TABLE OF CONTENTS
TABLE OF CONTENTS
1.0
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1
1.2
SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SIX-STEP TROUBLE SHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0
IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.0
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .2
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.0
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FUNCTION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.1
FUEL CONTROL (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.2
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.3
TRANSMISSION CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2.3.1 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUS OIL TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.3.2 LINE PRESSURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.3.3 DRIVE LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.4
TRANSMISSION CONTROL (RE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.2.5
O2 SENSOR (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.2.6
OTHER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.2.7
NON-MONITORED CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.3.1
HARD CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3.2
ONE TRIP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3.3
INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3.4
STARTS SINCE SET COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3.5
TROUBLE CODE ERASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.3.6
QUICK LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.3.7
CLUTCH VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.3.8
NO START INFORMATION (POWERTRAIN) . . . . . . . . . . . . . . . . . . . .28
USING THE DRBIIIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
DRBIIIT ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . .28
3.5.1
DRBIIIT DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.5.2
DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.5.3
SOME DISPLAY ITEMS READ ‘‘___’’ . . . . . . . . . . . . . . . . . . . . . . . . . .29
EATX DTC EVENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND ELECTRONIC
TRANSMISSION ADAPTER KIT (MILLER TOOL #8333-1A) . . . . . . . . . . . . . . 29
DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.1
4.2
4.3
DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.2.1
TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . .30
4.2.2
VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .30
4.2.3
SEVICING SUB-ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.2.4
DRBIIIT SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.3.1
ROAD TEST WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.3.1
VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.3.2
ROAD TESTING A COMPLAINT VEHICLE (TRANSMISSION) . . . . . .31
4.3.3
ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) . . . .32
4.4.4
BULLETINS AND RECALLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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TABLE OF CONTENTS - Continued
5.0
REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.0
ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.2
7.0
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .35
COMMUNICATION
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . . .36
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . .38
*NO RESPONSE FROM FRONT CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . .40
*NO RESPONSE FROM PCM (PCI BUS) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . . .42
*NO RESPONSE FROM PCM (PCI BUS) - JTEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
*NO RESPONSE FROM PCM (PCI BUS) - NGC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
*NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC . . . . . . . . . . . . . . . . . . . . . . . .46
*NO RESPONSE FROM PCM (SCI ONLY) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . .49
*NO RESPONSE FROM PCM (SCI ONLY) - JTEC . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE . . . . . . . . . . . . . . . .54
*NO RESPONSE FROM TRANSFER CASE CONTROL MODULE. . . . . . . . . . . . . . . .56
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 3.7/5.7 . . . . . . . . . .58
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 4.7 . . . . . . . . . . . . .61
*PCI BUS COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
DRIVEABILITY - DIESEL
INTERMITTENT CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
P0016-ENGINE SPEED SIGNAL MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
P0071-INLET AIR TEMP SENSOR RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .70
P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . .72
P0088-FUEL RAIL PRESSURE SIGNAL IS ABOVE MAX LIMIT . . . . . . . . . . . . . . . . . .74
P0106-INLET AIR PRESSURE SENSOR RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . .75
P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . .76
P0108-INLET AIR PRESSURE SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . .79
P0111-INTAKE AIR TEMPERATURE (IAT) SENSOR RATIONALITY. . . . . . . . . . . . . . .81
P0112-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO LOW. . . . . . . . .82
P0113-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO HIGH . . . . . . . .84
P0116-ENGINE COOLANT TEMPERATURE (ECT) SENSOR RATIONALITY . . . . . . .86
P0117-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE
TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0118-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE
TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
P0128-THERMOSTAT RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM . . . . . . . . . . . . . . . . .92
P0169-WATER IN FUEL (WIF) LIGHT ON TOO LONG . . . . . . . . . . . . . . . . . . . . . . . . .95
P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . .96
P0193-FUEL PRESSURE SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . .99
P0201-INJECTOR #1 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0202-INJECTOR #2 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0203-INJECTOR #3 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0204-INJECTOR #4 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0205-INJECTOR #5 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0206-INJECTOR #6 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
ii
TABLE OF CONTENTS - Continued
P0217-DECREASED ENGINE PERFORMANCE DUE TO ENGINE OVERHEAT
CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
P0219-CRANKSHAFT POSITION SENSOR OVER SPEED SIGNAL . . . . . . . . . . . . .105
P0234-TURBO BOOST LIMIT EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
P0236-MAP SENSOR TOO HIGH TOO LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
P0237-MAP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
P0238-MAP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
P0251-CP3 PUMP REGULATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
P0300-MULTIPLE CYLINDER MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0301-CYLINDER # 1 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0302-CYLINDER # 2 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0303-CYLINDER # 3 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0304-CYLINDER # 4 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0305-CYLINDER # 5 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0306-CYLINDER # 6 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0335-CRANKSHAFT POSITION (CKP) LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . .123
P0337-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO LOW . . . . . . . . .126
P0338-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO HIGH. . . . . . . . .128
P0340-CAMSHAFT POSITION (CMP) LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . .132
P0381-WAIT TO START LAMP INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME . . . . . . . . . . . . . . . . . . . . . . . . .138
P0462-LOW VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR. . . . . . . . . . . . .140
P0463-HIGH VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR . . . . . . . . . . . .142
P0477-LOW VOLTAGE ON THE ENGINE BRAKE DRIVER . . . . . . . . . . . . . . . . . . . .143
P0478-HIGH VOLTAGE ON THE ENGINE BRAKE DRIVER . . . . . . . . . . . . . . . . . . . .145
P0480-FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
P0483-FAN SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
P0500-NO VEHICLE SPEED SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
P0514-BAT TEMPERATURE SENSOR RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . .154
P0516-LOW VOLTAGE AT THE BAT TEMP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . .155
P0521-OIL PRESSURE SWITCH RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
P0524-OIL PRESSURE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
P0533-A/C SENDING UNIT VOLTS TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY. . . . . . . . . . . . . . .167
P2607-LOW VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY . . . . . . . . . . . . . . .167
P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY . . . . . . . . . . . . . .169
P2608-HIGH VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY . . . . . . . . . . . . . . .169
P0562-BATTERY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
P0563-BATTERY VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
P0572-LOW VOLTAGE DETECTED AT THE BRAKE SWITCH . . . . . . . . . . . . . . . . . .175
P0573-HIGH VOLTAGE DETECTED AT THE BRAKE SWITCH . . . . . . . . . . . . . . . . .176
P0580-LOW VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH. . . . . . . .177
P0581-HIGH VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH . . . . . . .179
P0602-CHECKSUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
P0604-ECM SOFTWARE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
P0606-ECM HARDWARE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
P0607-ECM INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY . . . . . . . . . . . . . . . . . . . .186
P0628-LOW VOLTAGE DETECTED AT THE FUEL LIFT PUMP . . . . . . . . . . . . . . . . .188
P0629-HIGH VOLTAGE DETECTED AT THE FUEL LIFT PUMP. . . . . . . . . . . . . . . . .190
P0630-VIN NOT ENTERED ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
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TABLE OF CONTENTS - Continued
P0633-SKIM SECRET KEY NOT ENTERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
P0642-LOW VOLTAGE AT THE #2 SENSOR SUPPLY CIRCUIT . . . . . . . . . . . . . . . .194
P0646-LOW VOLTAGE DETECTED AT THE A/C CLUTCH RELAY . . . . . . . . . . . . . .196
P0647-HIGH VOLTAGE DETECTED AT THE A/C CLUTCH RELAY . . . . . . . . . . . . . .198
P0652-LOW VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT . . . . . . . . . . . . . . . .200
P0653-HIGH VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT . . . . . . . . . . . . . . . .201
P0698-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
P0699-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
P0700-TRANSMISSION MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
P1652-J1850 SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
P2121-APP VOLTS DO NOT AGREE WITH IDLE VALIDATION SIGNAL. . . . . . . . . .210
P2122-LOW VOLTAGE AT THE APP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
P2123-HIGH VOLTAGE AT THE APP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH. . . . . . . . . . . . . .223
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH . . . . . . . . . . . . .227
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW . . . . . . . . . . . . . . . . . .231
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW . . . . . . . . . . . . . . . . . .235
P2266-WATER IN FUEL (WIF) SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . .239
P2269-WATER IN FUEL (WIF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
P2502-CHARGING SYSTEM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
P2503-CHARGING SYSTEM LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
P2504-CHARGING SYSTEM HIGH ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
P2509-POWERDOWN DATA LOST ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
*CHECKING PRESSURE LIMITING VALVE ON THE FUEL RAIL FOR INTERNAL
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
*CHECKING THE ACCELERATOR PEDAL SENSOR CALIBRATION. . . . . . . . . . . . .251
*CHECKING THE ECM POWER AND GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
*CHECKING THE PCM POWER AND GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
*ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE) . . . . .254
*ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE
WHILE CRANKING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
*ENGINE SPEED SURGES IN PTO OR CRUISE CONTROL . . . . . . . . . . . . . . . . . . .256
*ENGINE SPEED SURGES LOW OR HIGH IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
*ENGINE SPEED SURGES UNDER LOAD OR IN OPERATING RANGE . . . . . . . . .258
*FUEL HEATER THERMOSTAT TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
*FUEL LIFT PUMP FLOW AND INLET RESTRICTION TEST . . . . . . . . . . . . . . . . . . .260
*EXCESSIVE INJECTOR RETURN FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
*FUEL SYSTEM VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . .263
*INJECTOR RETURN FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
*INTAKE AIR SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
DRIVEABILITY - GAS
INTERMITTENT CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE . . . . . . . . . . . . . . . . .270
iv
TABLE OF CONTENTS - Continued
P0107-MAP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
P0108-MAP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
P0111-INTAKE AIR TEMP PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . .279
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . .281
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . .283
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . .285
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP . . . . . . . . . . . . . . . .287
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW. . . . . . . . . . . . . . .292
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH . . . . . . . . . . . . . .295
P0125-CLOSED LOOP TEMP NOT REACHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .300
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .300
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .300
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .300
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . .303
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . .303
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . .303
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . .303
P0133-O2 SENSOR 1/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
P0139-O2 SENSOR 1/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
P0153-O2 SENSOR 2/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
P0159-O2 SENSOR 2/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
P0135-O2 SENSOR 1/1 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
P0141-O2 SENSOR 1/2 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
P0155-O2 SENSOR 2/1 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
P0161-O2 SENSOR 2/2 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION . . . . . . . . . . . . . . . . . . .313
P0171-1/1 FUEL SYSTEM LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
P0174-2/1 FUEL SYSTEM LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
P0172-1/1 FUEL SYSTEM RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
P0175-2/1 FUEL SYSTEM RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
P0201-INJECTOR #1 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0202-INJECTOR #2 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0203-INJECTOR #3 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0204-INJECTOR #4 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0205-INJECTOR #5 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0206-INJECTOR #6 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0207-INJECTOR #7 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0208-INJECTOR #8 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0209-INJECTOR #9 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0210-INJECTOR #10 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
P0300-MULTIPLE CYLINDER MIS-FIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0301-CYLINDER #1 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0302-CYLINDER #2 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0303-CYLINDER #3 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0304-CYLINDER #4 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0305-CYLINDER #5 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0306-CYLINDER #6 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0307-CYLINDER #7 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0308-CYLINDER #8 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0309-CYLINDER #9 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
P0310-CYLINDER #10 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
v
TABLE OF CONTENTS - Continued
P0320-NO CRANK REFERENCE SIGNAL AT PCM . . . . . . . . . . . . . . . . . . . . . . . . . . .337
P0325-KNOCK SENSOR #1 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
P0330-KNOCK SENSOR #2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
P0340-NO CAM REFERENCE SIGNAL AT PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
P0351-IGNITION COIL #1 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
P0352-IGNITION COIL #2 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
P0353-IGNITION COIL #3 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
P0354-IGNITION COIL #4 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
P0355-IGNITION COIL #5 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
P0351-IGNITION COIL #1 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0352-IGNITION COIL #2 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0353-IGNITION COIL #3 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0354-IGNITION COIL #4 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0355-IGNITION COIL #5 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0356-IGNITION COIL #6 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . .355
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . .355
P0441-EVAP PURGE FLOW MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED. . . . . . . . . . . . . .359
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED . . . . . . . . . . . . . . . . . . . . .359
P0456-EVAP LEAK MONITOR SMALL (.020) LEAK DETECTED . . . . . . . . . . . . . . . .359
P0443-EVAP PURGE SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362
P0460-FUEL LEVEL SENDING UNIT NO CHANGE OVER MILES. . . . . . . . . . . . . . .364
P0461-FUEL LEVEL SENDING UNIT NO CHANGE OVER TIME . . . . . . . . . . . . . . . .364
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW. . . . . . . . . . . . . . . . . . . . . . .365
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH . . . . . . . . . . . . . . . . . . . . . .367
P0500-NO VEHICLE SPEED SIGNAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
P0505-IDLE AIR CONTROL MOTOR CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
P0523-OIL PRESSURE CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
P0551-POWER STEERING SWITCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
P0601-PCM INTERNAL CONTROLLER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .377
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY . . . . . . . . . . . . . . . . . . . .378
P0645-A/C CLUTCH RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
P0700-TRANSMISSION CONTROL SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . . . .382
P1195-O2 SENSOR 1/1 SLOW DURING CATALYST MONITOR . . . . . . . . . . . . . . . .383
P1196-O2 SENSOR 2/1 SLOW DURING CATALYST MONITOR . . . . . . . . . . . . . . . .383
P1281-ENGINE IS COLD TOO LONG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . .386
P1294-TARGET IDLE NOT REACHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388
P1296-NO 5-VOLTS TO MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
P1297-NO CHANGE IN MAP FROM START TO RUN . . . . . . . . . . . . . . . . . . . . . . . . .392
P1299-VACUUM LEAK FOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . .396
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM . . . . . . . . . . . . . . . . . . . . . . . . .398
P1391-INTERMITTENT LOSS OF CMP OR CKP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . .404
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND . . . . . . . . . . . . . . . . . . . . . .407
P1491-COOLING FAN RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .409
P1492-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH . . . . .411
P1493-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW . . . . .413
P1494-LEAK DETECTION PUMP SWITCH OR MECHANICAL FAULT . . . . . . . . . . .415
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .417
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .419
vi
TABLE OF CONTENTS - Continued
P1595-SPEED CONTROL SOLENOID CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT . . . . . . . . . . . . . . . . . . .421
P1596-SPEED CONTROL SWITCH ALWAYS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .425
P1597-SPEED CONTROL SWITCH ALWAYS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . .428
P1598-A/C PRESSURE SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . .430
P1599-A/C PRESSURE SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . .432
P1682-CHARGING SYSTEM VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . .434
P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM . . . . . . . . . . . . . . .437
P1686-NO SKIM BUS MESSAGE RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439
P1687-NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441
P1696-PCM FAILURE EEPROM WRITE DENIED . . . . . . . . . . . . . . . . . . . . . . . . . . . .442
P1698-NO BUS MESSAGE FROM TCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443
P1899- TRS PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIT. . . . . . . . . . .447
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS . . . . . . . . . . . . . . . . . . . . .450
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS . . . . . . . . . . . . . .453
*CHECKING CONDENSER FAN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456
*CHECKING THE PCM POWER AND GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
DRIVEABILITY - NGC
INTERMITTENT CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT . . . . . . . . . . . . . . . . . .460
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
P0057-O2 SENSOR 2/2 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
P0058-O2 SENSOR 2/2 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK
DETECTED (4.7L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK
DETECTED (5.7L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
P2172-HIGH AIR FLOW/VACUUM LEAK DETECTED (INSTANTANEOUS
ACCUMULATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
P2173-HIGH AIRFLOW/VACUUM LEAK DETECTED (SLOW ACCUMULATION) . . .476
P0070-AMBIENT TEMPERATURE SENSOR STUCK . . . . . . . . . . . . . . . . . . . . . . . . .482
P0071-AMBIENT TEMPERATURE SENSOR PERFORMANCE . . . . . . . . . . . . . . . . .482
P0072-AMBIENT TEMPERATURE SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . . . .485
P0073-AMBIENT TEMPERATURE SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . . . .487
P0106-MAP SENSOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489
P0107-MAP SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492
P0108-MAP SENSOR CIRCUIT HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK. . . . . . . . . . . . . . . . . . . . . . . .496
P0111-INTAKE AIR TEMPERATURE SENSOR PERFORMANCE . . . . . . . . . . . . . . . .496
P0112-INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW. . . . . . . . . . . . . . . . . .499
P0113-INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . .501
P0116-ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE. . . . . . . . . .503
P0117-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW . . . . . . . . . . .506
P0118-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH . . . . . . . . . . .508
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L) . . . . . . . . . . . . .510
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L) . . . . . . . . . . . . .514
vii
TABLE OF CONTENTS - Continued
P0221-THROTTLE POSITION SENSOR #2 PERFORMANCE . . . . . . . . . . . . . . . . . .514
P2135-THROTTLE POSITION SENSOR #1 AND #2 VOLTAGE CORRELATION . . .514
P0122-THROTTLE POSITION SENSOR #1 LOW (4.7L) . . . . . . . . . . . . . . . . . . . . . . .518
P0122-THROTTLE POSITION SENSOR #1 LOW (5.7L) . . . . . . . . . . . . . . . . . . . . . . .521
P0123-THROTTLE POSITION SENSOR #1 HIGH (4.7L) . . . . . . . . . . . . . . . . . . . . . .524
P0123-THROTTLE POSITION SENSOR #1 HIGH (5.7L) . . . . . . . . . . . . . . . . . . . . . .527
P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL . .530
P0128-THERMOSTAT RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE . . . . . . . . . . . . . . . . . . . . . . . . .537
P0131-O2 SENSOR 1/1 CIRCUIT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .540
P0137-O2 SENSOR 1/2 CIRCUIT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .540
P0151-O2 SENSOR 2/1 CIRCUIT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .540
P0157-O2 SENSOR 2/2 CIRCUIT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .540
P0132-O2 SENSOR 1/1 CIRCUIT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .543
P0138-O2 SENSOR 1/2 CIRCUIT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .543
P0152-O2 SENSOR 2/1 CIRCUIT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .543
P0158-O2 SENSOR 2/2 CIRCUIT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .543
P0133-O2 SENSOR 1/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
P0139-O2 SENSOR 1/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
P0153-O2 SENSOR 2/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
P0159-O2 SENSOR 2/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
P0135-O2 SENSOR 1/1 HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .549
P0141-O2 SENSOR 1/2 HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .549
P0155-O2 SENSOR 2/1 HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .549
P0161-O2 SENSOR 2/2 HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .549
P0171-FUEL SYSTEM 1/1 LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .552
P0174-FUEL SYSTEM 2/1 LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .552
P0172-FUEL SYSTEM 1/1 RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
P0175-FUEL SYSTEM 2/1 RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
P0201-FUEL INJECTOR #1 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0202-FUEL INJECTOR #2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0203-FUEL INJECTOR #3 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0204-FUEL INJECTOR #4 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0205-FUEL INJECTOR #5 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0206-FUEL INJECTOR #6 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0207-FUEL INJECTOR #7 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0208-FUEL INJECTOR #8 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
P0222-THROTTLE POSITION SENSOR #2 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .567
P0223-THROTTLE POSITION SENSOR #2 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .570
P0300-MULTIPLE CYLINDER MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0301-CYLINDER #1 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0302-CYLINDER #2 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0303-CYLINDER #3 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0304-CYLINDER #4 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0305-CYLINDER #5 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0306-CYLINDER #6 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0307-CYLINDER #7 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0308-CYLINDER #8 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
P0315-NO CRANK SENSOR LEARNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580
P0325-KNOCK SENSOR #1 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .582
P0330-KNOCK SENSOR #2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .582
P0335-CRANKSHAFT POSITION SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . .585
P0339-CRANKSHAFT POSITION SENSOR INTERMITTENT . . . . . . . . . . . . . . . . . . .589
viii
TABLE OF CONTENTS - Continued
P0340-CAMSHAFT POSITION SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .593
P0344-CAMSHAFT POSITION SENSOR INTERMITTENT . . . . . . . . . . . . . . . . . . . . .597
P0351-IGNITION COIL #1 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0352-IGNITION COIL #2 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0353-IGNITION COIL #3 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0354-IGNITION COIL #4 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0355-IGNITION COIL #5 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0356-IGNITION COIL #6 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0357-IGNITION COIL #7 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0358-IGNITION COIL #8 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
P0420-CATALYTIC 1/1 EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605
P0432-CATALYTIC 2/1 EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605
P0440-GENERAL EVAP SYSTEM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
P0441-EVAP PURGE SYSTEM PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
P0442 SYSTEM MEDIUM LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
P0455-EVAP SYSTEM LARGE LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
P0443-EVAP PURGE SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
P0452-NVLD PRESSURE SWITCH STUCK CLOSED. . . . . . . . . . . . . . . . . . . . . . . . .620
P0453-NVLD PRESSURE SWITCH STUCK OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . .623
P0456-EVAP SYSTEM SMALL LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625
P0461-FUEL LEVEL SENSOR #1 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .627
P0462-FUEL LEVEL SENSOR #1 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629
P0463-FUEL LEVEL SENSOR #1 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631
P0480-LOW SPEED FAN CONTROL RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . .633
P0498-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW. . . . . . . . . . . . . .635
P0499-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH . . . . . . . . . . . . .637
P0501-VEHICLE SPEED SIGNAL #1 PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . .639
P0503-VEHICLE SPEED SIGNAL #1 ERRATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639
P0506-IDLE SPEED PERFORMANCE LOWER THAN EXCEPTED . . . . . . . . . . . . . .641
P0507-IDLE SPEED PERFORMANCE HIGHER THAN EXCEPTED . . . . . . . . . . . . .643
P0508-IAC VALVE SIGNAL CIRCUIT LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645
P0509-IAC VALVE SIGNAL CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .647
P0513-INVALID SKIM KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649
P0516-BATTERY TEMPERATURE SENSOR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . .651
P0517-BATTERY TEMPERATURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . .653
P0522-OIL PRESSURE CIRCUIT LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655
P0523-OIL PRESSURE CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655
P0532-A/C PRESSURE SENSOR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .658
P0533-A/C PRESSURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660
P0551-POWER STEERING SWITCH PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . .662
P0562-BATTERY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .664
P0563-BATTERY VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667
P0571-BRAKE SWITCH #1 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .669
P0572-BRAKE SWITCH #1 CIRCUIT LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .671
P0573-BRAKE SWITCH #1 CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .673
P0579-SPEED CONTROL SWITCH #1 PERFORMANCE (4.7L). . . . . . . . . . . . . . . . .675
P0579-SPEED CONTROL SWITCH #1 PERFORMANCE (5.7L). . . . . . . . . . . . . . . . .678
P0580-SPEED CONTROL SWITCH #1 LOW (4.7L). . . . . . . . . . . . . . . . . . . . . . . . . . .681
P0580-SPEED CONTROL SWITCH #1 LOW (5.7L). . . . . . . . . . . . . . . . . . . . . . . . . . .683
P0581-SPEED CONTROL SWITCH #1 HIGH (4.7L) . . . . . . . . . . . . . . . . . . . . . . . . . .686
P0581-SPEED CONTROL SWITCH #1 HIGH (5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . .689
P0582-SPEED CONTROL VACUUM SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . .692
P0585-SPEED CONTROL SWITCH #1 AND #2 CORRELATION . . . . . . . . . . . . . . . .694
ix
TABLE OF CONTENTS - Continued
P0586-SPEED CONTROL VENT SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . .698
P0591-SPEED CONTROL SWITCH #2 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .700
P0592-SPEED CONTROL SWITCH #2 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .703
P0593-SPEED CONTROL SWITCH #2 HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .705
P0594-SPEED CONTROL SERVO POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . .708
P0600-SERIAL COMMUNICATION LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711
P0601-INTERNAL MEMORY CHECKSUM INVALID. . . . . . . . . . . . . . . . . . . . . . . . . . .711
P0606-ECM/PCM PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711
P0622-GENERATOR FIELD CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .712
P0627-FUEL PUMP RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
P0630-VIN NOT PROGRAMMED IN PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .716
P0632-ODOMETER NOT PROGRAMMED IN PCM . . . . . . . . . . . . . . . . . . . . . . . . . . .717
P0633-SKIM KEY NOT PROGRAMMED IN PCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .718
P0642-PRIMARY 5-VOLT SUPPLY LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .719
P0643-PRIMARY 5-VOLT SUPPLY HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721
P0645-A/C CLUTCH RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
P0652-AUXILIARY 5-VOLT SUPPLY LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724
P0653-AUXILIARY 5-VOLT SUPPLY HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726
P0685-ASD RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727
P0688-ASD RELAY SENSE CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .729
P0700-TRANSMISSION CONTROL SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . . . .732
P0703-BRAKE SWITCH #2 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .733
P0850-PARK/NEUTRAL SWITCH PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .736
P1115-GENERAL TEMPERATURE RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .738
P1501-VSS 1/2 CORRELATION - DRIVE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . .740
P1502-VSS 1/2 CORRELATION - NON DRIVE WHEELS . . . . . . . . . . . . . . . . . . . . . .740
P1572-BRAKE PEDAL STUCK ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743
P1573-BRAKE PEDAL STUCK OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .745
P1593-SPEED CONTROL SWITCH #1 AND #2 STUCK (5.7L). . . . . . . . . . . . . . . . . .747
P1602-PCM NOT PROGRAMMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750
P1603-PCM INTERNAL DAUL-PORT RAM COMMUNICATION . . . . . . . . . . . . . . . . .751
P1604-PCM INTERNAL DAUL-PORT RAM READ/WRITE INTEGRITY FAILURE . . .751
P1607-PCM INTERNAL SHUTDOWN TIMER RATIONALITY . . . . . . . . . . . . . . . . . . .751
P1618-PRIMARY 5-VOLT SUPPLY ERRATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
P1628-AUXILIARY 5-VOLT SUPPLY ERRATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756
P1686-NO SKIM BUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759
P1687-NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .761
P1695-NO BODY BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762
P1696-PCM FAILURE EEPROM WRITE DENIED . . . . . . . . . . . . . . . . . . . . . . . . . . . .764
P1697-PCM FAILURE SRI MILES NOT STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . .764
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE . . . . . . . . . . . . . . .766
P2100-ELECTRONIC THROTTLE CONTROL MOTOR CIRCUIT . . . . . . . . . . . . . . . .768
P2118-ELECTRONIC THROTTLE CONTROL MOTOR CURRENT
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768
P2101-ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE . . . . . . . . .772
P2106-ETC SYSTEM - FORCED LIMITED POWER . . . . . . . . . . . . . . . . . . . . . . . . . .774
P2107-ELECTRONIC THROTTLE CONTROL MODULE PROCESSOR. . . . . . . . . . .775
P2108-ELECTRONIC THROTTLE CONTROL MODULE PERFORMANCE . . . . . . . .775
P2110-ELECTRONIC THROTTLE CONTROL - FORCED LIMIT RPM . . . . . . . . . . . .776
P2111-ELECTRONIC THROTTLE CONTROL - UNABLE TO CLOSE. . . . . . . . . . . . .779
P2112-ELECTRONIC THROTTLE CONTROL - UNABLE TO OPEN. . . . . . . . . . . . . .782
P2115-ACCELERATOR PEDAL POSITION SENSOR #1 MINIMUM STOP
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
x
TABLE OF CONTENTS - Continued
P2116-ACCELERATOR PEDAL POSITION SENSOR #2 MINIMUM STOP
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
P2166-ACCELERATOR PEDAL POSITION SENSOR #1 MAXIMUM STOP
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
P2167-ACCELERATOR PEDAL POSITION SENSOR #2 MAXIMUM STOP
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
P2122-ACCELERATOR PEDAL POSITION SENSOR # 1 LOW . . . . . . . . . . . . . . . . .787
P2123-ACCELERATOR PEDAL POSITION SENSOR #1 HIGH . . . . . . . . . . . . . . . . .790
P2127-ACCELERATOR PEDAL POSITION SENSOR #2 LOW . . . . . . . . . . . . . . . . . .793
P2128-ACCELERATOR PEDAL POSITION SENSOR #2 HIGH . . . . . . . . . . . . . . . . .796
P2138-ACCELERATOR PEDAL POSITION SENSOR #1 AND #2 VOLTAGE
CORRELATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799
P2161-VEHICLE SPEED SIGNAL #2 ERRATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
P2174-LOW AIRFLOW/RESTRICTION DETECTED (INSTANT ACCUMULATION) . .803
P2175-LOW AIRFLOW/RESTRICTION DETECTED (SLOW ACCUMULATION) . . . .803
P2181-COOLING SYSTEM PERFORMACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .809
P2299-BRAKE SWITCH POSITION / APPS INCOMPATIBLE . . . . . . . . . . . . . . . . . . .813
P2302-IGNITION COIL #1 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2305-IGNITION COIL #2 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2308-IGNITION COIL #3 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2311-IGNITION COIL #4 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2314-IGNITION COIL #5 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2317-IGNITION COIL #6 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2320-IGNITION COIL #7 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2323-IGNITION COIL #8 SECONDARY CIRCUIT- INSUFFICIENT IONIZATION. . .815
P2503-CHARGING SYSTEM OUTPUT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .818
*CHECKING A/C OPERATION WITH NO DTCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .821
*CHECKING PCM POWERS AND GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .824
SENTRY KEY IMMOBILIZER
ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825
PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .827
SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .827
ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829
TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .831
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE . . . . . . . . . . . . .831
TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .831
TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .831
STARTING
*5.7L INTERMITTENT NO CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .834
*CHECKING FUEL DELIVERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .835
*CHECKING HARD START (FUEL SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837
*ENGINE CRANKS BUT DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .839
*FUEL PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .841
*NO CRANK CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .842
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TABLE OF CONTENTS - Continued
*NO RESPONSE FROM PCM WITH A NO START CONDITION . . . . . . . . . . . . . . . .845
*START AND STALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .849
TRANSFER CASE - ELECTRONIC
12 VOLT OVER VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .851
12 VOLT UNDER VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .852
2WD/AWD INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .854
2WD/AWD INDICATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .857
4WD HI INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .859
4WD HI INDICATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .861
4WD LO INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .863
4WD LO INDICATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .865
5 VOLT OVER VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .867
5 VOLT UNDER VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .869
INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .871
MISSING BRAKE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .872
MISSING ENGINE RPM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
MISSING IGNITION MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .874
MISSING LAMP DIMMING MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .875
MISSING SPEED DIFFERENCE MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .876
MISSING TRANSFER CASE TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .878
MISSING TRANSMISSION POSITION INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879
MISSING TRANSMISSION TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .881
MISSING VEHICLE SPEED INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .882
NEUTRAL INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .884
NEUTRAL INDICATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887
SELECTOR SWITCH/TRANSFER CASE - MISMATCH . . . . . . . . . . . . . . . . . . . . . . . .889
TRANSFER CASE MODE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893
TRANSFER CASE SELECTOR SWITCH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . .896
TRANSFER
P0836-4WD
P0837-4WD
P0838-4WD
P0839-4WD
CASE - MECHANICAL
MUX SWITCH STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899
MUX SWITCH PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
MODE SENSOR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .904
MODE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .906
TRANSMISSION - NGC
P0122-THROTTLE POSITION SENSOR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .908
P0123-THROTTLE POSITION SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .910
P0124-THROTTLE POSITION SENSOR INTERMITTENT. . . . . . . . . . . . . . . . . . . . . .912
P0218-HIGH TEMPERATURE OPERATION ACTIVATED . . . . . . . . . . . . . . . . . . . . . .915
P0562-LOW BATTERY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
P0604-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922
P0605-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923
P0613-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924
P0706-CHECK SHIFTER SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE . . . . . . . . . . . .934
P0712-TRANSMISSION TEMPERATURE SENSOR LOW. . . . . . . . . . . . . . . . . . . . . .937
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . .940
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT . . . . . . . . . . . .944
P0715-INPUT SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947
P0720-OUTPUT SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .952
P0725-ENGINE SPEED SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .957
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TABLE OF CONTENTS - Continued
P0731-GEAR RATIO ERROR IN 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959
P0732-GEAR RATIO ERROR IN 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .961
P0733-GEAR RATIO ERROR IN 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .964
P0734-GEAR RATIO ERROR IN 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .967
P0735-GEAR RATIO ERROR 4TH PRIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .969
P0736-GEAR RATIO ERROR IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .971
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT. . . . . . . . . . . . . . . . . .973
P0750-LR SOLENOID CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975
P0755-2C SOLENOID CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .980
P0760-OD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .985
P0765-UD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .990
P0770-4C SOLENOID CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995
P0841-LR PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .1000
P0845-2C HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . .1005
P0846-2C PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .1012
P0868-LINE PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1016
P0869-LINE PRESSURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1021
P0870-OD HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . .1026
P0871-OD PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .1033
P0875-UD HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . .1037
P0876-UD PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .1044
P0884-POWER UP AT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1049
P0888-RELAY OUTPUT ALWAYS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1051
P0890-SWITCHED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1056
P0891-TRANSMISSION RELAY ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1058
P0932-LINE PRESSURE SENSOR CIRCUIT FAULT . . . . . . . . . . . . . . . . . . . . . . . . .1061
P0934-LINE PRESSURE SENSOR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1064
P0935-LINE PRESSURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1067
P0944-LOSS OF PRIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1071
P0987-4C HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . .1074
P0988-4C PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .1081
P1684-BATTERY WAS DISCONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1086
P1694-BUS COMMUNICATION WITH ENGINE MODULE . . . . . . . . . . . . . . . . . . . .1088
P1715-RESTRICTED PORT IN T3 RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1090
P1736-GEAR RATIO ERROR IN 2ND PRIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1092
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION . . . . . . . . . . . . .1094
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION. . . . . . . . . . . . . . .1099
P1790-FAULT IMMEDIATELY AFTER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1104
P1793-TRD LINK COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1106
P1794-SPEED SENSOR GROUND ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1108
P2700-INADEQUATE ELEMENT VOLUME LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
P2701-INADEQUATE ELEMENT VOLUME 2C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1113
P2702-INADEQUATE ELEMENT VOLUME OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1115
P2703- INADEQUATE ELEMENT VOLUME UD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1117
P2704-INADEQUATE ELEMENT VOLUME 4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1119
P2706-MS SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1121
*BACKUP LAMPS COME ON WHILE SHIFTER IS NOT IN REVERSE POSITION .1126
*BACKUP LAMPS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1127
*BUMP FELT SHORTLY AFTER STOP WITH NO DTC’S PRESENT . . . . . . . . . . . .1129
*BUMP FELT WHILE COASTING IN NEUTRAL WITH NO DTC’S PRESENT . . . . .1130
*POOR SHIFT QUALITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1131
*TRANSMISSION NOISY WITH NO DTC’S PRESENT . . . . . . . . . . . . . . . . . . . . . . .1132
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S . . . . . . . . . . . . . . . . . . . . . . . . .1134
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TABLE OF CONTENTS - Continued
*TRANSMISSION SHIFTS ROUGH AFTER PCM REPLACEMENT OR
REFLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1135
*TRANSMISSION SIMULATOR WILL NOT POWER UP . . . . . . . . . . . . . . . . . . . . . .1136
*VEHICLE IS SLUGGISH WITH NO DTC’S PRESENT . . . . . . . . . . . . . . . . . . . . . . .1137
TRANSMISSION - RE
P0711-TRANS TEMP SENSOR, NO TEMP RISE AFTER START . . . . . . . . . . . . . . .1139
P0712-TRANS TEMP SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . . .1142
P0713-TRANS TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . .1147
P0720-LOW OUTPUT SPEED SENSOR - RPM ABOVE 15 MPH. . . . . . . . . . . . . . .1152
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS. .1156
P0748-PRESSURE SOL CONTROL/TRANS RELAY CIRCUITS . . . . . . . . . . . . . . . .1161
P0751-O/D SWITCH PRESSED (LO) MORE THAN 5 MINUTES . . . . . . . . . . . . . . .1165
P0753-TRANS 3-4 SHIFT SOL/TRANS RELAY CIRCUITS . . . . . . . . . . . . . . . . . . . .1167
P1740-TCC O/D SOL PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1171
P1756-GOV PRESS NOT EQUAL TO TARGET @ 15-20 PSI . . . . . . . . . . . . . . . . . .1176
P1756-GOV PRESS NOT EQUAL TO TARGET @ 35 - 40 PSI (DIESEL) . . . . . . . .1176
P1757-GOV PRESS ABOVE 3 PSI IN GEAR WITH 0 MPH . . . . . . . . . . . . . . . . . . .1183
P1762-GOV PRESS SEN OFFSET VOLTS TOO LO OR HIGH . . . . . . . . . . . . . . . .1188
P1763-GOVERNOR PRESSURE SENSOR VOLTS TOO HI . . . . . . . . . . . . . . . . . . .1192
P1764-GOVERNOR PRESSURE SENSOR VOLTS TOO LOW. . . . . . . . . . . . . . . . .1197
P1765-TRANS 12 VOLT SUPPLY RELAY CTRL CIRCUIT . . . . . . . . . . . . . . . . . . . .1200
P2638-TORQUE MANAGEMENT FEEDBACK SIGNAL PERFORMANCE
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1203
VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1206
8.0
COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223
8.1
8.2
8.3
8.4
8.5
9.0
CONTROL MODULES AND IPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223
SENSORS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1223
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1237
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1239
CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
4WD SWITCH (MANUAL TRANSFER CASE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
A/C PRESSURE TRANSDUCER (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
ACCELERATOR PEDAL POSITION SENSOR (5.7L/DIESEL M/T NORMAL
BUILD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1242
AMBIENT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1242
BATTERY TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1242
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1242
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID . . . . . . . . . . . . . . . . . . . .1243
C205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
CAMSHAFT POSITION SENSOR (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
CLOCKSPRING C1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
CLOCKSPRING C3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
CLUTCH INTERLOCK BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
xiv
TABLE OF CONTENTS - Continued
COIL ON PLUG NO. 1 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
COIL ON PLUG NO. 2 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
COIL ON PLUG NO. 3 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
COIL ON PLUG NO. 4 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
COIL ON PLUG NO. 5 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
COIL ON PLUG NO. 6 (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
COIL ON PLUG NO. 7 (4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1246
COIL ON PLUG NO. 8 (4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1246
CONDENSER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1246
CONTROLLER ANTILOCK BRAKE C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1246
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247
ELECTRIC BRAKE PROVISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247
ELECTRONIC THROTTLE CONTROL MODULE (5.7L) . . . . . . . . . . . . . . . . . . . . . .1248
ENGINE COOLANT TEMPERATURE SENSOR (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . .1248
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . .1248
ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1248
EVAP/PURGE SOLENOID (EXCEPT NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
EVAP/PURGE SOLENOID (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
FUEL CONTROL ACTUATOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
FUEL HEATER (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
FUEL INJECTOR NO. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
FUEL INJECTOR NO. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
FUEL INJECTOR NO. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
FUEL INJECTOR NO. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
FUEL INJECTOR NO. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
FUEL INJECTOR NO. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1251
FUEL INJECTOR NO. 7 (4.7L/5.7L/5.9L/8.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1251
FUEL INJECTOR NO. 8 (4.7L/5.7L/5.9L/8.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1251
FUEL INJECTOR NO. 9 (8.0L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1251
FUEL INJECTOR NO. 10 (8.0L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
FUEL PUMP MOTOR (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
GOVERNOR PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
IDLE AIR CONTROL MOTOR (3.7L/5.9L/8.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1253
IDLE AIR CONTROL MOTOR (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1253
IGNITION COIL (5.9L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1253
IGNITION COIL-LEFT (8.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1253
IGNITION COIL-RIGHT (8.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1254
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1254
INLET AIR TEMPERATURE/ PRESSURE SENSOR (DIESEL) . . . . . . . . . . . . . . . . .1254
INPUT SPEED SENSOR (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1255
INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1255
INTAKE AIR TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1255
FUSES (IPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1257
A/C COMPRESSOR CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1258
AUTO SHUT DOWN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1258
CONDENSER FAN RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1258
INTEGRATED POWER MODULE (FCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1259
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1260
xv
TABLE OF CONTENTS - Continued
OXYGEN SENSOR DOWNSTREAM RELAY (CALIFORNIA) . . . . . . . . . . . . . . . . . .1260
STARTER MOTOR RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1260
TRAILER TOW LEFT TURN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1260
TRAILER TOW RIGHT TURN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1260
TRANSMISSION CONTROL RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1260
INTEGRATED POWER MODULE C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1261
INTEGRATED POWER MODULE C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1261
INTEGRATED POWER MODULE C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1262
INTEGRATED POWER MODULE C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1262
INTEGRATED POWER MODULE C5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1263
INTEGRATED POWER MODULE C6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1263
INTEGRATED POWER MODULE C7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1264
LEAK DETECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1264
LEAK DETECTION PUMP (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1264
LINE PRESSURE SENSOR (4.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1265
MANIFOLD ABSOLUTE PRESSURE SENSOR (3.7L/4.7L/5.7L). . . . . . . . . . . . . . . .1265
MANIFOLD ABSOLUTE PRESSURE SENSOR (5.9L/8.0L). . . . . . . . . . . . . . . . . . . .1265
OUTPUT SPEED SENSOR (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1265
OUTPUT SPEED SENSOR (5.9L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1266
OUTPUT SPEED SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1266
OVERDRIVE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1266
OXYGEN SENSOR 1/1 UPSTREAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1266
OXYGEN SENSOR 1/2 DOWNSTREAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1267
OXYGEN SENSOR 2/1 UPSTREAM (CALIFORNIA 4.7L/CALIFORNIA 5.9L) . . . . .1267
OXYGEN SENSOR 2/2 DOWNSTREAM (CALIFORNIA 4.7L/CALIFORNIA 5.9L) . .1267
POWER STEERING PRESSURE SWITCH (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . . . . .1267
POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1268
POWERTRAIN CONTROL MODULE C1 (JTEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1269
POWERTRAIN CONTROL MODULE C1 (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1270
POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1271
POWERTRAIN CONTROL MODULE C2 (JTEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1272
POWERTRAIN CONTROL MODULE C2 (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1273
POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1274
POWERTRAIN CONTROL MODULE C3 (JTEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1275
POWERTRAIN CONTROL MODULE C3 (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1276
POWERTRAIN CONTROL MODULE C4 (NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1277
SENTRY KEY IMMOBILIZER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1277
SPEED CONTROL SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1278
SPEED CONTROL SWITCH-LEFT (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1278
SPEED CONTROL SWITCH-LEFT (EXCEPT ETC) . . . . . . . . . . . . . . . . . . . . . . . . . .1278
SPEED CONTROL SWITCH-RIGHT (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1278
SPEED CONTROL SWITCH-RIGHT (EXCEPT ETC). . . . . . . . . . . . . . . . . . . . . . . . .1278
TAIL/STOP/TURN SIGNAL LAMP-LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1279
TAIL/STOP/TURN SIGNAL LAMP-RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1279
THROTTLE POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1279
THROTTLE POSITION SENSOR (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1279
TRAILER TOW CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1280
TRAILER TOW CONNECTOR-ADD ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1280
TRANSMISSION RANGE SENSOR (5.9L/DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . .1280
TRANSMISSION SOLENOID ASSEMBLY (5.9L/8.0L) . . . . . . . . . . . . . . . . . . . . . . . .1280
TRANSMISSION SOLENOID/TRS ASSEMBLY (3.7L/4.7L/5.7L) . . . . . . . . . . . . . . . .1281
xvi
TABLE OF CONTENTS - Continued
10.0
SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1283
10.1 3.7L FEDERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1283
10.2 3.7L CALIFORNIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1284
10.3 4.7L NGCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1285
10.4 5.7L NGCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1286
10.5 5.9L FEDERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1287
10.6 5.9L CALIFORNIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1288
10.7 8.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1289
10.8 5.9L DIESEL AUTOMATIC (EARLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1290
10.9 5.9L DIESEL MANUAL TRANS (EARLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1291
10.10 5.9L DIESEL MANUAL TRANS (LATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1292
10.11 5.9L DIESEL AUTOMATIC (LATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1293
10.12 45/545 RFE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1294
11.0
CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1295
11.1 ENGINE VACUUM READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1295
11.2 O2 SENSOR CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1296
11.3 NGC CAM AND CRANK PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1297
11.4 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1297
11.5 5.9L GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1298
11.6 8.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1298
11.7 PRESSURE SWITCH STATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1299
11.8 SHIFT LEVER ERROR CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1299
11.9 TRS SWITCH STATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1300
11.10 5.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1300
11.11 5.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1301
11.12 EELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1301
xvii
NOTES
xviii
GENERAL INFORMATION
Important
New for the 2003 DR, the Powertrain Control Module and Transmission Control Module have
been combined into single control module on vehicles equipped with a 4.7L. This new module is
the Next Generation Controller (NGC1). Also new for 2003 DR is 5.7L engine which uses the Next
Generation Control Module 2 (NGC2). The NGC2 controller removes RFE transmission control
system and installs Electronic Throttle Control (ETC) module system. ETC utilizes a new
electronically controlled Throttle Body with two new TP Sensors and Accelerator Pedal
Position Sensors to control throttle opening. These new control modules for DaimlerChrysler
will be referred to as the Powertrain Control Module (PCM). For 3.7L/5.7L engines, the
transmission control module is a separate controller (EATX). On 5.9L gas and 8.0L gas engines
the Powertrain Control Module utilizes the JTEC module which includes RE transmission
control information. Also new for 2003 5.9L Electronic fuel Injection 24valve Turbo Diesel with
a new Engine control module (ECM) CM845. New Diagnostics procedures and New DTC
numbers are two of the changes you will see which reflect the new combined module technology.
The NGC modules will have four color coded connectors C1 (A) through C4 (C), (C1-BLK,
C2-GRAY, C3-WHITE, C4-GREEN). Each PCM connector has 38 pins. Two new tools were
introduced to help diagnose and repair the new PCM (NGC) terminals and harness connectors.
The Miller #3638 terminal removal pick must be used to release the connector terminals, or
harness and connector damage will occur. Also, the Miller #8815 Pinout Box was introduced. You
must use the Miller #8815 tool instead of probing the PCM terminals, or harness and connector
damage will occur. There are new Verification tests and module replacement procedures for the
new PCM.
1.0
When repairs are required, refer to the appropriate service manual for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; current systems
may be enhanced. READ THIS MANUAL BEFORE
TRYING TO DIAGNOSE A VEHICLE DTC. It is
recommended that you review the entire manual to
become familiar with all new and enhanced diagnostic procedures.
After using this book, if you have any comments
or recommendations, please fill out the form at the
back of the book and mail it back to us.
INTRODUCTION
The procedures contained in this manual include
specifications, instructions, and graphics needed to
diagnose the PCM/ECM Powertrain System. The
diagnostics in this manual are based on the
failure condition or symptom being present at
the time of diagnosis. New for the 2003 JTEC
and NGC engine diagnostics, once a component has been disconnected or the state of the
ignition switch has been changed during a
diagnostic procedure, it will remain that way
for the entire test or until you are advised
otherwise.
Please follow the recommendations below when
choosing your diagnostic path.
1.1
SYSTEM COVERAGE
This diagnostic procedure manual covers Powertrain and NGC1 or RE controlled Transmission
diagnostics for the 2003 Dodge Truck (DR) vehicles
equipped with JTEC, Next Generation Control
Module 1(NGC1) and, Next Generation Control
Module 2 (NGC2). Also including diagnostics for the
Cummins (CM845) 24-valve turbo diesel engine
with electronic Fuel Injection (ECM).
1. First make sure the DRBIIIt is communicating
with the appropriate modules; i.e., if the
DRBIIIt displays a ‘‘No Response’’ condition, you
must diagnose this first before proceeding.
2. Read DTCs (diagnostic trouble codes) with the
DRBIIIt.
3. If no DTCs are present, identify the customer
complaint.
4. Once the DTC or customer complaint is identified, locate the matching test in the Table of
Contents and begin to diagnose the symptom.
All component location views are in Section 8.0.
All connector pinouts are in Section 9.0. All system
schematic diagrams are in Section 10.0. All charts
and graphs are in section 11.0.
An * placed before the symptom description indicates a customer complaint.
1.2
SIX-STEP TROUBLE SHOOTING
PROCEDURE
Diagnosis of the Powertrain/Engine Control Module (PCM)/(ECM) is done in six basic steps:
• verification of complaint
•
•
•
1
verification of any related symptoms
symptom analysis
problem isolation
GENERAL INFORMATION
•
repair of isolated problem
•
verification of proper operation
2.0
PCM of the position of the throttle plate. The ETC
Motor has a positive and negative circuit. The PCM
controls these circuits using Pulse Width Modulation. To open the throttle plate the PCM provides
pulse width voltage to the positive side of the ETC
motor and grounds the negative side. To close the
throttle plate the PCM provides pulse width voltage
to the negative side of the ETC motor and grounds
the positive side. One of the springs is used against
opening the throttle plate and the other is used
against closing the throttle plate. The PCM uses the
APP Sensor inputs along with inputs from the other
Sensors to determine throttle opening. Duplicate
sensors are used to check one sensor against its
counterpart. Two TP Sensor, two, APP Sensors, two
Brake Switch inputs, and two Speed Control inputs
are used with the NGCII system. When duplicate
Sensors are not used, the single Sensor is checked
against a value that is calculated by the PCM.
When a sensor fails, the PCM limits the opening of
the Throttle blade. The customer may complain
limited power or no throttle control after the MIL
and or ETC light illuminate. The ETC Light will
constantly illuminate or flash depending on which
component has failed. The ETC Motor Assembly
will be referred to as Throttle Body Assembly in the
Diagnostic and Service Manual. A slight delay in
cranking may be noticed when starting the engine.
When starting the vehicle the ETC Motor is tested
before the engine is allowed to crank. The test
includes opening and closing the throttle plate to
verify proper operation before starting the engine
for safety reasons. A No Crank Condition may occur
if the Ignition in left in the on position for a period
of time before actually cranking the engine. The
PCM will test the throttle plate as often as it wants
and will not allow cranking during this procedure.
If this occurs, the mileage at which this happened
will be stored in the PCM and can be looked at using
the DRBIIIt under ETC Starter Inhibit.
IDENTIFICATION OF
SYSTEM
The Powertrain/Engine Control Module (PCM)/
(ECM) monitors and controls:
•
•
•
•
•
•
•
•
•
•
•
fuel system
ignition system
charging system
speed control system
The NGC2 module is only used on trucks with a
5.7L engine.
The NGC1 module is only used on trucks with a
4.7L engine and an automatic transmission.
The JTEC module is used on trucks with a 3.7L,
5.9L gas and, 8.0L.
Cummins CM845 24Valve electronic fuel injection 5.9L Turbo Diesel engine.
The 45RFE/545RFE transmission uses a stand
alone EATX module for the 3.7L and 5.7L engines
The 45RFE/545RFE transmission is used with
4.7L engine
The RE transmission is used with 5.9L and 8.0L
engines
3.0
3.1
SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
GENERAL DESCRIPTION
POWERTRAIN
The on-board OBDII diagnostics incorporated
with the PCM are intended to assist the field
technician in repairing vehicle problems by the
quickest means.
NOTE: The battery must be disconnected
before replacing the Throttle Body (ETC
Motor Assembly). After replacing the Throttle
Body Assembly, PCM, and/or the APP Sensor
Assembly, with the DRBIIIT, under the
Miscellaneous Menu, select the LEARN ETC
feature and follow the directions on the
DRBIIIT screen.
ELECTRONIC THROTTLE CONTROL
5.7L engines are equipped with a NGCII control
module, which controls the Throttle Plate Position,
based on torque management (request). This system has a throttle cable that is attached to two
Accelerator Position Sensors instead of the throttle
body. The throttle plate will not move with the
ignition on while pressing the Accelerator Pedal.
The only way to move the throttle plate with the
ignition on is by using the DRBIIIt. The ETC Motor
Assembly contains two Throttle Position Sensors,
two springs, and the ETC Motor, which are replaced
as a complete assembly. The TP Sensors inform the
TRANSMISSION
The 45RFE/545RFE electronic transmission is a
conventional transmission in that it uses hydraulically applied clutches to shift a planetary gear
train. However, the electronic control system re-
2
GENERAL INFORMATION
places many of the mechanical and hydraulic components used in conventional transmission valve
bodies.
The 45RFE/545RFE electronic transmission is a
fully electronically controlled transmission. The
Powertrain Control Module (PCM) is similar to (but
not the same as) the one used in the 41TE and 42LE
transmissions, therefore many similarities exist in
function and diagnosis.
The 45RFE/545RFE has an overrunning clutch
(used in 1st gear), an electronically controlled
torque converter clutch, 3 planetary gearsets, and
six clutch packs. The clutches are called 2nd Clutch
(2C), 4th Clutch (4C), Low/Reverse Clutch (LR),
Reverse Clutch (RC), Underdrive Clutch (UD), and
Overdrive Clutch (OD).
Although the 45RFE is considered a 4 speed
transmission, it really has 5 forward gear ratios.,
the 545RFE is considered a 5 speed transmission, it
really has 6 forward gear ratios. 2nd gear (1.67:1)
and 2nd prime (1.50:1) gear are so close in ratio that
they are not considered to be different gear ratios,
although both are used as 2nd gear under certain
conditions. During most upshift and downshift maneuvers, 2nd gear will be used. 2nd prime gear is
only used for a high speed 4-2 downshift. The
545RFE transmission is essentially a software
change to the PCM that allows an additional overdrive ratio of (.667:1). The gear ratio of 4th Prime is
achieved by applying the 2C and OD clutches. The
4th Prime is used above 52 MPH. All gear ratios in
the 45RFE/545RFE are achieved by applying two
elements (clutches). During a shift, one element is
released and another is applied, resulting in a
different ratio. This is called a clutch to clutch shift.
In order to perform a 4-2 downshift, two elements
would have to be released and two different elements applied. The 2nd prime gear ratio allows a
clutch to clutch 4-2’ (2nd prime) downshift.
The oil pump in the 45RFE/545RFE is a dual
stage positive displacement gear type pump. At idle
and low engine speeds, both stages are working.
Once the engine speed reaches a point where one
side of the pump can supply the necessary system
requirements, the second stage is vented. This
pump configuration gives the pressure and flow of a
large displacement pump at low speeds, and the
economy of a small displacement pump at higher
engine speeds. The oil pump housing also contains
some of the valves that are found in the valve body
in a 41TE or 42LE transmission. The Converter
Clutch Switch Valve, Converter Clutch Regulator
Valve, Torque Converter Limit Valve, and the Pressure Regulator Valve, are all found in the oil pump
housing.
The electronic control system consists of a Powertrain Control Module (PCM), a Transmission
Range Sensor (TRS), an Input Speed Sensor (ISS),
an Output Speed Sensor (OSS), a Line Pressure
Sensor (LPS), a Transmission Temperature Sensor
(TTS), five pressure switches, and seven solenoids.
Each clutch pack has a corresponding solenoid and
pressure switch except for the reverse clutch which
is controlled by the manual valve. The other two
solenoids are called the Multi Select (MS) solenoid
and the Pressure Control Solenoid (PCS).
The PCS is used to control line pressure. The
45RFE/545RFE controls line pressure based on
inputs to the PCM. The line pressure is torque
based (line pressure increases with torque) most of
the time, however it is set to a predetermined value
just prior to a shift and reverts back to torque based
after the shift.
The MS solenoid is used to control the LR clutch
during P-R and N-R garage shifts and to control the
OD clutch when the Manual Valve is in the ‘‘D’’
position as reported by the TRS. If the manual valve
is slightly out of position, the TRS will indicate a
temporary zone (T3 or T4). In this case the OD
clutch will be controlled by the OD solenoid. Note
that if the TRS indicates a temporary zone, this is a
valid PRNDL code and will not set a DTC
P0706(28). If the PRNDL code consistently indicates a temporary zone while the shift lever is in the
‘‘D’’ position, this would indicate some sort of mechanical problem in the shift linkage as opposed to
an electrical TRS problem. Note: vehicle operation
in the T3 temporary zone can set a DTC P1715(65).
3.2
3.2.1
FUNCTION OPERATION
FUEL CONTROL (GAS)
The PCM controls the air/fuel ratio of the engine
by varying fuel injector-on time. Mass air flow is
calculated using the speed density method using
engine speed and manifold absolute pressure (IAT
is a modifier in Speed Density).
Different fuel calculation strategies are used depending on the operational state of the engine.
During crank mode, a prime shot fuel pulse is
delivered followed by fuel pulses determined by a
crank time strategy. Cold engine operation is determined via an open loop strategy until the O2
sensors have reached operating temperature. At
this point, the strategy enters a closed loop mode
where fuel requirements are based upon the state of
the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant
temperature.
3.2.2
ON-BOARD DIAGNOSTICS
The PCM/ECM has been programmed to monitor
any circuit or system that has an effect on vehicle
emissions, or is used by the PCM/ECM to determine
3
GENERAL INFORMATION
the proper functionality of these systems. This
monitoring is called ‘‘on-board diagnosis.’’
Certain criteria or, ‘‘arming conditions’’, must be
met before a trouble code will be entered into the
PCM/ECM memory. The criteria range from engine
rpm, engine temperature, and/or input voltage to
the PCM/ECM. If a problem is detected with a
monitored circuit, and all of the criteria or arming
conditions are met, a trouble code will be stored in
the PCM/ECM.
It is possible that a trouble code for a monitored
circuit may not be entered into the PCM/ECM
memory even though a malfunction has occurred.
This may happen because one of the trouble code
criteria (arming conditions) has not been met.
The PCM/ECM compares input signal voltage
from each input component to specifications (the
established high and low limits of the range) that
are preprogrammed for that component. If the input voltage is not within specifications, and other
trouble code criteria (arming conditions) are met, a
trouble code will store in the PCM/ECM memory.
The On Board Diagnostics have evolved to the
second Generation of Diagnostics referred to as
OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These
requirements specify the inclusion of a Malfunction
Indicator Light (MIL) located on the instrument
panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty
vehicles. The purpose of the MIL is to inform the
vehicle operator in the event of the malfunction of
any emission system or component failures that can
affect emissions and which provide input to, or
receive output from, the PCM/ECM.
2003 MIL Lamp Strategy
I/M Readiness OK to test = Key On Engine OFF
- MIL Lamp will remain on until the vehicle is
started or Ignition is turned off.
I/M not ready for testing = Key On Engine OFF
- MIL Lamp on solid for (15) seconds then MIL
Lamp will flash on/off for (5) seconds then it will
remain on until the vehicle is started or the Ignition
is turned off.
4
GENERAL INFORMATION
The following table summarizes the various OBDII monitors operation.
OBD II Monitor Operation
Comprehensive
Components
Monitor
Major Monitors
Non Fuel Control
& Non Misfire
Major Monitors
Fuel Control
& Misfire
Run constantly
Run Once Per Trip
Run constantly
Includes All Engine Hardware
Sensors, Switches,
Solenoids, etc.
Monitors Entire Emission
System
Monitors Entire System
Most are One Trip Faults Usually Turns On
The MIL and Sets DTC After
One Failure
Most are Two Trip Faults Turns On
The MIL and Sets DTC After
Two Consecutive Failure
Two Trip Faults - Turns On
The MIL and Sets DTC After Two
Consecutive Failure
Priority 3
Priority 1 or 3
All Checked For Continuity
Open
Short To Ground
Short To Voltage
Done Stop Testing = Yes
Oxygen Sensor Heater
Oxygen Sensor Response
Inputs Checked For
Rationality
Catalytic Converter Efficiency
Except EWMA
up to 6 tests per trip and a one
trip fault (SBEC) and a two-trip
fault on JTEC
Outputs Checked For
Functionality
Requires 3 Consecutive Global
Good Trips to Extinguish the MIL*
Priority 2 or 4
Fuel Control Monitor
Monitors Fuel Control System For:
Fuel System Lean
Fuel System Rich
Requires 3 Consecutive
Fuel System Good Trips to
Extinguish the MIL
EGR System
Evaporative Emission System
(Purge and Leak)
Non-LDP
or
LDP
Misfire Monitor
Monitors for Engine Misfire At:
4 X 1000 RPM Counter (4000
Revs)
(Type B)
**200 X 3 (600) RPM Counter
(Type A)
Requires 3 Consecutive Global
Good Trips to Extinguish the MIL*
Requires 3 Consecutive Global
Good Trips To Extinguish the MIL
*40 Warm Up Cycles are required to erase
DTCs after the MIL has been extinguished.
5
**Type A misfire is a one trip failure on pre-1999, 2 Trip failure on
1999 and later.. The MIL will illuminate at the first or second failure, based on MY.
GENERAL INFORMATION
JTEC CONTROLLED REAR WHEEL DRIVE
VEHICLES
*NOTE: The most efficient order has been
outlined below. The first two monitors have
very similar enable criteria. It is possible that
the Evaporative Leak Detection Monitor will
run during the O2 Sensor Heater Monitor.
The following procedure has been established to
assist Dealer Technicians in the field with enabling
and running OBD II Monitors. The order listed in
the following procedure is intended to allow the
technician to effectively complete each monitor and
to set the CARB Readiness Status in the least time
possible.
**NOTE**
A. Once the monitor run process has begun, do not
turn off the ignition. By turning the ignition key
off, monitor enabling conditions will be lost.
B. By performing a Battery Disconnect, or Selecting
Erase DTCs, the CARB Readiness and all additional OBD information will be cleared.
Monitor Preliminary Checks:
1. Plug scantool into the vehicle’s DLC.
2. Turn the ignition, KEY ON - ENGINE OFF.
Watch for MIL lamp illumination during the
bulb check. MIL lamp must have illuminated, if
not, repair MIL lamp.
3. With the scantool check for any DTCs
* Verify that No Emissions Related DTCs are
Present and MIL is not illuminated.
* If an Emissions DTC is Present and the MIL is
ON, the OBD II Monitors may not run and the
CARB Readiness will not update.
*The Emissions related DTC, which is causing
the MIL, will need to be repaired, then cleared.
By clearing DTCs, the OBD Monitors will need
to be run and completed to set the CARB Readiness Status.
*Group 25 of the Service Manual can assist in
determining which faults will illuminate the
MIL Lamp.
With the scantool check for CARB Readiness Status:
Do all the CARB Readiness Status Locations read
YES?
*YES, then all monitors have been completed and
this vehicle is ready to be I/M or Emission Tested.
*NO, then the following procedures will aid in
running and completing all available monitors.
1. O2 Sensor Heater Monitor
This monitor requires a cold start, usually an
overnight soak or parked for at least 8 hours
without the engine running. The engine coolant
temperature must be within 10 degrees of
ambient/battery temperature, and the sensed
Ambient (outside temperature) must be between
approximately 0 F and 100 F. For the monitor
run conditions,
2. Evaporative Leak Detection Monitor (If the
vehicle is equipped with an LDP system)
This monitor requires a cold start, usually an
overnight soak or parked for at least 8 hours
without the engine running. The engine coolant
temperature must be within 10 degrees of
ambient/battery temperature, and the sensed
Ambient (outside) Temperature must be between
approximately 40 F and 90 F. For the monitor
run conditions select the EVAP LEAK PRETEST in the DRBIIIt, OBD II Monitors Menu.
3. Catalyst Monitor
The vehicle will need to be driven at highway
speed for a few minutes (approximately 35 to 40
mph for 2.5L and 4.0L engines, 50 to 60 mph for
all others). If the vehicle is equipped with a
manual transmission, using 4th gear may assist
in meeting the monitor running criteria. For the
monitor run conditions, select the CATALYST
PRE-TEST in the DRBIIIt, OBD II Monitors
Menu.
4. O2 Sensor Monitor
The vehicle will need to be driven for a period of
time (approximately 35 to 40 mph for 2.5L and
4.0L engines, 50 to 60 mph for all others) and
brought to a stop for a short period of time (with
the Automatic Transmission left in Drive. The
O2 Monitor will not run in Park or Neutral on an
Automatic Transmission equipped vehicle). For
the monitor run conditions, select the O2 SENSOR PRE-TEST in the DRBIIIt, OBD II Monitors Menu.
5. Purge Monitor
The Purge Free (PF) cells must update on the
PURGE FLOW PRE-TEST screen. For the enable conditions, select 9F19 while looking at the
PURGE FLOW PRE-TEST screen. Similar Test
conditions as the O2 Sensor Monitor, that is,
Normal Operating Temperature, come to a stop
while leaving the Automatic Transmission in
Drive (not Park or Neutral). The Purge Flow
MONTIOR RUN PROCESS
Outlined below is the Monitor Run Process, including suggestions and tips in order to aid in the
process of meeting the enabling criteria to allow any
of these monitors to run.
6
GENERAL INFORMATION
Monitor will attempt to run every OTHER
Throttle Closure. If all of the parameters are met
and it still does not run, with your foot firmly on
the Service Brake, slightly (1/4) open the Throttle and quickly close the Throttle. This will allow
the Purge Free update to happen, and then the
Purge Flow Monitor will Run.
**NOTE**
A. Only the monitors, which are not YES in the
CARB Readiness Status, need to be completed.
B. Specific criteria need to be met for each monitor.
Each monitor has a Pre-Test screen to assist in
running the monitor.
For additional information, refer to the Chrysler
Corporation Technical Training Workbook titled
On Board Diagnostics: OBDII/EOBD, part number 81-699-01050.
C. The most efficient order to run the monitors has
been outlined below, including suggestions to aid
the process.
1. Natural Vacuum Leak Detection with
Purge Monitor
This monitor requires a cool down cycle, usually
an overnight soak for at least 8 hours without
the engine running. The ambient temperature
must decrease overnight - parking the vehicle
outside is advised. To run this test the fuel level
must be between 15-85% full. For the monitor
run conditions select the EVAP MON PRE-TEST
in the DRBIIIt, OBD II Monitors Menu. The
Purge monitor will run if the small leak test
reports a pass.
Criteria for NVLD monitor
1) Engine off time greater than one hour
2) Fuel Level between 15% and 85%
3) Start Up ECT and IAT within 10° C (18° F).
4) Vehicle started and run until Purge Monitor
reports a result.
Note: If the vehicle does not report a result and
the conditions where correct. It may take up to
two weeks to fail the small leak monitor. DO
NOT use this test to attempt to determine a
fault. Use the appropriate service information
procedure for finding a small leak. If there are no
faults and the conditions are correct this test will
run and report a pass. Note the Small leak test
can find leaks less than 10 thousands of an inch.
If a small leak is present it takes approximately
one week of normal driving to report a failure.
2. Catalyst / O2 Monitor
With NGC, Catalyst and O2 Monitor information
are acquired and processed at the same time.
Most vehicles will need to be driven at highway
speed (< 50 mph) for a few minutes. Some trucks
run the monitor at idle in drive. If the vehicle is
equipped with a manual transmission, using 4th
gear may assist in meeting the monitor running
criteria. For the monitor run conditions, select the
BANK 1 CAT MON PRE-TEST in the DRBIIIt,
OBD II Monitors Menu.
3. EGR Monitor
The EGR monitor now runs in a closed throttle
decel or at idle on a warm vehicle. However, it is
necessary to maintain the TPS, Map and RPM
OBDII MONITOR RUN PROCESS NGC
VEHICLES
The following procedure has been established to
assist Chrysler Dealer Technicians in the field with
enabling and running OBD II Monitors. The order
listed in the following procedure is intended to
allow the technician to effectively complete each
monitor and to set the CARB Readiness Status in
the least time possible.
**NOTE**
C. Once the monitor run process has begun, do not
turn off the ignition. By turning the ignition key
off, monitor enabling conditions will be lost.
NVLD Monitor runs after key off.
D. By performing a Battery Disconnect, or Selecting
Erase DTCs, the CARB Readiness and all additional OBD II information will be cleared.
Monitor Preliminary Checks:
4. Plug a DRBIIIt into the vehicle’s DLC.
5. Turn the ignition, KEY ON - ENGINE OFF.
Watch for MIL lamp illumination during the
bulb check. MIL lamp must have illuminated, if
not, repair MIL lamp.
6. On the DRBIIIt Select #1 DRBIIIt Standalone.
7. Select #1 1998-2003 Diagnostics
8. Select #1 Engine
9. Select #2 DTCs and Related Functions
10. Select #1 Read DTCs
* Verify that No Emissions Related DTCs are
Present.
* If an Emissions DTC is Present, the OBD II
Monitors may not run and the CARB Readiness
will not update.
*The Emissions related DTC, will need to be
repaired, then cleared. By clearing DTCs, the
OBD Monitors will need to be run and completed to set the CARB Readiness Status.
11. Return to Engine Select Function Menu and
Select #9, OBD II Monitors.
12. Select #3 CARB Readiness Status.
Do all the CARB Readiness Status Locations read
YES?
*YES, then all monitors have been completed and
this vehicle is ready to be I/M or Emission Tested.
*NO, then the following procedure needs to be
followed to run/complete all available monitors.
7
GENERAL INFORMATION
2. The wait-to start, water-in-fuel, check engine,
check gauges, and transmission temperature
(auto trans only) lamps are turned on by the
PCM, ECM, or BCM for at least 2 seconds as a
bulb test. This is done by direct wire or through
the Bus to the smart cluster.
3. The ECM monitors the intake air temperature
signal. If the intake air temperature is below a
predetermined temperature, the ECM will start
the air intake preheat cycle. The ECM will
energize the intake heaters by grounding the air
intake relays. The ECM will turn the wait-tostart lamp on until the preheat cycle is over. If
the ECM receives a crank signal before the
preheat (Fig 1.) cycle is over, the preheat cycle
will be aborted.
4. The ECM will request the water-in-fuel lamp on
if a signal is received from the water-in-fuel
sensor.
ranges to allow the monitor to complete itself.
For the monitor run conditions, select the EGR
PRE-TEST in the DRBIIIt, OBD II Monitors
Menu.
4. O2 Sensor Heater Monitor
This monitor is now continuously running once
the heaters are energized. Pass information will
be processed at power down. For the monitor run
conditions, select the O2S HEATER MON PRETEST in the DRBIIIt, OBD II Monitors Menu.
PCM (JTEC) AND ECM (CM845) OPERATING
MODES (DIESEL)
As input signals to the Engine Control Module
(ECM) change, the ECM adjusts its response to
output devices. There are several different modes of
operation that determine how the ECM responds to
the various input signals.
IGNITION SWITCH ON (ENGINE OFF) MODE
When the ignition switch is in the ‘‘on’’ position,
the following actions occur:
1. When the PCM and ECM receive an ignition
sense input, they power up. Battery voltage is
supplied through the battery voltage input.
INTAKE AIR
TEMPERATURE
PREHEAT
HEATERS
DURATION
DUTY CYCLE
< -40F
Both
30 Sec
Continuous
-40 F to -15 F
Both
30 Sec
Continuous
-15 F to 0 F
Both
30 Sec
Continuous
0 F to 15 F
Both
15 Sec
Continuous
15 F to 30 F
Both
10 Sec
Continuous
30 F to 66 F
Both
10 Sec
Continuous
> 66 F
Both
0 Sec (off)
Continuous
NOTE: If the water-in-fuel lamp remains illuminated after the 2-second bulb check, the vehicle
should not be started until the fuel filter has been drained.
ENGINE START-UP MODE
disabled. However, the post-heat cycle will begin
if the engine is in the run state or speed is above
1200 rpm.
When the ignition key is held in the ‘‘start’’
position, the following occurs:
1. The ECM receives the crank signal input from
the camshaft position sensor.
2. The air intake heaters are not energized during
cranking.
3. The ECM monitors engine speed and when the
engine speed is above 650 rpm, the ECM determines that the engine is running.
4. If the ECM receives a crank signal before the
preheat (Fig 2) cycle is over, the heaters will be
8
GENERAL INFORMATION
INTAKE AIR TEMP
or
BATTERY TEMP
SENSOR
< - 40 F
POSTHEAT
HEATERS
DURATION
DUTY CYCLE
Both
20 Sec
Continuous
One
10 Sec
Continuous
One
120 Sec
25 / 75
Both
20 Sec
Continuous
One
10 Sec
Continuous
One
120 Sec
25 / 75
Both
20 Sec
Continuous
One
10 Sec
Continuous
One
120 Sec
25 / 75
0 F to 15 F
RPM < Threshold
Both
10 Sec
Continuous
One
130 Sec
25 / 75
0 F to 15 F
RPM > Threshold
Both
10 Sec
Continuous
One
90 Sec
Continuous
One
40 Sec
50 / 50
15 F to 30 F
RPM < Threshold
Both
10 Sec
Continuous
One
130 Sec
25 / 75
15 F to 30 F
RPM > Threshold
Both
10 Sec
Continuous
One
90 Sec
Continuous
One
40 Sec
50 / 50
30 F to 66 F
RPM < Threshold
Both
10 Sec
Continuous
One
130 Sec
25 / 75
30 F to 66 F
RPM > Threshold
Both
10 Sec
Continuous
One
90 Sec
Continuous
One
40 Sec
50 / 50
- 40 F to -15 F
-15 F to 0 F
> 66 F
Off
ENGINE WARM-UP MODE
CRUISE OR IDLE MODE
1. The ECM may start the air intake heater postheat cycle depending on intake air temperature.
If manifold air temperature was 66°F or less
when the ignition was turned on, the cycle is
started.
2. If the transmission temperature sensor shows it
is below 59°F, the automatic transmission will
not be allowed to enter overdrive.
3. If the transmission temperature sensor shows it
is below 69°F, the transmission’s torque converter clutch will not be allowed to engage.
4. The ECM will request the water-in-fuel lamp on
if a signal is received from the water-in-fuel
sensor.
During the cruising speed, the following inputs
are received by the ECM:
1. The ECM monitors intake manifold air temperature through the intake air temperature sensor.
2. The intake air heater post-heat cycle will be
complete, if it is not already over.
3. The vehicle speed, and throttle position sensors
are used by the PCM to control the transmission
overdrive and torque converter clutch operation.
