriate thread locking


compound on retainer attaching screw.
4. Electrical connect or to fuel injector.

^ Tighten |~i~| FUEL INJECTOR


Injector retainer attaching screw to 3.0 | 2 | INJECTOR RETAINEn p |
N-m (27.0 lb. in.). [~3~| FUEL METER BODY A TTACHING^ W ^ g J \
5. With engine "OFF and ignition "ON, check for SCREW & WASHER ASSEMBLY
fuel leaks. [ T ] FUEL METER ASSEMBLY |T

PRESSURE REGULATOR ASSEMBLY f j ~ | FUEL METER BODY TO THROTTLE BODY GASKET

(Figure 4-37) [~~6~~1 FUEL OUTLET NUT


|~ T | FUEL LINE OUTLET NUT O-RING
NOTICE: To prevent leaks, the pressure regulator
[~8~[ FUEL NUT SEAL
diaphragm assembly m ust be replaced
whenever the cover is removed. [~9~| PRESSURE REGULATOR COVER ASSEMBLY

[Tol AIR FILTER GASKET


1------ 1 8P 0 9 15-A S
4*+ Remove or Disconnect
1 . Four pressure regulator attaching screws, while Figure 4-38 - Fuel M eter Assembly - TBI 700
keeping pressure regulator compressed.
4-26 FUEL CONTROL

NOTICE: Use care while installing the pressure


regulator to prevent misalignment of Tighten
diaphragm and possible leaks. Inlet and outlet nuts to 27 N-m (20 lb. ft.).
(Use back-up wrench J-29698-A, or
4. Four screw assemblies that have been coated with BT-8251-A to keep TBI nuts from turning.)
ap p ro p riate th re a d locking com pound, while
m aintaining pressure on regulator spring. 7. Grommet with wires to fuel meter assembly.
8. Electrical connector to fuel injector, making sure
it is fully seated and latched.
Attaching screw assemblies to 2.5 N-m (22.0 9. With engine "OFF and ignition "ON, check for
lb. in.). leaks around fuel line nuts.

5. With engine "OFF and ignition "ON, check for THROTTLE POSITION SENSOR
fuel leaks. (Figure 4-39)

|<-| Remove or Disconnect


FUEL METER ASSEMBLY 1 . Electrical connector from TPS.
(Figure 4-38) 2. Screw assemblies and TPS.
|++| Remove or Disconnect NOTICE: The th ro ttle position sensor is an
1. Electrical connector from fuel injector. electrical component, and should not
2 . Grommet with wires from fuel meter assembly. be immersed in any type of liquid
3. Inlet and outlet fuel line n u ts, using backup solvent or cleaner, as dam age may
wrench J-29698-A, or BT-8251-A. result.
4. Fuel line O-rings from nuts and discard.
5. TBI mounting hardware. -- Install or Connect
6. Two fuel meter body attaching screws. 1. With throttle valve in normally closed position,
7. Fuel meter assembly from throttle body assembly. in s ta ll T P S on t h r o t tle s h a f t an d r o ta te
8. Fuel m eter body to th ro ttle body g ask et and counterclockwise to align mounting holes.
discard. 2. Attaching screw and washer assemblies.
|+ 7 Install or Connect
1. New fuel m eter body to th ro ttle body gasket.
Match cut-out portions of gasket with openings in
throttle body assembly.
2. Fuel meter assembly.
3. Two fuel meter body attaching screws that have
been coated with appropriate locking compound.

^ 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

Figure 4-39 - Throttle Position Sensor (TPS) - TBI 700


5. New O-rings on fuel line nuts.
6. Fuel line inlet and outlet nuts by hand.
FUEL CONTROL 4-27

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.

NOTICE: If the IAC valve has been removed during


service, its o p eratio n m ay be te ste d
electrically with the IAC/ISC Motor Tester
(J-37027, or BT-8256K). However, if the
valve pintle is extended electrically, it
must also be retracted electrically. Before
in stallin g an IAC valve, m easure the
distance betw een the tip of the valve
pintle and the mounting surface. If the
dimension is g reater th an 28 mm (1.10
inches) it m ust be reduced to p rev en t
damage to the valve. This may be done
electrically using an IAC/ISC M otor
Tester (J-37027 or BT-8256K) or manually
be exerting firm pressure as shown in
Figure 4-41, with a slight side-to-side
Figure 4-41 - Adjusting Valve Pintle - TBI 700
movement on the valve pintle to retract it.

-<- 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.).

THROTTLE BODY ASSEMBLY


(Figure 4-43)

NOTICE: Procedures related to replacement of the


individual components below have been
[T| THROTTLE BODY ASSEMBLY d escrib ed p rev io u sly and sh o u ld be
|~2~| TUBE MODULE ASSEMBLY GASKET followed, or damage could occur.
1~3~] TUBE MODULE ASSEMBLY
Remove or Disconnect
I T ] TUBE MODULE SCREW ASSEMBLY
8P 0 9 18-A S
1. Throttle body injection (TBI) unit, as described
below.
Figure 4-42 - Tube Module Assembly - TBI 700 2. Fuel meter body-to-throttle body attaching screw
NOTICE: New IAC valves that have been preset and washer assemblies.
at the factory should be installed in 3. Fuel meter assembly.
th e th r o ttle body in an "as i s 4. Fuel m eter body to th ro ttle body g ask et and
condition, without any adjustment. discard.

3. IAC valve attaching screw assemblies th at have


been coated w ith ap p ro p ria te th rea d locking
compound.

Screw assemblies to 3.2 N-m (28.0 lb. in.).

4. Electrical connector to idle air control valve.


5. Start engine and allow engine to reach operating
temperature.

TUBE MODULE ASSEMBLY


(Figure 4-42)

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

TPS, IAC valve and tube module assembly


from old throttle body assembly, according to
previous instructions.

* Assemble
1 TPS, IAC valve, and tube module assembly
onto replacem ent th ro ttle body assem bly,
according to previous instructions.

-4- Install or Connect


1. New fuel meter body to throttle body gasket.
2. Fuel meter assembly on throttle body assembly.
3. Fuel meter body-to-throttle body attaching screws
coated with appropriate thread-locking compound.

[ ^ T ig h t e n
Screws to 6.0 N-m (53 lb. in.)

4. TBI unit onto engine, as described below.


rn FUEL PUMP & [ T ] ELECTRICAL CONNECTOR
5. Check minimum idle speed of engine as described SENDER [ j ^ SEAL
below. 1 2 [ CAM | i t - . IL,
i-----1 6 FUEL TANK __
I 3 [ GROUND WIRE 1------ 1 7S3789-6E
FUEL PUMP
(Figure 4-44) Figure 4-44 - Fuel Pump - Typical

NOTICE: Care should be taken not to fold over or


Remove or Disconnect tw ist the strain er, when installing the
1. Relieve full system pressure (2.5L Engine only). sending unit as this will restrict fuel flow.
2. Raise the vehicle on a hoist.
3. Negative battery cable. 2. Sending unit and fuel pump assembly into the fuel
4. Fuel tank. tank.
5. Sender unit and pump by turning the cam lock Use a new O-ring seal.
counterclockwise using tool J-36608 or J-24187. 3. Cam lock assembly.
6. Fuel pump from the sending unit. Turn the cam lock clockwise to lock it.
Pull the fuel pump up into the attaching hose 4. Fuel tank.
while p u llin g o u tw ard from th e b ottom 5. Negative battery cable.
support.
Do not damage the rubber insulator or the FUEL PUMP RELAY
strainer. (Figure 4-45 through 4-50)

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

Figure 4-49 - Fuel Pump Relay (G)

fTI R E T A IN E R [ ] D O W N S H IF T R E LA Y fTI R E TA IN E R [T ] BRACKET


fTI FU E L P U M P R E LA Y [ 4] FU E L P U M P FUSE l~2~| FU E L P U M P R E LA Y [ 5 1 E LE C TR IC A L

IT I DASH PANEL ITI D A S H A N D TO E P A N E L CONNECTOR

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

0C f-l Install or connect


1. Relay.
2. Electrical connector.
3. Retainer.
4. Protective cover (CK).

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

Figure 53 - Fuel Module (G)

OIL PRESSURE SWITCH


(Figures 4-54 through 4-56)

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.

Figure 4-52 - Fuel Module (CK)


4-32 FUEL CONTROL

[~T1 FUEL FEED PIPE-TIGHTEN NUT TO 26 N m


(20 FT. LBS.)
[ T 1 O-RING
fTI IN-LINE FUEL FILTER
fTI FUEL FEED HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.)
I T I FUEL RETURN HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.) 7S 3 6 4 5 -6 E

Figure 4-57 - Fuel Filter - 2.5L

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.

Figure 4-56 - Oil Pressure Switch (4.3L/V8) In-Tank Filter Replacement


FUEL FILTER Refer to fuel pump replacem ent, if the in-tank
filter required service.
In-Line Filter Replacement
(Figures 4-57 through 4-63)

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

RIGHT FRAME CLAMP


SIDE MEMBER
REAR FUEL FEED INTERMEDIATE FUEL
PIPE-TIGHTEN NUT TO FEED PIPE-TIGHTEN
26 N-m (20 FT. LBS.) NUT TO 26N-m
(20 FT. LBS.)
BOLT-TIGHTEN TO
16 N-m (24 FT. LBS.) m TRANSMISSION
SUPPORT
IN-LINE FUEL
FILTER 7S 36 44-6 E

Figure 4-60 - Fuel Filter (RV)


P H FUEL RETURN PIPE
m CLAMP
in FUEL RETURN HOSE
n IN-LINE FUEL FILTER
n CLAMP (DOUBLE)
r n FUEL FEED HOSE
rn O-RING
rn FUEL FEED PIPE-TIGHTEN NUT TO
26 N-m (20 FT. LBS.)

Figure 4-58 - Fuel Filter - 2.8L (ST)

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

Figure 4-61 Fuel Filter (CK)

fT l REAR FUEL FEED PIPE-TIGHTEN NUT


rn FUEL FEED PIPE-TIGHTEN NUT TO
26 N-m (20 FT. LBS.)
rn
TO 26 N-m (20 FT. LBS.)
IN-LINE FUEL FILTER
rn IN-LINE FUEL FILTER n CLAMP
rn LEFT FRAME SIDE MEMBER m INTERMEDIATE FUEL FEED PIPE-TIGHTEN
NUT TO 26 N-m (20 FT. LBS.)
[~ 4 l FRONT FUEL FEED PIPE-TIGHTEN NUT TO rn RIGHT fr a m e sid e m e m b e r

Figure 4-62 - Fuel Filter (P)


Figure 4-59 - Fuel Filter - 4.3L (M )
4-34 FUEL CONTROL

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)

AUXILIARY FUEL TANK CONTROL FUEL HOSE AND PIPE ASSEMBLIES

The auxiliary fuel tank is controlled by a selector M aterials


valve and m eter switch and selector switch. The
diagnosis of these components are p art of the fuel Fuel Lines - These are welded steel tubes, meeting
pump circuit diagnosis and can be found in Section GM Specifications 124-M, or its equivalent. The fuel
"3. feed line is 3/8 diameter and the fuel return line is
5/16 diam eter. Do not use copper or alum inum
Selector Valve and M e ter Switch tubing to replace steel tubing. Those m aterials do not
(Figure 4-64) have satisfactory durability to w ith stan d norm al
vehicle vibration.
-- Remove or Disconnect Coupled hose - These are not to be repaired and
1 . Battery. are replaced only as an assembly.
2 . Hose shield, if required. U ncoupled Hose - Use only re in fo rc e d fu rl
3. Electrical connector from valve and switch. resistant hose, made of "Fluoroelastomer m aterial.
4. Fuel feed and return hose. Note position and color Do not use a hose within 4 inches (100 mm) of any part
of hoses. of the exhaust system, or within 10 inches (254 mm) of
5. Selector valve and m eter switch from frame. the catalytic converter. The hoses inside diam eter
must match the outside diameter of the steel tubing.
Clamps - These are stainless steel, screw bank-
Install and Connect type clamps, #2494772, or equivalent.
1 . Selector valve and meter switch. Fuel Line Repair
2 . Fuel feed and return hoses.
3. Electrical connector. 1 . Cut a piece of fuel hose 4 inches (100 mm) longer
4. Hose shield. than the section of line to be removed. If more
5. Battery. than 6 inches (152 mm) is to be removed, use a
combination of steel pipe and hose. The hose
length should not be more than 10 inches total.
FUEL CONTROL 4-35

2. Cut a section of the pipe to be replaced with a tube Replacement


cutter. Use the first step of a double flaring tool to Figures (4-65 through 4-82)
form a bead on the ends of the pipe and, also, on
the new section of pipe, if used. |7 + | Remove or Disconnect
3. Slide the hose clamps onto the pipe and push the 1 . Fuel from the fuel tank.
hose 2 inches (51 mm) onto each portion of the fuel 2. Clamps from filler neck hose and vent line.
pipe. Tighten a clamp on each side of the repair. 3. Fuel tank retaining straps.
4. Secure fuel line to the frame. Support the fuel tank.
4. Sender unit wires, hoses, and ground strap.
FUELTANK Lower the fuel tank to gain access.
5. Fuel tank from the vehicle.
Draining 6. Fuel sender and pump from the fuel tank.
7. Purge tank, if being repaired.
1. Disconnect the negative battery cable.
H ave a d ry c h e m ic a l ( C la s s B) f ir e |-4-| Install or Connect
extinguisher nearby.
1. Fuel sender and pump into fuel tank.
2. Fuel tank into the vehicle.
CAUTION: N ever drain or store g a so lin e or
3. Sender unit wires, hoses, and ground straps.
d iesel fuel in an open con tain er,
4. Fuel tank retaining straps with insulator strips in
due to the p o s sib ility o f fire or
place.
explosion.
5. Clamp to filler neck hose and vent line.
6. Bolts and nuts.
2. Use a hand operated pump device to drain as much
fuel as possible through the filler neck. On some
fuel tank installations, the filler neck is too long to
gain access to the fuel. If the tank is not full, Bolts, as shown in the illustrations.
disconnect filler neck nose, at the fuel tank, to
gain access to the fuel. Purging
Alternate method:
a. Disconnect fuel feed pipe and attach a hand The fuel tank should be purged, before being
operated pump device. repaired.
b. Energize the fuel pump relay.
c. With fuel pump running, operate hand pump |<-+| Remove or Disconnect
to remove fuel. 1. Fuel tank from the vehicle.
3. After servicing fuel tank, install removed hose, 2. Fuel gage sending and pump unit.
lines, and fuel filler cap. 3. All remaining fuel from the tank.

JjB* Inspect
Fuel tank for any remaining fuel.

Figure 4-65 - Filler Neck - ST Utility


4-36 FUEL CONTROL

[ 7 ] VENT PIPE [ T ] GROUND STRAP


nn FILLER PIPE 1X1 SUPPORT
[~3~1 FUEL FILLER PIPE [ F ] SHIELD 7S 3825-6E

Figure 4-68 - Filler Neck - ST Chassis Cab

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

Figure 4-66 - Fuel Tank - ST Utility

fTl FUEL TANK


[~2~1 BOLT TIGHTEN TO 18 N-m (13 FT. LBS.)
fTl STRAP
m VENT HOSE 1~4~] FUEL FILLER CAP
f T l PROTECTOR
m FILLER PIPE f T l GROUND STRAP [~5~l BOLT TIGHTEN TO 35 N-m (26 FT. LBS.)
HOUSING 7S3824-6E I 6 I BOLT TIGHTEN TO 35 N-m (26 FT. LBS.)
Figure 4-67 - Filler Neck - ST Pickup m NUT TIGHTEN TO 7 N-m (5 FT. LBS.) 7S 3820-6E

Figure 4-69 - Fuel Tank - ST (except Utility)

Install or Connect 3. W ater to the fuel tank.


1. Tap water into the tank, Refer to the emulsifying agent specifications
Move the tank to the flushing area (wash for the mixture ratio.
rack.) Agitate the mixture for ten minutes.
Agitate the water vigorously, and then, drain Drain the tank completely.
it. Fill the tank with water, until it overflow.
2. Gasoline emulsifying agent into the tank. Completely flush out any remaining mixture.
Use an available emulsifying agent, such as Drain the fuel tank.
Product-Sol No. 913, or equivalent. Use an explosion meter (if available) to check
for a negative reading.
Perform the required service work.
FUEL CONTROL 4-37

4. Repair fuel tank.


5. Fuel gage sending and pump unit.
6. Fuel tank into vehicle.

FUEL SYSTEM CLEANING

|+ + | 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

Figure 4-72 - Filler Neck - RV Chassis Cab


4-38 FUEL CONTROL

f T I NUT TIGHTEN TO 12 N m (10 FT. LBS.)