4. If the transmission temperature sensor shows it
is below 59°F or above 275°F, the automatic
transmission will not be allowed to enter overdrive. If the transmission is in overdrive when
the transmission temperature is above 275°F,
9
GENERAL INFORMATION
the transmission will downshift and not upshift
again until the transmission temperature drops
to 240°F.
4. The PCM/ECM will disable the speed control
when:
- the brakes are applied
- excessive engine speed
- the clutch is disengaged (manual transmission)
- the gear selector is shifted to neutral (automatic transmission)
- the speed control off switch is activated
the transmission will downshift and not upshift
again until the transmission temperature drops
to 240°F.
5. The water-in-fuel sensor signal is used by the
ECM to request the water-in-fuel lamp on, if
water is sensed in the fuel.
ACCELERATION MODE
When there is an abrupt demand for increased
engine output and vehicle acceleration, the following occurs:
1. The vehicle speed, and throttle position signals
are used to control transmission overdrive and
torque converter clutch operation.
2. If the transmission temperature sensor shows it
is below 59°F, the torque converter clutch will
not be allowed to engage.
3. If the transmission temperature sensor shows it
is below 59°F or above 275°F, the automatic
transmission will not be allowed to enter overdrive. If the transmission is in overdrive when
the transmission temperature is above 275°F,
the transmission will downshift and not upshift
again until the transmission temperature drops
to 240°F.
4. If the speed control system resume/accelerate
function is being used, the PCM/ECM (Diesel
applications with manual transmission use the
CM845 ECM to conduct speed control system)
will only allow the vehicle to accelerate at a
predetermined rate. If a speed control has been
set and the resume/accelerate button is momentarily pushed in, the PCM/ECM will increase
vehicle speed by two miles per hour.
5. The PCM/ECM will disable the speed control
when:
- the brakes are applied
- excessive engine speed
- the clutch is disengaged (manual transmission)
- the gear selector is shifted to neutral (automatic transmission)
- the speed control off switch is activated
IGNITION SWITCH OFF MODE
When the ignition switch is turned to the ‘‘off ’’
position, the PCM and ECM still stores in memory
trouble codes and the throttle position sensor value
from the previous key-on.
NON-MONITORED CIRCUITS (DIESEL)
The ECM does not directly monitor the following
circuits, systems, and conditions even though they
could have malfunctions that result in driveability
problems. A diagnostic code may not be displayed
for the following conditions. However, problems
with these systems may cause a diagnostic code to
be displayed for other systems.
Engine Timing - The ECM can detect incorrectly
indexed timing gears; however, cannot detect improper valve adjustment.
Fuel Inlet Restriction - On a CARB certified
vehicle, the ECM can detect a clogged fuel pump
inlet filter, clogged in-tank filter, or a pinched
supply line. On an EPA certified vehicle, the ECM
cannot detect a clogged fuel pump inlet filter,
clogged in-tank filter, or a pinched supply line.
Fuel Injectors - On a CARB certified vehicle, the
ECM can detect if a fuel injector is clogged, or if the
pintle is sticking. On an EPA certified vehicle, the
ECM cannot detect if a fuel injector is clogged, or if
the pintle is sticking.
Fuel Requirements - Poor quality or air in fuel
can cause problems such as hard starting, no starting, stalling, and stumble.
DECELERATION MODE
During deceleration, the following inputs are
received by the PCM/ECM:
1. 1. The vehicle speed, crank position, and throttle
position signals are used to control transmission
overdrive and torque converter clutch operation.
2. The torque converter clutch will disengage, if the
brakes are applied.
3. If the transmission temperature sensor shows it
is below 59°F or above 275°F, the automatic
transmission will not be allowed to enter overdrive. If the transmission is in overdrive when
the transmission temperature is above 275°F,
PCM Grounds - The PCM and ECM cannot
detect a poor system ground. However, a diagnostic
trouble code may be stored as a result of this
condition.
Air Cleaner Air Flow - The PCM and ECM
cannot detect a clogged or restricted air cleaner
inlet or filter element, however, this condition may
lead to a low power/hard start type of complaint.
Exhaust System
10
- The PCM and ECM cannot
GENERAL INFORMATION
lates how much excess fuel is used for lubrication
for the pump and how much is returned to the tank.
The fuel that enters the High Pressure Pump is
pressurized between 4350-23,200 psi (300-1600
bar) by three radial pumping chambers. The pressurized fuel is then supplied to the Fuel Rail.
detect a plugged, restricted, or leaking exhaust
system, however, this condition may lead to a low
power/hard start type of complaint.
Fuel System - General Information
WARNING: HIGH-PRESSURE FUEL LINES
DELIVER DIESEL FUEL UNDER EXTREME
PRESSURE FROM THE INJECTION PUMP TO
THE FUEL INJECTORS. THIS MAY BE AS
HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS . FUEL
UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN CAUSING PERSONAL
INJURY
OR
DEATH.
INSPECT
FOR
HIGH-PRESSURE FUEL LEAKS WITH A
SHEET OF CARDBOARD. WEAR SAFETY
GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING
WHEN
SERVICING
FUEL
SYSTEM.
3.2.3
TRANSMISSION CONTROL
The 45RFE/545RFE electronic transmission has
a fully adaptive control system. The system performs its functions based on continuous real-time
sensor feedback information. The control system
automatically adapts to changes in engine performance and friction element variations to provide
consistent shift quality. The control system ensures
that clutch operation during upshifting and downshifting is more responsive without increased
harshness.
The Powertrain Control Module (PCM) continuously checks for electrical problems, mechanical
problems, and some hydraulic problems. When a
problem is sensed, the PCM stores a diagnostic
trouble code (DTC). Some of these codes cause the
transmission to go into ‘‘limp-in’’ or ‘‘default’’ mode.
The 45RFE/545RFE has three default modes:
The fuel system is a Robert Bosch High Pressure
Common Rail (HPCR) electronically controlled fuel
system. The HPCR system consists of five main
components: Electronic Fuel Lift Pump, Fuel Pump
Gear Pump, High Pressure Pump (CP3), Fuel Rail,
and Injectors. The High Pressure Pump (CP3) supplies high-pressure fuel to the fuel rail independent
of engine speed. This high-pressure fuel is then
accumulated in the Fuel Rail. High-pressure fuel is
constantly supplied to the Injectors by the Fuel
Rail. The Electronic Control Module (ECM) controls
the fueling and timing of the engine by actuating
the Injectors.
Fuel enters the system from the Electronic Fuel
Lift Pump, which is attached to the fuel filter
assembly. Fuel is forced through the fuel filter
element and then enters the Fuel Pump Gear
Pump, which is attached to the rear of the High
Pressure Pump (CP3). The Fuel Pump Gear Pump
is a low-pressure pump and produces pressures
ranging from 80 to 180 psi (5.5 to 12.4 bar).
Then the fuel enters the High Pressure Pump
(CP3). The low-pressure fuel is then supplied to the
Fuel Control Actuator (FCA). The Fuel Control
Actuator is an electronically controlled solenoid
valve. The ECM controls the amount of fuel that
enters the high pressure pumping chambers by
opening and closing the Fuel Control Actuator
based on a demanded fuel pressure. The Pressure
Sensor on the Fuel Rail provides the actual fuel
pressure. When the Actuator is opened, the maximum amount of fuel is being supplied to the High
Pressure Pump. Any fuel that does not enter the
High Pressure Pump is directed to the Cascade
Overflow Valve. The Cascade Overflow Valve regu-
(I) Immediate shutdown - The PCM deenergizes the transmission control relay. This
causes the transmission system to immediately
default to third gear if shift lever is in the ‘‘D’’
position, or 2nd gear if it is in the ‘‘2’’ or ‘‘L’’
positions. Park, Neutral, and Reverse are still
available.
(O) Orderly Shutdown - If the PCM recognizes a
problem that does not require an immediate shutdown, the transmission will maintain the current
gear and the transmission control relay will remain
energized until de-energizing it will not overspeed
the engine. When the vehicle speed reaches a reasonable level the PCM de-energizes the transmission control relay. This causes the transmission
system to immediately default to third gear if shift
lever is in the ‘‘D’’ position, or 2nd gear if it is in the
‘‘2’’ or ‘‘L’’ positions. Park, Neutral, and Reverse are
still available.
(L) Logical Shutdown with Recovery - The
PCM does not de-energize the Transmission Control
Relay. Instead, the transmission will utilize 1st and
3rd gears while in ‘‘D’’, and will use 2nd while in ‘‘2’’
or ‘‘L’’. All transmission operation in this mode will
be at a preset line pressure (open loop). The transmission will resume normal operation (recover) if
the detected problem goes away. Three recoveries
are permitted in a given key, after the fourth
occurrence the operation described above will be
maintained.
11
GENERAL INFORMATION
sure gauge to compare the line pressure sensor
reading on the DRBIIIt to the gauge pressure.
Technicians should compare the mechanical gauge
reading with the ‘‘actual’’ and ‘‘desired’’ line pressure reading on the DRBIIIt. All three readings
should closely match in pressure. Because the mechanical and actual line pressure may not match
the desired at low engine speeds (due to low pump
output RPM), line pressure should always be
checked at 1500 - 2000 RPM.
Once the DRBIIIt is in the ‘‘EATX’’ portion of the
diagnostic program, it constantly monitors the
PCM to see if the system is in limp-in mode. If the
transmission is in limp-in mode, the DRBIIIt will
flash the red LED.
3.2.3.1
TRANSMISSION OPERATION AND
SHIFT SCHEDULING AT VARIOUS
OIL TEMPERATURES
The transmission covered in this manual has
unique shift schedules depending on the temperature of the transmission oil. The shift schedule is
modified to extend the life of the transmission while
operating under extreme conditions.
The oil temperature is measured with a Temperature Sensor on the 45RFE/545RFE transmission.
The Temperature Sensor is an integral component
of the Transmission Range Sensor (TRS). If the
Temperature Sensor is faulty, the transmission will
default to a ‘‘calculated’’ oil temperature. Oil temperature will then be calculated using engine coolant temperature, battery/ambient temperature,
and engine off time from the Body Control Module
(BCM). These inputs are received from the communication bus periodically and are used to initialize
the oil temperature at start up. Once the engine is
started, the PCM updates the transmission oil
temperature based on torque converter slip speed,
vehicle speed, gear, and engine coolant temperature
to determine an estimated oil temperature during
vehicle operation. Vehicles using ‘‘calculated oil
temperature’’ track oil temperature reasonably accurately during normal operation. However, if a
transmission is overfilled, a transmission oil cooler
becomes restricted, or if a customer drives aggressively in low gear, the calculated oil temperature
will be inaccurate. Consequently the shift schedule
selected may be inappropriate for the current conditions.
3.2.3.2
Typical Line Pressure problems include:
c
c
c
Mechanical and ‘‘actual’’ readings both less than
desired
- If the mechanical and ‘‘actual’’ readings do not
increase significantly as engine speed is raised
above 2000 RPM, the pressure control solenoid is
usually at fault. The pressure control solenoid is
usually accompanied by DTCs P0867(C8) and
P0868(C9). The PCS is located in the Transmission Solenoid/TRS assembly.
- If the mechanical and ‘‘actual’’ readings vary
with engine speed (above 2000 RPM), the fault is
often a sticking main regulator valve. This valve
is located in the transmission pump assembly.
‘‘Actual’’ reading on the DRBIIIt differs from the
Mechanical Pressure reading (higher or lower)
by more than 69kPa (10 PSI). This is sometimes
accompanied by a DTC P0869(CB). The fault is
usually in the Line Pressure Sensor or the Line
Pressure Sensor Wiring.
All three readings match, but the ‘‘actual’’ reading exhibits momentary intermittent pressure
increases to 1724 kPa (250 PSI). The line Pressure Sensor is usually the problem. This will
cause erratic shift quality (particularly a harsh
3-1 coast down shift), repair by replacing the
Line Pressure Sensor.
3.2.3.3
LINE PRESSURE CONTROL
DRIVE LEARN PROCEDURE
Procedure To Learn A Smooth 1st Neutral To
Drive Shift:
Perform this procedure only if the complaint is for a
delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to
set with the engine not running for at least 10
minutes. Use the following steps to have the PCM
learn the 1st N-D UD CVI.
Proper control of the transmission line pressure
is essential for proper operation. The 45RFE/
545RFE normally uses closed loop line pressure
control, where actual line pressure (reported by the
line pressure sensor) is continuously monitored.
The PCM determines the desired (target) line pressure which is required, and adjusts the Pressure
Control Solenoid (PCS) until the actual line pressure matches the desired line pressure value. In the
event of a line pressure sensor failure DTC
P0932(CA), the PCM changes to an open loop control at an essentially constant line pressure.
Proper diagnosis of line pressure systems is facilitated by the use of a special tool (T-fitting - Miller
#8259) which allows the use of a mechanical pres-
NOTE: The transmission oil temperature
must be between 80 - 110°F (27 - 43°C).
1. Start the engine only when the engine and
ignition have been off for at least ten (10) minutes.
12
GENERAL INFORMATION
4. This procedure may be performed at any temperature that experiences poor N-D shift quality.
Although the UD CVI may not change, shift
quality should improve.
2. With the vehicle at a stop and the service brake
applied, record the 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D
UD CVI account for air entrapment in the UD
clutch that may occur after the engine has been
off for a period of time.
Procedure To Learn The 1st 2-3 Shift After A
Restart Or Shift To Reverse:
Use the following steps to have the PCM learn the
1st 2-3 shift OD CVI.
3. Repeat steps 1 and 2 until the recorded 1st N-D
UD CVI value stabilizes.
NOTE: It is important that this procedure be
performed when the transmission temperature is between 80 - 110°F (27 - 43°C). If this
procedure takes too long to complete fully
for the allowed transmission oil temperature,
the vehicle may be returned to the customer
with an explanation that the shift will improve
daily during normal vehicle usage. The PCM
also learns at higher oil temperatures, but
these values (line pressure correction
values) are not available for viewing on the
DRBIIIT.
NOTE: The transmission oil temperature
must be above 80°F (27°C).
1. With the vehicle engine running, select reverse
gear for over 2 seconds.
2. Shift the transmission to Drive and accelerate
the vehicle from a stop at a steady 15 degree
throttle opening and perform a 2-3 shift while
noting the OD CVI. During the shift, a different
value may appear on the screen, which is the 1st
2-3 OD CVI.
3. Repeat steps 1 and 2 until the 1st 2-3 upshift
becomes smooth and the 1st 2-3 OD CVI stabilizes.
Procedure To Learn A Smooth Neutral To
Drive Garage Shift:
Perform this procedure if the complaint is for a
delayed or harsh shift when the transmission is put
into gear after the vehicle has had its first shift. Use
the following steps to have the PCM learn the
NORM N-D UD CVI.
Procedure To Learn A Smooth 2-3 And 3-4
Upshift:
Use the following steps to have the PCM learn the
OD and 4C CVI’s.
NOTE: The transmission oil temperature
must be above 110°F (43°C).
NOTE: The transmission oil temperature
must be between 80 - 110°F (27 - 43°C) to
learn the UD CVI. Additional learning occurs
at temperatures as low as 0°F and as high as
200°F. This procedure may be performed at
any temperature that experiences poor shift
quality. Although the UD CVI may not change,
shift quality should improve.
1. Accelerate the vehicle from a stop at a steady 15
degree throttle opening and perform multiple
1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift
following a restart or shift to reverse will be
shown during the shift as a value between the
1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the
2nd shift into 3rd gear, following a restart or
shift to reverse.
2. Repeat step 1 until the 2-3 and 3-4 shifts become
smooth and the OD and 4C CVI become stable.
1. Start the vehicle engine and shift to drive.
2. Move the vehicle forward to a speed of at least 16
km/h (10 MPH) and come to a stop. This ensures
no air is present in the UD hydraulic circuit.
3. Perform repeated N-D shifts at a stop while
pausing in Neutral for at least 2-3 seconds and
monitor NORM N-D UD CVI volume until the
value stabilizes. The value will change during
the N-D shift. This is normal since the UD value
is different for the N-D shift then the normal
value shown which is used for 4-3 coastdown and
kickdowns. Perform repeated shifts in this temperature range until the NORM N-D UD CVI.
value stabilizes and the N-D shifts become
smooth.
Procedure To Learn A Smooth 4-3 Coastdown
And Part Throttle 4-3 Kickdown:
Use the following steps to have the PCM learn the
UD shift volume.
13
GENERAL INFORMATION
NOTE: The transmission oil temperature
must be above 110°F (43°C).
NOTE: The transmission oil temperature
must be above 110°F (43°C).
1. At a vehicle speed between 64-97 km/h (40-60
MPH), perform repeated 4-3 kickdown shifts.
2. Repeat step 1 until the UD volume becomes
somewhat stable and the shift becomes smooth.
1. Accelerate the vehicle through 88 km/h (55mph)
at a steady 10-15 degree throttle opening and
perform multiple 4-5 upshifts.
2. Repeat step 1 until the 4-5 shift become smooth
and the ALT 2C CVI become stable. Note: There
is a separate ALT 2C CVI volume used and
learned for 4-5 shifts. It is independent of the 2C
CVI learned on 3-2 kickdowns.
Procedure To Learn A Smooth 1-2 Upshift and
3-2 Kickdown:
Use the following steps to have the PCM learn the
2C shift volume.
3.2.4
NOTE: The transmission oil temperature
must be above 110°F (43°C).
TRANSMISSION CONTROL (RE)
The PCM also controls the 4 speed automatic
transmissions utilizing electronic governor pressure control, eliminating the need for a separate
transmission controller.
Transmission control is achieved through regulation of governor pressure using a Governor Pressure Solenoid valve. Valve position is controlled by
pulse width modulation. Torque converter clutch
and overdrive solenoids are also controlled by the
PCM, as are the transmission relay and dashboard
overdrive off lamp. PCM inputs affecting transmission operation include the throttle position sensor,
output shaft speed sensor, vehicle speed, engine
speed sensor (CKP), brake switch, ignition, overdrive on/off switch, torque converter clutch solenoid, transmission temperature sensor, and governor pressure sensor.
The PCM continuously checks for internal transmission problems, electrical problems, and some
hydraulic problems. When a problem is sensed, the
PCM stores a diagnostic trouble code. Any of these
codes cause the transmission to go into ‘‘default’’
mode. When the PCM detects a problem, the transmission will default to third gear. When this happens, the only transmission functions are:
• PARK and NEUTRAL
• REVERSE
• THIRD GEAR
• MANUAL SHIFTING of FIRST, SECOND and
THIRD GEAR
No upshifts or downshifts are allowed. The position of the manual valve alone allows the ranges
that are available. Although engine performance is
seriously degraded while in this mode, it allows the
owner to drive the vehicle in for service. The transmission can be shifted manually by quickly downshifting into 1st to achieve 1st gear, then shifting to
2nd, then to third. However, default mode will not
allow 4th gear or any EMCC operation.
Once the DRBIIIt is in the RE transmission
portion of the diagnostic program, it constantly
monitors the PCM, updating the screens with
1. With a vehicle speed below 48 km/h (30 MPH)
and the transmission in 3rd gear, perform multiple 3-2 kickdowns.
2. Repeat step 1 until the 3-2 kickdowns become
smooth and the 2C CVI becomes stable.
Procedure To Learn A Smooth Manual 2-1
Pulldown Shift As Well As A Neutral To Reverse Shift:
Use the following steps to have the PCM learn the
LR volume.
NOTE: The transmission oil temperature
must be above 110°F (43°C).
1. With the vehicle speed around 40-48 km/h (25-30
MPH) in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle.
2. Repeat step 1 until the LR CVI become stable
and the manual 2-1 becomes smooth.
Procedure To Learn A Smooth Neutral To Reverse Shift:
Perform the following shifts.
NOTE: The transmission oil temperature
must be above 110°F (43°C).
1. With the vehicle at a stop, perform Neutral to
Reverse shifts until the shift is smooth. An
unlearned Neutral to Reverse shift may be harsh
or exhibit a double bump.
If any of the shifts are still not smooth after the
clutch volume stabilizes, an internal transmission
problem may be present.
Procedure To Learn A Smooth 4-5 Upshift for
545RFE:
Use the following steps to have the PCM learn the
ALT 2C CVI.
14
GENERAL INFORMATION
switch, sensor, and input/output states, as well as
displaying diagnostic trouble codes and default status.
output speed (called governor pressure) against a
pressure signal determined by throttle position
(called throttle pressure). The four curves are used
during the following operating conditions.
Transmission Identification
The transmission part/identification numbers
and codes are stamped on the left side of the case
just above the oil pan gasket surface. The first
letter/number group is the assembly part number.
The next number group is the transmission serial
number. Refer to this information when ordering
replacement parts.
Low Transmission Fluid Temperature - When
the transmission fluid is cold at or below 30°F, the
conventional governor can delay shifts, resulting in
higher than normal shift speeds and harsh shifts.
The electronically controlled low temperature governor pressure curve is higher than normal to make
the transmission shift at normal speeds and sooner.
The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed.
Governor Pressure Solenoid Valve
The solenoid valve generates the governor pressure needed for upshifts and downshifts. It is an
electro-hydraulic device and is located in the governor body on the valve body transfer plate. The inlet
side of the solenoid valve is exposed to normal
transmission line pressure while in forward gears.
The outlet side of the valve leads to the valve body
governor circuit. The solenoid valve regulates line
pressure to produce governor pressure. The average
current supplied to the solenoid valve controls governor pressure. One amp current produces zero psi
governor pressure. Zero amps set the maximum
governor pressure. Current is regulated by modulation of the pulse width of a 512 Hz driver frequency. The transmission control relay supplies
electrical power to the solenoid valve. Operating
voltage is 12 volts (DC) and is provided through the
relay’s fused B+ contact. The solenoid is polarity
sensitive. The PCM energizes the solenoid by
grounding it through the power ground terminal on
the PCM.
Transfer Case Low-Range Operation - On
four-wheel drive vehicles operating in low range,
the engine can accelerate to its peak more rapidly
than in Normal range, resulting in delayed shifts
and undesirable engine ‘‘flare.’’ The low range governor pressure curve is also higher than normal to
initiate upshifts sooner. The PCM compares the
electronic vehicle speed signal to the transmission
output shaft speed signal to determine when the
transfer case is in low range.
Wide-Open Throttle Operation - In wide-open
throttle (WOT) mode, adaptive memory in the PCM
assures that up-shifts occur at the preprogrammed
optimum speed. WOT operation is determined from
the throttle position sensor, which is also a part of
the emission control system. The initial setting for
the WOT upshift is below the optimum engine
speed. As WOT shifts are repeated, the PCM learns
the time required to complete the shifts by comparing the engine speed when the shifts occur to the
optimum speed. After each shift, the PCM adjusts
the shift point until the optimum speed is reached.
The PCM also considers vehicle loading, grade and
engine performance changes due to high altitude in
determining when to make WOT shifts. It does this
by measuring vehicle and engine acceleration and
then factoring in the shift time.
Governor Pressure Sensor
The governor pressure sensor measures output
pressure of the governor pressure solenoid valve.
The sensor output signal provides the necessary
feedback to the PCM. This feedback is needed to
accurately control pressure. The unit is an absolute
pressure device and the output is calibrated to be
0.35 to 0.65 volts at 14.7 psi (normal barometric
pressure). Since this is an absolute pressure device,
0 psi calibration is required often to compensate for
changing atmospheric pressure or altitude. This
voltage measured at 0 psi is referred to as zero
pressure offset.
Normal Operation - Normal operation is refined
through the increased computing power of the PCM
and through access to data on engine operating
conditions provided by the PCM. This facilitated
the development of a load adaptive shift strategy the ability to alter the shift schedule in response to
vehicle load conditions. One manifestation of this
capability is grade ‘‘hunting’’ prevention - the ability
of the transmission logic to delay an upshift on a
grade if the engine does not have sufficient power to
maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears
occurs with a heavily loaded vehicle or on steep
grades. When hunting occurs, it is very objection-
Governor Shift Schedules
The electronic governor has several governor
curves possible as opposed to a conventional governor, which has a single governor curve with two
stages. These transmissions are mechanically and
hydraulically the same as the ones they replace.
As with all-hydraulic transmissions, the vehicle
shift speeds are determined by balancing a hydraulic pressure signal proportional to transmission
15
GENERAL INFORMATION
Transmission Output Shaft Speed Sensor
The output shaft speed sensor is located in the
overdrive housing. The sensor is positioned over the
park gear and monitors transmission output shaft
rotating speed. Speed sensor signals are triggered
by the park gear lugs as they rotate past the sensor
pickup face. One revolution of the output shaft
produces 23 pulses. Input signals from the sensor
are sent to the PCM for processing.
able because shifts are frequent and accompanied
by large changes in noise and acceleration.
Governor Operation
The electronic governor control system replaces
the old centrifugal governor pressure control and is
located on the valve body. The control system uses a
governor pressure solenoid that can vary pressure,
a pressure sensor, and the output shaft speed sensor. The electronic governor control system regulates pressure to control shifts in the first three
gears. Output shaft speed and throttle position is
used to determine target pressure. Actual governor
pressure is read from the sensor and the difference
between the target pressure and actual pressure is
used to determine duty cycle correction. The duty
cycle is the amount of time the governor pressure
solenoid needs to be off to meet the target pressure.
Output shaft speed, throttle position, controller
calculations, and shift lever position, all determine
different governor pressure curves. Governor pressures can be different at the same output shaft
speed. The desired governor pressure is determined
by many things; including the acceleration of the
vehicle. There is no need for concern if the same
output shaft speed has different requested pressures. There is a need for concern if the target
pressure and actual pressure are not within three
PSI for five seconds or more. If this occurs the
control system could result in erratic shifting. The
only time the governor control system stays at zero
is when the gear selector is in park, neutral, reverse
or drive with the vehicle at a stop. When the
transmission is in park, neutral, or reverse no line
pressure is supplied to the governor pressure solenoid, making governor pressure zero.
Torque Converter Electronics
The torque converter contains a converter clutch
mechanism. The converter clutch is an electronically controlled mechanism. It is engaged in fourth
gear, and in third gear only when the overdrive
control switch is in the OFF position, and also, in
third gear over temp mode. The torque converter is
not a serviceable component. It should be replaced
as an assembly when: diagnosis indicates a malfunction has occurred, or when a major malfunction
allows debris to enter the converter.
3.2.5
O2 SENSOR (NGC)
The O2 system will with ignition on and engine
off have a normalized O2 voltage of around 5 volts
as displayed on the DRBIIIt or measured with a
high impedance voltmeter. As the O2 sensor starts
generating a signal the voltage will move towards
2.5 volts. The voltage will typically vary between
2.5 volts and 3.5 volts on a normal running engine.
The goal voltage is also typically between 2.5 and
3.5 volts. This implies that the 0-volt through 1-volt
range that you are used to is still valid, only it is
shifted up by a 2.5 volt offset. This 2.5 volt supply is
being delivered through the sensor return line.
3.2.6
Transmission Temperature sensor
Transmission fluid temperature readings are
supplied to the PCM by the trans temp sensor. The
temp sensor is located in the governor pressure
sensor connector. The temperature readings are
used to control engagement of the overdrive clutch,
the converter clutch, and governor pressure. Normal resistance value for the thermistor at room
temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement
of the converter clutch and overdrive clutch, when
fluid temperature is below approximately 30°F. If
fluid temperature exceeds 260°F, the PCM will
cause a 4-3 downshift and engage the converter
clutch. Engagement is according to the third gear
converter clutch engagement schedule.
The overdrive OFF lamp in the instrument panel,
also illuminates when the shift back to third occurs.
The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F.
OTHER CONTROLS
Charging System (NGC)
The charging system is turned on when the
engine is started. The Generator Field is controlled
by the PCM using a 12-volt high side driver and a
body ground. The PCM determines the Generator
output voltage by an input from the Battery Temperature Sensor. The PCM applies a longer duty
cycle on time to the Generator Field Control circuit
when more system voltage is needed. When a lower
system voltage is needed, the PCM shortens the
duty cycle on time of the high side driver.
Vehicle Speed Control (NGCI)
The PCM controls vehicle speed by operation of
the speed control servo vacuum and vent solenoids.
Energizing the vacuum solenoid applies vacuum to
the servo to increase throttle position. Operation of
the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump
solenoid allows immediate release of throttle posi16
GENERAL INFORMATION
tion caused by braking, cruise control turn off,
shifting into neutral, excessive RPM (tires spinning) or ignition key off.
Vehicle Speed Control (NGCII)
The PCM controls vehicle speed by controlling
the throttle opening to achieve the selected vehicle
speed under all driving conditions. Cruise control
switches used on NGCII vehicles have two inputs
per switch. No servo or solenoids are used with this
system.
LEAK DETECTION OPERATION
The evaporative emission system is designed to
prevent the escape of fuel vapors from the fuel
system. Leaks in the system, even small ones, can
allow fuel vapors to escape into the atmosphere.
Government regulations require onboard testing to
make sure that the evaporative (EVAP) system is
functioning properly. The leak detection system
tests for EVAP system leaks and blockage. It also
performs self-diagnostics.
During self-diagnostics, the Powertrain Control
Module (PCM) first checks the Leak Detection
Pump (LDP) for electrical and mechanical faults. If
the first checks pass, the PCM then uses the LDP to
seal the vent valve and pump air into the system to
pressurize it. If a leak is present, the PCM will
continue pumping the LDP to replace the air that
leaks out. The PCM determines the size of the leak
based on how fast/long it must pump the LDP as it
tries to maintain pressure in the system.
Figure 1
Leak Detection Pump (LDP) Components:
The main purpose of the LDP is to pressurize the
fuel system for leak checking. It closes the EVAP
system vent to atmospheric pressure so the system
can be pressurized for leak testing. The diaphragm
is powered by engine vacuum. It pumps air into the
EVAP system to develop a pressure of about 7.59
H2O (1/4) psi. A reed switch in the LDP allows the
PCM to monitor the position of the LDP diaphragm.
The PCM uses the reed switch input to monitor how
fast the LDP is pumping air into the EVAP system.
This allows detection of leaks and blockage.
The LDP assembly consists of several parts (Figure 2). The solenoid is controlled by the PCM, and it
connects the upper pump cavity to either engine
vacuum or atmospheric pressure. A vent valve
closes the EVAP system to atmosphere, sealing the
system during leak testing. The pump section of the
LDP consists of a diaphragm that moves up and
down to bring air in through the air filter and inlet
check valve, and pump it out through an outlet
check valve into the EVAP system.
EVAP LEAK DETECTION SYSTEM COMPONENTS
(FIGURE 1)
Service Port: Used with special tools like the
Miller Evaporative Emissions Leak Detector
(EELD) to test for leaks in the system.
EVAP Purge Solenoid: The PCM uses the EVAP
purge solenoid to control purging of excess fuel
vapors stored in the EVAP canister. It remains
closed during leak testing to prevent loss of pressure.
EVAP Canister: The EVAP canister stores fuel
vapors from the fuel tank for purging.
EVAP Purge Orifice: Limits purge volume.
EVAP System Air Filter: Provides air to the LDP
for pressurizing the system. It filters out dirt while
allowing a vent to atmosphere for the EVAP system.
17
GENERAL INFORMATION
DIAPHRAGM UPWARD MOVEMENT
When the PCM energizes the LDP solenoid, the
solenoid blocks the atmospheric port leading through
the EVAP air filter and at the same time opens the
engine vacuum port to the pump cavity above the
diaphragm. The diaphragm moves upward when
vacuum above the diaphragm exceeds spring force.
This upward movement closes the vent valve. It also
causes low pressure below the diaphragm, unseating
the inlet check valve and allowing air in from the
EVAP air filter. When the diaphragm completes its
upward movement, the LDP reed switch turns from
closed to open (Figure 4).
Figure 2
The diaphragm is pulled up by engine vacuum,
and pushed down by spring pressure, as the LDP
solenoid turns on and off. The LDP also has a
magnetic reed switch to signal diaphragm position
to the PCM. When the diaphragm is down, the
switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up,
the switch is open, and there is no voltage sent to
the PCM. This allows the PCM to monitor LDP
pumping action as it turns the LDP solenoid on and
off.
LDP AT REST (NOT POWERED)
When the LDP is at rest (no electrical/vacuum)
the diaphragm is allowed to drop down if the
internal (EVAP system) pressure is not greater than
the return spring. The LDP solenoid blocks the
engine vacuum port and opens the atmospheric
pressure port connected through the EVAP system
air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric
pressure (Figure 3).
Figure 4
DIAPHRAGM DOWNWARD MOVEMENT
Based on reed switch input, the PCM deenergizes the LDP solenoid, causing it to block the
vacuum port, and open the atmospheric port. This
connects the upper pump cavity to atmosphere
through the EVAP air filter. The spring is now able
to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve
and opens the outlet check valve pumping air into
the evaporative system. The LDP reed switch turns
from open to closed, allowing the PCM to monitor
LDP pumping (diaphragm up/down) activity (Figure 5). During the pumping mode, the diaphragm
will not move down far enough to open the vent
valve.
Figure 3
18
GENERAL INFORMATION
•
P1495 - LEAK DETECTION PUMP SOLENOID
CIRCUIT
ENABLING CONDITIONS TO RUN EVAP
LEAK DETECTION TEST
1. Cold start: with ambient temperature (obtained
from modeling the inlet air temperature sensor
on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between
4°C (40°F) and 32°C (90°F) for 0.040 leak. Between 4°C (40°F) and 29°C (85°F) for 0.020 leak.
2. Engine coolant temperature within:-12° to -8°C
(10° to 18°F) of battery/ambient.
3. Battery voltage between 10 and 15 volts.
NOTE: If battery voltage drops below 10 volts
for more than 5 seconds during engine
cranking, the EVAP Leak Detection test will
not run.
Figure 5
The pumping cycle is repeated as the solenoid is
turned on and off. When the evaporative system
begins to pressurize, the pressure on the bottom of
the diaphragm will begin to oppose the spring
pressure, slowing the pumping action. The PCM
watches the time from when the solenoid is deenergized, until the diaphragm drops down far
enough for the reed switch to change from opened to
closed. If the reed switch changes too quickly, a leak
may be indicated. The longer it takes the reed
switch to change state, the tighter the evaporative
system is sealed. If the system pressurizes too
quickly, a restriction somewhere in the EVAP system may be indicated.
4. Low fuel warning light off (fuel level must be
between 15% and 85%).
5. MAP sensor reading 22 in Hg or above (This is
the manifold absolute pressure, not vacuum).
6. No engine stall during test.
NOTE: The following values are approximate
and vehicle specific. Use the values seen in
pre test/monitor test screen on the DRBIIIT.
See TSB 25-02-98 for more detail.
A DTC will not set if a one-trip fault is set or of
the MIL is illuminated for any of the following:
• Purge Solenoid
• All engine Controller Self Test Faults
• All Cam and/or Crank Sensor Faults
PUMPING ACTION
During portions of this test, the PCM uses the
reed switch to monitor diaphragm movement. The
solenoid is only turned on by the PCM after the reed
switch changes from open to closed, indicating that
the diaphragm has moved down. At other times
during the test, the PCM will rapidly cycle the LDP
solenoid on and off to quickly pressurize the system.
During rapid cycling, the diaphragm will not move
enough to change the reed switch state. In the state
of rapid cycling, the PCM will use a fixed time
interval to cycle the solenoid.
If the system does not pass the EVAP Leak
Detection Test, the following DTCs may be set:
• P0442 - EVAP LEAK MONITOR 0.0409 LEAK
DETECTED
•
•
•
•
•
•
•
•
•
•
•
•
•
•
P0455 - EVAP LEAK MONITOR LARGE LEAK
DETECTED
P0456 - EVAP LEAK MONITOR 0.0209 LEAK
DETECTED
P1486 - EVAP LEAK MON PINCHED HOSE
FOUND
P1494 - LEAK DETECTION PUMP SW OR
MECH FAULT
19
MAP Sensor Faults
Ambient/Battery Temperature Sensor Electrical
Faults
All Coolant Sensor Faults
All TPS Faults
LDP Pressure Switch Faults
EGR Solenoid Electrical Faults
All Injector Faults
Baro Out Of Range
Vehicle Speed Faults
LDP Solenoid Circuit
GENERAL INFORMATION
sure in the EVAP system, or an actual fault. The
PCM stores information in memory on EVAP system purging from previous engine run or drive
cycles.
If little or no purging took place, residual pressure could be holding the LDP diaphragm up,
causing the LDP switch to be open. Since this is not
a malfunction, the PCM cancels the EVAP Leak
Detection Test without setting the temporary fault.
If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the
PCM judges that this is a malfunction and sets a
temporary fault in memory. The next time that the
Enabling Conditions are met, the test will run
again. If the fault is again detected, the MIL will
illuminate and DTC 1494 will be stored. If the fault
is not detected, the temporary fault will be cleared.
Figure 6
FIGURE 6 SECTION 3
If no fault has been detected so far, the PCM
begins testing for possible blockage in the EVAP
system between the LDP and the fuel tank. This is
done by monitoring the time required for the LDP to
pump air into the EVAP system during two to three
pump cycles. If no blockage is present, the LDP
diaphragm is able to quickly pump air out of the
LDP each time the PCM turns off the LDP solenoid.
If a blockage is present, the PCM detects that the
LDP takes longer to complete each pump cycle. If
the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a
blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is
again detected, P1486 is stored, and the MIL is
illuminated.
FIGURE 6 SECTION 1
When the ignition key is turned to ‘‘ON’’, the LDP
diaphragm should be in the down position and the
LDP reed switch should be closed. If the EVAP
system has residual pressure, the LDP diaphragm
may be up. This could result in the LDP reed switch
being open when the key is turned to ‘‘ON’’ and a
P1494 fault could be set because the PCM is expecting the reed switch to be closed.
After the key is turned ‘‘ON’’, the PCM immediately tests the LDP solenoid circuit for electrical
faults. If a fault is detected, DTC P1495 will set, the
MIL will illuminate, and the remaining EVAP Leak
Detection Test is canceled.
NOTE: If battery temperature is not within
range, or if the engine coolant temperature is
not within a specified range of the battery
temperature, the PCM will not run tests for
DTCP1494, P1486, P0442, P0455 and P0441.
These temperature calibrations may be
different between models.
FIGURE 6 SECTION 4
After the LDP blockage tests are completed, the
PCM then tests for EVAP system leakage. First, the
PCM commands the LDP to rapidly pump for 20 to
50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system
to see if it can be sufficiently pressurized. This
evaluation (rapid pump cycling) may occur several
times prior to leak checking. The LDP reed switch
does not close and open during rapid pumping
because the diaphragm does not travel through its
full range during this part of the test.
FIGURE 6 SECTION 2
If DTC P1495 is not set, the PCM will check for
DTC P1494. If the LDP reed switch was closed
when the key was turned to ‘‘ON’’, the PCM energizes the LDP solenoid for up to 8 seconds and
monitors the LDP switch. As the LDP diaphragm is
pulled up by engine vacuum, the LDP reed switch
should change from closed to open. If it does not, the
PCM sets a temporary fault (P1494) in memory, and
waits until the next time the Enabling Conditions
are met to run the test again. If this is again
detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next
enabling cycle, the temporary fault will be cleared.
However, if the PCM detects the reed switch open
when the key is turned to ‘‘ON’’, the PCM must
determine if this condition is due to residual pres-
FIGURE 6 SECTION 5
Next, the PCM performs one or more test cycles
by monitoring the time required for the LDP reed
switch to close (diaphragm to drop) after the LDP
solenoid is turned off.
If the switch does not close, or closes after a long
delay, it means that the system does not have any
significant leakage and the EVAP Leak Detection
Test is complete.
20
GENERAL INFORMATION
However, if the LDP reed switch closes quickly,
there may be a leak or the fuel level may be low
enough that the LDP must pump more to finish
pressurizing the EVAP system. In this case, the
PCM will rapidly pump the LDP again to build
pressure in the EVAP system, and follow that by
monitoring the time needed for several LDP test
cycles. This process of rapid pumping followed by
several LDP test cycles may repeat several times
before the PCM judges that a leak is present.
When leaks are present, the LDP test cycle time
will be inversely proportional to the size of the leak.
The larger the leak, the shorter the test cycle time.
The smaller the leak, the longer the test cycle time.
DTCs may be set when a leak as small as 0.5 mm
(0.0209) diameter is present.
If the system detects a leak, a temporary fault
will be stored in PCM memory. The time it takes to
detect a .020, .040, or Large leak is based on
calibrations that vary from model to model. The
important point to remember is if a leak is again
detected on the next EVAP Leak Detection Test, the
MIL will illuminate and a DTC will be stored based
on the size of leak detected. If no leak is detected
during the next test, the temporary fault will be
cleared.
P1486 and this fault can set due to pressure being
in the EVAP system during the test sequence.
Multiple actuation’s of the DRBIIIt Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak
because of excess vapor generation. Additionally,
any source for additional vapor generation can hide
a small leak in the EVAP system. Excess vapor
generation can delay the fall of the LDP diaphragm
thus hiding the small leak. An example of this
condition could be bringing a cold vehicle into a
warm shop for testing or high ambient temperatures.
Fully plugged and partially plugged underhood
vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason.
Always, thoroughly, check plumbing for pinches or
blockage before condemning components.
TEST EQUIPMENT
The Evaporative Emission Leak Detector (EELD)
Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will
take the place of the ultrasonic leak detector 6917A.
The EELD utilizes shop air and a smoke generator
to visually detect leaks down to 0.020 or smaller.
The food grade oil used to make the smoke includes
an UV trace dye that will leave telltale signs of the
leak under a black light. This is helpful when
components have to be removed to determine the
exact leak location. For detailed test instructions,
follow the operators manual packaged with the
EELD.
DIAGNOSTIC TIPS
During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure
6. If the PCM detects a problem that could set a
DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it
indicates that the previous section passed successfully. By watching to see which tests complete, you
can see if any conditions are present that the PCM
considers abnormal.
For example, if the LDP solenoid is energized for
the test cycles to test for blockage (P1486), it means
that the LDP has already passed its test for P1494.
Then, if the PCM detects a possible blockage, it will
set a temporary fault without turning on the MIL
and continue the leak portion of the test. However,
the PCM will assume that the system is already
pressurized and skip the rapid pump cycles.
Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections
may mask a leak condition.
Keep in mind that if the purge solenoid seat is
leaking, it could go undetected since the leak would
end up in the intake manifold. Disconnect the purge
solenoid at the manifold when leak checking. In
addition, a pinched hose fault (P1486) could set if
the purge solenoid does not purge the fuel system
properly (blocked seat). The purge solenoid must
vent the fuel system prior to the LDP system test. If
the purge solenoid cannot properly vent the system
the LDP cannot properly complete the test for
IMPORTANT
Be sure that the PCM has the latest software
update. Reprogram as indicated by any applicable
Technical Service Bulletin. After LDP repairs are
completed, verify the repair by running the
DRBIIIt Leak Detection Pump (LDP) Monitor Test
as described in Technical Service Bulletin 18-12-99.
NATURAL VACUUM LEAK DETECTION (NVLD)
The Natural Vacuum Leak Detection (NVLD)
system is the next generation evaporative leak
detection system that will first be used on vehicles
equipped with the Powertrain Control Module
(PCM) or Next Generation Controller (NGC) starting in 2002 M.Y. This new system replaces the leak
detection pump as the method of evaporative system leak detection. The current CARB requirement
is to detect a leak equivalent to a 0.0209 (0.5 mm)
hole. This system has the capability to detect holes
of this size very dependably.
The basic leak detection theory employed with
NVLD is the ‘‘Gas Law’’. This is to say that the
pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel
will only see this effect if it is indeed sealed. Even
21
GENERAL INFORMATION
small leaks will allow the pressure in the vessel to
come to equilibrium with the ambient pressure. In
addition to the detection of very small leaks, this
system has the capability of detecting medium as
well as large evaporative system leaks.
the evaporative system. The seal will be opened at
about 0.59 H2O (0.12 KPA) pressure to permit the
venting of vapors during refueling. An added benefit to this is that it will also allow the tank to
‘‘breathe’’ during increasing temperatures, thus
limiting the pressure in the tank to this low level.
This is beneficial because the induced vacuum during a subsequent declining temperature will
achieve the switch closed (pass threshold) sooner
than if the tank had to decay from a built up
pressure.
The NVLD Assembly itself has 3 wires: Switch
sense, solenoid driver and ground. It also includes a
resistor to protect the switch from a short to battery
or a short to ground. The PCM utilizes a high-side
driver to energize and duty-cycle the solenoid.
The NVLD utilizes the Gas Law principles
A vent valve seals the canister vent during engine
off conditions. If the vapor system has a leak of less
than the failure threshold, the evaporative system
will be pulled into a vacuum, either due to the cool
down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak
determination by this diagnostic.
When the vacuum in the system exceeds about 19
H2O (0.25 KPA), a vacuum switch closes. The
switch closure sends a signal to the PCM. The PCM,
via appropriate logic strategies (described below),
utilizes the switch signal, or lack thereof, to make a
determination of whether a leak is present.
The PCM’s Role in NVLD Diagnosis:
The integral part of the diagnostic system that
makes engine-off leak detection possible is a special
circuit in the PCM controller. After the vehicle is
turned off, a special part of the controller stays alive
and monitors for an NVLD switch closure. This
circuit within the PCM is very specific in its function and consumes very little power. If a switch
closure is detected, it will log the event and time
from key-off, and then power down. This information will be processed at the next key cycle.
The NVLD Device and how it functions
The NVLD Assembly is designed with a normally
open vacuum switch, a normally closed solenoid,
and a seal, which is actuated by both the solenoid
and a diaphragm. The NVLD is located on the
atmospheric vent side of the canister. The NVLD
Assembly is mounted on top of the canister outlet
for the DN.
The normally open vacuum switch will close with
about 19 H2O (0.25 KPA) vacuum in the evaporative
system. The diaphragm actuates the switch. This is
above the opening point of the fuel inlet check valve
in the fill tube so cap off leaks can be detected.
Submerged fill systems must have recirculation
lines that do not have the in-line normally closed
check valve that protects the system from failed
nozzle liquid ingestion, in order to detect cap off
conditions.
The normally closed valve in the NVLD is intended to maintain the seal on the evaporative
system during the engine off condition. If vacuum in
the evaporative system exceeds 39 to 69 H2O (0.75 to
1.5 KPA), the valve will be pulled off the seat,
opening the seal. This will protect the system from
excessive vacuum as well as allowing sufficient
purge flow in the event that the solenoid was to
become inoperative. The solenoid actuates the valve
to unseal the canister vent while the engine is
running. It also will be used to close the vent during
the medium and large leak tests and during the
purge flow check. This solenoid requires initial 1.5
amps of current to pull the valve open but after 100
ms. will be duty cycled down to an average of about
150 mA for the remainder of the drive cycle.
Another feature in the NVLD Assembly is a
diaphragm that will open the seal with pressure in
NVLD Leak Detection
Small Leak Test (Passive)
If, after a specified delay after key off (perhaps 5
minutes), the switch closes or is closed, the test will
be pass, indicating that there is no leak. The PCM
records the switch closure. The NVLD circuit in the
PCM will shut down for the remainder of that
particular engine off (soak) period. When the engine
is started, the switch closure is recorded as a ‘‘Pass,’’
and the timers that are recording accumulated time
are reset.
This diagnostic test can take at least a week to
mature a leak fault. A week has been chosen for this
because the vehicle will have been exposed to the
largest possible drive scenarios before a decision is
made (most vehicles should see both daily work and
weekend driving cycles). This also satisfies CARB’s
stated goal of getting 3 MIL illuminations within a
month for 0.0209 (0.5 mm) leak detection diagnostic.
The diagnostics will log engine run time and
engine off time to determine when a week has
elapsed. There is a limit on the total amount of run
time that is applied to the one-week timer. There is
also a limit on the total soak time that will be
allowed to apply to the one-week timer. There will
be a limit on the amount of accrued run time during
one specific drive that can be applied to the oneweek timer.
The enabling criteria to run this monitor are:
22
GENERAL INFORMATION
•
Fuel level less than 85%
• Ambient temperature greater than 40°F (4.4°C)
Rationality Tests
1. The rationality check of the switch, solenoid and
seal will be performed as follows:
• At key-on, the NVLD solenoid will be energized to
vent any vacuum that may be trapped in the
evaporative system from the previous soak. This
should result in an open switch condition.
•
•
•
Fuel level less than 85%
The intrusive Medium and Large leak are conducted as follows:
•
•
The solenoid will be de-energized (to seal the
system) at the point where purge begins. The
system / NVLD component rationality passes for
that drive cycle if the switch closes after purge
begins.
• The solenoid is then re-energized for the remainder of the drive cycle.
• If the switch events are not seen in a certain
period of time, the rationality check will have
failed (2 trip rule).
2. Purge Flow:
The above rationality check is considered sufficient to confirm purge solenoid function and
conformance with the purge flow test requirement. The Purge Flow Monitor is passed based
on switch activity when purge is turned on or
based on a rich fuel control shift when purge is
turned on.
Medium and Large Leak Test (Intrusive)
•
NOTE: This intrusive test will only be run if
the Small Leak (passive) test fails, or is
inconclusive (the switch does not close)
Enabling Conditions:
•
•
40°F to 90°F
Engine temperature at startup within 10°F of the
ambient temperature
23
De-energize the NVLD solenoid to seal the canister vent.
Activate purge shortly after closed loop. Pull the
tank vacuum past the vacuum switch point (19
H2O vacuum) of the NVLD for a specific time
while tracking the standard purge flow rate.
Turn purge off and determine how long it takes to
decay the tank vacuum and reopen the switch.
Determine the leak size from the time it took to
reopen the switch. Note: Fuel level is an important determining factor.
If the switch does not close, a more aggressive
purge flow will be applied to determine if it is a
very large leak, missing fuel cap, problem with
the NVLD device, purge flow problem, etc...
GENERAL INFORMATION
24
GENERAL INFORMATION
3.2.7
NON-MONITORED CIRCUITS
NOTE: Any of these conditions could result
in a rich or lean condition causing an oxygen
sensor trouble code to be stored in the PCM,
or the vehicle may exhibit one or more of the
driveability symptoms listed in the Table of
Contents.
The PCM does not monitor the following circuits,
systems, and conditions even though they could
have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the
following conditions. However, problems with these
systems may cause a diagnostic code to be displayed
for other systems. For example, a fuel pressure
problem will not register a diagnostic code directly,
but could cause a rich or lean condition. This could
cause an oxygen sensor, fuel system, or misfire
monitor trouble code to be stored in the PCM.
3.3
DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTCs) are codes stored
by the Powertrain Control Module (PCM) that help
us diagnose Powertrain, Transmission problems.
The Electronic Transfer Case Diagnostic trouble
codes (DTCs) are stored in the Transfer Case Control Module. They are viewed using the DRBIIIt
scan tool. Some engine driveability problems can be
misinterpreted as a transmission problem. Ensure
that the engine is running properly and that no
engine DTCs are present that could cause a transmission complaint.
If there is a communication bus problem, trouble
codes will not be accessible until the problem is
fixed. The DRBIIIt will display an appropriate
message. The following is a possible list of causes
for a bus problem:
Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket,
or crankshaft sprocket. The PCM also cannot detect
an incorrectly indexed distributor or Cam sensor.(*)
Fuel Pressure - Fuel pressure is controlled by the
fuel pressure regulator. The PCM cannot detect a
clogged fuel pump inlet filter, clogged in-line filter,
or a pinched fuel supply.(*)
Fuel Injectors - The PCM cannot detect a clogged
fuel injector, a sticking pintle, or that an incorrect
injector is installed.(*)
– open or short to ground/battery in PCI bus
circuit.
– internal failure of any module or component on
the bus
Each diagnostic trouble code is diagnosed by
following a specific testing sequence. The diagnostic
test procedures contain step-by-step instructions
for determining the cause of a transmission diagnostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not necessary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.
If the Engine or Transmission records a DTC that
will adversely affect vehicle emissions, it will request (via the communication bus) that the PCM
illuminate the Malfunction Indicator Lamp (MIL).
Although these DTCs will be stored in the PCM
immediately as a 1 trip failure, it may take up to
five minutes of accumulated trouble confirmation to
set the DTC and illuminate the MIL. Three consecutive successful OBDII/EURO III trips or clearing
the DTCs with a diagnostic tool (DRBIIIt or equivalent) is required to extinguish the MIL. When the
Transmission requests that the PCM illuminate the
MIL, the PCM sets a DTC P0700 ($89) to alert the
technician that there are DTCs in the Transmission. The PCM DTC ($89) must also be erased in the
PCM in order to extinguish the MIL.
Fuel Requirements - Poor quality gasoline can
cause problems such as hard starting, stalling, and
stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See
individual symptoms and their definitions in Section 6.0 (Glossary of Terms).
PCM Grounds - The PCM cannot detect a poor
system ground.
However, a diagnostic trouble code may be stored
in the PCM as a result of this condition.
Throttle Body Air Flow - The PCM cannot detect
a clogged or restricted air cleaner inlet or filter
element.(*)
Exhaust System - The PCM cannot detect a
plugged, restricted, or leaking exhaust system.(*)
Cylinder Compression - The PCM cannot detect
uneven, low, or high engine cylinder compression.(*)
Excessive Oil Consumption - Although the PCM
monitors the exhaust oxygen content through the
oxygen sensor when the system is in a closed loop, it
cannot determine excessive oil consumption.
25
GENERAL INFORMATION
3.3.1
•
HARD CODE
•
Powertrain
A diagnostic trouble code that comes back within
one cycle of the ignition key is a ‘‘hard’’ code. This
means that the problem is present when the PCM
checks that circuit or function. Most procedures in
this manual verify if the trouble code is a hard code
at the beginning of each test. When it is not a hard
code, an ‘‘intermittent’’ test must be performed.
Codes that are for OBDII monitors will not set
with just the ignition key on. Comparing these to
non-emission codes, they will seem like an intermittent. These codes require a set of parameters to be
performed (The DRBIIIt pre-test screens will help
with this for MONITOR codes), this is called a
‘‘TRIP’’. All OBDII DTCs will be set after two or in
some cases one trip failures, and the MIL will be
turned on. These codes require three successful, no
failures, TRIPS to extinguish the MIL, followed by
40 warm-up cycles to erase the code. For further
explanation of TRIPS, Pre-test screens, Warm-up
cycles, and the use of the DRBIIIt, refer to the On
Board Diagnostic training booklet #81-699-97094.
•
Use the DRBIIIt data recorder or co-pilot.
Some Transmission intermittent DTCs are
caused by wiring or connector problems. However
intermittent Speed ratio codes are usually caused
by intermittent hydraulic seal leakage in the clutch
and/or accumulator circuits. Intermittent speed ratio codes can be set by intermittent speed sensor
circuitry or by line noise being induced onto one or
both of the speed sensor signal circuits. Problems
that come and go like this are the most difficult to
diagnose, they must be looked for under the specific
conditions that cause them.
3.3.4
This reset counter counts the number of times the
vehicle has been started since codes were last set or
erased. This counter will count up to 255 start
counts. The number of starts helps determine when
the trouble code actually happened. This is recorded
by the PCM and can be viewed on the DRBIIIt as
STARTS since set. When there are no trouble codes
stored in memory, the DRBIIIt will display ‘‘NO
TROUBLE CODES FOUND’’ and the reset counter
will show ‘‘STARTS since set = XXX.’’ OBDII vehicles will also display a DTC Specific or Global ‘‘Good
Trip’’ counter which will indicate the number of
‘‘Good Trips’’ since the DTC was set. After 3 consecutive ‘‘Good Trips,’’ the MIL is extinguished and the
good trip counter is replaced by a ‘‘Warm Up Cycle’’
counter. 40 Warm-Up Cycles will erase the DTC and
Freeze Frame information.
Any Diagnostic Trouble Code (DTC) that is set
whenever the system or component is monitored is
a HARD code. This means that the problem is there
every time the PCM checks that system or component. Some codes will set immediately at start up
and others will require a road test under specific
conditions. It must be determined if a code is
repeatable (Hard) or intermittent before attempting transmission diagnosis.
ONE TRIP FAILURE
A One Trip Failure, when read from the PCM, is
a hard OBDII/EURO III code that has not matured
to the full 5 minutes. This DTC can take up to five
minutes of problem identification before illuminating the MIL
3.3.3
STARTS SINCE SET COUNTER
Powertain
Transmission
3.3.2
Visually inspect the related harnesses. Look for
chafed, pierced, or partially broken wire.
Refer to any S.T.A.R. Hotline Newsletters or
technical service bulletins that may apply.
TRANSMISSION
The Starts Since Set counter counts the number
of times the vehicle has started since the most
recent DTC was set. The counter will count up to
255 starts. Note that this counter only applies to the
last code set.
When there are no diagnostic trouble codes stored
in memory, the DRBIIIt will display ‘‘NO DTC’s
PRESENT’’ and the reset counter will show
‘‘STARTS SINCE CLEAR’’ = XXX.
The number of starts helps determine if the
diagnostic trouble code is hard or intermittent.
– If the number of starts is less than 3, the code
is usually a hard code.
– If the number of starts is greater than 3, it is
considered an intermittent code. This means
that the engine has been started most of the
time without the code recurring.
INTERMITTENT CODE
A diagnostic trouble code that is not present every
time the PCM checks the circuit is an ‘‘intermittent’’
code. Most intermittent codes are caused by wiring
or connector problems. Intermittent conditions that
come and go like this are the most difficult to
diagnose; they must be looked for under specific
conditions that cause them. The following procedures may assist you in identifying a possible
intermittent problem:
• Visually inspect related wire harness connectors.
Look for broken, bent, pushed out, or corroded
terminals.
26
GENERAL INFORMATION
3.3.5
TROUBLE CODE ERASURE
– Upon installation of a new service PCM
– After replacement or rebuild of internal transmission components or the torque converter
– If one or more of the clutch volumes indexes
(CVI’s) contain skewed readings because of
abnormal conditions.
The Quick Learn procedure is performed with the
DRBIIIt by selecting ‘‘Transmission’’ system then
‘‘Miscellaneous’’ functions, then ‘‘Quick Learn’’. Follow the procedure instructions displayed on the
DRBIIIt.
To perform the Quick Learn procedure, the following conditions must be met.
A Diagnostic trouble code will be cleared from
PCM memory if it has not reset for 40 warm-up
cycles.
A warm-up cycle is defined as ‘‘sufficient vehicle
operation such that the coolant temperature has
risen by at least 22°C (40°F) from engine starting
and reaches a minimum temperature of 71°C
(160°F).
The Malfunction Indicator Lamp (MIL) will turn
off after 3 good trips or when the DTC’s are cleared
from the PCM
3.3.6
QUICK LEARN
NOTE: The oil temperature must be between
16°C (60°F) and 93°C (200°F). Above 32°C
(90°F) for best results.
Cycle the transmission through all gears 2-3
times immediately before performing Quick
Learn.
The Quick Learn function customizes adaptive
parameters of the PCM to the transmission Characteristics of a vehicle. This gives the customer
improved ‘‘as received’’ shift quality compared to the
initial parameters stored in the PCM.
Notes about Quick Learn Features
The nature of the Quick Learn function requires
that certain features must be taken into consideration.
– It is imperative that the vehicle oil level set to
the correct level. Shift the transmission into
OD with the engine running, this step will
purge the air in the clutch circuits to prevent
erroneous clutch volume values, which could
cause poor initial shift quality.
– Shift the transmission to neutral.
> Quick Learn should generally not be used as a
repair procedure unless directed by a repair or
diagnostic procedure. If the transmission system
is exhibiting a problem that you think is caused
by an invalid CVI, you should try to relearn the
value by performing the appropriate driving maneuver . In most cases, if a Quick Learn makes a
vehicle shift better, the vehicle will return with
the same problem.
> Before performing Quick Learn, it is imperative
that the vehicle be shifted into OD with the engine
running and the oil level set to the correct level.
This step will purge air from the clutch circuits to
prevent erroneous clutch volume values which
could cause poor initial shift quality. Cycle the
transmission through all gears 2-3 times immediately before performing Quick Learn. For best
results, Quick Learn should be run with the
transmission sump temperature > 90°F.
> If an unused PCM is installed on a vehicle with a
HOT engine, Quick Learn will cause the PCM to
report a cold calculated oil temperature. This
requires monitoring the calculated oil temperature using the DRBIIIt. If the temperature is
below 16°C (60°F), the transmission must be run
at idle or driven in gear until it goes above 16°C
(60°F). If the temperature is above 93°C (200°F),
the transmission must cool to below 93°C
(200°F).
> First gear is engaged in overdrive after Quick
Learn is completed. Place the vehicle in park
after performing Quick Learn.
The Quick Learn function should be performed:
– The brakes must be applied.
– The engine must be idling.
– The throttle angle (TP sensor) must be less
than 3 degrees.
– The shift lever position must stay in neutral,
after shifting to neutral the engine idle speed
will ramp up to 1600rpm and the DRBIIIt will
prompt the operator to shift to OD. Do not shift
to OD until the engine idle speed stabilizes at
1600rpm.
– The shift lever must stay in OD after the ‘‘Shift
to Overdrive’’ prompt until the DRBIIIt indicates the procedure is complete.
NOTE: The above conditions must be
maintained during the procedure to keep the
procedure from being aborted.
NOTE: After the Quick Learn Procedure is
complete, the vehicle should be drive learned
per the Drive Learn Procedure
3.3.7
CLUTCH VOLUMES
The LR clutch volume is updated when doing a
manual downshift into 1st gear with vehicle speed
above 40 km/h (25 MPH) and throttle angle below
5°. The transmission temperature must be above
43°C (110°F).
27
GENERAL INFORMATION
the Run/Start position for one hour. Ensure all
accessories are turned off. Also monitor the battery state and connect a battery charger if necessary.
After reading Section 3.0 (System Description
and Functional Operation), you should have a better understanding of the theory and operation of the
on-board diagnostics, and how this relates to the
diagnosis of a vehicle that may have a driveabilityrelated symptom or complaint.
The clutch volume should be between 45 and 134.
Note: you must manually move the shift lever
into the low position.
The 2C clutch volume is updated when doing a
3-2 shift with throttle angle between 10° and 54°.
The transmission temperature must be above 43°C
(110°F). The clutch volume should be between 25
and 85
The ALT 2C clutch volume is updated when doing
a 4th-4 prime shift with throttle angle between 10°
and 54°. The transmission temperature must be
above 43°C (110°F). The clutch volume should be
between 25 and 85
The OD clutch volume is updated when doing a
2-3 shift with throttle angle between 10° and 54°.
The transmission temperature must be above 43°C
(110°F). The clutch volume should be between 30
and 100.
The 4C clutch volume is updated when doing a
3-4 shift with throttle angle between 10° and 54°.
The transmission temperature must be above 43°C
(110°F). The clutch volume should be between 30
and 85.
The UD clutch volume is updated when doing a
4-3 shift with throttle angle between 10° and 54°.
The transmission temperature must be above 43°C
(110°F). The clutch volume should be between 30
and 100.
3.3.8
3.4
USING THE DRBIIIT
Refer to the DRBIIIt user’s guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIIt functions.
3.5
DRBIIIT ERROR MESSAGES AND
BLANK SCREEN
Under normal operation, the DRBIIIt will display one of only two error messages:
– User-Requested WARM Boot by pressing
MORE and NO at the same time.
ver: 2.29
date: 1 oct 93
file: key_itf.cc
date: Jan 12 1994
line: 544
err: 0x1User-Requested WARM Boot
NO START INFORMATION
(POWERTRAIN)
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
or
User Requested COLD Boot by pressing
MORE YES at the same time.
IMPORTANT NOTE:
If the Powertrain Control Module has been programmed, a DTC will set in the ABS and Air Bag
modules. In addition, if the vehicle is equipped with
a Sentry Key Immobilizer Module (SKIM), Secret
Key data must be updated to enable starting.
ver: 2.29
date: 1 oct 99
file: key HND1.CC
date: Mar 8 2000
line: 1297
err: 0x1
User-Requested COLD Boot
FOR ABS AND AIR BAG SYSTEMS:
1. Enter correct VIN and Mileage in PCM.
2. Erase codes in ABS and Air Bag modules.
FOR SKIM THEFT ALARM:
1. Connect the DRBIIIt to the data link connector.
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
2. Go to Theft Alarm, SKIM, Misc. and place the
SKIM in secured access mode, by using the
appropriate PIN code for this vehicle.
3. Select Update the Secret Key data, data will be
transferred from the SKIM to the PCM (This is
required to allow the vehicle to start with the
new PCM).
4. If three attempts are made to enter secured
access mode using the incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lock out mode, leave the ignition key in
3.5.1
DRBIIIT DOES NOT POWER UP
If the LED’s do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage (data link
connector cavity 16). Check for proper ground connection at DLC cavity. A minimum of 11 volts is
required to adequately power the DRBIIIt.
28
GENERAL INFORMATION
several examples on how to interpret the information and suggested training material to help understand all the specifics.
EATX DTC EVENT DATA can only be erased by:
1. Disconnecting the battery.
2. Performing a DRBIIIt QUICK LEARN procedure.
3. Reprogramming the EATX/NGC controller.
Erasing Transmission DTCs does not clear the
EATX DTC EVENT DATA
If all connections are proper between the DRBIIIt
and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIIIt
may be the result of a faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate body
diagnostics manual.
3.5.2
DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
3.7
TRANSMISSION SIMULATOR (MILLER
TOOL # 8333) AND ELECTRONIC
TRANSMISSION ADAPTER KIT
(MILLER TOOL #8333-1A)
NOTE: Remove the starter Relay when using
the transmission simulator
*Failure to remove the Starter Relay can
cause a PCM - No Response condition.
*The removal of the Starter Relay will also
prevent the engine from starting in gear.
*The Transmission Simulator will not
accurately diagnose intermittent faults
3.5.3
The transmission simulator, simply put, is an
electronic device that simulates the electronic functions of any EATX or NGC controlled transmission.
The Simulators basic function is to aid the technician in determining if an internal transmission
problem exists or if the problem resides in the
vehicle wiring or control module. It is only useful for
electrical problems. It will not aid in the diagnosis
of a failed mechanical component, but it can tell you
that the control module and wiring are working
properly and that the problem is internal to the
transmission.
The ignition switch should be in the lock position
before attempting to install the simulator. Follow
all instructions included with the simulator. If the
feedback from the simulator is in doubt, you can
verify it’s operation by installing it on a known good
vehicle. A ‘‘known good vehicle’’ would be defined as
a vehicle that does not set any DTC’s and drives and
shifts as expected. One important point to remember is that the Simulator receives it’s power from
the Trans Relay Output circuit. If the transmission
system is in Limp-in (Relay open), the simulator
will not operate. This is not really an indication of a
problem, but an additional symptom. If the simulator does not power up (‘‘P’’ led lit), this is an
indication that the problem is still present with the
simulator hooked up. This indicates that the problem is in the wiring or control module and not the
transmission.
SOME DISPLAY ITEMS READ ‘‘___’’
This is caused by scrolling the DRBIIIt display a
single line up or down. The line which was scrolled
onto the screen might read ‘‘___’’. Use the page
down or page up function to display the information.
3.6
EATX DTC EVENT DATA
EATX DTC EVENT DATA can be used as a
diagnostic aid when experiencing Electronic Transmissions with intermittent problems. When a Diagnostic Trouble Code (DTC) is set, the vehicles EATX
inputs are stored in the controller memory and are
retrievable with the DRBIIIt. This information can
be helpful when a DTC can not be duplicated.
The EATX DTC EVENT DATA is located in the
DRBIIIt, under the Transmission system menu, in
the sub-screen Miscellaneous. It is a good practice
to document the EATX DTC EVENT DATA before
beginning any diagnostic or service procedure.
A thorough understanding of how the transmission works is beneficial in order to interpret the
data correctly. These skills are necessary in order to
avoid an incorrect diagnosis.
A MASTERTECH video and reference book was
produced in January 2002 that explains many of
the features of the EATX DTC EVENT DATA with
29
GENERAL INFORMATION
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
applicable. These procedures can be found in the
service manual procedures. Following these procedures is very important to the safety of individuals
performing diagnostic tests.
Miller Tool # 8333-1A consists of the adapter
cables and overlay necessary to adapt the simulator
to TE/AE/LE/RLE transmissions.
4.0
DISCLAIMERS, SAFETY,
WARNINGS
4.2.2
4.1
DISCLAIMERS
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic
DTC’s or error messages may occur. It is extremely
important that accurate shift lever position data is
available to the PCM. The accuracy of any DTC
found in memory is doubtful unless the Shift Lever
Test, performed on the DRBIIIt Scan Tool, passes
without failure.
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2
4.2.1
VEHICLE PREPARATION FOR
TESTING
SAFETY
4.2.3
TECHNICIAN SAFETY INFORMATION
SEVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
WARNING: HIGH-PRESSURE FUEL LINES
DELIVER DIESEL FUEL UNDER EXTREME
PRESSURE FROM THE INJECTION PUMP TO
THE FUEL INJECTORS. THIS MAY BE AS
HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS . FUEL
UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN CAUSING PERSONAL
INJURY
OR
DEATH.
INSPECT
FOR
HIGH-PRESSURE FUEL LEAKS WITH A
SHEET OF CARDBOARD. WEAR SAFETY
GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING
WHEN
SERVICING
FUEL
SYSTEM.
4.2.4
DRBIIIT SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIT MULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS INJURY.
CAREFULLY READ AND UNDERSTAND THE
CAUTIONS AND
THE
SPECIFICATION
LIMITS.
Follow the vehicle manufacturer’s service specifications at all times.
• Do not use the DRBIIIt if it has been damaged.
• Do not use the test leads if the insulation is
damaged or if metal is exposed.
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
•
•
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
•
30
To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
Choose the proper range and function for the
measurement. Do not try voltage or current measurements that may exceed the rated capacity.
Do not exceed the limits shown in the table below:
Function
Input Limit
Volts
0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)*
0 - 1.12 megohms
Frequency Measured
Frequency Generated
0 - 10 kHz
GENERAL INFORMATION
Function
Input Limit
Temperature
- 50 - 600°C
- 58 - 1100°F
through the insulation: this will damage the wire
and eventually cause the wire to fail because of
corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second DTC could be set, making diagnosis of the
original problem more difficult.
When replacing a blown fuse, it is important to
use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.
* Ohms cannot be measured if voltage is
present.
Ohms can be measured only in a non-powered
circuit.
•
•
•
•
•
•
•
•
Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
Use caution when measuring voltage above 25v
DC or 25v AC.
A 10A fuse or circuit breaker must protect the
circuit being tested.
Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or
current before accepting a zero reading.
4.3.2
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
DTC or symptom condition.
When measuring current, connect the meter in
series with the load.
Disconnect the live test lead before disconnecting
the common test lead.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read the
DRBIIIT screen while in motion. Do not hang
the DRBIIIT from the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIIIT
When using the meter function, keep the DRBIIIt
away from spark plug or coil wires to avoid
measuring error from outside interference.
4.3
4.3.1
Road testing is an essential step in the diagnostic
process that must not be overlooked. Along with the
diagnostic information obtained from the DRBIIIt
Scan Tool and the original customer concern, the
road test helps verify the problem was current and
any repairs performed, fixed the vehicle correctly.
Always operate and observe the vehicle under actual driving conditions.
Just as important as the road test is, there are
preliminary inspections that should be performed
prior to the road test. Always check the fluid level
and condition before taking the vehicle on a road
test. Determine if the incorrect fluid is being used,
improper fluid will result in erratic transmission
operation.
Some of the conditions of incorrect fluid level are
as follows:
• Delayed engagement
• Poor shifting or erratic shifting
• Excessive noise
• Overheating
The next step is to verify that the shifter is
correctly adjusted. If the shifter is incorrectly adjusted, a number of complaints can result.
The PCM monitors the Shift Lever Position (SLP)
Sensor continuously. If the shifter is incorrectly
WARNINGS AND CAUTIONS
ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read the
DRBIIIT screen while in motion. Do not hang
the DRBIIIT from the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIIIT
4.3.1
ROAD TESTING A COMPLAINT
VEHICLE (TRANSMISSION)
VEHICLE DAMAGE WARNINGS
Before disconnecting any control module, make
sure the ignition is ‘‘lock’’ position. Failure to do so
could damage the module.
When testing voltage or continuity at any control
module, use the Miller tool #8815 (not the wire end
or terminal) in the connector. Do not probe a wire
31
GENERAL INFORMATION
Diagnostic Pinout Box #8815
Evaporative Emissions Leak Detector #8404
Terminal Removal tool #3638
Fuel filler adapter #8382
Fuel pressure adapter (C-6631) or #6539
Fuel pressure kit (C-4799-B) or #5069
Fuel pressure kit #8978
Fuel release hose (C-4799-1)
Jumper wires
Line pressure adapter (Miller # 8259)
Ohmmeter
Oscilloscope
Pressure gauge 0-2068 kPa (0-300 PSI)
Transmission simulator #8833
Vacuum gauge
Voltmeter
12 volt test light minimum 25 ohms resistance with
probe #6801
Fuel pressure gauge #6828 - Diesel
Fuel test fitting #9011 - Diesel
Fuel test fitting #9012 - Diesel
Fuel test fitting #9013 - Diesel
Fuel test fitting #9014 - Diesel
Fuel test fitting #9015 - Diesel
Fuel injector harness tester #9008 - Diesel
Air induction test tool #9022
adjusted, the PCM will sense a shift lever position
that is not correct for the gear chosen by the driver.
This may cause a DTC to be set.
The following complaints may also be the result
of an incorrectly adjusted or worn linkage:
• Delayed clutch engagement
• Erratic shifts
• Vehicle will drive in neutral
• Engine will not crank in park or neutral
•
Shifter will be able to be moved without the key
in the ignition
• Not able to remove the ignition key in park
• Parking pawl will not engage properly
The shift linkage should also be adjusted when
replacing the Transmission, repairing the valve
body, or when repairing any component between the
shift lever and the Transmission.
Some questions to ask yourself when performing
the road test are as follows:
• Is the complaint or concern what you think the
problem is, based on the drivers description of the
problem?
• Is the Transmission operating normally, or is
there a real problem?
•
•
•
•
•
When does the problem occur?
Is the problem only in one gear range?
What temperature does the problem occur?
Does the vehicle have to sit over night for the
problem to occur?
CAUTION: A 12 volt test light should not be
used for the following circuits, damage to the
powertrain controller will occur.
Does the transmission go into Limp-in mode?
•
4.3.3
•
•
•
ELECTRONIC PINION FACTOR
WARNINGS (IF APPLICABLE)
•
•
The pinion factor must be set when replacing the
PCM. Note: The pinion factor is a fixed number and
cannot be changed or updated in some vehicle
applications. If the pinion factor is not set or incorrectly set, any speed related functions will not
operate correctly i.e. speedometer, speed control,
rolling door locks, other control modules will be
affected that depend on speed information.
•
•
5-volt Supply
J1850 PCI Bus
CCD Bus
PCI Bus
CKP Sensor Signal
CMP Sensor Signal
Vehicle Speed Sensor Signal
O2 Sensor Signal
6.0
ACRONYMS
A/C
Air Conditioning
ABS
Anti-lock Brake System
ASD Relay
Auto Shutdown Relay
APPS
Accelerator Pedal Position
Sensor
Baro
Barometric Pressure
REQUIRED TOOLS AND
EQUIPMENT
BCM
Body Control Module
BTS
Battery Temperature Sensor
DRBIIIt (diagnostic read-out box) scan tool - must
use the latest release level.
CAA
Clean Air Act
CAB
Controller Antilock Brakes
4.4.4
BULLETINS AND RECALLS
Always perform all Safety Recalls and Technical
Service Bulletins that are applicable to the problem. Under the provisions of the warranty.
5.0
32
GENERAL INFORMATION
CARB
California Air Resources Board
FEMCC
CCD BUS
Chrysler Collision Detection
Bus
Fully Electronically Modulated
Converter Clutch
FTP
Federal Test Procedure
CKP Sensor
Crankshaft Position Sensor
FSS
Fan Speed signal
CKT
Circuit
HC
Hydrocarbons
CMP
Sensor Camshaft Position
Sensor
HO2S
Heated Oxygen Sensor
Generator
Previously called ‘‘alternator’’
CM840
Cummins Engine controller
IAC Motor
Idle Air Control Motor
CO
Carbon Monoxide
IAT Sensor
Intake Air Temperature Sensor
CVI
Clutch Volume Index
IOD
Ignition off draw
DCP
Solenoid
Duty-Cycle Purge Solenoid
IRT
Intelligent Recovery Timer
DLC
Data Link Connector
ISS
Input Speed Sensor
DRBIIIt
Diagnostic Readout Box - 3rd
Generation
I/M
Inspection and Maintenance
Testing
DTC
Diagnostic Trouble Code
JTEC
Jeep/Truck Engine Controller
DVOM
Digital Volt Ohm Meter
LDP
Leak Detection Pump
EATX
Electronic Automatic
Transmission Controller n
LED
Light Emitting Diode
LPS
Line Pressure Sensor
EC
European Community
LR
Low/reverse Clutch
ECT Sensor
Engine Coolant Temperature
Sensor
LSIACV
Linear Solenoid Idle Air Control
Valve
EEPROM
Electrically Erasable Programmable Read Only Memory
MAF
Mass Air flow
MAP Sensor
EGR Valve
Exhaust Gas Recirculation
Valve
Manifold Absolute Pressure
Sensor
MDS2t
EMCC
Electronically Modulated
Converter Clutch
Mopar Diagnostic System 2nd
Generation
MIL
Malfunction Indicator Lamp
EMI
Electro-Magnetic Interference
MS
Multi Select
EOBD
European OBD (based upon
Euro Stage III)
MTV
Manifold Tuning Valve
EPA
Environmental Protection
Agency
NGC
Next Generation Controller
NTC
Negative Temperature
Coefficient
EPP
Engine Position Pulse
ETC
Electronic Throttle Control
NVLD
Natural Vacuum Leak Detection
EU
European Union
O2 Sensor
Oxygen Sensor
EVAP
Evaporative Emission System
O2S
Oxygen Sensor
EVR
Electronic Voltage Regulator
OBD I
On Board Diagnostics 1st
Generation
EWMA
Exponentially Weighted Moving
Average
OBD II
On-Board Diagnostics 2nd
Generation
33
GENERAL INFORMATION
OD
Overdrive Clutch
SCW
Similar Conditions Window
ORVR
On-Board Refueling Vapor
Recovery
SKIM
Sentry Key Immobilizer Module
SRV
Short Runner Valve
OSS
Output Speed Sensor
SSV
Solenoid Switch Valve
PCI BUS
Programmable Communications
Interface BUS (J1850)
SW
Switch
PCM
Powertrain Control Module
TCC
Torque Converter Clutch
PCS
Pressure Control Solenoid
TCCM
Transfer Case Control Module
PCV
Positive Crankcase Ventilation
TDC
Top Dead Center
PDC
Power Distribution Center
TP
Throttle Position Sensor
PEMCC
Partial Electronically Modulated
Converter Clutch
TRD
Torque Reduction
TRS
Transmission Range Sensor
TTS
Transmission Temperature
Sensor
UD
Underdrive Clutch
VSS
Vehicle Speed Signal
WOT
Wide Open Throttle
2C
2nd Clutch
4C
4th Clutch
PEP
Peripheral Expansion Port
P/N
Park/Neutral
PPS
Proportional Purge Solenoid
PS
Power Steering
PSP
Power Steering Pressure
(Switch)
PTC
Positive Temperature Coefficient
PWM
Pulse-Width Modulation
RAM
Random Access Memory
REV
Reverse Clutch
RFI
Radio Frequency Interference
RKE
Remote Keyless Entry
RPM
Revolutions Per Minute
SAE
Society of Automotive Engineers
SBEC
Single Board Engine Controller
6.2
DEFINITIONS
OBDII/EURO III Trip - A vehicle start and drive
cycle such that all once per trip diagnostic monitors
have run.
Key Start - A vehicle start and run cycle of at least
20 seconds.
Warm-up Cycle - A vehicle start and run cycle
such that the engine coolant must rise to at least
71°C (160°F) and must rise by at least 22°C (40°F)
from initial start up. To count as a warm-up cycle,
no DTCs may occur during the cycle.
34
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
35
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
ECM PCI NO RESPONSE
PCI BUS CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRBIIIt, enter Anti-Lock Brakes.
With the DRBIIIt, enter Body then Electro/Mechanical Cluster (MIC).
With the DRBIIIt, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
All
Yes
→ Go To
No
→ Refer to symptom PCI Bus Communication Failure in the Communications category.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
36
COMMUNICATION
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY —
Continued
TEST
ACTION
APPLICABILITY
2
With the DRBIIIt read ECM Diagnostic Trouble Codes. This is to ensure power and
grounds to the ECM are operational.
NOTE: If the DRBIIIt will not read ECM DTC’s, follow the NO RESPONSE
TO ECM (SCI only) symptom path.
NOTE: If the vehicle will not start and the DRBIIIt displays a no response
message, refer to the appropriate symptom in the powertrain diagnostic
procedures.
Turn the ignition off.
Disconnect the ECM harness connectors.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRBIIIt. Attach
the red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the ECM ground. Connect the Red lead to the PCI Bus
circuit in the ECM connector.
Turn the ignition on.
Observe the voltage display on the DRBIIIt Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
Yes
→ Replace and program the Engine Control Module in accordance
with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair the PCI Bus circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
37
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY
POSSIBLE CAUSES
INSPECT WIRING HARNESS AND CONNECTORS
CHECK ECM POWERS AND GROUNDS
SCI CIRCUIT(S) SHORTED TO GROUND
SCI CIRCUIT(S) SHORTED TO VOLTAGE
SCI CIRCUIT(S) OPEN
SCI CIRCUIT(S) SHORTED TOGETHER
ENGINE CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Perform the symptom Checking ECM Power and Ground Circuits in the Driveability
category.
Did the vehicle pass this test?
All
2
3
Yes
→ Go To
No
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance between ground and the SCI Transmit circuit.
Measure the resistance between ground and the SCI Receive circuit.
Is the resistance below 10.0 ohms for both measurements?
Yes
→ Repair the SCI circuit(s) for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
All
3
Turn the ignition off.
Disconnect the DRB from the DLC.
Disconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage of the SCI Transmit circuit at the DLC.
Measure the voltage of the SCI Receive circuit at the DLC.
Is the voltage above 1.0 volt for either measurement?
Yes
→ Repair the SCI circuit(s) for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
38
All
COMMUNICATION
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance of the SCI Transmit circuit between the ECM harness
connector and the DLC.
Measure the resistance of the SCI Receive circuit between the ECM harness
connector and the DLC.
Is the resistance below 10.0 ohms for each measurement?
All
5
6
Yes
→ Go To
No
→ Repair the SCI circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance between the SCI Transmit and SCI Receive circuits at the
DLC.
Is the resistance below 10.0 ohms?
Yes
→ Repair the SCI circuit(s) for a short together.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
All
6
Turn the ignition off.
Using the Service Information inspect the SCI Transmit and SCI Receive circuits
between the DLC and ECM.
Check the wiring and connectors for damage, corrosion or other problems that may
cause circuit interruption.
Are there any problems evident?
Yes
→ Repair as wiring/ connectors necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace and program the Engine Control Module in accordance
with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
39
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM FRONT CONTROL MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH ANOTHER MODULE
OPEN GROUND CIRCUIT(S)
OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT
OPEN PCI BUS CIRCUIT
FRONT CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRB, attempt to communicate with the Airbag Control Module.
With the DRB, attempt to communicate with the Controller Antilock Brake (CAB)
module.
With the DRB, attempt to communicate with the Instrument Cluster.
Was the DRB able to I/D or communicate with any of the modules?
All
2
3
Yes
→ Go To
No
→ Refer to symptom list for problems related to the PCI Bus
Communication Failure.
Perform BODY VERIFICATION TEST - VER 1.
2
Turn the ignition off.
Remove the Front Control Module from the IPM.
Using a 12-volt test light connected to 12-volts, probe each Ground circuit in the IPM
FCM connector.
Is the test light illuminated for each circuit?
Yes
→ Go To
No
→ Repair the Ground circuit(s) for an open between the IPM
connector and the grounding point. If OK, replace the power
distribution center.
Perform BODY VERIFICATION TEST - VER 1.
All
3
NOTE: Check IPM fuse #50 for an open before continuing.
Turn the ignition off.
Remove the Front Control Module from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
Output circuit in the IPM FCM connector.
Is the test light illuminated?
Yes
→ Go To
No
→ Check IPM fuse #50 for an open. If OK, replace the power
distribution center.
Perform BODY VERIFICATION TEST - VER 1.
4
40
All
COMMUNICATION
*NO RESPONSE FROM FRONT CONTROL MODULE —
Continued
TEST
ACTION
APPLICABILITY
4
Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Remove the Front Control Module from the IPM.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set the probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the IPM FCM connector.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
Yes
→ Replace the Front Control Module in accordance with the service
information.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Repair the PCI Bus circuit for an open. If OK, replace the power
distribution center.
Perform BODY VERIFICATION TEST - VER 1.
41
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
PCM PCI NO RESPONSE
PCI BUS CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRBIIIt, enter Anti-Lock Brakes.
With the DRBIIIt, enter Body then Electro/Mechanical Cluster (MIC).
With the DRBIIIt, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
All
Yes
→ Go To
No
→ Refer to symptom PCI Bus Communication Failure in the Communications category.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
42
COMMUNICATION
*NO RESPONSE FROM PCM (PCI BUS) - DIESEL ONLY —
Continued
TEST
ACTION
APPLICABILITY
2
With the DRBIIIt read PCM Diagnostic Trouble Codes. This is to ensure power and
grounds to the PCM are operational.
NOTE: If the DRBIIIt will not read PCM DTC’s, follow the NO RESPONSE
TO PCM (SCI only) symptom path.
NOTE: If the vehicle will not start and the DRBIIIt displays a no response
message, refer to the appropriate symptom in the powertrain diagnostic
procedures.
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRBIIIt. Attach
the red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the PCM ground. Connect the Red lead to the PCI Bus
circuit in the PCM connector.
Turn the ignition on.
Observe the voltage display on the DRBIIIt Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
Yes
→ Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair the PCI Bus circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
43
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (PCI BUS) - JTEC
POSSIBLE CAUSES
PCM PCI NO RESPONSE
PCI BUS CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRBIIIt, enter Anti-Lock Brakes.
With the DRBIIIt, enter Body then Electro/Mechanical Cluster (MIC).
With the DRBIIIt, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
All
2
Yes
→ Go To
No
→ Refer to symptom PCI Bus Communication Failure in the Communications category.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
2
With the DRBIIIt read PCM Diagnostic Trouble Codes. This is to ensure power and
grounds to the PCM are operational.
NOTE: If the DRBIIIt will not read PCM DTC’s, follow the NO RESPONSE
TO PCM (SCI only) symptom path.
NOTE: If the vehicle will not start and the DRBIIIt displays a no response
message, refer to the appropriate symptom in the powertrain diagnostic
procedures.
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRBIIIt. Attach
the red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the PCM ground. Connect the Red lead to the PCI Bus
circuit in the PCM connector.
Turn the ignition on.
Observe the voltage display on the DRBIIIt Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
Yes
→ Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Repair the PCI Bus circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
44
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (PCI BUS) - NGC
POSSIBLE CAUSES
PCM PCI NO RESPONSE
POWERTRAIN CONTROL MODULE
PCI BUS CIRCUIT OPEN
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, enter Body then Electro/Mechanical Cluster (MIC).
With the DRB, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
All
2
Yes
→ Go To
No
→ Refer to symptom PCI Bus Communication Failure in the Communications category.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
2
With the DRB read the Powertrain DTC’s. This is to ensure power and grounds to the
PCM are operational.
NOTE: If the DRB will not read PCM DTC’s, follow the NO RESPONSE TO
PCM (PCM SCI only) symptom path.
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the appropriate terminal of special tool #8815.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
Yes
→ Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Repair the PCI Bus circuit for an open.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
45
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC
POSSIBLE CAUSES
CHECK PCM POWERS AND GROUNDS
PCM SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE
PCM SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE
PCM SCI CIRCUITS SHORTED TOGETHER
PCM SCI TRANSMIT CIRCUIT SHORTED TO GROUND
PCM SCI RECEIVE CIRCUIT SHORTED TO GROUND
PCM SCI RECEIVE CIRCUIT OPEN
PCM SCI TRANSMIT CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Perform the symptom Checking PCM Power and Ground Circuits in the Driveability
category.
NOTE: With the DRBIIIt in the generic scan tool mode, attempt to communicate with the PCM.
NOTE: If the DRBIIIt can communicate with the PCM in the generic scan
tool mode, it may not be necessary to perform this step.
Did the vehicle pass this test?
All
2
3
Yes
→ Go To
No
→ Repair as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
2
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Turn the ignition on.
Measure the voltage of the PCM SCI Transmit circuit at the Data Link harness
connector (cav 7).
Is the voltage above 1.0 volt?
Yes
→ Repair the PCM SCI Transmit circuit for a short to voltage.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Turn the ignition on.
Measure the voltage of the PCM SCI Receive circuit at the Data Link harness
connector (cav 12).
Is the voltage above 1.0 volt?
Yes
→ Repair the PCM SCI Receive circuit for a short to voltage.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
4
46
All
COMMUNICATION
*NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Measure the resistance between the PCM SCI Transmit circuit and the PCM SCI
Receive circuit at the Data Link harness connector (cavs 7 and 12).
Is the resistance below 5.0 ohms?
All
5
6
7
Yes
→ Repair the short between the PCM SCI Transmit and the PCM
SCI Receive circuits.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the DRBIIIt from the DLC.
Measure the resistance between ground and the PCM SCI Transmit circuit at the
Data Link harness connector (cav 7).
Is the resistance below 5.0 ohms?
Yes
→ Repair the PCM SCI Transmit circuit for a short to ground.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
6
Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the DRBIIIt from the DLC.
Measure the resistance between ground and the PCM SCI Receive circuit in the Data
Link harness connector (cav 12).
Is the resistance below 5.0 ohms?
Yes
→ Repair the PCM SCI Receive circuit for a short to ground.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
7
Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the DRBIIIt from the DLC.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the PCM SCI Receive circuit from the Data Link harness
connector (cav 12) to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the PCM SCI Receive circuit for an open.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
8
47
All
COMMUNICATION
*NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC —
Continued
TEST
ACTION
APPLICABILITY
8
Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the DRBIIIt from the DLC.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the PCM SCI Transmit circuit from the Data Link harness
connector (cav 7) to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
9
Yes
→ Go To
No
→ Repair the PCM SCI Transmit circuit for an open.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
9
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 1.
48
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (SCI ONLY) - DIESEL ONLY
POSSIBLE CAUSES
INSPECT WIRING HARNESS AND CONNECTORS
CHECK PCM POWERS AND GROUNDS
SCI CIRCUIT(S) SHORTED TO GROUND
SCI CIRCUIT(S) SHORTED TO VOLTAGE
SCI CIRCUIT(S) OPEN
SCI CIRCUIT(S) SHORTED TOGETHER
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Perform the symptom Checking PCM Power and Ground Circuits in the Driveability
category.
Did the vehicle pass this test?
All
2
3
Yes
→ Go To
No
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance between ground and the SCI Transmit circuit.
Measure the resistance between ground and the SCI Receive circuit.
Is the resistance below 10.0 ohms for both measurements?
Yes
→ Repair the SCI circuit(s) for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
All
3
Turn the ignition off.
Disconnect the DRB from the DLC.
Disconnect the PCM harness connectors.
Turn the ignition on.
Measure the voltage of the SCI Transmit circuit at the DLC.
Measure the voltage of the SCI Receive circuit at the DLC.
Is the voltage above 1.0 volt for either measurement?
Yes
→ Repair the SCI circuit(s) for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
49
All
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) - DIESEL ONLY —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance of the SCI Transmit circuit between the PCM harness
connector and the DLC.
Measure the resistance of the SCI Receive circuit between the PCM harness
connector and the DLC.
Is the resistance below 10.0 ohms for each measurement?
All
5
6
Yes
→ Go To
No
→ Repair the SCI circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the DRB from the DLC.
Measure the resistance between the SCI Transmit and SCI Receive circuits at the
DLC.
Is the resistance below 10.0 ohms?
Yes
→ Repair the SCI circuit(s) for a short together.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
All
6
Turn the ignition off.
Using the Service Information inspect the SCI Transmit and SCI Receive circuits
between the DLC and PCM.
Check the wiring and connectors for damage, corrosion or other problems that may
cause circuit interruption.
Are there any problems evident?
Yes
→ Repair as wiring/ connectors necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
50
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (SCI ONLY) - JTEC
POSSIBLE CAUSES
CHECK PCM POWERS AND GROUNDS
SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE
TRANSMISSION CONTROL MODULE
SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE
SCI CIRCUITS SHORTED TOGETHER
SCI TRANSMIT CIRCUIT SHORTED TO GROUND
SCI RECEIVE CIRCUIT SHORTED TO GROUND
SCI RECEIVE CIRCUIT OPEN
SCI TRANSMIT CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Perform the symptom Checking PCM Power and Ground Circuits in the Driveability
category.
NOTE: With the DRBIIIt in the generic scan tool mode, attempt to communicate with the PCM.
NOTE: If the DRBIIIt can communicate with the PCM in the generic scan
tool mode, it may not be necessary to perform this step.
Did the vehicle pass this test?
All
2
3
Yes
→ Go To
No
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
2
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Disconnect the DRBIIIt from the DLC.
Measure the resistance between ground and the SCI Transmit circuit.
Is the resistance below 5.0 ohms?
Yes
→ Go To
3
No
→ Go To
4
Turn the ignition off.
Disconnect the TCM harness connector (if equipped).
NOTE: If vehicle is not equipped with a TCM, answer yes to the question.
Measure the resistance between ground and the SCI Transmit circuit.
Is the resistance below 5.0 ohms?
Yes
→ Repair the SCI Transmit circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Replace the Transmission Control Module in accordance with the
service information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
51
All
All
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) - JTEC —
TEST
4
5
6
7
8
Continued
ACTION
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Disconnect the TCM harness connector (if equipped).
Turn the ignition on.
Measure the voltage of the SCI Transmit circuit at the DLC.
Is the voltage above 1.0 volt?
Yes
→ Repair the SCI Transmit circuit for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
APPLICABILITY
All
5
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Turn the ignition on.
Measure the voltage of the SCI Receive circuit at the DLC.
Is the voltage above 1.0 volt?
Yes
→ Repair the SCI Receive circuit for a short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
6
Turn the ignition off.
Disconnect the DRBIIIt from the DLC.
Disconnect the PCM harness connectors.
Measure the resistance between the SCI Transmit circuit and the SCI Receive circuit
at the PCM connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the SCI Transmit and the SCI Receive
circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
7
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Disconnect the DRBIIIt from the DLC.
Measure the resistance between ground and the SCI Receive circuit.
Is the resistance below 5.0 ohms?
Yes
→ Repair the SCI Receive circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Disconnect the DRBIIIt from the DLC.
Measure the resistance of the SCI Receive circuit between the PCM C3 connector and
the DLC.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the SCI Receive circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
9
52
All
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) - JTEC —
Continued
TEST
ACTION
APPLICABILITY
9
Turn the ignition off.
Disconnect the PCM C3 harness connector.
Disconnect the DRBIIIt from the DLC.
Measure the resistance of the SCI Transmit circuit between the PCM C3 connector
and the DLC.
Is the resistance below 5.0 ohms?
All
10
Yes
→ Go To
No
→ Repair the SCI Transmit circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
10
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
53
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE MIC
GROUND CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
OPEN PCI BUS CIRCUIT
SENTRY KEY IMMOBILIZER MODULE
TEST
1
2
3
4
ACTION
Turn the ignition on.
With the DRB, attempt to communicate with the Instrument Cluster.
Was the DRB able to I/D or communicate with the MIC?
Yes
→ Go To
No
→ Refer to the symptom list for problems related to no communication with the MIC.
Perform SKIS VERIFICATION.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the SKIM harness connector.
Using a 12-volt test light connected to 12-volts, probe the ground circuit.
Is the test light illuminated?
Yes
→ Go To
No
→ Repair the ground circuit for an open.
Perform SKIS VERIFICATION.
All
3
Turn the ignition off.
Disconnect the SKIM harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
Output circuit.
Is the test light illuminated?
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output circuit for an open.
Perform SKIS VERIFICATION.
All
4
Turn the ignition off.
Disconnect the SKIM harness connector.
Using a 12-volt test light connected to ground, probe the Fused B(+) circuit.
Is the test light illuminated?
Yes
→ Go To
No
→ Repair the Fused B+ circuit for an open.
Perform SKIS VERIFICATION.
5
54
All
COMMUNICATION
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE —
Continued
TEST
ACTION
APPLICABILITY
5
Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Disconnect the SKIM harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the SKIM connector.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
6
Yes
→ Go To
No
→ Repair the PCI Bus circuit for an open.
Perform SKIS VERIFICATION.
6
If there are no possible causes remaining, view repair.
Repair
Replace and program the Sentry Key Immobilizer Module in
accordance with the Service Information.
Perform SKIS VERIFICATION.
55
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM TRANSFER CASE CONTROL MODULE
POSSIBLE CAUSES
NO RESPONSE FROM TRANSFER CASE CONTROL MODULE
FUSED B(+) CIRCUIT OPEN
GROUND CIRCUIT OPEN
OPEN PCI BUS CIRCUIT
TRANSFER CASE CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRBIIIt,
answer the question.
With the DRBIIIt, attempt to communicate with the Airbag Control Module.
With the DRBIIIt, attempt to communicate with the Front Control Module.
Was the DRBIIIt able to I/D or establish communications with either of the modules?
All
2
3
Yes
→ Go To
No
→ Refer to the Communications category and perform the symptom
PCI Bus Communication Failure.
Perform TRANSFER CASE VERIFICATION TEST.
2
Turn the ignition off to the lock position.
Disconnect the TCCM harness connectors.
Using a 12-volt test light connected to ground, check the Fused B(+) circuit in the
TCCM harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the Fused B(+) circuit for an open. If the fuse is open make
sure to check for a short to ground. Refer to the wiring diagrams
located in the Service Information.
Perform TRANSFER CASE VERIFICATION TEST.
All
3
Turn the ignition off to the lock position.
Disconnect the TCCM harness connectors.
Using a 12-volt test light connected to 12-volts, check each ground circuit in the
TCCM harness connectors.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly for each Ground circuit?
Yes
→ Go To
No
→ Repair the Ground circuit for an open. Refer to the wiring
diagrams located in the Service Information.
Perform TRANSFER CASE VERIFICATION TEST.
4
56
All
COMMUNICATION
*NO RESPONSE FROM TRANSFER CASE CONTROL MODULE —
Continued
TEST
ACTION
APPLICABILITY
4
Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Turn the ignition off to the lock position.
Disconnect the TCCM harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the TCCM connector.
Turn the ignition on.
Observe the voltage display on the DRBIIIt Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
5
Yes
→ Go To
No
→ Repair the PCI Bus circuit for an open.
Perform TRANSFER CASE VERIFICATION TEST.
5
If there are no possible causes remaining, view repair.
Repair
Replace the Transfer Case Control Module in accordance with the
service information.
Perform TRANSFER CASE VERIFICATION TEST.
57
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 3.7/
5.7
POSSIBLE CAUSES
NO RESPONSE FROM TRANSMISSION CONTROL MODULE
FUSED IGNITION SWITCH OUTPUT (RUN/ST) CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT (START) CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT (START) CIRCUIT SHORT
FUSED B(+) CIRCUIT OPEN
GROUND CIRCUIT(S) OPEN
OPEN PCI BUS CIRCUIT
TRANSMISSION CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
Note: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, attempt to communicate with the Airbag Control Module.
With the DRB, attempt to communicate with the Instrument Cluster.
Was the DRB able to I/D or establish communications with either of the modules?
All
2
Yes
→ Go To
No
→ Refer to the Body Communication category and perform the
symptom PCI Bus Communication Failure.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
2
Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output (Run/St) circuit.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output (Run/St) circuit for an
open. Refer to the wiring diagrams location in the Service Information.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
3
58
All
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 3.7/5.7 —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Remove the starter relay from the IPM.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output (Start) circuit.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Observe the test light while momentarily turning the ignition switch to the Start
position.
Does the test light illuminate brightly?
All
4
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output (Start) circuit for an
open. Refer to the wiring diagrams located in the Service Information.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
4
Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
With a voltmeter in the millivolt scale, measure the voltage of the Fused Ignition
Switch Output (Start) circuit.
NOTE: A no response condition can exist if voltage is present on this circuit
with the ignition switch in any position except for the Start position.
NOTE: Voltage up to .080 millivolts can cause this condition.
NOTE: Check for after market components that could cause this condition.
Perform this step with the Ignition Switch in every position except for the Start
position.
Is any voltage present?
Yes
→ Repair the Fused Ignition Switch Output (Start) circuit for a
short to voltage. Refer to the wiring diagrams located in the
Service Information.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
No
→ Go To
All
5
Note: Reinstall the original Starter Relay.
5
Turn the ignition off.
Disconnect the TCM harness connector.
Using a 12-volt test light connected to ground, check the Fused B(+) circuit.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the Fused B(+) circuit for an open. Refer to the wiring
diagrams located in the Service Information.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
6
59
All
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 3.7/5.7 —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Using a 12-volt test light connected to 12-volts, check each ground circuit in the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly at all the ground circuits?
All
7
8
Yes
→ Go To
No
→ Repair the Ground circuit(s) for an open. Check the main ground
connection to engine block and/or chassis. Refer to the wiring
diagrams located in the Service Information.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
7
Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Disconnect the TCM harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the TCM connector.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
Yes
→ Go To
No
→ Repair the PCI Bus circuit for an open.
Perform 45RFE/545RFE TRANSMISSION
TEST - VER 1.
All
8
VERIFICATION
Using the schematics as a guide, inspect the wiring and connectors. Repair as
necessary. Pay particular attention to all power and ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace the Transmission Control Module in accordance with the
service information. WITH THE DRBIIIt PERFORM QUICK
LEARN.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION
TEST - VER 1.
60
All
COMMUNICATION
Symptom:
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 4.7
POSSIBLE CAUSES
NO RESPONSE FROM TRANSMISSION CONTROL MODULE
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
GROUND CIRCUIT(S) OPEN
PCI BUS CIRCUIT OPEN
POWERTRAIN CONTROL MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
Note: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, attempt to communicate with the Instrument Cluster.
With the DRB, attempt to communicate with the Airbag Control Module.
Was the DRB able to I/D or establish communications with both of the modules?
All
2
Yes
→ Go To
No
→ Refer to the Communications category and perform the appropriate symptom.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe both Fused Ignition Switch
Output circuits (cavs 11 and 12) in the appropriate terminal of special tool #8815.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Is the test light illuminated for both circuits?
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output circuit for an open.
Refer to the wiring diagrams located in the Service Information.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
3
61
All
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 4.7 —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Using a 12-volt test light connected to ground, probe the Fused B(+) circuit in the
appropriate terminal of special tool #8815.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Is the test light illuminated?
All
4
Yes
→ Go To
No
→ Repair the Fused B(+) circuit for an open. Refer to the wiring
diagrams located in the Service Information.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
4
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Using a 12-volt test light connected to 12-volts, probe each ground circuit in the
appropriate terminal of special tool #8815.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Is the light illuminated at all ground circuits?
Yes
→ Go To
No
→ Repair the Ground circuit(s) for an open. Check the main ground
connection to engine block and/or chassis. Refer to the wiring
diagrams located in the Service Information.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
5
62
All
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE - 4.7 —
Continued
TEST
ACTION
APPLICABILITY
5
Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the appropriate terminal of special tool #8815.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
6
Yes
→ Go To
No
→ Repair the PCI Bus circuit for an open.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
6
Using the schematics as a guide, inspect the wiring and connectors. Repair as
necessary. Pay particular attention to all power and ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module in accordance with the service information. WITH THE DRBIIIt PERFORM QUICK LEARN.
Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1.
63
All
COMMUNICATION
Symptom:
*PCI BUS COMMUNICATION FAILURE
POSSIBLE CAUSES
WIRING HARNESS INTERMITTENT
OPEN PCI BUS CIRCUIT AT THE DATA LINK CONNECTOR (DLC)
PCI BUS CIRCUIT SHORTED TO VOLTAGE
MODULE SHORT TO VOLTAGE
PCI BUS CIRCUIT SHORTED TO GROUND
MODULE SHORT TO GROUND
TEST
ACTION
APPLICABILITY
1
Note: Determine which modules this vehicle is equipped with before beginning.
Note: When attempting to communicate with any of the modules on this
vehicle, the DRB will display 1 of 2 different communication errors: a NO
RESPONSE message or a BUS +/- SIGNALS OPEN message.
Turn the ignition on.
Using the DRB, attempt to communicate with the following control modules:
Airbag Control Module
Front Control Module
Instrument Cluster
Was the DRBIIIt able to communicate with one or more Module(s)?
All
2
Yes
→ Go To
2
No
→ Go To
3
Turn the ignition off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
Note: Visually inspect the related wire harness connectors. Look for broken,
bent, pushed out, or corroded terminals.
Note: If the DRB can not communicate with a single module, refer to the
category list for the related symptom.
Were any problems found?
Yes
→ Repair wiring harness/connectors as necessary.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Test Complete.
64
All
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM/ECM harness connector. Note: If equipped with NGC follow the
caution below.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Disconnect the DRB from the Data Link Connector (DLC).
Disconnect the negative battery cable.
Measure the resistance of the PCI Bus circuit between the Data Link Connector
(DLC) and the PCM/ECM harness connector.
Is the resistance below 5.0 ohms?
All
4
5
Yes
→ Go To
No
→ Repair the PCI Bus circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
4
NOTE: Reconnect the PCM/ECM harness connector and the negative battery cable.
Turn the ignition on.
Measure the voltage of the PCI Bus circuit at the Data Link Connector (DLC).
Is the voltage above 7.0 volts?
Yes
→ Go To
5
No
→ Go To
6
Turn the ignition off.
Using a voltmeter, connect one end to the PCI Bus circuit at the DLC, and the other
end to ground.
Note: When performing the next step turn the ignition off (wait one minute)
before disconnecting any module. When the module is disconnected turn
the ignition on to check for a short to voltage.
Turn the ignition on.
While monitoring the voltmeter, disconnect each module the vehicle is equipped with
one at a time.
Is the voltage steadily above 7.0 volts with all the modules disconnected?
Yes
→ Repair the PCI Bus circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Replace the module that when disconnected the short to voltage
was eliminated.
Perform BODY VERIFICATION TEST - VER 1.
65
All
All
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off.
Disconnect the negative battery cable.
Using a ohmmeter, connect one end to the PCI Bus circuit at the DLC, and the other
end to ground.
While monitoring the ohmmeter, disconnect each module the vehicle is equipped with
one at a time.
NOTE: Total bus resistance to ground thru all of the modules is typically
between 350 to 1000 ohms. The more modules on the bus, the lower the total
bus resistance will be.
Is the resistance below 150.0 ohms with all the modules disconnected?
All
Yes
→ Repair the PCI Bus circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Replace the module that when disconnected the short to ground
was eliminated.
Perform BODY VERIFICATION TEST - VER 1.
66
DRIVEABILITY - DIESEL
Symptom:
INTERMITTENT CONDITION
POSSIBLE CAUSES
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Refer to any Technical Service Bulletins (TSBs) that may apply.
Review the DRBIIIt Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the DRBIIIt
parameters related to the DTC while wiggling the wire harness. Look for parameter
values to change and/or a DTC to set.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched,
partially broken wires and broken, bent, pushed out, or corroded terminals.
Inspect and clean all ECM, engine, and chassis grounds that related to the DTC set.
If numerous trouble codes were set, use a wire schematic to help you find any
common ground or supply circuits
For any Relay DTCs, actuate the Relay with the DRBIIIt and wiggle the related wire
harness to try to interrupt the actuation.
A data recording, and/or lab scope should be used to help diagnose intermittent
conditions.
Use the DRBIIIt to perform a System Test if one applies to failing component.
Were any problems found during the above inspections?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5 (DIESEL).
No
→ Test Complete.
67
DRIVEABILITY - DIESEL
Symptom:
P0016-ENGINE SPEED SIGNAL MISMATCH
When Monitored and Set Condition:
P0016-ENGINE SPEED SIGNAL MISMATCH
When Monitored:
While Engine is running.
Set Condition: When the engine speed detected by the Engine Position Sensor (cam) and
the Engine Speed Sensor (crank) differ by a specified RPM amount.
POSSIBLE CAUSES
DAMAGE TO THE ESS OR EPS
MECHANICAL MISALIGNMENT OF THE ESS OR EPS
MECHANICAL MISALIGNMENT OF THE CAMSHAFT AND CRANKSHAFT GEARS
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Visually inspect the condition of the tone wheel, ESS, and EPS for damage.
Are any of the components damaged?
Yes
→ Repair or replace any damaged component.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Verify the speed indicator ring is properly positioned relative to the locating pin in
the front face of the crankshaft.
Is the speed indicator ring properly installed?
Yes
→ Go To
No
→ Repair the speed ring indicator ring installation.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Check the mechanical alignment of the camshaft gear to the crankshaft gear. Refer
to service manual for assistance.
Are the gear teeth in proper alignment?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair the gear alignment.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
68
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0071-INLET AIR TEMP SENSOR RATIONALITY
When Monitored and Set Condition:
P0071-INLET AIR TEMP SENSOR RATIONALITY
When Monitored:
Set Condition:
While the engine is running.
The ECM does not read a change in value from the sensor over time.
POSSIBLE CAUSES
INLET AIR TEMPERATURE SENSOR
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
Remove the temperature sensor and reconnect the wiring to the sensor.
With the DRBIIIt in Sensors, Monitor the inlet Air Temperature.
While heating the sensor with an external heat source (DO NOT USE OPEN
FLAME).
Does the reading from the sensor increase at least 5 degrees F. on the DRBIIIt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the inlet air temperature sensor
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
69
DRIVEABILITY - DIESEL
Symptom:
P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
SENSOR OUT OF SPEC
INTERMITTENT CONDITION
HARNESS SHORTED
5-VOLT SUPPLY OPEN
HARNESS SHORTED (ECM SIDE)
INTERMITTENT CONDITION
ECM
ECM
TEST
1
2
ACTION
Turn the ignition off.
Disconnect the Inlet Air Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the temperature sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Reconnect the Inlet Air Temp Sensor harness connector.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
Did the DTC return?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
70
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the inlet Air Temp sensor harness connector.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the engine ground and the temperature sensor
signal wire at the sensor connector.
Is the resistance more than 100 k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Replace or Repair the shorted harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance between the signal circuit and all other circuits at the ECM
harness connector.
Is the resistance more than 100 k ohms?
Yes
→ Go To
No
→ Repair or replace the ECM harness shorted.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connector.
Turn the ignition on.
Measure the voltage between the supply circuit and the return circuit in the Air Temp
sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
6
No
→ Go To
7
Reconnect the Air Temp sensor harness connector.
Reconnect the ECM harness connector.
With the DRBIIIt, erase DTCs.
While monitoring with DRBIIIt, disconnect the Air Temp sensor harness connector.
Did the DTC P0073 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Disconnect the ECM harness connector.
Measure the voltage at the 5-volt supply circuit at he ECM harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Fix or repair the 5-volt supply wire.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
71
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
DTC RETURNS
INLET AIR TEMPERATURE SENSOR
SIGNAL WIRE OPEN
RETURN WIRE OPEN
SIGNAL WIRE SHORTED
INTERMITTENT CONDITION
ECM
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
With the DRBIIIt, record all Freeze frame data.
Did the DTC return?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Turn the ignition off.
Disconnect the Inlet Air Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Inlet Air temp sensor
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the Inlet air temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
72
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Reconnect the Inlet Air Temp sensor harness connector.
Measure the resistance between the temperature sensor signal and return pins at the
ECM connector.
Is the resistance between 300 and 90k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
6
No
→ Go To
4
Disconnect the inlet Air Temp sensor harness connector.
Measure the resistance of the sensor signal Circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance of the sensor return circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Check for a short circuit from the signal circuit to all other circuits at the ECM
harness connector.
Is the resistance more than 100 k ohms?
Yes
→ Go To
No
→ Repair or replace the harness for a short to ground in the signal
wire.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connector.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
While monitoring with DRBIIIt, use a jumper wire and connect the sensor signal
wire to the sensor return wire at the sensor connector.
Did the DTC P0072 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
73
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0088-FUEL RAIL PRESSURE SIGNAL IS ABOVE MAX LIMIT
When Monitored and Set Condition:
P0088-FUEL RAIL PRESSURE SIGNAL IS ABOVE MAX LIMIT
When Monitored:
Set Condition:
Engine running.
Fuel pressure is above a calibrated value for a calibrated amount of time.
POSSIBLE CAUSES
FUEL CONTROL ACTUATOR (FCA)
FUEL PRESSURE SENSOR
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
NOTE: This DTC will only clear by turning the ignition off. It is necessary to
operate the engine for at least five seconds to verify the DTC will clear.
Check for a mechanically stuck Fuel Control Actuator by turning the key switch on
and off and listening for a click at the FCA.
Do you hear a click from the actuator when the key is cycled off?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Go To
No
→ Check the electrical connector of the Fuel Control Actuator, if the
connection is tight, replace the fuel control actuator.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
2
Using the DRBIIIt, monitor the fuel pressure while operating the engine at several
different RPM settings.
Did the fuel pressure reading on the DRBIIIt change?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Replace the Fuel Pressure Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
74
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0106-INLET AIR PRESSURE SENSOR RATIONALITY
When Monitored and Set Condition:
P0106-INLET AIR PRESSURE SENSOR RATIONALITY
When Monitored:
Set Condition:
When the ignition is on.
The Inlet air pressure is above a calibrated threshold.
POSSIBLE CAUSES
INLET AIR PRESSURE SENSOR
INTERMITTENT CONDITION
TROUBLESHOOT OTHER DTC’S FIRST
TEST
1
2
ACTION
Using the DRBIIIt, check for additional DTC’s.
Do you have any other air pressure related DTC’s?
Yes
→ Troubleshoot other DTC’s First.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Using the DRBIIIt, monitor the Inlet air pressure sensor values.
Do the readings on the DRBIIIt fluctuate slightly?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the Inlet Air Temperature/ Pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
75
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
OTHER DTC’S PRESENT
INLET AIR PRESSURE SENSOR
INLET AIR SENSOR SIGNAL CIRCUIT SHORTED TO THE RETURN CIRCUIT
INLET AIR PRESSURE SENSOR SUPPLY CIRCUIT SHORTED TO THE RETURN CIRCUIT
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO GROUND
ECM
SUPPLY CIRCUIT SHORTED TO GROUND
INTERMITTENT CONDITION
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs.
Do you have multiple DTC’s?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Disconnect the Inlet Air Pressure sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the voltage between the supply circuit and return circuits of the sensor
harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
No
→ Test Complete.
3
76
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
While monitoring DRBIIIt, use a jumper wire to connect the 5 volt supply circuit
with the signal circuit at the sensor harness connector.
Does the DRBIIIt show a pressure sensor out of range high DTC?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Replace the Inlet Air Temperature/Pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
Turn the ignition off.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal circuit and return circuit in the Inlet Air
pressure sensor harness connector.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Repair or replace wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the supply circuit and return circuit in the Inlet Air
Pressure sensor harness connector.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Repair the short or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the signal circuit in the Inlet Air Pressure sensor
harness connector and the signal circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the open wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the supply circuit in the Inlet Air Pressure sensor
harness connector with the supply circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the Engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the signal circuit in the inlet Air Pressure sensor
connector and battery negative.
Is the resistance greater than 100 K Ohms?
Yes
→ Go To
No
→ Repair the signal circuit shorted to ground or replace the wire
harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
9
77
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the supply Circuit in the Inlet Air Pressure sensor
connector and battery negative.
Is the resistance greater than 100 K Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
Yes
→ Go To
No
→ Repair the supply circuit shorted to ground or replace the wire
harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
10
Install the ECM harness connector.
Turn the ignition on.
While monitoring DRBIIIt, use a jumper wire to connect the 5 volt supply circuit pin
with the signal circuit pin at the sensor harness connector.
Does the DRBIIIt show a pressure sensor out of range high DTC?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
78
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0108-INLET AIR PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0108-INLET AIR PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
OTHER DTC’S PRESENT
INLET AIR PRESSURE SENSOR
INLET AIR PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
AMBIENT AIR SENSOR SUPPLY CIRCUIT SHORTED TO VOLTAGE
SIGNAL CIRCUIT SHORTED TO 5-VOLT SUPPLY
RETURN CIRCUIT OPEN
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs.
Do you have multiple DTC’s?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Disconnect the Inlet Air Pressure sensor harness connector.
Measure the voltage between the supply circuit and return circuit of the Inlet Air
Pressure sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
While monitoring DRBIIIt, use a jumper wire to connect the return circuit to the
signal circuit at the Inlet Air Pressure sensor harness connector.
Does the DRBIIIt show a P0107 Inlet Air Pressure Sensor Low DTC.
Yes
→ Replace the Inlet Air Temperature/Pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
79
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0108-INLET AIR PRESSURE SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
4
Disconnect the ECM connectors.
Measure the voltage between the signal circuit of the Inlet Air Pressure sensor
connector and battery negative.
Is the voltage less than 1 volt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
7
8
Yes
→ Go To
No
→ Repair or replace short to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Measure the voltage between the supply circuit of the sensor connector and battery
negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair the short to voltage or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Turn the ignition off.
Measure the resistance between the signal circuit and the supply circuit of the Inlet
Air Pressure sensor harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the shorted wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the return circuit in the Inlet Air Pressure sensor
harness connector with the return circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the Engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Install the ECM harness connector.
Turn the ignition on.
While monitoring DRBIIIt, use a jumper wire to connect the return circuit with the
signal circuit at the Inlet Air Pressure sensor harness connector.
Does the DRBIIIt show DTC P0107?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
80
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0111-INTAKE AIR TEMPERATURE (IAT) SENSOR RATIONALITY
When Monitored and Set Condition:
P0111-INTAKE AIR TEMPERATURE (IAT) SENSOR RATIONALITY
When Monitored:
Set Condition:
While the engine is running.
The ECM does not read a change in value from the sensor over time.
POSSIBLE CAUSES
FAILED IAT SENSOR
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
Remove the temperature sensor and reconnect the wiring to the sensor. Monitor
DRBIIIt, while heating the sensor with an external heat source (DO NOT USE
OPEN FLAME).
Does the reading from the sensor increase at least 5 degrees F. on the DRB?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the Intake air temp sensor/MAP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
81
DRIVEABILITY - DIESEL
Symptom:
P0112-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO
LOW
When Monitored and Set Condition:
P0112-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
INTAKE AIR TEMP SENSOR OUT OF SPEC
INTERMITTENT CONDITION
SENSOR SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT
WIRING HARNESS SHORTED
SUPPLY CIRCUIT OPEN
ECM
ECM
TEST
1
2
ACTION
Disconnect the Intake Air Temperature sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Intake Air Temp sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the Intake Air temperature sensor/MAP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Reconnect the circuit.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
Did the DTC reappear?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
82
DRIVEABILITY - DIESEL
P0112-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO LOW
— Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the engine ground and the temperature sensor
signal wire at the sensor harness connector.
Is the resistance more than 100 k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Repair or replace the engine wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance between the signal circuit and all other circuits at the ECM
harness connector.
Is the resistance more than 100 k ohms?
Yes
→ Go To
No
→ Repair or replace the shorted wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connector connected.
Turn the ignition on.
Measure the voltage between the supply circuit and the return circuit the sensor
harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
7
No
→ Go To
6
Turn the ignition off.
Disconnect the ECM harness connector.
Measure the voltage at the supply circuit of the sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connector.
Reconnect the intake air temp sensor harness connector.
Turn the ignition on.
While monitoring with DRBIIIt, disconnect the temperature sensor
Did the DTC P0113 set?
Yes
→ Clear DTC’s, repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
83
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0113-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO
HIGH
When Monitored and Set Condition:
P0113-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO HIGH
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
FAILED SENSOR
INTERMITTENT CONDITION
OPEN SENSOR SIGNAL CIRCUIT
OPEN RETURN CIRCUIT
SHORT IN HARNESS
ECM
ECM
TEST
1
2
ACTION
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Turn the ignition off.
Disconnect the IAT sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the IAT sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the Intake Air Temperature Sensor/map sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Reconnect the IAT harness connector.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
Is P0113 still set?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
84
DRIVEABILITY - DIESEL
P0113-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO HIGH
— Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connector(s).
Measure the resistance between the temperature sensor signal and return circuit at
the ECM harness connector with the sensor connected
Is the resistance between 300 and 90k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
6
No
→ Go To
4
Measure the resistance of the sensor signal circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open Sensor signal circuit or the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance of the sensor Return circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open return circuit or the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Check for a short circuit from signal circuit to all other circuits at the ECM harness
connector.
Is the resistance more than 100 k ohms?
Yes
→ Go To
No
→ Repair the short in the wiring harness or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
While monitoring with DRBIIIt, use a jumper wire and connect the sensor signal
circuit to the sensor return circuit at the sensor harness connector.
Did the DTC P0112 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
85
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0116-ENGINE COOLANT TEMPERATURE (ECT) SENSOR RATIONALITY
When Monitored and Set Condition:
P0116-ENGINE COOLANT TEMPERATURE (ECT) SENSOR RATIONALITY
When Monitored:
Set Condition:
While the engine is running.
The ECM does not read a change in value from the sensor over time.
POSSIBLE CAUSES
LOW COOLANT LEVEL
COOLANT TEMPERATURE SENSOR
THERMOSTAT
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
With the engine cold, verify the level of coolant in the radiator.
Is the radiator full of coolant?
Yes
→ Go To
No
→ Fill the radiator with coolant- refer to the owners manual for
assistance.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Remove the temperature sensor and reconnect the wiring to the sensor.
Turn the ignition on.
Monitor DRBIIIt, while heating the sensor with an external heat source (DO NOT
USE OPEN FLAME).
Does the reading from the sensor increase at least 5 degrees F. on the DRBIIIt?
Yes
→ Go To
No
→ Replace the coolant temp sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
NOTE: refer to the no trouble code test9*Thermostat Test9 to ensure the thermostat
is operating properly.
Is the thermostat operating properly?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the Thermostat.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
86
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0117-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0117-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO LOW
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
COOLANT TEMPERATURE SENSOR
INTERMITTENT CONDITION
SENSOR SIGNAL WIRE SHORTED TO GROUND OR RETURN
WIRING HARNESS SHORTED
5-VOLT SUPPLY WIRE OPEN
ECM
TEST
1
2
ACTION
Disconnect the Coolant Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Temp sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the Coolant Temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Reconnect the coolant temp sensor connected.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
Did the DTC reset?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
87
DRIVEABILITY - DIESEL
P0117-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE
TOO LOW — Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the engine ground and the temperature sensor
signal circuit at the sensor harness connector.
Is the resistance more than 100 k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Repair or replace the short harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance between the signal circuit and all other circuits at the ECM
harness connector.
Is the resistance more than 100k ohms?
Yes
→ Go To
No
→ Repair or replace shorted wiring harness
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connector.
Turn the ignition on.
Measure the voltage between the supply circuit and the return circuit in the sensor
connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
7
No
→ Go To
6
Turn the ignition off.
Disconnect the ECM harness connector.
Measure the voltage at the supply circuit of the sensor.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Repair or replace the 5-volt supply wire open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
While monitoring the DRBIIIt, Disconnect the temperature sensor harness connector.
Did the DTC P0118 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
88
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0118-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0118-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO
HIGH
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
COOLANT TEMPERATURE SENSOR
INTERMITTENT CONDITION
SIGNAL CIRCUIT OPEN
SENSOR RETURN CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED
ECM
TEST
1
2
ACTION
Disconnect the coolant temperature sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the coolant temperature sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the coolant temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Reconnect the disconnected coolant temp sensor harness connector.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, read DTCs.
Did the DTC return?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
89
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0118-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE
TOO HIGH — Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the temperature sensor signal and return circuits at
the ECM harness connector with the coolant temp sensor harness connected.
Is the resistance between 300 and 90k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
6
No
→ Go To
4
Disconnect the coolant temperature sensor harness connector.
Measure the resistance of the coolant temperature sensor signal circuit between the
coolant temperature sensor connector and the ECM connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance of the coolant temperature sensor, sensor return circuit
between the coolant temperature sensor connector and the ECM connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the open sensor return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of signal circuit to all other circuits at the ECM harness
connector.
Is the resistance more than 100k ohms?
Yes
→ Go To
No
→ Repair or replace the coolant temperature sensor signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
While monitoring with DRBIIIt, use a jumper wire and connect the sensor signal
wire to the sensor return wire at the sensor connector.
Did the DTC P0117 set?
Yes
→ Test Complete.
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
90
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0128-THERMOSTAT RATIONALITY
When Monitored and Set Condition:
P0128-THERMOSTAT RATIONALITY
When Monitored:
While the engine is running.
Set Condition: The coolant temperature does not rise by a calibrated amount over a
calibrated amount of time.
POSSIBLE CAUSES
COOLING FAN
COOLANT TEMPERATURE SENSOR
THERMOSTAT
TEST
ACTION
APPLICABILITY
1
NOTE: refer to the no trouble code test9*Fan Operation Test9 to ensure the fan is
operating properly.
Is the cooling fan operating properly?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Repair the cooling fan.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
2
Did the coolant temperature change over time while the engine was running?
Yes
→ Go To
No
→ Replace the coolant temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
NOTE: refer to the no trouble code test9*Thermostat Test9 to ensure the thermostat
is operating properly.
is the thermostat operating properly?
Yes
→ Test Complete.
No
→ Replace the thermostat.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
91
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM
When Monitored and Set Condition:
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM
When Monitored:
Set Condition:
pressure.
While the engine is running.
A deviation between the fuel pressure set point and the actual fuel
POSSIBLE CAUSES
OTHERS DTC’S PRESENT
FUEL LEAKS
FUEL CONTROL ACTUATOR
FUEL PRESSURE SENSOR
CASCADE OVERFLOW VALVE
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
LIFT PUMP FLOW
AIR IN FUEL SYSTEM
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
HIGH PRESSURE FUEL PUMP
INTERMITTENT CONDITION
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Are any other DTC’s present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Ensure that the fuel level is above 15% using the DRBIIIt.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or
damaged components.
Do you have any fuel leaks or damaged components?
Yes
→ Repair the fuel leak.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
92
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM — Continued
TEST
ACTION
APPLICABILITY
3
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the DRBIIIt,
actuate the fuel control actuator. NOTE: The fuel control actuator will only click
when cycled off.
Do you hear a click from the actuator when you cycle the actuator off with the
DRBIIIt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Go To
No
→ Replace the fuel control actuator.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Using the DRBIIIt, monitor the fuel pressure reading from the fuel rail pressure
sensor at idle and at 2000 RPM
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
Yes
→ Go To
No
→ Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Using the DRBIIIt compare the fuel rail pressure set point with the actual fuel rail
pressure.
Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Yes
→ Go To
6
No
→ Go To
9
Perform the no trouble code test 9*fuel pump return flow test9 .
Did the fuel injection pump pass the test?
Yes
→ Go To
No
→ Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Check the fuel drain line check valve in the rear of the cylinder head for signs of
damage, blockage, or debris.
Is the check valve damaged or blocked?
Yes
→ Repair the cause of the damaged or blocked check valve or replace
the valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Check the fuel return lines for signs of obstruction, damage, or debris.
Are the fuel drain lines damaged or blocked?
Yes
→ Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
9
93
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM — Continued
TEST
9
10
11
12
13
ACTION
Perform the no trouble code 9Lift Pump flow and inlet restriction test9.
Did the Lift pump pass the test?
Yes
→ Go To
No
→ Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
Perform the no trouble code test 9Fuel system vacuum test9.
Is there air in the fuel system?
Yes
→ Go To
No
→ Repair cause of air in fuel system.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
11
Perform the no trouble code test 9 Pressure Limiting Valve on the Fuel Rail for
internal leaks9.
Did the pressure limiting valve pass the test procedure?
Yes
→ Go To
No
→ Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
12
Perform the no trouble test 9*Injector return flow test9.
Are any Injectors leaking or high pressure connectors leaking?
Yes
→ Replace or repair the leaking fuel injectors or high pressure
connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
13
Perform the no trouble code test9HIGH PRESSURE FUEL PUMP PERFORMANCE
TEST9
Did the fuel pump pass the high pressure fuel pump performance test?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
94
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0169-WATER IN FUEL (WIF) LIGHT ON TOO LONG
When Monitored and Set Condition:
P0169-WATER IN FUEL (WIF) LIGHT ON TOO LONG
When Monitored:
Set Condition:
While the engine is running.
Water in fuel light was on for a calibrated amount of time.
POSSIBLE CAUSES
OTHER DTC’S PRESENT
WATER IN FUEL
TEST
1
ACTION
With the DRBIIIt, read DTCs.
Is P2269 displayed?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P2269 DTC first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Drain water in fuel.
95
DRIVEABILITY - DIESEL
Symptom:
P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
OTHER DTC’S
FUEL PRESSURE SENSOR
SUPPLY CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO GROUND
SUPPLY CIRCUIT SHORTED TO GROUND
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs.
Do you have multiple DTC’s?
Yes
→ Repair other DTC’s first.
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the voltage between the supply and return circuits of the Fuel pressure
sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
96
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
Reconnect the disconnected Fuel Pressure Sensor harness connector.
Ignition on, engine not running.
While monitoring DRBIIIt, disconnect the Fuel Pressure sensor harness connector.
Does the DTC P0193 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
9
Yes
→ Replace the Fuel Pressure Sensor.
No
→ Go To
4
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Fuel Pressure sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the supply circuit and return circuit in the sensor
harness connector.
Is the resistance greater than 100 K Ohms?
Yes
→ Go To
No
→ Repair the shorted circuits.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the signal circuit and return circuit in the sensor
connector.
Is the resistance greater than 100 K Ohms?
Yes
→ Go To
No
→ Repair the shorted circuits.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the signal circuit in the sensor harness connector
with the signal circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the supply circuit in the sensor harness connector
with the supply circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open supply circuit.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the signal circuit in the sensor harness connector
and battery negative.
Is the resistance greater than 100 K Ohms?
Yes
→ Go To
No
→ Repair signal circuit shorted to ground.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
Measure the resistance between the supply circuit in the sensor harness connector
and battery negative.
Is the resistance greater than 100 K Ohms?
Yes
→ Go To
No
→ Repair Supply circuit shorted to ground.
10
97
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
10
Reconnect the disconnected Fuel pressure sensor harness connector and ECM
harness connectors.
While monitoring DRBIIIt, disconnect the Fuel Pressure sensor connector.
Does the DTC P0193 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Test Complete.
No
→ Replace the ECM.
98
DRIVEABILITY - DIESEL
Symptom:
P0193-FUEL PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0193-FUEL PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
OTHER DTC’S
FUEL PRESSURE SENSOR
SIGNAL CIRCUIT SHORTED TO VOLTAGE
SUPPLY CIRCUIT SHORTED TO VOLTAGE
SIGNAL CIRCUIT SHORTED TO SUPPLY CIRCUIT
RETURN CIRCUIT OPEN
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs.
Do you have multiple DTC’s?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to multiple fault troubleshooting tree.
No
→ Go To
2
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the voltage between the supply and return circuits of the Fuel pressure
sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
Reconnect the disconnected Fuel Pressure Sensor harness connector.
Ignition on, engine not running.
While monitoring DRBIIIt, connect a jumper wire between the signal circuit and the
return circuit of the Fuel Pressure sensor connector.
Does the DTC P0192 set?
Yes
→ Replace the Fuel Pressure Sensor.
No
→ Go To
4
99
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0193-FUEL PRESSURE SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the signal circuit of the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
7
8
Yes
→ Go To
No
→ Repair the signal circuit shorted to voltage.
5
Measure the voltage between the supply circuit of the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair the supply circuit shorted to voltage.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Turn the ignition off.
Measure the resistance between the signal circuit and supply circuit in the sensor
connector.
Is the resistance greater than 10 K Ohms?
Yes
→ Go To
No
→ Repair the shorted circuits.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the return circuit in the sensor harness connector
with the return circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open return circuit.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Reconnect the disconnected ECM harness connectors.
While monitoring DRBIIIt, connect a jumper wire between the signal circuit of the
sensor connector and the return circuit of the sensor connector.
Does the DTC P0192 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
No
→ Replace the ECM.
100
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P0201-INJECTOR
P0202-INJECTOR
P0203-INJECTOR
P0204-INJECTOR
P0205-INJECTOR
P0206-INJECTOR
Test Note:
#1
#2
#3
#4
#5
#6
CONTROL
CONTROL
CONTROL
CONTROL
CONTROL
CONTROL
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0201-INJECTOR #1 CONTROL
CIRCUIT.
When Monitored and Set Condition:
P0201-INJECTOR #1 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
P0202-INJECTOR #2 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
P0203-INJECTOR #3 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
P0204-INJECTOR #4 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
P0205-INJECTOR #5 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
P0206-INJECTOR #6 CONTROL CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
When the injector current falls below a calibrated threshold.
POSSIBLE CAUSES
PASS TROUGH CONNECTORS OPEN
101
DRIVEABILITY - DIESEL
P0201-INJECTOR #1 CONTROL CIRCUIT —
Continued
POSSIBLE CAUSES
FUEL INJECTOR
INJECTOR HARNESS OPEN
HIGH SIDE DRIVER HARNESS OPEN
LOW SIDE DRIVER HARNESS OPEN
ECM
TEST
1
2
3
4
5
ACTION
With the DRBIIIt, read DTCs.
Are all 6 of the injector DTC’s (P0201 - P0206) present?
Yes
→ Go To
2
No
→ Go To
3
Inspect wiring harness for signs of multiple open circuits between the ECM and the
injector pass through connectors. Inspect the wiring harness between the pass
through connectors to the injectors.
Are there open circuits in the wiring harness?
Yes
→ Repair or replace the open connectors or wiring.
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Turn the ignition off.
Disconnect the pigtail nuts from the suspect injector. Using an Ohmmeter, check the
resistance between the solenoid posts of the injector.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Yes
→ Go To
No
→ Replace the fuel injector.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
Connect the pigtail nuts for the suspect injector.
Disconnect the injector harness connector for the suspect injector.
Measure the resistance of the injector harness circuit between the high side driver
pin and the low side driver pin for the suspect injector at the injector harness
connector.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Yes
→ Go To
No
→ Replace or repair the injector harness.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Disconnect the ECM harness connectors.
Disconnect the Injector harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Bank 1 high side driver wire between the ECM
connector and the injector harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Replace or repair the open engine harness.
6
102
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0201-INJECTOR #1 CONTROL CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
6
Measure the resistance of the Bank 1 low side driver wire between the ECM
connector and the injector harness connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Test Complete.
No
→ Replace or repair the open engine harness.
103
DRIVEABILITY - DIESEL
Symptom:
P0217-DECREASED ENGINE PERFORMANCE DUE TO ENGINE
OVERHEAT CONDITION
POSSIBLE CAUSES
ECT SENSOR
OTHER DTC’S
MECHANICAL FAILURE
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Are other Cooling system DTC’s present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Trouble shoot the other DTC’s first
No
→ Go To
2
Allow the engine to reach normal operating temperature.
Use a temperature probe and measure the engine temperature near the ECT Sensor.
With the DRBIIIt, read the Engine Temperature.
Compare the temperature probe reading with the DRBIIIt reading.
Are the readings within 10°F of each other?
Yes
→ Repair the cause of mechanical failure
No
→ Replace the coolant temp sensor.
104
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0219-CRANKSHAFT POSITION SENSOR OVER SPEED SIGNAL
When Monitored and Set Condition:
P0219-CRANKSHAFT POSITION SENSOR OVER SPEED SIGNAL
When Monitored:
Set Condition:
While the engine is running.
The ECM detects engine speed is above a calibrated threshold.
POSSIBLE CAUSES
OTHER DTC’S
MECHANICAL OVERSPEED OF ENGINE
INTERMITTENT CONDITION
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read and record the freeze frame data.
With the DRBIIIt, read the Engine DTC’s.
Is there other Crankshaft position sensor DTC’s set?
Yes
→ Refer to symptom list for problems related to the other Crankshaft position sensor DTC’s.
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Visually inspect the engine for signs of mechanical overspeed. Such as, bent push rod,
broken rocker arms, bent valves, etc.
Did you notice any overspeed damage?
Yes
→ Repair or replace any damaged components.
No
→ Test Complete.
105
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0234-TURBO BOOST LIMIT EXCEEDED
When Monitored and Set Condition:
P0234-TURBO BOOST LIMIT EXCEEDED
When Monitored:
Set Condition:
of time.
While running.
The intake air pressure is above a calibrated value for a calibrated amount
POSSIBLE CAUSES
OTHER DTC’S
WASTEGATE STUCK
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read the Engine DTC’s.
Do you have additional Boost Pressure related faults?
Yes
→ Repair other boost related DTC’s first.
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Turn the ignition on.
With the DRBIIIt, go to the Freeze Frame screen record all data.
With the DRBIIIt, read DTCs.
Operate the vehicle in the Freeze Frame parameters.
Did the DTC P-0234 return?
Yes
→ Replace the Wastegate.
No
→ Test Complete.
106
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0236-MAP SENSOR TOO HIGH TOO LONG
When Monitored and Set Condition:
P0236-MAP SENSOR TOO HIGH TOO LONG
When Monitored:
Ignition on.
Set Condition: The intake air pressure is above a calibrated value past a calibrated
amount of time.
POSSIBLE CAUSES
OTHER CODES
INTERMITTENT CONDITION
MAP SENSOR
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Turn the ignition on.
With the DRBIIIt, read the Engine DTC’s.
Are there any other MAP Sensor related DTC’s.
Yes
→ Repair other MAP Sensor DTC’s.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Start the engine.
With the DRBIIIt, read the MAP Sensor voltage.
Is the pressure reading of the MAP sensor less than 35.85 in Hg?
Yes
→ Go To
No
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Operate the engine under normal driving conditions (no load) for at least 30 seconds.
Monitor the MAP sensor reading with the DRBIIIt.
Did the pressure reading from the MAP sensor go above 22.5 in Hg for more than 2.5
seconds?
Yes
→ Replace the Map sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
107
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0237-MAP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0237-MAP SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
OTHER DTC’S
5-VOLT CIRCUIT SHORTED TO SENSOR RETURN CIRCUIT
SIGNAL CIRCUIT SHORTED TO SENSOR RETURN CIRCUIT
MAP SENSOR
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
MAP SIGNAL CIRCUIT SHORT TO GROUND
ECM
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read the Engine DTC’s.
Is there a 5-volt Supply DTC set?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to symptom list for problems related to the 5-volt Supply
DTC.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Turn the ignition off.
Disconnect the Map sensor harness connector.
Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the 5-volt supply circuit and sensor return Circuit of
the Map sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
108
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0237-MAP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
While monitoring the DRBIIIt, jumper the 5-volt supply circuit to the signal circuit
in the map sensor harness connector.
Did the P0238-MAP SENSOR VOLTAGE TOO HIGH, DTC set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Replace the MAP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
Turn the ignition off.
Disconnect the ECM harness 60 pin connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal pin and sensor return pin in the MAP
sensor harness connector.
Is the resistance greater than 100 K Ohms?
Yes
→ Repair signal circuit shorted to sensor return circuit or replace
harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the 5-volt circuit and sensor return circuit in the
MAP sensor harness connector.
Is the resistance greater than 100 K Ohms?
Yes
→ Repair 5-volt circuit shorted to sensor return circuit or replace
harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the signal circuit in the Map sensor harness
connector with the signal circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the supply circuit in the Map sensor harness
connector with the supply circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
8
109
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0237-MAP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
8
Measure the resistance between the MAP Sensor Signal circuit and the Battery neg.
Is the resistance above 100k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
10
Yes
→ Go To
No
→ Repair the MAP Sensor Signal circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
9
Measure the resistance between the supply circuit in the sensor harness connector
and battery negative.
Is the resistance above 100k ohms?
Yes
→ Go To
No
→ Test Complete.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
While monitoring the DRBIIIt, jumper the 5-volt supply circuit to the signal circuit
in the map sensor harness connector.
Did the P0238-MAP SENSOR VOLTAGE TOO HIGH, DTC set?
Yes
→ Test Complete.
No
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
110
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0238-MAP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0238-MAP SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
OTHER DTC’S
SIGNAL CIRCUIT SHORTED TO BATTERY
5-VOLT CIRCUIT SHORTED TO BATTERY
MAP SENSOR
SIGNAL CIRCUIT SHORT TO SUPPLY
SUPPLY CIRCUIT SHORT TO BATTERY
INTERMITTENT
ECM
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read the Engine DTC’s.
Is there a 5-volt Supply DTC set?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to symptom list for problems related to the 5-volt Supply
DTC.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Turn the ignition off.
Disconnect the Map sensor harness connector.
Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the 5-volt supply circuit and sensor return Circuit of
the Map sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
111
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0238-MAP SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
While monitoring DRBIIIt, use a jumper wire to connect the return circuit with the
signal circuit at the sensor connector.
Did the P0237-MAP SENSOR VOLTAGE TOO LOW, DTC set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Replace the MAP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the voltage between the signal circuit at the MAP sensor harness connector
and Battery Negative.
Is the voltage less than 1 volt?
Yes
→ Repair signal circuit shorted to Battery or replace harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the voltage between the 5-volt supply circuit at the MAP sensor harness
connector and Battery negative.
Is the voltage less than 1 volt?
Yes
→ Repair 5-volt circuit shorted to Battery or replace harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Turn the ignition off.
Disconnect the ECM harness connectors.
Measure the resistance between the signal circuit of the sensor harness connector
and the supply circuit of the sensor harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the sensor return circuit in the Map sensor harness
connector with the sensor return circuit in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
8
112
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0238-MAP SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
8
Reconnect the ECM harness connector.
Turn the ignition on.
While monitoring DRBIIIt, connect a jumper wire between the signal circuit of the
sensor harness connector and the return circuit of the sensor harness connector.
Does the DRBIIIt show P0237-Map Sensor Voltage Too Low DTC?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
113
DRIVEABILITY - DIESEL
Symptom:
P0251-CP3 PUMP REGULATOR CONTROL
When Monitored and Set Condition:
P0251-CP3 PUMP REGULATOR CONTROL
When Monitored:
When the ignition is on.
Set Condition: The ECM detects a discrepancy between the PWM supplied to the
Electronic Fuel Control Actuator and the PWM returned from the Electronic Fuel Control
Actuator.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL CONTROL ACTUATOR
RETURN WIRE OPEN FROM FCA TO ECM
SUPPLY WIRE OPEN FROM FCA TO ECM
SUPPLY CIRCUIT SHORTED TO VOLTAGE
ECM
TEST
1
2
3
ACTION
With the DRBIIIt, record all freeze frame data and erase DTC’s.
With the DRBIIIt, read DTCs.
Is the DTC P0251 set?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the fuel control actuator (FCA).
Check connectors - Clean/repair as necessary.
Measure the resistance between the supply and return circuits of the FCA.
Is the resistance between 2.8 and 4.0 ohms?
Yes
→ Go To
No
→ Replace the fuel control actuator (FCA).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the return wire between the FCA and the ECM connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair or replace the engine wiring harness.
4
114
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0251-CP3 PUMP REGULATOR CONTROL —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance of the supply wire between the FCA and the ECM connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
Yes
→ Go To
No
→ Repair or replace the engine wiring harness.
5
Turn the ignition off.
Measure the voltage between the supply pin in the electronic fuel control actuator
connector and battery negative.
Is the voltage greater than 1 volts?
Yes
→ Repair the supply circuit shorted to voltage.
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Reconnect the ECM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
Monitor with the DRBIIIt while connecting a jumper wire between the supply and
return circuits in the actuator connector.
Did the DTC return?
Yes
→ Replace the ECM.
No
→ Test Complete.
115
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P0300-MULTIPLE
P0301-CYLINDER
P0302-CYLINDER
P0303-CYLINDER
P0304-CYLINDER
P0305-CYLINDER
P0306-CYLINDER
Test Note:
CYLINDER MISFIRE
# 1 MISFIRE
# 2 MISFIRE
# 3 MISFIRE
# 4 MISFIRE
# 5 MISFIRE
# 6 MISFIRE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0300-MULTIPLE CYLINDER
MISFIRE.
When Monitored and Set Condition:
P0300-MULTIPLE CYLINDER MISFIRE
When Monitored:
Set Condition:
While the engine is idling.
Misfire detected on multiple cylinders.
P0301-CYLINDER # 1 MISFIRE
When Monitored:
Set Condition:
While the engine is idling at operating temperature.
Misfire detected on this cylinder.
P0302-CYLINDER # 2 MISFIRE
When Monitored:
Set Condition:
While the engine is idling at operating temperature.
Misfire detected on this cylinder.
P0304-CYLINDER # 4 MISFIRE
When Monitored:
Set Condition:
While the engine is idling at operating temperature.
Misfire detected on this cylinder.
P0305-CYLINDER # 5 MISFIRE
When Monitored:
Set Condition:
While the engine is idling at operating temperature.
Misfire detected on this cylinder.
P0306-CYLINDER # 6 MISFIRE
When Monitored:
Set Condition:
While the engine is idling at operating temperature.
Misfire detected on this cylinder.
116
DRIVEABILITY - DIESEL
P0300-MULTIPLE CYLINDER MISFIRE —
Continued
POSSIBLE CAUSES
LOW FUEL
OTHER DTC’S
DAMAGED FUEL LINES
VALVE TRAIN
OBSTRUCTED FUEL INJECTOR SUPPLY LINES
DAMAGED OR OBSTRUCTED HIGH PRESSURE CONNECTORS
EXTERNAL DAMAGED FUEL INJECTORS
INTERNAL DAMAGED FUEL INJECTOR
NO COMPRESSION
EXCESSIVE ENGINE LEAK DOWN
TEST
1
2
3
4
ACTION
Using the DRBIIIt, verify that the fuel level is above 15%.
Is the fuel level above 15%?
Yes
→ Go To
No
→ Add fuel go to step 2.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Read the Freeze frame data.
Is the DTC equal to the freeze frame DTC?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Go To
No
→ Repair any other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
Visually inspect the injector supply lines for damage.
Do you have any kinked or bent fuel lines?
Yes
→ Repair or replace damaged fuel lines.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
Visually inspect the valve train and check the valve lash on the suspect cylinders.
Is the valve train functional and the lash within the specifications listed in the
service manual?
Yes
→ Go To
No
→ Adjust the lash or fix or repair any damaged component(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
117
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0300-MULTIPLE CYLINDER MISFIRE —
Continued
TEST
ACTION
APPLICABILITY
5
Remove the fuel injector supply lines for the suspect cylinders.
Inspect both ends of the fuel injector supply lines for damage.
Using shop air pressure, blow out the fuel injector supply lines to verify that they are
not obstructed.
Are the fuel lines free of debris or damage?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
7
8
9
Yes
→ Go To
No
→ Replace the damaged or obstructed fuel injector supply lines.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
6
Remove the high pressure connectors for the suspect cylinders.
Inspect both ends of the high pressure connectors for signs of damage.
Using shop air pressure, blow out the high pressure connectors to verify that they are
not obstructed.
Are the high pressure connectors free of debris or damage?
Yes
→ Go To
No
→ Replace the damaged or obstructed high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Remove the suspect fuel injectors.
Are the fuel injectors damaged?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Replace the external damaged fuel injectors & high pressure
connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
8
With the DRBIIIt, erase DTCs.