[ T ] BOLT TIGHTEN TO 12 N m (10 FT. LBS.)
fTI BOLT TIGHTEN TO 33 N m (24 FT. LBS.)
I T I FUELTANK
[~ 5 l SHIELD
I 6 [ REAR STRAP
|~T1 FRONT STRAP
Figure 4-76 - Fuel Tank - CK Chassis Cab

COMPLETELY INSTALL ONE STRAP PRIOR TO


INSTALLATION OF THE SECOND STRAP, HOWEVER
THE TANK MUST REMAIN SUPPORTED UNTIL ALL
FOUR BOLTS ARE TORQUED TO SPECIFICATIONS.

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 4-75 - Fuel Tank - M


T

FUEL CONTROL 4-39

[~T~| BOLT TIGHTEN TO 9.5 N-m (85 IN. LBS.)


IT 1 STRAP
P H SUPPORTBASE (LEFT) FUEL TANK LOCATION m FUEL TANK
CHI SUPPORTAUXILIARY (RIGHT) FUEL TANK LOCATION m LOWER NUT TIGHTEN TO 14 N-m (10 FT. LBS.)
m NUTTIGHTEN TO 7 N-m (60 IN. LBS.) ----- AND THEN TIGHTEN UPPER NUT [ T ] TO
f i n BOLTTIGHTEN TO 33 N-m (22 FT. LBS.) 7S 38 17-6 E 14 N-m (10 FT. LBS.) 7 S 3 8 1 6 -6 E

Figure 4-78 - Fuel Tank - RV Pickup Figure 4-80 - Fuel Tank - G

F T ] STRAP HOOK MUST FACE FORWARD fTl STRAP


fTl FUEL TANK f T l NUT TIGHTEN TO 12 N-m (10 FT. LBS.)
|~3~| UPPER NUT TIGHTEN TO 14 N-m fT l UPPER NUT TIGHTEN TO 35 N-m (23 FT. LBS.)
(10 FT. LBS.) AND THEN TIGHTEN AND THEN TIGHTEN LOWER NUT [ T ]
LOWER NUT [ T ] TO 14 N-m (10 FT. LBS.) TO 35 N m (25 FT. LBS.)
7 S 3 8 1 8 -6 E f T l FUEL TANK 7S 38 39-6 E

Figure 4-79 - Fuel Tank - RV U tility & Suburban Figure 4-81 - Fuel Tank - P (32)
4-40 FUEL CONTROL

6 . Negative battery cable.


7. Twenty three liters (six gallons) of clean fuel into
the fuel tank.
8 . Energize fuel pump relay, to operate the fuel
pump, until two liters (1/2 gallon) of fuel flows into
the fuel can. this will purge the fuel pump.
9. Fuel line, at the front of the vehicle.
10. Engine harness connector to the distributor.
Check all connections, for leaks, and tighten
all hose clamps.

Leak Test

If fuel is leaking, from the tank, the tank should


be replaced. Make sure that the fuel lines are not
leaking onto the tank.
1. Remove the fuel tank.
2. Drain the tank.
3. Plug all of the outlets.
4. Apply 7 to 10 kPa (1 to 1 ^ psi) a ir p ressu re
m STRAP
through the vent tube.
LOWER NUT TIGHTEN TO 12 N-m ITI FUEL TANK 5. T est for leak s, w ith a soap s o lu tio n , or by
(10 FT. LBS.), THEN TIGHTEN
MIDDLE NUT CO TO 58 N-m L_ZJ INSULATOR submersion.
(42 FT. LBS.) AND THEN TIGHTEN ITI NUT
6. Replace the tank, if a leak is found.
LOWER AND UPPER NUT S ----- TIGHTEN TO
TO 58 N-m (42 FT. LBS.) 58 N-m (42 FT. LBS.)
NUT TIGHTEN TO 58 N-m 7S3841-6E ACCELERATOR CONTROL
(42 FT. LBS.)

Figure 4-82 - Fuel Tank - P (42) Accelerator Control Cable


In-Line Fuel Filter (Figures 4-83 through 4-85)
There are no linkage adjustments. The throttle
Inspect cable must be replaced with an identical replacement
part.
In-Line fuel filter, for contamination.
Replace the filter, if it is plugged
All linkages and cables m ust be checked, to assure
free movement, with no rubbing, chafing, or binding.
1JJI Clean
The throttle must operate freely, without binding
Fuel lines, by applying air pressure in the between full closed and side open throttle.
opposite direction of fuel flow. Observe the following, when performing service
on the accelerator control cable.
-- Install or Connect The retainer must be installed with the tanks
1 . New strain er (if necessary) on the fuel gage secured over the head of the stud.
sending and pump unit. The conduit fitting, at both ends of the cable,
must have the locking tanks expanded and
NOTICE: Care should be taken not to fold over or locked into the attaching holes.
tw ist the strain er, when in stallin g the The braided portion of the cable must not come
sending unit, as this will restrict fuel flow. into contact with the front of dash sealer
2. Fuel gage sender and pump unit, with a new seal during replacement.
into the fuel tank. Flexible components (hoses, w ires, conduit,
3. Fuel tank. etc.) m ust not be routed w ithin 50 mm (2
4. Disconnect the fuel feed line at the front of the inches) of the moving parts of the accelerator
vehicle. lin k a g e , u n le s s r o u tin g is p o s itiv e ly
5. Hose to the fuel feed line at the front of the vehicle controlled.
and insert the other end of the hose into a 3.8 liter
(one gallon) fuel can.
FUEL CONTROL 4-41

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

|<--| Remove or Disconnect


1. R etainer from th ro ttle lever stud or on 2.5L
release cable from pulley.
2. Retainer locking tangs from support bracket.
3. Retainer from accelerator pedal rod or release
cable from rod.
4. Retainer locking tanks from dash panel.

-- 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

m SPRING [ T ] PLATE r n pedal 1 5 [ SUPPORT


m ROD [ T ] PIN 1 2 | PIN I 6 1 CABLE
fTI CABLE \j2 PEDAL fTI SPRING fTI RETAINER
fTI RETAINER 7 S 3 8 3 6 -6E
m ROD 1 8 I PLATE 7S 3 8 37-6 E

Figure 4-86 - Accelerator Pedal -ST Figure 4-87 - Accelerator Pedal - M

Observe the following, when performing service


on the accelerator pedal.
The mounting surface between the support
and the dash panel, must be free of insulation.
The carpet and padding in the pedal and
tunnel area must be positioned to lay flat and
be free of wrinkles and bunches.
Slip the accelerator control cable through the
slot in the rod, before installing the retainer in
the rod. Make sure it is seated properly. Use
care in pressing retainer into the hole, so the
cable if not kinked, or damaged.
The linkage m ust operator freely, w ithout
binding, betw een closed th ro ttle and full
throttle.
W ire, hoses, cab le, an d o th e r fle x ib le
components, must not be placed within 13 mm
(0.52 inch) of the cable or rod, at any point, in
their travel.

r n pedal ITI SUPPORT


m pin |~6~| CABLE
fTI SPRING [~7~| RETAINER
m ROD fTI PLATE 75 38 37-6 E

Figure 4-88 - Accelerator Pedal - RV


FUEL CONTROL 4-43

fTI PIN [T] ROD


fTI SPRING [IF] RETAINER
IT] SUPPORT [T] PLATE
7 S 3 8 3 2 -6 E
[~4~l CABLE |T ] PEDAL

Figure 4-91 - Accelerator Pedal -P (42)

Figure 4-89 - Accelerator Pedal - CK

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

Figure 4-92 - Accelerator Pedal -P (32)

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

CONTROLLED IDLE SPEED


Engine Transmission Gear Idle Speed IAC Counts* Open/Closed
___________________________ (D/N)___________ (RPM)________________________ L o o p **

2.5L Man. N 900(ST) 5-20 CL


800(M)
A u to . D 800(S) 15-40 CL
650(T)
750(M)
2.8L M an. N 800 5-20 OL
4.3L Man. N 500-550 2-12 CL
A u to . D 500-550 10-25 CL
A u to.(1) D 500-550 2-20 CL
5.0L Man. N 600 5-30 OL
A u to . D 500 5-30 OL
A u to.(2) D 550 5-30 CL
5.7L Man. N 600 5-30 OL
(under 8500
GVW) A u to . D 525 5-30 OL
5.7L Man. 600 5-30
(over 8500
GVW) M a n .(3) N 600 5-30 OL
A u to . D 550 5-30 OL
7.4L Man. N 800 5-30 OL
A u to . D 750 5-30 OL
* A d d 2 counts fo r e ngines w ith less th a n 500 m iles. A dd 2 counts fo r every 1000 ft. above sea level (4.3 L and V8).
A d d 1 c o u n t fo r every 1000 ft. above sea level (2.5L and 2.8 L).
* * Let en g in e id le u n til p ro p e r fu e l c o n tro l status (op e n /d o se d loop) is reached.
(1) 4.3 ST series.
(2) 3 speed A u to in a C10 Pickup w / Fed. emissions and no AIR system.
(3) G van o r S uburban w ith a single c a ta ly tic co n ve rte r.

M IN IM U M IDLE AIR RATE


Engine Transmission Gear Engine Speed Open/Closed
___________________________________________ (D/N)_____________ (RPM)___________ Loop*

2.5L Man. N 600 50 CL


A uto. N 500 50 CL
2.8L Man. N 700 50 OL
4.3L Man. N 450 50 CL
A uto. D 400 50 CL
A uto.(1) N 475 50 CL
5.0L Man. N 500 25 OL
A uto . D 425 25 OL
A uto .(2) D 425 2 5 CL
5.7L Man. N 500 25 OL
(under 8500 GVW) A u to. D 425 2 5 OL
5.7L Man. N 550 25 CL
(over 8500 GVW) A uto. D 450 25 CL
7.4L Man. N 700 25 OL
A u to . D 700 2 5 OL
* Let e n g in e idle u n til p ro p e r fu e l c o n tro l status (open/closed lo o p ) is reached
(1) 4.3L ST series.
(2) 5.0L w ith o u t AIR system.
EVAPORATIVE EMISSION CONTROL 5-1

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

The evaporative emission control system lim its


fuel vapor escape into the atmosphere. The system
(EECS) transfers fuel vapor from a sealed fuel tank,
through a single vapor pipe to an activated carbon
(charcoal) storage device (vapor canister) to store the
vapors when the vehicle is not operating. When the
engine is running, the fuel vapor is purged from the
carbon element by intake air flow and consumed in
the normal combustion process.
The fuel tank has a fuel cap that is not normally
vented to the atm osphere, but has a valve which
allows both pressure and vacuum relief.

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

VISUAL CHECK OF VAPOR CANISTER

Replace vapor canister if cracked or damaged.


Replace vapor canister if fuel is leaking from
bottom and check o p eratio n of th e to ta l
system.
Replace filter at the bottom of the canister if
dirty, plugged or damaged. (2.5L, 2.8L & 4.3L
(ST) only).

FUNCTIONAL TESTS

Vapor Canister - A ltitu d e Only

Apply a short length of hose to the lower tube of


purge valve, and attem pt to blow through it. Little or
no air should pass into the canister. (A small amount
of air will pass if the canister has a constant purge
hole).
With hand vacuum pump, apply vacuum (15 Hg.
or 51 kPa) to the control valve tube (upper tube). If
1 DIAPHRAGM the diaphragm does not hold vacuum for at least 20
2 VENT RESTRICTION seconds, the diaphragm is leaking, and the canister
3 TUBE TO MANIFOLD VACUUM must be replaced.
4 TUBE TO FUELTANK If the diaphragm holds vacuum, again try to blow
5 TUBE TO CANISTER 1 0 -1 -8 5 through the hose connected to the lower tube while
*6S 29 71-6 E vacuum is still being applied. An increased flow of air
Figure 5-4 - Fuel Tank Pressure Control Valve should be observed. If not, the canister m ust be
replaced.
Tank Pressure Control Valve
Tank Pressure Control Valve
The tank pressure control valve (Figure 5-4), used
only on altitude applications, allows vapors to flow Install a short piece of hose on the valve inlet tube
from the fuel tank into the system. When fuel tank (fuel tank side) and blow into hose. You should feel
pressure exceeds the spring pressure on the valve the diaphragm pop open and air should pass through
diaphragm (4.3 kPa), the valve opens and allow s the valve. If the valve does not open, it should be
vapors to enter the canister or go directly to the engine replaced.
when purge is enabled. The tank pressure control
valve is located in the engine compartment on C & K Therm ostatic Vacuum Switch
applications, and near the fuel tank on the others.
With the engine tem perature below 38C (100F),
DIAGNOSIS apply vacuum to manifold side of switch. Switch
should hold vacuum.
RESULTS OF INCORRECT OPERATION R aise te m p e ra tu re of engine to above 50C
V
(122F), vacuum should drop off.
Poor idle, stalling and poor driveability can be If switch fails either test, replace it.
caused by:
Damaged canister. ON-VEHICLE SERVICE
Hoses split, cracked and or, not connected to
the proper tubes. VAPOR CANISTER
Evidence of fuel loss or fuel vapor odor can be
caused by: |+ + | Remove or Disconnect
Liquid fuel leaking from fuel lines or TBI unit.
Cracked or damaged vapor canister. 1. Hoses from canister. Mark hoses for installation
Disconnected, misrouted, kinked, deteriorated on new canister.
or damaged vapor pipe, or canister hoses. 2. Screw from bracket and canister.
Air cleaner or air cleaner gasket improperly
seated.
5-4 EVAPORATIVE EMISSION CONTROL

a
r
r?


I [ 2 ^

TBI UNIT FUEL TANK El VAPOR PIPE

VAPOR CANISTER FUEL CAP


VAPOR RESTRICTION

5 -2 1 -8 6 El CANISTER HOSE 7 S 3 5 1 3 -6 E

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

TBI UNIT El FUELTANK E J FUEL CAP

El VAPOR CANISTER VAPOR RESTRICTION El VAPOR CANISTER


THERMOSTATIC 5 -2 3 -8 7
VAPOR PIPE El VACUUM SWITCH 7S -3 512-6E

Figure 5-6 - Evaporative Emissions Control System Schematic - 2.8L

TBI UNIT VAPOR RESTRICTION m VAPOR PIPE

m VAPOR CANISTER m FUELTANK m FUEL CAP


A .n.t.. .--r I r I AUXIL
AUXILLIARY^FUELTANK g| CANISTER H 0 SE
S AIR INLET I 6 I ( R &v
6 -5 -8 7
7S -3 514-6E

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

<-- REMOVE OR DISCONNECT PART NAME GROUP


1. Drain cooling system below level of switch Canister, Fuel Vapor .... 3.130
2. Vacuum hoses from switch Valve,Tank Pressure Control 3.140
3. Thermostatic vacuum switch
IGNITION SYSTEM/EST 6-1

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

The ignition system controls fuel combustion by


providing a spark top ignite the compressed air/fuel
mixture at the correct time. To provide improved
engine performance, fuel economy, and control of
exhaust emission, the ECM controls distributor spark
advance (timing) with the Electronic Spark Timing
(EST) system.
Only the EST system will be described here.
Additional information on the ignition system is found
in Section "6D.

OPERATION

The ignition system has a distributor module with


four terminals for the EST system (Figure 6-1 and 6-2) Figure 6-1 - Module (Except 2.5L & 2.8L)
that are connected by the ECM.
To properly control ignition/combustion timing,
the ECM needs to know:
Crankshaft position
Engine speed (rpm)
Engine load (manifold pressure or vacuum)
Atmospheric (barometric) pressure
Engine coolant temperature

All engines except 2.5L S/T Truck

The EST system consists of the d is trib u to r


module, an ECM, and connecting wires. The four
terminals for EST are lettered in the module.
The distributor four term inal connector is lettered
A-B-C-D.
These circuits perform the following functions:
TERMINAL A - Reference Ground Lo
This wire may be grounded in the distributor. It
makes sure the ground circu it, betw een the
module and ECM, has no voltage drop which could
affect performance. If it is open, it may cause poor
performance.
6-2 IGNITION SYSTEM/EST

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.

S/T Truck w ith 2.5L

The EST system consists of a hall effect switch, the


distributor module, an ECM, and connecting wires.
The four term inal connector is lettered A-B-C-D.
These circuits perform the following functions:
TERMINAL A - 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. the presence or absence of a m agnetic field on an
Therefore, if the base timing is set incorrectly, the electronic circuit. This system tells the ECM when
engine spark curve will be incorrect. the next cylinder is ready to be fired.
TERMINAL B - Distributor Reference Hi
This provides the ECM with rpm and crankshaft
DIAGNOSIS
position inform ation through the hall effect
switch.
The description and operation of the ig n ition
TERMINAL C - Bypass
system can be found in Section "6D.
At about 400 rpm, the ECM applies 5 volts to this
Refer to charts in this section for ignition system
circuit to switch spark timing control from the
check.
module to the ECM. An open or ground bypass
circuit will set a Code 42 and the engine will run EST SYSTEM
at base timing, plus a small amount of advance
built into the module.
Code 12 is used during the System Check in
TERMINAL D - Reference Ground Lo
Section "3 procedure to test the code display ability of
This wire is grounded in the d istrib u to r and
the ECM. This code indicates that the ECM is not
makes sure the ground circuit has no voltage drop
receiving the engine rpm (Reference) signal.
which could affect performance. If it is open, it
The "Reference signal also trig g e rs the fuel
may cause poor performance.
injection system. Without the "Reference signal, the
engine cannot run.
Hall Effect Switch
(Figure 6-3)
Results of Incorrect EST Operation
The hall effect switch used on the 2.5L engine for S
Truck is mounted above the pick-up coil in the
The ECM uses information from the MAP and
distributor. It takes the place of the reference "R
coolant sensors in addition to rpm to calculate spark
term inal on the module. The switch is an electronic
advance as follows:
device, which puts out a voltage signal controlled by
IGNITION SYSTEM/EST 6-3

Low MAP output voltage = More spark advance


Cold Engine = More spark advance
High MAP output voltage = Less spark advance
Hot engine = Less spark advance
Therefore, detonation could be caused by high
MAP output or low resistance in the coolant sensor
circuit.
Poor performance could be caused by high MAP
output or low resistance in the coolant sensor circuit.

CODE 42

A fault in the EST system will usually set a Code


42, as diagnosed in Section "3.
When the system is running on the distributor [~T1 TIMING CONNECTOR [T] ECM
module, there is no voltage on the bypass line and the [T1 ELAPSED TIMER [ T ] I P- HARNESS
module grounds the EST signal. The ECM expects to M0DULE 6S 30 35-6 E
see no voltage on the EST line during this condition. Figure 6-4 - Timing Connector (2.8L)
If it sees a voltage, it sets Code 42 and will not go into
the EST mode.
When the rpm for EST is reached (about 400 rpm),
ON-VEHICLE SERVICE
the ECM applies 5 volts to the bypass line and the EST
IGNITION SYSTEM
should no longer be grounded in the module, so the
EST voltage should be varying.
Refer to Section "6D for On-Vehicle Service of
If the bypass line is open, the module will not
distributor, pick-up coil, distributor cap, ignition coil,
switch to test mode, so the EST voltage will be low and
hall effect switch, rotor, or distributor module.
Code 42 will be set.
If the EST line is grounded, the module will switch
SETTING TIMING
to EST but, because the line is grounded, there will be
no EST signal and the engine will not run. A Code 42
Set timing according to instructions on Vehicle
may or may not be set.
Emission Control Information label under the hood.
An open in the EST circuit will set a Code 42 and
Timing specifications for each engine are listed on
cause the engine to run on the distributor module
the Vehicle Emissions Control Information label on
timing. This will cause poor performance and poor
the radiator support. When using a tim ing light,
fuel economy. A ground may set a Code 42, but the
connect an adapter between the No. 1 spark plug and
engine will not run.
the No. 1 spark plug wire, or use an inductive type
pickup. Do not pierce the plug lead. Once the
EST PERFORMANCE CHECK
insulation of the spark plug cable has been broken,
voltage will jump to the nearest ground, and the spark
2.5L Engine
plug will not fire properly. Always follow Vehicle
Emissions Control Information label procedures when
The ECM will set a specified value timing when
adjusting timing.
the ALDL diagnostic term inal is grounded. To check
the EST operation, record the timing at 2000 rpm with Some engines incorporate a m agnetic tim in g
probe hole for use with special electronic tim in g
the diagnostic term inal not grounded. Then, ground
equipment. Consult m anufacturers instructions for
the diagnostic term inal and the timing should change
use of this equipment.
at 2000 rpm, indicating that EST is operating.
Put the EST system in Bypass mode on the 2.5L
engine by connecting term inal "B to "A at the ALDL
Except 2.5L Engine
connector. On the V6 and V8 engines, the system will
go into Bypass mode by disconnecting the tim ing
To check EST operation, place the vehicle in
connector. This is a single wire sealed connector that
"Park or "N eutral and block the drive wheels. Start
has a tan with black stripe lead. On the 4.3L and V8
the engine and accelerate to 2000 rpm. Note the
engine, this connector breaks out of the engine wiring
ignition tim ing. D isconnect th e "S et T im in g
connector and again note the timing. The timing will harness conduit adjacent to the distributor. On the
2.8L engine, the connector breaks out of a taped
change if the EST system is working.
section below the h e a te r case in the passenger
compartment (Figure 6-4).
6-4 IGNITION SYSTEM/EST

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

IGNITION SYSTEM CHECK


(REMOTE COIL)
2 .5 L & 2 .8 L T R U C K
Test Description: Numbers below refer to circled 5. Applying a voltage (1.5 to 8 volts) to module
numbers on the diagnostic chart. term inal "P should turn the module "ON and the
1 . Two wires are checked, to ensure that an open is "Tach. terminal voltage should drop to about 7-9
not present in a spark plug wire. volts. This test will d eterm in e w hether the
1A. If spark occurs w ith 4 te rm in al d is trib u to r module or coil is faulty or if the pick-up coil is not
connector disconnected, pick-up coil output is too generating the proper signal to turn the module
low for EST operation. "ON. This test can be performed by using a DC
2. A spark indicates the problem m ust be th e battery with a rating of 1.5 to 8 volts. The use of
distributor cap or rotor. the test light is mainly to allow the "P term inal to
3. Normally, there should be battery voltage at the be probed more easily.
"C and " + te rm in als. Low voltage would Some digital m ulti-m eters can also be used to
indicate an open or a high resistance circuit from trigger the module by selecting ohms, usually the
the distributor to the coil or ignition switch. If "C diode position. In this position, the m eter may
term inal voltage was low, b ut " + te rm in al have a voltage across its term inals which can be
voltage is 10 volts or more, circu it from "C used to trigger the module. The voltage in the
term inal to ignition coil or ignition coil primary ohms position can be checked by using a second
winding is open. m e te r or by c h e c k in g th e m a n u f a c tu r e s
4. Checks for a shorted module or grounded circuit specification of the tool being used.
from the ignition coil to the module. The dist. 6. This should turn "OFF the module and cause a
module should be turned "OFF, so normal voltage spark. If no spark occurs, the fault is most likely in
should be about 12 volts. the ignition coil because most module problems
If the module is turned "ON, the voltage would be would have been found before this point in the
low, but above 1 volt. This could cause the procedure. A module te s te r (J24642) could
ignition coil to fail from excessive heat. determine which is at fault.
With an open ignition coil prim ary winding, a
small amount of voltage will leak through the Diagnostic Aids:
module from the "Bat. to the "tach terminal.
The "Scan tool does not have any ability to help
diagnose a ignition system check.
Refer to Section "2 for "ECM Interm ittent Codes or
Performance.
IGNITION SYSTEM/EST 6-5

P erform S ystem Check b e fo re proceeding w ith th is te s t. (If a

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

Reconnect dist. 2 te rm . conn.


W ith ian. " O N " , check v o lta g e fro m tach. te rm ,
to g n cf (te rm , m a y be ta p e d back in harness).
R epair w ire fro m m o d u le " + " te rm ,
to "B" te rm , of black Ign. coil
connector or p rim ary ckt. to ign. sw .
Check fo r o p en or cjnd. in ckt.
fro m "C " te rm , to ign. coil. If Ckt.
is OK, fa u lt is. ign. coil or conn..

O v e rlO volts U n d er 1 vo lt 1 to 10 volts

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. .

Light on stead y Light Spark N o Spark


blinks
I



Disconnect d is trib u to r 4 te rm , connector.
Rem ove dist. cap.
Disconnect pick-u p coil connector fro m m odu le.
System
OK
Replace ign. coil,
it to o is fa u lty

Connect v o ltm e te r fro m tach. te rm , to ground.


Ignition on.
Insulate a te s t lig h t probe to 1/4" fro m tip and notfe Replace ig n itio n coil an d recheck
v o lta g e , as te st fight is m o m e n ta rily connected fro m a fo r spark w it h spark te s te r. If still
v o lta g e source (1 .5 to 8V ) to m o d u le te rm . "P ". (Fig. 1). no spark, re-in sta ll o rig in a l coil
an d replace dist. m o d u le..

V o lta g e drops N o dro p in vo lta g e


I i

Check fo r spark fro m coil w ire w it h spark te s te r


as te s t lig ht is re m o v e d fro m m o d u le te rm .
Check m o d u le gro u n d .
If O K , replace m odu le.

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

<<- 4 2 4 TAN/BLK D5 BYPASS


SET T IM IN G -
CONNECTOR
4 5 3 BLK/RED B3

TACH LEAD

5-9 -8 8
6 -2 5 -8 7
5S 1784-6E

IGNITION SYSTEM CHECK


(REMOTE COIL / SEALED MODULE CONNECTOR DISTRIBUTOR)
ALL ENGINES EXCEPT 2.5L & 2.8L TRUCK

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

P erform S ystem Check b e fo re proceed ing w ith this te st. (If a


ta c h o m e te r is co n n ecte d to th e Tach te rm ., disco nnect it b e fo re
p roceed ing w it h th e te st).
IGNITION SYSTEM
CHECK
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 -12 5 )
w h ile cran king (if no spark on one w ir e , check a second w ir e ) A fe w (REMOTE COIL/SEALED MODULE
sparks and th e n n o th in g is considered no spark.
CONNECTOR DISTRIBUTOR)
1 ALL ENGINES
N o Spark Spark
EXCEPT 2.5L & 2.8L TRUCK
l - - _ ~ i
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

"L
TO D.C.
N o spark Spark POW ER SUPPLY
I-------- mz (1 .5 to 8V )

Check fo r spark a t coil w ir e w ith te s te r w h ile cran king .


(L eav e spark te s te r co nn ected to coil w ir e fo r Steps 3-6).
Replace pick-u p coil

N o Spark Spark
nzzzn n r

Disconnect d is trib u to r 2 te rm . "C / + " connector.


Ig n itio n sw itch " o n " , Engine stopp ed .
Check volts a t " + " and "C " te rm 's , o f dist. h arn . conn.
Inspect cap fo r w a t e r , cracks,
etc. If OK, rep la ce ro to 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..

O v e rlO volts U n d er 1 v o lt 1 to 10 vo lts


T
C onnect te s t lig h t fro m tach. te rm , to g rou nd . Repair op en tach. lea d or Replace m o d u le an d check fo r
Crank en g in e an d o b serve lig ht. conn and r e p e a t te s t # 4 . spark fro m coil as in S tep 6.

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

C onnect v o ltm e te r fro m ta ch . te rm , to g rou nd .


Ig n itio n on.
In sulate a te s t lig h t p rob e to 1/4 " fro m tip an d n o te v o lta g e , as te s t lig h t R eplace ig n itio n coil an d recheck
is m o m e n ta rily co nn ected fro m a v o lta g e source (1 .5 to 8V ) to m o d u le fo r spark w it h spark te s te r. If still
te rm . "P ". (Fig. 1). no sp ark, re -in s ta ll o rig in a l coil
an d replace dist. m o d u le..

L
V o lta g e drops N o d ro p in v o lta g e
I X

Check fo r spark fro m coil w ir e w it h spark te s te r


as te s t lig h t is re m o v e d fro m m o d u le te rm .
Check m o d u le g ro u n d .
If OK, rep la ce m o d u le .

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

Refer to Section "6D for replacem ent of the


distributor module or hall effect switch.
Refer to Section "3 for repair of the EST wires or
connectors.
Refer to Section "3 for replacement of the ECM.

Hall Effect Switch Test

1 . Disconnect and remove hall effect switch from


distributor.
2. Noting polarity marking on the switch, connect a
12 volt battery and voltmeter (Figure 6-5).
3. Voltmeter should read less than 0.5 volts without
blade against magnet. Replace switch if above 0.5
voits.
4. With blade against magnet, voltage should be
within 0.5 volts of battery voltage. Replace switch
if there is a low voltage reading. m HALL EFFECT SWITCH
f T l MAGNET
[ 3 [ INSERT KNIFE BLADE IN
PARTS INFORMATION THIS AREA WITH BLADE ,
STRAIGHT DOWN AGAINST
PART NAME THE MAGNET
GROUP
f~4~l TERMINAL (UNDERNEATH)

Distributor ........................................................ 1.150 I 5 I BATTERY


I 6 1 VOLTMETER
Module, D istr..................................................... 2.383 6 S 2 7 1 7 -6 E
Coil, D istr............................................................ 2.170
Figure 6-5 - Hall Effect Switch
ELECTRONIC SPARK CONTROL 7-1

SECTION 7

ELECTRONIC SPARK CONTROL (ESC)


ALL ENGINES EXCEPT 2.5L AND 7.4L
CONTENTS
GENERAL DESCRIPTION ON-VEHICLE SERVICE.............................................. ..7-1
PURPOSE.................... ESC KNOCK SENSOR............................................ ..7-1
OPERATIO N............... ESC MODULE AND BRACKET ........................... ..7-4
D IA G N O S IS .................... PARTS INFORMATION ............................................ ..7-4
CODE 4 3 ......................

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.

The electronic spark control (ESC) system is DIAGNOSIS


designed to retard spark timing up to 20 to reduce
spark knock (detonation) in the engine. This allows Loss of the ESC knock sensor signal or loss of
the engine to use maximum spark advance to improve ground at ESC module would cause the signal to the
driveability and fuel economy. ECM to remain high. This condition would cause the
V arying octane levels in todays gasoline can ECM to control EST as if there was no spark knock.
cause detonation in an engine. Detonation is called No retard would occur, and spark knocking could
spark knock. become severe under heavy engine load conditions.
Spark retard without the knock sensor connected
OPERATION could indicate a noise signal on the wire to the ECM or
a malfunctioning ESC module.
The ESC system has three components: Loss of the ESC signal to the ECM would cause the
ESC Module ECM to constantly retard EST. This could result in
ESC Knock Sensor sluggish performance and cause a Code 43 to be set.
ECM When no Code 43 is present but the ESC system is
The ESC knock sensor (F igure 7-1) d e te c ts a possible cause of excessive spark knock, refer to
abnormal vibration (spark knocking) in the engine. diagnosis chart for ESC system check.
The sensor is mounted in the engine block near the
cylinders (Figures 7-2 or 7-3). The ESC module CODE 43
receives the knock sensor inform ation and sends a
signal to the ECM. The ECM th en ad ju sts the Code 43 indicates that the ECM is receiving less
electronic sp ark tim in g (EST) to reduce s p a rk than 6 volts for a 4 second period with the engine
knocking. running. If code is present, refer to Code 43 chart in
The ESC module (Figures 7-4 through 7-6) sends a Section "3.
voltage signal (8 to 10 volts) to the ECM when no
spark knocking is detected by the ESC knock sensor, ON-VEHICLE SERVICE
and the ECM provides normal spark advance.
ESC KNOCK SENSOR
(Figures 7-2 or 7-3)
The ESC knock sensor is located on the left side of
the engine block, below the spark plugs for the 4.3L
engine and the right side of the engine block for the
2.8L, 5.0L and 5.7L engine.