Switch the misfiring injectors & high pressure connectors with injectors & high
pressure connectors from cylinders that are firing properly.
Operate the vehicle.
Did the misfire DTC follow the suspect injectors & high pressure connectors?
Yes
→ Replace the internal damaged fuel injector and high pressure
connector.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
Perform engine compression test
Did the suspect cylinders pass the compression test?
Yes
→ Go To
No
→ Repair the internal damage to the engine.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
10
118
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0300-MULTIPLE CYLINDER MISFIRE —
TEST
10
Continued
ACTION
Perform engine leak down test
Did the suspect cylinders pass the leak down test?
Yes
→ Test Complete.
No
→ Repair the internal damage to the engine.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
119
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0335-CRANKSHAFT POSITION (CKP) LOST
When Monitored and Set Condition:
P0335-CRANKSHAFT POSITION (CKP) LOST
When Monitored:
Set Condition:
While the engine is running.
The ECM no longer detects a signal from the Crankshaft Position Sensor.
POSSIBLE CAUSES
OTHER DTC’S
P0337 PRESENT
CKP SENSOR
OPEN CIRCUIT
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
RETURN CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SUPPLY CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT SHORTED GROUND
SIGNAL CIRCUIT SHORTED TO SUPPLY CIRCUIT
SUPPLY CIRCUIT SHORTED BATTERY NEGATIVE
INTERMITTENT CONDITION
ECM
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Is DTC P2146 and/or P2149 present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
With the DRBIIIt, read DTCs.
Is P0337 present?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P0337 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
120
DRIVEABILITY - DIESEL
P0335-CRANKSHAFT POSITION (CKP) LOST —
Continued
TEST
ACTION
APPLICABILITY
3
Visually inspect the sensor, engine belt, sensor connector, and the ECM connector.
Is there any damage?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Repair or replace the sensor, engine belt, harness, or the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
Disconnect the CKP sensor harness connector.
Measure the resistance between the supply circuit and the signal circuit of the sensor
harness connector.
Is the resistance between 900 and 1100 ohms?
Yes
→ Go To
No
→ Replace the CKP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Disconnect the ECM harness connectors.
Disconnect the CKP sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the hall effect (signal) circuit between the ECM harness
connector and the CKP sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the supply circuit between the ECM harness connector and
the CKP sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance of the return circuit between the ECM harness connector and
the CKP sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the signal circuit and the return circuit in the sensor
connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
9
121
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0335-CRANKSHAFT POSITION (CKP) LOST —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the supply circuit and the return circuit in the
sensor connector.
Is the resistance greater than 100k Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
11
12
13
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
10
Measure the resistance between the signal circuit and ground.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
11
Measure the resistance between the supply circuit and ground.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
12
Measure the resistance between the signal circuit and the supply circuit in the sensor
connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
13
Reconnect the ECM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
Connect a jumper wire between the sensor supply circuit and the sensor return
circuit in the sensor harness connector.
Did DTC P0337 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
122
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL
When Monitored and Set Condition:
P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL
When Monitored:
With the key on.
Set Condition: The voltage detected at the Crankshaft position sensor is below a
calibrated value.
POSSIBLE CAUSES
CKP SENSOR
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
RETURN CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SUPPLY CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT SHORTED GROUND
SIGNAL CIRCUIT SHORTED TO SUPPLY CIRCUIT
SUPPLY CIRCUIT SHORTED BATTERY NEGATIVE
INTERMITTENT CONDITION
ECM
TEST
ACTION
APPLICABILITY
1
Disconnect the CKP sensor harness connector.
Measure the resistance between the supply circuit and the signal circuit of the sensor
harness connector.
Is the resistance between 900 and 1100 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Go To
No
→ Replace the CKP sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
Disconnect the ECM harness connectors.
Disconnect the CKP sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the hall effect (signal) circuit between the ECM harness
connector and the CKP sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
123
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the resistance of the supply circuit between the ECM harness connector and
the CKP sensor harness connector.
Is the resistance less than 10 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Go To
No
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance of the return circuit between the ECM harness connector and
the CKP sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the signal circuit and the return circuit in the sensor
connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the supply circuit and the return circuit in the
sensor connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the signal circuit and ground.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the supply circuit and ground.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
9
124
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the signal circuit and the supply circuit in the sensor
connector.
Is the resistance greater than 100k Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
10
Reconnect the ECM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
Connect a jumper wire between the sensor supply circuit and the sensor return
circuit in the sensor harness connector.
Did DTC P0337 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
125
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0337-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO
LOW
When Monitored and Set Condition:
P0337-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO LOW
When Monitored:
With the key on.
Set Condition: Voltage detected at the CKP is below a calibrated value for a calibrated
amount of time.
POSSIBLE CAUSES
CKP SENSOR
SUPPLY CIRCUIT SHORTED TO RETURN CIRCUIT
SUPPLY CIRCUIT SHORTED BATTERY NEGATIVE
INTERMITTENT CONDITION
ECM
TEST
ACTION
APPLICABILITY
1
Disconnect the CKP sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the supply circuit and the signal circuit of the sensor
harness connector.
Is the resistance between 900 and 1100 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Replace the CKP sensor.
2
Disconnect the ECM harness connectors.
Measure the resistance between the supply circuit and the return circuit in the
sensor connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the resistance between the supply circuit and battery negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the short circuit or replace the engine harness.
4
126
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0337-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Reconnect the ECM harness connectors.
Ignition on, engine not running.
Connect a jumper wire between the sensor supply circuit in the sensor harness
connector 12-volts.
Did DTC P0338 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
No
→ Replace the ECM.
127
DRIVEABILITY - DIESEL
Symptom:
P0338-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO
HIGH
When Monitored and Set Condition:
P0338-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO HIGH
When Monitored:
With the key on.
Set Condition: Voltage detected at the CKP is above a calibrated value for a calibrated
amount of time.
POSSIBLE CAUSES
SUPPLY CIRCUIT SHORTED TO VOLTAGE
INTERMITTENT CONDITION
ECM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM harness connector(s).
Disconnect the CKP sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure voltage between the supply circuit in the sensor harness connector and
battery negative.
Is the voltage greater than 1 volt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Repair or replace the shorted wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Reconnect the ECM harness connectors.
Ignition on, engine not running.
Connect a jumper wire between the sensor supply circuit and the sensor return in the
sensor harness connector.
Did DTC P0337 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
128
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0340-CAMSHAFT POSITION (CMP) LOST
When Monitored and Set Condition:
P0340-CAMSHAFT POSITION (CMP) LOST
When Monitored:
Set Condition:
While the engine is running.
The ECM no longer detects a signal from the Engine Position Sensor.
POSSIBLE CAUSES
INJECTOR DTC’S PRESENT
OTHER DTC’S
CAMSHAFT SENSOR
OPEN SUPPLY CIRCUIT
OPEN RETURN CIRCUIT
SIGNAL CIRCUIT SHORTED TO GROUND
SIGNAL CIRCUIT SHORTED TO SUPPLY CIRCUIT
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT SHORT TO VOLTAGE
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Do you have a DTC for P2146 or P2149?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair injector DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
2
With the DRBIIIt, read DTCs.
Is any other DTC’s present?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
3
129
DRIVEABILITY - DIESEL
P0340-CAMSHAFT POSITION (CMP) LOST —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the cam sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the supply circuit and the signal circuit of the
sensor.
Is the resistance between 900 and 1100 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Replace the camshaft sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
4
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the supply circuit between the ECM harness connector and
the cam sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance of the return circuit between the ECM harness connector and
the cam sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open Return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the signal circuit in the sensor harness connector
and battery negative.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Repair signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the signal circuit and the supply circuit in the sensor
harness connector.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Repair signal circuit shorted to the supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
8
130
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0340-CAMSHAFT POSITION (CMP) LOST —
Continued
TEST
ACTION
APPLICABILITY
8
Measure the resistance between the signal circuit and the return circuit in the sensor
harness connector.
Is the resistance greater than 100k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
10
Yes
→ Go To
No
→ Repair signal circuit shorted to the return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
9
Measure the voltage between the signal circuit in the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair signal circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
Reconnect the ECM harness connectors.
Measure the voltage between the signal circuit in the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
131
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL
When Monitored and Set Condition:
P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL
When Monitored:
Set Condition:
While the engine is running.
The ECM no longer detects a signal from the Engine Position Sensor.
POSSIBLE CAUSES
INJECTOR DTC’S PRESENT
OTHER DTC’S
CAMSHAFT SENSOR
SIGNAL CIRCUIT OPEN
SUPPLY CIRCUIT OPEN
RETURN CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO GROUND
SIGNAL CIRCUIT SHORTED TO SUPPLY CIRCUIT
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT SHORT TO VOLTAGE
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Do you have a DTC for P2146 or P2149?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair injector DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
2
With the DRBIIIt, read DTCs.
Is any other DTC’s present?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
3
132
DRIVEABILITY - DIESEL
P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the cam sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the supply circuit and the signal circuit of the
sensor.
Is the resistance between 900 and 1100 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Go To
No
→ Replace the camshaft sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
4
Disconnect the ECM harness connectors.
Measure the resistance of the signal circuit between the ECM harness connector and
the sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance of the supply circuit between the ECM harness connector and
the sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the return circuit between the ECM harness connector and
the sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the signal circuit in the sensor harness connector
and battery negative.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Repair signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the signal circuit and the supply circuit in the sensor
harness connector.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Repair signal circuit shorted to the supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
9
133
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the signal circuit and the return circuit in the sensor
harness connector.
Is the resistance greater than 100k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
11
Yes
→ Go To
No
→ Repair signal circuit shorted to the return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
10
Measure the voltage between the signal circuit in the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair signal circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
11
Reconnect the ECM harness connectors.
Measure the voltage between the signal circuit in the sensor harness connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Test Complete.
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
134
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0381-WAIT TO START LAMP INOPERATIVE
When Monitored and Set Condition:
P0381-WAIT TO START LAMP INOPERATIVE
When Monitored:
Set Condition:
start lamp.
Ignition on .
The cluster sends a signal to the ECM that it has detected a failed wait to
POSSIBLE CAUSES
WAIT-TO-START LAMP STAYS ON ALL THE TIME
WAIT-TO-START LAMP DRIVER CIRCUIT SHORTED TO GROUND
WAIT-TO-START LAMP DRIVER CIRCUIT OPEN FROM ECM TO CLUSTER.
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
WAIT-TO-START LIGHT BULB
ECM DRIVER CIRCUIT OPEN
WIRING/CONNECTOR PROBLEM
ECM
TEST
1
2
ACTION
Turn the ignition off.
While watching the wait-to-start lamp, turn the ignition key on.
Did the wait-to-start lamp light?
Yes
→ Go To
2
No
→ Go To
4
Turn the ignition off.
While watching the wait-to-start lamp, turn the ignition key on.
Does the wait-to-start lamp stay on all the time?
Yes
→ Go To
No
→ Wait-to-start Lamp operating normally. Test passed.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
135
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0381-WAIT TO START LAMP INOPERATIVE —
TEST
3
4
5
6
7
Continued
ACTION
Turn the ignition off.
Disconnect the ECM harness connector.
NOTE: Check connectors - Clean/repair as necessary.
While watching the wait-to-start lamp, turn the ignition key on.
Did the Wait-to-start lamp light?
Yes
→ Repair Diesel Wait-to-start Lamp driver circuit for a short to
ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Test Complete.
Turn the ignition off.
Disconnect the ECM harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Connect a jumper between the ECM Wait-to-start Lamp driver and a good ground.
Did the Wait-to-lamp illuminate?
Yes
→ Go To
No
→ Repair the open Wait-to-start lamp driver circuit open from ECM
to cluster.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition off.
Remove the cluster.
NOTE: Check connectors - Clean/repair as necessary.
Turn the ignition on.
Using a 12-Volt test Light, check the Fused Ignition Switch Run/Start circuit.
Is the light illuminated and bright?
Yes
→ Go To
No
→ Repair the open fused Ignition Switch Output circuit
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Remove and inspect the Wait-to-Start Bulb.
Is the Bulb Ok?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Go To
No
→ Replace the Wait-to-Start Bulb.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
7
Measure the Wait-to-start driver circuit at the ECM harness connector.
Is the voltage above 10.0 volts?
Yes
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
8
136
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0381-WAIT TO START LAMP INOPERATIVE —
Continued
TEST
ACTION
APPLICABILITY
8
Using a schematic as a guide, inspect the related wiring and connectors for problems.
Check the Fuses.
Were any problems found?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Test Complete
Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
137
DRIVEABILITY - DIESEL
Symptom:
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME
When Monitored and Set Condition:
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME
When Monitored:
While the engine is running.
Set Condition: Fuel level does not change by a calibrated amount over a calibrated
amount of time.
POSSIBLE CAUSES
EXTERNAL DAMAGE TO FUEL TANK
FUEL LEVEL SENSOR
FUEL LEVEL SENSOR
INSIDE OF FUEL TANK OBSTRUCTED DAMAGED
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Visually inspect the fuel tank for external damage.
Is the fuel tank damaged from the outside?
Yes
→ Fix or replace the fuel tank.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the wiring harness from the fuel level sensor.
Check connectors - Clean/repair as necessary.
Remove the fuel level sensor from the fuel tank.
Does the fuel level float move freely?
Yes
→ Go To
No
→ Replace the fuel level sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the resistance between the sensor signal and return circuits while moving
the sensor float arm.
Does the resistance level change as you move the sensor arm?
Yes
→ Go To
No
→ Replace the fuel level sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
138
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME —
TEST
4
Continued
ACTION
Visually inspect the inside of the fuel tank for obstructions.
Is the inside of the fuel tank damaged or obstructing the fuel level sensor?
Yes
→ Test Complete.
No
→ Replace the fuel tank.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
139
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0462-LOW VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR
When Monitored and Set Condition:
P0462-LOW VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR
When Monitored:
Ignition on and battery voltage above 10.4 volts.
Set Condition: The signal voltage from the sensor falls below a calibrated value for a
calibrated amount of time.
POSSIBLE CAUSES
FUEL LEVEL SENSOR
SIGNAL CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTERMITTENT CONDITION
ECM
TEST
1
2
3
ACTION
Turn the ignition off.
Disconnect the Fuel Level Sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the sensor across the signal and return pins.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Replace the fuel level sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the signal circuit between the ECM harness connector and
the sensor harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the voltage between the signal circuit and battery negative.
Is the voltage greater than 1 volt?
Yes
→ Repair the signal circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
140
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0462-LOW VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR —
Continued
TEST
ACTION
APPLICABILITY
4
Reconnect the ECM harness connector.
While monitoring with the DRBIIIt, connect a jumper wire between the signal circuit
in the sensor harness connector and battery negative.
Did the DTC P0463 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Test Complete.
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
141
DRIVEABILITY - DIESEL
Symptom:
P0463-HIGH VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR
When Monitored and Set Condition:
P0463-HIGH VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR
When Monitored:
Ignition on and battery voltage above 10.4 volts.
Set Condition: The signal voltage from the sensor goes above a calibrated value for a
calibrated amount of time.
POSSIBLE CAUSES
FUEL LEVEL SENSOR
SIGNAL CIRCUIT SHORTED TO GROUND
INTERMITTENT CONDITION
ECM
TEST
ACTION
APPLICABILITY
1
Disconnect the ECM harness connectors.
Disconnect the Fuel level sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Fuel level sensor across the signal and return circuits.
Is the resistance less than 10 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Replace the Fuel level sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
Measure the resistance between the signal circuit in the sensor harness connector
and battery negative.
Is the resistance less than 10 Ohms?
Yes
→ Repair the signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Reconnect the ECM harness connector.
While monitoring with the DRBIIIt, disconnect the Fuel level sensor harness
connector.
Did the DTC P0462 set?
Yes
→ Test Complete.
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
142
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0477-LOW VOLTAGE ON THE ENGINE BRAKE DRIVER
When Monitored and Set Condition:
P0477-LOW VOLTAGE ON THE ENGINE BRAKE DRIVER
When Monitored:
When the ignition is on .
Set Condition: When the signal from the engine brake driver output does not match the
signal from the engine brake driver feedback.
POSSIBLE CAUSES
WIRING HARNESS
ENGINE BRAKE DRIVER RELAY
FUSED B+ OPEN
ENGINE BRAKE DRIVER SIGNAL CIRCUIT OPEN
INTERMITTENT CONDITION
ENGINE BRAKE DRIVER SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
TEST
1
2
3
ACTION
Turn the engine off (ignition on).
With the DRBIIIt, actuate the exhaust brake relay.
Can you hear the Relay clicking?
Yes
→ Go To
No
→ Test Complete.
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
With the DRBIIIt, actuate the exhaust brake relay.
While the relay is clicking, wiggle the wiring harness and connectors throughout the
circuit.
Does this interrupt the clicking?
Yes
→ Repair or replace the wiring harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Remove the Engine Brake Driver Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between terminals 1 and 2 of the engine brake relay.
Is the resistance less than 100 Ohms?
Yes
→ Go To
No
→ Replace the Engine Brake Driver Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
143
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0477-LOW VOLTAGE ON THE ENGINE BRAKE DRIVER —
TEST
4
5
6
7
ACTION
Ignition on, engine not running.
Measure the voltage of the Fused B+ Supply circuit at the Engine Brake Relay.
Is the voltage within 10% of battery voltage?
Yes
→ Go To
No
→ Repair the open B+ circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Continued
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition off.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Engine Brake Driver signal circuit between the Relay
harness connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open Engine Brake driver circuit open from relay to
ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the Engine Brake Driver signal circuit between the Relay
connector and battery negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair Engine brake driver shorted to Battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Using the DRBIIIt, actuate the Engine Brake Driver Relay.
While monitoring with the DRBIIIt, use a jumper wire to connect 12 volts to the
relay signal circuit with the relay disconnected.
Did the DTC P0478 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
144
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0478-HIGH VOLTAGE ON THE ENGINE BRAKE DRIVER
When Monitored and Set Condition:
P0478-HIGH VOLTAGE ON THE ENGINE BRAKE DRIVER
When Monitored:
When the ignition is on.
Set Condition: When the signal from the engine brake driver output does not match the
signal from the engine brake driver feedback.
POSSIBLE CAUSES
RELAY LOOSE
ENGINE BRAKE DRIVER CONTROL CIRCUIT SHORTED TO VOLTAGE
ENGINE BRAKE RELAY
INTERMITTENT CONDITION
ECM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the Engine Brake Driver Relay.
Can you hear the Relay clicking?
Yes
→ Go To
2
No
→ Go To
3
While the relay is clicking, wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Yes
→ Repair the loose connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Turn the ignition off.
Remove the Engine Brake Driver Relay.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the voltage of the Engine Brake Driver Control Circuit between the relay
terminal and battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair Engine Brake Driver Control Circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
145
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0478-HIGH VOLTAGE ON THE ENGINE BRAKE DRIVER —
TEST
4
5
ACTION
Measure the resistance between terminals 1 and 2 of the engine brake relay.
Is the resistance less than 10 ohms?
Yes
→ Replace the engine brake relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
Continued
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connectors.
Reinstall the Engine Brake relay.
Ignition on, engine not running.
While monitoring with the DRBIIIt, remove the Engine Brake Driver Relay.
Did P0477 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
146
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0480-FAN CLUTCH
When Monitored and Set Condition:
P0480-FAN CLUTCH
When Monitored:
When the ignition is on.
Set Condition: The PWM signal to the fan clutch does not match the PWM signal from
the fan clutch.
POSSIBLE CAUSES
FAN CLUTCH
WIRE HARNESS DAMAGED
OPEN FAN CLUTCH DRIVER CIRCUIT
DRIVER CIRCUIT SHORTED TO RETURN CIRCUIT
DRIVER CIRCUIT SHORTED TO BATTERY NEGATIVE
INTERMITTENT CONDITION
ECM
TEST
ACTION
APPLICABILITY
1
Disconnect the fan clutch harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the fan clutch driver circuit and the fan speed sensor
return circuit on the fan clutch assembly.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Replace the fan clutch.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Measure the resistance between the fan clutch driver circuit and the fan clutch
battery supply circuit on the fan clutch assembly.
Is the resistance less than 6 Ohms or greater than 10 Ohms?
Yes
→ Replace the fan clutch.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
147
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0480-FAN CLUTCH —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the fan clutch driver circuit between the ECM harness
connector and the fan clutch harness connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
Yes
→ Go To
No
→ Repair the open fan clutch driver circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance between the fan clutch driver circuit and the fan speed sensor
return circuit at the sensor harness connector.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Repair the Driver circuit shorted to Return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the fan clutch driver circuit and the battery
negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the Driver circuit shorted to battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the fan clutch driver circuit between the fan clutch
connector and battery negative.
Is the resistance greater than 100k Ohms?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
148
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0483-FAN SPEED
When Monitored and Set Condition:
P0483-FAN SPEED
When Monitored:
Set Condition:
While the engine is running.
The actual fan speed does not match the commanded fan speed.
POSSIBLE CAUSES
OTHER DTC’S
SIGNAL CIRCUIT SHORT TO SUPPLY CIRCUIT
SIGNAL WIRE OPEN FROM ECM TO FAN CLUTCH ASSEMBLY
INTERMITTENT CONDITION
SUPPLY CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO FAN CLUTCH HARNESS CONNECTOR
SIGNAL CIRCUIT SHORTED TO RETURN IN THE HARNESS
SIGNAL CIRCUIT SHORTED TO VOLTAGE
SIGNAL CIRCUIT IN ECM SHORTED TO GROUND INSIDE ECM
SIGNAL CIRCUIT SHORTED TO VOLTAGE IN THE ECM
(Y3) 5-VOLT SUPPLY IN ECM
TEST
1
2
ACTION
With the DRBIIIt, read DTCs.
Is DTC P0480 present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Disconnect the
Measure the resistance between the signal circuit in the fan clutch assembly and the
battery supply circuit in the fan clutch assembly.
Is the resistance less than 10 Ohms?
Yes
→ Replace the Fan clutch assembly.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
149
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0483-FAN SPEED —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the signal circuit between the ECM harness connector and
the fan clutch assembly harness connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Repair the open circuit from the ECM harness connector to the
Fan clutch harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance of the supply circuit between the ECM harness connector and
the fan clutch assembly harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open circuit from ECM harness connector to Fan
clutch connector.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the signal circuit in the fan clutch assembly harness
connector and the return circuit in the fan clutch assembly harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Repair the shorted circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the voltage between the signal circuit in the fan clutch assembly harness
connector and battery negative.
Is the voltage greater than 1 volt?
Yes
→ Repair the signal circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Measure the resistance between the signal circuit in the fan clutch assembly harness
connector and battery negative.
Is the resistance less than 10 Ohms?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
8
150
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0483-FAN SPEED —
Continued
TEST
ACTION
APPLICABILITY
8
Reconnect the fan harness connector.
Turn the ignition on.
While back probing the fan connector measure the voltage between the fan speed
signal circuit in the fan clutch assembly harness connector and battery negative
while manually rotating the fan blade.
Did voltage go from less than 0.7 volts to 4.7 to 5.7 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
Yes
→ Repair the Fan Speed Signal circuit in the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
9
Turn the ignition on.
Measure the voltage between the supply circuit in the fan clutch assembly harness
connector and battery negative.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
151
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0500-NO VEHICLE SPEED SENSOR SIGNAL
When Monitored and Set Condition:
P0500-NO VEHICLE SPEED SENSOR SIGNAL
When Monitored:
Set Condition:
While the engine is running.
The ECM indicates signals of motion; however, the VSS does not.
POSSIBLE CAUSES
(G7) VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO VOLTAGE
(G7) VEHICLE SPEED SIGNAL CIRCUIT OPEN BETWEEN CAB AND ECM
(G7) VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO GROUND
ECM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the ABS/RWAL Module harness connector.
Ignition on, engine not running.
Measure the voltage of the (G7) Vehicle Speed Signal circuit in the ABS/RWAL or
ECM harness connector.
Is the voltage above 4.9 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Repair the short to voltage in the (G7) Vehicle Speed Signal
circuit between the CAB and ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
2
Turn the ignition off.
Measure the resistance of the (G7) Vehicle Speed Signal circuit between the ECM
harness connector and the ABS/RWAL harness connector.
Is the resistance above 5.0 ohms?
Yes
→ Repair the open in the (G7) Vehicle Speed Signal circuit between
the CAB and ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the resistance between ground and the (G7) Vehicle Speed Signal circuit at
the ECM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G7) Vehicle Speed Signal circuit
between the CAB and ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
No
→ Go To
4
152
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0500-NO VEHICLE SPEED SENSOR SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
4
NOTE: Before continuing, check the ECM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Replace and program the ECM per Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
153
DRIVEABILITY - DIESEL
Symptom:
P0514-BAT TEMPERATURE SENSOR RATIONALITY
When Monitored and Set Condition:
P0514-BAT TEMPERATURE SENSOR RATIONALITY
When Monitored:
Set Condition:
While the engine is running.
The ECM does not read a change in value from the sensor over time.
POSSIBLE CAUSES
BATTERY TEMP SENSOR
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
Remove the temperature sensor and reconnect the wiring harness connector to the
sensor.
Monitor DRBIIIt, while heating the sensor with an external heat source (DO NOT
USE OPEN FLAME).
Does the reading from the sensor increase at least 5 degrees F. on the DRBIIIt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Replace the battery temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
154
DRIVEABILITY - DIESEL
Symptom:
P0516-LOW VOLTAGE AT THE BAT TEMP SENSOR
When Monitored and Set Condition:
P0516-LOW VOLTAGE AT THE BAT TEMP SENSOR
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
BATTERY TEMP SENSOR
SIGNAL CIRCUIT SHORTED TO GROUND
SIGNAL CIRCUIT SHORTED
5-VOLT SUPPLY SHORTED TO VOLTAGE
INTERMITTENT CONDITION
ECM
TEST
1
2
ACTION
Turn the ignition off.
Disconnect the Battery temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Battery temp sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the battery temp sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance between the engine ground and the temperature sensor
signal wire at the sensor connector.
Is the resistance more than 100 k ohms?
Yes
→ Go To
No
→ Repair the Battery temp sensor signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
155
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0516-LOW VOLTAGE AT THE BAT TEMP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the resistance between the Battery temp sensor signal circuit and all other
circuits in the ECM harness connector of the engine harness.
Is the resistance more than 100k ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
Yes
→ Go To
No
→ Repair the signal circuit shorted to another circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Reconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage between the supply circuit and the return circuit in the sensor
harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
5
No
→ Go To
6
Reconnect the disconnected Battery temp sensor harness connector.
While monitoring with DRBIIIt, disconnect the temperature sensor harness connector.
Did P0517 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Disconnect the ECM harness connectors.
Measure the voltage of the supply circuit of the sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Repair the 5-volt supply shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
156
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Symptom:
P0517-HIGH VOLTAGE AT THE BAT TEMP SENSOR
When Monitored and Set Condition:
P0517-HIGH VOLTAGE AT THE BAT TEMP SENSOR
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
BATTERY TEMP SENSOR
SIGNAL CIRCUIT OPEN
RETURN CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Disconnect the Battery temp sensor harness connector.
Check connector - Clean/repair as necessary.
Measure the resistance of the Battery temp sensor.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
No
→ Replace the Battery temp sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Reconnect the disconnected Battery temp sensor harness connector.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance between the temperature sensor signal and return circuits at
the ECM harness connector.
Is the resistance between 300 and 90k ohms?
Yes
→ Go To
5
No
→ Go To
3
Disconnect the Battery temp sensor harness connector.
Measure the resistance of the sensor signal circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
157
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
P0517-HIGH VOLTAGE AT THE BAT TEMP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance of the sensor return circuit between the sensor harness
connector and the ECM harness connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
Yes
→ Go To
No
→ Repair the open return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Check for a short circuit from signal circuit to all other circuits at the ECM harness
connector.
Is the resistance more than 100k ohms?
Yes
→ Go To
No
→ Repair the shorted signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Reconnect the ECM harness connectors.
While monitoring with DRBIIIt, use a jumper wire and connect the sensor signal
circuit to the sensor return circuit at the sensor harness connector.
Did P0516 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
158
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0521-OIL PRESSURE SWITCH RATIONALITY
When Monitored and Set Condition:
P0521-OIL PRESSURE SWITCH RATIONALITY
When Monitored:
Set Condition:
While the key is on.
Oil pressure is detected with engine RPM = 0 for 30 seconds.
POSSIBLE CAUSES
OIL PRESSURE SWITCH
SIGNAL CIRCUIT OPEN
INTERMITTENT CONDITION
ECM
TEST
1
2
ACTION
Turn the ignition off.
Disconnect the Oil pressure switch harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the oil pressure switch terminal and ground.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Replace the oil pressure switch.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the oil pressure switch signal circuit between the oil
pressure switch harness connector and the ECM harness connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Repair the open Oil pressure signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
159
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0521-OIL PRESSURE SWITCH RATIONALITY —
Continued
TEST
ACTION
APPLICABILITY
3
Reconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage between the oil pressure signal circuit at the oil pressure switch
harness connector and ground.
Is the voltage between 4.5 and 5.5 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
160
DRIVEABILITY - DIESEL
Symptom:
P0524-OIL PRESSURE TOO LOW
When Monitored and Set Condition:
P0524-OIL PRESSURTE TOO LOW
When Monitored:
Set Condition:
While the engine is running.
The oil pressure detected by the ECM is less than a calibrated value.
POSSIBLE CAUSES
LOW OIL LEVEL
SIGNAL CIRCUIT SHORT TO GROUND
OIL PRESSURE SWITCH
INTERNAL ENGINE DAMAGE
TEST
1
2
3
ACTION
Check the engine oil level.
Is the engine oil in the safe operating range?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Go To
No
→ Repair any condition that may cause the oil level to be above or
below the safe operating range.
2
With the DRBIIIt, erase DTCs.
Turn the ignition off.
Disconnect the oil pressure switch harness connector.
Turn the ignition on for 1 minute.
Did DTC P0521 set?
Yes
→ Go To
No
→ Repair the signal circuit shorted to ground.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the engine oil pressure with a mechanical gauge.
Is the oil pressure within the acceptable operating range?
Yes
→ Replace the oil pressure switch.
No
→ Repair internal engine damage
161
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Symptom:
P0532-A/C SENDING UNIT VOLTS TOO LOW
When Monitored and Set Condition:
P0532-A/C SENDING UNIT VOLTS TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a
certain period of time.
POSSIBLE CAUSES
OTHER DTC’S
A/C PRESSURE SENSOR
SIGNAL CIRCUIT SHORTED TO RETURN CIRCUIT
SUPPLY CIRCUIT SHORTED TO RETURN CIRCUIT
SIGNAL CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO A/C HARNESS CONNECTOR
SUPPLY CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO A/C HARNESS CONNECTOR
SIGNAL CIRCUIT SHORTED TO GROUND
SUPPLY CIRCUIT SHORTED TO GROUND
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read DTCs.
Are other DTC’s present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Disconnect the A/C pressure sending unit harness connector.
Check connectors -Clean/repair as necessary.
Measure the voltage between the supply and return circuits of the sensor harness
connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
162
ENGINE- 5.9L
CUMMINS 24V
DIESEL
P0532-A/C SENDING UNIT VOLTS TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
While monitoring DRBIIIt, use a jumper wire to connect the 5 volt supply circuit to
the signal circuit at the sensor harness connector.
Did P0533 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
8
Yes
→ Replace the A/C pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
Turn the ignition off.
Disconnect the ECM harness connectors.
Measure the resistance between the signal circuit and return circuit in the sensor
harness connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the Signal circuit shorted to the Return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the supply circuit and return circuit in the sensor
harness connector.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the Supply circuit shorted to the Return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the signal circuit between the sensor harness connector
and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance of the supply circuit between the sensor harness connector
and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Measure the resistance between the signal circuit in the sensor harness connector
and battery nevative.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Repair the Signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
9
163
ENGINE- 5.9L
CUMMINS 24V
DIESEL
P0532-A/C SENDING UNIT VOLTS TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the supply circuit in the sensor harness connector
and battery negative.
Is the resistance greater than 100K Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
10
Yes
→ Go To
No
→ Repair the Supply circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
10
Reconnect the ECM harness connectors.
Turn the ignition on.
While monitoring DRBIIIt, use a jumper wire to connect the 5 volt supply circuit
with the signal circuit at the sensor harness connector.
Did DTC P0533 set?
Yes
→ Test Complete.
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
164
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0533-A/C SENDING UNIT VOLTS TOO HIGH
When Monitored and Set Condition:
P0533-A/C SENDING UNIT VOLTS TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain
period of time.
POSSIBLE CAUSES
OTHER DTC’S
A/C PRESSURE SENSOR
5-VOLT SUPPLY SHORTED TO BATTERY NEGATIVE
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
RETURN CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO A/C HARNESS CONNECTOR
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
Turn the ignition on.
With the DRBIIIt, read DTCs.
Are other DTC’s present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Disconnect the A/C pressure sending unit harness connector.
Check connectors - Clean/repair as necessary.
Measure the voltage between the supply and return circuits of the sensor harness
connector.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
3
No
→ Go To
4
While monitoring DRBIIIt, use a jumper wire to connect the return circuit to the
signal circuit at the sensor harness connector.
Did P0532 set?
Yes
→ Replace the A/C pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
165
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0533-A/C SENDING UNIT VOLTS TOO HIGH —
TEST
4
5
6
7
Continued
ACTION
Turn the ignition off.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the voltage between the 5-volt circuit and battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair the 5-volt supply circuit shorted to the battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the voltage between the signal circuit and battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Repair the signal circuit shorted to the battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the return circuit between the sensor harness connector
and the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open return circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
Turn the ignition on.
While monitoring DRBIIIt, use a jumper wire to connect the return circuit with the
signal circuit at the sensor harness connector.
Did DTC P0532 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
166
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY
P2607-LOW VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0541-LOW VOLTAGE ON THE
#1 INTAKE AIR HEATER RELAY.
When Monitored and Set Condition:
P0541-Low Voltage On The #1 Intake Air Heater Relay
When Monitored:
When the ignition is on.
Set Condition: When the signal from the #1 intake air heater output does not match the
signal from the #1 intake air heater feedback.
P2607-LOW VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY
When Monitored:
When the ignition is on.
Set Condition: When the signal from the #2 intake air heater output does not match the
signal from the #2 intake air heater feedback.
POSSIBLE CAUSES
LOOSE CONNECTION
INTAKE AIR HEATER RELAY
SIGNAL CIRCUIT OPEN FROM RELAY TO ECM
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the #1 Intake Air Heater.
Can you hear the Relay clicking?
Yes
→ Go To
2
No
→ Go To
3
While the relay is clicking , wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Yes
→ Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
167
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Remove the Intake Air Heater #1 Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal and return posts of the intake air heater
relay.
Is the resistance between 15 and 25 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
Yes
→ Go To
No
→ Replace the Intake Air Heater #1 relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the intake air heater relay signal circuit between the ECM
connector and the intake air heater relay connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open signal circuit from PDC to ECM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the voltage between the signal circuit of the intake air heater relay and
battery negative.
Is the voltage greater than 1 volts?
Yes
→ Repair the signal circuit shorted to Battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Reconnect the ECM harness connectors.
Disconnect the intake air heater relay signal wire and use a jumper to connect it to
battery negative.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Did DTC P0542 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
168
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY
P2608-HIGH VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0542-HIGH VOLTAGE ON THE
#1 INTAKE AIR HEATER RELAY.
When Monitored and Set Condition:
P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY
When Monitored:
When the ignition is on.
Set Condition: When the signal from the #1 Intake Air Heater output does not match the
signal from the #1 Intake Air Heater feedback.
P2608-HIGH VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY
When Monitored:
When the ignition is on.
Set Condition: When the signal from the #2 Intake Air Heater output does not match the
signal from the #2 Intake Air Heater feedback.
POSSIBLE CAUSES
LOOSE CONNECTION
INTAKE AIR HEATER RELAY
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
INTERMITTENT CONDITION
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the Intake Air Heater relay.
Can you hear the Relay clicking?
Yes
→ Go To
2
No
→ Go To
3
While the relay is clicking , wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Yes
→ Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
169
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Remove the Intake Air Heater Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal and return posts of the intake air heater
relay.
Is the resistance between 15 and 25 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
Yes
→ Go To
No
→ Replace the Intake Air Heater relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance voltage between the signal circuit of the intake air heater
relay and battery negative.
Is the resistance greater than 100k ohms?
No
→ Repair signal circuit shorted to battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Yes
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connectors.
Turn the ignition on.
Disconnect the intake air heater relay signal wire and use a jumper to connect it to
battery negative.
Did DTC P0541 or P2607 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
170
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0562-BATTERY VOLTAGE LOW
When Monitored and Set Condition:
P0562-BATTERY VOLTAGE LOW
When Monitored:
Set Condition:
With the key on or the engine running.
The battery voltage detected by the ECM is less than a calibrated value.
POSSIBLE CAUSES
P0622 PRESENT
P2502 PRESENT
P2503 PRESENT
BATTERY TERMINAL CONNECTIONS
ACCESSORY WIRING
BATTERY
HIGH RESISTANCE IN WIRE HARNESS
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
With the DRBIIIt, read DTCs.
Is P0622 set?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P0622 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
With the DRBIIIt, read DTCs.
Is P2502 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P2502 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
With the DRBIIIt, read DTCs.
Is P2503 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P2503 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
171
DRIVEABILITY - DIESEL
P0562-BATTERY VOLTAGE LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Visually inspect the positive and negative connections at the batteries and inspect
the battery negative connections at the engine block.
Are the connections free of corrosion and are they tight?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
7
8
Yes
→ Go To
No
→ Repair the poor connections.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Check for add-on or accessory wiring at positive (+) terminal of the battery
Are there any damaged wires at the battery?
Yes
→ Repair accessory wiring.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Perform battery load test using the Midtronics Micro 420 battery system tester.
Did the battery(s) pass the test?
Yes
→ Go To
No
→ Replace the weak battery or batteries.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the battery terminals.
Measure the resistance from the positive and negative battery posts to the appropriate circuits in the ECM harness connector
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the high resistance in the wire harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Reconnect the battery terminals.
Measure and record the voltage between battery positive pins of the ECM connector
and the battery negative circuits of the ECM harness connector.
Reconnect the ECM harness connectors.
Use the DRBIIIt to measure and record battery voltage.
Are the readings within 3 volts of each other?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
172
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0563-BATTERY VOLTAGE HIGH
When Monitored and Set Condition:
P0563-BATTERY VOLTAGE HIGH
When Monitored:
Set Condition:
value.
With the key on or the engine running.
The battery voltage detected by the ECM is greater than a calibrated
POSSIBLE CAUSES
P0622 PRESENT
P2502 PRESENT
P2504 PRESENT
BATTERIES IMPROPERLY INSTALLED
ECM
INTERMITTENT CONDITION
TEST
1
2
3
ACTION
With the DRBIIIt, read DTCs.
Is P0622 set?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P0622 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
With the DRBIIIt, read DTCs.
Is P2502 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P2502 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
With the DRBIIIt, read DTCs.
Is P2504 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair P2504 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
173
DRIVEABILITY - DIESEL
P0563-BATTERY VOLTAGE HIGH —
Continued
TEST
ACTION
APPLICABILITY
4
Disconnect the ECM harness connectors.
Measure the battery voltage between the positive circuits and ground of the ECM
harness connector.
Is the voltage less than 19 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Yes
→ Go To
No
→ Install the battery system correctly.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Reconnect the battery terminals.
Measure and record the voltage between battery positive pins of the ECM connector
and the battery negative circuits of the ECM harness connector.
Reconnect the ECM harness connectors.
Use the DRBIIIt to measure and record battery voltage.
Are the readings within 3 volts of each other?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
174
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0572-LOW VOLTAGE DETECTED AT THE BRAKE SWITCH
When Monitored and Set Condition:
P0572-LOW VOLTAGE DETECTED AT THE BRAKE SWITCH
When Monitored:
While the ignition is on.
Set Condition:
POSSIBLE CAUSES
BRAKE SWITCH INPUT SHORTED TO GROUND
Repair Instructions:
BRAKE SWITCH INPUT SHORTED TO GROUND
Repair Brake switch circuit shorted to ground.
175
DRIVEABILITY - DIESEL
Symptom:
P0573-HIGH VOLTAGE DETECTED AT THE BRAKE SWITCH
When Monitored and Set Condition:
P0573-HIGH VOLTAGE DETECTED AT THE BRAKE SWITCH
When Monitored:
While the ignition is on.
Set Condition:
POSSIBLE CAUSES
BRAKE SWITCH SHORTED TO VOLTAGE
Repair Instructions:
BRAKE SWITCH SHORTED TO VOLTAGE
Repair Brake switch shorted to voltage.
176
DRIVEABILITY - DIESEL
Symptom:
P0580-LOW VOLTAGE DETECTED AT THE CRUISE CONTROL
SWITCH
When Monitored and Set Condition:
P0580-LOW VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH
When Monitored:
Set Condition:
While the ignition is on
Cruise control MUX switch below 1.0 volts for 5 seconds.
POSSIBLE CAUSES
S/C WIRING HARNESS OBSERVABLE PROBLEM
S/C SWITCH (ON/OFF)
CLOCKSPRING SHORTED TO GROUND
S/C SWITCH (RESUME/ACCEL)
S/C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND
S/C SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
ECM
TEST
1
2
3
ACTION
Turn the ignition on.
With the DRBIIIt, read the S/C Switch volts status in the ECM.
Is the S/C Switch voltage below 1.0 volt?
Yes
→ Go To
3
No
→ Go To
2
Turn the ignition off.
Using the Schematics as a guide, inspect the Wiring and Connectors.
Were any problems found?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Turn the ignition off.
Disconnect the S/C ON/OFF Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Turn the ignition on.
With the DRBIIIt in Sensors, read the S/C Switch volts in the ECM.
Did the S/C Switch volts change to 5.0 volts?
Yes
→ Replace the S/C ON/OFF Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
4
177
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0580-LOW VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH
— Continued
TEST
4
5
6
7
ACTION
Turn the ignition off.
Disconnect the S/C RESUME/ACCEL Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
With the DRBIIIt in Sensors, read the S/C Switch volts in the ECM.
Did the S/C Switch volts go above 4.0 volts?
Yes
→ Replace the Resume/Accel Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition off.
Disconnect the clockspring 6-way harness connector (instrument panel wiring side).
Turn the ignition on.
With the DRBIIIt in Sensors, read the S/C Switch volts in the ECM.
Did the S/C Switch volts change to 5.0 volts?
Yes
→ Replace the Clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Turn the ignition off.
Disconnect the S/C ON/OFF Switch harness connector.
Disconnect the ECM harness connectors.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between the S/C Switch Signal circuit and ground (B-) at S/C
ON/OFF Switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair S/C Switch Signal Circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the S/C Signal Circuit and the Sensor Ground
Circuit at the ON/OFF switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair S/C Signal Circuit shorted to Sensor Ground.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
178
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0581-HIGH VOLTAGE DETECTED AT THE CRUISE CONTROL
SWITCH
When Monitored and Set Condition:
P0581-HIGH VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH
When Monitored:
Set Condition:
Key on or Engine running.
Cruise control MUX switch above 11.5 volts for 5 seconds.
POSSIBLE CAUSES
S/C WIRING HARNESS OBSERVABLE PROBLEM
CLOCKSPRING SIGNAL/GROUND CIRCUIT OPEN
SPEED CONTROL ON/OFF SWITCH
SPEED CONTROL SWITCH SIGNAL CKT SHORTED TO VOLTAGE
SPEED CONTROL SW SIG CKT OPEN ECM TO CLOCK SPRING
SPEED CONTROL SW SIG CKT OPEN CLOCKSPRING TO S/C SWITCH
SPEED CONTROL SWITCH GROUND CIRCUIT OPEN CLOCKSPRING TO S/C SWITCH
SPEED CONTROL SWITCH GROUND CIRCUIT OPEN ECM TO CLOCKSPRING
ECM
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRBIIIt in Inputs/Outputs, read the Speed Control inputs state in ECM.
While monitoring the DRBIIIt, push the Speed Control On/Off Switch several times,
then leave it on.
Did the DRBIIIt show Speed Control Switch off and on?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Go To
No
→ Test Complete.
2
Turn the ignition off.
Using the Schematics as a guide, inspect the Wiring and Connectors.
Were any problems found?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
3
179
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0581-HIGH VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH
— Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the upper and lower 6-way clockspring harness connectors.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the sensor ground circuit between the upper and lower
6-way clockspring harness connectors.
Measure the resistance of the speed control switch signal circuit between the upper
and lower 6-way clockspring harness connectors.
Was the resistance above 5.0 ohms for either circuit?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Replace the clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
4
Disconnect the Speed Control On/Off Switch 2-way harness connector only.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance across the S/C On/Off Switch.
Is the resistance between 20.3K and 20.7K ohms?
Yes
→ Go To
No
→ Replace the On/Off Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition on.
Measure the voltage of the S/C Switch Signal Circuit at the On/Off Switch 2-way
connector.
Is the voltage above 6.0 volts?
Yes
→ Repair the Speed Control Switch Signal Circuit for a short to
voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Turn the ignition off.
Disconnect the ECM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the S/C Switch Signal Circuit between the ECM connector
and the Clockspring Connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair open Speed Control Switch Signal Circuit ECM to Clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance of the S/C Switch Signal Circuit from the clockspring harness
connector to the On/Off switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open Speed Control Switch Signal Circuit Clockspring
to S/C switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
8
180
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0581-HIGH VOLTAGE DETECTED AT THE CRUISE CONTROL SWITCH
— Continued
TEST
ACTION
APPLICABILITY
8
Measure the resistance of the S/C Switch Sensor Ground Circuit between the On/Off
Switch 2-way harness connector to the clockspring harness connector.
Is the resistance below 5.0 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
9
Yes
→ Go To
No
→ Repair open ground circuit from clockspring to S/C switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
9
Measure the resistance of the S/C Switch Sensor Ground Circuit between the ECM
harness connector to the clockspring harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
No
→ Repair open ground circuit from ECM to clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
181
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0602-CHECKSUM ERROR
When Monitored and Set Condition:
P0602-CHECKSUM ERROR
When Monitored:
Set Condition:
While the ignition is on.
A deviation between the ECM memory and a stored calibration.
POSSIBLE CAUSES
FLASH ECM
ECM
TEST
ACTION
APPLICABILITY
1
Using the DRBIIIt, reflash the ECM with the proper calibration for the particular
truck.
Is the flash successful?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Repair complete.
No
→ Go To
2
With the DRBIIIt, read DTCs.
Did P0602 set after the reflash?
Yes
→ Replace the ECM.
No
→ Test Complete.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
182
DRIVEABILITY - DIESEL
Symptom:
P0604-ECM SOFTWARE ERROR
When Monitored and Set Condition:
P0604-ECM SOFTWARE ERROR
When Monitored:
Set Condition:
While the key is on.
Internal ECM software error.
POSSIBLE CAUSES
REFLASH ECM
ECM
TEST
1
2
ACTION
Using the DRBIIIt, reflash the module with latest calibration
Was the flash successful?
Yes
→ Go To
No
→ Replace the ECM.
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Run the engine for one minute and shut off.
With the DRBIIIt, read DTCs.
Did P0604 set?
Yes
→ Replace the ECM.
No
→ Test Complete.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
183
DRIVEABILITY - DIESEL
Symptom:
P0606-ECM HARDWARE ERROR
When Monitored and Set Condition:
P0606-ECM HARDWARE ERROR
When Monitored:
Set Condition:
With the key on or engine running.
ECM had detected internal failures.
POSSIBLE CAUSES
ECM
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: This DTC is caused by an internal Engine Control Module failure.
Repairs are not possible to the ECM.
With the DRBIIIt, erase DTCs.
Is the DTC still set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Test Complete.
184
DRIVEABILITY - DIESEL
Symptom:
P0607-ECM INTERNAL FAILURE
When Monitored and Set Condition:
P0607-ECM INTERNAL FAILURE
When Monitored:
Set Condition:
With the key on or engine running.
ECM had detected internal failures.
POSSIBLE CAUSES
ECM
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
NOTE: This DTC is caused by an internal Engine Control Module failure.
Repairs are not possible to the ECM.
Is the DTC P0606 set?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Replace and program the ECM in accordance with the Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Test Complete.
185
DRIVEABILITY - DIESEL
Symptom:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored:
Set Condition:
regulator.
When the ignition is on.
The feedback signal does not match the commanded signal for the voltage
POSSIBLE CAUSES
GENERATOR
OPEN DRIVER CIRCUIT
GEN SOURCE SHORTED TO BATTERY NEGATIVE
FIELD DRIVER CIRCUIT SHORTED TO VOLTAGE
GEN SOURCE OPEN
ECM
TEST
1
2
3
ACTION
Turn the ignition off.
Disconnect the Generator field harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the generator field terminals.
Is the resistance between .5 and 15 Ohms?
Yes
→ Go To
No
→ Replace the Generator.
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the generator driver wire between the generator harness
connector and the ECM harness connector.
Is the resistance less than 10 ohms.
Yes
→ Go To
No
→ Repair the open driver circuit.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the resistance of the generator source circuit between the generator harness
connector and battery negative.
Is the resistance less than 10 ohms.
Yes
→ Repair the Gen source shorted to Battery negative.
No
→ Go To
4
186
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the voltage between the generator field driver circuit in the generator
harness connector and battery negative.
Is the voltage greater than 1 volt?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Yes
→ Repair the Generator field driver circuit shorted to voltage.
No
→ Go To
5
Measure voltage of the Gen source circuit at the generator harness connector.
Is voltage within one volt of battery voltage?
Yes
→ Replace the ECM.
No
→ Repair the open or high resistance of Gen source circuit.
187
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0628-LOW VOLTAGE DETECTED AT THE FUEL LIFT PUMP
When Monitored and Set Condition:
P0628-LOW VOLTAGE DETECTED AT THE FUEL LIFT PUMP
When Monitored:
While the key is on.
Set Condition: The voltage detected on the Fuel Lift Pump is above a calibrated value for
a calibrated amount on time.
POSSIBLE CAUSES
LOOSE CONNECTION
LIFT PUMP SHORTED TO VOLTAGE
RETURN CIRCUIT OPEN
LIFT PUMP
ECM
TEST
1
2
3
ACTION
With the DRBIIIt, in system test actuate the lift pump.
Does the lift pump run?
Yes
→ Go To
No
→ Test Complete.
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Lift pump actuation still running.
While the lift pump is running, wiggle the wiring harness and connectors throughout
the circuit.
Does this interrupt the pump operation?
Yes
→ Repair the loose connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Disconnect the ECM harness connectors.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance of the lift pump supply circuit between the ECM harness
connector and the lift pump harness connector.
Is the resistance less than 1 Ohms?
Yes
→ Go To
No
→ Test Complete.
4
188
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0628-LOW VOLTAGE DETECTED AT THE FUEL LIFT PUMP — Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance of the return circuit between the lift pump connector and
battery negative.
Is the resistance less than 1 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
6
Yes
→ Go To
No
→ Repair the open circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
5
Measure the voltage between the supply and return circuits of the lift pump
connector.
Is the voltage greater than 1 volt?
Yes
→ Repair the lift pump circuits shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Reconnect the ECM harness connectors.
Connect a jumper wire between the supply and return circuits of the lift pump
harness connector.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Did DTC P0628 set?
Yes
→ Replace the lift pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
189
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0629-HIGH VOLTAGE DETECTED AT THE FUEL LIFT PUMP
When Monitored and Set Condition:
P0629-HIGH VOLTAGE DETECTED AT THE FUEL LIFT PUMP
When Monitored:
While the key is on.
Set Condition: The commanded signal to the lift pump does not match the feedback
signal from the lift pump.
POSSIBLE CAUSES
LOOSE CONNECTION
SUPPLY CIRCUIT SHORTED TO VOLTAGE
SUPPLY CIRCUIT SHORTED
LIFT PUMP
ECM
TEST
1
2
3
4
ACTION
With the DRBIIIt, in system test actuate the lift pump.
Does the lift pump run?
Yes
→ Go To
No
→ Test Complete.
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Lift pump actuation still running.
While the lift pump is running, wiggle the wiring harness and connectors throughout
the circuit.
Does this interrupt the pump operation?
Yes
→ Repair the loose connection.
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Disconnect the ECM harness connectors.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between the lift pump supply circuit of the lift pump
connector and battery negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the supply circuit shorted to voltage.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
Measure the resistance between the lift pump supply circuit and all other circuits in
the ECM harness connectors.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the supply circuit shorted to another circuit.
5
190
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0629-HIGH VOLTAGE DETECTED AT THE FUEL LIFT PUMP — Continued
TEST
5
ACTION
Reconnect the disconnected Lift pump harness connector.
Reconnect the ECM harness connectors.
Turn the ignition on.
With the DRBIIIt, read DTCs while disconnecting the lift pump.
Did P0628 set?
Yes
→ Replace the lift pump.
No
→ Replace the ECM
191
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0630-VIN NOT ENTERED ERROR
When Monitored and Set Condition:
P0630-VIN NOT ENTERED ERROR
When Monitored:
Set Condition:
While the key is on.
The VIN was not calibrated into the ECM.
POSSIBLE CAUSES
VIN NOT CALIBRATED INTO ECM
TEST
1
ACTION
Using the DRBIIIt, recalibrate the ECM with the proper VIN.
Did the DTC P0630 reset?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Test Complete.
192
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0633-SKIM SECRET KEY NOT ENTERED
When Monitored and Set Condition:
P0633-SKIM SECRET KEY NOT ENTERED
When Monitored:
Set Condition:
While the key is on.
The SKIM secret key was not calibrated into the ECM.
POSSIBLE CAUSES
IMPROPER IGNITION KEY IS BEING USED
SKIM DTC’S
SKIM NOT CALIBRATED PROPERLY
TEST
1
2
3
ACTION
With the DRBIIIt, read SKIM DTCs.
Are any SKIM DTC’s present?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair all SKIM DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Verify that the proper ignition key is in the ignition lock on the steering column.
Are the proper keys being used?
Yes
→ Go To
No
→ Use the proper key for the vehicle.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Using the DRBIIIt, recalibrate the ECM with the proper SKIM secret key.
With the DRBIIIt, erase DTCs.
Cycle the ignition switch from on to off to on.
With the DRBIIIt, read DTCs.
Did the DTC reset?
Yes
→ Test Complete.
No
→ Verify information is correct and replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
193
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0642-LOW VOLTAGE AT THE #2 SENSOR SUPPLY CIRCUIT
When Monitored and Set Condition:
P0642-LOW VOLTAGE AT THE #2 SENSOR SUPPLY CIRCUIT
When Monitored:
Set Condition:
value.
With the key on.
Voltage detected on the #2 sensor supply circuit is below a calibrated
POSSIBLE CAUSES
FAN CLUTCH ASSEMBLY
5-VOLT SHORTED TO GROUND
5-VOLT SUPPLY SHORTED TO ANOTHER CIRCUIT
FAN DTC
INTERMITTENT CONDITION
ECM
TEST
1
2
ACTION
Disconnect the Fan clutch harness connector.
NOTE: Check connectors - Clean/repair as necessary.
With the DRBIIIt, read DTCs.
Did P0483 set?
Yes
→ Replace the Fan clutch assembly.
Perform POWERTRAIN VERIFICATION TEST VER 1 - (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Turn the ignition off.
Disconnect the ECM harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between the #2 5-volt supply (fan speed sensor power) circuit
in the sensor harness connector and battery negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the #2 5-volt supply shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
194
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0642-LOW VOLTAGE AT THE #2 SENSOR SUPPLY CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the resistance between the #2 sensor 5-volt supply (fan speed sensor power)
circuit in the ECM harness connector to all other circuits in the ECM harness
connectors.
Is the resistance greater than 100k Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
Yes
→ Go To
No
→ Repair the 5-volt supply shorted to another circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Reconnect the ECM harness connectors.
Reconnect the disconnected Fan harness connector.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Is DTC P0483 set?
Yes
→ Repair the Fan DTC.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition off.
Disconnect the Fan harness connector.
Turn the ignition on.
Measure the voltage between the #2 sensor 5-volt supply (fan speed sensor power)
circuit at the fan clutch harness connector and the fan speed sensor ground.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
195
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0646-LOW VOLTAGE DETECTED AT THE A/C CLUTCH RELAY
When Monitored and Set Condition:
P0646-LOW VOLTAGE DETECTED AT THE A/C CLUTCH RELAY
When Monitored:
When the ignition is on.
Set Condition: When the signal from the A/C Clutch output does not match the signal
from the A/C Clutch feedback.
POSSIBLE CAUSES
A/C CLUTCH RELAY
LOOSE CONNECTION
FUSED BATTERY SUPPLY
A/C SIGNAL CIRCUIT OPEN
A/C SIGNAL CIRCUIT SHORTED TO GROUND
INTERMITTENT CONDITION
ECM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the A/C clutch relay.
Can you hear the Relay clicking?
Yes
→ Go To
2
No
→ Go To
3
Actuation still running.
While the relay is clicking, wiggle the wiring harness and connectors throughout the
circuit.
Does this interrupt the clicking?
Yes
→ Repair the loose connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Remove the A/C Clutch Relay from the PDC.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between terminals 85 and 86 of the A/C Clutch Relay.
Is the resistance less than 100 Ohms?
Yes
→ Go To
No
→ Replace the A/C clutch relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
196
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0646-LOW VOLTAGE DETECTED AT THE A/C CLUTCH RELAY —
Continued
TEST
4
5
6
7
ACTION
Ignition on, engine not running.
Measure the voltage on the Fused Battery Supply circuit in the PDC.
Is the voltage within 1 volt of battery voltage?
Yes
→ Go To
No
→ Repair the open Fused battery supply.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Turn the ignition off.
Disconnect the ECM harness connectors.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance of the A/C Clutch signal circuit between the PDC and the
ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open A/C signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance of the A/C Clutch signal circuit between the PDC and battery
negative.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the A/C signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Reconnect the ECM harness connectors.
While monitoring with the DRBIIIt, use a jumper wire to connect 12 volts to the
relay signal cavity (86) in the PDC with the relay disconnected.
Did DTC P0647 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
197
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0647-HIGH VOLTAGE DETECTED AT THE A/C CLUTCH RELAY
When Monitored and Set Condition:
P0647-HIGH VOLTAGE DETECTED AT THE A/C CLUTCH RELAY
When Monitored:
When the ignition is on.
Set Condition: When the signal from the A/C Clutch output does not match the signal
from the A/C Clutch feedback.
POSSIBLE CAUSES
LOOSE CONNECTION
FUSED BATTERY SUPPLY
A/C CLUTCH RELAY
INTERMITTENT CONDITION
ECM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the A/C clutch relay.
Can you hear the Relay clicking?
Yes
→ Go To
2
No
→ Go To
3
Actuation still running.
While the relay is clicking, wiggle the wiring harness and connectors throughout the
circuit.
Does this interrupt the clicking?
Yes
→ Repair the loose connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Ignition on, engine not running.
Measure the voltage on the Fused Battery Supply circuit in the PDC.
Is the voltage within 1 volt of battery voltage?
Yes
→ Go To
No
→ Repair the open Fused battery supply.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
198
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P0647-HIGH VOLTAGE DETECTED AT THE A/C CLUTCH RELAY —
Continued
TEST
4
5
ACTION
Remove the A/C Clutch Relay from the PDC.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between terminals 85 and 86 of the A/C Clutch Relay.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Replace the A/C clutch relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Reconnect the ECM harness connectors.
Reinstall the A/C clutch relay.
With the DRBIIIt, actuate the A/C clutch relay.
Turn the ignition on.
While monitoring with the DRBIIIt, disconnect the A/C Clutch Relay from the PDC.
Did DTC P0646 set?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
199
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0652-LOW VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT
When Monitored and Set Condition:
P0652-LOW VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT
When Monitored:
Set Condition:
With the key on.
Voltage detected on the sensor supply is below a calibrated value.
POSSIBLE CAUSES
#1 5-VOLT SUPPLY SHORTED
ECM
#1 5-VOLT SUPPLY SHORTED TO GROUND
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM 60 pin harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the Sensor #1 5-volt Supply and the Sensor #1 Return
pin at the ECM.
Is the voltage between 4.5 and 5.5 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
2
Disconnect the Pressure sensors harness connectors and the engine position sensor.
Measure the resistance between the #1 sensor supply circuits at the ECM harness
connector and battery negative.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Repair the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Measure the resistance between the #1 sensor supply circuit of the ECM harness
connector and all other circuits in both ECM harness connectors.
Is the resistance greater than 100K Ohms?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair the shorted circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
200
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0653-HIGH VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT
When Monitored and Set Condition:
P0653-HIGH VOLTAGE AT THE #1 SENSOR SUPPLY CIRCUIT
When Monitored:
Set Condition:
While the engine is running.
Voltage detected on the sensor supply is above a calibrated value.
POSSIBLE CAUSES
ECM
5-VOLT SUPPLY SHORTED TO VOLTAGE
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM 60 way harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the Sensor #1 5-volt Supply and the Sensor #1 Return
pin at the ECM.
Is the voltage between 4.5 and 5.5 volts?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Go To
No
→ Replace the ECM.
2
Disconnect the ECM 50 way harness connector.
Disconnect the sensor connectors for each pressure sensor, and the engine position
sensor.
Measure the voltage between the supply circuit at each pressure sensor harness
connector and battery negative.
Measure voltage between the supply circuit at the engine position sensor harness
connector and battery negative.
Is the voltage less than 1 volt?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
No
→ Repair the 5-volt supply shorted to voltage.
201
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0698-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO LOW
When Monitored and Set Condition:
P0698-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO LOW
When Monitored:
With engine running.
Set Condition: Low voltage detected at the APPS supply circuit or low voltage detected at
the PPS 1 supply.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS.
SENSOR SUPPLY SHORTED TO APPS RETURN, PPS RETURN, SENSOR #1 RETURN, OR BATTERY NEGATIVE
FAILED SENSOR
FAILED ECM
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensors, depending on transmission configuration and build date.
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 10
2
3
Visually inspect the sensor harness for damage.
Do you see any damage?
Yes
→ Fix or replace the sensor harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
3
Measure the voltage between the supply pin at the sensor connector and battery
negative.
Is voltage between 4.5 and 5.5 volts?
Yes
→ Go To
4
No
→ Go To
5
202
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P0698-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE
TOO LOW — Continued
TEST
ACTION
APPLICABILITY
4
Using the DRBIIIt, monitor the DTC while connecting a jumper wire between the
supply pin in the sensor connector and battery voltage.
Did the DTC for APPS high voltage set?
ENGINE- 5.9L
DIESEL
5
6
7
8
9
Yes
→ Replace the APPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
5
Disconnect the APPS.
Measure the resistance between the supply pin of the sensor and the APPS return pin
of the sensor.
Is the resistance between 2000 and 3000 Ohms, depressed as well as released?
Yes
→ Go To
No
→ Replace the APPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Disconnect the sensor harness from the ECM.
Inspect for any damaged wires or pins.
Are any wires or pins damaged?
Yes
→ Fix or replace the sensor harness or the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
7
Disconnect the ECM connector.
Measure the resistance between the supply pin in the sensor connector and the APPS
return pin in the sensor connector.
Measure the resistance between the supply pin in the sensor connector and battery
negative.
Measure the resistance between the supply pin in the sensor connector and the
sensor #1 return pin in the sensor connector.
Is the resistance less than 10 Ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
8
Connect the ECM connector.
Using the DRBIIIt, monitor the DTC while connecting a jumper wire between the
supply pin in the sensor connector and battery voltage.
Did the DTC for APPS high voltage set?
Yes
→ Go To
No
→ Replace the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE - 5.9L
DIESEL
9
Using the DRB, clear the DTC.
ENGINE- 5.9L
DIESEL
Repair complete
203
DRIVEABILITY - DIESEL
P0698-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE
TOO LOW — Continued
TEST
10
11
12
13
14
15
ACTION
Verify that the PPS is connected. Inspect the harness and the PPS connector.
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
DIESEL
11
Disconnect the ECM connectors. Inspect for any damaged wires or pins.
Are any wires or pins damaged?
Yes
→ Fix or replace the sensor harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
12
Disconnect the sensor connector.
Measure the resistance of the PPS 1 supply circuit between the sensor connector and
battery negative.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
13
Measure the resistance between the PPS 1 supply pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
14
Connect the ECM connector.
While monitoring with the DRBIIIt, connect a jumper wire between the PPS 1 signal
pin at the sensor connector and the PPS 1 supply pin at the sensor connector.
NOTE: With the sensor disconnected it is normal to have a PPS 1 and PPS
2 low voltage DTC set.
Did a PPS 1 voltage too high DTC set?
Yes
→ Go To
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
15
Connect the sensor connector.
Monitor the PPS 1 and PPS 2 voltage with the DRBIIIt while depressing the throttle
pedal.
Is the voltage transition shown on the DRBIIIt smooth while depressing the throttle
and is the voltage from PPS 1 twice as much as the voltage from PPS2?
Yes
→ Repair complete.
No
→ Replace the PPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
204
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0699-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0699-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE TOO
HIGH
When Monitored:
While engine is running.
Set Condition: High voltage detected at the APPS supply circuit or high voltage detected
at the PPS 1 supply circuit.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS
FAILED APPS
FAILED PPS
SENSOR SUPPLY SHORTED TO 12 VOLTS
FAILED ECM
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensors, depending on transmission configuration and build date.
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 8
2
3
Visually inspect the sensor harness for damage.
Do you see any damage?
Yes
→ Fix or replace the sensor harness
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
3
Measure the voltage between the supply pin at the sensor connector and battery
negative.
Is voltage between 4.5 and 5.5 volts?
Yes
→ Replace the APPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
205
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P0699-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE
TOO HIGH — Continued
TEST
ACTION
APPLICABILITY
4
Disconnect the sensor harness from the ECM. Inspect for any damaged wires or pins.
Are any wires or pins damaged?
ENGINE- 5.9L
DIESEL
5
6
7
Yes
→ Fix or replace the sensor harness or the ECM..
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
5
Disconnect the sensor connector.
Measure the voltage between the supply pin in the sensor connector and battery
negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Fix or replace the harness
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Connect the ECM connector.
Measure the voltage between the supply pin at the sensor connector and battery
negative.
Is voltage greater than 6 volts?
Yes
→ Replace the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
7
Using the DRBIIIt, clear the DTC.
ENGINE- 5.9L
DIESEL
Repair complete
8
9
Verify that the PPS is connected. Inspect the harness and the PPS connector.
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
9
Disconnect the sensor connector.
Measure the voltage between the PPS 1 supply pin at the sensor connector and
battery negative.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Replace the PPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
10
206
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P0699-ACCELERATOR POSITION SENSOR (APP) SUPPLY VOLTAGE
TOO HIGH — Continued
TEST
10
11
12
ACTION
Disconnect the ECM connectors. Inspect for any damaged wires or pins.
Are any wires or pins damaged?
Yes
→ Fix or replace the sensor harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
DIESEL
11
Disconnect the ECM connectors and the sensor connector.
Measure the voltage between the PPS 1 supply pin in the sensor connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
12
Connect the ECM connectors.
Using a Voltmeter, measure the voltage between the PPS 1 supply pin at the sensor
connector and battery negative.
Is the voltage greater than 6 volts?
Yes
→ Replace the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
207
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P0700-TRANSMISSION MESSAGE
POSSIBLE CAUSES
TRANSMISSION RELATED DTC IN JTEC
Repair Instructions:
TRANSMISSION RELATED DTC IN JTEC
Repair the Transmission related DTC in JTEC PCM.
Perform TRANSMISSION VERIFICATION TEST VER - 1.
208
DRIVEABILITY - DIESEL
Symptom:
P1652-J1850 SHORT TO GROUND
When Monitored and Set Condition:
P1652-J1850 SHORT TO GROUND
When Monitored:
Set Condition:
While the ignition is on.
The ECM detects a short to ground on the J1850.
POSSIBLE CAUSES
ECM
J1850 SHORTED
COMMUNICATION
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM harness connectors.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between the J1850 circuit in the ECM harness connector and
battery negative.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Yes
→ Go To
No
→ Replace the ECM.
2
Measure the resistance between the J1850 circuit and all other circuits in both ECM
connectors.
Is the resistance greater than 100k ohms?
Yes
→ Refer to the Body Diagnostic book Communications section.
No
→ Repair J1850 shorted to another circuit.
209
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2121-APP VOLTS DO NOT AGREE WITH IDLE VALIDATION SIGNAL
When Monitored and Set Condition:
P2121-APP VOLTS DO NOT AGREE WITH IDLE VALIDATION SIGNAL
When Monitored:
While the engine is running.
Set Condition: IVS indicates idle while APPS signal voltage indicates not at idle condition
or IVS indicates not at idle while APPS signal voltage indicates idle condition. Or, the ECM
detected a conformance error between PPS 1 and PPS 2.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTOR
FAILED APPS
RATIOMETRIC CIRCUIT SHORTED TO NOT IDLE CIRCUIT
SUPPLY SHORTED TO 12 VOLTS
FAILED ECM
OTHER DTC’s
FAILED PPS
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensors, depending on transmission configuration and build date.
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 11
2
3
Using the DRBIIIt, check for any additional accelerator sensor fault codes.
Do you have any additional accelerator sensor fault codes?
Yes
→ Troubleshoot other DTC’s first
Go To 3
No
→ Go To
ENGINE- 5.9L
DIESEL
3
Verify that the APPS is connected.
Inspect the harness and the APPS connector.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
210
DRIVEABILITY - DIESEL
P2121-APP VOLTS DO NOT AGREE WITH IDLE VALIDATION SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the ratiometric pin of the sensor and the not idle pin
of the sensor.
Is the resistance less than 10 ohms?
ENGINE- 5.9L
DIESEL
5
6
7
8
9
Yes
→ Replace the sensor
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
5
Disconnect the ECM connector.
Inspect the connector for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
6
Disconnect the ECM connector and the sensor connector.
Measure the voltage between the supply pin of the sensor connector and battery
negative.
Is the voltage greater than 1 volt?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
7
Measure the resistance between the ratiometric pin of the sensor connector and not
idle pin of the sensor connector.
Is the resistance less than 10 ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
8
Connect the ECM connector.
Measure the resistance between the ratiometric pin of the sensor connector and not
idle pin of the sensor connector.
Is the resistance less than 10 ohms?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
9
Measure the voltage of the supply pin at the sensor connector and battery negative.
Is the voltage greater than 5.5 volts?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
10
211
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2121-APP VOLTS DO NOT AGREE WITH IDLE VALIDATION SIGNAL —
Continued
TEST
10
ACTION
Using DRBIIIt, clear DTC.
APPLICABILITY
ENGINE- 5.9L
DIESEL
Repair complete.
11
12
13
Using the DRBIIIt, check for any additional PPS fault codes.
Do you have any additional PPS faults?
Yes
→ Troubleshoot other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER 1 (DIESEL).
Go To 12
No
→ Go To
ENGINE- 5.9L
DIESEL
12
Verify that the PPS is connected.
Inspect the harness and the PPS connector.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
13
Connect the sensor connector.
Monitor the PPS 1 and PPS 2 voltage with the DRBIIIt while depressing the throttle
pedal.
Is the voltage transition shown on the DRB smooth while depressing the throttle and
is the voltage from PPS 1 twice as much as the voltage from PPS 2?
Yes
→ Repair complete.
No
→ Replace the PPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
212
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2122-LOW VOLTAGE AT THE APP SENSOR
When Monitored and Set Condition:
P2122-LOW VOLTAGE AT THE APP SENSOR
When Monitored:
While the key is on and during engine operation.
Set Condition: The APPS circuit voltage at the ECM goes below 0.13 volt for more than
2 seconds. Or, the voltage detected at the PPS 1 circuit was below a calibrated value.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS
FAILED APPS
OPEN CIRCUIT ON THE RATIOMETRIC WIRE
OPEN CIRCUIT ON THE SUPPLY WIRE
RATIOMETRIC CIRCUIT SHORTED TO APPS RETURN, BATTERY NEGATIVE, OR SENSOR 1 RETURN
RATIOMETRIC CIRCUIT SHORTED TO IDLE SWITCH CIRCUIT
RATIOMETRIC CIRCUIT SHORTED TO NOT IDLE SWITCH CIRCUIT
SUPPLY CIRCUIT SHORTED TO APPS RETURN, BATTERY NEGATIVE, OR SENSOR 1 RETURN
FAILED ECM
FAILED PPS
OPEN PPS 1 SIGNAL CIRCUIT
OPEN PPS 1 SUPPLY CIRCUIT
PPS 1 SIGNAL CIRCUIT SHORTED TO GROUND OR RETURN
PPS 1 SUPPLY CIRCUIT SHORTED TO GROUND OR RETURN
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensors, depending on transmission configuration and build date.
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 13
213
DRIVEABILITY - DIESEL
P2122-LOW VOLTAGE AT THE APP SENSOR —
TEST
2
3
Continued
ACTION
Verify that the APPS is connected.
Inspect the harness and APPS connector pins
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
APPLICABILITY
ENGINE- 5.9L
DIESEL
3
Disconnect the APPS connector.
Measure the resistance between the ratiometric pin on the sensor to the supply pin
on the sensor.
Is the resistance between 1500 - 3000 Ohms with the accelerator pedal released?
Is the resistance between 200 - 1500 Ohms with the accelerator pedal depressed?
Yes
→ Go To
No
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
4
NOTE: Released resistance must be at least 1000 Ohms greater than depressed resistance.
4
5
6
Measure the resistance between the supply pin of the sensor and the APPS return pin
of the sensor.
Is the resistance between 2000 and 3000 ohms, depressed as well as released?
Yes
→ Go To
No
→ Replace the APPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Using the DRBIIIt, monitor the DTC while connecting a jumper wire between the
ratiometric pin in the sensor connector and the supply pin in the sensor connector.