Remove or Disconnect
1. Negative battery cable.
2. Wiring harness connector from ESC knock sensor.
3. ESC knock sensor from engine block.

Figure 7-1 - ESC Knock Sensor


7-2 ELECTRONIC SPARK CONTROL

ECM 1

ESC
MODULE

ZZ3
,J
...... J
7 -3 0 -8 7

ELECTRONIC SPARK CONTROL SYSTEM CHECK


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 is shut "OFF and this signals
the ECM to retard timing, if engine rpm is over about 900.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1 . If a Code 43 is not set, but a knock signal is "Scan tools may be used to diagnose the ESC
indicated while running at 1500 rpm, listen for an system. The knock signal can be monitored to see if
internal engine noise. Under a no load condition the knock sensor is detecting a knock condition and if
there should not be any detonation, and if knock is the ESC module is functioning, knock signal should
indicated, an internal engine problem may exist. display "YES, whenever detonation is present. For
2. U sually a knock sig n al can be g enerated by 2.5L engines, the knock retard position on the "Scan
tapping on the right exhaust manifold. This test displays the am ount of spark re ta rd th e ECM is
can also be performed at idle. Test number 1 was commanding. The ECM can retard the tim ing up to 20
run at 1500 rpm to determine if a constant knock degrees.
signal was present, which would affect engine If the ESC system checks OK, but detonation is
performance. the complaint, refer to "Detonation/Spark Knock in
3. This tests whether the knock signal is due to the Section "2.
sensor, a basic engine problem , or the ESC This check should be used after other causes of
module. spark knock have been checked such as engine timing,
4. If the module ground circuit is faulty, the ESC EGR systems, engine tem perature or excessive engine
module will not function correctly. The test light noise.
should light indicating the ground circuit is OK.
5. Contacting CKT 496, with a test light to 12 volts,
should generate a knock signal to d eterm ine
whether the knock sensor is faulty, or the ESC
module cant recognize a knock signal.
ELECTRONIC SPARK CONTROL 7-3

ELECTRONIC SPARK CONTROL


SYSTEM CHECK
ALL ENGINES EXCEPT 2.5L AN D 7.4L

7 S 3 7 1 1 -6 E
7 -8 -8 6
7-4 ELECTRONIC SPARK CONTROL

m ESC KNOCK SENSOR

m TRANSMISSION M O U T IN G FLANGE gs 5608-6 E

Figure 7-2 - ESE Knock Sensor - 4.3L

m ESC MODULE
l~2~1 ELECTRICAL CONNECTOR 7S3713-6E

Figure 7-5 - ESC Module - CK RV MP Series

f T l ESC KNOCK SENSOR


I 2 I ELECTRICAL CONNECTOR 6S2892-6E

Figure 7-3 - ESC Knock Sensor - 2.8L, 5.0L, 5.7L

+4- Install or Connect


1 . Knock sensor into engine block. Apply water base
calk to sensor threads. Do not use silicon tape as
this will insulate sensor from the engine block.
ESC wiring harness connector to the ESC knock
sensor.
3. Negative battery cable.

ESC MODULE AND BRACKET fT] ESC MODULE [T 1 SEAT RISER


(Figures 7-4 through 7-6) [T 1 ELECTRICAL CONNECTOR 7S3714-6E

|<-+| Remove or Disconnect Figure 7-6 - ESC Module - G Series


1 . ESC module connector.
PARTS INFORMATION
2. Attaching screws.
3. ESC module.
PART NAME GROUP
Install or Connect
Sensor, ESC K n o c k .......................................... .3.682
1 . ESC module. Module, Elek Spark C o n t..................................2.383
2. Attaching screws. Bracket, Elek Spark Cont M d ...........................2.383
3. ESC module connector. Shield, Elek Spark Cont Knock ..................... .2.383
AIR MANAGEMENT 8-1

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

The air m anagem ent system is used to reduce


carbon monoxide and hydrocarbon emissions on some
engines.
This system, air injection reaction (AIR), under
certain conditions, adds air (oxygen) to the exhaust
manifold to continue combustion after the exhaust
gases leave the combustion chamber. This added air
also brings the catalytic converter up to operating
tem perature more quickly when the engine is cold.

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

Figure 8-2 - AIR System - 4.3L & V8


AIR OPERATION

The system consists of an air pump, an (electric)


m a ir pu m p
air control valve with solenoid, check valve(s), and
[T 1 EAC VALVE
m AIR TO AIR CLEANER
necessary plumbing.
A belt driven air pump supplies a ir through a
[ T 1 AIR TO EAC VALVE
centrifugal filter fan to the electric air control (EAC)
f T l AIR TO EXHAUST PORT
valve 2.8L (Figure 8-3) or an electric air control valve
l~6~| MANIFOLD VACUUM SIGNAL
with relief tube (ECT) 4.3L and V8 (Figure 8-4). The
f T l ECM
shape of the centrifugal filter fan blades and the
m EAC SOLENOID
direction of fan rotation prevents foreign m aterial
[~ 9 ~ 1
CHECK VALVE
R o l EXHAUST MANIFOLD 6S 30 40-6E
from entering the pump with the incoming air. The
EAC or ECT valve, directs the air to either the engine
Figure 8-1 - AIR System - 2.8L exhaust manifold ports or to the air cleaner.
8-2 AIR MANAGEMENT

NOTICE: On the EAC valve, the divert and signal


tube locations are reversed from the
previous model year.

When the engine is cold or in wide open throttle


condition, the ECM energizes the solenoid on the
valve and air is directed to the exhaust manifold ports.
When the coolant tem perature increases, the solenoid
is de-energized and air goes into the air cleaner which
also acts as a silencer. At higher engine speeds, air is
directed to the air cleaner through the pressure relief
valve even though the solenoid may be energized.
There should be no air going to the exhaust ports
while operating in the "Closed Loop mode.
During engine decel, when there is a rise in the
manifold vacuum signal, air is directed to the air
cleaner.
A check valve, on the air injection pipe, prevents rn CONTROL
ELECTRIC AIR
VALVE WITH
[71 ORIFICE
DIVERT ASSIST
back flow of exhaust into the air pump if there is an RELIEF TUBE [][] DIAPHRAGM & GUIDE
exhaust backfire or pump drive belt failure. f T I OUTLET SEAT ASSEMBLY
If the engine is operating under a rich condition or [~3~| METERING VALVE UH DIAPHRAGM SPRING
CHAMBER Q o]
the "Service Engine Soon lamp lights, the solenoid is VACUUM CHAMBER
T H RELIEF VALVE & q jj
de-energized and air goes to the air cleaner. BODY ASM MANIFOLD VACUUM
SIGNAL TUBE
ITI PRESSURE PASSAGE
m DIAPHRAGM COVER
T 1 BAND CLAMP ASSEMBLY
7 S 3 6 1 3 -6 E

Figure 8-4 - ECT Valve

DIAGNOSIS

AIR SYSTEM

Refer to "Air Management Check ch art for the


diagnosis of the AIR system.

NOTICE: If the engine or underhood compartment is


to be cleaned with steam or high-pressure
detergent, the centrifugal filter fan should
be masked off to prevent liq u id s from
entering the pump.

If no air (oxygen) flow enters the exhaust stream at


the exhaust ports, HC and CO emission levels may be
too high.
HH e l e c t r ic a ir c o n t r o l nn DECEL TIMING CHAMBER Air flowing to the exhaust ports at all times could
(EAC) VALVE j T ] AIR TO AIR CLEANER cau se a ric h ECM co m m an d an d in c r e a s e d
| 2 1DECEL TIMING ASSEMBLY [~8~1 AIR FROM AIR PUMP temperature of the converter.
fTI M ANIFOLD VACUUM [ T 1 AIR TO EXHAUST PORTS The AIR system is not completely noiseless. Under
SIGNAL TUBE OR M ANIFOLD normal conditions, noise rises in pitch as engine speed
IT] ELECTRICAL TERMINAL [T q ] PRESSURE RELIEF increases. To determine if excessive noise is the fault
[~5~| EAC SOLENOID ASSEMBLY 6 S 2 6 0 9 -6 E of the AIR system pump, m om entarily operate the
engine with the pump drive belt removed.
Figure 8-3 - EAC Valve
AIR MANAGEMENT 8-3

If noise is caused by the AIR system pump, check ON-VEHICLE SERVICE


fo r:
A seized air pump. DRIVE BELT
Proper mounting and bolt torque of pump.
Proper routine and connections of hoses. 4-+ Remove or Disconnect

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

AIR MANAGEMENT CHECK


(ELECTRONIC AIR CONTROL VALVE)
Circuit Description:
An electric air control valve solenoid directs air into the exhaust ports or the air cleaner. During cold start
the ECM completes the ground circuit, the EAC solenoid is energized, and air is directed to the exhaust ports.
As "coolant tem perature increases, or system goes to "Closed Loop, the ECM opens the ground circuit, the
EAC solenoid is de-energized, and air goes to the air cleaner. If the system is not operating properly, check
manifold vacuum signal (10Hg/34kPa) at the valve and check the electrical circuit from the solenoid to the
ECM.

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

AIR MANAGEMENT CHECK


(ELECTRONIC AIR CONTROL VALVE)

7-27-87
*6S 2839-6EB
8-6 AIR MANAGEMENT

sealing lip has worn in. This may require a short


period of pump operation a t v ario u s engine
speeds.
6. Pump drive belt and adjust.
7. Check a ir m an ag em en t sy ste m for p ro p e r
operation (see Air Management Check chart).

AIR CONTROL VALVE


(Figures 8-7 thru 8-11)

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

Figure 8-5 - Pump Filter Fan Service


CHECK VALVE
(Figures 8-7 thru 8-11)
AIR PUMP (Figure 8-6)
4- + Remove or Disconnect
<-- Remove or Disconnect
1. Any parts required for access.
1. Hold pump pulley from turning by compressing 2. Release clamp and disconnect air hoses from
drive belt, then loosen pump pulley bolts. check valve.
2. Loosen bolt, holding pump to mounting brackets, 3. Unscrew check valve from air injection pipe.
release tension on drive belts.
3. Move belts out of the way, then remove pump
hoses, vacuum and electrical connections, and E
t + l Install or Connect
1. Screw check valve onto air injection pipe.
control valve.
4. Pulley, then pump. 2. Position air hose on check valve and secure with
5. If required, insert needle nose pliers and pull clamp.
filter fan from hub (see Figure 8-5). 3. Any parts removed for access.

Install or Connect AIR INJECTION PIPE ASSEMBLY

1. Air pump assembly, and tighten mounting bolts. Remove or Disconnect


2. Hose.
3. New filter fan on pump hub. 1. Hose.
4. Spacer and pump pulley ag ain st cen trifu g al 2. Check valve.
filter fan. 3. Nuts attaching pipes-to-manifold.
5. Pump pulley bolts and tighten equally to torque 4. Pipe assembly.
spec, in Figure 8-6. This will compress the
centrifugal filter fan onto the pump hole. Do not + 4- Install or Connect
drive filter fan on with a hammer. A slight
1. Nuts attaching pipes-to-manifold.
amount of interference with the housing bore is 2. Check Valve.
normal. After a new filter fan has been installed,
3. Hose.
it may squeal upon initial operation or until O.D.
AIR MANAGEMENT 8-7

f T | AIR P U M P [ T ] BRACE [ T ] BOLT - TO RQ UE TO 30 N m (22 FT. LBS.)

f T l PULLEY [ T ] SUPPORT [To] BOLT - TO RQ UE TO 4 0 N m (2 9 FT. LBS.)

f T l SPACER [7 ] BOLT - TO RQ UE TO 15 N m (11 FT. LBS.) Q T ] BOLT - TO RQ UE TO 80 N-m (5 9 FT. LBS.)

|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

Figure 8-6 - AIR Pump Mounting


8-8 AIR MANAGEMENT

rn airpump m AIR INJECTION PIPE TIGHTEN NUTS TO 28N-m (20FT. LBS.)


fTI SILENCER f T I BOLT TIGHTEN TO 15 N-m (11 FT. LBS.)
m EAC VALVE [ T ! GASKET
FT] HOSE [T 1 SHIELD
fTI CHECK VALVE TIGHTEN TO 85 N-m (26 FT. LBS.) Q o ] PORT VACUUM HARNESS 6S 28 9 7 -6 E

Figure 8-7 - A I R System - 2.8L

[~T] AIR PUMP [ T ] DIVERTER VALVE OR EAC VALVE


[ T ] ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N-m (18 FT. LBS.) [ j f ] AIR CLEANER
FT] AIR INJECTION PIPE TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) [T ] BOLT - TIGHTEN TO 34 N-m (25 FT. LBS.)
FTI CHECK VALVE - TIGHTEN TO 25 N-m (18 FT. LBS.) [T ] NUT-TIGHTEN TO 34 N-m (25 FT. LBS.)
7 S 3 3 0 9 -6 E

Figure 8-8 - A I R System - 4.3L - G & M Series


AIR MANAGEMENT 8-9

NOTE: ON SOME VEHICLES THE EAC VALVE IS MOUNTED ON THE PUMP ADAPTER

m AIR PUMP [T] DIVERTER VALVE OR EAC VALVE


[T] ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N-m (18 FT. LBS.) [T] AIR CLEANER
IT] AIR INJECTION PIPE TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) [7] BOLT - TIGHTEN TO 34 N-m (25 FT. LBS.)
fTl CHECK VALVE - TIGHTEN TO 35 N-m (26 FT. LBS.) [ T ] NUT - TIGHTEN TO 34 N-m (25 FT. LBS.)

7S 34 12-6 E

Figure 8-9 - A I R System - 4.3L, 5.0L, 5.7L - C, K, P, R, & V Series

fTl AIR PUMP [T] DIVERTER VALVE OR EAC VALVE


|~2~| ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N-m (18 FT. LBS.) [ T ] AIR CLEANER
m AIR INJECTION PIPE TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) QH BOLT - TIGHTEN TO 3 N-m (26 IN. LBS.)
[~4~| CHECK VALVE - TIGHTEN TO 25 N-m (18 FT. LBS.)
7 S 3 4 1 1 -6 E

Figure 8-10 - A I R System - 5.0L, 5.7L - G Series


8-10 AIR MANAGEMENT

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

Figure 8-11 - A IR System - 7.4L - All Series

PARTS INFORMATION

PART NAME GROUP

Adapter, AIR Inj Cont V I v .............................. ..3.671


Bracket, AIR Inj Pump Supt ............................3.655
Bracket, AIR Inj P u m p ..................................... ..3.655
Fan, AIR P u m p ...................................................3.665
Gasket, AIR Inj Dvtr Vlv E l ............................ ..3.671
Harness, AIR Inj Cont Vlv V a c ....................... ..3.675
Hose, AIR Inj Cont V lv ..................................... ..3.675
Hose, AIR Inj Cont Vlv D v tr............................ ..3.675
Pulley, AIR Inj P u m p ..........................................3.650
Pump, AIR I n j ................................................... ..3.660
Valve, AIR Inj C o n t............................................3.670
Valve, AIR Inj Eng C h k .....................................3.670
Valve, AIR Inj Control (Divert)....................... ..3.670
Valve, AIR Inj S w itch in g ...................................3.670
EXHAUST GAS RECIRCULATION 9-1

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

The EGR system is used to lower NOx (oxides of


nitrogen) emission levels caused by high combustion
temperatures. The EGR valve feeds small amounts of
exhaust gas back into the combustion cham ber to
decrease combustion tem perature.
The main element of the system is an EGR valve
operated by vacuum, and mounted on the in tak e
manifold.

OPERATION

The EGR valve is opened by vacuum to let exhaust


gas flow into the intake manifold. The exhaust gas
then moves w ith the air/fu el m ix tu re into the
combustion chamber. If too much exhaust gas enters,
combustion will not occur. For this reason, very little
exhaust gas is allowed to pass through the valve,
especially at idle. The EGR valve is usually open FTI EGR VALVE [m AIR BLEED
under the following conditions: IT ] PINTLE VALVE HOLE
Warm engine operation CHI INTAKE AIR r n SMALL SPRING
Above idle speed H VACUUM PORT m LARGE SPRING
Q D DIAPHRAGM 6 S 2 6 0 8 -6 E
EGRCONTROL
Figure 9-1 - Negative Backpressure EGR Valve 2.5L,
Solenoid 2.5L, 4.3L (except ST), 5.0L & 5.7L (under 4.3L (except ST), 5.0L& 5.7L (under 8500 GVW)
8500 GVW) EVRV 2.8L, 4.3L (ST), 7.4L & 5.7L (over 8500 GVW)
To regulate EGR flow an ECM controlled solenoid To reg u la te EGR flow, an ECM co n tro lle d
is used in the vacuum line. This is a normally closed electronic vacuum regulator valve (EVRV) solenoid is
solenoid vacuum valve which is opened when the ECM used in the vacuum line. The ECM uses information
completes the ground. The ECM will energize the from the following sensors to regulate the solenoid:
EGR solenoid (EGR "ON) when the engine is warm Coolant Temperature
and above idle. There is little EGR flow at wide open Throttle Position (TPS)
throttle due to lack of vacuum. P/N Switch
2.5L only Distributor (rpm Signal)
On cold engine start-up the ECM receives input The EGR vacuum control has an EVRV solenoid that
from the MAT sensor (manifold air temperature), and uses "pulse width modulation. This means the ECM
if the MAT reading is less than 12C (57F) the EGR turns the solenoid "ON and "OFF many tim es a
solenoid is "OFF until the coolant warms to 80C second and varies the amount of "ON time ("pulse
(176F). If there is a malfunction of the MAT sensor width) to vary the amount of EGR.
then the ECM receives input from the coolant sensor.
9-2 EXHAUST GAS RECIRCULATION

TYPES OF EGR VALVES

Two types of EGR valves are used on these


engines:
Port (2.8L, 4.3L (ST), 7.4L & 5.7L over 8500
GVW)
Negative backpressure (2.5L, 4.3L (except ST),
5.0L & 5.7L under 8500 GVW)

Port EGR Valve

This valve is controlled by a flexible diaphragm


which is spring loaded to hold the valve closed.
Vacuum applied to the top side of the diaphragm
overcomes the spring pressure and opens the valve in
the exhaust gas port. This allows exhaust gas to be
pulled into the intake manifold and enter the engine
cylinders.

f T l EGR VALVE m MAP SENSOR


|~2~| EXHAUST GAS | 8 I COOLANT TEMPERATURE
SENSOR
f T l INTAKE AIR
[~9~1 THROTTLE POSITION
[~~4~~| DIAPHRAGM SENSOR
| 5 | MANIFOLD VACUUM
[Tol ELECTRONIC CONTROL
|~6l VACUUM SOLENOID MODULE
6S 28 61-6 E

Figure 9-3 - EGR System - w ith Solenoid

CD EGR VALVE m DIAPHRAGM


m EXHAUST GAS VALVE OPEN
m INTAKE AIR VALVE CLOSED
VACUUM PORT j[ ] SPRING 4 S 0 5 3 6 -6 E

Figure 9-2 - Port EGR Valve no tzr


2.8L, 4.3L (ST), 7.4L & 5.7L(over 8500 GVW)

N egative Backpressure EGR Valve [T~| ASSEMBLY PLANT CODE


[~2~1 PART NUMBER
The negative backpressure EGR valve has the [~3~| DATE BUILT
bleed valve spring below the diaphragm, and the valve fTl LOOK HERE FOR LETTER
----- P = POSITIVE BACK PRESSURE
is normally closed. The negative backpressure valve N = NEGATIVE BACK PRESSURE
BLANK = PORT VALVE 7S3219-6E
varies the am ount of ex h au st gas flow into the
m anifold dep en d in g on m an ifo ld vacuum an d Figure 9-4 - EGR Valve Identification
variations in exhaust back pressure.
The diaphragm on this valve has an internal air
bleed hole which is held closed by a small spring when EGR VALVE IDENTIFICATION
there is no exhaust backpressure.
Engine vacuum opens the EGR valve against the Positive backpressure EGR valves will have a "P
pressure of a large spring. When manifold vacuum stamped on the top side of the valve after the part
combines with negative exhaust backpressure, the number.
vacuum bleed hole opens and the EGR valve closes. Negative backpressure EGR valves will have a
This valve will open if vacuum is applied with the "N stamped on the top side of the valve after the
engine not running. part number.
Port EGR valves have no identification stamped
after the part number.
EXHAUST GAS RECIRCULATION 9-3

DIAGNOSIS

RESULTS OF INCORRECT OPERATION

With too much EGR flow at idle, cruise, or cold


operation, any of the following conditions may occur:
Engine stops after cold start.
Engine stops at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
If the EGR valve should stay open all of the time,
the engine may not idle.
Too little or no EGR flow allow s com bustion
temperatures to get too high during acceleration and EGR VALVE fTI PORTED MANIFOLD
VACUUM (PORT F)
load conditions. This could cause: VACUUM HARNESS
[ T 1 BOLT TIGHTEN TO
Spark knock (detonation). EGR SOLENOID 4 N-m (35 LBS. IN.)
Engine overheating. 7 S 3 0 2 9 -6 E

Figure 9-5 - EGR & Solenoid (2.5L)


SYSTEM CHECK

Diagnosis of the EGR system is covered in the


following charts. These charts begin on page 9-4.
EGR System Check on a 2.5L, 4.3L (except ST),
5.0L & 5.7L (under 8500 GVW) engine.
EGR System Check on a 2.8L, 4.3L (ST), 7.4L &
5.7L (over 8500 GVW) engine.

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.

EGR M anifold Passage

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

Figure 9-7 - EGR & Solenoid (4.3L except ST)


9-4 EXHAUST GAS RECIRCULATION

TO EGR VALVE

ECM

2.5L
ONLY

EXCEPT
2.5L
7-15-87
7-31-87 7S3737

EGR SYSTEM CHECK


2.5L, 4.3L (EXCEPT ST), 5.0L & 5.7L (UNDER 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 control of the EGR is based on the following inputs:
Engine coolant tem perature - above 25C.
TPS - "OFF idle
MAP
If Code 24 is stored, use that chart first.
Code 32 will detect a faulty solenoid, vacuum supply, EGR valve or plugged passage. This chart checks for
plugged EGR passages, a sticking EGR valve, or a stuck open or inoperative solenoid.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1 . Checks for solenoid stuck open. Before replacing ECM, use an ohm m eter and
2. Checks for solenoid always being energized. check the resistance of each ECM controlled relay
3. Grounding test term inal should energize solenoid and solenoid coil. Refer to "ECM QDR Check
and vacuum should drop. procedure in Section "3. See ECM w irin g
4. Negative backpressure valve should hold vacuum diagram for coil terminal I.D. of solenoid(s) and
with engine "OFF. relay(s) to be checked. Replace any solenoid where
5. When engine is started, exhaust backpressure resistance measures less than 20 ohms.
should cause vacuum to bleed off and valve to fully
close.
EXHAUST GAS RECIRCULATION 9-5
9-6 EXHAUST GAS RECIRCULATION

EGR SYSTEM CHECK


2.8L, 7.4L, 4.3L (ST), & 5.7L (OVER 8500 GVW )
Circuit Description:
The EGR valve is controlled by a normally closed solenoid (allows a vacuum to pass when energized). The
ECM pulses the solenoid to turn "ON and regulate the EGR. The ECM diagnoses the system using an internal
EGR test procedure.
The ECM control of the EGR is based on the following inputs:
Engine coolant tem perature - above 25C.
TPS "OFF idle
MAP
If Code 24 is stored, use that chart first.
Code 32 will detect a faulty solenoid, vacuum supply, EGR valve or plugged passage. This chart checks for
plugged EGR passages, a sticking EGR valve, or a stuck open or inoperative solenoid.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. With the ignition "O N , engine stopped, the Before replacing ECM, use ohmmeter and check
solenoid should not be energized and vacuum resistance of each ECM controlled relay and
should not pass to the EGR valve. solenoid coil. Refer to "ECM QDR Check in
2. Grounding the diagnostic term inal will energize Section "3.
the solenoid and allow vacuum to pass to valve. See ECM w iring diag ram for coil te rm in a l
3. Checks for plugged EGR passages. If passages are identification of solenoid(s) and relay(s) to be
plugged, the engine may have severe detonation checked. Replace any relay or solenoid if the coil
on acceleration. resistance measures less than 20 ohms.
4. The vehicle must be driven during this test in
order to produce sufficient engine load to operate
the EGR. Lightly accelerating (approximately 1/4
throttle) will produce a large and stable enough
reading to determine if the ECM is commanding
the system "ON.
EXHAUST GAS RECIRCULATION 9-7
9-8 EXHAUST GAS RECIRCULATION

F T I EGR VALVE fTI EGR VALVE


f T I VACUUM HARNESS m VACUUM HARNESS
FTI EGR SOLENOID (MOUNTED ON TOP SIDE OF ITI EGR SOLENOID (MOUNTED ON TOP SIDE OF
BRACKET ON G-SERIES) BRACKET ON G-SERIES)
[ T ] MANIFOLD VACUUM (PORT-J) FTI MANIFOLD VACUUM (PORT-S)
BOLTTIGHTEN TO 2 N m (18 IN. LBS.) I 5 I BOLTTIGHTEN TO 4 N m (35 LBS. IN.)
HARNESS CONNECTOR fTI HARNESS CONNECTOR
BRACKET IT] BRACKET
IS34 60-6E _____________________________________________________7 S 3 4 6 1 -6 E

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

SYSTEM HOSES Figure 9-10 - EGR & Solenoid (7.4L)

Refer to Vehicle Emission Control Inform ation


label for routing of system hoses.
When replacing hoses, use hose identified with the
word "Fluoroelastomer.
EXHAUST GAS RECIRCULATION 9-9

fTI EGR V A L V E
m GASKET

ITI GASKET m STUD


fT I B O LT T IG H T E N T O 25 N m (18 FT. LB S .) 7S 3455-6E m N U T -T IG H T E N T O 20 N -m (15 FT. LB S .) 7S 34 57-6 E

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

Figure 9 -1 2 - EGR Valve (2.8L) Figure 9-15 - EGR Valve (7.4L)

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

Figure 9-13 - EGR Valve (4.3L)


9-10 EXHAUST GAS RECIRCULATION

EGR SOLENOID EGR VACUUM SOLENOID


2.8L, 4.3L (ST), 7.4L & 5.7L (over 8500 GVW) 2.5L, 4.3L, 5.0L & 5.7L (under 8500 GVW )
(Figure 9-16) (Figure 9-17)

|4~| Remove or Disconnect |<-+| Remove or Disconnect


l. Negative battery cable. l. Negative battery cable.
2. Air cleaner, if necessary. 2. Electrical connector at solenoid.
3. Electrical connector at solenoid. 3. Vacuum hoses.
4. Vacuum hoses. 4. Bolt(s) and solenoid.
5. Bolt(s) and solenoid.
6. Filter, if required. + 4- Install or Connect

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.

EGR FILTER CLEANING / REPLACEMENT

1. Grasp and pull filter off with a rocking motion.


2. Push new filter on making sure cut-out for
wires is properly aligned.

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

Figure 9-17 - EGR Control Solenoid


(2.5L, 4.3L (except ST), 5.0L & 5.7L Under 8500 GVW)

PARTS INFORMATION

PARTS NAME GROUP


Valve, EGR ................................................... 3.670
Valve, Elect Vac Reg ................................. 3.670
Solenoid, EGR C o n t........................................ 3.670
(2.8L,4.3L (ST), 7.4L, & 5.7L Over 8500 GVW) Gasket, EGR V a lv e ........................................ 3.680
TRANSMISSION CONTROLS 10-1

SECTION 10

AUTOMATIC AND MANUAL TRANSMISSION CONTROLS


CONTENTS
GENERAL DESCRIPTION.................................. .. 10-1 M ANUAL TRANSMISSION SHIFT
AUTOMATIC TR AN SM ISSIO N ...................... 10-1 LIGHT CHECK.............................................. 10-8
TCC System .............................................. .. 10-1 D IA G N O S IS ........................................................ ..10-10
O p e r a t io n ............................................ .. 10-1 TCC SYSTEM ................................................. ..10-10
D o w n sh ift C o n t r o l.................................. .. 10-1 DOWNSHIFT CONTROL SYSTEM............... ..10-10
M ANUAL TRANSMISSION........................... .. 10-1 SHIFT LIGHT SYSTEM .................................. ..10-10
S h ift Light S ystem ....................................... 10-1 ON-VEHICLE SERVICE....................................... ..10-10
TCC ELECTRICAL DIAGNOSIS TCC SYSTEM ...................................................10-10
2.5L .......................................................... .. 10-2 DOWNSHIFT CONTROL SY S TE M ............... ..10-10
4 .3 L & V -8 .............................................. .. 10-4 SHIFT LIG H TS Y S T E M .................................. ..10-10
DOWNSHIFT CONTROL DIAGNOSIS ____10-6 PARTS INFORMATION .......................................10-10

GENERAL DESCRIPTION D ow nshift Control System


While operating a vehicle equipped with a THM
AUTOMATIC TRANSMISSION
400 transmission, at speeds below 70 mph, a forced or
TCC System d eten t dow nshift is possible, by d ep ressin g the
The torque converter clutch (TCC) system, used on accelerator fully.
a 7004R transmission, uses a solenoid operated valve, The ECM will recognize the rapid increase in
to couple the engine flywheel to the output shaft of the MAP sensor voltage, due to a drop in m anifold
transm ission through the torque converter. This vacuum, and turn on the downshift control relay. The
reduces the slippage losses in the converter, which relay will, then, send battery voltage to the detent
increases fuel economy. solenoid, in the transmission, which opens an orifice
and forces a transm ission downshift.
Operation
MANUAL TRANSMISSION
For the converter clutch to apply, two conditions Shift Light System
must be met:
Internal transm ission fluid p ressu re m ust be A vehicle, with manual transm ission, has a shift
correct. For information on in tern al transm ission light, on the instrum ent panel, to indicate the best
operation, see Section "7A. This section will cover shift point for maximum fuel economy. The light is
only the electrical operation of the TCC system. controlled by the ECM and is tu rn e d "O N by
The ECM completes a ground circuit to energize a grounding CKT 456.
TCC apply solenoid in the transm ission which moves a
check ball in a fluid line (Figure 10-1). This allows the
converter clutch to apply, if the hydraulic pressure is
correct, as described above.
The ECM controls the TCC apply solenoid by
looking at several sensors:
Coolant tem perature sensor. Engine m ust be
warmed up, before clutch can apply.
T h ro ttle p o sitio n sen so r (TPS). A fter th e
converter clutch ap plies, th e ECM uses th e
information from the TPS to release the clutch,
when the vehicle is accelerating, or decelerating
at a certain rate.
Brake Switch. This switch in the TCC circuit
opens, when the brake pedal is depressed. This de
energizes the TCC solenoid. T] TCC S O LEN O ID [J ] CHECK BALL SEAT

Pulse switch. This is a downshift 4-3 pulse switch, T | CHECK BALL


__________________________________________________4S 05 48-6 E
w h ich o p en s th e TCC s o le n o id c i r c u i t ,
momentarily, during a downshift. Figure 10-1 - TCC Solenoid
Vehicle speed sensor. The VSS signals vehicles
speed to ECM.
10-2 TRANSMISSION CONTROLS

TORQUE CONVERTER CLUTCH (TCC)


(ELECTRICAL DIAGNOSIS)
2.5L ENGINE
Circuit Description:
The purpose of the automatic torque converter clutch feature is to eliminate the power loss of the torque
converter stage when the vehicle is in a cruise condition. This allows the convenience of the autom atic
transmission and the fuel economy of a manual transmission.
Fused battery ignition is supplied to the TCC solenoid through the TCC brake switch.
The ECM will engage TCC by grounding CKT 422 to energize the solenoid.
TCC will engage when:
Vehicle speed above 24 mph (39 km/h.)
Engine at normal operating tem perature (above 65C) (149F).
Throttle position sensor output not changing, indicating a steady road speed.
Brake switch closed.
3rd or 4th gears.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1 . Checks continuity through brake switch and TCC Solenoid coil resistance must measure more than
solenoid. 20 ohms. Less resistance will cause early failure of
2. Checks capability of ECM to energize solenoid. the ECM "driver. Refer to "ECM QDR check in
G rounding the d iag n o stic co n n ecto r should Section "3. Using an ohmmeter, check the solenoid
energize the relay and cause the light to go out. coil resistance of all ECM controlled solenoids and
3. This test bypasses the TCC solenoid and checks for relays, before installing a replacement ECM. Replace
an open or short in CKT 422. any solenoid, or relay, th at m easures less than 20
ohms resistance.
TRANSMISSION CONTROLS 10-3

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

vss 4 3 7 BRN A10 SPEED IN P U T


BRAKE SW. 20A

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

TORQUE CONVERTER CLUTCH (TCC)


(ELECTRICAL DIAGNOSIS)
4.3L, 5.0L AND 5.7L (UNDER 8500 G VW )
Circuit Description:
The purpose of the automatic transmission torque converter clutch feature is to eliminate the power loss of
the torque converter stage when the vehicle is in a cruise condition. This allows the convenience of the
automatic transmission and the fuel economy of a manual transmission.
Fused battery ignition is supplied to the TCC solenoid through the TCC brake switch.
The ECM will engage TCC by grounding CKT 422 to energize the solenoid.
TCC will engage when:
Vehicle speed above 30 mph (48 km/h.)
Engine at normal operating temperature (above 65C) (149F).
Throttle position sensor output not changing, indicating a steady road speed.
Brake switch closed.
3rd or 4th gears.