Did the DTC for low voltage go inactive and the DTC for high voltage set?
Yes
→ Replace the APPS
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
ENGINE- 5.9L
DIESEL
6
Disconnect the ECM connector.
Inspect the connector for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
7
214
DRIVEABILITY - DIESEL
P2122-LOW VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
7
Disconnect the APPS connector.
Measure the resistance of the supply wire between the APPS connector and the ECM
connector.
Measure the resistance of the ratiometric wire between the APPS connector and the
ECM connector.
Is the resistance less than 10 ohms?
ENGINE- 5.9L
DIESEL
8
9
10
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER 1 (DIESEL).
8
Measure the resistance between the ratiometric pin in the sensor connector and the
APPS return pin in the sensor connector.
Measure the resistance between the ratiometric pin in the sensor connector and
battery negative.
Measure the resistance between the ratiometric pin in the sensor connector and the
#1 sensor return pin of the ECM sensor connector.
Is the resistance less than 10 ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
9
Measure the resistance between the supply pin in the sensor connector and the APPS
return pin in the sensor connector.
Measure the resistance between the suply pin in the sensor connector and battery
negative.
Measure the resistance between the supply pin of the sensor connector and the #1
sensor return pin of the ECM sensor connector.
Is the resistance less than 10 ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
10
Measure the resistance between the ratiometric pin in the sensor connector and the
idle switch pin in the sensor connector.
Measure the resistance between the ratiometric pin in the sensor connector and the
not idle switch pin in the sensor connector.
Is the resistance less than 10 ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
11
215
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2122-LOW VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
11
Connect the ECM connector.
Using the DRBIIIt, monitor the DTC while connecting a jumper wire between the
ratiometric pin in the sensor connector and the supply pin in the sensor connector.
Did the DTC for low voltage go inactive and the DTC for high voltage become active?
ENGINE- 5.9L
DIESEL
12
Yes
→ Go To
No
→ Replace ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
12
Using DRBIIIt,
ENGINE- 5.9L
DIESEL
Clear DTC
13
14
15
16
Verify that the PPS is connected.
Inspect the harness and the PPS connector.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
14
Disconnect the ECM connectors.
Inspect the connectors for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
15
Disconnect the sensor connector.
Measure the resistance of the PPS 1 signal circuit between the PPS sensor connector
and the ECM connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
16
Measure the resistance of the PPS 1 supply circuit between the PPS sensor connector
and the ECM connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
17
216
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2122-LOW VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
17
Measure the resistance between the PPS 1 signal pin at the sensor connector and
battery negative.
Is the resistance greater than 100K ohms?
ENGINE- 5.9L
DIESEL
18
19
20
21
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
18
Measure the resistance between the PPS 1 signal pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100 k ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
19
Measure the resistance between the PPS 1 supply pin at the sensor connector and
battery negative.
Is the resistance greater than 100 K ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
20
Measure the resistance between the PPS 1 supply pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100 k ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
21
Connect the ECM connector.
While monitoring with the DRB, connect a jumper wire between the PPS 1 signal pin
at the sensor connector and the PPS 1 supply pin at the sensor connector.
NOTE:With the sensor disconnected it is normal to have a PPS 1 and PPS 2
low voltage DTC set.
Did a PPS 1 voltage too high DTC set?
Yes
→ Go To
No
→ Replace ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
22
217
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2122-LOW VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
22
Connect the sensor connector.
Monitor the PPS 1 and PPS 2 voltage with the DRB while depressing the throttle
pedal.
Is the voltage transition shown on the DRB smooth while depressing the throttle and
is the voltage from PPS 1 twice as much as the voltage from PPS 2?
ENGINE- 5.9L
DIESEL
Yes
→ Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Replace the PPS.
218
DRIVEABILITY - DIESEL
Symptom:
P2123-HIGH VOLTAGE AT THE APP SENSOR
When Monitored and Set Condition:
P2123-HIGH VOLTAGE AT THE APP SENSOR
When Monitored:
While the key is on and during engine operation.
Set Condition: The APPS signal circuit voltage at the ECM goes above 4.24 volts for more
than 2 seconds. Or, the voltage detected on the PPS 1 circuit is above a callibrated value.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS
FAILED APS
OPEN APPS RETURN WIRE
RATIOMETRIC CIRCUIT SHORTED TO SUPPLY
RATIOMETRIC CIRCUIT SHORTED TO 12 VOLTS
FAILED ECM
OPEN PPS 1 RETURN CIRCUIT
PPS 1 SIGNAL CIRCUIT SHORTED TO 5 VOLT SUPPLY
FAILED PPS
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensors, depending on transmission configuration and build date.
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 11
2
Verify that the APPS is connected.
Inspect the harness and APPS connector pins.
Are any pins damaged?
Yes
→ Repair or replace harness or sensor
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
219
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2123-HIGH VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the APPS connector.
Measure the resistance between the ratiometric pin on the sensor to the supply pin
on the sensor.
Is the resistance between 1500 - 3000 Ohms with the accelerator pedal released?
Is the resistance between 200 - 1500 Ohms with the accelerator pedal depressed?
ENGINE- 5.9L
DIESEL
Yes
→ Go To
No
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
NOTE: Released resistance must be at least 1000 Ohms greater than depressed resistance.
4
5
6
7
Connect the ECM connector and the APPS connector.
Using the DRBIIIt, monitor the DTC while disconnecting the APPS connector.
Did the DTC for high voltage become inactive and the DTC for low voltage become
active?
Yes
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
5
Disconnect the ECM connector.
Inspect the connector for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
6
Disconnect the sensor connector.
Measure the resistance of the APPS return wire between the sensor connector and
the ECM connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
7
Disconnect the ECM connector and the sensor connector.
Measure the resistance between the ratiometric pin in the sensor connector and the
supply pin in the sensor connector.
Is the resistance less than 10 Ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
8
220
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2123-HIGH VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
8
Measure the voltage between the ratiometric pin in the sensor connector and battery
negative.
Is the voltage greater than 1 volt?
ENGINE- 5.9L
DIESEL
9
10
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
9
Connect the ECM connector and the APPS conductor.
Using the DRB, monitor the DTC while disconnecting the APPS connector.
Did the DTC for high voltage become inactive and the DTC for low voltage become
active?
Yes
→ Go To
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
10
Using DRB,
ENGINE- 5.9L
DIESEL
Clear DTC
11
12
13
Verify that the PPS is connected.
Inspect the harness and the PPS connector.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
12
Disconnect the ECM connectors.
Inspect the connectors for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
13
Disconnect sensor connector.
Measure the resistance on the PPS 1 return circuit between the sensor connector and
the ECM connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
14
221
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2123-HIGH VOLTAGE AT THE APP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
14
Measure the resistance between the PPS 1 signal pin in the sensor connector and the
PPS 1 supply pin in the sensor connector.
Is the resistance greater than 100 k ohms?
ENGINE- 5.9L
DIESEL
15
16
17
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
15
Measure the resistance between the PPS 1 signal pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100 k ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
16
Connect the ECM connectors and the sensor connector.
While monitoring with the DRBIIIt, disconnect the sensor connector.
Did a PPS 1 and PPS 2 voltage too low DTC set?
Yes
→ Go To
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
17
Connect the sensor connection.
Monitor the PPS 1 and PPS 2 voltage with the DRBIIIt while depressing the throttle
pedal.
Is the voltage transition shown on the DRB smooth while depressing the throttle and
is the voltage from PPS 1 twice as much as the voltage from PPS 2?
Yes
→ Repair complete.
No
→ Replace the PPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
222
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH
When Monitored and Set Condition:
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH
When Monitored:
Key on.
Set Condition: Both Idle and Not Idle switches are in the same state simultaneously for
a calibrated amount of time. Or, the voltage detected on the PPS 2 circuit is below a
calibrated value.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS
FAILED APPS
IDLE SWITCH OPEN CIRCUIT
NOT IDLE SWITCH OPEN CIRCUIT
SENSOR 1 RETURN OPEN CIRCUIT
IDLE SWITCH CIRCUIT SHORTED TO SUPPLY OR 12 VOLTS
NOT IDLE SWITCH CIRCUIT SHORTED TO SUPPLY OR 12 VOLTS.
FAILED ECM
FAILED PPS
OPEN PPS 2 SIGNAL CIRCUIT
OPEN PPS 2 SUPPLY CIRCUIT
PPS 2 SIGNAL CIRCUIT SHORTED TO GROUND OR RETURN
PPS 2 SUPPLY CIRCUIT SHORTED TO GROUND OR RETURN
TEST
1
ACTION
The diesel engine uses two types of throttle position sensors.
APPLICABILITY
ENGINE- 5.9L
DIESEL
If the throttle position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 9
2
Verify that the APPS is connected.
Inspect the harness and APPS connector pins
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
223
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the APPS.
Using a Voltmeter, measure the voltage between the idle switch pin of the APPS
connector and sensor #1 return.
Measure the voltage between the not idle switch pin of the APPS connector and
sensor #1 return.
Is the voltage between 4.5 and 5.5 volts?
ENGINE- 5.9L
DIESEL
4
5
6
7
Yes
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
ENGINE- 5.9L
DIESEL
Disconnect the ECM connector.
Inspect the connectors for damaged pins.
Are any pins damaged?
Yes
→ Repair or replace harness or ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
5
Measure the resistance of the idle switch wire between the APPS connector and the
ECM connector.
Measure the resistance of the not idle switch wire between the APPS connector and
the ECM conector.
Measure the resistance of the sensor 1 return wire between the APPS connector and
the ECM connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Disconnect the APPS connector and the ECM connector.
Measure the voltage between the idle switch pin of the APPS connector and battery
negative.
Measure the voltage between the not idle switch pin of the APPS connector and
battery negative.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
7
Measure the voltage between the idle switch pin of the APPS connector and sensor #1
return.
Measure the voltage between the not idle switch pin of the APPS connector and
sensor #1 return battery negative.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
8
224
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
8
ACTION
Using DRB,
APPLICABILITY
ENGINE- 5.9L
DIESEL
Clear DTC
9
10
11
12
13
ENGINE- 5.9L
DIESEL
Verify that the PPS is connected.
Inspect the harness and the PPS connector.
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
10
Disconnect the ECM connectors.
Inspect the connectors for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
11
Disconnect the sensor connector.
Measure the resistance of the PPS 2 signal circuit between the PPS sensor connector
and the ECM connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
12
Measure the resistance of the PPS 2 supply circuit between the PPS sensor connector
and the ECM connector.
Is the resistance less than 10 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
13
Measure the resistance between the PPS 2 signal pin at the sensor connector and
battery negative.
Is the resistance greater than 100 K ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
14
225
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2127-LOW VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
ACTION
APPLICABILITY
14
Measure the resistance between the PPS 2 signal pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100 K ohms?
ENGINE- 5.9L
DIESEL
15
16
17
18
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
15
Measure the resistance between the PPS 2 supply pin at the sensor connector and
battery negative.
Is the resistance greater than 100 K ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
16
Measure the resistance between the PPS 2 supply pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100 K ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
17
Connect the ECM connectors.
While monitoring with the DRB, connect a jumper wire between the PPS 2 signal pin
at the sensor connector and the PPS 2 supply pin at the sensor connector.
NOTE: With the sensor disconnected it is normal to have a PPS 1 and PPS
2 low voltage DTC set.
Did a PPS 2 voltage too high DTC set?
Yes
→ Go To
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
18
Connect the sensor connector.
Monitor the PPS 1 and PPS 2 voltage with the DRB while depressing the throttle
pedal.
Is the voltage transition shown on the DRB smooth while depressing the throttle and
is the voltage from PPS 1 twice as much as the voltage from PPS 2?
Yes
→ Repair complete
No
→ Replace the PPS
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
226
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH
When Monitored and Set Condition:
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH
When Monitored:
Key on.
Set Condition: Both Idle and Not Idle switches are in the same state simultaneously for
a calibrated amount of time. Or, the voltage detected on the PPS 2 circuit is above a
calibrated value.
POSSIBLE CAUSES
DAMAGED WIRING HARNESS OR CONNECTORS
FAILED APPS
NOT IDLE SWITCH SHORTED TO SENSOR #1 RETURN, APPS RETURN, OR BATTERY NEGATIVE
IDLE SWITCH SHORTED TO NOT IDLE SWITCH
IDLE SWITCH SHORTED TO SENSOR #1 RETURN, APPS RETURN, OR BATTERY NEGATIVE
FAILED ECM
PPS 2 SIGNAL CIRCUIT SHORTED TO 5 VOLT SUPPLY
FAILED PPS
TEST
ACTION
APPLICABILITY
1
The diesel engine uses two types of throttle position sensor, if the throttle position
sensor is located on the engine.
SELECT ONE:
ENGINE- 5.9L
DIESEL
The diesel engine uses two types of throttle position sensors, if the throttle
position sensor is located on the engine
Go To 2
If the throttle position sensor is located under the battery on the driver side
of the vehicle
Go To 11
2
Verify that the APPS is connected.
Inspect the harness and APPS connector pins
Are any pins damaged?
Yes
→ Repair or replace harness or sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
3
227
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the APPS.
Measure the voltage between the idle switch pin of the APPS connector and sensor #1
return.
Measure the voltage between the not idle switch pin of the APPS connector and
sensor #1 return.
Is the voltage between 4.5 and 5.5 volts?
ENGINE- 5.9L
DIESEL
4
5
6
7
Yes
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
4
ENGINE- 5.9L
DIESEL
Disconnect the ECM connector.
Inspect the connectors for damaged pins.
Are any pins damaged?
Yes
→ Repair or replace harness or ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
5
Measure the resistance between the idle switch pin of the APPS connector and
battery negative.
Measure the resistance between the idle switch pin of the APPS connector and the
APPS.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Measure the resistance between the not idle switch pin of the APPS connector and
battery negative.
Measure the resistance between the not idle switch pin of the APPS connector and
the APPS return pin of the APPS connector.
Measure the resistance between the not idle switch of the APPS connector and the
sensor #1 return pin of the APPS connector.
Is the resistance greater than 100K Ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
7
Disconnect the APPS connector and the ECM connector.
Measure the resistance between the idle switch pin of the APPS connector and the
not idle switch pin of the APPS connector.
Is the resistance less than 10 Ohms?
Yes
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
8
228
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
ACTION
APPLICABILITY
8
Connect the ECM connector.
Measure the resistance between the idle switch pin of the APPS connector and the
not idle switch pin of the APPS connector.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
DIESEL
9
10
Yes
→ Replace the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
9
Measure the voltage between the idle switch pin of the APPS connector and battery
negative sensor #1 return.
Measure the voltage between the not idle switch pin of the APPS connector and
battery negative sensor #1 return.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Go To
No
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
10
Using the DRB,
Clear DTC.
ENGINE- 5.9L
DIESEL
Repair complete.
11
12
13
Verify that the PPS is connected.
Inspect the harness and the PPS connector.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Repair or replace harness or sensor
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
12
Disconnect the ECM connectors.
Inspect the connectors for damage.
Are any pins damaged?
ENGINE- 5.9L
DIESEL
Yes
→ Fix or replace the harness or the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
13
Disconnect the sensor connector.
Measure the resistance between the PPS 2 signal pin in the sensor connector and the
PPS 2 supply pin in the sensor connector.
Is the resistance greater than 100K ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
14
229
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2128-HIGH VOLTAGE AT THE THROTTLE VALIDATION SWITCH —
Continued
TEST
ACTION
APPLICABILITY
14
Measure the resistance between the PPS 2 signal pin at the ECM connector and all
other pins in the ECM connector.
Is the resistance greater than 100K ohms?
ENGINE- 5.9L
DIESEL
15
16
Yes
→ Go To
No
→ Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
15
Connect the ECM connectors and the sensor connector.
While monitoring with the DRB, disconnect the sensor connector.
Did a PPS 1 and PPS 2 voltage too low DTC set?
Yes
→ Go To
No
→ Replace ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
16
Monitor the PPS 1 and PPS 2 voltage with the DRBIIIt while depressing the throttle
pedal.
Is the voltage transition shown on the DRBIIIt smooth while depressing the throttle
and is the voltage from PPS 1 twice as much as the voltage from PPS 2?
Yes
→ Repair complete.
No
→ Replace the PPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
230
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW
When Monitored and Set Condition:
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW
When Monitored:
While the engine is running.
Set Condition: A circuit failure detected at cylinders 1,2, or 3 or any combination of
cylinders 1,2, or 3.
POSSIBLE CAUSES
DAMAGED OR LOOSE CONNECTIONS
INJECTOR SHORTED - SINGLE OR MULTIPLE INJECTORS
OPEN CIRCUIT ON MULTIPLE INJECTORS
OPEN HIGH SIDE OR LOW SIDE DRIVER WIRES IN THE INJECTOR HARNESS FOR MULTIPLE
CYLINDERS
OPEN HIGH SIDE OR LOW SIDE DRIVER WIRES IN THE ENGINE HARNESS FOR MULTIPLE
CYLINDERS
INJECTOR HARNESS LOW SIDE DRIVER SHORTED LOW
INJECTOR HARNESS HIGH SIDE DRIVER SHORTED LOW
ENGINE HARNESS HIGH SIDE DRIVER SHORTED HIGH OR LOW
ENGINE HARNESS LOW SIDE DRIVER SHORTED HIGH OR LOW
LOW SIDE DRIVER SHORTED TO A HIGH SIDE DRIVER ON THE SAME BANK IN THE ENGINE
OR INJECTOR HARNESS
TWO OR MORE LOW SIDE DRIVERS SHORTED TOGETHER IN THE INJECTOR HARNESS OR
THE ENGINE HARNESS
FAILED ECM
TEST
1
ACTION
Using the DRB, check for DTC’s.
Do you have any combination of DTC’s P-0201, P-0202, or P-0203?
Yes
→ Troubleshoot them first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
231
APPLICABILITY
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW —
TEST
2
3
4
5
6
ACTION
Disconnect the ECM connectors and the injector harness connectors.
Inspect the ECM connector and harness pins.
Also inspect the injector harness connectors and pins for injectors 1-3.
Are the pins damaged?
Yes
→ Fix or replace the harness, or the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
Continued
APPLICABILITY
ENGINE- 5.9L
DIESEL
3
Reconnect the circuit and start the engine.
Using the DRB, check for DTC’s.
Is the DTC still active?
ENGINE- 5.9L
DIESEL
Yes
→ Go To
No
→ Repair is complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Disconnect the pigtail nuts from injectors 1-3.
Using an Ohmmeter, check the resistance between the solenoid posts of each injector.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Yes
→ Go To
No
→ Replace the injector or injectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
5
Connect the pigtail nuts for injectors 1-3.
Disconnect the injector harness connectors for cylinders 1-3.
Using an Ohmmeter, check the resistance of the injector harness circuit between the
high side driver pin and the low side driver pin for each of the injectors at the injector
harness connectors.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Disconnect the ECM connector and the injector harness connectors.
Using an Ohmmeter, measure the resistance of the injector high side driver wire
between the Bank 1 high side driver pin in the ECM connector and the high side
driver pins in the injector harness connectors for cylinders 1-3.
Measure the resistance of the #1, #2, and #3 injector low side driver wires between
the ECM connector and the injector harness connectors..
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
7
232
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW —
Continued
TEST
ACTION
APPLICABILITY
7
Measure the resistance of the injector harness high side and low side driver wires to
battery negative for injectors1-3.
Is the resistance more than 100k Ohms?
ENGINE- 5.9L
DIESEL
8
9
10
11
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
8
Using an Ohmmeter, check the resistance of the engine harness high side and low
side driver wires to battery negative for injectors 1-3.
Is the resistance more than 100k Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
9
Using a Voltmeter, measure the voltage between the Bank 1 high side driver wire in
the engine harness and battery negative.
Measure the voltage between the low side driver wires in the engine harness and
battery negative for cylinders 1-3.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
10
Using an Ohmmeter, measure the resistance between the Bank 1 high side driver
wire at the ECM connector and the low side driver wires for injectors 1-3 at the ECM.
Is the resistance more than 100k Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
11
Connect the injector harness connectors.
Disconnect the ECM connectors and the injector pigtail nuts for injectors 1-3.
Using an Ohmmeter, measure the resistance between the Bank 1 high side driver
wire at the ECM connector and the low side driver wires for injectors 1-3 at the ECM
connector.
Is the resistance more than 100k Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
12
233
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2146-BANK 1 (CYLINDERS 1-3) SHORTED HIGH OR LOW —
Continued
TEST
ACTION
APPLICABILITY
12
Disconnect the ECM connectors and the injector harness connectors.
Using an Ohmmeter, check the resistance of each of the Bank 1 low side driver wires
to all other Bank 1 low side driver wires at the ECM connector.
Is the resistance greater than 100k ohms?
ENGINE- 5.9L
DIESEL
13
14
15
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
13
Connect the injector harness connectors.
Disconnect the ECM connectors.
Using an Ohmmeter, check the resistance of each of the Bank 1 low side driver wires
to all other Bank 1 low side driver wires at the ECM connector.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
14
Connect the injector pig tail nuts, the injector harness connectors and the ECM
connectors.
Start the engine.
Using the DRB, check DTC’s.
Is this DTC still active?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
DIESEL
15
Using the DRB, verify the DTC is inactive and clear DTC.
Repair complete
234
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW
When Monitored and Set Condition:
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW
When Monitored:
Set Condition:
4, 5, or 6.
While the engine is running.
A misfire detected at cylinders 4, 5, or 6 or any combination of cylinders
POSSIBLE CAUSES
DAMAGED OR LOOSE CONNECTIONS
INJECTOR SHORTED - SINGLE OR MULTIPLE INJECTORS
OPEN CIRCUIT ON MULTIPLE INJECTORS
OPEN HIGH SIDE OR LOW SIDE DRIVER WIRES IN THE INJECTOR HARNESS FOR MULTIPLE
CYLINDERS
OPEN HIGH SIDE OR LOW SIDE DRIVER WIRES IN THE ENGINE HARNESS FOR MULTIPLE
CYLINDERS
INJECTOR HARNESS LOW SIDE DRIVER SHORTED LOW
INJECTOR HARNESS HIGH SIDE DRIVER SHORTED LOW
ENGINE HARNESS HIGH SIDE DRIVER SHORTED HIGH OR LOW
ENGINE HARNESS LOW SIDE DRIVER SHORTED HIGH OR LOW
LOW SIDE DRIVER SHORTED TO A HIGH SIDE DRIVER ON THE SAME BANK IN THE ENGINE
OR INJECTOR HARNESS
TWO OR MORE LOW SIDE DRIVERS SHORTED TOGETHER IN THE INJECTOR HARNESS OR
THE ENGINE HARNESS
FAILED ECM
TEST
1
ACTION
Using the DRBIIIt, check for DTC’s.
Do you have any combination of DTC’s P-0204, P-0205, or P-0206?
Yes
→ Troubleshoot them first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
235
APPLICABILITY
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW —
TEST
2
3
4
5
6
ACTION
Disconnect the ECM connectors and the injector harness connectors.
Inspect the ECM connector and harness pins.
Also inspect the injector harness connectors and pins for injectors 4-6.
Are the pins damaged?
Yes
→ Fix or replace the harness, or the ECM
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
Continued
APPLICABILITY
ENGINE- 5.9L
DIESEL
3
Reconnect the circuit and start the engine.
Using the DRBIIIt, check for DTC’s.
Is the DTC still active?
ENGINE- 5.9L
DIESEL
Yes
→ Go To
No
→ Repair is complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Disconnect the pigtail nuts from injectors 4-6.
Using an Ohmmeter, check the resistance between the solenoid posts of each injector.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greaater than 0 ohms?
Yes
→ Go To
No
→ Replace the injector or injectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
5
Connect the pigtail nuts for injectors 4-6.
Disconnect the injector harness connectors for cylinders 4-6.
Using an Ohmmeter, check the resistance of the injector harness circuit between the
high side driver pin and the low side driver pin for each of the injectors at the injector
harness connection.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
6
Disconnect the ECM connector and the injector harness connectors.
Using an Ohmmeter, measure the resistance of the injector high side driver wire
between the Bank 2 high side driver pin in the ECM connector and the high side
driver pins in the injector harness connectors for cylinders 4-6.
Measure the resistance of the #4, #5, and #6 injector low side driver wires between
the ECM connector and the injector harness connectors.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
7
236
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW —
Continued
TEST
ACTION
APPLICABILITY
7
Using an Ohmmeter, check the resistance of the injector harness high side and low
side driver wires to battery negative for injectors 4-6.
Is the resistance more than 100k Ohms?
ENGINE- 5.9L
DIESEL
8
9
10
11
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
8
Disconnect the injector harness connectors.
Measure the resistance of the engine harness high side and low side driver wires to
battery negative for injectors 4-6.
Is the resistance more than 100k Ohm?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
9
Disconnect the ECM connectors and the injector harness connector.
Measure the voltage between the Bank 2 high side driver wire in the engine harness
and battery negative.
Measure the voltage between the low side driver wires in the engine harness and
battery negative for cylinders 4-6.
Is the voltage less than 1 volt?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
10
Measure the resistance between the Bank 2 high side driver wire at the ECM
connector and the low side driver wires for injectors 4-6 at the ECM connector.
Is the resistance more than 100k Ohms?
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
11
Connect the injector harness connectors.
Remove the injector pigtail nuts for injectors 4-6.
Using an Ohmmeter, measure the resistance between the Bank 2 high side driver
wire at the ECM connector and the low side driver wires for injectors 4-6 at the ECM
connector.
Is the resistance more than 100k Ohms?
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
12
237
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2149-BANK 2 (CYLINDERS 4-6) SHORTED HIGH OR LOW —
Continued
TEST
ACTION
APPLICABILITY
12
Disconnect the ECM connectors and the injector harness connectors.
Using an Ohmmeter, check the resistance of each of the Bank 2 low side driver wires
to all other Bank 2 low side driver wires at the ECM connector.
Is the resistance greater than 100k ohms?
ENGINE- 5.9L
DIESEL
13
14
Yes
→ Go To
No
→ Fix or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
13
Connect the injector harness connectors.
Disconnect the ECM connectors.
Using an Ohmmeter, check the resistance of each of the Bank 2 low side driver wires
to all other Bank 2 low side driver wires at the ECM connector.
Is the resistance greater than 100k ohms?
Yes
→ Go To
No
→ Fix or replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
DIESEL
14
Connect the injector pig tail nuts, the injector harness connectors and the ECM
connectors.
Start the engine.
Using the DRB, check DTC’s.
Is this DTC still active?
Yes
→ Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Test complete.
238
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P2266-WATER IN FUEL (WIF) SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P2266-WATER IN FUEL (WIF) SENSOR VOLTAGE TOO LOW
When Monitored:
Set Condition:
Ignition on.
Low voltage detected at the WIF signal circuit at the ECM.
POSSIBLE CAUSES
OTHER DTC PRESENT - P2503
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
WATER IN FUEL SENSOR
ECM
TEST
1
2
ACTION
Turn the ignition on.
With the DRBIIIt, read the engine DTCs.
Does the DRBIIIt display DTC P2503?
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Refer to symptom P2503-CHARGING SYSTEM VOLTAGE TOO
LOW (DIESEL) in the DRIVEABILITY category.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
2
Turn the ignition off.
Disconnect the Water In Fuel Sensor harness connector.
Disconnect the ECM harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Water In Fuel Sensor.
Signal circuit at the WIF harness connector.
Is the resistance below 100.0 ohms?
Yes
→ Repair the Water In Fuel Sensor Signal circuit for a short to
ground.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL).
No
→ Go To
3
239
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P2266-WATER IN FUEL (WIF) SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the Water In Fuel Sensor harness connector.
Disconnect the ECM harness connector.
Measure the resistance between Sensor Ground and the Water In Fuel Sensor Signal
circuit.
Is the resistance below 100.0 ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
Yes
→ Repair the Water In Fuel Sensor Signal circuit for a short to
ground.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL).
No
→ Go To
4
Turn the ignition on.
Measure the voltage of the Water In Fuel Sensor Signal circuit.
Is the voltage between 4.5 and 5.5 volts?
Yes
→ Replace the Water In Fuel Sensor.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL).
No
→ Test complete.
240
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom List:
P2269-WATER IN FUEL (WIF)
When Monitored and Set Condition:
P2266-WATER IN FUEL (WIF) SENSOR VOLTAGE TOO LOW
When Monitored:
Set Condition:
Ignition on.
Low voltage detected at the WIF signal circuit at the ECM.
POSSIBLE CAUSES
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORT TO GROUND
ECM
TEST
1
2
ACTION
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Drain the Water in fuel separator.
With the DRBIIIt, erase DTCs.
Cycle the ignition switch from on to off to on.
With the DRBIIIt, read DTCs.
Did the DTC P2269 return?
Yes
→ Refer to symptom P0178-WATER IN FUEL SENSOR VOLTAGE
TOO LOW in the DRIVEABILITY category.
No
→ Go To
2
Disconnect the Water In Fuel Sensor harness connector.
Monitor the DRBIIIt while jumping the signal circuit of the Water in Fuel sensor and
Battery (+).
Did the Water In Fuel Light go out?
Yes
→ Test Complete.
No
→ Replace the ECM.
241
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2502-CHARGING SYSTEM ERROR
When Monitored and Set Condition:
P2502-CHARGING SYSTEM ERROR
When Monitored:
While the engine is running.
Set Condition: The ECM cycles the voltage regulator in the generator while monitoring
for a change in output voltage. If the voltage does not drop when the regulator is off, the
fault is set.
POSSIBLE CAUSES
DAMAGED OR LOOSE CONNECTIONS IN THE WIRING HARNESS
OPEN CIRCUIT IN THE WIRING HARNESS
HIGH RESISTANCE IN THE WIRING HARNESS
FAILED GENERATOR
FAILED ECM
TEST
1
2
3
4
ACTION
Using the DRB, check for EVR driver DTC’s.
Do you have any DTC’s for the EVR driver?
APPLICABILITY
ENGINE- 5.9L
DIESEL
Yes
→ Troubleshoot EVR DTC’s first.
No
→ Go To
2
Visually inspect the positive and negative connections at the battery.
Visually inspect the battery negative connections at the engine block.
Are the connections free of corrosion and are they tight?
Yes
→ Go To
No
→ Clean and/or tighten the connections.
ENGINE- 5.9L
DIESEL
3
Disconnect the wiring harness from the ECM and inspect the pins for damage.
Are any pins damaged?
Yes
→ Repair or replace the harness or the ECM.
No
→ Go To
ENGINE- 5.9L
DIESEL
4
Disconnect the ECM connectors.
Using an Ohmmeter, measure the resistance from the positive and negative battery
posts to the appropriate pins in the ECM harness connector.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
5
242
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2502-CHARGING SYSTEM ERROR —
Continued
TEST
ACTION
APPLICABILITY
5
Using a Voltmeter, measure the voltage between the B+ post of the generator and the
B+ post of the battery while the engine is running.
Is the voltage above .4 volts?
ENGINE- 5.9L
DIESEL
6
7
8
9
10
Yes
→ Repair the high resistance in the B+ circuit between the generator and the battery.
No
→ Go To
6
Using a Voltmeter, measure the voltage between the B+ post of the driver side battery
and the B+ post of the passenger side battery.
Is the voltage above .4 volts?
Yes
→ Repair the high resistance in the battery cross over cable.
No
→ Go To
7
Using a Voltmeter, measure the voltage between the generator case and the B2 post
of the battery.
Is the voltage above .1 volts?
Yes
→ Repair the high resistance in the B2 circuit between the generator case and the B2 post.
No
→ Go To
ENGINE- 5.9L
DIESEL
8
Using a Ohmmeter, measure the resistance between the generator field terminals.
Is the resistance between .5 and 15 Ohms?
Yes
→ Go To
No
→ Replace the generator.
ENGINE- 5.9L
DIESEL
9
Disconnect the ECM connectors.
Using a Voltmeter, measure and record the voltage between battery positive pins of
the ECM connector and the battery negative pins of the ECM connector.
Connect the ECM connectors.
Use the DRB to measure and record battery voltage.
Compare the voltage reading from the voltmeter with that of the DRB.
Are the readings within 3 volts of each other?
Yes
→ Go To
No
→ Replace the ECM
ENGINE- 5.9L
DIESEL
10
Using the DRB, verify the DTC is inactive and clear DTC.
Yes
ENGINE- 5.9L
DIESEL
→ Repair complete.
243
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
Symptom:
P2503-CHARGING SYSTEM LOW ERROR
When Monitored and Set Condition:
P2503-CHARGING SYSTEM LOW ERROR
When Monitored:
Set Condition:
value.
While the engine is running.
The battery voltage exceeds target voltage by more than a calibrated
POSSIBLE CAUSES
GENERATOR FIELD COIL SHORT TO GROUND
GENERATOR FIELD DRIVER WIRE SHORT TO GROUND
FAILED ECM
TEST
1
2
3
4
ACTION
Using the DRB, check for EVR driver DTC’s.
Do you have any DTC’s for the EVR driver?
APPLICABILITY
ENGINE- 5.9L
DIESEL
Yes
→ Troubleshoot EVR DTC’s first.
No
→ Go To
2
Using the DRB, check for the charging system error DTC.
Do you have the charging system error DTC?
Yes
→ Troubleshoot the charging system error first.
No
→ Go To
ENGINE- 5.9L
DIESEL
3
Disconnect the generator connector.
Inspect the generator connector and the generator for damaged pins.
Using an Ohmmeter, measure the resistance between ground and the generator field
terminals at the generator.
Is the resistance less than 100 ohms?
Yes
→ Fix or replace the generator.
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
Disconnect the ECM connectors and the generator connector.
Using an Ohmmeter, measure the resistance of the generator field driver wire
between the generator and battery negative.
Is the resistance greater than 100 ohms?
Yes
→ Go To
No
→ Fix or replace the harness.
5
244
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2503-CHARGING SYSTEM LOW ERROR —
Continued
TEST
ACTION
APPLICABILITY
5
Disconnect the ECM connectors.
Using a Voltmeter, measure and record the voltage between battery positive pins of
the ECM connector and the battery negative pins of the ECM connector.
Connect the ECM connectors.
Use the DRB to measure and record battery voltage.
Compare the voltage reading from the voltmeter with that of the DRB.
Are the readings within 3 volts of each other?
ENGINE- 5.9L
DIESEL
6
Yes
→ Go To
No
→ Replace the ECM
6
Using the DRB,
clear the DTC,
Yes
ENGINE- 5.9L
DIESEL
→ Repair complete.
245
DRIVEABILITY - DIESEL
Symptom:
P2504-CHARGING SYSTEM HIGH ERROR
When Monitored and Set Condition:
P2504-CHARGING SYSTEM HIGH ERROR
When Monitored:
While the engine is running.
Set Condition: Battery voltage is less than 11.5 volts for more than 8 seconds. Battery
voltage must exceed 12 volts for more than 5 seconds for fault to become inactive.
POSSIBLE CAUSES
DAMAGED, CORRODED, OR LOOSE CONNECTIONS
HIGH RESISTANCE IN THE BATTERY SUPPLY CABLE OR THE BATTERY CROSSOVER CABLE
HIGH RESISTANCE IN THE GENERATOR GROUND CIRCUIT
FAILED ECM
FAILED GENERATOR
TEST
1
2
3
4
ACTION
Using the DRB, check for EVR driver DTC’s.
Do you have any DTC’s for the EVR driver?
APPLICABILITY
ENGINE- 5.9L
DIESEL
Yes
→ Troubleshoot EVR DTC’s first.
No
→ Go To
2
Using the DRB, check for the charging system error DTC.
Do you have the charging system error DTC?
Yes
→ Troubleshoot the charging system error first.
No
→ Go To
ENGINE- 5.9L
DIESEL
3
Visually inspect the positive and negative connections at the battery.
Visually inspect the battery negative connections at the engine block.
Are the connections free of corrosion and are they tight?
Yes
→ Go To
No
→ Clean and/or tighten the connections.
ENGINE- 5.9L
DIESEL
4
Check for add-on or accessory wiring at positive (+) terminal of the batttery.
Are there any damaged wires at the battery?
Yes
→ Fix or replace the wires.
No
→ Go To
5
246
ENGINE- 5.9L
DIESEL
DRIVEABILITY - DIESEL
P2504-CHARGING SYSTEM HIGH ERROR —
Continued
TEST
ACTION
APPLICABILITY
5
Using a Voltmeter, measure the voltage between the B+ post of the generator and the
B+ post of the battery while the engine is running.
Is the voltage above .4 volts?
ENGINE- 5.9L
DIESEL
6
7
8
9
10
Yes
→ Repair the high resistance in the B+ circuit between the generator and the battery.
No
→ Go To
6
Using a voltmeter, measure the voltage between the B+ post of the driver side battery
and the B+ post of the passenger side battery while the engine is running.
Is the voltage above .4 volts?
Yes
→ Repair the high resistance in the battery cross over cable.
No
→ Go To
7
Using a Voltmeter, measure the voltage between the generator case and the B2 post
of the battery while the engine is running.
Is the voltage above .1 volts?
Yes
→ Repair the high resistance in the B2 circuit between the generator case and the B2 post.
No
→ Go To
ENGINE- 5.9L
DIESEL
8
Using an Ohmmeter, measure the resistance between the generator field terminals.
Is the resistance between .5 and 15 Ohms?
Yes
→ Go To
No
→ Replace the generator.
ENGINE- 5.9L
DIESEL
9
Disconnect the ECM connectors.
Using a Voltmeter, measure and record the voltage between battery positive pins of
the ECM connector and the battery negative pins of the ECM connector.
Connect the ECM connectors.
Use the DRB to measure and record battery voltage.
Compare the voltage reading from the voltmeter with that of the DRB.
Are the readings within 3 volts of each other?
Yes
→ Go To
No
→ Replace the ECM.
ENGINE- 5.9L
DIESEL
10
Using the DRB,
clear the DTC,
Yes
ENGINE- 5.9L
DIESEL
ENGINE- 5.9L
DIESEL
→ Repair complete.
247
DRIVEABILITY - DIESEL
Symptom:
P2509-POWERDOWN DATA LOST ERROR
When Monitored and Set Condition:
P2509-POWERDOWN DATA LOST ERROR
When Monitored:
Set Condition:
Continuous - key on or key off.
Loss of voltage detected at the ECM for a calibrated amount of time.
POSSIBLE CAUSES
POOR CONNECTIONS AT THE BATTERIES
LOW BATTERY VOLTAGE
OPEN FUSED B+ TO ECM
OPEN GROUND CIRCUIT
BATTERY + SHORTED TO OTHER CIRCUITS
RETURN CIRCUIT SHORTED
BATTERY + SHORTED TO GROUND
INTERMITTENT CONDITION
TEST
1
2
ACTION
Visually inspect the wiring at the battery for damaged wires, or corrosion.
Are the connections tight and free of corrosion?
Yes
→ Go To
No
→ Repair the poor connections at the batteries.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Measure the voltage between the positive and negative posts of the batteries.
Is the battery voltages both above 12 volts?
Yes
→ Go To
No
→ Recharge or replace the battery (s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
3
248
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
P2509-POWERDOWN DATA LOST ERROR —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition on.
Measure the resistance between the positive battery post and the ECM supply
circuits.
Is the resistance less than 10 Ohms?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
4
5
6
7
Yes
→ Go To
No
→ Repair the open fused B+ circuit to ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4
Measure the resistance between the negative battery post and the ECM ground wire.
Is the resistance less than 10 Ohms?
Yes
→ Go To
No
→ Repair the open ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
5
Measure the resistance between the ECM supply circuits and all other circuits in the
ECM harness connector, except other supply circuits.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair the battery circuit short to other circuits in engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
6
Measure the resistance between the ECM return circuits and all other circuits in the
ECM harness connector, except other return circuits.
Is the resistance greater than 100k Ohms?
Yes
→ Go To
No
→ Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
ENGINE- 5.9L
CUMMINS 24V
DIESEL
7
Measure the resistance between the ECM B+ supply circuit and ground.
Is the resistance greater than 100k Ohms?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair Battery + shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
249
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
*CHECKING PRESSURE LIMITING VALVE ON THE FUEL RAIL
FOR INTERNAL LEAKS
POSSIBLE CAUSES
PRESSURE LIMITING VALVE DIAGNOSTICS
TEST
ACTION
APPLICABILITY
1
Using the DRBIIIt, measure the rail pressure and determine if the rail pressure is
excessive (above 185,000 kpa/26,831 psi), if it is, troubleshoot for excessive rail
pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose
into a container.
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the fuel pressure override test with the
DRBIIIt. Watch for fuel flow into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does
not leak from the pressure-limiting valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed.
view repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Yes
→ Repair complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
250
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE ACCELERATOR PEDAL SENSOR CALIBRATION
POSSIBLE CAUSES
MIS-WIRED APPS
VOLTAGE NOT CHANGING DURING SWEEP
THROTTLE PEDAL NOT MOVING FREELY
APPS
TEST
1
2
3
ACTION
Turn the ignition off.
Remove the APPS cover.
Inspect both APPS connector and ECM for proper wiring.
Are both connectors wired correctly?
Yes
→ Go To
No
→ Repair mis-wired APPS connector at APPS or ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
APPLICABILITY
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
Ignition on, engine not running.
Remove APPS cover.
With the DRBIIIt in Sensors, read the APPS voltage while sweeping the APPS from
the lower to the upper stops.
Does voltage vary between less than 1.0 volt (closed) and more than 3.0 volts (open)?
Yes
→ Test complete. No trouble found.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Go To
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Ignition on, engine not running.
Remove APPS cover.
Look for proper Throttle operation.
Does the Throttle Pedal move freely between the upper and lower stops?
Yes
→ Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
251
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE ECM POWER AND GROUNDS
POSSIBLE CAUSES
ECM GROUND CIRCUIT(S) OPEN
FUSED B+ CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the ECM harness connectors.
Using a 12-volt test light connected to 12-volts, check each of the ECM ground
circuits in ECM harness connector.
Did the test light illuminate for each cavity?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Repair the ECM Ground circuit(s) for an open.
2
Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output circuit in ECM harness connector.
Is the test light on?
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output circuit for an open.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Turn the ignition off.
Disconnect the ECM harness connectors.
Using a 12-volt test light connected to ground, check each Fused B+ circuit in the
ECM harness connector.
Does the test light illuminate brightly for each circuit?
Yes
→ Test Complete.
No
→ Repair the Fused B+ Output circuit for an open.
252
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE PCM POWER AND GROUNDS
POSSIBLE CAUSES
FUSED B+ CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
PCM GROUND CIRCUIT(S) OPEN
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the PCM harness connectors.
Using a 12-volt test light connected to 12-volts, check both ECM ground circuits in
ECM harness connector.
Did the test light illuminate for each cavity?
ENGINE- 5.9L
CUMMINS 24V
DIESEL
2
3
Yes
→ Go To
No
→ Repair the PCM Ground circuit(s) for an open.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output circuit in PCM harness connector.
Is the test light on?
Yes
→ Go To
No
→ Repair the Fused Ignition Switch Output circuit for an open.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Using a 12-volt test light connected to ground, check each Fused B+ circuit in the
PCM harness connector.
Does the test light illuminate brightly for each circuit?
Yes
→ Test Complete.
No
→ Repair the Fused B+ Output circuit for an open.
253
ENGINE- 5.9L
CUMMINS 24V
DIESEL
DRIVEABILITY - DIESEL
Symptom:
*ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST
SMOKE)
POSSIBLE CAUSES
POSSIBLE CAUSES
TEST
ACTION
APPLICABILITY
1
This is a list of possible causes:
Check for any TSBs for ECM calibration updates that my apply.
Fuel level low.
Battery voltage low.
Fuel filter plugged.
Poor quality or improper grade of fuel.
Fuel tank venting.
Low fuel pressure.
Air in fuel system
Fuel Lift Pump malfunctioning.
Fuel Inlet restriction.
Fuel line kinked or restricted.
Fuel return passage or fuel return line kinked or restricted.
Injectors are incorrect.
Injector shim thickness is incorrect.
Injector malfunction.
Fuel connector leaking fuel.
Crankshaft position sensor (CKP) or Camshaft position sensor (CMP) and/or circuit
malfunction.
Moisture in harness connectors or corroded terminals.
Internal engine damage.
Air intake restriction.
Exhaust restriction.
Fuel inlet temperature high.
Overhead adjustments.
Ignition switch output voltage low and/or open.
Starting accessories for cold weather such as engine block heaters, fuel heaters if
equipped.
Engine cranking speed is low.
Electrical noise.
Fuel control actuator circuit
Speed indicator ring
Pressure limiting valve
Injector circuit
Air inlet restriction
External fuel leaks
View repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Repair as necessary. Refer to Service Information for the related
symptom(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
254
DRIVEABILITY - DIESEL
Symptom:
*ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE WHILE CRANKING)
POSSIBLE CAUSES
POSSIBLE CAUSES
TEST
ACTION
APPLICABILITY
1
This is a list of possible causes:
Check for any TSBs for ECM calibration updates that may apply.
Fuel level low.
Poor quality or improper grade of fuel.
Fuel filter plugged.
Fuel tank venting.
Low fuel pressure.
Air in fuel system
Fuel Lift Pump malfunctioning.
Fuel Inlet restriction.
Fuel control actuator circuit
Fuel inlet line kinked or restricted.
Fuel return passage or fuel return line kinked or restricted.
Injectors are incorrect.
Injector shim thickness is incorrect.
Injector malfunction.
Fuel connector leaking fuel.
Crankshaft position sensor (CKP) or Camshaft position sensor (CMP) and/or circuit
malfunction.
Moisture in harness connectors or corroded terminals.
Skim issues.
Battery voltage low.
Ignition switch supply voltage low or open.
Battery voltage to ECM is low or open.
Electrical noise.
Fuel injection pump.
Engine Control Module.
Internal engine damage.
Speed indicator ring.
Pressure limiting valve.
Injector circuit.
Air inlet resistriction.
External fuel leaks.
View repair.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Repair as necessary. Refer to Service Information for the related
symptom(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
255
DRIVEABILITY - DIESEL
Symptom:
*ENGINE SPEED SURGES IN PTO OR CRUISE CONTROL
POSSIBLE CAUSES
POSSIBLE CAUSES
TEST
ACTION
APPLICABILITY
1
This is a list of possible causes:
Check for any TSBs for ECM calibration updates that my apply.
Fuel filter plugged.
Fuel Inlet restriction.
Fuel line kinked or restricted.
Fuel return passage or fuel return line kinked or restricted.
Accelerator pedal is restricted or out of calibration.
Vehicle Speed sensor (VSS) and/or circuit malfunction.
Transmission gear shift.
Check vehicle brakes for dragging, transmission malfunction, cooling fan operation
cycle time and engine driven devices.
Moisture in harness connectors or corroded terminals.
ECM control, PTO speed governor.
Engine overload.
Air inlet resistriction.
View repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Repair as necessary. Refer to Service Information for the related
symptom(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
256
DRIVEABILITY - DIESEL
Symptom:
*ENGINE SPEED SURGES LOW OR HIGH IDLE
POSSIBLE CAUSES
POSSIBLE CAUSES
TEST
ACTION
APPLICABILITY
1
This is a list of possible causes:
Check for any TSBs for ECM calibration updates that my apply.
Fuel level low.
Fuel filter plugged.
Poor quality or improper grade of fuel.
Fuel tank venting.
Low fuel pressure.
Air in fuel system
Fuel Lift Pump malfunctioning.
Fuel Inlet restriction.
Fuel line kinked or restricted.
Fuel control actuator.
Fuel return passage or fuel return line kinked or restricted.
Injectors are incorrect.
Injector shim thickness is incorrect.
Injector circuit.
Injector malfunction.
Fuel connector leaking fuel.
High pressure Fuel pump.
Accelerator pedal is restricted or out of calibration.
Vibration damper is damaged.
Crankshaft position sensor (CKP) or Camshaft position sensor (CMP) and/or circuit
malfunction.
Vehicle Speed sensor (VSS) and/or circuit malfunction.
Incorrect Transmission Clutch operation.
Check vehicle brakes for dragging, transmission malfunction, cooling fan operation
cycle time and engine driven devices.
Check for proper turbocharger, turbo charger wheel clearance is out of specifications,
waste gate for correct operation.
Bus communication problems.
Moisture in harness connectors or corroded terminals.
Internal engine damage.
Electronic noise.
Idling with excessive load.
Clutch is malfunctioning or incorrect.
View repair.
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Repair as necessary. Refer to Service Information for the related
symptom(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
257
DRIVEABILITY - DIESEL
Symptom:
*ENGINE SPEED SURGES UNDER LOAD OR IN OPERATING
RANGE
POSSIBLE CAUSES
POSSIBLE CAUSES
TEST
ACTION
APPLICABILITY
1
This is a list of possible causes:
Check for any TSBs for ECM calibration updates that my apply.
Fuel level low.
Fuel filter plugged.
Poor quality or improper grade of fuel.
Fuel tank venting.
Low fuel pressure.
Air in fuel system
Fuel Lift Pump malfunctioning.
Fuel Inlet restriction.
Fuel line kinked or restricted.
Fuel return passage or fuel return line kinked or restricted.
Injectors are incorrect.
Injector shim thickness is incorrect.
Injector malfunction.
Fuel connector leaking fuel.
Accelerator pedal is restricted or out of calibration.
Crankshaft position sensor (CKP) or Camshaft position sensor (CMP) and/or circuit
malfunction.
Vehicle Speed sensor (VSS) and/or circuit malfunction.
Incorrect Transmission Clutch operation.
Check vehicle brakes for dragging, transmission malfunction, cooling fan operation
cycle time and engine driven devices.
Check for proper turbocharger, turbo charger wheel clearance is out of specifications,
waste gate for correct operation.
Bus communication problems.
Moisture in harness connectors or corroded terminals.
Internal engine damage.
Fuel control actuator
Speed indicator ring
Pressure Limiting valve
Air inlet restriction
External fuel leaks
Injector circuit
High pressure fuel pump
View repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Repair as necessary. Refer to Service Information for the related
symptom(s).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
258
DRIVEABILITY - DIESEL
Symptom:
*FUEL HEATER THERMOSTAT TEST
POSSIBLE CAUSES
FUEL HEATER THERMOSTAT TEST
TEST
ACTION
APPLICABILITY
1
To check the operating resistance levels on the thermostat and fuel heater perform
the following:
Unplug the wiring harness from the thermostat.
Check the resistance across the two pins of the thermostat with
The ambient temperature must be below the 9Circuit close temperature; 1 +/- 3 C9 to
perform this check. ( If necessary, induce this ambient temperature by placing ice
packs on the thermostat to produce an 9effective ambient temperature9 below the
circu
The resistance across the two pins should be within the range of 0.3 Ohms to 0.45
Ohms for a properly operating thermostat and heater.
If the resistance from step 2 is out of range, remove the thermostat and check the
resistance across the terminal connections of the heater (the heater can be checked
at room temperatures). The resistance across the terminal pins of the heater should
be
Replace the heater if resistance is not within the proper operation range. Re-install
the thermostat with a new o-ring.
If the heater resistance is within the proper operating.
Circuit close temperature; 1 +/- 3 C
Circuit open temperature; 18 +/- 4 C
Fuel Heater Thermostat 0.3 - 0.45 Ohms at less than 1 degree C
Fuel Heater 0.3 - 0.45 Ohms at room temperature
View Repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
259
DRIVEABILITY - DIESEL
Symptom:
*FUEL LIFT PUMP FLOW AND INLET RESTRICTION TEST
POSSIBLE CAUSES
*FUEL LIFT PUMP FLOW AND INLET RESTRICTION TEST
TEST
ACTION
1
Disconnect the wiring harness from the fuel lift pump.
Measure the resistance between the lift pump return pin of the wiring harness
connector and battery negative.
If the resistance is greater than 1 ohm, repair high resistance in the ground circuit.
If the resistance is less than 1 ohm then continue to the next step.
Connect a voltmeter between the supply and return pins of the wiring harness
connector.
Use the DRB to actuate the fuel lift pump.
If the voltage is greater than 11.5 volts, continue the test.
If not, troubleshoot the vehicle for low battery voltage.
Reconnect the lift pump connector.
Inspect the fuel line between the fuel filter housing and the high-pressure fuel pump
for signs of damage.
Replace as necessary.
Disconnect the vehicle fuel supply line from the fuel lift pump hose at the frame rail
connection.
Install Fuel Pressure Adapter -6631 between the vehicle fuel supply line and the fuel
lift pump hose at the fuel rail connection.
Install the pressure/vacuum gauge to the brass T fitting on the Fuel Pressure
Adapter -6631.
Remove the fuel pump supply banjo fitting from the fuel injection pump.
Install Miller Tool #9014 fuel system test fitting into the fuel injection pump.
Connect one end of a section of fuel hose to the test fitting.
Put the other end of the fuel hose into a 1000 ml graduated cylinder.
Use the DRB to actuate the lift pump for 10 seconds.
If the vacuum reading on the pressure/vacuum gauge is less than 6 in hg then the test
has successfully passed.
If the vacuum is higher than 6 in hg a restriction exists between the fuel tank module
and the fuel supply side of the fuel lift pump.
Inspect the fuel line between the fuel tank and the fuel lift pump for damage (bends,
kinks, dents, etc.) or obstructions.
Repair or replace any damaged component.
If fuel lines are acceptable remove the fuel tank module; inspect the fuel module for
signs of restriction.
Repair or replace any damaged component.
Repeat Fuel Restriction test segment to confirm fix.
Remove the Fuel Pressure Adapter -6631 and empty the 1000 ml granulated cylinder,
reconnect the vehicle fuel supply line to the fuel lift pump.
Use the DRB to actuate the lift pump for 10 seconds.
If you have more than 400 ml of fuel in the graduated cylinder, the test has
successfully passsed.
If you have less than 400 ml of fuel in the graduated cylinder replace the Fuel Filter
and retest.
If you have less than 400 ml of fuel in the graduated cylinder with a new Fuel Filter
installed, then replace the fuel lift pump.
Repeat Lift Pump Flow test segment to confirm fix.
Spec - MAX = 6 in Hg restriction
Spec - Min fuel flow is 40 ml/second
260
APPLICABILITY
DRIVEABILITY - DIESEL
Symptom:
*EXCESSIVE INJECTOR RETURN FLOW
POSSIBLE CAUSES
FUEL PUMP RETURN FLOW
TEST
ACTION
APPLICABILITY
1
Using the DRBIIIt, idle the engine and measure the rail pressure and determine if
the rail pressure is excessive (above 185,00 kpa/26,831 psi), if it is, troubleshoot for
excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting #9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose
into a container
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the fuel pressure override test with the
DRBIIIt. Watch for fuel flow into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does
not leak from the pressure-limiting valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter
housing
Install fuel system test fitting #9012 in place of the banjo connector.
Install a piece of fuel line onto the test fitting and put the open end into the graduated
cylinder .
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 1000-ml/minute at idle, the test has successfully passed.
If the flow is greater than 1000 ml/minute at idle, replace the fuel injection pump.
Retest to confirm repair.
View Repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test Complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
261
DRIVEABILITY - DIESEL
Symptom:
*FUEL SYSTEM VACUUM TEST
POSSIBLE CAUSES
FUEL SYSTEM VACUUM TEST
TEST
ACTION
APPLICABILITY
1
NOTE: Drain fuel out of fuel lines if observed.
Disconnect the fuel supply line as close to the fuel tank as possible; plug the fuel
supply at the fuel tank connection.
Disconnect fuel supply line from the fuel lift pump hose at the frame rail connection
point.
Connect the hand held vacuum pump to the fuel supply line.
Apply vacuum with the hand held pump - vacuum should not exceed 15-20 in Hg.
The vacuum should not drop more than 0.1 in Hg per minute.
Test the system for at least 5 minutes.
If the system does not hold vacuum, repair the air leak between the fuel tank and the
fuel lift pump connection. If the system holds vacuum, continue to next step.
Install fuel system test fitting #9012 in the inlet line at the high-pressure fuel pump.
Connect the hand held vacuum pump to the fitting.
Plug the inlet hose on the fuel lift pump.
Apply vacuum with the hand held pump - vacuum should not exceed 15-20 in Hg.
If the system does not hold vacuum, replace the fuel lift pump repair the air leak
between the high pressure fuel pump and the inlet to the fuel lift pump.
If the system does hold vacuum, continue to next step.
Remove the plugs from the fuel supply line and reconnect the fuel connections.
Start the engine and check for external fuel leaks.
Repair complete.
View Repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
262
DRIVEABILITY - DIESEL
Symptom:
*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST
POSSIBLE CAUSES
*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST
TEST
ACTION
APPLICABILITY
1
Monitor rail pressure with DRBIIIt while cranking the engine
Compare the fuel pressure set point with the actual fuel pressure reading.
If the engine is not generating fuel pressure, use the DRBIIIt to check for fuel
pressure sensor fault codes.
If no fuel pressure sensor faults are present, verify that the engine has adequate fuel
delivery using the fuel lift pump flow test.
Monitor rail pressure with DRBIIIt while cranking the engine.
If the engine is not generating fuel pressure, check the torque on the fuel pump drive
gear. Torque - 105 Nm.
Retest to confirm fix.
Test complete
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
263
DRIVEABILITY - DIESEL
Symptom:
*INJECTOR RETURN FLOW TEST
POSSIBLE CAUSES
*INJECTOR RETURN FLOW TEST
TEST
ACTION
APPLICABILITY
1
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter
housing.
Install fuel system test fitting in place of the banjo connector.
Remove the vehicle fuel return line from the engine fuel drain tube.
Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel
tank.
Install one end of a test hose onto the fuel drain tube. Place the other end of the test
hose into a graduated cylinder.
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 180-ml/minute, the test has successfully passed.
If the flow is greater than 180 ml/minute, shut off the engine and remove all of the
fuel injector supply lines. Retorque all of the high-pressure connector nuts. Install all
of the fuel injector supply lines.
Start the engine and idle for one minute. Measure the amount of fuel in the
graduated cylinder.
If the flow is less than 180ml/minute, the condition has been fixed.
If the flow is greater than 180 ml/minute after step 12, shut off the engine and
remove the #1 fuel injector supply line. Retorque the high-pressure connector nut.
Cap the #1 fuel port on the fuel rail and the #1 high pressure connector. Start the eng
Measure the amount of fuel in the graduated cylinder.
If the amount of fuel is less than 180 ml/minute, shut off the engine and remove the
#1 high pressure connector and the #1 fuel injector. Inspect for damage, repair/
replace as necessary.
If the amount of fuel is not less than 180-ml/minute, repeat steps 14-16 for cylinders
2-6.
Install all high-pressure connectors, fuel injectors, and fuel injector supply lines.
Repeat steps 1-8 to confirm repair.
SPECIFICATION:Less than 180 ml/minute total fuel return flow
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test Complete.
264
DRIVEABILITY - DIESEL
Symptom:
*INTAKE AIR SYSTEM PRESSURE TEST
POSSIBLE CAUSES
CHARGE AIR COOLER PRESSURE TEST
TEST
ACTION
APPLICABILITY
1
Loosen air inlet tube clamp at the turbocharger.
Remove the air filter housing and the inlet tube from the vehicle as an assembly.
Install the CAC Pressure Tester into the inner diameter of the turbocharger, securing
it in place with the supplied three-fingered band clamp, tighten tool clamp to 8n.m
(72 in lbs).
NOTE: NEVER ATTEMPT TO START OR RUN THE VEHICLE AT ANY TIME
DURING THIS TEST, ENGINE DAMAGE MAY OCCUR.
Fasten the safety chain around a solid surface behind the turbocharger. Warning:
Never run CAC Pressure test without the safety chain securely fastened.
Before attaching shop air to the pressure regulator verify that the regulator is at its
lowest pressure setting (0 psi). Attach an air supply to the regulator and slowly
increase the pressure until the pressure gauge reads 20 psi. Warning: Never apply
mo
Using a solution of soap and water spray the Turbocharger, Turbocharger wastegate,
Charge Air Cooler Heat Exchange and CAC Hoses while watching for leaks.
Before any attempt to repair the CAC system is made, its necessary to completely
discharge the system. This can be accomplished by turning the regulator knob
counter-clockwise. Allow for adequate time to pass before removing the CAC
Pressure tester from
Position the Air Filter Housing over the three mounting studs located on the inside
front fender well and press down firmly to lock housing into place.
Install Air Inlet Tube over the Turbocharger inlet and torque the band clamp to 35
in.lbs.
View Repair
ENGINE- 5.9L
CUMMINS 24V
DIESEL
Repair
Test complete.
265
DRIVEABILITY - GAS
Symptom:
INTERMITTENT CONDITION
POSSIBLE CAUSES
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Refer to any Technical Service Bulletins (TSBs) that may apply.
Review the DRBIIIt Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the DRBIIIt
parameters related to the DTC while wiggling the wire harness. Look for parameter
values to change and/or a DTC to set.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched,
partially broken wires and broken, bent, pushed out, or corroded terminals.
Inspect and clean all PCM, engine, and chassis grounds that related to the DTC set.
If numerous trouble codes were set, use a wire schematic to help you find any
common ground or supply circuits
For any Relay DTCs, actuate the Relay with the DRBIIIt and wiggle the related wire
harness to try to interrupt the actuation.
For intermittent Evaporative Emission trouble codes perform a visual and physical
inspection of the related parts including hoses and the Fuel Filler cap.
For intermittent Misfire DTCs check for restrictions in the Intake and Exhaust
system, improper installation of Sensors, vacuum leaks, and binding components
driven by the accessory drive belt.
A co-pilot, data recording, and/or lab scope should be used to help diagnose
intermittent conditions.
Use the DRBIIIt to perform a System Test if one applies to failing component.
Were any problems found during the above inspections?
All
Yes
→ Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
266
DRIVEABILITY - GAS
Symptom List:
P0031-O2
P0032-O2
P0037-O2
P0038-O2
P0051-O2
P0052-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/1
1/2
1/2
2/1
2/1
HEATER
HEATER
HEATER
HEATER
HEATER
HEATER
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
LOW
HIGH
LOW
HIGH
LOW
HIGH
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0031-O2 SENSOR 1/1 HEATER
CIRCUIT LOW.
When Monitored and Set Condition:
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW
When Monitored:
on.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not match Actual state.
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH
When Monitored:
off.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not equal Actual state.
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW
When Monitored:
on.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not equal Actual state.
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH
When Monitored:
off.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not equal Actual state.
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW
When Monitored:
on.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not equal Actual state.
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH
When Monitored:
off.
Set Condition:
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Desired state does not equal Actual state.
267
DRIVEABILITY - GAS
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW —
Continued
POSSIBLE CAUSES
O2 HEATER TEST
O2 SENSOR HEATER ELEMENT
(A141) FUSED ASD RELAY OUTPUT CIRCUIT
HEATER CONTROL CIRCUIT OPEN
HEATER CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, actuate the O2 Heater test.
Monitor the O2 Heater Voltage for 5 minutes.
Did the voltage drop down close to zero during the Heater test?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
APPLICABILITY
All
2
NOTE: Stop the actuation before continuing.
2
3
Turn the ignition off.
Disconnect the O2 Sensor harness connector.
Measure the resistance of the O2 Heater element at the O2 Sensor connector
(component side).
On a four O2 Sensor system the resistance value for 1/1 and 2/1 O2 Heater elements
is between 3.3 and 4.1 ohms and the 1/2 and 2/2 O2 Heater elements is between 4.0
and 5.0 ohms at 70°F (21.1°C).
On a two O2 Sensor system the resistance value for the 1/1 and 1/2 O2 Heater
elements is between 4.0 and 5.0 ohms at 70°F (21.1°C).
NOTE: The resistance value will increase with warmer temperatures.
Is the resistance within the listed specifications?
Yes
→ Go To
No
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
Using a 12-volt test light connected to ground, probe the (A141) Fused ASD Relay
Output circuit at the O2 Sensor harness connector.
Did the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the (A141) Fused ASD Relay
Output circuit. Inspect the related fuse and repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
NOTE: Stop the actuation before continuing.
268
All
DRIVEABILITY - GAS
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the Ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the O2 Heater Control circuit (PWM) from the O2 Sensor
to the PCM harness connector.
Is the resistance below 5.0 ohms?
All
5
6
Yes
→ Go To
No
→ Repair the open in the O2 Heater Control (PWM) circuit or the O2
Heater Relay Control circuit depending on the O2 Sensor being
tested.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
Measure the resistance between ground and the O2 Heater Control (PWM) circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Heater Control (PWM) circuit or
the Heater Relay Control circuit depending on the O2 Sensor
being tested.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
269
All
DRIVEABILITY - GAS
Symptom:
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE
When Monitored and Set Condition:
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE
When Monitored:
Faults present.
With the ignition on and no Battery Temperature Sensor Open or Short
Set Condition: After 5 warm cycles have occurred (coolant increases at least 22°C (40°F)
to a minimum of 71°C (160°F) and the odometer mileage has increased 196.6 miles and the
Battery Temperature has changed less than 4°C (7.2°F) change in temperature. One trip
fault.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K118) BATTERY TEMP SIGNAL CIRCUIT SHORTED TO VOLTAGE
BATTERY TEMPERATURE SENSOR
RESISTANCE IN THE (K118) BATTERY TEMP SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
(K118) BATTERY TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Battery Temp Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K118) Battery Temp Signal circuit at the Sensor
connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage on the (K118) Batt Temp Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
270
All
DRIVEABILITY - GAS
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
3
With the DRBIIIt, read the Battery Temp Sensor voltage with the Batt Temp Sensor
still disconnected.
Is the voltage above 4.6 volts?
All
4
Yes
→ Go To
4
No
→ Go To
7
Connect a jumper wire between the (K118) Battery Temp Signal circuit and the (K4)
Sensor ground circuit at the Sensor harness connector.
With the DRBIIIt, read the Battery Temp Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the Battery Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
NOTE: Remove the jumper wire before continuing.
5
6
Turn the ignition off.
Connect the Battery Temp Sensor harness connector.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe the (K118) Battery Temp Sensor Signal circuit at the Sensor harness
connector and the PCM harness connector with both voltmeter leads.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K118) BatteryTemp Sensor
Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
Turn the ignition off.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe the (K4) Sensor ground circuit at the Battery Temperature Sensor
harness connector and the PCM harness connector using both volt meter leads.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8
271
All
DRIVEABILITY - GAS
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
7
Turn the ignition off.
Disconnect the Battery Temp Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K118) Battery Temp Signal circuit.
Is the resistance below 100 ohms?
All
8
Yes
→ Repair the short to ground in the (K118) Battery Temp Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
272
All
DRIVEABILITY - GAS
Symptom:
P0107-MAP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0107-MAP SENSOR VOLTAGE TOO LOW
When Monitored: With the engine RPM above 416 but less than 1500, the TPS voltage
less than 1.13 volts, and battery voltage greater than 10.4 volts.
Set Condition: The MAP Sensor signal voltage is below 0.1 of a volt for 2.0 seconds with
the engine running.
POSSIBLE CAUSES
MAP SENSOR VOLTAGE BELOW 0.1 OF A VOLT
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MAP SENSOR
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
With the DRBIIIt, read the MAP Sensor voltage.
Is the voltage below 0.1 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit at the MAP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
6
273
All
DRIVEABILITY - GAS
P0107-MAP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
With the DRBIIIt, monitor the MAP Sensor voltage with the Sensor still disconnected.
Is the voltage above 1.2 volts?
All
4
5
6
7
8
Yes
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K1) MAP Sensor Signal circuit at
the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the ( K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
Measure the resistance between the (K1) MAP Sensor Signal circuit and the (K4)
Sensor ground circuit at the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance in the (K7) 5-volt Supply circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
274
All
DRIVEABILITY - GAS
Symptom:
P0108-MAP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0108-MAP SENSOR VOLTAGE TOO HIGH
When Monitored: With the engine RPM above 400, the TPS voltage less than 1.13 volts,
and battery voltage greater than 10.4 volts
Set Condition: The MAP Sensor signal voltage is greater than 4.88 volts at start or with
the engine running for 2.2 seconds.
POSSIBLE CAUSES
MAP SENSOR VOLTAGE ABOVE 4.8 VOLTS
MAP SENSOR
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K1) MAP SENSOR SIGNAL CIRCUIT OPEN
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
With the DRBIIIt, read the MAP Sensor voltage.
Is the voltage above 4.8 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Connect a jumper wire between the (K1) MAP Sensor Signal circuit and the (K4)
Sensor ground circuit.
Ignition on, engine not running.
With the DRBIIIt, monitor the MAP Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
275
All
DRIVEABILITY - GAS
P0108-MAP SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K1) MAP Sensor Signal circuit at the MAP Sensor
harness connector.
Is the voltage above 5.3 volts?
All
4
5
6
7
Yes
→ Repair the short to voltage in the (K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (K1) MAP Sensor Signal circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between the (K1) MAP Sensor Signal circuit and the (K7)
5-volt Supply circuit at the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K7) 5-volt Supply circuit and the
(K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
Measure the resistance of the (K4) Sensor ground circuit from the PCM harness
connector to the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
276
All
DRIVEABILITY - GAS
Symptom:
P0111-INTAKE AIR TEMP PERFORMANCE
When Monitored and Set Condition:
P0111-INTAKE AIR TEMP PERFORMANCE
When Monitored: With the ignition on and no Intake Air Temperature Sensor open/
shorted faults present.
Set Condition: After 5 warm cycles have occurred (coolant increases at least 22°C (40°F)
to a minimum of 71°C (160°F) and the odometer mileage has increased 196.6 miles and the
Intake Air Temperature has had less than 5°C (9°F) change in temperature.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
IAT SENSOR
RESISTANCE IN THE (K21) IAT SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Intake Air Temperature Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage above 4.6 volts?
Yes
→ Go To
3
No
→ Go To
5
277
All
DRIVEABILITY - GAS
P0111-INTAKE AIR TEMP PERFORMANCE —
TEST
3
Continued
ACTION
Turn the ignition off.
Connect a jumper wire across the IAT Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the Intake Air Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
APPLICABILITY
All
4
NOTE: Remove the jumper wire and connect the Sensor harness connector
before continuing.
4
5
Turn the ignition off.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe the (K21) IAT Sensor Signal circuit at the IAT Sensor harness connector
and PCM harness connector with the voltmeter leads.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K21) IAT Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
Turn the ignition off.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Backprobe the (K4) Sensor ground circuit at the IAT Sensor harness connector and
PCM harness connector with both leads of a voltmeter.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Turn the ignition off before continuing.
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
278
All
DRIVEABILITY - GAS
Symptom:
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The Intake Air Temperature (IAT) Sensor circuit voltage at the PCM goes
below 0.8 of a volt.
POSSIBLE CAUSES
IAT SENSOR VOLTAGE BELOW 1.0 VOLT
IAT SENSOR
(K21) IAT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K21) IAT SENSOR SIGNAL SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the IAT Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Intake Air Temp Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read IAT Sensor voltage.
Is the voltage above 1.0 volt?
Yes
→ Replace the IAT Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K21) IAT Sensor Signal circuit at
the IAT Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K21) IAT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
279
All
DRIVEABILITY - GAS
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (K21) IAT Sensor Signal circuit and the (K4)
Sensor ground circuit at the IAT Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(K21) IAT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
280
All
DRIVEABILITY - GAS
Symptom:
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The Intake Air Temperature (IAT) Sensor circuit voltage at the PCM goes
above 4.9 volts.
POSSIBLE CAUSES
IAT SENSOR VOLTAGE ABOVE 4.8 VOLTS
IAT SENSOR
(K21) IAT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K21) IAT SENSOR SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the IAT voltage.
Is the voltage above 4.8 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the IAT Sensor harness connector.
Connect a jumper wire between the (K21) IAT Sensor Signal circuit and the (K4)
Sensor ground circuit in the IAT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the IAT Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
281
All
DRIVEABILITY - GAS
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH —
TEST
3
4
5
6
ACTION
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K21) IAT Sensor Signal circuit.
Is the voltage above 5.3 volts?
Yes
→ Repair the short to voltage in the (K21) IAT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
Continued
APPLICABILITY
All
4
Turn the ignition off.
Measure the resistance of the (K21) IAT Sensor Signal circuit from the IAT Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K21) IAT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance of the (K4) Sensor ground circuit from the IAT Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
282
All
DRIVEABILITY - GAS
Symptom:
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The Engine Coolant Temperature (ECT) Signal circuit voltage at the PCM
goes below 0.8 of a volt for more than 3 seconds.
POSSIBLE CAUSES
ECT VOLTAGE BELOW 1.0 VOLT
ECT SENSOR
(K2) ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K2) ECT SENSOR SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the ECT Sensor voltage.
Is the ECT Sensor voltage below 1.0 volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
All
Turn the ignition off.
Disconnect the ECT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read ECT voltage.
Is the voltage above 1.0 volt?
Yes
→ Replace the ECT Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K2) ECT Sensor Signal circuit at
the ECT Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K2) ECT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
283
All
DRIVEABILITY - GAS
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (K2) ECT Sensor Signal circuit and the (K4)
Sensor ground circuit at the ECT Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short to the (K4) Sensor ground circuit in the (K2) ECT
Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
284
All
DRIVEABILITY - GAS
Symptom:
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The Engine Coolant Temperature (ECT) Sensor circuit voltage at the PCM
goes above 4.94 volts for more than 3 seconds.
POSSIBLE CAUSES
ECT VOLTAGE ABOVE 4.9 VOLTS
ECT SENSOR
(K2) ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K2) ECT SENSOR SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read ECT voltage.
Is the voltage above 4.9 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the ECT harness connector.
Ignition on, engine not running.
Connect a jumper wire between the (K2) ECT Sensor Signal circuit and the (K4)
Sensor ground circuit in the ECT harness connector.
With the DRBIIIt, read the ECT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the ECT Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
285
All
DRIVEABILITY - GAS
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K2) ECT Sensor Signal circuit at the ECT Sensor
harness connector.