Test Description: Numbers below refer to circled Diagnostic Aids:


numbers on the diagnostic chart.
1. A test light "ON indicates battery voltage and Solenoid coil resistance must measure more than
continuity through the TCC solenoid is OK. 20 ohms. Less resistance will cause early failure of
2. Checks for vehicle speed sensor signal to ECM the ECM "driver. Refer to "ECM QDR check in
using a "Scan tool. Section "3. Using an ohmmeter, check the solenoid
3. Checks for 4th gear signal to ECM. This signal coil resistance of all ECM controlled solenoids and
will not prevent TCC engagement, but could cause relays before installing a replacement ECM. Replace
a change in the engage and disengage speecl any solenoid or relay that measures less than 20 ohms
points. resistance.
TRANSMISSION CONTROLS 10-5

TORQUE CONVERTER CLUTCH


(TCC)
USE A "S C A N " TO O L TO CHECK THE
FO LLO W IN G A N D CORRECT IF NECESSARY
(ELECTRICAL DIAGNOSIS)
C O O LA N T TEMPERATURE 4.3L, 5.0L AND 5.7L (UNDER 8500 G V W )
TPS
VSS
C O D E S -IF 2 4 IS PRESENT, SEE CODE
CHART 24. ALSO, PERFORM
M E C H A N IC AL CHECKS, SUCH AS
LINKAGE, OIL LEVEL. ETC., BEFORE
USING THIS CHART.

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

THM 400 TRANSMISSION DOWNSHIFT CONTROL


(ELECTRICAL DIAGNOSIS)
Circuit Description:
When the accelerator pedal is fully depressed, manifold vacuum in the engine drops causing the MAP sensor
signal voltage to increase to approximately 4 volts. The ECM responds by grounding CKT 422 to turn "ON the
downshift control relay. The relay then sends battery voltage to the detent solenoid, which causes a forced
transmission downshift.

Diagnostic Aids: Relay coil resistance must measure more than 20


ohms. Less resistance will cause early failure of
If problem is diagnosed as being an in te rn a l the ECM "driver. Refer to "ECM QDR check
transm ission problem , see Section "7 of the (Figure 3-18). Using an ohmmeter, check the coil
appropriate series Service Manual as listed in the resistance of all ECM controlled solenoids and
"Forward. relays before in sta llin g a rep lacem en t ECM.
Replace any solenoid or relay th at measures less
than 20 ohms resistance.
TRANSMISSION CONTROLS 10-7

THM 400 TRANSMISSION


THIS CHART A S SU M E S THERE IS NO
CODE 33 OR 3 4 STORED DOWNSHIFT CONTROL
(ELECTRICAL DIAGNOSIS)

NO FORCED DOWNSHIFT TRANSMISSION WILL NOT UPSHIFT

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

MANUAL TRANSMISSION SHIFT LIGHT CHECK


VEHICLES BELOW 8500 G VW ONLY
Circuit Description:
The ECM uses information from the following inputs to control the shift light:
Coolant temperature
TPS
VSS
RPM
The ECM uses the measured rpm and the vehicle speed to calculate what gear the vehicle is in. Its this
calculation that determines when the shift light should be turned "ON.

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

If the converter clutch is applied at all times, the


engine will stall immediately, ju st as in a manual
transmission with the clutch applied.
If the converter clutch does not apply, fuel
economy may be lower than expected. If the vehicle
speed sensor fails, the TCC will not apply. If the 4th
gear switch does not operate, the TCC will not apply at
the right time.
The torque converter clutch (TCC) system has
different operating characteristics than an automatic [T] RETAINER [T] DOWNSHIFT RELAY
transmission without TCC. If the driver complains of F T I FUEL PUMP RELAY [T ] FUEL PUMP FUSE
a "chuggle or "surge condition, the vehicle should be I 5 [ DASH PANEL
road tested and compared to a similar vehicle to see if
7 S 3 7 5 6 -6 E
a real problem exists. The Owners Manual section on
TCC operation should be reviewed with the driver. Figure 10-2 - Downshift Control Relay (CK)
Another TCC complaint may be a downshift felt when
going up a grade, especially with cruise control. This
may not be a downshift, but a clutch disengagement
due to the change in TPS to m aintain cruising speed.
The electrical diagnosis of the TCC system is
covered in the appropriate "Torque Converter Clutch
Electrical Diagnosis chart.
If the ECM detects a problem in the VSS system, a
Code 24 should set. In this case see Code 24 Chart.

DOWNSHIFT CONTROL SYSTEM

If the downshift control system is "ON, at all


times, the transmission will not upshift.
If the downshift control system is inoperative, a m CONNECTOR R PLENUM PANEL
forced downshift of the transmission will not occur. ITI DOWNSHIFT CONTROL
1-----1 RELAY
QQBRACKET
[ 6 j FUEL PUMP RELAY
In either case, refer to the "THM400 Transmission
Downshift Control Electrical Diagnosis chart. [ T ] RETAINER 8S4699.6E

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.

DOWNSHIFT CONTROL SYSTEM


PARTS INFORMATION
PART NAME GROUP
Refer to Section "3, for repair of wiring.
Refer to Section "3, for replacement of the ECM. Sensor, VSS (1 ) ............................................... 9.761
Valve, Clutch and Cruise Vac. Sw .............. 3.885
Solenoid, TCC ................................................. 4.122
POSITIVE CRANKCASE VENTILATION 11-1

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

GENERAL DESCRIPTION DIAGNOSIS

A positive crankcase ventilation (PCV) system is RESULTS OF INCORRECT OPERATION


used to provide m ore com plete sc av en g in g of
crankcase vapors. Fresh air from the a ir cleaner A plugged valve or hose may cause:
through a filter is supplied to the crankcase, mixed Rough idle.
with blow-by gases and then passed through a positive Stalling or slow idle speed.
crankcase ventilation (PCV) valve into the intake Oil leaks.
manifold (Figure 11-1 or 11-2). Oil in air cleaner.
The prim ary control is through the PCV valve Sludge in engine.
(F igure 11-3), which m eters the flow a t a ra te
depending on manifold vacuum.
To m aintain idle quality, the PCV valve restricts
the flow when intake manifold vacuum is high. If
abnormal operating conditions arise, the system is
designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent tube into the
air cleaner to be consumed by normal combustion.

CLEAN AIR

VOLATILE OIL FUMES


- MIXTURE OF AIR AND FUMES

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

A leaking valve or hose would cause:


Rough idle.
Stalling.
High idle speed.

FUNCTIONAL CHECK

If an engine is idling rough, check for a clogged


PCV valve, dirty vent filter or air cleaner element, or
plugged hose. Replace as required. Use the following
procedure:
1 . Remove PCV valve from rocker arm cover.
2. Run the engine at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at valve, check for
plugged hoses, manifold port at TBI unit, or PCV
valve. Replace plugged or deteriorated hoses or
plugged PCV valve.
4. Turn "OFF the engine and remove PCV valve.
Shake valve and listen for the ra ttle of check
needle inside the valve. If valve does not rattle, ON-VEHICLE SERVICE
replace valve.
With this system, any blow-by in excess of the An engine can be damaged if it is operated without
system capacity (from a badly-worn engine, sustained crankcase ventilation. Therefore, it is im portant to
heavy load, etc.) is exhausted into the air cleaner and perform the "Functional Check at intervals shown in
is drawn into the engine. Section "OB of the appropriate Service Manual or the
Proper operation of the PCV system is dependent vehicles maintenance schedule.
upon a sealed engine. If oil sludging or dilution is Replace PCV components as diagnosis requires.
noted and the PCV system is functioning properly, The recommended replacement parts are listed in the
check engine for possible cause and correct to ensure "S pecifications section of the v eh icles ow ners
th at system will function as intended. manual.
Periodically, inspect the hoses and clamps and
replace any showing signs of deterioration.

PARTS INFORMATION
PART NAME GROUP

Air C le a n e r........................................................ 1.150


Tube, C/Case V e n t............................................ 2.383
Hose, C/Case Vent V lv ..................................... 2.170

m CHECK VALVE
4S 00 68-6E

Figure 11-3- PCV Valve Cross Section


POSITIVE CRANKCASE VENTILATION 11-3

VIEW A

ITI TUBE ASSEMBLY


[~2~| PCV VALVE
[~ 3 l GROMMET
fTI BOLTTIGHTEN TO 25 N m
(18 LBS. FT.)
fTI CONNECTOR
[T 1 HOSE

IS36 29-6 E

Figure 11-5- PCV System (2.5L)

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

Figure 11-6 - PCV System (2.8L)


11-4 POSITIVE CRANKCASE VENTILATION

4.3L, 5.0L & 5.7L

n~| PCV VALVE [T] HOSE ALTITUDE ONLY


f T l GROMMET [X TUBE ASSEMBLY

5.0L & 5:7L


[~3~1 HOSE [T] AIR CLEANER EXTENTION
l~T ] TBI UNIT - PORT "C "
7S3631-6E

Figure 11-7- PCV System (4.3L, 5.0L & 5.7L)

Figure 11-8 - PCV System (7.4L)


THERMOSTATIC AIR CLEANER 12-1

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

A heated intake air system is used to give good


d riv e a b ility under v ary in g clim atic co n d itio n s.
Having a uniform inlet air tem perature improves fuel
vaporization.

OPERATION

All Except S/T Series

The THERMAC system (Figure 12-1) regulates fTI SNORKEL


incoming air tem perature without the use of vacuum. [T1 TEMPERATURE SENSOR ACTUATOR
The air regulating damper is controlled by means of a fTI DAMPER ASSEMBLY
self-contained, wax-pellet actuated assembly mounted
in the air cleaner. When incoming air is cold, the wax Figure 12-1 - THERMAC Air Cleaner
m a te ria l sealed in th e a c tu a to r is in a solid All Except S/T Series
(contracted) phase and the damper closes off the cold
air inlet. This causes all incoming air to be heated by DIAGNOSIS
the exhaust manifold. As the incoming air warms, the
wax m aterial expands by changing to liquid phase RESULTS OF INCORRECT OPERATION
which forces out a piston to reposition the dam per
allowing a cold and hot air mix or all cold air to enter All Except S/T Series
the engine.
Hesitation during warm-up can be caused by:
S/T Series Heat stove tube disconnected.
Missing or damaged air cleaner-to-TBI gasket.
The THERMAC system (F igure 1 2 -2) uses a Loose air cleaner cover & air cleaner.
sensor, vacuum motor, and damper to regulate intake Missing air cleaner cover seal.
air temperature. The sensor monitors air tem perature Damper door does not close.
and controls the vacuum m otor w hich in tu rn Lack of power, sluggish, or spongy (on a hot
positions the damper. When the incoming air is cold, engine) can be caused by:
the sensor will apply manifold vacuum to the vacuum Damper door does not open to outside air.
motor, cutting off the cold air supply. This causes all
incoming air to be heated up by the exhaust manifold.
As the incoming air warms up, the sensor will reduce
the vacuum to the motor via an air bleed valve, thus
re-positioning the damper to allow a cold and hot air
mix or all cold air to enter the engine.
12-2 THERMOSTATIC AIR CLEANER

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

[ 4 A l AIR BLEED V ALVE - CLOSED

[ T b ] AIR BLEED V ALVE - P AR ITA LLY OPEN

R c l AIR BLEED V ALVE - OPEN

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

f T o l OUTSIDE INLET AIR

rm SNORKEL

A - HOT AIR DELIVERY MODE


B - REGULATING MODE
C - OUTSIDE AIR DELIVERY MODE

| ip

4S 00 73-6 E

Figure 12-4 - THERMAC Operation - S/T Series


THERMOSTATIC AIR CLEANER 12-3

S/T Series VACUUM MOTOR FUNCTIONAL CHECK

Hesitation during warm-up can be caused by: S/T Series


Heat stove tube disconnected.
Vacuum diaphragm motor inoperative (open 1. With engine "OFF, disconnect vacuum hose at
to snorkel). vacuum diaphragm motor.
No manifold vacuum. 2. Apply at least 23 kPa (7 in. Hg.) of vacuum to the
Damper door does not move. vacuum diaphragm motor. Damper door should
Missing air cleaner to TBI seal. completely block off to outside air when vacuum is
Missing air cleaner cover seal or loose cover. applied. If not, check to see if linkage is hooked up
Loose air cleaner. correctly.
Lack of power, sluggish, or spongy (on a hot 3. W ith vacuum s till applied, tra p v acu u m in
engine) can be caused by: vacuum d iap h rag m m otor by b e n d in g hose.
Damper door does not open to outside air. Damper door should remain closed. If not, replace
Temperature sensor doesnt bleed off vacuum. vacuum diaphragm motor assembly. (Failure of
the vacuum diaphragm motor assembly is more
THERMAC AIR CLEANER FUNCTIONAL CHECK likely to be caused from binding linkage or a
corroded snorkel than from a failed diaphragm .
All Except S/T Series This should be checked first, before replacing the
diaphragm.)
1 . Remove air cleaner assembly and cool to below 4C 4. If vacuum motor checks OK, check vacuum hoses
(40F). The dam per door should be closed to and connections. If OK, replace the tem perature
outside air (cold air). sensor.
2. Check for presence and condition of air cleaner to
throttle body gasket. TEMPERATURE SENSOR CHECK
3. Reinstall air cleaner assembly and be sure heat
stove tube is connected at air cleaner snorkel and S/T Series
exhaust manifold.
4. Start engine. Watch damper door in air cleaner 1 . Start test with air cleaner tem perature below 86F
snorkel. As air cleaner warms up, damper door (30C). If engine has been run recently, remove
should open slowly to outside air (cold air). air cleaner cover and place therm om eter as close
5. If air cleaner fails to operate as described, be sure as possible to the sensor. Let air cleaner cool until
calibrated spring is properly installed and damper therm om eter reads below 86F (30C) about 5 to 10
is not binding. If OK, replace wax pellet actuator m inutes. R einstall air cleaner on engine and
assembly. continue to Step 2.
2 . S tart and idle engine. Damper door should move
S/T Series to close off outside air immediately, if engine is
cool enough. When damper door starts to open (in
1 . Inspect system to be sure all hoses and heat stove a few minutes), remove air cleaner cover and read
tube are connected. Check for kinked, plugged or thermometer. It must read about 131F (55C).
deteriorated hoses. 3. If the damper door is not open to outside air at
2. Check for presence and condition of air cleaner to tem p eratu re indicated, te m p eratu re sensor is
throttle body gasket seal. malfunctioning and must be replaced.
3. With air cleaner assembly installed, damper door
should be open to outside air. ON-VEHICLE SERVICE
4. Start engine. Watch damper door in air cleaner
snorkel. When engine is first started, damper door AIR CLEANER ELEMENT
should move and close off outside air. As air
cleaner warms up, dam per door should open Remove or Disconnect
slowly to outside air.
1. Air cleaner cover.
5. If the air cleaner fails to operate as described
2. Old element.
above, perform vacuum m otor check. If it
3. Clean housing.
operates, the door may not be moving at the right
temperature. If the driveability problem is during
Install or Connect
warm-up, make the tem perature sensor check
below. 1 . New element.
2. Air cleaner cover. Do not over-torque nut(s)
(install finger-tight).
12-4 THERMOSTATIC AIR CLEANER

AIR CLEANER W A X PELLET ACTUATOR

Refer to Figures "12-8 to 12-13 for repair or All Except S/T Series
replacement of air cleaner. (Figure 12-6)

VACUUM DIAPHRAGM MOTOR |<--| Remove or Disconnect

S/T Series 1. Air cleaner.


(Figure 12-5) 2. Spring.
3. Rivets retaining actuator
Remove or Disconnect 4. Actuator.

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)

1. Drill a 2.8mm (7/64) hole in snorkel tube at Remove or Disconnect


center of vacuum motor retaining strap.
2. Vacuum m otor linkage into control d am p er 1. Air cleaner.
assembly. 2. Hoses at sensor.
3. Use the motor retaining strap and sheet m etal 3. Pry up tabs on sensor retaining clip. Remove clip
screw provided in the motor service package to and sensor from air cleaner. Note position of
secure motor to the snorkel tube. Make sure the sensor for installation.
screw does not interfere with the operation of the
damper assembly. Shorten screw if required. -- Install or Connect
4. Vacuum hose to motor and install air cleaner. 1 . Sensor and gasket assembly in original position.
2. Retainer clip on hose connectors.
3. Vacuum hoses and air cleaner on engine.

-m

~r
m SPOT WELDS
m MOTOR ASM. FTl W A X PELLET A C T U A T O R [T] SNORKEL

m RETAINING STRAP CHI R IV IT 7 S 3 8 1 2 -6 E


fTl INSTALL REPLACEMENT SENSOR ASM.
1------1 IN SAME POSITION AS ORIGINAL ASM. 4S 0 6 4 g .6E Figure 12-6 - Replacing W ax Pellet Actuator
All except S/T Series
Figure 12-5 - Replacing THERMAC Vacuum M otor
S/T Series
THERMOSTATIC AIR CLEANER 12-5

SENSOR RETAINING CLIP

Figure 12-7 - Replacing THERMAC Sensor - S/T Series

PARTS INFORMATION

PART NAME GROUP

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)

m NUT TIGHTEN TO 6 (50


N-m IN. LBS.) m AIR CLEANER ASSEMBLY
fTI AIR CLEANER I 2 | SEAL
fTI PCV FILTER [ T 1 STUD
IT] GASKET REMOVE PAPER FROM NEW SEAL |~T1 NUT-TIGHTEN TO 2 N m (18 IN. LBS.)
f T I FULL MANIFOLD VACUUM HOSE 6S 28 94-6 E IT] TUBE ASSEMBLY 7 S 3 7 0 2 -6 E

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

m AIR CLEANER ASSEMBLY fTl AIR CLEANER ASSEMBLY


cm SEAL |~2~| SEAL
cm EXTENSION m EXTENSION
E STUD m STUD
cm NUT-TIGHTEN TO 2 N-m (18 IN. LBS.) ?s g fTl NUT-TIGHTEN TO 2 N-m (18 IN. LBS.)

Figure 12-11 - AirCleaner Figure 12-13 - Air Cleaner


(4.3L, 5.0L & 5.7L - M & G Series) (4.3L., 5.0L & 5.7L - C, K, P, R & V Series)

fTl AIR CLEANER ASSEMBLY


FTl SEAL AIR CLEANER ASSEMBLY
m
[~3~| EXTENSION
[ T l STUD
cm
tm
SEAL
STUD
m NUT-TIGHTEN TO 2 N-m (18 LBS. IN.)
8S 4 6 6 4 -6 E
m NUT-TIGHTEN TO 2 N-m (18 IN. LBS.)
7S 3 7 05-6 E

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

GENERAL In some cases, " S c a n to o ls w ill p ro v id e


inform ation th a t is eith er ex trem ely d ifficult or
The special tools required to service the fuel and impossible to get with other equipment.
emission systems are illu strated in F igures 13-1
through 13-3. A "SCAN" TOOL THAT DISPLAYS FAULTY
You should know how to use a test light, how to DATA SHOULD NOT BE USED A N D THE
connect and use a tachometer, and how to use jumper PROBLEM SHOULD BE REPORTED TO THE
wires to bypass components to test circuits. A test MANUFACTURER. THE USE OF A FAULTY
light or voltmeter must be used when specified in the "SCAN" TOOL CAN R E S UL T IN
procedures. They must NOT be interchanged. Care MISDIAGNOSIS AND UNNECESSARY PARTS
should be taken to not deform term inals when testing. REPLACEMENT.
You should be familiar with the Digital Volt-Ohm
Meter, particularly essential tool J-29125-A, J34029A Tree code charts incorporate diagnosis procedures
or equivalent. You should be able to measure voltage, using an ALDL "Scan tool where possible.
resistance, and current and know how to use the meter Some electronic control modules have three modes
correctly. for transm itting information but some only read data
in the open mode.
"SCA N"TO O L The following information will describe each of
the three modes where applicable and the affects they
The Computer Command Control ALDL connector may cause.
under the dash, has a variety of information available
on serial data line terminal "J5 or "M (depending on "SCAN" TOOL MODES
engine). There are several "Scan tools available for
reading this information. Normal (O pen) M ode
"Scan tools do not make the use of diagnostic
charts unnecessary. They do not tell exactly where a Not all systems will transm it information on the
problem is in a given circuit. However, with an serial data line while in this mode.
understanding of what each position on the equipment On systems that can be monitored in the open
measures, and knowledge of the circuit involved, the mode, it allows certain p aram eters to be obtained
tools can be very useful in getting information which w ith o u t c h a n g in g th e e n g in e o p e r a t in g
would be more time consuming to get with other characteristics. The param eters capable of being read
equipment. vary from engine family to engine family. Most
13-2 SPECIAL TOOLS

"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

Codes The integrator is short term corrective action while


the block le arn portion (w hich is a long te rm
Will display any code stored in the ECM memory. correction) will only change if the integrator has seen
a condition which lasts for a calibrated period of time.
C oolant Tem perature
Knock Retard
E ngine coolant te m p e ra tu re is d isp lay ed in
C elsiu s d eg ree s. A fte r en g in e is s ta r te d th e Indicates the num ber of degrees the ECM is
tem perature should rise steadily to about 85-95C retarding the Electronic Spark Timing.
then stabilize when the therm ostat opens.
Knock Signal
Desired RPM
Displays a "YES when knock is detected by the
Indicates the rpm to which the ECM is trying to ECM and displays a "NO when knock is not detected.
control the idle.
M anifold Air Tem perature (M A T) Sensor
EGR (D uty Cycle)
Displays tem perature of the intake manifold air.
The EGR system uses a valve to feed a small Should read close to ambient air tem perature when
amount of exhaust gas back into the intake manifold the engine is cold, and rise as underhood and engine
to control formation of NOx. Like all ECM outputs the temperature increases.
S c a n tool only in d ic a te s th a t th e ECM h as
commanded the function and does not indicate th a t M anifold Absolute Pressure (M AP) Sensor
the function has really happened.
The MAP Sensor produces a low signal voltage
EGR Position when manifold pressure is low (high vacuum) and a
high voltage when the pressure is high (low vacuum).
Indicates the position of the EGR pintle. With the ignition "ON and the engine stopped,
the m anifold p ressu re is equal to a tm o sp h e ric
4th gear pressure and the signal voltage will be high. This
information is used by the ECM as an indication of
Displays state of the 4th gear switch. "Yes = 4th vehicle a ltitu d e and is re fe rre d to as BARO.
gear. Comparison of this BARO reading with a known good
vehicle with the same sensor ** is a good way to check
IAC (Idle Air Control) accuracy of a "suspect sensor. Readings should be the
same .4 volt.
This system is used to control engine idle speed to
the desired rpm, for different operating conditions. In ** A MAP Sensor has a colored plastic insert visible in
this mode, the numbers will indicate what position the the connector cavity. Sensors with the same insert
ECM thinks the valve is in. The ECM moves the IAC color are id en tical in calib ratio n . The h arn ess
in counts and these counts are are what is displayed electrical connector color should also be the same as
on a "Scan tool. the sensor insert color.

Injector Pulse W idth M ode

In th is p o sitio n , th e re a d in g is g iv e n in Check with the manufacturer to determine what


milliseconds which is the on time th a t the ECM is the function of this mode is. In most cases it allows the
commanding to the injector(s). user to place the ECM in different operating modes.

In teg rator and Block Learn MPH

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

Oxygen (O 2) Sensor RPM


%
+
The reading will be read out in millivolts (mV) Displays engine rpm. Often useful if ex tra
with a range from 1 to 999 mV. If the reading is reference pulses are suspected. A sudden high rpm
consistently below 350 (350 mV), the fuel system is indication while at a steady throttle would indicate
running lean as seen by the ECM and if the reading is electrical interference (EMI) in the reference circuit.
consistently above 550 (550 mV), the system is This interference is usually caused by ECM wires too
running rich. close to ig n itio n seco n d ary w ires or an open
distributor ground circuit.
Park/Neutral Switch
Shift Light
The indication in th is mode may vary w ith
manufacturer so the type of reading for a particular Displays "YES when the ECM is commanding
tool should be checked in the operators manual. The the shift light to turn "ON.
im portant thing is that the the reading changes state
(switches) when the gear selector is moved from Throttle Angle
park/neutral to drive or reverse.
Displays in percent the am ount the th ro ttle is
Power Steering Pressure Switch open. 0% is closed throttle and 100% is wide open
throttle.
Displays the state of switch. This reading may
vary with the tool used and the type of switch installed Throttle Position Sensor (TPS)
on the vehicle. The im portant thing is th a t the
reading changes state (switches) when the steering is Values read will be the voltage as seen by the
moved against the stops. ECM. The voltage should be the TPS specification
with the throttle closed and go up to about 5 volts with
PROM ID throttle wide open (WOT).

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------------------------------

VOLTMETER - V oltage Position Measures am ount o f


voltage. W hen connected in parallel to an existing
circuit. A digital voltm eter w ith 10 meg ohm input
impedence is used because this type o f m eter will
n o t load d o w n th e circuit and resu lt in fa u lty
readings.some circuits require accurate low voltage
readings, and some circuits in the ECM have a very
high resistance.

AMMETER - W hen used as am m eter, this m eter also


accurately measures extrem ely lo w current flo w .
Refer to m eter instructions for more inform ation.
Selector must be set properly fo r both function
and range. DC is used fo r most au to m o tive
measurements.

OHMMETER - Measures resistance o f circuit directly


in ohms. Refer to m eter for more inform ation.
OL Display in all ranges indicates open circuit.
Zero display in all ranges in dicates a short
circuit.
In te r m itte n t c o n n e c tio n in c irc u it m ay be
in d ic a te d by d ig ita l r e a d i n g t h a t wi l l n o t
stabilize on circuit.
Range Switch.
200Q - Reads ohms directly
HIGH IMPEDANCE MULTIMETER
2K,20K,200KQ - Reads ohms in thousands
(DIGITAL VOLTMETER-DVM)
2M and 20MQ - Reads ohms in millions
J34029-A/BT8623
VACUUM PUMP (20 IN. HG. M IN IM U M )
Use gage to m onitor m anifold engine vacuum and the
hand pump to check vacuum sensors, solenoids and
valves.
J23738-A/BT8334

UNPOWERED TEST LIGHT


Used to check w iring fo r complete circuit and short to
ground or voltage.
J34142-A

TACHOMETER
Use inductive trigg er signal pickup type to check RPM.
eSo

CONNECTOR TEST ADAPTER KIT


Used to m ake electrical test connections in current
W e a th e r Pack, M etri - Pack and Micro-Pack style
terminals.
J35616/BT8256
7S 3534-6E

Figure 13-1 - Special Tools (1 of 3)


13-6 SPECIAL TOOLS

OXYGEN SENSOR WRENCH


U sed to re m o v e or install th e o x yg e n sensor

j 29533a /B T 8 127

IDLE AIR CONTROL WRENCH


U sed to re m o v e o r install IAC v a lv e on th ro ttle body.

J 3 3 0 3 1 /B T 8 1 3 0

INJECTOR TEST LIGHT


( B T 8 320 \ U sed to check electrical circu it to a TBI 220 fu el in jector

-------^y B T8320

INJECTOR TEST LIGHT


r \ U sed to check electrical circu it to a TB I 700 fu el in jector.

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

OIL PRESSURE TRANSDUCER WRENCH


U sed to re m o v e or install oil pressure tran sd u cer on en g in e.

J2 8 6 8 7 -B /B T 8 2 2 0

METRI-PACK TERMINAL REMOVER


U sed to re m o v e 150 series M e tri-P ack " p u ll-to -s e a t" te rm in a ls
fro m co n n ecto rs. R efer to w irin g harness service in S ection ''3 ''
fo r re m o v a l pro c ed u re .

J 3 5 6 8 9 /B T 8 4 4 6

WEATHER PACK TERMINAL REMOVER


U sed to re m o v e te rm in a ls fro m W e a th e r Pack connectors. Refer
to w irin g h arn ess service in S ection 3 fo r re m o v a l procedu re.

J 2 8 7 4 2 -A /B T 8 2 3 4 -A

ECM CONNECTOR TERMINAL REMOVER


U sed to re m o v e te rm in a l fro m M ic ro -P ack connectors. Refer to
w irin g h arn ess service in S ection " 6 E " fo r rem o val procedure.

J 3 3 0 9 5 /B T 8 2 3 4 -A

7 S 3 5 3 5 -6 E

Figure 13-2 - Special Tools (2 of 3)


SPECIAL TOOLS 13-7
--------- ' -----------------------

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

FUEL LINE WRENCH


Used to d isco n n e ct o r co n n ect fu e l lin e s at TBI u n it by h o ld in g fu e l n u t
at th ro ttle body.

J29698-A/BT8251

M INIM UM AIR RATE ADJUSTING WRENCH


Used to a d ju st th ro ttle sto p scre w on TBI u n it.

J 3 3 179-20

FUEL PRESSURE GAGE


U sed to check and m o n ito r fu e l lin e pressure.

J29658-B/BT8205

FUEL PRESSURE GAGE


Used to check and m o n ito r fu e l lin e pressure.

J34020

FUEL TANK SENDING AND PUMP UNIT


Used to rem o ve and in sta ll cam lock n u t on th e fu e l ta n k s e n d in g and
p u m p u n it in S ection 4.

J36608(C K)/J24187

IGNITION MODULE TESTER


Used to te st ig n itio n m o d u le in S ection 6.

VYv N\ J S il

^ ^P
J24642-F/BT7220

7S 3 5 3 6 -6 E

Figure 13-3 - Special Tools (3 of 3)


13-8 SPECIAL TOOLS

SPECIFICATIONS
SPECIFICATION LOCATION OF INFORMATION

Engine Timing Vehicle Emission Control Information label.

Idle Speed, ECM Not adjustable. ECM controls idle.


Controlled

Spark Plug Type See Owners Manual, Section "7.

Spark Plug Gap Vehicle Emission Control Information label.

Engine Code 8th digit of VIN number. See Section "OA. Also Owners
Manual, Section "7.

Engine Family Vehicle Emission Control Information label.

Filter P art Numbers See Owners Manual, Section "7.

P art Numbers of GM SPO Parts Book.


Major Components

Replacement of GM SPO Standard Parts Catalog.