Is the voltage above 5.3 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (K2) ECT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (K2) ECT Sensor Signal circuit from the ECT Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K2) ECT Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance of the (K4) Sensor ground circuit from the ECT Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
286
All
DRIVEABILITY - GAS
Symptom:
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP
When Monitored and Set Condition:
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP
When Monitored: With the engine running and no MAP Sensor or TP Sensor DTC’s set.
Engine speed must be greater than 1600 RPM.
Set Condition: The PCM performs two separate tests. When the manifold vacuum is high,
the TP Sensor should be low. When the manifold vacuum is low, the TP Sensor signal
should be high. If the proper TP Sensor voltage is not detected when the two conditions are
met, a DTC will be set after 4 seconds.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
RESISTANCE IN THE (K7) 5-VOLT SUPPLY CIRCUIT
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MAP SENSOR
RESISTANCE IN THE (K1) MAP SENSOR SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K1) MAP SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
TP SENSOR OPERATION
RESISTANCE IN THE TP SENSOR (K7) 5-VOLT SUPPLY
TP SENSOR (K7) 5-VOLT SUPPLY SHORTED TO GROUND
THROTTLE POSITION SENSOR
RESISTANCE IN THE (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE IN (K4) SENSOR GROUND CIRCUIT
PCM
287
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP —
Continued
TEST
ACTION
APPLICABILITY
1
NOTE: Diagnose any TP Sensor or MAP component DTCs first before
continuing.
NOTE: If the P0500 - No Vehicle Speed Signal is set along with this DTC,
refer to the P0500 diagnostics before continuing.
NOTE: The throttle plate and linkage should be free of binding and carbon
build up.
NOTE: Ensure the throttle plate is at the idle position.
Ignition on, engine not running.
NOTE: Repair any vacuum leaks that are present before continuing.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
4
5
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Start the engine.
With the DRBIIIt, monitor the MAP Sensor voltage.
Snap the throttle.
Does the DRBIIIt display MAP voltage from below 2.0 volts at idle to above 3.5 volts
at WOT?
Yes
→ Go To
3
No
→ Go To
10
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor voltage while slowly depressing the
throttle pedal from the idle position to the wide open throttle position.
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
4
Turn the ignition off.
Disconnect the TP Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance of the (K7) 5-volt Supply circuit from the TP Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the TP
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
288
All
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP —
Continued
TEST
ACTION
APPLICABILITY
6
Connect the PCM harness connectors.
With the DRBIIIt, monitor the TP Sensor voltage.
Ignition on, engine not running.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit.
Does the DRBIIIt display TP Sensor voltage from approximately 4.9 volts to below
0.5 of a volt?
All
Yes
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
NOTE: Remove the jumper wire before continuing.
7
8
9
10
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the TP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K22) TP Sensor #1 Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
8
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit at
the TP Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the short to ground in the (K22) TP Sensor #1 Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
9
Measure the resistance of the (K4) Sensor ground circuit from the TP Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
16
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance of the (K7) 5-volt Supply circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
11
289
All
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP —
Continued
TEST
ACTION
APPLICABILITY
11
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the
MAP Sensor harness connector.
Is the resistance above 100k ohms?
All
12
Yes
→ Go To
No
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
12
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, monitor the MAP Sensor voltage.
Connect a jumper wire between the (K1) MAP Sensor Signal circuit and the (K4)
Sensor ground circuit .
Cycle the ignition switch from off to on.
Does the DRBIIIt display MAP voltage from approximately 4.9 volts to below 0.5 of
a volt?
Yes
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
13
NOTE: Remove the jumper wire before continuing.
13
14
15
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K1) MAP Sensor Signal circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K1) MAP Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
14
Measure the resistance between ground and the (K1) MAP Sensor Signal circuit at
the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Go To
No
→ Repair the short to ground in the (K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
15
Measure the resistance of the (K4) Sensor ground circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
16
290
All
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP —
Continued
TEST
ACTION
APPLICABILITY
16
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
291
DRIVEABILITY - GAS
Symptom:
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW
When Monitored and Set Condition:
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW
When Monitored:
Set Condition:
1.3 seconds.
With the ignition on and battery voltage above 10.4 volts.
Throttle Position Sensor voltage at the PCM is lower than 0.1 of a volt for
POSSIBLE CAUSES
TP SENSOR SWEEP
INTERMITTENT CONDITION
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
TP SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO GROUND
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
TCM INTERNALLY SHORTED TP SENSOR SIGNAL CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the Throttle Position Sensor voltage.
Is the voltage below 0.2 of a volt?
Yes
→ Go To
2
No
→ Go To
10
Turn the ignition off.
Disconnect the TP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage of the (K7) 5-volt Supply circuit at the TP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
7
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor voltage.
Is the voltage above 4.5 volts?
Yes
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
292
APPLICABILITY
All
All
All
DRIVEABILITY - GAS
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit at
the TP Sensor harness connector.
Is the resistance below 100 ohms?
All
5
6
7
8
Yes
→ Repair the short to ground in the (K22) TP Sensor #1 Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit at the TP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (K22)
TP Sensor #1 Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: If the vehicle is not equipped with a TCM, answer No to this test and
continue.
Connect the PCM harness connectors.
Disconnect the TCM harness connector.
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor voltage.
Is the voltage above 4.5 volts?
Yes
→ Replace and program the Transmission Control Module per
Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K7) 5-volt Supply circuit from the TP Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
8
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the TP
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
9
293
All
DRIVEABILITY - GAS
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10
Ignition on, engine not running.
With the DRBIIIt, monitor the Throttle Position Sensor voltage.
Slowly open the throttle from the idle position to the wide open throttle position.
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
294
All
DRIVEABILITY - GAS
Symptom:
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH
When Monitored:
Set Condition:
3.2 seconds.
With the ignition on and battery voltage above 10.4 volts.
Throttle Position Sensor signal voltage at the PCM goes above 4.5 volts for
POSSIBLE CAUSES
TP SENSOR SWEEP
INTERMITTENT CONDITION
TP SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K22) TP SENSOR #1 SIGNAL CIRCUIT OPEN
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
NOTE: Ensure the throttle is fully closed and free from binding or carbon
build up.
Start the engine.
With the DRBIIIt, read the Throttle Position Sensor voltage.
Is the voltage above 4.5 volts?
All
2
Yes
→ Go To
2
No
→ Go To
8
Turn the ignition off.
Disconnect the Throttle Position Sensor harness connector.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit.
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor voltage.
Is the voltage below 0.5 of a volt?
Yes
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
295
All
DRIVEABILITY - GAS
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K22) TP Sensor #1 Signal circuit at the TP Sensor
harness connector.
NOTE: If the voltage reading is below 5.3 volts answer NO to this test and
continue.
If the voltage is above 5.3 volts, disconnect the Clock Spring harness connectors per
Service Information.
With the Clock Spring harness disconnected and if the TP Sensor voltage drops to 5.0
volts, replace the Clock Spring.
Is the voltage still above 5.3 volts with the Clock Spring harness disconnected?
All
Yes
→ Repair the short to voltage in the (K22) TP Sensor #1 Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
NOTE: Turn the ignition off and connect the Clockspring harness connectors per Service Information before continuing.
4
5
6
7
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the TP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K22) TP Sensor #1 Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K7)
5-volt Supply circuit at the TP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K7) 5-volt Supply circuit and the
(K22) TP Sensor #1 Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
Measure the resistance of the (K4) Sensor ground circuit from the TP Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
296
All
DRIVEABILITY - GAS
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
8
Ignition on, engine not running.
With the DRBIIIt, monitor the Throttle Position Sensor voltage.
Slowly open the throttle from the idle position to the wide open throttle position.
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
All
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
297
DRIVEABILITY - GAS
Symptom:
P0125-CLOSED LOOP TEMP NOT REACHED
When Monitored and Set Condition:
P0125-CLOSED LOOP TEMP NOT REACHED
When Monitored:
ten minutes.
With battery voltage greater than 10.4 volts, after engine is started, for
Set Condition: The engine temperature does not go above 18 deg. F after the engine has
been running for 10 minutes. Two trips are required to set this DTC.
POSSIBLE CAUSES
ECT SENSOR
GOOD TRIP EQUAL TO ZERO
LOW COOLANT LEVEL
THERMOSTAT OPERATION
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
NOTE: If a ECT DTC set along with this code, diagnose the ECT DTC first.
NOTE: Inspect the ECT terminals and related PCM terminals. Ensure the
terminals are free from corrosion and damage.
NOTE: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
Note: Extremely cold outside ambient temperatures may have caused this
DTC to set.
WARNING: Never open the cooling system when the engine is hot. The
system is under pressure. Extreme burns or scalding may result. Allow the
engine to cool before opening the cooling system.
Check the coolant system to make sure that the coolant is in good condition and at
the proper level.
Is the coolant level and condition OK?
Yes
→ Go To
No
→ Inspect the vehicle for a coolant leak and add the necessary
amount of coolant.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
3
298
All
DRIVEABILITY - GAS
P0125-CLOSED LOOP TEMP NOT REACHED —
Continued
TEST
ACTION
APPLICABILITY
3
Note: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Eng Coolant Tmp Deg value. If the engine was allowed
to sit overnight (cold soak), the temperature value should be a sensible value that is
somewhere close to the ambient temperature.
Note: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up monitor the Eng Coolant Tmp Deg value. The temp deg
value change should be a smooth transition from start up to normal operating temp
82°C (180°F) . Also monitor the actual coolant temperature with a thermometer.
NOTE: As the engine warms up to operating temperature, the actual coolant
temperature (thermometer reading) and the Eng Coolant Tmp Deg in the
DRBIIIt values should stay relatively close to each other.
Using the appropriate service information, determine the proper opening temperature of the thermostat.
Did the thermostat open at the proper temperature?
All
4
Yes
→ Go To
No
→ Replace the thermostat.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt in sensors, read the Eng Coolant Tmp Deg value. If the engine was
allowed to sit overnight (cold soak), the temperature value should be a sensible value
that is somewhere close to the surrounding temperature (ambient temperature).
Note: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the engine.
During engine warm-up, monitor the Eng Coolant Tmp Deg value. The temp deg
value change should be a smooth transition from start up to normal operating temp
82°C (180°F). The value should reach at least 82°C (180°F).
Was the Eng Coolant Tmp Deg value increase a smooth transition and did it reach at
least 180°F?
Yes
→ Test Complete.
No
→ Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
299
All
DRIVEABILITY - GAS
Symptom List:
P0131-O2
P0137-O2
P0151-O2
P0157-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
TOO
TOO
TOO
TOO
LOW
LOW
LOW
LOW
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0131-O2 SENSOR 1/1 CIRCUIT
VOLTAGE TOO LOW.
When Monitored and Set Condition:
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO LOW
When Monitored: At a cold start, engine coolant below 98°F, Ambient/Battery Sensor
reading within 27°F, and Engine Coolant Temperature above 170°F on the previous key off.
Set Condition: The Oxygen Sensor signal voltage is below 0.156 of a volt for 28 seconds
after starting engine.
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO LOW
When Monitored: At a cold start, engine coolant below 98°F, Ambient/Battery Sensor
reading within 27°F, and Engine Coolant Temperature above 170°F on the previous key off.
Set Condition: The Oxygen Sensor signal voltage is below 0.156 of a volt for 28 seconds
after starting engine.
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO LOW
When Monitored: At a cold start, engine coolant below 98°F, Ambient/Battery Sensor
reading within 27°F, and Engine Coolant Temperature above 170°F on the previous key off.
Set Condition: The Oxygen Sensor signal voltage is below 0.156 of a volt for 28 seconds
after starting engine.
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO LOW
When Monitored: At a cold start, engine coolant below 98°F, Ambient/Battery Sensor
reading within 27°F, and Engine Coolant Temperature above 170°F on the previous key off.
Set Condition: The Oxygen Sensor signal voltage is below 0.156 of a volt for 28 seconds
after starting engine.
POSSIBLE CAUSES
O2 SENSOR BELOW 0.16 OF A VOLT
O2 SENSOR OPERATION
O2 SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
O2 SENSOR SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
300
DRIVEABILITY - GAS
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO LOW —
Continued
POSSIBLE CAUSES
O2 SENSOR SIGNAL SHORTED TO THE HEATER GROUND CIRCUIT
PCM
TEST
1
2
3
4
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
Allow the engine to idle for 4 to 5 minutes.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage below 0.16 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Disconnect the O2 Sensor harness connector.
Start the engine.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage above 0.16 of a volt?
Yes
→ Replace the O2 Sensor
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the O2 Sensor Signal circuit at the O2
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Measure the resistance between the O2 Sensor Signal circuit and the (K4) Sensor
ground circuit at the O2 Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
301
All
DRIVEABILITY - GAS
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
5
NOTE: Two types of O2 Sensor Heater Ground circuits may be used on this
vehicle. One type uses an engine ground and the other type uses the PCM as
a ground through the Pulse Width Modulated circuit.
* Measure the resistance between the PWM O2 Sensor Heater Control circuit and the
O2 Sensor Signal circuit if it applies to the O2 Sensor being tested.
OR
* Measure the resistance between the O2 Sensor Signal circuit and the O2 Heater
ground circuit if it applies to the O2 Sensor being tested.
Is the resistance below 100 ohms?
All
6
Yes
→ Repair the short between the O2 Sensor Signal circuit and the
Heater ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
302
All
DRIVEABILITY - GAS
Symptom List:
P0132-O2
P0138-O2
P0152-O2
P0158-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
TOO
TOO
TOO
TOO
HIGH
HIGH
HIGH
HIGH
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0132-O2 SENSOR 1/1 CIRCUIT
VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH
When Monitored: With battery voltage greater than 10.4 volts, engine running for more
than 4 minutes and coolant temperature above 180°F.
Set Condition:
The oxygen sensor voltage is above 1.5 volts.
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO HIGH
When Monitored: With battery voltage greater than 10.4 volts, engine running for more
than 4 minutes and coolant temperature above 180°F.
Set Condition:
The oxygen sensor voltage is above 1.5 volts.
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO HIGH
When Monitored: With battery voltage greater than 10.4 volts, engine running for more
than 4 minutes and coolant temperature above 180°F.
Set Condition:
The oxygen sensor voltage is above 1.5 volts.
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO HIGH
When Monitored: With battery voltage greater than 10.4 volts, engine running for more
than 4 minutes and coolant temperature above 180°F.
Set Condition:
The oxygen sensor voltage is above 1.5 volts.
POSSIBLE CAUSES
O2 SENSOR ABOVE 1.5 VOLTS
O2 SENSOR OPERATION
O2 SENSOR SIGNAL SHORTED TO VOLTAGE
O2 SENSOR SIGNAL CIRCUIT OPEN
O2 SENSOR SIGNAL CIRCUIT SHORTED TO O2 HEATER SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
O2 SENSOR HEATER CONTROL CIRCUIT OPEN
303
DRIVEABILITY - GAS
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH —
Continued
POSSIBLE CAUSES
O2 SENSOR HEATER GROUND CIRCUIT OPEN
PCM
TEST
1
2
3
4
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
Allow the engine to idle for 4 to 5 minutes.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage above 1.5 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Turn the ignition off.
Disconnect the O2 Sensor harness connector.
Start the engine.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage below 1.5 volts?
Yes
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the O2 Sensor Signal circuit at
the O2 Sensor harness connector.
Does the test light illuminate brightly?
Yes
→ Repair the short to voltage in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Turn the ignition off.
Measure the resistance of the O2 Sensor Signal circuit from the O2 Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
304
All
DRIVEABILITY - GAS
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
5
NOTE: Two relays may be used on this vehicle for the different types of
Heated O2 Sensors. One uses the ASD Relay which is only used with PWM
O2 Sensor Heaters and the other uses the O2 Heater Relay.
Verify which relay is used to supply power for the O2 Sensor Heater being tested.
Measure the resistance between the O2 Sensor Signal circuit and the O2 Heater
Supply circuit at the O2 Sensor harness connector.
Is the resistance below 100 ohms?
All
6
7
8
Yes
→ Repair the short between the O2 Sensor Signal circuit and the
(A141) ASD Relay Output or (A42) O2 Heater Relay Output
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
Measure the resistance of the (K4) Sensor ground circuit from the O2 Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt actuate the O2 Heater Test.
Measure the voltage on the O2 Heater Supply circuit.
Is the voltage above 11.0 volts?
No
→ Repair the open in the Heater Supply circuit. The Heater Supply
circuit can be and output from the ASD Relay or an O2 Heater
Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
Yes
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM harness connectors.
NOTE: The O2 Sensor Heater ground may be a Pulse Width Modulated
circuit or a chassis ground depending on the type of O2 Sensor being tested.
* Measure the resistance of the PWM O2 Sensor Heater Control circuit from the O2
Sensor harness connector to the PCM harness connector if it applies to the O2 Sensor
being tested
OR
* Measure the resistance of the O2 Sensor Heater ground circuit from the O2 Sensor
harness connector to the PCM harness connector if it applies to the O2 Sensor being
tested.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Sensor ground (PWM) circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9
305
All
DRIVEABILITY - GAS
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
306
DRIVEABILITY - GAS
Symptom List:
P0133-O2
P0139-O2
P0153-O2
P0159-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
SLOW
SLOW
SLOW
SLOW
RESPONSE
RESPONSE
RESPONSE
RESPONSE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0133-O2 SENSOR 1/1 SLOW
RESPONSE.
When Monitored and Set Condition:
P0133-O2 SENSOR 1/1 SLOW RESPONSE
When Monitored: With ECT greater than 147°F, after reaching a vehicle speed of 10 mph,
and the throttle remaining open (off idle) for 2 minutes, bring the vehicle to a stop and
allow the engine to idle with the transmission in DRIVE.
Set Condition: The oxygen sensor signal voltage is switching from below 0.27 of a volt to
above 0.62 of a volt and back fewer times than required.
P0139-O2 SENSOR 1/2 SLOW RESPONSE
When Monitored: Start engine. Allow engine to idle. For 1st part of test, if limits are
exceeded, test passes. If not, 2nd part of test runs. amb/batt temp >44°F, Baro >22.139
H2O, battery >10.5 volts, MAP >11.79 & <18.159 H2O, RPM >1350 & <2200 and vss >50
and <65.
Set Condition: The oxygen sensor signal voltage is switching from below 0.39 of a volt to
above 0.58 of a volt and back fewer times than required.
P0153-O2 SENSOR 2/1 SLOW RESPONSE
When Monitored: With ECT greater than 147°F, after reaching a vehicle speed of 10 mph,
and the throttle remaining open (off idle) for 2 minutes, bring the vehicle to a stop and
allow the engine to idle with the transmission in DRIVE.
Set Condition: The oxygen sensor signal voltage is switching from below 0.27 of a volt to
above 0.62 of a volt and back fewer times than required.
P0159-O2 SENSOR 2/2 SLOW RESPONSE
When Monitored: Start engine. Allow engine to idle. For 1st part of test, if limits are
exceeded, test passes. If not, 2nd part of test runs. amb/batt temp >44°F, Baro >22.139
H2O, battery >10.5 volts, MAP >11.79 & <18.159 H2O, RPM >1350 & <2200 and vss >50
and <65.
Set Condition: The oxygen sensor signal voltage is switching from below 0.39 of a volt to
above 0.58 of a volt and back fewer times than required.
307
DRIVEABILITY - GAS
P0133-O2 SENSOR 1/1 SLOW RESPONSE —
Continued
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
EXHAUST LEAK
RESISTANCE IN THE O2 SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
O2 SENSOR
TEST
ACTION
APPLICABILITY
1
NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Start the engine.
Inspect the exhaust for leaks between the engine and the related O2 Sensor.
Are there any exhaust leaks?
Yes
→ Repair or replace the leaking exhaust parts as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
While backprobing, measure the voltage of the O2 Sensor Signal circuit between the
O2 Sensor harness connector and PCM harness connector.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection and are connected for
positive polarity.
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
308
All
DRIVEABILITY - GAS
P0133-O2 SENSOR 1/1 SLOW RESPONSE —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
While backprobing, measure the voltage of the (K4) Sensor ground circuit between
the O2 Sensor harness connector and PCM harness connector.
NOTE: Ensure the voltmeter leads meet the terminals in the connector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
All
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
NOTE: Turn the ignition off before continuing.
5
If there are no possible causes remaining, view repair.
Repair
Replace the O2 Sensor
Perform POWERTRAIN VERIFICATION TEST VER - 5.
309
All
DRIVEABILITY - GAS
Symptom List:
P0135-O2
P0141-O2
P0155-O2
P0161-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
HEATER
HEATER
HEATER
HEATER
FAILURE
FAILURE
FAILURE
FAILURE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0135-O2 SENSOR 1/1 HEATER
FAILURE.
When Monitored and Set Condition:
P0135-O2 SENSOR 1/1 HEATER FAILURE
When Monitored: With battery voltage greater than 9 volts, at a cold start, ECT less than
147°F, battery temperature sensor equal to or less than 27°F, and engine at idle for at least
12 seconds.
Set Condition:
O2 sensor voltage greater than 3 volts for 30 to 90 seconds.
P0141-O2 SENSOR 1/2 HEATER FAILURE
When Monitored: With battery voltage greater than 10.5 volts, at a cold start, ECT less
than 147°F, battery temperature sensor equal to or less than 27°F, and engine at idle for
at least 12 seconds.
Set Condition:
O2 sensor voltage greater than 3 volts for 60 to 240 seconds.
P0155-O2 SENSOR 2/1 HEATER FAILURE
When Monitored: With battery voltage greater than 9 volts, at a cold start, ECT less than
147°F, battery temperature sensor equal to or less than 27°F, and engine at idle for at least
12 seconds.
Set Condition:
O2 sensor voltage greater than 3 volts for 60 to 240 seconds.
P0161-O2 SENSOR 2/2 HEATER FAILURE
When Monitored: With battery voltage greater than 10.5 volts, at a cold start, ECT less
than 147°F, battery temperature sensor equal to or less than 27°F, and engine at idle for
at least 12 seconds.
Set Condition:
O2 sensor voltage greater than 3 volts for 60 to 240 seconds.
POSSIBLE CAUSES
O2 SENSOR HEATER OPERATION
O2 HEATER ELEMENT
O2 HEATER SUPPLY CIRCUIT OPEN
HEATER CONTROL CIRCUIT OPEN
310
DRIVEABILITY - GAS
P0135-O2 SENSOR 1/1 HEATER FAILURE —
Continued
POSSIBLE CAUSES
HEATER CONTROL CIRCUIT SHORTED TO GROUND
HEATER GROUND CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down
before continuing the test.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stabilize between 0.1 and 0.3 of a volt during the Heater test?
All
2
3
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
2
Turn the ignition off.
NOTE: Allow the O2 Sensor to cool to room temperature.
Disconnect the O2 Sensor harness connector.
Measure the resistance across the O2 Sensor Heater element component side.
NOTE: The resistance value will increase with warmer temperatures.
On a two O2 Sensor system the resistance value for the 1/1 and 1/2 O2 Heater
elements is between 4.0 and 5.0 ohms at 70°F (21.1°C).
On a four O2 Sensor system the resistance value for 1/1 and 2/1 O2 Heater elements
is between 3.3 and 4.1 ohms and the 1/2 and 2/2 O2 Heater elements is between 4.0
and 5.0 ohms at 70°F (21.1°C).
Is the resistance within the listed specifications?
Yes
→ Go To
No
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
3
NOTE: The O2 Heater Supply circuit may be a fused (A141) ASD Relay
Output or an O2 Sensor (A42) Heater Relay Output, depending on the O2
Sensor being tested.
Ignition on, engine not running and the O2 Sensor still disconnected.
With the DRBIIIt, actuate the O2 Heater Test.
Using a 12-volt test light connected to ground, probe the (A141) Fused ASD Relay
Output or (A42) O2 Heater Relay Output circuit at the O2 Sensor harness connector..
Does the light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the (A141) Fused ASD Relay Output circuit or
the (A42) O2 Heater Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
311
All
DRIVEABILITY - GAS
P0135-O2 SENSOR 1/1 HEATER FAILURE —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Remove the O2 Heater Relay, if it applies to the O2 Sensor being tested.
* Measure the resistance of the O2 Heater Control circuit (PWM) from the O2 Sensor
to the PCM harness connector if it applies to the O2 Sensor being tested.
OR
* Measure the resistance of the (K127) O2 Heater Relay Control circuit from the O2
Heater Relay to the PCM harness connector, if it applies to the O2 Sensor being
tested.
Is the resistance below 5.0 ohms?
All
5
6
7
Yes
→ Go To
No
→ Repair the excessive resistance in the O2 Heater Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
NOTE: Before beginning this test, verify what type of Heated O2 Sensor is
being tested, either the PWM Heated O2 Sensor or the Heater Relay
controlled Heated O2 Sensor.
* Measure the resistance between ground and the O2 Heater Control (PWM) circuit
if it applies to the O2 Sensor being tested.
OR
* Measure the resistance between ground and the (K127) O2 Heater Relay Control
circuit at the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the O2 Heater Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: If the O2 Sensor being tested does not use an O2 Heater Relay to
supply voltage to the O2 Sensor Heater, answer YES to this test and
continue.
Using a 12-volt test light connected to 12-volts, probe the (Z192) or (Z193) O2 Heater
Ground circuit.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the O2 Sensor Heater ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
312
All
DRIVEABILITY - GAS
Symptom:
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION
When Monitored and Set Condition:
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION
When Monitored:
Ignition ON, with battery voltage greater than 10.4 volts.
Set Condition: The state of the PCM relay control circuit, between the PCM and relay
coil, does not match the desired state.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
O2 SENSOR HEATER RELAY
(A141) FUSED ASD RELAY OUTPUT CIRCUIT
(K127) O2 HEATER RELAY CONTROL CIRCUIT OPEN
(K127) O2 HEATER RELAY CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Remove the Heater Relay from the IPM.
Measurement is taken at the Heater Relay component.
Measure the resistance of the O2 Sensor Heater Relay Coil.
Is the resistance above 100 ohms?
Yes
→ Replace the O2 Sensor Heater Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Relay.
Using a 12-volt test light connected to ground, probe the (A141) Fused ASD Relay
Output circuit of the O2 Heater Relay in the PDC.
Does the test light illuminate brightly when the relay actuates?
Yes
→ Go To
No
→ Repair the open or short to ground in the (A141) ASD Relay
Output circuit. Inspect the related fuse and repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
313
All
DRIVEABILITY - GAS
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K127) O2 Heater Relay Control circuit from the IPM
(Heater Relay) connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
All
5
6
Yes
→ Go To
No
→ Repair the open in the (K127) O2 Heater Relay Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
Measure the resistance between ground and the (K127) O2 Heater Relay Control
circuit at the IPM connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K127) O2 Sensor Heater Relay
Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are not possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
314
All
DRIVEABILITY - GAS
Symptom List:
P0171-1/1 FUEL SYSTEM LEAN
P0174-2/1 FUEL SYSTEM LEAN
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0171-1/1 FUEL SYSTEM LEAN.
When Monitored and Set Condition:
P0171-1/1 FUEL SYSTEM LEAN
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20° F and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a certain percentage is exceeded for two trips, a freeze frame is stored, the MIL illuminates
and a trouble code is stored.
P0174-2/1 FUEL SYSTEM LEAN
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20° F and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a certain percentage is exceeded for two trips, a freeze frame is stored, the MIL illuminates
and a trouble code is stored.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
O2 SENSOR
O2 SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
O2 SENSOR HEATER OPERATION
TP SENSOR VOLTAGE GREATER THAN 0.92 OF A VOLT WITH THROTTLE CLOSED
TP SENSOR SWEEP
MAP SENSOR OPERATION
ECT SENSOR OPERATION
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR
INTERMITTENT CONDITION
PCM
315
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN —
Continued
TEST
ACTION
APPLICABILITY
1
NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Install a fuel pressure gauge.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49.2 psi +/- 5 psi).
Turn the ignition off.
Choose a conclusion that best matches your fuel pressure reading.
All
Below Specification
Go To 3
Within Specification
Go To 6
Above Specification
Replace the fuel filter/pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
CAUTION: Stop All Actuations.
3
Turn the ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 or #6631 for 3/8 fuel line adapter,
between the disconnected fuel line and the fuel pump module.
Attach a fuel pressure test gauge to the T fitting on tool #6539 or #6631.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49.2 psi +/- 5 psi).
Is the fuel pressure within specification?
Yes
→ Repair or replace fuel supply line as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Caution: Stop All Actuations.
316
All
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
All
5
Yes
→ Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
If there are no possible causes remaining, view repair.
All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6
7
8
9
Turn the ignition off.
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor and Exhaust
System to cool down before continuing the test.
Ignition on, engine not running.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage above 4.5 volts?
Yes
→ Go To
7
No
→ Go To
13
Turn the ignition off.
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down
before continuing the test.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 4.5 volts?
Yes
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
8
With the DRBIIIt, read TP Sensor voltage.
NOTE: The throttle must be against the stop.
Is the voltage 0.92 of a volt or less with the Throttle closed?
Yes
→ Go To
No
→ Check for a binding throttle condition. If OK, replace the Throttle
Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
9
With the DRBIIIt, read the TP Sensor voltage.
While monitoring the DRBIIIt, slowly open and close the throttle.
Does the voltage increase and decrease smoothly?
Yes
→ Go To
No
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10
317
All
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN —
TEST
10
Continued
ACTION
Turn the ignition off.
Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
Note: If engine will not idle, maintain a constant RPM above idle.
With the DRBIIIt in Sensors, read the MAP Sensor vacuum value.
Is the DRBIIIt reading within 19 of the Vacuum Gauge reading?
Yes
→ Go To
No
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
11
NOTE: Remove the vacuum gauge before continuing.
11
12
Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Engine Coolant Temperature Sensor value. If the engine
was allowed to sit overnight (cold soak), the temperature value should be a sensible
value that is somewhere close to the ambient temperature.
Note: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The temp
value change should be a smooth transition from start up to normal operating temp
82°C (180°F). The value should reach at least 82°C (180°F).
Did the Engine Coolant Temperature increase smoothly and did it reach at least 82°C
(180°F)?
Yes
→ Go To
No
→ Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
12
Check for any of the following conditions/mechanical problems.
AIR INDUCTION SYSTEM - must be free from leaks.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
ENGINE PCV SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
318
All
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN —
Continued
TEST
ACTION
APPLICABILITY
13
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down
before continuing the test.
Ignition on, engine not running.
Disconnect the O2 Sensor harness connector.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage above 4.5 volts?
All
14
15
Yes
→ Replace the O2 Sensor
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
14
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the O2 Sensor Signal circuit at the PCM
harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
15
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
319
All
DRIVEABILITY - GAS
Symptom List:
P0172-1/1 FUEL SYSTEM RICH
P0175-2/1 FUEL SYSTEM RICH
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0172-1/1 FUEL SYSTEM RICH.
When Monitored and Set Condition:
P0172-1/1 FUEL SYSTEM RICH
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20° F and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
the result is below a certain value for two trips, a freeze frame is stored, the MIL
illuminates and a trouble code is stored.
P0175-2/1 FUEL SYSTEM RICH
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20° F and altitude below 8000 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
the result is below a certain value for two trips, a freeze frame is stored, the MIL
illuminates and a trouble code is stored.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
INTERMITTENT CONDITION
O2 SENSOR
O2 SENSOR SIGNAL CIRCUIT OPEN
O2 SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
O2 SENSOR HEATER OPERATION
EVAP SYSTEM OPERATION
TP SENSOR VOLTAGE GREATER THAN 0.92 OF A VOLT WITH THROTTLE CLOSED
TP SENSOR SWEEP
FUEL FILTER/PRESSURE REGULATOR
MAP SENSOR OPERATION
ECT SENSOR OPERATION
ENGINE MECHANICAL PROBLEM
PCM
320
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH —
Continued
TEST
ACTION
APPLICABILITY
1
NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
NOTE: Any O2 Sensor, TPS, ECT, MAP, or EVAP DTCs must be repaired
before continuing.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Install a fuel pressure gauge.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49.2 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
All
Within Specification
Go To 3
Above Specification
Replace the fuel filter/pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
Caution: Stop All Actuations.
3
4
Ignition on, engine not running.
With the DRBIIIt, read the O2 Sensor voltage.
Is the O2 Sensor voltage above 4.5 volts?
Yes
→ Go To
4
No
→ Go To
11
Turn the ignition off.
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize between
4 and 5 volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 4.5 volts?
Yes
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
321
All
All
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH —
Continued
TEST
ACTION
APPLICABILITY
5
NOTE: The engine must be at operating temperature and in closed loop to
perform this test.
Start the engine.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Allow the engine to reach normal operating temperature.
With the DRBIIIt select System Tests, perform the Purge Vapors Test.
Observe the Short Term Adaptive value and press 3 to flow.
NOTE: Short Term Adaptive value change.
Did the Short Term Adaptive value change?
All
6
7
8
Yes
→ Go To
No
→ Refer to the Driveability category and perform the appropriate
Diagnostic test.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6
Ignition on, engine not running.
With the DRBIIIt, read TP Sensor voltage.
NOTE: The throttle must be against the stop.
Is the voltage 0.92 of a volt or less with the Throttle closed?
Yes
→ Go To
No
→ Check for a binding throttle condition. If OK, replace the Throttle
Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
With the DRBIIIt, read the TP Sensor voltage.
While monitoring the DRBIIIt, slowly open and close the throttle.
Does the voltage increase and decrease smoothly?
Yes
→ Go To
No
→ Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
8
Turn the ignition off.
Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
Note: If engine will not idle, maintain a constant RPM above idle.
With the DRBIIIt in Sensors, read the MAP Sensor vacuum value.
Is the DRBIIIt reading within 19 of the Vacuum Gauge reading?
Yes
→ Go To
No
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9
NOTE: Remove the vacuum gauge before continuing.
322
All
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH —
Continued
TEST
ACTION
APPLICABILITY
9
Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Engine Coolant Temperature Sensor value. If the engine
was allowed to sit overnight (cold soak), the temperature value should be a sensible
value that is somewhere close to the ambient temperature.
Note: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The temp
value change should be a smooth transition from start up to normal operating temp
82°C (180°F). The value should reach at least 82°C (180°F).
Did the Engine Coolant Temperature value increase smoothly and reach at least
82°C?
All
10
11
12
Yes
→ Go To
No
→ Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10
Check for any of the following conditions/mechanical problems.
AIR INDUCTION SYSTEM - must be free from restrictions.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
ENGINE PCV SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
Disconnect the O2 Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage above 4.5 volts?
Yes
→ Replace the O2 Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
12
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the O2 Sensor Signal circuit from the PCM harness
connector to the O2 Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
13
323
All
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH —
Continued
TEST
ACTION
APPLICABILITY
13
Ignition on, engine not running.
Leave the O2 Sensor and PCM harness connectors disconnected.
Measure the voltage on the O2 Sensor Signal circuit at the O2 Sensor harness
connector.
Is the voltage above 5.2 volts?
All
Yes
→ Repair the short to voltage in the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
14
NOTE: Turn the ignition off before continuing.
14
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
324
All
DRIVEABILITY - GAS
Symptom List:
P0201-INJECTOR
P0202-INJECTOR
P0203-INJECTOR
P0204-INJECTOR
P0205-INJECTOR
P0206-INJECTOR
P0207-INJECTOR
P0208-INJECTOR
P0209-INJECTOR
P0210-INJECTOR
Test Note:
#1 CONTROL CIRCUIT
#2 CONTROL CIRCUIT
#3 CONTROL CIRCUIT
#4 CONTROL CIRCUIT
#5 CONTROL CIRCUIT
#6 CONTROL CIRCUIT
#7 CONTROL CIRCUIT
#8 CONTROL CIRCUIT
#9 CONTROL CIRCUIT
#10 CONTROL CIRCUIT
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0201-INJECTOR #1 CONTROL
CIRCUIT.
When Monitored and Set Condition:
P0201-INJECTOR #1 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0202-INJECTOR #2 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0203-INJECTOR #3 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0204-INJECTOR #4 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
325
DRIVEABILITY - GAS
P0201-INJECTOR #1 CONTROL CIRCUIT —
Continued
P0205-INJECTOR #5 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0206-INJECTOR #6 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0207-INJECTOR #7 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0208-INJECTOR #8 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0209-INJECTOR #9 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
P0210-INJECTOR #10 CONTROL CIRCUIT
When Monitored: With battery voltage greater than 10.4 volts, the auto shutdown relay
energized, injector pulse width less than 10ms, and engine speed less than 3000 rpm.
Set Condition: This trouble code takes .64 to 10.0 seconds to set when no inductive kick
is sensed .18ms after injector turn off, and with no other injectors on.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(A142) ASD RELAY OUTPUT CIRCUIT
FUEL INJECTOR
FUEL INJECTOR CONTROL CIRCUIT OPEN
326
DRIVEABILITY - GAS
P0201-INJECTOR #1 CONTROL CIRCUIT —
Continued
POSSIBLE CAUSES
FUEL INJECTOR CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
NOTE: Diagnose any Misfire DTCs before continuing. If a Misfire is detected
for a particular cylinder, the PCM will shut down that Injectors Control
circuit.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDTION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the Fuel Injector harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Relay.
Using a 12-volt test light connected to ground, probe the (A142) ASD Relay Output
circuit at the Fuel Injector harness connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the (A142) ASD Relay
Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Using a 12-volt test light connected to 12-volts, backprobe the Fuel Injector Driver
circuit.
With the DRBIIIt, actuate the Fuel Injector.
What is the state of the test light while actuating the Fuel Injector?
All
Brightly blinking or flickering.
Replace the Fuel Injector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ON constantly.
Go To
4
OFF constantly.
Go To 5
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the Fuel Injector Control circuit at the
Fuel Injector harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Fuel Injector Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
327
All
DRIVEABILITY - GAS
P0201-INJECTOR #1 CONTROL CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the Fuel Injector Control circuit from the Fuel Injector
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
All
6
Yes
→ Go To
No
→ Repair the open in the Fuel Injector Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
328
All
DRIVEABILITY - GAS
Symptom List:
P0300-MULTIPLE
P0301-CYLINDER
P0302-CYLINDER
P0303-CYLINDER
P0304-CYLINDER
P0305-CYLINDER
P0306-CYLINDER
P0307-CYLINDER
P0308-CYLINDER
P0309-CYLINDER
P0310-CYLINDER
Test Note:
CYLINDER MIS-FIRE
#1 MISFIRE
#2 MISFIRE
#3 MISFIRE
#4 MISFIRE
#5 MISFIRE
#6 MISFIRE
#7 MISFIRE
#8 MISFIRE
#9 MISFIRE
#10 MISFIRE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0300-MULTIPLE CYLINDER
MIS-FIRE.
When Monitored and Set Condition:
P0300-MULTIPLE CYLINDER MIS-FIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0301-CYLINDER #1 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0302-CYLINDER #2 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0303-CYLINDER #3 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
329
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
P0304-CYLINDER #4 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0305-CYLINDER #5 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0306-CYLINDER #6 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0307-CYLINDER #7 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0308-CYLINDER #8 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0309-CYLINDER #9 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
P0310-CYLINDER #10 MISFIRE
When Monitored: Any time the engine is running, and the adaptive numerator has been
successfully updated.
Set Condition: When more than a 1% misfire rate is measured during two trips, or with
a 6% to 30% misfire rate during one trip.
330
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
POSSIBLE CAUSES
INTERMITTENT MISFIRE
VISUAL INSPECTION
IGNITION WIRE
ASD RELAY OUPUT CIRCUIT
ENGINE MECHANICAL PROBLEM
IGNITION COIL
COIL CONTROL CIRCUIT
SPARK PLUG
CHECKING FUEL PRESSURE
FUEL PUMP INLET STRAINER PLUGGED
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP MODULE
CHECKING FUEL LEAK DOWN
FUEL INJECTOR
INJECTOR CONTROL CIRCUIT
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Check for any TSB’s that apply to a Misfire condition. Review the
vehicle repair history for any misfire condition repairs that have been
performed.
Read and record the FREEZE FRAME DATA. Select OBD II MONITORS. Read and
record the MIS-FIRE SIMILAR CONDITIONS WINDOW DATA.
With these screens, attempt to duplicate the condition(s) that has set this DTC.
When the vehicle is operating in the SIMILAR CONDITIONS WINDOW, refer to the
WHICH CYLINDER IS MISFIRING screen.
Observe the WHICH CYLINDER IS MISFIRING screen for at least one minute.
Is there a misfire present?
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
331
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
TEST
ACTION
APPLICABILITY
2
NOTE: Anything that affects the speed of the crankshaft can cause a misfire
DTC.
NOTE: When a Misfire is detected for a particular cylinder, the PCM will
shut down that cylinders Injector Control circuit.
- Visually inspect the engine for any of the following conditions.
- Worn serpentine belt
- Binding Engine-Driven accessories: A/C Compressor, P/S Pump, Water pump.
- Misalignment Water pump, P/S Pump and A/C Compressor pulleys
- Corroded PCM power and ground circuits.
- Improper CKP, CMP, MAP, and TP Sensor mounting
- Poor connector/terminal to component connection. i.e., CKP sensor, Fuel Injector,
Ign coil, etc.
- Vacuum leaks
- Restricted Air Induction system or Exhaust system.
Were any of the above conditions present?
All
3
4
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Turn the ignition off.
Disconnect the Ignition Coil harness connectors.
Disconnect the Fuel Injector harness connectors.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Relay.
Using a 12-volt test light connected to ground, probe the (A142) ASD Relay Output
circuit at the Ignition Coil harness connector and Fuel Injector harness connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the excessive resistance or short to ground in the (A142)
ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
4
Turn the ignition off.
Connect the Ignition Coil harness connector.
Disconnect the Ignition wire from the spark plug.
Disconnect the Fuel Injector harness connector of the cylinder being tested.
NOTE: Before continuing inspect the ignition wire for damage or carbon
tracking. Replace as necessary.
Install a spark tester on the ignition wire.
While cranking the engine observe the spark coming from the spark tester.
NOTE: A crisp blue spark that is able to jump the gap of the spark tester
should be generated.
Is good spark present?
Yes
→ Go To
5
No
→ Go To
14
NOTE: Connect the Fuel Injector harness connector before continuing.
332
All
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
TEST
ACTION
APPLICABILITY
5
Turn the ignition off.
Remove the Spark Plug.
Inspect the Spark Plug for the following conditions.
- Cracks
- Carbon Tracking
- Foreign Material
- Gap size out of specifications
- Loose or broke electrode
NOTE: Lightly tap the bottom of the spark plug on a solid surface. The
electrode in the spark plug should not move.
Were any of the above condition present?
All
6
Yes
→ Replace the Spark Plug.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Install a fuel pressure gauge to the fuel rail.
Start the engine and observe the fuel pressure reading.
NOTE: Fuel pressure specification is 334 KPa +/- 34 KPa (49 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
All
Within Specification
Go To 7
Below Specification
Go To 12
Above Specification
Replace the fuel filter/pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7
NOTE: Before continuing visually and physically inspect the fuel delivery
system for external leaks or damage. Repair /replace as necessary.
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install special tool #6539 (5/169) or #6631 (3/89) fuel line adapter.
Install the fuel pressure gauge.
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: Fuel specification is 334 KPa +/- 34 KPa (49 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the
fuel pressure gauge and the engine.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure gauge fall below the listed specification?
Yes
→ Replace the leaking Fuel Injector(s).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
333
All
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
TEST
ACTION
APPLICABILITY
8
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
CAUTION: After each Fuel Injector actuation, start the engine to clean the
cylinder of fuel. Failure to do so could cause engine damage.
Remove special tool #C4390.
Start the engine and allow the fuel pressure to reach maximum pressure.
Using the DRBIIIt, actuate the Fuel Injector for the cylinder that indicated the
misfire.
Monitor the fuel pressure gauge.
Does the fuel pressure gauge indicate a drop in fuel pressure?
All
Yes
→ Go To
9
No
→ Go To
10
NOTE: Turn the ignition off, remove the Fuel Pressure gauge, and connect
the fuel lines before continuing.
9
10
Check for any of the following conditions/mechanical problems.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
ENGINE PCV SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
CAM LOBES - must not be worn excessively
CYLINDER LEAKAGE TEST - must be within specifications
VALVE SPRINGS - cannot be weak or broken
Are there any engine mechanical problems?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
17
Turn the ignition off.
Disconnect the Fuel Injector harness connector.
Ignition on, engine not running.
NOTE: When a Misfire is detected for a particular cylinder, the PCM will
shut down that cylinders Injector Control circuit.
With the DRBIIIt, erase DTCs.
Using a 12-volt test light connected to 12-volts, probe the Injector Control circuit.
With the DRBIIIt, actuate the Fuel Injector.
Does the test light blink/flicker?
Yes
→ Replace the Fuel Injector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
11
334
All
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
TEST
ACTION
APPLICABILITY
11
Turn the ignition off.
Disconnect the PCM harness connectors.
Check the Injector Control circuit for an open, short to ground, and short to voltage.
Was a problem found with the Injector Control circuit?
All
12
13
14
Yes
→ Repair the excessive resistance or short in the Injector Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
17
Turn the ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose, fitting or line, the fuel
system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special tool #6539 (5/169) #6631(3/89) fuel line adapter and the fuel pressure
gauge between the fuel supply line and the fuel pump module.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49 psi +/- 5 psi).
Is the fuel pressure within specification?
Yes
→ Repair or replace fuel supply line as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
13
Turn the ignition off.
Warning: The fuel system is under a constant pressure (even with the engine
off). Before testing or servicing any fuel system hose,fitting or line, the fuel
system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
Yes
→ Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ NOTE: Before continuing, check the Fuel Pump Module harness
connector terminals for corrosion, damage, or terminal push out.
Ensure the ground circuit is operating properly. Repair as necessary. Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
NOTE: If the vehicle being tested does not have an ignition wire answer YES
to this test and continue.
Turn the ignition off.
Remove the ignition wire.
Measure the resistance of the ignition wire.
Is the resistance below 10K ohms?
Yes
→ Go To
No
→ Replace the Ignition Wire.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
15
335
All
All
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE —
Continued
TEST
ACTION
APPLICABILITY
15
Remove the Fuel Pump Relay or ASD Relay.
Using a 12-volt test light connected to 12-volts, probe the Ignition Coil Control circuit
in the Ignition Coil harness connector.
Crank the engine for 5 second while observing the test light.
NOTE: The primary resistance of the 8.0L Ignition coil is 0.53 to 0.65 of an
ohm, the resistance of a 5.9L Ignition coil is 0.95 of an to 1.2 ohms, and the
resistance of a 3.7L coil is 0.6 to 0.9 of an ohm at 77°F (25°C).
Does the test light brightly blink/flicker?
All
16
17
Yes
→ Replace the Ignition Coil.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
16
Turn the ignition off.
Disconnect the PCM harness connectors.
Check the Coil Control circuit for an open, short to ground, and short to voltage.
Was a problem found with the Coil Control circuit?
Yes
→ Repair the Coil Control circuit for an open or shorted condition.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
17
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors.
Pay particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information
Perform POWERTRAIN VERIFICATION TEST VER - 5.
336
All
DRIVEABILITY - GAS
Symptom:
P0320-NO CRANK REFERENCE SIGNAL AT PCM
When Monitored and Set Condition:
P0320-NO CRANK REFERENCE SIGNAL AT PCM
When Monitored:
With the ignition on.
Set Condition: No signal from the Crankshaft Position Sensor is present during engine
cranking, and at least 3 Camshaft Position Sensor signals have occurred.
POSSIBLE CAUSES
CAM POSITION SENSOR SIGNAL
INTERMITTENT CRANK POSITION SIGNAL
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
(K24) CKP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K24) CKP SENSOR SIGNAL CIRCUIT OPEN
(K24) CKP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K24) CKP SENSOR SIGNAL SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
CRANKSHAFT POSITION SENSOR
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, erase DTCs.
Start the engine.
If the DTC does not set right away it may be necessary to test drive the vehicle.
Does the DTC return?
Yes
→ Go To
2
No
→ Go To
14
Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage of the (K7) 5-volt Supply circuit at the CKP Sensor harness
connector.
Is the voltage between 4.8 and 5.2 volts?
Yes
→ Go To
3
No
→ Go To
10
337
APPLICABILITY
All
All
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the voltage on the (K24) CKP Sensor Signal circuit at the CKP Sensor
harness connector.
Is the voltage between 4.5 and 5.0 volts?
All
4
5
Yes
→ Go To
4
No
→ Go To
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K4) Sensor ground circuit from the CKP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
NOTE: Inspect the slots on the flywheel for damage. If a problem is found
repair as necessary.
If there are no possible causes remaining, view repair.
All
Repair
Replace the Crankshaft Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6
7
8
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage of the (K24) CKP Sensor Signal circuit at the CKP Sensor
harness connector.
Is the voltage above 5.3 volts?
Yes
→ Repair the short to voltage in the (K24) CKP Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Turn the ignition off.
Measure the resistance of the (K24) CKP Sensor Signal circuit from the CKP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K24) CKP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
8
Measure the resistance between ground and the (K24) CKP Sensor Signal circuit at
the CKP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K24) CKP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
9
338
All
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the (K24) CKP Sensor Signal circuit and the (K7)
5-volt Supply circuit at the CKP Sensor harness connector.
Is the resistance below 5.0 ohms?
All
10
11
12
13
Yes
→ Repair the short between the (K7) 5-volt Supply circuit and the
(K24) CKP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
13
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage of the (K7) 5-volt Supply circuit at the CKP Sensor harness
connector.
Is the voltage above 5.3 volts?
Yes
→ Repair the short to voltage in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
11
Turn the ignition off.
Measure the resistance of the (K7) 5-volt Supply circuit from the CKP Sensor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
12
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the CKP
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
13
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
339
All
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
14
NOTE: The following tests may help in identifying a possible intermittent
condition with the Crank Sensor or its related wire harness.
Ignition on, engine not running.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K24) CKP Signal circuit in the Crank Sensor connector and the PCM
harness connector.
Wiggle the related wire harness and connections.
Monitor the lab scope screen.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Lightly tap on the Crank Sensor and wiggle the CKP Sensor connector and the
related wire harness.
Observe the lab scope screen.
Look for any erratic pulses generated by the CKP Sensor.
Did the CKP Sensor generate any erratic pulses?
All
15
Yes
→ Carefully inspect the wire harness and connections, repair as
necessary, if ok, replace the Crank Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
15
NOTE: An intermittent failure with the Cam Position Sensor may cause the
P0320 code to set.
Turn the ignition off.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K44) CMP Signal circuit in the CMP Sensor connector and the PCM
harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Ignition on, engine not running.
Wiggle the related wire harness and gently tap on the Cam Position Sensor.
Monitor the lab scope screen.
Start the engine.
Lightly tap on the CMP Sensor and wiggle the related wire harness.
Observe the lab scope screen, looking for any erratic pulses generated by the CMP
Sensor.
Did the CMP Sensor generate any erratic pulses?
Yes
→ Carefully inspect the wire harness and connections, repair as
necessary, if ok, replace the Cam Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
340
All
DRIVEABILITY - GAS
Symptom List:
P0325-KNOCK SENSOR #1 CIRCUIT
P0330-KNOCK SENSOR #2 CIRCUIT
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0325-KNOCK SENSOR #1
CIRCUIT.
When Monitored and Set Condition:
P0325-KNOCK SENSOR #1 CIRCUIT
When Monitored:
With the ignition on and the engine running.
Set Condition: Knock Sensor #1 signal below minimum acceptable threshold voltage at
particular engine speeds or above 5.0 volts.
P0330-KNOCK SENSOR #2 CIRCUIT
When Monitored:
With the ignition on and the engine running.
Set Condition: Knock Sensor #2 signal below minimum acceptable threshold voltage at
particular engine speeds or above 5.0 volts.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K73) OR (K74) KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K73) OR (K74) KNOCK SENSOR SIGNAL CIRCUIT OPEN
(K73) OR (K74) KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K73) OR (K74) KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Record the Freeze Frame Information that set along with the DTC.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
341
DRIVEABILITY - GAS
P0325-KNOCK SENSOR #1 CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
2
NOTE: (K73) is the Knock Sensor No.1 Signal circuit and (K74) is the Knock
Sensor No.2 Signal circuit.
Turn the ignition off.
Disconnect the Knock Sensor harness connector.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K73) or (K74) Knock Sensor Signal circuit in the Knock
Sensor harness connector.
Is the voltage above 2.0 volts?
All
3
4
5
6
Yes
→ Repair the short to voltage in the (K73) or (K74) Knock Sensor
Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Turn the ignition off.
Measure the resistance of the (K73) or (K74) Knock Sensor Signal circuit from the
Knock Sensor harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K73) or (K74) Knock Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
4
Measure the resistance between ground and the appropriate Knock Sensor Signal
circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K73) or (K74) Knock Sensor
Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
Measure the resistance between the (K73) or (K74) Knock Sensor Signal circuit and
the (K4) Sensor ground circuit in the Knock Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K73) or (K74) Knock Sensor Signal
circuit and the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
Measure the resistance of the (K4) Sensor ground circuit from the Knock Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7
342
All
DRIVEABILITY - GAS
P0325-KNOCK SENSOR #1 CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
7
Connect the PCM harness connectors.
Replace the Knock Sensor.
Ignition on, engine not running.
With the DRBIIIt, erase DTC.
Attempt to operate the vehicle within the operating range of the information in
Freeze Frame.
With the DRBIIIt, read DTC’s.
Does the Knock Sensor DTC return?
All
Yes
→ NOTE: Before continuing, check the PCM harness connector
terminals for corrosion, damage, or terminal push out. Repair as
necessary. Replace and program the Powertrain Control Module
per Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
343
DRIVEABILITY - GAS
Symptom:
P0340-NO CAM REFERENCE SIGNAL AT PCM
When Monitored and Set Condition:
P0340-NO CAM REFERENCE SIGNAL AT PCM
When Monitored:
Engine cranking/running.
Set Condition: At least 5 seconds have elapsed with Crankshaft Position Sensor signals
present but no Camshaft Position Sensor signal.
POSSIBLE CAUSES
CHECKING INTERMITTENT CMP SIGNAL WITH LAB SCOPE
CRANK POSITION SENSOR SIGNAL
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
(K44) CMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K44) CMP SENSOR SIGNAL CIRCUIT OPEN
(K44) CMP SENSOR SIGNAL CIRCUIT SHORTED GROUND
(K44) CMP SENSOR SIGNAL SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
CAMSHAFT POSITION SENSOR
PCM
TEST
ACTION
APPLICABILITY
1
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, erase DTCs.
Start the engine.
If the DTC does not set right away it may be necessary to take the vehicle on a test
drive.
Does the DTC return?
All
2
Yes
→ Go To
2
No
→ Go To
14
Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit at the CMP Sensor harness
connector.
Is the voltage between 4.8 and 5.2 volts?
Yes
→ Go To
3
No
→ Go To
10
344
All
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the voltage on the (K44) CMP Sensor Signal circuit at the CMP Sensor
harness connector.
Is the voltage between 4.5 and 5.0 volts?
All
4
5
Yes
→ Go To
4
No
→ Go To
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K4) Sensor ground circuit from the CMP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
NOTE: Inspect the Camshaft sprocket for damage per the Service Information. If a problem is found repair as necessary.
If there are no possible causes remaining, view repair.
All
Repair
Replace the Camshaft Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6
7
8
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K44) CMP Sensor Signal circuit at the CMP Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K44) CMP Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Turn the ignition off.
Measure the resistance of the (K44) CMP Sensor Signal circuit from the CMP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K44) CMP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
8
Measure the resistance between ground and the (K44) CMP Sensor Signal circuit at
the CMP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K44) CMP Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
9
345
All
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between the (K44) CMP Sensor Signal circuit and the (K7)
5-volt Supply circuit in the CMP Sensor harness connector.
Is the resistance below 100 ohms?
All
10
11
12
13
Yes
→ Repair the short between the (K7) 5-volt Supply circuit and the
(K44) CMP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
13
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit at the CMP Sensor harness
connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
11
Turn the ignition off.
Measure the resistance of the (K7) 5-volt Supply circuit from the CMP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
12
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the
CMP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
13
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
346
All
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM —
Continued
TEST
ACTION
APPLICABILITY
14
NOTE: The following tests may help in identifying a possible intermittent
condition with the Cam Sensor or its related wire harness.
Ignition on, engine not running.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K44) CMP Signal circuit in the Cam Sensor connector and the PCM
harness connector.
Wiggle the related wire harness and connections.
Monitor the lab scope screen.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Lightly tap on the Cam Sensor and wiggle the CMP Sensor connector and wire
harness.
Observe the lab scope screen.
Look for any erratic pulses generated by the CMP Sensor.
Did the CMP Sensor generate any erratic pulses?
All
15
Yes
→ Carefully inspect the wire harness and connections, repair as
necessary, if ok, replace the Cam Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
15
NOTE: An intermittent Crank Position Sensor failure may cause the P0340
code to set.
Ignition on, engine not running.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K24) CKP Signal circuit in the Crank Sensor connector and the PCM
harness connector.
Wiggle the related wire harness and connections.
Monitor the lab scope screen.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Lightly tap on the Crank Sensor and wiggle the CKP Sensor connector and wire
harness.
Observe the lab scope screen.
Look for any erratic pulses generated by the CKP Sensor.
Did the CKP Sensor generate any erratic pulses?
Yes
→ Carefully inspect the wire harness and connections, repair as
necessary, if ok, replace the Crank Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
347
All
DRIVEABILITY - GAS
Symptom List:
P0351-IGNITION
P0352-IGNITION
P0353-IGNITION
P0354-IGNITION
P0355-IGNITION
Test Note:
COIL
COIL
COIL
COIL
COIL
#1
#2
#3
#4
#5
PRIMARY
PRIMARY
PRIMARY
PRIMARY
PRIMARY
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0351-IGNITION COIL #1 PRIMARY CIRCUIT.
When Monitored and Set Condition:
P0351-IGNITION COIL #1 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0352-IGNITION COIL #2 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0353-IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0354-IGNITION COIL #4 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
348
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT —
Continued
P0355-IGNITION COIL #5 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(A142) ASD RELAY OUTPUT CIRCUIT
IGNITION COIL RESISTANCE
IGNITION COIL
IGNITION COIL CONTROL CIRCUIT OPEN
IGNITION COIL CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDTION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
2
Turn the ignition off.
Disconnect the Ignition coil harness connector.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the (A142) ASD Relay Output
circuit at the coil harness connector.
With the DRBIIIt, actuate the ASD Relay.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Inspect the related fuse. Repair the open/excessive resistance or
short to ground in the (A142) ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
3
Stop All Actuations
349
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT —
TEST
3
4
Continued
ACTION
Turn the ignition off.
The resistance of the 5.9L Primary Ignition coil is 0.95 of and ohm to 1.2 ohms.
The resistance of a 8.0L Primary Ignition coil is 0.53 to 0.65 of an ohm.
Measure the resistance of the primary Ignition coil.
Is the resistance within the appropriate specification?
Yes
→ Go To
No
→ Replace the Ignition coil.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
4
Using a 12-volt test light connected to a 12-volt source, probe the Ignition Coil Driver
circuit.
Crank the engine for 5 seconds while observing the test light.
What is the condition of the test light while cranking the engine?
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
Brightly blinking.
Replace the Ignition Coil Rail.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ON constantly.
Go To
5
OFF constantly.
Go To 6
5
6
7
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between the Ignition Coil Control circuit and ground.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Ignition Coil Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
7
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the Ignition Coil Control circuit from the Ignition Coil
connector to the PCM connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the Ignition Coil Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
350
ENGINE - 9MAGNUM9 8.0L V10
MPI or ENGINE 9MAGNUM9 5.9L
SMPI V8
DRIVEABILITY - GAS
Symptom List:
P0351-IGNITION
P0352-IGNITION
P0353-IGNITION
P0354-IGNITION
P0355-IGNITION
P0356-IGNITION
Test Note:
COIL
COIL
COIL
COIL
COIL
COIL
#1
#2
#3
#4
#5
#6
PRIMARY
PRIMARY
PRIMARY
PRIMARY
PRIMARY
PRIMARY
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0351-IGNITION COIL #1 PRIMARY CIRCUIT.
When Monitored and Set Condition:
P0351-IGNITION COIL #1 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0352-IGNITION COIL #2 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0353-IGNITION COIL #3 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0354-IGNITION COIL #4 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
351
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT —
Continued
P0355-IGNITION COIL #5 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
P0356-IGNITION COIL #6 PRIMARY CIRCUIT
When Monitored: With battery voltage greater than 8 volts during engine cranking or
greater than 12 volts with engine running, engine rpm less than 2016, and none of the coils
in dwell when checked.
Set Condition: Peak current is not achieved with battery based dwell plus 1.5 msec of
diagnostic offset. It takes less than 3 seconds during cranking or up to 6 seconds while
running to set.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(A142) ASD RELAY OUTPUT CIRCUIT OPEN
CAPACITOR(S) SHORTED TO GROUND
(A142) ASD RELAY OUTPUT CIRCUIT SHORTED TO GROUND
COIL ON PLUG RESISTANCE
COIL ON PLUG
COIL CONTROL CIRCUIT SHORTED TO GROUND
COIL CONTROL CIRCUIT OPEN
PCM
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero for?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
352
APPLICABILITY
ENGINE - 9MAGNUM9 3.7L V6
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
2
Turn the ignition off.
Disconnect the coil on plug harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Relay.
Using a 12-volt test light connected to ground, probe the (A142) ASD Relay Output
circuit at the Coil on plug harness connector.
Does the test light illuminate brightly?
ENGINE - 9MAGNUM9 3.7L V6
Yes
→ Go To
3
No
→ Go To
8
Stop All Actuations
3
4
Turn the ignition off.
Disconnect the coil on plug harness connector.
NOTE: The following resistance measurement should be taken at 70°-80° F.
Measure the resistance of the Primary Ignition Coil.
3.7L Primary Ignition Coil resistance is 0.6 to 0.9 of an ohm at 77°F (25°C).
Is the resistance within the given specification for the Ignition Coil being tested?
Yes
→ Go To
No
→ Replace the coil on plug.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 3.7L V6
4
Using a 12-volt test light connected to a 12-volt source, probe the Ignition Coil Driver
circuit.
Crank the engine for 5 seconds while observing the test light.
What is the condition of the test light while cranking the engine?
ENGINE - 9MAGNUM9 3.7L V6
Brightly blinking.
Replace the Coil on plug.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ON constantly.
Go To
5
OFF constantly.
Go To 6
5
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between the Coil Control circuit and known good ground.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Coil Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 3.7L V6
7
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the Coil Control circuit from the Coil on plug connector to
the PCM connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the Coil Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7
353
ENGINE - 9MAGNUM9 3.7L V6
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, review repair.
ENGINE - 9MAGNUM9 3.7L V6
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8
9
Turn the ignition off.
Remove the ASD Relay from the IPM.
Measure the resistance of the (A142) ASD Relay Output circuit between the ASD
Relay connector and the Ignition Coil harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (A142) ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 3.7L V6
9
Install the ASD Relay.
NOTE: Repeat the following test for both capacitors
NOTE: The Capacitors are attached to the side of each valve cover.
Disconnect the Capacitor harness connector.
Install a good INJ/COIL fuse.
With the DRBIIIt, actuate the ASD Relay.
NOTE: If the above test results in an open fuse for both capacitor tests, the
problem is a short to ground in the (A142) ASD Relay Output circuit. Repair
the short to ground in the (A142) ASD Relay Output circuit and refer to
VER-5
Is the INJ/COIL fuse OK for both capacitor tests?
Yes
→ Replace the Capacitor(s)
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Repair the short to ground in the (A142) ASD Relay Output
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
354
ENGINE - 9MAGNUM9 3.7L V6
DRIVEABILITY - GAS
Symptom List:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0420-1/1 CATALYTIC CONVERTER EFFICIENCY.
When Monitored and Set Condition:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 147° F, 180 seconds of open throttle operation,
at a speed greater than 20 mph, with the engine at 1200-1700 rpm and MAP vacuum
between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY
When Monitored: After engine warm up to 147° F, 180 seconds of open throttle operation,
at a speed greater than 20 mph, with the engine at 1200-1700 rpm and MAP vacuum
between 15.0 and 21.0 inches of mercury (Hg).
Set Condition: As catalyst efficiency deteriorates, the switch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. If at any point during the test the
switch ratio reaches a predetermined value a counter is incremented by one.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
VISUALLY INSPECT CATALYTIC CONVERTER
EXHAUST LEAK
ENGINE MECHANICAL PROBLEM
UPSTREAM O2 SENSOR OLDER THAN DOWNSTREAM O2 SENSOR
CATALYTIC CONVERTER
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
355
APPLICABILITY
All
DRIVEABILITY - GAS
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY —
TEST
2
3
4
5
6
Continued
ACTION
Inspect the Catalytic Converter for the following damage.
Damage Catalytic Converter, dent and holes.
Severe discoloration caused by overheating the Catalytic Converter.
Catalytic Converter broke internally.
Leaking Catalytic Converter.
Were any problems found?
Yes
→ Replace the Catalytic Converter. Repair the condition that may
have caused the failure.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
APPLICABILITY
All
3
Start Engine and let idle.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Check for exhaust leaks between the engine and the appropriate downstream O2
Sensor.
Is there any exhaust leaks?
Yes
→ Repair or replace leaking exhaust parts as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Check the exhaust for excessive smoke from internal oil or coolant leaks.
Is there an oil or coolant consumption condition present?
Yes
→ Repair engine mechanical condition as necessary and replace
Catalytic Converter.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
Turn the ignition off.
NOTE: A new Downstream O2 Sensor along with an aging Upstream O2
Sensor may cause this trouble code to set.
Review vehicle repair history.
Has the Downstream O2 Sensor been replaced without replacing the Upstream O2
Sensor?
Yes
→ Replace the appropriate Upstream Oxygen Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
If there are no possible causes remaining, view repair.
Repair
Replace the Catalytic Converter.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
356
All
DRIVEABILITY - GAS
Symptom:
P0441-EVAP PURGE FLOW MONITOR
When Monitored and Set Condition:
P0441-EVAP PURGE FLOW MONITOR
When Monitored: With engine temperature greater than 170° F, fuel control in closed
loop, engine idling for 2 minutes, no low fuel, MAP less than 15.7 inches mercury and
barometric altitude less than 8,000 feet.
Set Condition: After having passed the Leak Detection Pump (LDP) test, no air flow
through the evaporative system is detected by the EVAP monitor.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
INTERMITTENT CONDITION
VISUAL INSPECTION
EVAP PURGE HOSE (SOLENOID TO CANISTER)
EVAP PURGE HOSE (CANISTER TO FUEL TANK)
EVAP PURGE SOLENOID VACUUM SUPPLY
EVAP PURGE SOLENOID (LEAKS/STUCK OPEN)
EVAP PURGE SOLENOID
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Visually inspect the Evap canister. Look for any physical damage or any signs of fuel
that has entered the canister. Any signs of fuel may indicate a bad rollover valve.
Were any problems found?
Yes
→ Repair or Replace as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
357
All
DRIVEABILITY - GAS
P0441-EVAP PURGE FLOW MONITOR —
Continued
TEST
ACTION
APPLICABILITY
3
Visually inspect the Evap purge hose that goes from the Purge Solenoid to the Evap
Canister. Look for any physical damage such as a pinched, plugged, ripped or dry
rotted hose.
Were any problems found?
All
4
5
6
7
Yes
→ Repair or replace hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Visually inspect the Evap Purge hose that goes between the Evap canister and the
fuel tank. Look for any physical damage such as a pinched, plugged, ripped or dry
rotted hose.
Were any problems found?
Yes
→ Repair or replace hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
Carefully inspect the Evap Purge Solenoid vacuum supply hose for proper routing.
Also check for a pinched or plugged hose from the throttle body to the Purge Solenoid.
Inspect the vacuum nipple at the throttle body for any damage or plugging.
Make sure vacuum fitting at the purge solenoid is not over installed.
Is the vacuum supply hose and throttle body vacuum nipple free from defects?
Yes
→ Go To
No
→ Repair the vacuum supply hose/tube as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
Note: After disconnecting the Evap Purge Solenoid vacuum connections,
inspect the lines and solenoid for any signs of contamination from the EVAP
Canister. This may indicate a faulty rollover valve. Replace purge solenoid
if contamination is found
Disconnect the vacuum hoses at the EVAP Purge Solenoid.
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid
vacuum source port. (component side)
Does the Evap Purge Solenoid hold vacuum?
Yes
→ Go To
No
→ Replace the Evap Purge Solenoid and the Evap Canister and
clean out Evap lines as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
7
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid
vacuum source port. (component side)
Ignition on, engine not running.
With the DRBIIIt, actuate the EVAP Purge Solenoid and observe the vacuum gauge.
Does the vacuum drop when the solenoid is actuated?
Yes
→ Refer to the INTERMITTENT CONDTION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Evap Purge Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
358
All
DRIVEABILITY - GAS
Symptom List:
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
P0456-EVAP LEAK MONITOR SMALL (.020) LEAK DETECTED
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0442-EVAP LEAK MONITOR
MEDIUM (0.040) LEAK DETECTED.
When Monitored and Set Condition:
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 40° F and 90° F and coolant temperature within 10° F of battery/ambient.
Set Condition: If there is a leak larger than 0.0409 and smaller than 0.0809 in the
evaporative system.
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 40° F and 90° F and coolant temperature within 10° F of battery/ambient.
Set Condition:
There is a leak larger than 0.0809 in the evaporative system.
P0456-EVAP LEAK MONITOR SMALL (.020) LEAK DETECTED
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 40° F and 90° F and coolant temperature within 10° F of battery/ambient.
Set Condition: There is a leak larger than 0.0209 and smaller than 0.0409 in the
evaporative system.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
INTERMITTENT CONDITION
VERIFY EVAPORATIVE EMISSION SYSTEM LEAK
EVAPORATIVE EMISSION LEAK DETECTION
EVAP PURGE SOLENOID
359
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED —
Continued
TEST
ACTION
APPLICABILITY
1
Note: A loose gas cap could have caused this DTC to set. Make sure gas cap
is tight and in good condition. Ensure the gas cap meets OEM specifications.
NOTE: Engine vacuum at must be present at the LDP vacuum port.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
2
To continue testing you will need Miller Tool #8404 Evaporative Emission Leak
Detector (EELD).
WARNING: Keep lit cigarettes, sparks, flames, and other ignition sources
away from the test area to prevent the ignition of explosive gases. Keep the
test area well ventilated.
NOTE: The fuel tank should have between 20% and 80% of fuel tank capacity
to properly test the Evap system.
Disconnect the vacuum supply hose at the Leak Detection Pump.
Connect and apply a continuous vacuum supply (i.e. 209Hg) to the Leak Detection
Pump. A vacuum pump such as an A/C recovery unit works well.
Using the DRBIIIt, select Engine/System Tests and actuate the Leak Detect Pump
Test (Option 3/Hold PSI).
NOTE: The above energizes the LDP solenoid and allows the constant
vacuum source to apply vacuum to the LDP pump diaphragm. This lifts the
diaphragm up and seals the atmospheric canister vent valve at the bottom
of the Leak Detection Pump.
Connect the red power lead of Miller Tool #8404 to the battery positive terminal and
the black ground lead to battery negative terminal.
NOTE: See Charts and Graph support material EELD Calibration Setup for
an example.
Connect shop air to the #8404 EELD.
Set the smoke/air control switch to AIR.
Insert the tester’s AIR supply tip (clear hose) into the appropriate calibration orifice
on the tester’s control panel (based on DTC leak size).
Press the remote smoke/air start button.
Position the red flag on the air flow meter so it is aligned with the indicator ball.
When the calibration is complete, release the remote button. The EELD is now
calibrated the flow meter in liters per minute to the size leak indicated by the DTC
set in the PCM.
Install the service port adapter #8404-14 on the vehicle’s service port.
Connect the Air supply hose from the EELD to the service port.
Press the remote button to activate AIR flow.
NOTE: Larger volume fuel tanks, and/or those with less fuel, may require 4
to 5 minutes to fill.
Compare the flow meter indicator ball reading to the red flag.
ABOVE the red flag indicates a leak present.
BELOW the red flag indicates a sealed system.
Is the indicator ball above the red flag?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
3
360
All
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED —
Continued
TEST
ACTION
APPLICABILITY
3
NOTE: A thorough visual inspection of the Evap system hoses, tubes, and
connections may save time in your diagnosis. Look for any physical damage
or signs of wetness at connections. The strong smell of fuel vapors may aid
diagnosis also.
To continue testing, you will need Miller Tool #8404 Evaporative Emissions Leak
Detector (EELD).
Remove the Air supply hose from the service port.
Connect the SMOKE supply tip (black hose) to the service port.
Set the smoke/air control switch to SMOKE.
NOTE: The flow meter indicator ball will not move at this point.
Press the remote smoke/air start button.
NOTE: Ensure that smoke has filled the EVAP system by continuing to press
the remote smoke/air start button, remove the vehicle fuel cap, and wait for
the smoke to exit. Once smoke is indicated reinstall the fuel cap.
NOTE: For optimal performance, introduce smoke into the system for an
additional 60 seconds; continue introducing smoke at 15 second intervals,
as necessary.
While still holding the remote smoke/air start button, use the white light (#8404CLL) to follow the EVAP system path, and look for the source of the leak indicated by
exiting smoke.
If a leak is concealed from view (i.e., top of fuel tank), release the remote smoke/air
start button, and use the ultraviolet (UV) black light #8404-UVL and the yellow
goggles 8404-20 to look for residual traces of dye that is left behind by the smoke.
The exiting smoke deposits a residual fluid that is either bright green or bright
yellow in color when viewed with a UV light.
Was a leak found?
All
4
Yes
→ Repair or replace the leaking component as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Go To
4
NOTE: After disconnecting the Evap Purge Solenoid vacuum connections,
inspect the lines and solenoid for any signs of contamination from the EVAP
Canister. This may indicate a faulty rollover valve. Replace/repair as
necessary.
Turn the ignition off.
Disconnect the vacuum hoses at the Evap Purge Solenoid.
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid
vacuum source port on the component side.
NOTE: Monitor the vacuum gauge for at least 15 seconds.