Vehicle Emission
Control Information
7 -1 5 -8 8
Label
8S 47 03-6 E
ABBREVIATIONS -14-1

SECTION 14

ABBREVIATIONS AND GLOSSARY OF TERMS

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

ELECTRICAL CIRCUIT IDENTIFICATION FOR WIRING DIAGRAMS

CIRCUIT CIRCUIT CIRCUIT N A M E CIRCUIT CIRCUIT CIRCUIT N A M E


NUM B ER COLOR NUM BER COLOR

2 RED FEED. BATTERY-UNFUSED 442 LT BLUE/BLACK ELECTRONIC CONTROL


30 PINK FUEL GAGE M O D U L E TO IDLE AIR
39 PINK/BLACK FEED, IGN. SW . "O N A N D CONTROL. COIL A , LO W
CR A N K" CONTROLLED- 44 3 LT GREEN/W HITE ELECTRONIC CONTROL
FUSED M O D U L E TO IDLE AIR
55 ORANGE D O W N SHIFT SOLENOID C ONTROL. COIL B, HIGH
FEED 444 LT GREEN/BLACK ELECTRONIC C O N TR O L
59 DARK GREEN COMPRESSOR FEED M O D U LE TO IDLE AIR
66 LIGHT GREEN FEED, A/C SELECTOR S W f CONTROL, COIL B. L O W
CONTROLLED (C O M P.C T.) 446 LIGHT BLUE ECM TO H IG H GEAR SW ITCH
120 T A N /W H T ELECTRIC FUEL PU M P FEED 450 BLACK/W HITE ECM POW ER GRD.
150 BLACK G R O U N D CIRCUIT-DIRECT 451 W HITE/BLACK D IA G N O S TIC ENABLE
151 BLACK GROUND 452 BLACK LO W LEVEL G R O U N D
340 ORANGE FEED. BATTERY-FUSED 453 BLACK/RED EST REF. PULSE L O W
410 YELLO W ECM TO C O O LA N T TEMP. 455 PURPLE MAP GROUND
SENSOR 456 TAN/BLACK M A N U A L SHIFT LA M P
412 PURPLE 0 2 SENSOR SIGNAL 458 BLUE A/C RELAY C O N TR O L
413 TA N 0 2 SENSOR LO W 459 DK GREEN/W HITE A/C SIGNAL
416 GRAY ECM 5V REFERENCE 461 ORANGE SERIAL D A TA D IA G N O S TIC S
VOLTAGE 465 DK GREEN/W HITE FEED, ELECTRIC FUEL
417 DARK BLUE ECM TO THROTTLE 467 BLUE LO W SIDE OF INJECTOR " A "
POSITION SENSOR SIGNAL 46 8 GREEN L O W SIDE OF INJECTOR "B "
419 B R O W N /W H ITE ECM TO "SERVICE ENGINE 46 9 BLACK/RED M A P RETURN, L O W LEVEL
S O O N " LP. GROUND
420 PURPLE IGN TO BRAKE S W . 47 2 TAN M A N IF O L D AIR TE M P
421 DK BLUE/W HITE ECM TO COLD START SIGNAL
P ROGRAM M O D IFIER 481 RED FEED, FOR INJECTOR " A "
422 TAN/BLACK ECM TO TCC SOLENOID FUSED
423 W H ITE (N A T ) EST SIGNAL 482 W H ITE FEED, FOR INJECTOR "B "
424 TAN/BLACK EST BYPASS FUSED
430 PURPLE/W HITE ECM REF. PULSE HIGH 485 BLACK ESC SIGNAL
432 LIGHT GREEN ECM TO M A P SIGNAL 486 BLACK/RED ESC DISTRIBUTOR G R O U N D
434 ORANGE/BLACK ECM TO NEUTRAL PARK 49 0 RED FUEL P U M P TEST T E R M IN A L
SWITCH 495 BLUE/ORANGE POW ER STEERING SW ITCH
435 GRAY ELECTRONIC CONTROL 526 BROW N EGR VAC. DIG . SW . SIGNAL
M O D U LE TO EXH A U ST GAS 551 TA N /W H ITE SYSTEM G R O U N D TO ECM
RECIRCULATION SOLENOID 80 6 PURPLE/WHITE CRANK SIGNAL TO ECM
436 BROW N ECM TO AIR SWITCH 920 TAN FUEL TA N K SW . TO VALVE &
SOLEN O ID PU M P
437 BROW N ECM TO VEHICLE SPEED 920 PINK/BLACK FUEL P U M P RELAY TO CKT
SENSOR 1 2 0 (CK)
439 PINK/BLACK FEED IGN. SW ITCH "O N & 921 GRAY FUEL TA N K SW . TO VALVE 8.
C R ANK" CONTROLLED- PUMP
FUSED 930 PIN K /W H ITE LEFT TA N K S EN D IN G U N IT
440 ORANGE FEED, BATTERY-FUSED 931 PINK/BLACK RIGHT TA N K S EN D IN G U N IT
441 LT BLUE/W HITE ELECTRONIC CONTROL
M O D U LE TO IDLE AIR
CONTROL COIL A, HIGH

6 -1 2 -8 7
8S 4 3 4 9 -6 E
INDEX

SECTION PAGE SECTION PAGE

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

S E C T IO N PAG E SECTION PAGE


D F

Deceleration M o d e ..............................................4-3 Field Service M o d e .............................................. ..3-8


D e to n a tio n .......................................................... ..2-5 Filter Crankcase V e n tila tio n ........................... ..11-2
Diagnostic M o d e ................................................ ..3-8 F o rw a rd ................................................................. ..i
Diagnostic Tools.....................................................13-1 Fourth Gear S w itc h .............................................. ..10-4
Dieseling, Run-On .............................................. ..2-2 Fuel Control S y s te m ............................................4-1
Digital Voltm eter (DVM) .................................. ..13-5 Fuel C u to ff M o d e ...................................................4-3
Distributor Reference Signal ........................... ..3-7 Fuel Filter R e p la c e m e n t.......................................4-32
Downshift C o n tro l.............................................. ..10-1 Fuel F ilte rs ............................................................ ..4-7
Downshift Control Relay .................................. ..10-1 Fuel Hoses and Vapor Pipes ...............................4-7
Draining the Fuel T a n k .........................................4-35 S e rvice ................................................................4-34
D riv e a b ility .......................................................... ..1-2 Fuel In je c to r.......................................................... .4-4
Driveability Sym ptom s.........................................2-1 Fuel Lines R e p a ir ..................................................4-34
Fuel Line W re n c h ..................................................13-7
E Fuel M eter Assy. - TBI 700 .................................. .4-26
Fuel M eter Body - TBI 220 .................................. .4-21
EAC Valve ............................................................ ..8-2 Fuel M o d u le .......................................................... .4-31
ECM Code System................................................ ..3-9 Fuel Pressure G a g e .............................................. .13-7
ECM Term in als-2.5 L ......................................... ..3-105 Fuel Pump D ia g n o s is ......................................... .3-10
ECM Terminal - 2.8 L ..............................................3-106 Fuel Pump O p e ra tio n ......................................... .4-7
ECM T e r m in a l-4 .3 L & V 8 .................................. ..3-107 Fuel Pump R elay....................................................4-7
ECT V a lv e .................................................................8-2 R e p la c e m e n t....................................................4-29
EGR C o n tro l.......................................................... ..9-1 Fuel Pump R eplacem en t......................................4-29
EGR D iagno sis..................................................... ..9-3 Fuel Pump T e s ts ....................................................4-15
EGR Filter R ep la ce m e n t.................................... ..9-10 Fuel System C le a n in g ......................................... .4-35
EGR On-Vehicle S e rv ic e .................................... ..9-3 Fuel System Pressure Relief ............................. .4-12
EG R System Check................................................ 9-3 Fuel System Pressure T e s t.................................. .3-34
EGR Vacuum C ontrol............................................9-3 Fuel T a n k ................................................................4-7
EGR Vacuum S o le n o id .........................................9-10 Fuel Tank D ra in in g .............................................. .4-35
EGR V alves............................................................ ..9-2 Fuel Tank Filler Neck ......................................... .4-35
Electronic Control Module Fuel Tank Leak T e s t .............................................4-40
General D escription.........................................3-3 Fuel Tank P u r g in g .............................................. .4-35
Diagnosis.......................................................... ..3-9 Fuel Tank R e p la c e m e n t......................................4-35
Service.................................................................3-94 Fuel Tank Selector Valve .................................. .4-34
Electronic Spark C o n tro l.................................... ..7-1 Fuel Tank Selector Valve Replacement . . . . 4-34
Electronic Spark T im in g .................................... ..6-1
Electrostatic Discharge.........................................3-3 G
Emissions.................................................................1-2
Emissions, Above Normal (O d o rs )......................2-4 General In fo rm a tio n ......................................... 1-1
Engine Crank But Will Not R u n ........................ ..3-20 Glossary o f T e rm s .................................... .. 14-1
EST Performance C h e c k .................................... ..6-3
Evaporative Emission C o n tro l........................... ..5-1 H
Exhaust Gas Recirculation.................................. ..9-1
Exhaust System .....................................................3-14 Hall Effect S w itc h ................................................ 6-2
Restricted System ..............................................3-73 Hard S t a r t ............................................................ 2-4
Hesitation 2-6
INDEX

SECTION PAGE SECTION PAGE


M inim um A ir Rate A d ju stm e n t W rench . . . . 13-7
M inim um A ir Rate - TBI 220 ............................. ..4-17
IAC Valve Flange - TBI 220 ................. . 4-22 M inim um A ir Rate - TBI 700 ................................4-17
IAC Valve Flange - TBI 700 ................. . 4-27
Idle A ir C ontrol V a lv e ........................... . 4 4 N
Idle A ir C ontrol W r e n c h ...................... . 13-6
Idle S p e e d .............................................. 3-10 Negative Backpressure EGR Valve ................. ..9-2
Ig n itio n M o d u le ...................................... 6-2 Norm al (Open) M o d e ............................................13-1
Ig n itio n System D iagnosis..................... 6-2
Ig n itio n T im in g ...................................... 6 3 O
Incorrect I d l e ......................................... . 2-3
In fo rm a tio n Sensors ........................... . 3-3 Oil Pressure S w itc h .............................................. ..4-9
Injector C ircuit Diagnosis - 2 .5 L .......... . 3-24 R e p la c e m e n t................................................... ..4-31
Injector C ircuit Diagnosis - except 2.5L 3-26 Open Loop S y s te m .............................................. ..4-2
Injector Test L i g h t ................................. 13-6 Oxygen Sensor
In-Line Filter ......................................... . 4-32 General D e s c rip tio n ....................................... ..3-5
In-Tank F ilt e r ......................................... . 4-32 D ia g n o sis.......................................................... ..3-12
In te rm itte n t C odes................................. 2-2 S e rvice ............................................................... ..3-114
Oxygen Sensor W rench .......................................13-6
K
P
Knock Sensor
General D e s c rip tio n .......................... 3-7 Park/Neutral Switch
D ia g n o s is ............................................ 3-64 General D e s c rip tio n ....................................... ..3-7
S e rvice ................................................. 3-117 D ia g n o sis.......................................................... ..3-14
S e rvice ............................................................... ..3-117
L P a r t s ...................................................................... ..iv
PCV Valve ...............................................................11-2
Lack o f Power ....................................... . 2-5 Poor Fuel E conom y.............................................. ..2-1
Light, M anual Transmission S h ift . . . 10-1 Port EGR V a lv e ........................................................9-2
Light, Service Engine S o o n ................. 3-3 Positive Crankcase V e n tila tio n ...................... ..11-1
Power Steering Pressure Switch
M General D e s c rip tio n ....................................... ..3-7
D ia g n o sis.......................................................... ..3-14
M aintenance S ch e d u le ......................... 1-2 S e rvice ............................................................... ..3-117
M anual Transmission S h ift Light 10-1 Pressure Regulator ............................................ ..4-4
MAP Sensor PROM
General D e s c rip tio n ......................... 3-5 General D e s c rip tio n ....................................... ..3-4
D ia g n o sis............................................ 3-12 D iagnosis.......................................................... ..3-10
S e rv ic e ................................................. 3-112 S e rvice ............................................................... ..3-109
M AT Sensor Pump, F u e l...............................................................4-7
General D e s c rip tio n ........................ 3-6
D ia g n o sis............................................ 3-13 R
S e rvice ................................................. 3-117
MEM-CAL Relays
General D e s c rip tio n ......................... 3-4 A/C Clutch Control - 2.5 L ..................................3-14
D ia g n o sis ............................................ 3-10 A/C Clutch C ontrol - 2.8 L ..................................3-14
S e rvice ................................................. 3-94 D o w nshift C o n tr o l............................................10-1
M etri-Pack S e rv ic e ................................ 3-93 Fuel P u m p ........................................................ ..4-7
M etri-Pack Term inal Restricted Exhaust System ..................................3-73
Term inal R e m o v e r........................... 13-6 Rough, Idle .......................................................... ..2-3
Micro-Pack S e rv ic e ................................ 3-93 Run M o d e ...............................................................4-2
INDEX

SECTION PAGE SECTION PAGE


S TCC Pulse Switch ...................................................10-1
TC C Solenoid........................................................ ..10-1
Sag ........................................................................ ..2-6 TCC System .......................................................... ..10-1
"Scan" T o o l ............................................................13-1 Terminal Service ...................................................3-92
"Scan" Tool P o s itio n s .................................... ..13-2 Test Light ...............................................................13-5
Sensors Thermae Vacuum Diaphragm M o to r............... ..12-3
C o o la n t............................................................ ..3-5 Thermae Wax Pellet Actuator ...........................12-4
K n o c k .................................................................3-7 Thermostatic Air C le a n e r.................................. ..12-1
MAP ................................................................. ..3-5 TH M 400 ............................................................... ..10-1
MAT ................................................................. ..3-6 THM 700 ............................................................... ..10-1
O x y g e n ............................................................ ..3-5 Throttle Position Sensor
TPS ......................................................................3-6 General Description....................................... ..3-6
V S S ......................................................................3-6 Diagnosis.......................................................... ..3-13
Serial Data L i n e .....................................................3-8 Service............................................................... ..3-116
Service Engine Soon Lig h t ............................... ..3-3 Throttle Position Switch Adjustment .............3-13
S hift Light, M anual T ra n s m is s io n ......................10-1 TPS Output Check-TBI 220 ................................3-13
Solenoids Torque Converter Clutch .................................. ..10-1
D o w n s h ift..........................................................10-1 Transmission Gear Position Signal ................. ..3-7
E A C ......................................................................8-1
E G R ................................................................... ..9 1 u
T C C ................................................................... ..10-1
Spark K n o c k .......................................................... ..2-5 Unstable I d l e ..........................................................2-3
Spark Tester ..........................................................13-7
Special T o o ls ..........................................................13-1 V
S pe cificatio n s..........................................................13-8
Speed Sensor-VSS B u ffe r A m p lif ie r .................10-1 Vacuum P u m p ..................................................... ..13-5
S t a llin g ................................................................. ..2-3 Vapor P ip e s.......................................................... ..4-7
S tarting M o d e ..................................................... ..4-2 Vehicle Emission Control
S tu m b le ................................................................. ..2-6 Information Label ......................................... ..1-2
Surges and/or C h u g g le .........................................2-5 Vehicle Speed Sensor
Switches General Description....................................... ..3-6
Brake .................................................................10-1 Diagnosis.......................................................... ..3-13
Fourth G e a r ..................................................... ..10-4 Service............................................................... ..3-117
M anual Clutch S t a r t .........................................10-1 Voltmeter, D ig it a l.............................................. ..13-5
Oil P re s s u re ..................................................... ..4-9
Park/Neutral .....................................................3-7 w
Power Steering .............................................. ..3-7
System C h e c k ..........................................................3-7 W eather Pack Terminal Service ...................... ..3-93
Terminal R e m o v e r............................................13-6
T Wiring Harness
General D escription....................................... ..3-3
Table o f Contents .............................................. ..iii Service............................................................... ..3-92
T a c h o m e te r.......................................................... ..13-5 Wiring Diagram - 2.5 L ....................................... ..3-95
TBI M odel 220 ..................................................... ..4-3 Wiring Diagram - 2.8 L ....................................... ..3-98
TBI M odel 700 ..................................................... ..4-3 Wiring Diagram - 4.3L & V8 ............................. ..3-101
TCC Brake S w itc h ...................................................10-1
TCC Electrical Diagnosis
2.5L and 2 . 8 L .....................................................10-2
4.3L and V 8 ..................................................... ..10-4
These pre-addressed and prepaid reply cards are provided so that
you may advise us of any errors you might find in this manual. These reply cards are not to be used for ordering Service M anuals.
M anuals may be ordered using a form provided in the O w ners M anual.
W e also w elcom e your suggestions for improving our service
manual coverage.

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GMC Truck Division GMC Truck Division
Truck & Bus Group Truck & Bus Group
General Motors Corporation General Motors Corporation
31 Judson Street 31 Judson Street
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BUSINESS REPLY MAIL


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Service Publications Service Publications


GMC Truck Division GMC Truck Division
Truck & Bus Group Truck & Bus Group
General Motors Corporation General Motors Corporation
31 Judson Street 31 Judson Street
Pontiac, Michigan 48058 Pontiac, Michigan 48058
X-8936

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