Does the Evap Purge Solenoid hold vacuum?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Replace the EVAP Purge Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
361
All
DRIVEABILITY - GAS
Symptom:
P0443-EVAP PURGE SOLENOID CIRCUIT
When Monitored and Set Condition:
P0443-EVAP PURGE SOLENOID CIRCUIT
When Monitored:
above 10.4 volts.
Continuously after the ignition is turned on and the battery voltage is
Set Condition: Not powering down, not in limp-in and time since last solenoid activation
is greater than 72 micro seconds. The PCM will set a trouble code if the actual state of the
solenoid does not match the intended state on two consecutive key cycles.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(Y134) FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
EVAP PURGE SOLENOID
(K52) EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
(K52) EVAP PURGE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Evap Purge Solenoid connector.
Measure the resistance between the terminals of the Evap Purge Solenoid.
Is the resistance between 29.0 and 44.0 ohms?
Yes
→ Go To
No
→ Replace the Evap Purge Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
3
362
All
DRIVEABILITY - GAS
P0443-EVAP PURGE SOLENOID CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
3
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the (Y134) Fused Ignition
Switch Output circuit.
Does the test light illuminate brightly?
All
4
5
6
Yes
→ Go To
No
→ Repair the excessive resistance or short to ground in the (Y134)
Fused Ignition Switch Output circuit. Inspect related fuse and
repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the (K52) Evap Purge Solenoid Control circuit from the
PCM harness connector to the Evap Purge Solenoid harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K52) Evap Purge Solenoid Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between ground and the (K52) Evap Purge Solenoid Control
circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K52) Evap Purge Solenoid
Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
363
All
DRIVEABILITY - GAS
Symptom List:
P0460-FUEL LEVEL SENDING UNIT NO CHANGE OVER MILES
P0461-FUEL LEVEL SENDING UNIT NO CHANGE OVER TIME
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0460-FUEL LEVEL SENDING
UNIT NO CHANGE OVER MILES.
When Monitored and Set Condition:
P0460-FUEL LEVEL SENDING UNIT NO CHANGE OVER MILES
When Monitored:
capacity.
Engine running and fuel level either below 15% or above 85% of
Set Condition: The PCM sees low fuel, less than 15%, for more than 120 miles or fuel level
does not change by at least 4% for more than 250 miles.
P0461-FUEL LEVEL SENDING UNIT NO CHANGE OVER TIME
When Monitored:
capacity.
Engine running and fuel level either below 15% or above 85% of
Set Condition: The PCM sees low fuel, less than 15%, for more than 120 miles or fuel level
does not change by at least 4% for more than 250 miles.
POSSIBLE CAUSES
PHYSICALLY DAMAGED/DEFORMED/OBSTRUCTED FUEL TANK
FUEL LEVEL SENSOR
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
WARNING: The fuel system is under a constant pressure, even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Inspect the outside of the fuel tank for defects.
Remove the fuel tank.
Remove the fuel pump module from the fuel tank.
Inspect the inside of the fuel tank for any obstructions or deformities.
Is the fuel tank free from defects?
All
2
Yes
→ Go To
No
→ Repair or replace the fuel tank as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
2
If there are no possible causes remaining, view repair.
Repair
Replace the Fuel Level Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
364
All
DRIVEABILITY - GAS
Symptom:
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW
When Monitored and Set Condition:
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW
When Monitored:
Ignition on and battery voltage above 10.4 volts.
Set Condition: The Fuel Level Sensor signal voltage goes below 0.2 of a volt at the PCM
for more than 5 seconds.
POSSIBLE CAUSES
FUEL LEVEL SENSOR VOLTAGE BELOW 0.2 OF A VOLT
FUEL LEVEL SENSOR
(G8) FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(G8) FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the Fuel Level Sensor voltage.
Is the Fuel Level Sensor voltage below 0.2 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDTION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Ignition on, engine not running.
With the DRBIIIt, read the Fuel Level Sensor voltage.
Did the Fuel Level Sensor voltage change from below 0.2 of a volt to above 4.0 volts?
Yes
→ Replace the Fuel Level Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (G8) Fuel Level Sensor Signal
circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G8) Fuel Level Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
4
365
All
DRIVEABILITY - GAS
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (G8) Fuel Level Sensor Signal circuit and the
(K4) Sensor ground circuit.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(G8) Fuel Level Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
366
All
DRIVEABILITY - GAS
Symptom:
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
When Monitored and Set Condition:
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
When Monitored:
Ignition on and battery voltage above 10.4 volts.
Set Condition: The Fuel Level Sensor signal voltage at the PCM goes above 4.95 volts for
more than 90 seconds.
POSSIBLE CAUSES
FUEL LEVEL SENSOR VOLTAGE ABOVE 4.9 VOLTS
FUEL LEVEL SENSOR
(G8) FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
(G8) FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the Fuel Level Sensor voltage.
Is the Fuel Level Sensor voltage above 4.9 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Fuel Pump Module electrical harness connector.
Ignition on, engine not running.
Connect a jumper wire between the (G8) Fuel Level Sensor Signal circuit and the
(K4) Sensor ground circuit at the Fuel Pump Module harness connector.
With the DRBIIIt, read the Fuel Level Sensor voltage.
Did the Fuel Level Sensor voltage change from above 4.8 volts to below 0.4 of a volt?
Yes
→ Replace the Fuel Level Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
367
All
DRIVEABILITY - GAS
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (G8) Fuel Level Sensor Signal circuit in the Fuel Pump
harness connector.
Is the voltage above 10.0 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (G8) Fuel Level Sensor Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (G8) Fuel Level Sensor Signal circuit from the PCM
harness connector to the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (G8) Fuel Level Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
5
Measure the resistance of the (K4) Sensor ground circuit from the PCM harness
connector to the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
368
All
DRIVEABILITY - GAS
Symptom:
P0500-NO VEHICLE SPEED SIGNAL
When Monitored and Set Condition:
P0500-NO VEHICLE SPEED SIGNAL
When Monitored: Engine Temperature greater than 104 deg F, MAP vacuum approximately 159 to 169 inches of mercury and Engine RPM between 1400 and 3000 rpm.
Set Condition:
trips.
No Vehicle Speed Signal for more than 15 seconds on two consecutive
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(G7) VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO VOLTAGE
(G7) VEHICLE SPEED SIGNAL CIRCUIT OPEN BETWEEN CAB AND PCM
(G7) VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO GROUND
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
NOTE: With the DRBIIIt check for any related DTCs that may be present in
the ABS/RWAL Module or TCM, diagnose any ABS/RWAL Module DTC’s
before continuing.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDTION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the ABS/RWAL Module harness connector.
Ignition on, engine not running.
Measure the voltage of the (G7) Vehicle Speed Signal circuit in the CAB or PCM
harness connector.
Is the voltage above 4.9 volts?
Yes
→ Repair the short to voltage in the (G7) Vehicle Speed Signal
circuit between the CAB and PCM.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
369
All
DRIVEABILITY - GAS
P0500-NO VEHICLE SPEED SIGNAL —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Measure the resistance of the (G7) Vehicle Speed Signal circuit between the PCM
harness connector and the CAB harness connector.
Is the resistance above 5.0 ohms?
All
4
5
Yes
→ Repair the open in the (G7) Vehicle Speed Signal circuit between
the CAB and PCM.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Measure the resistance between ground and the (G7) Vehicle Speed Signal circuit at
the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G7) Vehicle Speed Signal circuit
between the CAB and PCM.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
370
All
DRIVEABILITY - GAS
Symptom:
P0505-IDLE AIR CONTROL MOTOR CIRCUITS
When Monitored and Set Condition:
P0505-IDLE AIR CONTROL MOTOR CIRCUITS
When Monitored:
At power-up and battery voltage greater than 11.5 volts.
Set Condition: The PCM senses a short to ground or battery voltage on any of the four
Idle Air Control (IAC) driver circuits for 100 msec while the IAC motor is active.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K40) IAC #1 DRIVER CIRCUIT SHORTED TO #2, #3, OR #4
(K60) IAC #2 DRIVER CIRCUIT SHORTED TO #3 OR #4
(K39) IAC #3 DRIVER CIRCUIT SHORTED TO (K59) IAC #4 DRIVER CIRCUIT
IAC DRIVER CIRCUIT SHORTED TO VOLTAGE
IAC DRIVER CIRCUIT SHORTED TO GROUND
IAC MOTOR OPERATION
IAC MOTOR
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the IAC Motor harness connector.
Disconnect the PCM harness connectors.
Note: The following steps are checking for a short between the IAC Driver
circuits.
Measure the resistance between the (K40) IAC #1 Driver circuit and #2, #3, #4 Driver
circuits.
Is the resistance below 100 ohms on any of the Drivers?
Yes
→ Repair the short between the IAC Driver circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
371
All
DRIVEABILITY - GAS
P0505-IDLE AIR CONTROL MOTOR CIRCUITS —
Continued
TEST
ACTION
APPLICABILITY
3
Note: The following steps are checking for a short between the IAC Driver
circuits.
Measure the resistance between the (K60) IAC #2 Driver circuit and #3, #4 Driver
circuits.
Is the resistance below 100 ohms on any of the Drivers?
All
4
5
Yes
→ Repair the shorted IAC Driver circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Note: The following steps are checking for a short between the Driver
Circuits.
Measure the resistance between the (K39) IAC #3 Driver circuit and the (K59) #4
Driver circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the IAC Driver circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
Remove the ASD Relay.
Using a jumper wire, jumper between the Fused B+ circuit and ASD Relay Output
circuit in the PDC.
Ignition on, engine not running with the PCM and IAC harness connectors disconnected.
Measure the voltage on each of the IAC Driver circuits.
Is the voltage above 1.0 volt at any IAC Driver circuit?
Yes
→ Repair the short to voltage on the appropriate IAC Driver circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
NOTE: Remove the jumper wire and install the ASD Relay before continuing.
6
7
Turn the ignition off.
Repeat each measurement for each IAC Driver circuit.
Measure the resistance between ground and each IAC Driver circuit.
Is the resistance below 100 ohms at any IAC Driver circuit?
Yes
→ Repair the short to ground in the appropriate IAC Driver circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Turn the ignition off.
Connect the PCM harness connectors.
Start and idle the engine.
Using a test light connected to ground, probe the (K40) IAC Driver #1 circuit for 10
seconds.
Repeat the above test for the remaining IAC Motor Driver circuits.
Does the test light turn on and off while probing each IAC Motor Driver circuits?
Yes
→ Replace the Idle Air Control Motor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
372
All
DRIVEABILITY - GAS
Symptom:
P0523-OIL PRESSURE CIRCUIT HIGH
When Monitored and Set Condition:
P0523-OIL PRESSURE CIRCUIT HIGH
When Monitored:
Set Condition:
Fault.
With the ignition on and battery voltage above 10.4 volts.
The oil pressure sensor signal at PCM goes above 4.9 volts. One Trip
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
OIL PRESSURE SWITCH
(G60) OIL PRESSURE SIGNAL CIRCUIT SHORTED TO VOLTAGE
(G60) OIL PRESSURE SIGNAL CIRCUIT OPEN
(G60) OIL PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Oil Pressure Switch harness connector.
Ignition on, engine not running.
Connect a jumper wire to the (G60) Oil Pressure Signal circuit in the Switch harness
connector.
With the DRBIIIt monitor the Oil Pressure Switch state.
Touch the other end of the jumper wire to Ground several times.
Did the Oil Pressure Switch state change from High to Low?
Yes
→ Replace the Oil Pressure Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
373
All
DRIVEABILITY - GAS
P0523-OIL PRESSURE CIRCUIT HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (G60) Oil Pressure Signal circuit at the Switch harness
connector.
Is the voltage above 5.3 volts?
All
4
5
6
Yes
→ Repair the short to voltage on the (G60) Oil Pressure Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (G60) Oil Pressure Signal circuit from the Oil Pressure
Switch harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (G60) Oil Pressure Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
5
Measure the resistance between (G60) Oil Pressure Signal circuit and ground at the
Switch connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G60) Oil Pressure Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
374
All
DRIVEABILITY - GAS
Symptom:
P0551-POWER STEERING SWITCH FAILURE
When Monitored and Set Condition:
P0551-POWER STEERING SWITCH FAILURE
When Monitored:
With the ignition key on and engine running.
Set Condition: With the vehicle above 40 mph for over 30 seconds, the power steering
pressure switch remains open.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
POWER STEERING PRESSURE SWITCH
(S28) POWER STEERING SWITCH SIGNAL CIRCUIT OPEN
(S28) POWER STEERING PRESSURE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND
(Z244) POWER STEERING PRESSURE SWITCH GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Power Steering Pressure Switch harness connector.
Ignition on, engine not running.
Connect a Jumper Wire to the (S28) Power Steering Pressure Switch Signal circuit
at harness connector.
Using the DRBIIIt, while monitoring the Power Steering Pressure Switch.
Touch the Jumper Wire to the (Z244) Ground circuit at the Power Steering Pressure
Switch harness connector several times.
Did the Power Steering Pressure Switch status change from Hi to Low?
Yes
→ Replace the Power Steering Pressure Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
375
All
DRIVEABILITY - GAS
P0551-POWER STEERING SWITCH FAILURE —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure resistance of (S28) Power Steering Pressure Switch Signal circuit from PCM
harness connector to Power Steering Pressure Switch harness connector.
Is the resistance below 5.0 ohms?
All
4
5
6
Yes
→ Go To
No
→ Repair the open in the (S28) Power Steering Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
4
Measure the resistance between ground and the (S28) Power Steering Pressure
Switch Signal circuit at the P/S Switch harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (S28) Power Steering Pressure
Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
5
With a 12-volt test light connected to 12-volts, probe the (Z224) P/S Pressure Switch
ground circuit.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the (Z244) Power Steering Pressure Switch
ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
376
All
DRIVEABILITY - GAS
Symptom:
P0601-PCM INTERNAL CONTROLLER FAILURE
POSSIBLE CAUSES
POWERTRAIN CONTROL MODULE
TEST
1
ACTION
NOTE: This DTC indicates an internal PCM problem.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
377
APPLICABILITY
All
DRIVEABILITY - GAS
Symptom:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored:
Set Condition:
monitoring.
With the ignition key on and the engine running.
When the PCM tries to regulate the generator field with no result during
POSSIBLE CAUSES
GENERATOR FIELD PERFORMANCE
(K125) GEN FIELD SOURCE CIRCUIT OPEN
(K20) GEN FIELD CONTROL CIRCUIT OPEN
(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND
GENERATOR
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
Record all DTCs and the related Freeze Frame data.
Using a 12-volt test light connected to ground, backprobe the (K20) Gen Field Control
circuit at the back of the Generator.
With the DRBIIIt, actuate the Generator Field Driver.
Does the test light blink?
All
2
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
2
Ignition on, engine not running.
Carefully inspect all connectors for corrosion or spread terminals before continuing.
Backprobe the (K125) Generator Field Source circuit at back of Generator with a volt
meter.
With the DRBIIIt actuate the Generator Field Driver.
Is the voltage above 10.0 volts?
Yes
→ Go To
No
→ Repair the open in the (K125) Gen Field Source circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
3
378
All
DRIVEABILITY - GAS
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance of the (K20) Generator Field Control circuit from the
Generator Field harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
All
4
5
6
Yes
→ Go To
No
→ Repair the open in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
4
Measure the resistance between ground and the (K20) Generator Field Control
circuit in the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
5
Measure resistance across the Generator Field Terminals at the Generator.
Is the resistance between 0.5 of and ohm and 15 ohms?
Yes
→ Go To
No
→ Repair the Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
379
All
DRIVEABILITY - GAS
Symptom:
P0645-A/C CLUTCH RELAY CIRCUIT
When Monitored and Set Condition:
P0645-A/C CLUTCH RELAY CIRCUIT
When Monitored:
volts.
Set Condition:
circuit.
With the ignition key in the run position and battery voltage above 10.4
An open or shorted condition is detected in the A/C clutch relay control
POSSIBLE CAUSES
A/C CLUTCH RELAY OPERATION
A/C CLUTCH RELAY
INTERNAL FUSED IGNITION SWITCH OUTPUT CIRCUIT
(C13) A/C CLUTCH RELAY CONTROL CIRCUIT OPEN
(C13) A/C CLUTCH RELAY CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, actuate the A/C Clutch Relay.
Is the A/C Clutch Relay clicking?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
APPLICABILITY
All
2
Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Measure the resistance between Coil Terminals of the A/C Clutch Relay.
Is the resistance between 50.0 and 90.0 ohms?
Yes
→ Go To
No
→ Replace the A/C Clutch Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
3
Ignition on, engine not running.
Measure the voltage on the Internal Fused Ignition Switch Output circuit for the A/C
Clutch in the IPM.
Is the voltage above 10.0 volts?
Yes
→ Go To
No
→ Repair the open or short to ground in the Internal Fused Ignition
Switch Output circuit. Inspect and replace fuses as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
4
380
All
DRIVEABILITY - GAS
P0645-A/C CLUTCH RELAY CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Measure the resistance of the (C13) A/C Clutch Relay Control circuit from the IPM to
the PCM harness connector.
Is the resistance below 5.0 ohms?
All
5
6
Yes
→ Go To
No
→ Repair the open in the (C13) A/C Clutch Relay Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5
Measure the resistance between ground and the (C13) A/C Clutch Relay Control
circuit at the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (C13) A/C Clutch Relay Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
381
All
DRIVEABILITY - GAS
Symptom:
P0700-TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
When Monitored and Set Condition:
P0700-TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
When Monitored:
Ignition on and battery voltage greater than 10 volts.
Set Condition: An active DTC is stored in the TCM. One Trip Fault. Three good trips to
turn off the MIL.
POSSIBLE CAUSES
TCM DTC PRESENT SET IN PCM
TEST
ACTION
APPLICABILITY
1
This DTC is an indicator that a Trans DTC has previously been set. A code may not
currently be present in the TCM if a Trans repair was made. If after reading
transmission DTC’s there are no codes in the TCM, this code can be erased from the
PCM.
Trans DTC present?
All
Continue
A DTC was registered in the Transmission Control Module. With
the DRB, go to the TCM and read codes. Refer to the appropriate
symptom (Diagnostic Procedure).
382
DRIVEABILITY - GAS
Symptom List:
P1195-O2 SENSOR 1/1 SLOW DURING CATALYST MONITOR
P1196-O2 SENSOR 2/1 SLOW DURING CATALYST MONITOR
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P1195-O2 SENSOR 1/1 SLOW
DURING CATALYST MONITOR.
When Monitored and Set Condition:
P1195-O2 SENSOR 1/1 SLOW DURING CATALYST MONITOR
When Monitored: With the engine running, coolant greater than 170°F, open throttle,
steady to slightly increasing vehicle speed greater than 18 mph but less than 55 mph, with
a light load on the engine, for a period no less than 5 minutes.
Set Condition: The oxygen sensor signal voltage is switching from below 0.39 of a volt to
above 0.6 of a volt and back fewer times than required.
P1196-O2 SENSOR 2/1 SLOW DURING CATALYST MONITOR
When Monitored: With the engine running, coolant greater than 170°F, open throttle,
steady to slightly increasing vehicle speed greater than 18 mph but less than 55 mph, with
a light load on the engine, for a period no less than 5 minutes.
Set Condition: The oxygen sensor signal voltage is switching from below 0.39 of a volt to
above 0.6 of a volt and back fewer times than required.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
EXHAUST LEAK
RESISTANCE IN THE O2 SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K4) O2 SENSOR GROUND CIRCUIT
O2 SENSOR
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
383
APPLICABILITY
All
DRIVEABILITY - GAS
P1195-O2 SENSOR 1/1 SLOW DURING CATALYST MONITOR —
TEST
2
3
4
5
ACTION
Start the engine.
Inspect the exhaust for leaks between the engine and the appropriate O2 Sensor.
Are there any exhaust leaks?
Yes
→ Repair or replace the leaking exhaust parts as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
Continued
APPLICABILITY
All
3
Turn the ignition off.
Backprobe the O2 Sensor Signal circuit at the O2 Sensor harness connector and PCM
harness connector.
NOTE: Ensure the voltmeter leads are connected for positive polarity, meet
the terminals in the connector, and that there is good terminal to wire
connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance on the O2 Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
4
Turn the ignition off.
Backprobe the (K4) Sensor ground circuit at the O2 Sensor harness connector and
PCM harness connector.
NOTE: Ensure the voltmeter leads are connected for positive polarity, meet
the terminals in the connector, and that there is good terminal to wire
connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Start the engine.
Allow the engine to idle.
Is the voltage below 0.10 of a volt?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Turn the ignition off.
If there are no possible causes remaining, view repair.
Repair
Replace the O2 Sensor
Perform POWERTRAIN VERIFICATION TEST VER - 5.
384
All
DRIVEABILITY - GAS
Symptom:
P1281-ENGINE IS COLD TOO LONG
When Monitored and Set Condition:
P1281-ENGINE IS COLD TOO LONG
When Monitored:
Set Condition:
start.
The ignition key on, engine running.
The engine does not warm to 176 deg. F while driving for 20 minutes after
POSSIBLE CAUSES
ENGINE COLD TOO LONG
TEST
ACTION
APPLICABILITY
1
Note: The best way to diagnose this DTC is to allow the vehicle to remain
outside overnight in order to have a completely cold soaked engine.
Note: Extremely cold outside ambient temperatures may cause this DTC to
set.
Verify that the coolant level is not low and correct as necessary.
Start the engine.
With the DRBIIIt, set the engine RPM to 1500 and allow the engine to warm up for
10-15 minutes.
With the DRBIIIt, monitor the ENG COOLANT TMP DEG value during the warm
up cycle. Make sure the transition of temperature change is smooth.
Did the engine temperature reach a minimum of 80° C (176° F)?
All
Yes
→ Test Complete.
No
→ Refer to the Service Information for cooling system performance
diagnosis. The most probable cause is a Thermostat problem.
Also, refer to any related TSBs.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
385
DRIVEABILITY - GAS
Symptom:
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT
When Monitored:
Set Condition:
circuit.
With the ignition on and battery voltage above 10.4 volts.
An open or shorted condition is detected in the Fuel Pump Relay Control
POSSIBLE CAUSES
FUEL PUMP RELAY OPERATION
FUEL PUMP RELAY
(Y135) FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
(K31) FUEL PUMP RELAY CONTROL CIRCUIT OPEN
(K31) FUEL PUMP RELAY CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, actuate the Fuel Pump Relay.
Is the Fuel Pump Relay clicking?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
APPLICABILITY
All
2
Turn the ignition off.
Remove the Fuel Pump Relay.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between the coil terminals of the Fuel Pump Relay.
Is the resistance between 50 and 90 ohms?
Yes
→ Go To
No
→ Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
3
386
All
DRIVEABILITY - GAS
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
3
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the (Y135) Fused Ignition
Switch output circuit in the Fuel Pump Relay connector.
Does the test light illuminate brightly?
All
4
5
6
Yes
→ Go To
No
→ Repair the open or short to ground in the (Y135) Fused Ignition
Switch Output circuit. Inspect the related fuse and repair as
necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K31) Fuel Pump Relay Control circuit from the Fuel
Pump Relay connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K31) Fuel Pump Relay Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
5
Measure the resistance between ground and the (K31) Fuel Pump Relay Control
circuit at the IPM.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K31) Fuel Pump Relay Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
387
All
DRIVEABILITY - GAS
Symptom:
P1294-TARGET IDLE NOT REACHED
When Monitored and Set Condition:
P1294-TARGET IDLE NOT REACHED
When Monitored: With the engine idling and in drive, if automatic. There must not be a
MAP sensor trouble code or a throttle position sensor trouble code.
Set Condition: Engine idle is not within 200 rpm above or 100 rpm below target idle for
14 seconds. Three separate failures are required to set a bad trip. Two bad trips are
required to set the code.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
VACUUM LEAK
AIR INDUCTION SYSTEM
THROTTLE BODY AND THROTTLE LINKAGE
IAC DRIVER CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
NOTE: All MAP Sensor, IAC, and/or TPS codes present must be diagnosed
first before proceeding.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
2
Inspect the Intake Manifold for vacuum leaks.
Inspect the Power Brake Booster for any vacuum leaks.
Inspect the PCV system for proper operation or any vacuum leaks.
Were any problems found?
Yes
→ Repair vacuum leak as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
3
388
All
DRIVEABILITY - GAS
P1294-TARGET IDLE NOT REACHED —
TEST
3
4
5
6
Continued
ACTION
Inspect the Air Induction System for the following problems.
Restrictions: Dirty Air Cleaner, Foreign material in the air intake tube, etc.
Leaks: Air Intake tube connection, Air Cleaner housing, etc.
Were any problems found?
Yes
→ Repair or replace as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
APPLICABILITY
All
4
Inspect the throttle body plate for carbon build up or other restrictions.
Inspect the throttle linkage for binding and smooth operation.
Ensure the throttle plate is resting on the stop at idle.
Remove IAC, inspect the pintle and its seating surface inside the throttle body.
Were any problems found?
Yes
→ Clean and/or replace the throttle body as needed.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
5
Turn the ignition off.
Disconnect IAC Motor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance of each of the IAC Driver circuit from the IAC Motor harness
connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the appropriate IAC Driver circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
389
All
DRIVEABILITY - GAS
Symptom:
P1296-NO 5-VOLTS TO MAP SENSOR
When Monitored and Set Condition:
P1296-NO 5-VOLTS TO MAP SENSOR
When Monitored:
Set Condition:
5 seconds.
During power-down and battery voltage greater than 10.4 volts.
The MAP sensor signal voltage goes below 2.35 volts with the key off for
POSSIBLE CAUSES
MAP SENSOR VOLTS BELOW 2.3 VOLTS
MAP SENSOR
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
SHORTED SENSOR
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: If the P0107 - MAP Sensor Voltage Too Low is also set, diagnose it
first before continuing with P1296 - No 5-volts To MAP Sensor.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt in Sensors, read the MAP Sensor voltage.
Is the voltage below 2.35 volts?
All
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit at the MAP Sensor harness
connector.
Is the voltage above 4.5 volts?
Yes
→ Go To
3
No
→ Go To
4
With the DRBIIIt in Sensors, read the MAP Sensor voltage with the Sensor harness
connector disconnected.
Is the voltage above 4.5 volts?
Yes
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
390
All
All
DRIVEABILITY - GAS
P1296-NO 5-VOLTS TO MAP SENSOR —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the voltage on the (K7) 5-volt Supply circuit in the MAP Sensor harness
connector while disconnecting the remaining Sensors that share the (K7) 5-volt
Supply circuit.
Does the voltage return to approximately 5.0 volts with any Sensor disconnected?
All
5
6
7
Yes
→ Replace the Sensor that pulled the (K7) 5-volt Supply circuit low.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K7) 5-volt Supply circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
6
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K7) 5-volt Supply circuit in the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
391
All
DRIVEABILITY - GAS
Symptom:
P1297-NO CHANGE IN MAP FROM START TO RUN
When Monitored and Set Condition:
P1297-NO CHANGE IN MAP FROM START TO RUN
When Monitored:
throttle.
With engine RPM +/- 64 of target idle and the throttle blade at closed
Set Condition: Too small of a difference is seen between barometric pressure with ignition
on (engine running) and manifold vacuum for 8.80 seconds.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
MAP SENSOR VACUUM PORT
MAP SENSOR VOLTAGE BELOW 3.19 VOLTS
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MAP SENSOR
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
(K1) MAP SENSOR SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: If a MAP high or Low DTC set along with P1297, diagnose the High
or Low DTC first before continuing.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Remove the MAP Sensor.
Inspect the vacuum port, check for restrictions or any foreign materials.
Were any restriction found?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
392
All
DRIVEABILITY - GAS
P1297-NO CHANGE IN MAP FROM START TO RUN —
TEST
3
4
5
6
7
8
Continued
ACTION
Install the MAP Sensor.
Ignition on, engine not running.
With the DRBIIIt, read the MAP Sensor voltage.
Is the voltage below 3.19 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
4
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit at the MAP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
5
No
→ Go To
8
With the DRBIIIt, monitor the MAP Sensor voltage with Sensor harness connector
disconnected.
Is the voltage above 1.2 volts?
Yes
→ Replace the MAP Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K1) MAP Sensor Signal circuit at
the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K1) MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Measure the resistance between the (K1) MAP Sensor Signal circuit and the (K4)
Sensor ground circuit at the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (K1)
MAP Sensor Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
10
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K7) 5-volt Supply circuit from the MAP Sensor
harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9
393
All
DRIVEABILITY - GAS
P1297-NO CHANGE IN MAP FROM START TO RUN —
Continued
TEST
ACTION
APPLICABILITY
9
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
All
10
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
10
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
394
All
DRIVEABILITY - GAS
Symptom:
P1299-VACUUM LEAK FOUND
POSSIBLE CAUSES
VACUUM LEAK
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
NOTE: This code is enabled on engines with plastic intake manifolds and is
intended to shut down the engine if a large crack occurs.
NOTE: A large vacuum leak is mostly the cause of this DTC.
Inspect the Intake manifold for vacuum leaks.
Inspect the Power Brake Booster for any vacuum leaks.
Inspect the PCV system for proper operation or any vacuum leaks.
Improperly installed MAP Sensor.
Were any vacuum leaks found?
All
Yes
→ Repair vacuum leak as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
395
DRIVEABILITY - GAS
Symptom:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored:
Set Condition:
With ignition key on and battery voltage above 10.4 volts.
An open or shorted condition is detected in the ASD Relay control circuit.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
ASD RELAY
INTERNAL FUSED B+ OUTPUT CIRCUIT
(K51) ASD RELAY CONTROL CIRCUIT OPEN
(K51) ASD RELAY CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Remove the ASD Relay from the IPM.
Measure the resistance between the coil terminals of the ASD Relay.
Is the resistance between 50 and 80 ohms?
Yes
→ Go To
No
→ Replace the ASD Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
3
Using a 12-volt test light connected to ground, probe the Internal Fused B+ Output
circuits in the ASD Relay connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the Internal Fused B+
Output circuit. Inspect the IPM for an internal open circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
4
396
All
DRIVEABILITY - GAS
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
4
Disconnect the PCM harness connectors.
Measure the resistance of the (K51) ASD Relay Control circuit from the ASD Relay
cavity in the IPM to the PCM harness connector.
Is the resistance below 5.0 ohms?
All
5
6
Yes
→ Go To
No
→ Repair the open in the (K51) ASD Relay Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5
Measure the resistance between ground and the (K51) ASD Relay Control circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K51) ASD Relay Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no more possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
397
All
DRIVEABILITY - GAS
Symptom:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored and Set Condition:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored: With ignition key on, battery voltage above 10.4 volts, and engine RPM
greater than 400.
Set Condition:
No voltage sensed at the PCM when the ASD Relay is energized.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
ASD RELAY
INTERNAL FUSED B+ CIRCUIT
(A142) ASD RELAY OUTPUT CIRCUIT OPEN
(A142) ASD OUTPUT CIRCUIT OPEN
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Attempt to start the engine.
Did the engine start?
Yes
→ Go To
3
No
→ Go To
4
All
Turn the ignition off.
Remove the ASD Relay from the IPM.
Disconnect the PCM harness connectors.
Measure the resistance of the (A142) ASD Relay Output circuit from the ASD Relay
cavity in the IPM to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (A142) ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
7
398
All
DRIVEABILITY - GAS
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM —
TEST
4
5
6
7
Continued
ACTION
Install a substitute relay for the ASD Relay.
Attempt to start the vehicle.
Did the engine start?
APPLICABILITY
All
Yes
→ Replace the ASD Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
5
Turn the ignition off.
Remove the ASD relay from the IPM.
Using a 12-volt test light, probe the Fused B+ circuit at the ASD Relay connector in
the IPM.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the Fused B+ circuit. The
Fused B+ circuit is internal to the IPM. Inspect and replace fuses
as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
6
Disconnect the PCM harness connectors.
Measure the resistance of the (A142) ASD Relay Output circuit from the ASD Relay
cavity in the IPM to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (A142) ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
399
All
DRIVEABILITY - GAS
Symptom:
P1391-INTERMITTENT LOSS OF CMP OR CKP
When Monitored and Set Condition:
P1391-INTERMITTENT LOSS OF CMP OR CKP
When Monitored:
Set Condition:
Engine running or cranking.
When the failure counter reaches 20 for 2 consecutive trips.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
CHECKING INTERMITTENT CMP SIGNAL WITH LAB SCOPE
CMP WIRE HARNESS INSPECTION
TONE WHEEL/PULSE RING INSPECTION
CKP WIRE HARNESS INSPECTION
TONE WHEEL/PULSE RING INSPECTION
CHECKING INTERMITTENT CKP SIGNAL WITH LAB SCOPE
CAMSHAFT POSITION SENSOR
CRANKSHAFT POSITION SENSOR
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine and run until operating temp is reached. (Closed Loop)
If the DTC does not return right away it may be necessary to test drive the vehicle
to duplicate the DTC.
Does the P1391 return?
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
2
400
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP —
Continued
TEST
ACTION
APPLICABILITY
2
Turn the ignition off.
With the DRBIIIt as a Dual Channel Lab Scope and Miller special tool #6801,
backprobe the (K44) CMP Signal circuit in the CMP harness connector and PCM
harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Observe the lab scope screen.
Are there any irregular or missing signals?
All
3
4
5
Yes
→ Go To
3
No
→ Go To
6
Turn the ignition off.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are
properly installed and the mounting bolt(s) are torqued to specification.
Refer to any TSB that may apply.
Were any of the above conditions present?
Yes
→ Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Remove the Camshaft Position Sensor.
Inspect the Tone Wheel/Pulse Ring for damage, foreign material, or excessive
movement.
Were any problems found?
Yes
→ Repair or replace the Tone Wheel/Pulse Ring as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
If there are no possible causes remaining, view repair.
Repair
Replace the Camshaft Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
401
All
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K44) CMP Signal circuit in the PCM harness connector and in the
CMP harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Carefully wiggle the related wire harness and gently tap on the CMP sensor.
Observe the lab scope screen.
Look for any differences in the two patterns generated by the CMP Sensor.
If the Channel 1 and Channel 2 patterns are different, repair the wiring/connection
concern
Does the DRBIIIt screen display any missing or irregular patterns?
All
7
8
9
Yes
→ Inspect the wire harness and connectors. If no problem is found
replace Cam Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
Turn the ignition off.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K24) CKP Signal circuit in the CKP harness connector and PCM
harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Observe the lab scope screen.
Are there any irregular or missing signals?
Yes
→ Go To
8
No
→ Go To
11
Turn the ignition off.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are
properly installed and the mounting bolt(s) are torqued to specification.
Refer to any TSB that may apply.
Were any of the above conditions present?
Yes
→ Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
9
Remove the Crankshaft Position Sensor.
Inspect the Tone Wheel/Flex Plate slots for damage, foreign material, or excessive
movement.
Were any problems found?
Yes
→ Repair or replace the Tone Wheel/Flex Plate as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
10
402
All
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP —
TEST
10
Continued
ACTION
If there are no possible causes remaining, view repair.
APPLICABILITY
All
Repair
Replace the Crankshaft Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
11
NOTE: The conditions that set this DTC are not present at this time. The
following test may help in identifying the intermittent condition.
Turn the ignition off.
With the DRBIIIt as a Dual Channel Lab Scope and the Miller special tool #6801,
backprobe the (K24) CKP Signal circuit in the PCM harness connector and CKP
harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Carefully wiggle the related wire harness and gently tap on the CKP sensor.
Compare the Channel 1 reading to the Channel 2 reading on the lab scope screen.
Both of the readings should be the same.
Were any of the above conditions present?
Yes
→ Repair the wiring or connector concern.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
403
All
DRIVEABILITY - GAS
Symptom:
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored and Set Condition:
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored:
seconds.
Under closed throttle decel and Fuel Pulse Width equal to zero for 30
Set Condition: One of the CKP sensor target windows has more than 2.86% variance from
the reference window.
POSSIBLE CAUSES
ADAPTIVE NUMERATOR RELEARN
CMP SENSOR CONNECTOR/WIRING
CKP SENSOR CONNECTOR/WIRING
DAMAGED TONE WHEEL/FLEX PLATE (CRANKSHAFT)
CRANKSHAFT POSITION SENSOR
PCM
TEST
ACTION
APPLICABILITY
1
Note: Check for any TSB’s that may apply to this symptom.
Read and record the Freeze Frame Data. Use this information to help you duplicate
the conditions that set the DTC. Pay particular attention to the DTC set conditions,
such as, VSS, MAP, ECT, and Load.
Ignition on, engine not running.
With the DRBIIIt in the miscellaneous menu, choose Clear PCM (battery disconnect)
to reset the PCM.
With the DRBIIIt, choose the Misfire Pretest screen.
Road test the vehicle and re-learn the adaptive numerator.
The adaptive numerator is learned when the Adaptive Numerator Done Learning
line on the Misfire screen changes to Yes.
Did the adaptive numerator re-learn?
All
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
2
404
DRIVEABILITY - GAS
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT —
Continued
TEST
ACTION
APPLICABILITY
2
Turn ignition off.
Visually inspect the related wire harness connectors. Look for broken, bent,
pushed out, or corroded terminals.
NOTE: Visually inspect the related wire harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Make sure the Camshaft Position Sensor is tight.
Note: Refer to any technical service bulletins that may apply.
Were any problems found?
All
3
4
5
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Note: Visually inspect the Crankshaft Position Sensor and related wire
harness connectors. Look for broken, bent, pushed out, or corroded terminals.
NOTE: Visually inspect the related wire harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Verify the Crank Position Sensor is properly installed.
Were any problems found?
Yes
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Disconnect and remove the Crankshaft Position Sensor.
Inspect the tone wheel/flexplate slots for damage, foreign material, or excessive
movement.
Is the tone wheel/flexplate free from defects?
Yes
→ Go To
No
→ Repair/replace tone wheel/flex plate as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
5
With the DRBIIIt lab scope probe and the Miller special tool #6801, back probe the
(K24) CKP Signal circuit in the PCM harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING..
Start the engine and observe the lab scope screen for any erratic CKP Sensor pulses.
Were any erratic Crank Position signals detected.
Yes.
Replace the Crankshaft Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No.
Go To
All
6
NOTE: Turn the ignition off before continuing.
405
All
DRIVEABILITY - GAS
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT —
Continued
TEST
ACTION
APPLICABILITY
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
406
DRIVEABILITY - GAS
Symptom:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored and Set Condition:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 40 deg. F and 90 deg. F and coolant temperature within 10 deg. F of battery/
ambient.
Set Condition: LDP test must pass first. If the PCM suspects a pinched hose it will not set
a fault until it runs the evap purge flow monitor. If the purge monitor does not pass then
the pinched hose fault will be set.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
EVAP CANISTER OBSTRUCTED
OBSTRUCTION IN HOSE/TUBE BETWEEN EVAP CANISTER AND PURGE SOLENOID
LDP PRESSURE HOSE OBSTRUCTED
LEAK DETECTION PUMP
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
APPLICABILITY
All
2
Pressurize the EVAP System. On Miller Tool #8404, hold down the remote smoke/air
start button and monitor the gauge.
When the flow meter gauge on the EELD reads 0 LPM, the EVAP system is
completely pressurized.
Disconnect the LDP Pressure hose at the EVAP Canister. The LDP Pressure hose is
the hose that connects the Evap Canister to the Leak Detection Pump.
Did the pressure drop when the hose was disconnected?
Yes
→ Go To
No
→ Replace the EVAP Canister.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
3
407
All
DRIVEABILITY - GAS
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND —
Continued
TEST
ACTION
APPLICABILITY
3
NOTE: Connect all previously disconnected hose(s).
Re-pressurize the EVAP System. On Miller Tool #8404, hold down the smoke/air start
button and monitor the gauge.
When the flow meter gauge on the EELD reads 0 LPM, the EVAP system is
completely pressurized.
Disconnect the EVAP hoses at the Purge Solenoid.
Did the pressure drop when the hose was disconnected?
All
4
Yes
→ Go To
No
→ Repair or replace hose/tube as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
4
Disconnect and remove the LDP pressure hose. The LDP pressure hose is the hose
that connects the EVAP Canister to the Leak Detection Pump.
Inspect the LDP pressure hose for any obstructions or physical damage.
Is the LDP pressure hose free from defects?
Yes
→ Replace the Leak Detection Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Repair/replace hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
408
All
DRIVEABILITY - GAS
Symptom:
P1491-COOLING FAN RELAY CONTROL CIRCUIT
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
INTERNAL FUSED B+ CIRCUITS
(Y145) CONDENSER FAN RELAY CONTROL CIRCUIT OPEN
(Y145) CONDENSER FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND
CONDENSER FAN RELAY
PCM
TEST
1
2
3
4
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
APPLICABILITY
All
2
Turn the ignition off.
Remove the Condenser Fan Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Internal Fused B+ circuits
in the IPM.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the Internal Fused B+
circuits. Inspect fuses and replace as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
3
Disconnect the PCM harness connectors.
Measure the resistance of the (Y145) Condenser Fan Relay Control circuit from the
IPM to PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (Y145) Condenser Fan Relay Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
4
Measure the resistance between ground and the (Y145) Condenser Fan Relay Control
circuit.
Is the resistance above 100 kohms?
Yes
→ Go To
No
→ Repair the short to ground in the (Y145) Condenser Fan Relay
Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5
409
All
DRIVEABILITY - GAS
P1491-COOLING FAN RELAY CONTROL CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
5
Momentarily connect a jumper wire between the internal Fused B+ circuit and the
(C23) Condenser Fan Relay Output circuit in the IPM connector.
Did the Condenser Fan actuate?
All
6
Yes
→ Go To
No
→ Replace the Condenser Fan Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
410
All
DRIVEABILITY - GAS
Symptom:
P1492-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE
TOO HIGH
When Monitored and Set Condition:
P1492-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
When Monitored:
With the ignition key on.
Set Condition: The PCM senses the voltage from the Battery Temperature Sensor above
4.9 volts for 3 seconds.
POSSIBLE CAUSES
BATTERY TEMP SENSOR VOLTAGE ABOVE 4.8 VOLTS
BATTERY TEMPERATURE SENSOR
(K118) BATT TEMP SIGNAL CIRCUIT SHORTED TO VOLTAGE
(K118) BATT TEMP SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
Record all DTCs and the related Freeze Frame data.
With the DRBIIIt, monitor the Battery Temperature Sensor voltage.
Is the voltage above 4.8 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 3.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Battery Temp Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt in sensors, read the Batt Temp Sensor voltage value.
Connect a jumper wire between the (K118) Batt Temp Signal circuit and the (K4)
Sensor ground circuit at the Battery Temp Sensor connector.
Did the Battery Temp Sensor voltage change from greater than 4.5 volts to less than
1.0 volt?
Yes
→ Replace the Battery Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
411
All
DRIVEABILITY - GAS
P1492-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO
HIGH — Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K118) Battery Temp Signal circuit at the Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (K118) Batt Temp Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (K118) Battery Temp Signal circuit from the Battery
Temp Sensor harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K118) Batt Temp Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
5
Measure the resistance in the (K4) Sensor ground circuit from the PCM harness
connector to the Sensor connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
412
All
DRIVEABILITY - GAS
Symptom:
P1493-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE
TOO LOW
When Monitored and Set Condition:
P1493-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
When Monitored:
With the ignition on.
Set Condition: The PCM senses the voltage from the Battery Temperature Sensor below
0.5 of a volt for 3 seconds.
POSSIBLE CAUSES
BATTERY TEMP SENSOR VOLTS BELOW 0.5 OF A VOLT
BATTERY TEMPERATURE SENSOR
(K118) BATT TEMP SIGNAL CIRCUIT SHORTED TO GROUND
(K118) BATT TEMP SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
Record all DTCs and the related Freeze Frame data.
With DRBIIIt, monitor the Ambient/Battery Temperature Sensor voltage.
Is the voltage below 0.5 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 3.
APPLICABILITY
All
2
Ignition on, engine not running.
With the DRBIIIt in sensors, read the Battery Temp Sensor voltage.
Disconnect the Battery Temp Sensor harness connector.
Did the Battery Temperature Sensor voltage change from below 1.0 volt to above 4.5
volts?
Yes
→ Replace the Battery Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K118) Battery Temp Signal circuit
at the Battery Temp Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K118) Batt Temp Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
4
413
All
DRIVEABILITY - GAS
P1493-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO
LOW — Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (K118) Battery Temp Signal circuit and the (K4)
Sensor ground circuit at the Battery Temp Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(K118) Batt Temp Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
414
All
DRIVEABILITY - GAS
Symptom:
P1494-LEAK DETECTION PUMP SWITCH OR MECHANICAL
FAULT
When Monitored and Set Condition:
P1494-LEAK DETECTION PUMP SWITCH OR MECHANICAL FAULT
When Monitored: Immediately after a cold start, with battery/ambient temperature
between 40 deg. F and 90 deg. F and coolant temperature within 10 deg. F of battery/
ambient.
Set Condition:
The state of the switch does not change when the solenoid is energized.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
LDP VACUUM SUPPLY
LEAK DETECTION PUMP
(K107) LDP SWITCH SENSE CIRCUIT OPEN
(K107) LDP SWITCH SENSE CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the vacuum supply hose at the Leak Detection Pump.
Connect a vacuum gauge to the disconnected vacuum supply hose at the Leak
Detection Pump.
Start the engine and read the vacuum gauge.
Does the vacuum gauge read at least 139 Hg?
Yes
→ Go To
No
→ Repair leak or obstruction in vacuum hose as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
3
415
All
DRIVEABILITY - GAS
P1494-LEAK DETECTION PUMP SWITCH OR MECHANICAL FAULT —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Connect the vacuum supply hose at the LDP.
Disconnect the Leak Detection Pump electrical harness connector.
Start the engine.
With the DRBIIIt in Inputs/Outputs, read the Leak Detect Pump Switch state.
Connect a jumper wire between 12-volts and the (K107) LDP Switch Signal circuit.
Did the Leak Detect Pump Sw state change when the jumper was connected?
All
Yes
→ Replace the Leak Detection Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Go To
4
NOTE: Remove the jumper wire before continuing.
4
5
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K107) LDP Switch Sense Circuit from the PCM
harness connector to LDP harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K107) Leak Detection Pump Switch Sense
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
All
5
Measure the resistance between ground and the (K107) LDP Switch Sense circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K107) LDP Switch Sense
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Go To
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
416
All
DRIVEABILITY - GAS
Symptom:
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
When Monitored and Set Condition:
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
When Monitored:
than 10.4 volts.
Set Condition:
Continuously when the ignition is on and battery voltage is greater
The state of the solenoid circuit does not match the PCM’s desired state.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K125) GENERATOR SOURCE CIRCUIT OPEN
(K106) LEAK DETECTION PUMP SOLENOID CONTROL CIRCUIT OPEN
(K106) LDP SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
LEAK DETECTION PUMP
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 6.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Leak Detection Pump electrical harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the Leak Detection Pump.
Using a 12-volt test light connected to ground, check the (K125) Generator Source
circuit at the LDP connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the (K125) Generator Source circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
3
417
All
DRIVEABILITY - GAS
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Connect a 12-volt test light to a good 12-volt source.
Ignition on, engine not running.
With the DRBIIIt, actuate the Leak Detection Pump.
Probe the (K106) LDP Solenoid Control circuit with the test light while the Pump is
actuating.
Does the test light blink?
All
4
Yes
→ Go To
4
No
→ Go To
5
If there are no possible causes remaining, view repair.
All
Repair
Replace the Leak Detection Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
5
6
7
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K106) LDP Solenoid Control circuit from the PCM
harness connector to the LDP harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K106) Leak Detection Pump Solenoid
Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
All
6
Measure the resistance between ground and the (K106) LDP Solenoid Control circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K106) LDP Solenoid Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
No
→ Go To
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 6.
418
All
DRIVEABILITY - GAS
Symptom:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Monitored and Set Condition:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Monitored:
With the ignition key on and the engine speed greater than 0 RPM.
Set Condition: When the PCM regulates the generator field and there are no detected
field problems, but the voltage output does not decrease.
POSSIBLE CAUSES
CHARGING SYSTEM OPERATION
(K20) GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND
GENERATOR FIELD COIL SHORTED TO GROUND
BATTERY TEMPERATURE SENSOR
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Battery must be fully charged and be capable of passing a load test.
Note: Generator Belt tension and condition must be checked before continuing.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and the related Freeze Frame data then clear the
DTCs.
With DRBIIIt, actuate the Generator Field Driver.
With a 12-volt test light connected to ground, backprobe the (K20) Gen Field Control
circuit in the back of Generator Field harness connector.
Does the test light illuminate brightly and flash?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 3.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Generator Field Harness connector.
Carefully inspect the related connectors for corrosion or spread terminals before
continuing.
Measure the resistance between ground and the (K20) Generator Field Driver circuit
at the Generator Field harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K20) Generator Field Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
3
419
All
DRIVEABILITY - GAS
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Measure the resistance between ground and the Generator Field terminals on the
Generator.
Is the resistance below 100 ohms?
All
4
5
Yes
→ Replace or repair the Generator Field Coil for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
4
Connect the PCM harness connectors and the Generator harness connector.
Ignition on, engine not running.
With the DRBIIIt in Inputs/Outputs, read the Batt Temp Sensor value.
Using a thermometer measure under hood temperature near Battery tray.
Is the temperature within 10 deg of Battery temperature?
Yes
→ Go To
No
→ Replace the Battery Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
420
All
DRIVEABILITY - GAS
Symptom List:
P1595-SPEED CONTROL SOLENOID CIRCUITS
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P1595-SPEED CONTROL SOLENOID CIRCUITS.
When Monitored and Set Condition:
P1595-SPEED CONTROL SOLENOID CIRCUITS
When Monitored: With the ignition key on, the speed control switched on, the SET switch
pressed and the vehicle in drive gear moving above 35 MPH.
Set Condition: The powertrain control module actuates the vacuum and vent solenoids
but they do not respond.
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT
When Monitored:
Set Condition:
With the ignition key on and the speed control switched on.
The speed control power supply circuit is either open or shorted to ground.
POSSIBLE CAUSES
(Z10) GROUND CIRCUIT OPEN
INTERMITTENT CONDITION
SPEED CONTROL SERVO
(V30) S/C BRAKE SWITCH OUTPUT CIRCUIT OPEN
BRAKE LAMP SWITCH
(V32) S/C POWER SUPPLY CIRCUIT OPEN
S/C VACUUM SOLENOID
(V36) S/C VACUUM SOL CONTROL CIRCUIT OPEN
(V36) S/C VACUUM SOL CONTROL CIRCUIT SHORTED TO GROUND
S/C VENT SOLENOID
(V35) S/C VENT SOL CONTROL CIRCUIT OPEN
(V35) S/C VENT SOL CONTROL CIRCUIT SHORTED TO GROUND
PCM
421
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS —
Continued
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
NOTE: In the below step you will need to actuate both S/C solenoids
separately. Note the operation of the each solenoid when actuated.
With the DRBIIIt, actuate the Speed Control Vacuum Solenoid and note operation.
With the DRBIIIt, actuate the Speed Control Vent Solenoid and note operation.
Choose the conclusion that best matches the solenoids operation.
All
Vacuum Solenoid not operating
Go To 2
Vent Solenoid not operating
Go To 5
Both S/C Solenoids not operating
Go To 8
Both S/C Solenoids operating
Go To 13
2
3
4
Turn the ignition off.
Disconnect the Speed Control Servo harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the Speed Control Vacuum Solenoid.
Using a 12-volt test light connected to 12-volts, probe the (V36) S/C Vacuum Sol
Control circuit.
Does the test light illuminate brightly and flash?
Yes
→ Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (V36) S/C Vacuum Sol Control circuit between the PCM
harness connector and Speed Control Servo harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V36) S/C Vacuum Sol Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
4
Measure the resistance between ground and the (V36) S/C Vacuum Sol Control
circuit at the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (V36) S/C Vacuum Sol Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
12
422
All
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS —
Continued
TEST
ACTION
APPLICABILITY
5
Turn the ignition off.
Disconnect the Speed Control Servo harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the S/C Vent Solenoid.
Using a 12-volt test light connected to 12-volts, probe the (V35) S/C Vent Sol Control
circuit in the Speed Control Servo harness connector.
Does the test light illuminate brightly and flash?
All
6
7
8
9
Yes
→ Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (V35) S/C Vent Sol Control circuit between the PCM
harness connector and S/C Servo harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V35) S/C Vent Sol Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
7
Measure the resistance between ground and the (V35) S/C Vent Sol Control circuit at
the PCM harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (V35) S/C Vent Sol Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
12
Turn the ignition off.
Disconnect the S/C Servo harness connector.
Ignition on, engine not running.
Turn the Cruise Control on.
Using a 12-volt test light connected to ground, probe the (V30) S/C Brake Switch
Output circuit in the S/C Servo harness connector.
Does the test light illuminate brightly?
Yes
→ Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
9
Turn the ignition off.
Disconnect the Brake Lamp Switch harness connector.
Measure the resistance of the (V30) S/C Brake Switch Output circuit from the S/C
Servo harness connector to the Brake Lamp Switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V30) S/C Brake Switch Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
10
423
All
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS —
Continued
TEST
ACTION
APPLICABILITY
10
Ignition on, engine not running.
Turn the Cruise Control on, it may be necessary to hold the On button down while
checking the following circuit.
Using a 12-volt test light connected to ground, probe the (V32) S/C Power Supply
circuit in the Brake Lamp Switch harness connector.
Does the test light illuminate brightly?
All
11
12
Yes
→ Replace the Brake Lamp Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
11
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (V32) S/C Power Supply circuit between the PCM
harness connector and the Brake Lamp Switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V32) S/C Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
12
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If the there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
13
Turn the ignition off.
Disconnect the S/C Servo harness connector.
Using a 12-volt test light connected to 12-volts, probe the (Z10) Ground circuit in the
S/C Servo harness connector.
Does the test light illuminate brightly?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Repair the open in the (Z10) Ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
424
All
DRIVEABILITY - GAS
Symptom:
P1596-SPEED CONTROL SWITCH ALWAYS HIGH
When Monitored and Set Condition:
P1596-SPEED CONTROL SWITCH ALWAYS HIGH
When Monitored:
With the ignition key on.
Set Condition: An open circuit is detected in the speed control on/off switch circuit. The
circuit must be above 4.8 volts for more than 2 minutes to set the DTC.
POSSIBLE CAUSES
SPEED CONTROL ON/OFF SWITCH OPERATION
S/C ON/OFF SWITCH
CLOCKSPRING
(V37) S/C SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE
(V37) S/C SWITCH SIGNAL CIRCUIT OPEN BETWEEN PCM AND CLOCKSPRING
(K4) SENSOR GROUND CIRCUIT OPEN BETWEEN PCM AND CLOCKSPRING
(V37) S/C SWITCH SIGNAL CIRCUIT OPEN BETWEEN CLOCKSPRING AND S/C SWITCH
(K4) SENSOR GROUND CIRCUIT OPEN BETWEEN CLOCKSPRING AND S/C SWITCH
PCM
TEST
ACTION
APPLICABILITY
1
Engine Running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt in Sensors, read the Speed Control inputs state.
While monitoring the DRBIIIt, push the Speed Control On/Off Switch several times,
then leave it on.
Did the DRBIIIt show Speed Control Switching off and on?
All
2
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
2
Turn the ignition off.
Disconnect the S/C On/Off Switch 2-way harness connector only.
Measure the resistance across the S/C On/Off Switch.
Is the resistance between 20.3K and 20.7K ohms?
Yes
→ Go To
No
→ Replace the On/Off Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
3
425
All
DRIVEABILITY - GAS
P1596-SPEED CONTROL SWITCH ALWAYS HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the upper and lower 6-way clockspring harness connector per Service
Information.
Measure the resistance of the (K4) Sensor ground circuit between the upper and
lower 6-way clockspring harness connectors.
Measure the resistance of the (V37) S/C Switch Signal circuit between the upper and
lower 6-way clockspring harness connectors.
Was the resistance above 5.0 ohms for either circuit?
All
4
5
6
7
Yes
→ Replace the clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
4
Connect the Clockspring harness connectors per Service Information.
Disconnect the Speed Control On/Off Switch 2-way harness connector only.
Ignition on, engine not running.
Measure the voltage on the (V37) S/C Switch Signal circuit in the On/Off Switch
2-way connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (V37) S/C Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
5
Turn the ignition off.
Disconnect the upper and lower Clockspring harness connectors per Service Information.
Disconnect the PCM harness connectors.
Measure the resistance of the (V37) S/C Switch Signal circuit from the PCM harness
connector to the lower Clockspring harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V37) S/C Switch Signal circuit between
the PCM and Clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
6
Measure the resistance of the (K4) Sensor ground circuit from the PCM harness
connector to the lower Clockspring harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open (K4) Sensor ground circuit between the PCM and
Clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
7
Measure the resistance of the (V37) S/C Switch Signal circuit from the upper
Clockspring harness connector to the On/Off switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (V37) S/C Switch Signal circuit, Clockspring to S/C Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
8
426
All
DRIVEABILITY - GAS
P1596-SPEED CONTROL SWITCH ALWAYS HIGH —
Continued
TEST
ACTION
APPLICABILITY
8
Measure the resistance of the (K4) Sensor ground circuit from the On/Off Switch
2-way harness connector to the upper Clockspring harness connector.
Is the resistance below 5.0 ohms?
All
9
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit between the
Clockspring and S/C Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
427
All
DRIVEABILITY - GAS
Symptom:
P1597-SPEED CONTROL SWITCH ALWAYS LOW
When Monitored and Set Condition:
P1597-SPEED CONTROL SWITCH ALWAYS LOW
When Monitored:
Set Condition:
With the ignition key on and battery voltage above 10.4 volts.
When switch voltage is less than 0.39 of a volt for 2 minutes.
POSSIBLE CAUSES
S/C SWITCH VOLTAGE BELOW 1.0 VOLT
S/C ON/OFF SWITCH
S/C RESUME/ACCEL SWITCH
CLOCKSPRING
(V37) S/C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND
(V37) S/C SWITCH SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the S/C Switch volts status.
Is the S/C Switch voltage below 1.0 volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 4.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the S/C ON/OFF Switch harness connector.
Ignition on, engine not running.
With the DRBIIIt in Sensors, read the S/C Switch volts.
Did the S/C Switch volts change to 5.0 volts?
Yes
→ Replace the S/C ON/OFF Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the S/C RESUME/ACCEL Switch harness connector.
Ignition on, engine not running.
With the DRBIIIt in Sensors, read the S/C Switch volts.
Did the S/C Switch volts go above 4.0 volts?
Yes
→ Replace the Resume/Accel Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
4
428
All
DRIVEABILITY - GAS
P1597-SPEED CONTROL SWITCH ALWAYS LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the clockspring 6-way harness connector (instrument panel wiring side)
per Service Information.
Ignition on, engine not running.
With the DRBIIIt in Sensors, read the S/C Switch voltage.
Did the S/C Switch volts change to 5.0 volts?
All
5
6
7
Yes
→ Replace the Clockspring.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
5
Turn the ignition off.
Connect the Clockspring harness connectors per Service Information.
Disconnect the PCM harness connectors.
Measure the resistance between the (V37) S/C Switch Signal circuit and ground at
S/C ON/OFF Switch harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (V37) S/C Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
6
Measure the resistance between the (V37) S/C Signal circuit and the (K4) Sensor
ground circuit at the ON/OFF Switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (V37)
S/C Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
429
All
DRIVEABILITY - GAS
Symptom:
P1598-A/C PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P1598-A/C PRESSURE SENSOR VOLTAGE TOO HIGH
When Monitored:
Set Condition:
With the engine running and the A/C Relay energized.
The A/C Pressure Sensor Signal at the PCM goes above 4.92 volts.
POSSIBLE CAUSES
A/C PRESSURE SENSOR VOLTAGE ABOVE 4.9 VOLTS
A/C PRESSURE SENSOR
(C18) A/C PRESSURE SIGNAL CIRCUIT SHORTED TO VOLTAGE
(C18) A/C PRESSURE SIGNAL CIRCUIT OPEN
(C18) A/C PRESSURE SIGNAL CIRCUIT SHORTED TO (K6) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Ensure the A/C refrigerant System is properly charged per the
Service Information.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
With the DRBIIIt, read the A/C Pressure Sensor voltage.
Is the voltage above 4.9 volts?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
2
Turn the ignition off.
Disconnect the A/C Pressure Sensor harness connector.
Connect a jumper wire between the (C18) A/C Pressure Signal circuit and the (K4)
Sensor ground circuit in the Sensor harness connector.
With the DRBIIIt, monitor the A/C Pressure Sensor voltage.
Ignition on, engine not running.
Is the voltage below 1.0 volt?
Yes
→ Replace the A/C Pressure Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
430
All
DRIVEABILITY - GAS
P1598-A/C PRESSURE SENSOR VOLTAGE TOO HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (C18) A/C Pressure Signal circuit in the A/C Pressure
Sensor harness connector.
Is the voltage above 5.2 volts?
All
4
5
6
7
Yes
→ Repair the short to voltage in the (C18) A/C Pressure Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
4
Turn the ignition off.
Measure the resistance of the (C18) A/C Pressure Signal circuit between the A/C
Pressure Sensor harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (C18) A/C Pressure Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
5
Measure the resistance between the (C18) A/C Pressure Signal circuit and the (K6)
5-volt Supply circuit in the A/C Pressure Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the (K6) 5-volt Supply circuit and the
(C18) A/C Pressure Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
6
Measure the resistance of the (K4) Sensor ground circuit from the A/C Pressure
Sensor harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
431
All
DRIVEABILITY - GAS
Symptom:
P1599-A/C PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P1599-A/C PRESSURE SENSOR VOLTAGE TOO LOW
When Monitored:
With the engine running and the A/C Relay energized.
Set Condition: The A/C Pressure Sensor Signal voltage at the PCM goes below 0.58 volts
for 2.6 seconds.
POSSIBLE CAUSES
A/C PRESSURE SENSOR VOLTAGE BELOW 0.6 OF A VOLT
(K6) 5-VOLT SUPPLY CIRCUIT OPEN
(K6) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
A/C PRESSURE SENSOR
(C18) A/C PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND
(C18) A/C PRESSURE SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND CIRCUIT
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Ensure the A/C refrigerant System is properly charged per the
Service Information.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine.
With the DRBIIIt, read the A/C Pressure Sensor voltage.
Is the voltage below 0.60 of a volt?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 2.
2
Turn the ignition off.
Disconnect the A/C Pressure Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K6) 5-volt Supply circuit in the A/C Pressure Sensor
harness connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
6
432
All
DRIVEABILITY - GAS
P1599-A/C PRESSURE SENSOR VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
3
With the DRBIIIt, monitor the A/C Pressure Sensor voltage with the Sensor
disconnected.
Is the voltage above 0.6 of a volt?
All
4
5
6
7
8
Yes
→ Replace the A/C Pressure Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (C18) A/C Pressure Signal circuit in
the A/C Pressure Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (C18) A/C Pressure Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
5
Measure the resistance between the (C18) A/C Pressure Signal circuit and the (K4)
Sensor ground circuit in the A/C Pressure Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (C18)
A/C Pressure Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance of the (K6) 5-volt Supply circuit between the A/C Pressure
Sensor harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K6) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
7
Measure the resistance between the (K6) 5-volt Supply circuit and ground in the A/C
Pressure Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K6) 5-volt Supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
433
All
DRIVEABILITY - GAS
Symptom:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored and Set Condition:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored:
25 seconds.
With the ignition key on and the engine running over 1500 RPM after
Set Condition: When the PCM regulates the generator field and there are no detected
field problems, but the voltage output does not increase.
POSSIBLE CAUSES
CHARGING VOLTAGE BELOW 15.1 VOLTS
BATTERY TEMPERATURE SENSOR
RESISTANCE IN THE BATTERY POSITIVE CIRCUIT
(K125) GENERATOR FIELD SOURCE CIRCUIT OPEN
RESISTANCE IN THE GENERATOR GROUND
(K125) GENERATOR FIELD SOURCE CIRCUIT SHORTED TO GROUND
(K20) GENERATOR FIELD CONTROL CIRCUIT OPEN
RESISTANCE IN THE GENERATOR FIELD COIL
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
NOTE: Battery must be fully charged and capable of passing a battery load
test.
Note: Generator Belt tension and condition must be checked before continuing.
NOTE: Inspect the vehicle for any aftermarket accessories that may exceed
the maximum Generator output.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Record all DTCs and the related Freeze Frame data.
With the DRBIIIt, read the target charging voltage.
Is the target charging voltage above 15.1 volts?
All
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
2
434
DRIVEABILITY - GAS
P1682-CHARGING SYSTEM VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
2
Turn the ignition off.
Note: Generator Belt tension and condition must be checked before continuing.
Start the engine.
Allow the engine to reach normal operating temperature.
With the DRBIIIt in sensors, read the Battery Temp Sensor value.
Using a Thermometer, measure under hood temperature.
Is the temperature within 10° F of Battery temperature?
All
3
4
5
Yes
→ Go To
No
→ Replace the Battery Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
3
Ignition on, engine not running.
Measure the voltage between the Generator B+ Terminal and the Battery Positive
Post.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
CAUTION: Ensure all wires are clear of the engine’s moving parts.
Start the engine.
Is the voltage above 0.4 of a volt?
Yes
→ Repair the excessive resistance in the Battery Positive circuit
between the Generator and Battery.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
4
Start the engine.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Warm the engine to operating temperature.
Caution: Ensure all wires are clear of the engine’s moving parts.
Measure the voltage between the Generator case and Battery Negative Post.
Is the voltage above 0.1 of a volt?
Yes
→ Repair the excessive resistance in the Generator Ground circuit
between the Generator Case and Battery Negative side.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
5
Ignition on, engine not running.
Carefully inspect all connectors for corrosion or spread terminals before continuing.
With the DRBIIIt actuate the Generator Field Driver.
While backprobing, measure the voltage on the (K125) Generator Field Source circuit
at back of Generator.
Is the voltage above 10.0 volts?
Yes
→ Go To
No
→ Repair the open in the (K125) Generator Field Source circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
6
435
All
DRIVEABILITY - GAS
P1682-CHARGING SYSTEM VOLTAGE TOO LOW —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance between ground and the (K125) Generator Field Source
circuit in the PCM harness connector.
Is the resistance below 100 ohms?
All
7
8
9
Yes
→ Repair the short to ground in the (K125) Generator Field Source
circuit and replace the PCM.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
7
Measure the resistance of the (K20) Generator Field Driver circuit from the
Generator harness connector to the PCM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K20) Generator Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
8
Measure resistance across the Generator Field Terminals at the Generator.
Is the resistance above 15 ohms?
Yes
→ Replace or repair the Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
436
All
DRIVEABILITY - GAS
Symptom:
P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM
When Monitored and Set Condition:
P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM
When Monitored:
Set Condition:
With the ignition on.
The PCM does not receive a Valid Key message from the SKIM.
POSSIBLE CAUSES
NO COMMUNICATION WITH SKIM
SKIM TROUBLE CODES SET
NO VIN PROGRAMMED IN THE PCM
INCORRECT VIN IN PCM
INVALID SKIM KEY NOT PRESENT
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt, read the PCM DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
4
Yes
→ Go To
2
No
→ Go To
7
With the DRBIIIt, attempt to communicate with the SKIM.
Can the DRBIIIt communicate with the SKIM?
Yes
→ Go To
No
→ Refer to symptom BUS +/- SIGNAL OPEN FROM SKIM in the
COMMUNICATION category.
Perform SKIS VERIFICATION.
All
3
With the DRBIIIt, check for SKIM DTCs.
Are any DTCs present in the SKIM?
All
Yes
→ Refer to BODY information for the related symptom(s).
Perform SKIS VERIFICATION.
No
→ Go To
4
With the DRBIIIt, display the VIN that is programmed in the PCM.
Has a VIN been programmed into the PCM?
Yes
→ Go To
No
→ Program the correct VIN into the PCM and retest.
Perform SKIS VERIFICATION.
5
437
All
DRIVEABILITY - GAS
P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM —
Continued
TEST
5
6
7
ACTION
With the DRBIIIt, display the VIN that is programmed in the PCM.
Was the correct VIN programmed into the PCM?
Yes
→ Go To
No
→ Replace and program the Powertrain Control Module per Service
Information.
Perform SKIS VERIFICATION.
APPLICABILITY
All
6
Turn the ignition off.
Replace and program the Sentry Key Immobilizer Module in accordance with the
Service Information.
Ignition on, engine not running.
With the DRBIIIt, erase all SKIM and PCM DTCs.
Attempt to start and idle the engine.
With the DRBIIIt, read the PCM DTCs.
Does the DRBIIIt display this code?
Yes
→ Replace and program the Powertrain Control Module per Service
Information.
Perform SKIS VERIFICATION.
No
→ Test Complete.
NOTE: You must obtain the SKIM pin number.
NOTE: This DTC could have been set if the SKIM harness connector was
disconnected, or if the SKIM was replaced recently.
NOTE: All keys that the customer uses for this vehicle must be tested to
verify they are operating properly.
Ignition on, engine not running.
Verify the correct VIN is programmed into the PCM and SKIM.
Turn the ignition off.
With the next customer key turn the ignition key on and crank the engine to start.
With the DRBIIIt, read the PCM DTCs. Look for P1685
Does the DTC return?
Yes
→ Replace the Ignition Key.
Perform SKIS VERIFICATION.
No
→ Test Complete.
NOTE: If this DTC cannot be reset, it could have been an actual theft
attempt.
438
All
All
DRIVEABILITY - GAS
Symptom:
P1686-NO SKIM BUS MESSAGE RECEIVED
When Monitored and Set Condition:
P1686-NO SKIM BUS MESSAGE RECEIVED
When Monitored:
Set Condition:
With the ignition on.
The PCM does not receive a Bus message from the SKIM when expected.
POSSIBLE CAUSES
NO SKIM BUS MESSAGE
LOSS OF SKIM COMMUNICATION
PCI BUS CIRCUIT OPEN FROM PCM TO SKIM
SKIM/PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt, read the PCM DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform SKIS VERIFICATION.
2
Ignition on, engine not running.
With the DRBIIIt, attempt to communicate with the SKIM.
NOTE: This test will indicate if the Bus is operational from the DLC to the
SKIM.
Was the DRBIIIt able to communicate with the SKIM?
Yes
→ Go To
No
→ Refer to symptom BUS +/- SIGNAL OPEN FROM SKIM in the
COMMUNICATION category.
Perform SKIS VERIFICATION.
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the SKIM harness connector.
Measure the resistance of the PCI Bus circuit between the PCM harness connector
and the SKIM harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the PCI Bus circuit between the PCM and the
SKIM.
Perform SKIS VERIFICATION.
4
439
All
DRIVEABILITY - GAS
P1686-NO SKIM BUS MESSAGE RECEIVED —
Continued
TEST
ACTION
APPLICABILITY
4
Replace the Sentry Key Immobilizer Module in accordance with the Service Information.
Ignition on, engine not running.
Display and erase all PCM and SKIM DTCs.
Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle.
With the DRB, display PCM DTCs.
Does the DRB display the same DTC?
All
Yes
→ Replace and program the Powertrain Control Module per Service
Information.
Perform SKIS VERIFICATION.
No
→ Test Complete.
440
DRIVEABILITY - GAS
Symptom:
P1687-NO CLUSTER BUS MESSAGE
When Monitored and Set Condition:
P1687-NO CLUSTER BUS MESSAGE
When Monitored:
With the ignition on.
Set Condition: The PCM has not received an expected Cluster Status Bus message from
the instrument cluster within the last 20 seconds.
POSSIBLE CAUSES
NO CLUSTER BUS MESSAGE
COMMUNICATE WITH CLUSTER
INSTRUMENT CLUSTER OPERATION
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
Cycle the ignition key on and off several times.
With the DRBIIIt, read DTCs.
Does the DTC reset?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1.
APPLICABILITY
All
2
Ignition on, engine not running.
With the DRBIIIt, attempt to communicate with the Instrument cluster.
Can communication be established with the Instrument Cluster?
Yes
→ Go To
No
→ Refer to the Communication Category of the Body Diagnostic
Manual and perform the appropriate symptom related to no
communication with cluster.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
All
3
Start the engine
Allow the engine to idle.
Is the correct engine speed display in the instrument cluster (Tach)?
Yes
→ Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Refer to the Instrument Category in the Body Diagnostic Manual
and perform the appropriate symptom.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
441
All
DRIVEABILITY - GAS
Symptom:
P1696-PCM FAILURE EEPROM WRITE DENIED
POSSIBLE CAUSES
DRBIIIt DISPLAYS WRITE FAILURE
DRBIIIt DISPLAYS WRITE REFUSED 2ND TIME
DRBIIIt DISPLAYS SRI MILEAGE INVALID
COMPARE SRI MILEAGE WITH ODOMETER
TEST
1
2
3
4
5
ACTION
Ignition on, engine not running.
With the DRBIIIt, perform the SRI Memory Test.
Does the DRBIIIt display Write Failure?
Yes
→ Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
APPLICABILITY
All
2
With the DRBIIIt, perform the SRI Memory Test.
Does the DRBIIIt display Write Refused?
Yes
→ Go To
3
No
→ Go To
4
With the DRBIIIt, perform the SRI Memory Test a second time.
NOTE: Retest the SRI Memory two more times.
Does the DRBIIIt display Write Refused again?
Yes
→ Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Test Complete.
With the DRBIIIt, perform the SRI Memory Test.
Does the DRBIIIt display SRI Mileage Invalid?
Yes
→ Update the mileage and retest the SRI Memory.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→ Go To
All
All
All
5
Compare the SRI Mileage stored with the Instrument Panel Odometer.
Is the mileage within the specified range displayed on the DRBIIIt?
Yes
→ Test Complete.
No
→ Update the mileage and retest the SRI Memory.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
442
All
DRIVEABILITY - GAS
Symptom:
P1698-NO BUS MESSAGE FROM TCM
POSSIBLE CAUSES
NO BUS MESSAGE FROM TRANS INTERMITTENT
NO BUS MESSAGE FROM TRANS
PCM PCI BUS CIRCUIT OPEN
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1.
APPLICABILITY
All
2
Note: This DTC could have been set when the TCM was disconnected for
transmission Diagnostics.
2
Ignition on, engine not running.
Connect the DRBIIIt and access Powertrain Control Module.
Note: This test checks for other PCI BUS codes. That indicates diferent
circuits in the BUS.
With the DRBIIIt, read DTCs.
Is a DTC also set for NO SKIM BUS MESSAGE and/or No MIC BUS MESSAGE?
Yes
→ Go To
No
→ Inspect the TCM Fused Ignition Switch circuits and ground
circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
3
443
All
DRIVEABILITY - GAS
P1698-NO BUS MESSAGE FROM TCM —
Continued
TEST
ACTION
APPLICABILITY
3
With the DRBIIIt, read DTCs. This is to ensure power and grounds to the PCM are
operational.
NOTE: If the DRBIIIt will not read PCM DTC’s, follow the (NO RESPONSE
TO PCM (SCI only)( symptom path, if vehicle will start. For NO START
Conditions follow symptom (NO RESPONSE( in Starting category .
Turn the ignition off.
Disconnect the PCM harness connectors.
Connect the DRBIIIt to the Data Link connector
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRBIIIt. Attach
the red and black leads and the cable to probe adapter to the scope input cable.
Select DRBIIIt Standalone.
Select lab scope.
Select Live.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Press F2 again
when complete.
Connect the Black lead to the PCM ground. Connect the Red lead to the PCM PCI
Bus circuit
Ignition on, engine not running.
Observe the voltage displayed on the DRBIIIt Lab Scope.
What is the voltage displayed on the scope?
All
Pulse from 0 to approximately 7.5 volts
Test Complete.
Steady 0 volts
Repair the open PCI Bus circuit to PCM.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
444
DRIVEABILITY - GAS
Symptom:
P1899- TRS PERFORMANCE
When Monitored and Set Condition:
P1899- TRS PERFORMANCE
When Monitored: Continuously with the transmission in Park, Neutral, or Drive and
NOT in Limp-in Mode.
Set Condition: This code will set if the PCM detects an incorrect Park/Neutral switch
state for a given mode of vehicle operation.
POSSIBLE CAUSES
DRBIIIt DISPLAYS P/N & D/R IN WRONG POSITION
(T24) P/N SENSE CIRCUIT OPEN
TRS (T24) P/N SENSE CIRCUIT SHORTED TO GROUND
TRS ASSEMBLY (P/N SWITCH)
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt, read the PNP switch input state.
While moving the gear selector through all gear positions Park to 1st and back to
Park, watch the DRBIIIt display.
Did the DRBIIIt display P/N and D/R in the correct gear positions?
All
2
3
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
2
Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the TRS (P/N switch) harness connector.
Check connectors - Clean/repair as necessary
Measure the resistance of the (T24) P/N Sense circuit between the PCM C1 harness
connector and the TRS (P/N) switch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (T24) P/N Sense circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Measure the resistance between ground and the (T24) P/N Sense circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (T24) P/N Sense circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
445
All
DRIVEABILITY - GAS
P1899- TRS PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Connect the TRS (P/N) harness connector.
Move the gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through the gear positions, measure the resistance
between ground and the (T24) P/N Sense circuit in the PCM C1 harness connector.
NOTE: The circuit is grounded in Park and Neutral and open in the other
positions.
Did the display change from above 100 kohms (open) to below 10.0 ohms (grounded)?
All
5
Yes
→ Go To
No
→ Replace the TRS Assembly (P/N Switch) per Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
446
All
DRIVEABILITY - GAS
Symptom:
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIt
POSSIBLE CAUSES
DRBIIIt DOES NOT SHOW BRAKE SW PRESSED OR RELEASED
(A108) FUSED B+ CIRCUIT OPEN
(Z241) BRAKE LAMP SWITCH GROUND CIRCUIT OPEN
BRAKE LAMP SWITCH
(K29) BRAKE LAMP SWITCH SIGNAL CIRCUIT OPEN
(K29) BRAKE LAMP SWITCH SIGNAL CIRCUIT SHORT TO GROUND
(K29) BRAKE LAMP SWITCH SIGNAL LESS THAN 10.0 VOLTS
(V32) S/C POWER SUPPLY CIRCUIT BELOW 10 VOLTS AT BRAKE SWITCH CONN
PCM
TEST
ACTION
APPLICABILITY
1
Ignition on, engine not running.
With the DRBIIIt in Inputs/Outputs, read the Brake Switch state.
While observing the DRBIIIt display, press and release the brake pedal several
times.
Does the DRBIIIt display Brake Switch PRESSED and RELEASED?
All
2
3
Yes
→ The Brake Lamp Switch is operating properly at this time.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
2
Turn the ignition off.
Disconnect the Brake Lamp Switch harness connector.
Using a 12-volt test light connected to ground, probe the (A108) Fused B+ circuit at
the Brake Lamp Switch harness connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open/high resistance in the (A108) Fused B+ circuit.
Check and replace fuses as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
3
Using a 12-volt test light connect to 12-volts, probe the Brake Lamp Switch ground
circuit.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the (Z241) Brake Lamp Switch Ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
4
447
All
DRIVEABILITY - GAS
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIt —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance across the Brake Lamp Switch Signal terminal and the
Ground terminal (measurement taken across the switch).
Apply and release the Brake Pedal while monitoring the ohmmeter.
Does the resistance change from below 5.0 ohms to open circuit?
All
5
6
7
8
Yes
→ Go To
No
→ Replace the Brake Lamp Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
5
Disconnect the PCM harness connectors.
Measure the resistance of the (K29) Brake Lamp Switch Signal circuit.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K29) Brake Lamp Switch Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
6
Disconnect the CAB harness connector.
Measure the resistance between ground and the (K29) Brake Lamp Switch Signal
circuit.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K29) Brake Lamp Switch
Signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No
→ Go To
All
7
Turn the ignition off.
Connect the PCM harness connectors.
Connect the CAB harness connector.
Connect the Brake Lamp Switch harness connector.
Brake pedal must be depressed in the next step.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the (K29) Brake Lamp Switch
Signal circuit at the Brake Lamp Switch harness connector.
Is the test light illuminated and bright?
Yes
→ Go To
No
→ Replace or adjust the brake switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
All
8
Turn the ignition off.
Disconnect the Brake Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
With the DRBIIIt, actuate the S/C Vacuum Solenoid.
Using a 12-volt test light, probe the (V32) S/C Power Supply circuit in the Brake
Lamp Switch harness connector.
Did the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the excesssive resistance in the (V32) S/C Power Supply
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
9
448
All
DRIVEABILITY - GAS
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIt —
Continued
TEST
ACTION
APPLICABILITY
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
449
DRIVEABILITY - GAS
Symptom:
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS
POSSIBLE CAUSES
DTC AND COMMUNICATION PRESENT
A/C SELECT CIRCUIT OPEN
A/C SELECT IN HVAC
PCM
A/C REQUEST CIRCUIT OPEN
REFRIGERATION SYSTEM NOT PROPERLY CHARGED
HIGH PRESS CUT-OFF SWITCH
LOW PRESSURE SWITCH
A/C CLUTCH COIL
A/C COMPRESSOR CLUTCH GROUND CIRCUIT OPEN
(C3) A/C CLUTCH RELAY OUTPUT CIRCUIT OPEN
FUSED B+ CIRCUIT OPEN
A/C CLUTCH RELAY
TEST
1
2
3
ACTION
Ignition on, engine not running.
Verify that communication with the HVAC and PCM is available over the BUS.
With the DRBIIIt, check for DTCs in the PCM and HVAC module.
Are any A/C DTC’s or communication failures present?
Yes
→ Diagnose the related DTC(s) or BUS failure before continuing.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
APPLICABILITY
All
2
Engine running.
With the DRBIIIt, read the A/C Select status in the PCM.
Turn the A/C Switch on and off a few times.
Does the A/C Select state change?
Yes
→ Go To
3
No
→ Go To
12
Engine Running.
Turn the A/C system on and the fan on high.
With the DRBIIIt in Inputs/Outputs, read the A/C request state.
Does the A/C request state change?
Yes
→ Go To
No
→ Repair the open in the A/C Request circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
4
450
All
All
DRIVEABILITY - GAS
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS —
TEST
4
5
6
7
8
9
ACTION
Turn the ignition off.
Verify that the Refrigerant System is properly charged per Service Procedure.
Is the Refrigerant System properly charged?
Yes
→ Go To
No
→ Properly charge the Refrigerant System per Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
Continued
APPLICABILITY
All
5
Verify the High Pressure Cut-Off Switch per Service Information.
Is the High Pressure Cut-Off Switch OK?
Yes
→ Go To
No
→ Replace the High Pressure Cut-Off Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
6
Verify the Low Pressure Switch operation per Service Information.
Is the Low Pressure Switch OK?
Yes
→ Go To
No
→ Replace the Low Pressure Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
7
Ignition on, engine not running.
Connect a test light between the ground circuit and the A/C Clutch Relay Output
circuit.
With the DRBIIIt, actuate the A/C Clutch Relay.
Does the test light illuminate brightly on and off with the relay actuation?
Yes
→ Replace the A/C Clutch Coil.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the A/C Clutch harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the A/C Compressor Clutch ground
circuit in the A/C Clutch harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the A/C Compressor Clutch ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
9
Remove the A/C Clutch Relay.
Measure the resistance of the (C3) A/C Clutch Relay Output circuit between the IPM
and the A/C Clutch Coil.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (C3) A/C Clutch Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
10
451
All
DRIVEABILITY - GAS
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS —
TEST
10
11
ACTION
Measure the voltage of the Fused B+ circuit at the A/C Clutch Relay connector.
Is the voltage above 11.0 volts?
Yes
→ Go To
No
→ Repair the open in the Fused B+ circuit. The open may be in the
IMP.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
Continued
APPLICABILITY
All
11
If there are no possible causes remaining, view repair.
All
Repair
Replace the A/C Clutch Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
12
Ignition on, engine not running.
With the DRBIIIt in the HVAC, under the Monitors screen, read the A/C Select
Switch state.
While monitoring the DRBIIIt screen, turn the A/C switch on and off a few times.
Does the A/C Select State change on the HVAC Monitors screen.
Yes
→ Check for any related TSBs. Replace and program the PCM in
accordance with the Service Information as long as no BUS
problems exist.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Replace the A/C-Heater Control module.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
452
All
DRIVEABILITY - GAS
Symptom:
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS
POSSIBLE CAUSES
GENERATOR BELT CONDITION
DTC RESET
WIRE HARNESS INSPECTION
RESISTANCE IN THE BATTERY POSITIVE CIRCUIT
(K125) GENERATOR FIELD SOURCE CIRCUIT OPEN
GENERATOR FIELD COIL HIGH RESISTANCE
(K20) GEN FIELD CONTROL CIRCUIT OPEN
RESISTANCE IN THE GENERATOR GROUND
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: Verify that the Battery is able to pass a load test before continuing.
Ignition on, engine not running.
With the DRBIIIt, read the Battery voltage and record the results.
Measure Battery voltage between the Battery Positive and Negative Terminals and
record the results.
Compare the two voltage readings.
Is the voltage difference less than one volt?
All
2
3
Yes
→ Go To
2
No
→ Go To
8
Ignition on, engine not running.
Measure the voltage between the Generator B+ Terminal and the Battery+ Post.
Caution: Ensure all wires are clear of the engine’s moving parts.
Start the engine.
Is the voltage above 0.4 of a volt?
Yes
→ Repair the excessive resistance in the Battery Positive circuit
between the Generator and Battery .
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
3
Ignition on, engine not running.
Record all DTCs and freeze frame data, now erase Codes.
Carefully inspect all connectors for corrosion or spread terminals before continuing.
With the DRBIIIt actuate the Generator Field Driver.
Measure the voltage of the (K125) Generator Field Source circuit by backprobing the
back of Generator Field harness connector.
Is the voltage above 10.0 volts?
Yes
→ Go To
No
→ Repair the (K125) Generator Field Source circuit for an open or
short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
4
453
All
DRIVEABILITY - GAS
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS —
Continued
TEST
4
5
6
7
ACTION
Start the engine.
Warm the engine to operating temperature.
Caution: Ensure all wires are clear of the engine’s moving parts.
Measure the voltage between the Generator case and Battery Negative Post.
Is the voltage above 0.1 of a volt?
Yes
→ Repair the excessive resistance in the Generator Ground circuit
between the Generator Case and Battery Ground side.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
APPLICABILITY
All
5
Turn the ignition off.
Disconnect the Generator Field harness connector at back of the Generator.
Measure resistance across the Generator Field Terminals at the Generator.
Is the resistance above 15 ohms?
Yes
→ Replace or repair the Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
All
6
Disconnect the PCM harness connectors.
Measure the resistance of the (K20) Generator Field Driver circuit between the PCM
harness connector and the Generator harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
8
9
Turn the ignition off.
NOTE: Battery condition must be verified prior to this test.
Inspect the Generator Belt tension and condition.
Is the Generator Belt OK?
Yes
→ Go To
No
→ Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
All
9
Start the engine.
Turn on all accessories.
Raise engine speed to 2000 RPM for 30 seconds then return to idle.
With the DRBIIIt, read DTCs.
Are there any 9Charging System9 Trouble Codes?
Yes
→ Refer to Symptom list for the related Charging DTCs.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Go To
10
454
All
DRIVEABILITY - GAS
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS —
Continued
TEST
ACTION
APPLICABILITY
10
Ignition on, engine not running.
With the DRBIIIt, actuate the Generator Field Driver.
Using a 12-volt test light, backprobe the Generator Field Driver Terminal at the back
of the Generator.
Note: The test light should blink On and Off every 1.4 seconds.
While monitoring the 12-volt test light, wiggle the Field Terminals back to the PCM
and ASD Relay.
Was there any interruption in the normal cycle of the test light?
All
Yes
→ Repair the wire or connector where the wiggling interrupted the
voltage cycle.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No
→ Test Complete.
455
DRIVEABILITY - GAS
Symptom:
*CHECKING CONDENSER FAN OPERATION
POSSIBLE CAUSES
INTERNAL FUSED B+ CIRCUITS
CONDENSER FAN RELAY
(Y145) CONDENSER FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND
(Y145) CONDENSER FAN RELAY CONTROL CIRCUIT OPEN
(Z212) CONDENSER FAN GROUND CIRCUIT OPEN
CONDENSER FAN MOTOR
TEST
1
2
3
4
ACTION
Ignition on, engine not running.
With the DRBIIIt, actuate the Condenser Fan Relay.
Does the Condenser Fan Motor cycle on and off?
Yes
→ Test Complete.
No
→ Go To
APPLICABILITY
All
2
Turn the ignition off.
Remove the Condenser Fan Relay.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the
Condenser Fan Relay connector.
Did the light illuminate brightly?
Yes
→ Go To
No
→ Repair the open or short to ground in the Internal Fused B+
circuits. Inspect the related fuse and repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
3
Install a known good Relay.
With the DRBIIIt, actuate the Condenser Fan Relay.
Does the Fan actuate?
Yes
→ Replace the Condenser Fan Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No
→ Go To
All
4
Turn the ignition off. .
Disconnect the PCM harness connectors.
Measure the resistance of the (Y145) Condenser Fan Relay Control circuit from the
Condenser Fan Relay to the PCM harness connectors.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the short to ground in the (Y145) Condenser Fan Relay
Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5
456
All
DRIVEABILITY - GAS
*CHECKING CONDENSER FAN OPERATION —
Continued
TEST
ACTION
APPLICABILITY
5
Measure the resistance of the (Y145) Condenser Fan Relay Output circuit between
the Condenser Fan Motor harness connector and the Condenser Fan Relay connector.
Is the resistance below 5.0 ohms?
All
6
7
Yes
→ Go To
No
→ Repair the open in the (Y145) Condenser Fan Relay Control
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
6
Disconnect the Condenser Fan Motor harness connector.
Measure the resistance between ground and the (Z212) Condenser Fan Motor ground
circuit.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (Z212) Condenser Fan ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
All
7
If there are no possible causes remaining, view repair.
Repair
Replace the Condenser Fan Motor.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
457
All
DRIVEABILITY - GAS
Symptom:
*CHECKING THE PCM POWER AND GROUNDS
POSSIBLE CAUSES
(A14) PCM FUSED B+ CIRCUIT
(Y135) PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT
(Z81) (Z82) PCM GROUND CIRCUITS
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
Disconnect the PCM harness connectors.
Using a 12-volt test light connected to ground, probe the (A14) PCM Fused B+ circuit
in the PCM harness connector.
Does the test light illuminate brightly?
All
2
3
Yes
→ Go To
No
→ Repair the open in the (A14) Fused B+ circuit. Inspect the related
fuse and repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, probe the (Y135) PCM Fused Ignition
Switch Output circuit in the PCM harness connector.
Does the test light illuminate brightly?
Yes
→ Go To
No
→ Repair the open in the (Y135) Fused Ignition Switch Output
circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
All
3
Turn the ignition off.
Using a 12-volt test light connected to battery voltage, probe the (Z81) (Z82) PCM
ground circuits in the PCM harness connector.
Does the test light illuminate brightly?
Yes
→ Test Complete.
No
→ Repair the open in the PCM ground circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
458
All
DRIVEABILITY - NGC
Symptom:
INTERMITTENT CONDITION
POSSIBLE CAUSES
INTERMITTENT CONDITION
TEST
ACTION
APPLICABILITY
1
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Refer to any Technical Service Bulletins (TSBs) that may apply.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wire harness. Look for parameter
values to change and/or a DTC to set.
Turn the ignition off.
Visually inspect the related wire harness. Disconnect all the related harness
connectors. Look for any chafed, pierced, pinched, partially broken wires and broken,
bent, pushed out, or corroded terminals.
Perform a voltage drop test on the related circuits between the suspected faulty
component and the PCM.
CAUTION: NEVER PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Inspect and clean all PCM, engine, and chassis grounds that are related to the most
current DTC.
If numerous trouble codes were set, use a wire schematic and look for any common
ground or supply circuits
For any Relay DTCs, actuate the Relay with the DRBIIIt and wiggle the related wire
harness to try to interrupt the actuation.
For intermittent Evaporative Emission trouble codes perform a visual and physical
inspection of the related parts including hoses and the Fuel Filler cap.
For intermittent Misfire DTC’s check for restrictions in the Intake and Exhaust
system, proper installation of Sensors, vacuum leaks, and binding components that
are run by the accessory drive belt.
Use the DRBIIIt to perform a System Test if one applies to failing component.
A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions.
Were any problems found during the above inspections?
All
Yes
→ Repair as necessary
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
459
DRIVEABILITY - NGC
Symptom:
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT
When Monitored and Set Condition:
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT
When Monitored:
Engine cranking and Engine running
Set Condition: Powertrain Control Module detects an error when the camshaft position is
out of phase with the crankshaft position. One Trip Fault. Three good trips to turn off the
MIL.
POSSIBLE CAUSES
INTERMITTENT CONDITION
CHECKING INTERMITTENT CMP SIGNAL WITH LAB
CMP WIRE HARNESS INSPECTION
TONE WHEEL/PULSE RING INSPECTION
CKP WIRE HARNESS INSPECTION
TONE WHEEL/PULSE RING INSPECTION
INTERMITTENT CKP SIGNAL
CAMSHAFT POSITION SENSOR
CRANKSHAFT POSITION SENSOR
TEST
ACTION
APPLICABILITY
1
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Start the engine and run until operating temp is reached. (Closed Loop)
If the DTC does not reset it may be necessary to test drive the vehicle.
Does the P0016 return?
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
460
DRIVEABILITY - NGC
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT —
Continued
TEST
ACTION
APPLICABILITY
2
With the DRBIIIt lab scope probe and the Miller special tool #6801, backprobe the
(K44) CMP Signal circuit at the CMP harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Observe the lab scope screen.
Are there any irregular or missing signals?
All
3
4
5
Yes
→ Go To
3
No
→ Go To
6
Turn the ignition off.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are
properly installed and the mounting bolt(s) tight.
Refer to any TSBs that may apply.
Were any of the above conditions present?
Yes
→ Repair as necessary
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Remove the Camshaft Position Sensor.
Inspect the Tone Wheel/Pulse Ring for damage, foreign material, or excessive
movement.
Were any problems found?
Yes
→ Repair or replace the Tone Wheel/Pulse Ring as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
If there are no possible causes remaining, view repair.
Repair
Replace the Camshaft Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
461
All
DRIVEABILITY - NGC
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off.
Remove the lab scope probe.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
Start the engine.
Gently tap on the Cam Position Sensor and wiggle the Sensor.
Ignition on, engine not running.
Inspect the Sensor harness connector, PCM harness connector, Sensor connector, and
PCM connector for loose, bent, corroded, or pushed out pins/terminals.
Inspect the related wire harness and the splices in the CMP circuits.
Does the P0016 return?
All
7
8
9
Yes
→ Repair the wiring/connector concerns as needed or replace the
Camshaft Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
Turn the ignition off.
With the DRBIIIt lab scope probe and the Miller special tool #6801, backprobe the
(K24) CKP Signal circuit at the CKP harness connector.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Observe the lab scope screen.
Are there any irregular or missing signals?
Yes
→ Go To
8
No
→ Go To
11
Turn the ignition off.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are
properly installed and the mounting bolt(s) tight.
Refer to any TSBs that may apply.
Were any of the above conditions present?
Yes
→ Repair as necessary
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
9
Remove the Crankshaft Position Sensor.
Inspect the Tone Wheel/Flex Plate slots for damage, foreign material, or excessive
movement.
Were any problems found?
Yes
→ Repair or replace the Tone Wheel/Flex Plate as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
10
462
All
DRIVEABILITY - NGC
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT —
TEST
10
ACTION
If there are no possible causes remaining, view repair.
Continued
APPLICABILITY
All
Repair
Replace the Crankshaft Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
11
NOTE: The conditions that set this DTC are not present at this time. The
following test may help in identifying the intermittent condition.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Gently tap on the Crank Position Sensor and wiggle the CKP Sensor.
Turn the ignition off.
Inspect the Sensor harness connector, PCM harness connector, Sensor connector, and
PCM connector for loose, bent, corroded, or pushed out pins/terminals.
Inspect the related wire harness and the splices in the CKP circuits.
Were any problems found?
Yes
→ Repair the wiring/connector concerns as needed or replace the
Crankshaft Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
463
All
DRIVEABILITY - NGC
Symptom List:
P0031-O2
P0037-O2
P0051-O2
P0057-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
HEATER
HEATER
HEATER
HEATER
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
LOW
LOW
LOW
LOW
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0031-O2 SENSOR 1/1 HEATER
CIRCUIT LOW.
When Monitored and Set Condition:
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW
When Monitored:
on.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not match Actual state. One Trip Fault. Three good
trips to turn off the MIL.
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW
When Monitored:
on.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW
When Monitored:
on.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
P0057-O2 SENSOR 2/2 HEATER CIRCUIT LOW
When Monitored:
on.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
POSSIBLE CAUSES
O2 SENSOR HEATER OPERATION
O2 HEATER ELEMENT
O2 HEATER CONTROL CIRCUIT
O2 HEATER CONTROL SHORTED TO GROUND
464
DRIVEABILITY - NGC
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW —
Continued
POSSIBLE CAUSES
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0
volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the O2 Sensor voltage stay above 4.5 volts?
All
2
3
4
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
NOTE: Allow the O2 Sensor to cool down to room temperature.
Disconnect the O2 Sensor harness connector.
Measure the resistance across the O2 Sensor Heater element component side.
NOTE: O2 Heater Element resistance values should be measured at 70°F
(21.1°C). The resistance value will increase with temperature.
* 4.7L O2 Sensor Heater Element resistance value is 4.6 to 5.6 ohms for the
Upstream and Downstream Sensors.
* 5.7L Upstream O2 Sensor Heater Element resistance value is 3.3 to 4.1 ohms and
the resistance value for the Downstream Sensor’s is 4.0 to 5.0 ohms.
Is the O2 Sensor Heater element within specification?
Yes
→ Go To
No
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test with the O2 Sensor harness connector
still disconnected.
Using a 12-volt test light connected to ground, probe the O2 Heater Control circuit in
the O2 Sensor harness connector.
Does the test illuminate brightly and flash on and off?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the O2 Heater Control circuit in the O2
Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short to ground in the O2 Sensor Heater Control
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
465
All
DRIVEABILITY - NGC
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
466
DRIVEABILITY - NGC
Symptom List:
P0032-O2
P0038-O2
P0052-O2
P0058-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
HEATER
HEATER
HEATER
HEATER
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
HIGH
HIGH
HIGH
HIGH
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0032-O2 SENSOR 1/1 HEATER
CIRCUIT HIGH.
When Monitored and Set Condition:
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH
When Monitored:
off.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH
When Monitored:
off.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH
When Monitored:
off.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
P0058-O2 SENSOR 2/2 HEATER CIRCUIT HIGH
When Monitored:
off.
Battery voltage above 10.6 volts, ASD is powered up, and O2 heater is
Set Condition: Desired state does not equal Actual state. One Trip Fault. Three good trips
to turn off the MIL.
POSSIBLE CAUSES
O2 SENSOR HEATER OPERATION
O2 HEATER ELEMENT
O2 HEATER GROUND CIRCUIT OPEN
O2 SENSOR
467
DRIVEABILITY - NGC
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH —
Continued
POSSIBLE CAUSES
O2 HEATER CONTROL SHORTED TO VOLTAGE
O2 HEATER CONTROL CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0
volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the O2 Sensor voltage stay above 4.5 volts?
All
2
3
4
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
NOTE: Allow the O2 Sensor to cool down to room temperature.
Disconnect the O2 Sensor harness connector.
Measure the resistance across the O2 Sensor Heater element component side.
NOTE: O2 Heater Element resistance values should be measured at 70°F
(21.1°C). The resistance value will increase with temperature.
* 4.7L O2 Sensor Heater Element resistance value is 4.6 to 5.6 ohms for the
Upstream and Downstream Sensors.
* 5.7L Upstream O2 Sensor Heater Element resistance value is 3.3 to 4.1 ohms and
the resistance value for the Downstream Sensor’s is 4.0 to 5.0 ohms.
Is the O2 Sensor Heater element within specification?
Yes
→ Go To
No
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test with the Sensor harness connector
still disconnected.
Using a 12-volt test light connected to ground, probe the O2 Heater Control circuit in
the O2 Sensor harness connector.
Does the test illuminate brightly and flash on and off?
Yes
→ Go To
4
No
→ Go To
5
Turn the ignition off.
Measure the resistance between engine ground and the O2 Heater ground circuit in
the O2 Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Repair the open in the O2 Heater ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
468
All
All
DRIVEABILITY - NGC
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH —
Continued
TEST
ACTION
APPLICABILITY
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the O2 Heater Control circuit at the O2 Sensor harness
connector.
Does the voltmeter indicate any voltage present?
All
6
7
Yes
→ Repair the short to voltage in the O2 Heater Control circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the O2 Heater Control circuit from the O2 Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Heater Control circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
469
All
DRIVEABILITY - NGC
Symptom:
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK
DETECTED (4.7L)
When Monitored and Set Condition:
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED
(4.7L)
When Monitored:
During all drive modes.
Set Condition: If vacuum drops below 1.59Hg with engine RPM greater than 2000 RPM
and closed throttle. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
VACUUM LEAK
RESISTANCE IN (K6) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K6) 5-VOLT SUPPLY CIRCUIT
MAP SENSOR
RESISTANCE IN THE (K1) MAP SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K1) MAP SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
TP SENSOR OPERATION
RESISTANCE IN THE (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K7) 5-VOLT SUPPLY CIRCUIT
TP SENSOR
RESISTANCE IN THE (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
PCM
470
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (4.7L) — Continued
TEST
1
2
3
4
ACTION
APPLICABILITY
NOTE: Diagnose any TP Sensor or MAP Sensor component DTCs before ENG - NEXT GENERATION 4.7L
continuing.
MAGNUM V8
NOTE: If the P0501 - No Vehicle Speed Signal is set long with this DTC, refer
to the P0500 diagnostics before continuing.
NOTE: The throttle plate and linkage should be free from binding and
carbon build up.
NOTE: Ensure the throttle plate is at the idle position.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
NOTE: This code is enabled on engines with a plastic intake manifold and is ENG - NEXT GENERATION 4.7L
intended to shut down the engine if a large crack occurs.
MAGNUM V8
NOTE: A large vacuum leak is most likely the cause of this DTC.
Inspect the Intake Manifold for leaks and cracks.
Inspect the Power Brake Booster for any vacuum leaks.
Inspect the PCV system for proper operation or any vacuum leaks.
Inspect the MAP Sensor for proper installation.
Were any vacuum leaks found?
Yes
→ Repair the vacuum leak as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
ENG - NEXT GENStart the engine.
ERATION 4.7L
With the DRBIIIt, monitor the MAP Sensor voltage.
MAGNUM V8
Snap the throttle.
Does the MAP Sensor voltage vary from below 2.0 volts at idle to above 3.5 volts at
WOT.
Yes
→ Go To
4
No
→ Go To
11
ENG - NEXT GENIgnition on, engine not running.
ERATION 4.7L
With the DRBIIIt, monitor the TP Sensor voltage while slowly depressing the
MAGNUM V8
throttle pedal from closed to wide open throttle.
Does voltage start approximately at 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
471
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (4.7L) — Continued
TEST
5
6
7
ACTION
APPLICABILITY
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the TP Sensor harness connector.
MAGNUM V8
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
Measure the resistance between ground and (K7) 5-volt Supply circuit at the TP ENG - NEXT GENSensor harness connector.
ERATION 4.7L
Is the resistance above 100k ohms?
MAGNUM V8
Yes
→ Go To
No
→ Repair the resistance between ground and the (K7) 5-volt Supply
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
ENG - NEXT GENConnect the PCM harness connectors.
ERATION 4.7L
Ignition on, engine not running.
MAGNUM V8
With the DRBIIIt, monitor the TP Sensor voltage.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit in the Sensor harness connector.
Does the TP Sensor voltage change from approximately 4.9 volts to below 0.5 of a
volt?
Yes
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
NOTE: Remove the jumper wire before continuing.
8
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the TP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
472
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (4.7L) — Continued
TEST
9
10
11
12
ACTION
APPLICABILITY
Measure the resistance between ground and the (K22) TP #1 Signal circuit in the TP ENG - NEXT GENSensor harness connector.
ERATION 4.7L
Is the resistance above 100k ohms?
MAGNUM V8
Yes
→ Go To
No
→ Repair the resistance between ground and the (K22) TP Sensor #1
Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
10
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING ENG - NEXT GENERATION 4.7L
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMIMAGNUM V8
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor Ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
17
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the MAP Sensor harness connector.
MAGNUM V8
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K6) 5-volt Supply circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
12
Measure the resistance between ground and the (K6) 5-volt Supply circuit at the ENG - NEXT GENMAP Sensor harness connector.
ERATION 4.7L
Is the resistance above 100k ohms?
MAGNUM V8
Yes
→ Go To
No
→ Repair the short between ground and the (K6) 5-volt Supply
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
13
473
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (4.7L) — Continued
TEST
13
ACTION
APPLICABILITY
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Connect the PCM harness connectors.
MAGNUM V8
Ignition on, engine not running.
With the DRBIIIt, monitor the MAP Sensor voltage.
Connect a jumper wire between the (K1) MAP Signal circuit and the (K4) Sensor
ground circuit .
Cycle the ignition switch from off to on.
Does the DRBIIIt display MAP voltage from approximately 4.9 volts to below 0.5 of
a volt?
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
14
NOTE: Remove the jumper wire before continuing.
14
15
16
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K1) MAP Signal circuit from the MAP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K1) MAP Signal circuit
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
15
Measure the resistance between ground and the (K1) MAP Signal circuit at the MAP ENG - NEXT GENSensor harness connector.
ERATION 4.7L
Is the resistance above 100k ohms?
MAGNUM V8
Yes
→ Go To
No
→ Repair the resistance between ground and the (K1) MAP Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
16
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING ENG - NEXT GENERATION 4.7L
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMIMAGNUM V8
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
17
474
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (4.7L) — Continued
TEST
17
ACTION
APPLICABILITY
NOTE: Before continuing, check the PCM harness connector terminals for ENG - NEXT GENERATION 4.7L
corrosion, damage, or terminal push out. Repair as necessary.
MAGNUM V8
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
475
DRIVEABILITY - NGC
Symptom List:
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK
DETECTED (5.7L)
P2172-HIGH AIR FLOW/VACUUM LEAK DETECTED (INSTANTANEOUS ACCUMULATION)
P2173-HIGH AIRFLOW/VACUUM LEAK DETECTED (SLOW ACCUMULATION)
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L).
When Monitored and Set Condition:
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED
(5.7L)
When Monitored:
During all drive modes.
Set Condition: If vacuum drops below 1.59Hg with engine RPM greater than 2000 RPM
and closed throttle. One Trip Fault. Three good trips to turn off the MIL.
P2172-HIGH AIR FLOW/VACUUM LEAK DETECTED (INSTANTANEOUS ACCUMULATION)
When Monitored:
Ignition on and engine running with no MAP Sensor DTCs.
Set Condition: A large vacuum leak has been detected or both of the TP Sensors have
failed based on their positio being 2.5 volts and the calculated MAP value is less than the
actual MAP minus an Offset value. One trip fault. ETC light will flash.
P2173-HIGH AIRFLOW/VACUUM LEAK DETECTED (SLOW ACCUMULATION)
When Monitored:
Ignition on and engine running with no MAP Sensor DTCs.
Set Condition: A large vacuum leak has been detected or both of the TP Sensors have
failed based on their positio being 2.5 volts and the Gas Flow Adaptation value too high.
One trip fault. ETC light will flash.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
VACUUM LEAK
RESISTANCE IN THE (K6) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K6) 5-VOLT SUPPLY CIRCUIT
MAP SENSOR
RESISTANCE IN THE (K1) MAP SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K1) MAP SIGNAL CIRCUIT
476
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L) — Continued
POSSIBLE CAUSES
RESISTANCE IN (K4) SENSOR GROUND CIRCUIT
TP SENSOR OPERATION
RESISTANCE IN THE (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K7) 5-VOLT SUPPLY CIRCUIT
TP SENSOR
RESISTANCE IN THE TP SENSOR SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE TP SENSOR SIGNAL CIRCUIT
RESISTANCE IN THE (K101) SENSOR RETURN CIRCUIT
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: The most likely cause of this DTC is a vacuum leak.
NOTE: Diagnose any TP Sensor or MAP Sensor component DTCs before
continuing.
NOTE: The throttle plate should be free from binding and carbon build up.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
NOTE: This code is enabled on engines with a plastic intake manifold and is
intended to limit the maximum engine speed if a large crack occurs.
NOTE: A large vacuum leak is most likely the cause of this DTC.
Inspect the Intake Manifold and Throttle body for leaks and cracks.
Inspect the Power Brake Booster for any vacuum leaks.
Inspect the PCV system for proper operation or any vacuum leaks.
Inspect the MAP Sensor for proper installation.
Were any vacuum leaks found?
Yes
→ Repair the vacuum leak as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
3
Start the engine.
With the DRBIIIt, monitor the MAP Sensor voltage.
Snap the Accelerator pedal.
Does the MAP Sensor voltage vary from below 2.0 volts at idle to above 3.5 volts at
WOT?
Yes
→ Go To
4
No
→ Go To
11
477
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L) — Continued
TEST
ACTION
APPLICABILITY
4
Ignition on, engine not running.
With the DRBIIIt, perform the Pedal Follower Test.
TP Sensor #1 should start at approximately 0.8 of a volt and increase to 4.2 volts.
TP Sensor #2 should start at approximately 4.2 volts and decrease to 0.8 of a volt.
Is the voltage transition smooth between the appropriate values?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
6
7
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Turn the ignition off.
Disconnect the Throttle Body harness connector.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
6
Measure the resistance between ground and (K7) 5-volt Supply circuit at the Throttle
Body harness connector.
Is the resistance above 100k ohms?
Yes
→ Go To
No
→ Repair the excessive resistance between ground and the (K7)
5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
7
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor voltage.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K101)
Sensor Return circuit in the Throttle Body harness connector.
TP Sensor #1 voltage should start at approximately 4.5 volts and decrease to 0.5 of
a volt.
Connect a jumper wire between the (K122) TP Sensor #2 Signal circuit and the (K7)
5-volt Supply circuit in the Throttle Body harness connector.
TP Sensor #2 voltage should start at approximately 0 volts and increase to 4.8 to 5.2
volts.
Does the TP Sensor voltage change to the appropriate voltage?
Yes
→ Disconnect the Battery before replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select LEARN
ETC.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
478
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L) — Continued
TEST
ACTION
APPLICABILITY
8
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) and (K122) TP Signal circuits from the Throttle
Body harness connector to the appropriate terminals of special tool #8815.
Is the resistance below 5.0 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
9
10
11
Yes
→ Go To
No
→ Repair the excessive resistance in the (K22) or (K122) TP Sensor
Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Measure the resistance between ground and the (K22) and (K122) TP Signal circuits
in the Throttle Body harness connector.
Is the resistance above 100k ohms?
Yes
→ Go To
No
→ Repair the excessive resistance between ground and the (K22) or
(K122) TP Sensor Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
10
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K101) Sensor Return circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K101) Sensor Return
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
17
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K6) 5-volt Supply circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
12
479
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L) — Continued
TEST
ACTION
APPLICABILITY
12
Measure the resistance between ground and the (K6) 5-volt Supply circuit at the
MAP Sensor harness connector.
Is the resistance above 100k ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
13
Yes
→ Go To
No
→ Repair the excessive resistance between ground and the (K6)
5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
13
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, monitor the MAP Sensor voltage.
Connect a jumper wire between the (K1) MAP Signal circuit and the (K4) Sensor
ground circuit.
Cycle the ignition switch from off to on.
With the DRBIIIt, monitor the MAP Sensor voltage.
Does the DRBIIIt display MAP voltage from approximately 4.9 volts to below 0.5
volt?
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
14
NOTE: Remove the jumper wire before continuing.
14
15
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K1) MAP Signal circuit from the MAP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K1) MAP Signal circuit
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
15
Measure the resistance between ground and the (K1) MAP Signal circuit at the MAP
Sensor harness connector.
Is the resistance above 100k ohms?
Yes
→ Go To
No
→ Repair the excessive resistance between ground and the (K1)
MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
16
480
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0068-MAP SENSOR/TP SENSOR CORRELATION - VACUUM LEAK DETECTED (5.7L) — Continued
TEST
ACTION
APPLICABILITY
16
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
17
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
17
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
481
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
Symptom List:
P0070-AMBIENT TEMPERATURE SENSOR STUCK
P0071-AMBIENT TEMPERATURE SENSOR PERFORMANCE
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0070-AMBIENT TEMPERATURE SENSOR STUCK.
When Monitored and Set Condition:
P0070-AMBIENT TEMPERATURE SENSOR STUCK
When Monitored:
Engine running.
Set Condition: The PCM does not see a 2 deg C (35 deg F) change in the Ambient
Temperature Sensor voltage after 4 warm up cycles within 200 miles. Two Trip Fault.
Three good trips to turn off the MIL.
P0071-AMBIENT TEMPERATURE SENSOR PERFORMANCE
When Monitored: Engine off time is greater than 480 minutes and Ambient Temperature
is greater than 4 deg C (39 deg F).
Set Condition: After a calibrated amount of cool down time, the PCM compares the ECT
Sensor, IAT Sensor and the Ambient Air Temperature Sensor values. If the Ambient Air
Temperature Sensor value is not within -10 deg C (18 deg F) of the other two temperature
sensor’s. Two Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
AAT SENSOR
(G31) AAT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
(G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND
(G31) AAT SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND
PCM
482
DRIVEABILITY - NGC
P0070-AMBIENT TEMPERATURE SENSOR STUCK —
TEST
1
2
3
4
Continued
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
NOTE: Visually inspect both the component and the PCM connectors. Look
for damage, partially broken wires and backed out or corroded terminals
Turn the ignition off
Disconnect the PCM harness connectors.
Disconnect the Ambient Air Temp Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (G31) AAT Signal circuit in the Ambient Temp Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, read the Ambient Air Temperature Sensor voltage.
Is the voltage above 4.6 volts?
Yes
→ Go To
4
No
→ Go To
7
Connect a jumper wire across the (G31) AAT Signal circuit and the (K4) Sensor
ground circuit terminals of the Sensor harness connector.
With the DRBIIIt, read the AAT Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the Ambient Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
5
NOTE: Remove the jumper wire before continuing.
5
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (G31) AAT Signal circuit from the AAT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
483
All
DRIVEABILITY - NGC
P0070-AMBIENT TEMPERATURE SENSOR STUCK —
Continued
TEST
ACTION
APPLICABILITY
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the AAT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
7
8
9
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (G31) AAT Signal circuit in the AAT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Measure the resistance between the (G31) AAT Signal circuit and the (K4) Sensor
ground circuit in the AAT Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
484
All
DRIVEABILITY - NGC
Symptom:
P0072-AMBIENT TEMPERATURE SENSOR CIRCUIT LOW
When Monitored and Set Condition:
P0072-AMBIENT TEMPERATURE SENSOR CIRCUIT LOW
When Monitored:
The ignition key on.
Set Condition: Ambient Temperture Sensor is less than .098 of a volt at the PCM for 3
seconds. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
AAT SENSOR VOLTAGE BELOW 0.3 OF A VOLT
AAT SENSOR
(G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND
(G31) ATT SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the Ambient Air Temperature Sensor voltage.
Is the voltage below 0.3 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Ambient Air Temperature Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read AAT Sensor voltage.
Is the voltage above 4.6 volts?
Yes
→ Replace the Ambient Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (G31) AAT Signal circuit in the AAT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
485
All
DRIVEABILITY - NGC
P0072-AMBIENT TEMPERATURE SENSOR CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (G31) AAT Signal circuit and the (K4) Sensor
ground circuit in the AAT Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
486
All
DRIVEABILITY - NGC
Symptom:
P0073-AMBIENT TEMPERATURE SENSOR CIRCUIT HIGH
When Monitored and Set Condition:
P0073-AMBIENT TEMPERATURE SENSOR CIRCUIT HIGH
When Monitored:
The ignition key on.
Set Condition: The Ambient Temperature Sensor voltage is greater than 4.9 volts at the
PCM for 3 seconds. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
AAT SENSOR VOLTAGE ABOVE 4.8 VOLTS
AAT SENSOR
(G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(G31) AAT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the Ambient Air Temperature Sensor voltage.
Is the voltage above 4.8 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the Ambient Air Temperature Sensor harness connector.
Connect a jumper wire between the (G31) AAT Signal circuit and the (K4) Sensor
ground circuit in the AAT Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read Ambient Air Temperature Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the Ambient Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
487
All
DRIVEABILITY - NGC
P0073-AMBIENT TEMPERATURE SENSOR CIRCUIT HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (G31) AAT Signal circuit in the AAT Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (G31) AAT Signal circuit from the AAT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (G31) AAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
5
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the AAT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
488
All
DRIVEABILITY - NGC
Symptom:
P0106-MAP SENSOR PERFORMANCE
When Monitored and Set Condition:
P0106-MAP SENSOR PERFORMANCE
When Monitored:
With engine speed greater than 64 RPM and the throttle blade closed.
Set Condition: Too small of a difference is seen between barometric pressure with ignition
on (engine running) and manifold vacuum for 2.80 seconds. One Trip Fault. Three good
trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
MAP SENSOR VACUUM PORT
(K1) MAP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
RESISTANCE IN THE (K6) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K6) 5-VOLT SUPPLY CIRCUIT
MAP SENSOR
RESISTANCE BETWEEN GROUND AND THE (K1) MAP SIGNAL CIRCUIT
(K1) MAP SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: If a MAP high or Low DTC set along with P0106, diagnose the High
or Low DTC first before continuing.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Remove the MAP Sensor.
Inspect the vacuum port, check for restrictions or any foreign materials.
Were any restrictions found?
Yes
→ Repair as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Properly install the MAP Sensor before continuing.
489
All
DRIVEABILITY - NGC
P0106-MAP SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
3
Disconnect the MAP Sensor harness connector.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K1) MAP Signal circuit in the MAP Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
7
Yes
→ Repair the short to voltage in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
Connect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K6) 5-volt Supply circuit in the MAP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
5
No
→ Go To
8
With the DRBIIIt, monitor the MAP Sensor voltage with the Sensor harness
connector disconnected.
Is the voltage above 1.2 volts?
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
6
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K1) MAP Signal circuit at the MAP
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Measure the resistance between the (K1) MAP Signal circuit and the (K4) Sensor
ground circuit in the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (K1)
MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
10
490
All
DRIVEABILITY - NGC
P0106-MAP SENSOR PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
8
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K6) 5-volt Supply circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
9
10
Yes
→ Go To
No
→ Repair the excessive resistance in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Measure the resistance between ground and the (K6) 5-volt Supply circuit in the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the excessive resistance between ground and the (K6)
5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
10
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
491
All
DRIVEABILITY - NGC
Symptom:
P0107-MAP SENSOR CIRCUIT LOW
When Monitored and Set Condition:
P0107-MAP SENSOR CIRCUIT LOW
When Monitored: Engine speed between 600 to 3500 RPM. TPS voltage less than 1.2
volts. Battery voltage greater than 10 volts.
Set Condition: The MAP sensor signal voltage is below 0.08 of a volt for 1.7 seconds. One
Trip Fault. Three good trips to turn off the MIL, (5.7L ETC light will flash.)
POSSIBLE CAUSES
MAP SENSOR VOLTAGE BELOW 0.1 OF A VOLT
(K6) 5-VOLT SUPPLY CIRCUIT OPEN
(K6) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MAP SENSOR
(K1) MAP SIGNAL CIRCUIT SHORTED TO GROUND
(K1) MAP SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the MAP Sensor voltage.
Is the voltage below 0.1 of a volt?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K6) 5-volt Supply circuit in the MAP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
6
With the DRBIIIt, monitor the MAP Sensor voltage with the Sensor harness
connector disconnected.
Is the voltage above 4.5 volts?
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
492
All
All
DRIVEABILITY - NGC
P0107-MAP SENSOR CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K1) MAP Signal circuit at the MAP
Sensor harness connector.
Is the resistance below 100 ohms?
All
5
6
7
8
Yes
→ Repair the short to ground in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Measure the resistance between the (K1) MAP Signal circuit and the (K4) Sensor
ground circuit in the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (K1)
MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K6) 5-volt Supply circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
7
Measure the resistance between ground and the (K6) 5-volt Supply circuit in the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
493
All
DRIVEABILITY - NGC
Symptom:
P0108-MAP SENSOR CIRCUIT HIGH
When Monitored and Set Condition:
P0108-MAP SENSOR CIRCUIT HIGH
When Monitored: Engine speed between 600 to 3500 RPM. TP sensor voltage less than
1.2 volts for greater than 1.7 seconds. Battery voltage greater than 10 volts
Set Condition: The MAP sensor signal voltage is greater than 4.96 volts. One trip fault.
Three good trips to turn off the MIL. (5.7L ETC light will flash).
POSSIBLE CAUSES
MAP SENSOR VOLTAGE ABOVE 4.6 VOLTS
MAP SENSOR
(K1) MAP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K1) MAP SIGNAL CIRCUIT OPEN
(K1) MAP SIGNAL CIRCUIT SHORTED TO THE (K6) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Start the engine.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the MAP Sensor voltage.
Is the voltage above 4.6 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Connect a jumper wire between the (K1) MAP Signal circuit and the (K4) Sensor
ground circuit in the harness connector.
Ignition on, engine not running.
With the DRBIIIt, monitor the MAP Sensor voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
494
All
DRIVEABILITY - NGC
P0108-MAP SENSOR CIRCUIT HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K1) MAP Signal circuit in the MAP Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
7
Yes
→ Repair the short to voltage in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K1) MAP Signal circuit from the MAP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between the (K1) MAP Signal circuit and the (K6) 5-volt
Supply circuit in the MAP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K6) 5-volt Supply circuit and the
(K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
495
All
DRIVEABILITY - NGC
Symptom List:
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK
P0111-INTAKE AIR TEMPERATURE SENSOR PERFORMANCE
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0110-INTAKE AIR TEMPERATURE SENSOR STUCK.
When Monitored and Set Condition:
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK
When Monitored:
Ignition on.
Set Condition: The PCM did not see a 2 deg C (35 deg F) change in the IAT Sensor voltage
after 4 warm up cycles within 250 miles. Two Trip Fault. Three good trips to turn off the
MIL.
P0111-INTAKE AIR TEMPERATURE SENSOR PERFORMANCE
When Monitored: The engine off time is greater than 480 minutes. Ambient Temperature
if greater than 4 deg C (38 deg F).
Set Condition: After a calibrated amount of cool down time the PCM compares the ECT
Sensor, IAT Sensor, and the Ambient Air Temp Sensor values. If the IAT Sensor value is not
within -10 deg C (18 deg F) of the other two temperature sensors. Two Trip Fault. Three
good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K21) IAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
IAT SENSOR
(K21) IAT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
(K21) IAT SIGNAL CIRCUIT SHORTED TO GROUND
(K21) IAT SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND
PCM
496
DRIVEABILITY - NGC
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK —
TEST
1
2
3
4
Continued
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the IAT Sensor harness connector.
Disconnect the PCM harness connectors.
NOTE: Visually inspect both the component and the PCM connectors. Look
for damaged, partially broken wires, and backed out or corroded terminals.
Ignition on, engine not running.
Measure the voltage on the (K21) IAT Signal circuit in the IAT Sensor harness
connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
All
Turn the ignition off.
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage above 4.6 volts?
Yes
→ Go To
4
No
→ Go To
7
Connect a jumper wire between the (K21) IAT Signal circuit and (K4) Sensor ground
circuit in the IAT Sensor harness connector.
With the DRBIIIt, read the IAT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the IAT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
NOTE: Remove the jumper wire before continuing.
5
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K21) IAT Signal circuit from the IAT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
497
All
DRIVEABILITY - NGC
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK —
Continued
TEST
ACTION
APPLICABILITY
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the IAT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
7
8
9
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K21) IAT Signal circuit in the IAT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Measure the resistance between the (K4) Sensor ground circuit and the (K21) IAT
Signal circuit at the IAT Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
(K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
498
All
DRIVEABILITY - NGC
Symptom:
P0112-INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW
When Monitored and Set Condition:
P0112-INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: The Intake Air Temperature (IAT) sensor circuit voltage at the PCM goes
below 0.5 of a volt. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
IAT SENSOR VOLTAGE BELOW 1.0 VOLT
IAT SENSOR
(K21) IAT SIGNAL CIRCUIT SHORTED TO GROUND
(K21) IAT SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage below 1.0 volt?
APPLICABILITY
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
All
Turn the ignition off.
Disconnect the IAT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read IAT voltage.
Is the voltage above 1.0 volt?
Yes
→ Replace the IAT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K21) IAT Signal circuit at the IAT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
499
All
DRIVEABILITY - NGC
P0112-INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (K21) IAT Signal circuit and the (K4) Sensor
ground circuit in the IAT Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground and the (K21)
IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
500
All
DRIVEABILITY - NGC
Symptom:
P0113-INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH
When Monitored and Set Condition:
P0113-INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: The Intake Air Temperature (IAT) sensor circuit voltage at the PCM goes
above 4.9 volts. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
IAT SENSOR VOLTAGE ABOVE 4.6 VOLTS
IAT SENSOR
(K21) IAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K21) IAT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the IAT voltage.
Is the voltage above 4.6 volts?
APPLICABILITY
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the IAT harness connector.
Connect a jumper wire between the (K21) IAT Signal circuit and the (K4) Sensor
ground circuit in the IAT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read IAT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the IAT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
501
All
DRIVEABILITY - NGC
P0113-INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH — Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K21) IAT Signal circuit in the IAT Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K21) IAT Signal circuit from the IAT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K21) IAT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
5
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the IAT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
502
All
DRIVEABILITY - NGC
Symptom:
P0116-ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE
When Monitored and Set Condition:
P0116-ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE
When Monitored: Engine off time is greater than 480 minutes. Ambient temperature is
greater than 4 deg C (38 deg F).
Set Condition: After a calibrated amount of cool down time the PCM compares the ECT
Sensor, IAT Sensor, and the Ambient Air Temp Sensor values. If the IAT Sensor value is not
within 10 deg C (18 deg F) of the other two temperature sensors. Two Trip Fault. Three
good trips to turn off the MIL. (5.7L ETC lamp will illuminate with the MIL.)
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K2) ECT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
ECT SENSOR
(K2) ECT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
(K2) ECT SIGNAL CIRCUIT SHORTED TO GROUND
(K2) ECT SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND
PCM
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
503
APPLICABILITY
All
DRIVEABILITY - NGC
P0116-ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
2
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the ECT Sensor harness connector.
NOTE: Visually inspect both the component and the PCM connectors. Look
for damaged, partially broken wires, and backed out or corroded terminals.
Ignition on, engine not running.
Measure the voltage on the (K2) ECT Signal circuit in the ECT Sensor harness
connector.
Is the voltage above 5.2 volts?
All
3
4
Yes
→ Repair the short to voltage in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
All
Turn the ignition off.
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, read the ECT voltage.
Is the voltage above 4.6 volts?
Yes
→ Go To
4
No
→ Go To
7
Connect a jumper between the (K2) ECT Signal circuit and the (K4) Sensor ground
circuit in the ECT Sensor harness connector.
With the DRBIIIt, read the ECT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the ECT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
5
NOTE: Remove jumper wire before continuing.
5
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K2) ECT Signal circuit from the ECT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
504
All
DRIVEABILITY - NGC
P0116-ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the ECT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
All
7
8
9
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K2) ECT Signal circuit in the ECT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Measure the resistance between the (K2) ECT Signal circuit and the (K4) Sensor
ground circuit at the ECT Sensor harness connector.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the (K4) Sensor ground and the (K2)
ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
505
All
DRIVEABILITY - NGC
Symptom:
P0117-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
When Monitored and Set Condition:
P0117-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: The Engine Coolant Temperature (ECT) sensor circuit voltage at the PCM
is less than 0.5 of a volt for more than 2.6 seconds. One Trip Fault. Three good trips to turn
off the MIL. (5.7L ETC lamp will illuminate with the MIL.)
POSSIBLE CAUSES
ECT SENSOR VOLTAGE BELOW 1.0 VOLTS
ECT SENSOR
(K2) ECT SIGNAL CIRCUIT SHORTED TO GROUND
(K2) ECT SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the ECT voltage.
Is the voltage below 1.0 volt?
APPLICABILITY
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
All
Turn the ignition off.
Disconnect the ECT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read ECT voltage.
Is the voltage above 1.0 volt?
Yes
→ Replace the ECT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K2) ECT Signal circuit in the ECT
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
506
All
DRIVEABILITY - NGC
P0117-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between the (K2) ECT Signal circuit and the (K4) Sensor
ground circuit in the ECT Sensor harness connector.
Is the resistance below 100 ohms?
All
5
Yes
→ Repair the short between the (K4) Sensor ground and the (K2)
ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
507
All
DRIVEABILITY - NGC
Symptom:
P0118-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
HIGH
When Monitored and Set Condition:
P0118-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: The Engine Coolant Temperature (ECT) sensor circuit voltage at the PCM
is greater than 4.96 volts for more than 2.6 seconds. One Trip Fault. Three good trips to
turn off the MIL. (5.7L ETC lamp will illuminate with the MIL.)
POSSIBLE CAUSES
ECT SENSOR VOLTAGE ABOVE 4.6 VOLTS
ECT SENSOR
(K2) ECT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K2) ECT SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the ECT voltage.
Is the voltage above 4.6 volts?
APPLICABILITY
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the ECT harness connector.
Connect a jumper wire between the (K2) ECT Signal circuit and the (K4) Sensor
ground circuit in the ECT harness connector.
Ignition on, engine not running.
With the DRBIIIt, read ECT voltage.
Is the voltage below 1.0 volt?
Yes
→ Replace the ECT Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
508
All
DRIVEABILITY - NGC
P0118-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K2) ECT Signal circuit in the ECT Sensor harness
connector.
Is the voltage above 5.2 volts?
All
4
5
6
Yes
→ Repair the short to voltage in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K2) ECT Signal circuit from the ECT Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K2) ECT Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
5
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the ECT Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
509
All
DRIVEABILITY - NGC
Symptom:
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L)
When Monitored and Set Condition:
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L)
When Monitored:
DTCs set.
With the engine running and no MAP Sensor DTCs or any other TPS
Set Condition: The PCM determines a valid range in which the TPS value should be at
a given RPM/Load. The actual TPS voltage is then compared to this value. If the TPS
voltage does not fall within the expected range within the predetermined time the fault
will set. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
TP SENSOR SWEEP
INTERMITTENT CONDITION
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
TP SENSOR OPERATION
THROTTLE POSITION SENSOR
RESISTANCE IN (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE IN (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K22) TP SENSOR #1 SIGNAL CIRCUIT
RESISTANCE IN THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
ACTION
APPLICABILITY
ENG - NEXT GENNOTE: Diagnose any other TP Sensor DTC(s) before continuing.
ERATION 4.7L
NOTE: The throttle plate and linkage should be free from binding and
MAGNUM V8
carbon build up.
NOTE: Ensure the throttle plate is at the idle position.
Ignition on, engine not running.
NOTE: Inspect the engine for vacuum leaks.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
2
No
→ Go To
11
510
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L) —
Continued
TEST
2
3
4
ACTION
APPLICABILITY
With the DRBIIIt, monitor the TP Sensor voltage while slowly depressing the ENG - NEXT GENERATION 4.7L
throttle pedal from closed to wide open throttle.
MAGNUM V8
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
Disconnect the TP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K22) TP Sensor #1 Signal circuit in the TP Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Connect the PCM harness connectors.
MAGNUM V8
Ignition on, engine not running.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit.
With the DRBIIIt, monitor the TP Sensor voltage.
Does the TP Sensor voltage change from approximately 4.9 volts to 0.5 of a volt?
Yes
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
NOTE: Remove the jumper wire before continuing.
5
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
511
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L) —
Continued
TEST
6
7
8
9
10
ACTION
APPLICABILITY
Measure the resistance between ground and the (K7) 5-volt Supply circuit at the TP ENG - NEXT GENSensor harness connector.
ERATION 4.7L
Is the resistance above 1.0 ohm?
MAGNUM V8
Yes
→ Go To
No
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING ENG - NEXT GENERATION 4.7L
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMIMAGNUM V8
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the TP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
8
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit at ENG - NEXT GENthe TP Sensor harness connector.
ERATION 4.7L
Is the resistance above 100k ohms?
MAGNUM V8
Yes
→ Go To
No
→ Repair the short to ground in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING ENG - NEXT GENERATION 4.7L
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMIMAGNUM V8
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
10
NOTE: Before continuing, check the PCM harness connector terminals for ENG - NEXT GENERATION 4.7L
corrosion, damage, or terminal push out. Repair as necessary.
MAGNUM V8
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, review repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
512
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (4.7L) —
Continued
TEST
11
ACTION
APPLICABILITY
ENG - NEXT GENWith the DRBIIIt, monitor the TP Sensor voltage.
ERATION 4.7L
Slowly open the throttle from the idle position to the wide open throttle position.
MAGNUM V8
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
513
DRIVEABILITY - NGC
Symptom List:
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L)
P0221-THROTTLE POSITION SENSOR #2 PERFORMANCE
P2135-THROTTLE POSITION SENSOR #1 AND #2 VOLTAGE CORRELATION
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0121-THROTTLE POSITION
SENSOR #1 PERFORMANCE (5.7L).
When Monitored and Set Condition:
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L)
When Monitored:
Ignition on and No MAP Sensor DTCs set.
Set Condition: TP Sensor signals do not corellate to the MAP Sensor signal. One Trip
Fault. 5.7L ETC light will illuminate. P2135 should set with this code also.
P0221-THROTTLE POSITION SENSOR #2 PERFORMANCE
When Monitored:
Ignition on with no MAP Sensor DTCs set.
Set Condition: TP Sensor signals do not correlate to the MAP Sensor signal. One Trip
Fault. ETC light will illuminate. P2135 should set with this code also.
P2135-THROTTLE POSITION SENSOR #1 AND #2 VOLTAGE CORRELATION
When Monitored:
With the ignition on and no other DTCs present for TP Sensor #1 or #2.
Set Condition: PCM recognizes TP Sensors #1 and #2 are not coherent. One trip fault.
ETC light is illuminated.
POSSIBLE CAUSES
TP SENSOR SWEEP
INTERMITTENT CONDITION
TP SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
THROTTLE POSITION SENSOR
RESISTANCE IN THE (K22) OR (K122) TP SIGNAL CIRCUIT
RESISTANCE BETWEEN GROUND AND THE (K22) OR (K122) TP SIGNAL CIRCUIT
RESISTANCE IN (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE TO GROUND IN THE (K7) 5-VOLT SUPPLY CIRCUIT
RESISTANCE IN THE (K101) SENSOR GROUND CIRCUIT
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO (K122) TP SENSOR #2 SIGNAL CIRCUIT
PCM
514
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L) —
Continued
TEST
ACTION
APPLICABILITY
1
NOTE: Diagnose any other TP Sensor DTC(s) before continuing.
NOTE: The throttle plate and linkage should be free from binding and
carbon build up.
NOTE: Ensure the throttle plate is at the idle position.
Ignition on, engine not running.
NOTE: Inspect the engine for vacuum leaks.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
2
3
Yes
→ Go To
2
No
→ Go To
11
Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Throttle Body harness connector.
Ignition on, engine not running.
Measure the voltage on the (K22) TP #1 Signal and the (K122) TP #2 Signal circuits
in the Throttle Body harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K22) TP #1 or (K122) TP #2
Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
3
Turn the ignition off.
Connect the PCM harness connectors.
Ignition on, engine not running.
With the DRBIIIt, monitor the TP Sensor #1 or #2 voltage.
Connect a jumper wire between the (K101) Sensor Return circuit and the (K22) TP
Sensor #1 Signal circuit.
TP Sensor #1 voltage should change from approximately 4.5 volts to 0.5 of a volt?
For TP Sensor #2, connect a jumper wire between (K7) 5-volt supply circuit and the
(K122) TP Sensor #2 signal circuit.
TP Sensor #2 voltage should change from approximately 0 volts to 5.0 volts?
Is the voltage reading within the listed specifications?
Yes
→ Replace the Throttle Body Assembly.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
NOTE: Remove the jumper wire before continuing.
515
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L) —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit or (K122) TP Sensor
#2 Signal circuit from the Throttle Body harness connector to the appropriate
terminal of special tool #8815.
Is the resistance below 5.0 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
6
7
Yes
→ Go To
No
→ Repair the excessive resistance in the (K22) or (K122) TP Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
5
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit or
(K122) TP Sensor #2 Signal circuit between the appropriate terminals of special tool
#8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K22) or (K122) TP Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the excessive resistance in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
7
Measure the resistance between ground and the (K7) 5-volt Supply circuit between
the appropriate terminals of special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
516
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE (5.7L) —
Continued
TEST
ACTION
APPLICABILITY
8
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K101) Sensor Return circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
9
10
Yes
→ Go To
No
→ Repair the excessive resistance in the (K101) Sensor Return
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K122)
TP Sensor #2 Signal circuit between the appropriate terminals of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Repair the short between the (K122) TP Sensor #2 Signal circuit
and the (K22) TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
10
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, review repair.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
11
Ignition on, engine not running.
With the DRBIIIt, perform the Pedal Follower Test and monitor the TP Sensor #1 or
#2 voltage.
Slowly depress the Pedal from the idle position to the wide open throttle position.
The voltage for TP Sensor #1 should start at approximately 0.8 of a volt and increase
to above 4.2 volts.
The voltage for TP Sensor #2 should start at approximately 4.2 volts and decrease to
approximately 0.8 of a volt.
Is the voltage within the range of the listed specification for the appropriate Sensor?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttly Body assembly.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
517
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
Symptom:
P0122-THROTTLE POSITION SENSOR #1 LOW (4.7L)
When Monitored and Set Condition:
P0122-THROTTLE POSITION SENSOR #1 LOW (4.7L)
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: Throttle Position Sensor voltage at the PCM is less than 0.16 of a volt for
0.7 of a second. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
THROTTLE POSITION SENSOR SWEEP
INTERMITTENT CONDITION
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
THROTTLE POSITION SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO GROUND
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO THE (K4) SENSOR GROUND CIRCUIT
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the TP Sensor voltage.
Is the voltage below 0.2 of a volt?
Yes
→ Go To
2
No
→ Go To
9
APPLICABILITY
ENG - NEXT GENERATION 4.7L
MAGNUM V8
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the TP Sensor harness connector.
MAGNUM V8
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit in the TP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
5
518
DRIVEABILITY - NGC
P0122-THROTTLE POSITION SENSOR #1 LOW (4.7L) —
TEST
3
4
5
6
7
Continued
ACTION
APPLICABILITY
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
4
Measure the resistance between ground and the (K7) 5-volt Supply circuit in the TP ENG - NEXT GENSensor harness connector.
ERATION 4.7L
Is the resistance below 100 ohms?
MAGNUM V8
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
With the DRBIIIt, monitor the TP Sensor voltage with the Sensor harness connector ENG - NEXT GENdisconnected.
ERATION 4.7L
Is the voltage above 4.5 volts?
MAGNUM V8
Yes
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit at
the TP Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K4) ENG - NEXT GENSensor ground circuit in the TP Sensor harness connector.
ERATION 4.7L
Is the resistance below 100 ohms?
MAGNUM V8
Yes
→ Repair the short between the (K4) Sensor ground and the (K22)
TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
519
DRIVEABILITY - NGC
P0122-THROTTLE POSITION SENSOR #1 LOW (4.7L) —
TEST
8
Continued
ACTION
APPLICABILITY
NOTE: Before continuing, check the PCM harness connector terminals for ENG - NEXT GENERATION 4.7L
corrosion, damage, or terminal push out. Repair as necessary.
MAGNUM V8
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
9
ENG - NEXT GENWith the DRBIIIt, monitor the Throttle Position Sensor voltage.
ERATION 4.7L
Slowly open the throttle from the idle position to the wide open throttle position.
MAGNUM V8
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
520
DRIVEABILITY - NGC
Symptom:
P0122-THROTTLE POSITION SENSOR #1 LOW (5.7L)
When Monitored and Set Condition:
P0122-THROTTLE POSITION SENSOR #1 LOW (5.7L)
When Monitored:
With the ignition on with no other TP Sensor #1 failures.
Set Condition: Throttle Position Sensor #1 voltage below 0.16 of a volt for 0.7 of a second.
One Trip Fault. 5.7L ETC light will illuminate.
POSSIBLE CAUSES
TP SENSOR #1 SWEEP
INTERMITTENT CONDITION
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
TP SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO GROUND
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO (K101) SENSOR RETURN CIRCUIT
PCM
TEST
1
2
3
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
2
No
→ Go To
9
Turn the ignition off.
Disconnect the Throttle Body harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit.
Is the voltage between 4.8 and 5.2 volts?
Yes
→ Go To
3
No
→ Go To
6
With the DRBIIIt, monitor the TP Sensor #1 voltage with the harness connector still
disconnected.
Is the voltage above 4.5 volts?
Yes
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select LEARN
ETC.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
521
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
ENGINE - 9MAGNUM9 5.7L SMPI
V8
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0122-THROTTLE POSITION SENSOR #1 LOW (5.7L) —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the (K22) TP Sensor #1 Signal circuit
between the appropriate terminals of special tool #8815.
Is the resistance below 100 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
6
7
8
Yes
→ Repair the short to ground in the (K22) TP Sensor #1 Signal.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K101)
Sensor Return circuit between the appropriate terminals of special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K101) Sensor Return circuit and
the (K22) TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
8
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
7
Measure the resistance between the (K7) 5-volt Supply circuit and ground at the
appropriate terminal of special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
522
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0122-THROTTLE POSITION SENSOR #1 LOW (5.7L) —
TEST
9
Continued
ACTION
With the DRBIIIt, perform the Pedal Follower Test.
Monitor the TP Sensor #1 voltage while pressing the Throttle pedal down.
Is there a smooth voltage change from low to high?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select the
LEARN ETC function.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
523
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
Symptom:
P0123-THROTTLE POSITION SENSOR #1 HIGH (4.7L)
When Monitored and Set Condition:
P0123-THROTTLE POSITION SENSOR #1 HIGH (4.7L)
When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
Set Condition: Throttle Position Sensor voltage at the PCM is greater than 4.5 volts for
0.7 of a second. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
THROTTLE POSITION SENSOR SWEEP
INTERMITTENT CONDITION
THROTTLE POSITION SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K22) TP SENSOR #1 SIGNAL CIRCUIT OPEN
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO THE (K7) 5-VOLT SUPPLY CIRCUIT
(K4) SENSOR GROUND CIRCUIT OPEN
PCM
TEST
1
2
ACTION
APPLICABILITY
NOTE: Ensure the throttle is fully closed and free from binding or carbon ENG - NEXT GENERATION 4.7L
build up.
MAGNUM V8
Start the engine.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
With the DRBIIIt, read the TP Sensor voltage.
Is the voltage above 4.5 volts?
Yes
→ Go To
2
No
→ Go To
8
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the TP Sensor harness connector.
MAGNUM V8
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K4)
Sensor ground circuit in the Sensor harness connector.
With the DRBIIIt, monitor the TP Sensor voltage.
Ignition on, engine not running.
Is the voltage below 0.5 of a volt?
Yes
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
524
DRIVEABILITY - NGC
P0123-THROTTLE POSITION SENSOR #1 HIGH (4.7L) —
TEST
3
4
5
6
7
Continued
ACTION
APPLICABILITY
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
Disconnect the PCM harness connectors.
MAGNUM V8
Ignition on, engine not running.
Measure the voltage on the (K22) TP Sensor #1 Signal circuit in the TP Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
ENG - NEXT GENTurn the ignition off.
ERATION 4.7L
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
MAGNUM V8
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the TP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K22) TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
5
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K7) ENG - NEXT GEN5-volt Supply circuit in the TP Sensor harness connector.
ERATION 4.7L
Is the resistance below 100 ohms?
MAGNUM V8
Yes
→ Repair the short between the (K7) 5-volt Supply circuit and the
(K22) TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING ENG - NEXT GENERATION 4.7L
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMIMAGNUM V8
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the TP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
NOTE: Before continuing, check the PCM harness connector terminals for ENG - NEXT GENERATION 4.7L
corrosion, damage, or terminal push out. Repair as necessary.
MAGNUM V8
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
525
DRIVEABILITY - NGC
P0123-THROTTLE POSITION SENSOR #1 HIGH (4.7L) —
TEST
8
Continued
ACTION
APPLICABILITY
ENG - NEXT GENWith the DRBIIIt, monitor the Throttle Position Sensor voltage.
ERATION 4.7L
Slowly open the throttle from the idle position to the wide open throttle position.
MAGNUM V8
Does voltage start at approximately 0.8 of a volt and go above 3.5 volts with a smooth
transition?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Replace the Throttle Position Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
526
DRIVEABILITY - NGC
Symptom:
P0123-THROTTLE POSITION SENSOR #1 HIGH (5.7L)
When Monitored and Set Condition:
P0123-THROTTLE POSITION SENSOR #1 HIGH (5.7L)
When Monitored:
With the ignition on.
Set Condition: Throttle Position Sensor #1 voltage is greater than 4.9 volts for 25 ms. One
Trip Fault. 5.7L ETC light will illuminate.
POSSIBLE CAUSES
TP SENSOR #1 SWEEP
INTERMITTENT CONDITION
TP SENSOR
(K22) TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K22) TP SENSOR #1 SIGNAL CIRCUIT OPEN
(K22) TP SENSOR SIGNAL CIRCUIT SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K101) SENSOR RETURN CIRCUIT OPEN
PCM
TEST
1
2
ACTION
Start the engine.
With the DRBIIIt, read the TP Sensor voltage.
Is the voltage above 4.5 volts?
Yes
→ Go To
2
No
→ Go To
8
Turn the ignition off.
Disconnect the Throttle Body Assembly harness connector.
Ignition on, engine not running.
Connect a jumper wire between the (K22) TP Sensor #1 Signal circuit and the (K101)
TP Sensor Return circuit.
With the DRBIIIt, monitor the TP Sensor #1 voltage.
Is the voltage below 0.5 volt?
Yes
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select the
LEARN ETC function.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
NOTE: Remove the jumper wire before continuing.
527
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0123-THROTTLE POSITION SENSOR #1 HIGH (5.7L) —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage of the (K22) TP Sensor #1 Signal circuit in the Throttle Body
harness connector.
Is the voltage above 5.2 volts?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
4
5
6
7
Yes
→ Repair the short to voltage in the (K22) TP Sensor #1 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K22) TP Sensor #1 Signal circuit from the Throttle
Body harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5 ohms?
Yes
→ Go To
No
→ Repair the open in the (K22) TP Sensor #1 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
Measure the resistance between the (K22) TP Sensor #1 Signal circuit and the (K7)
5-volt Supply circuit between the appropriate terminals of Special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K22) TP Sensor #1 Signal circuit
and the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
6
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K101) Sensor Return circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K101) Sensor Return circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
528
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0123-THROTTLE POSITION SENSOR #1 HIGH (5.7L) —
TEST
8
Continued
ACTION
With the DRBIIIt, perform the Pedal Follower Test.
Monitor the TP Sensor #1 voltage.
Is there a smooth voltage change from low to high?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select the
LEARN ETC function.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
529
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
Symptom:
P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL
CONTROL
When Monitored and Set Condition:
P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL
When Monitored:
With battery voltage greater than 10.4 volts and after engine is started.
Set Condition: The engine temperature does not go above -10°C (15°F). Failure time
depends on start-up coolant temperature and ambient temperature. (i.e. 2 minutes for a
start temp of -10°C (15°F) or up to 10 mintues for a vehicle with a start-up temp of -28°C
(5°F). Two Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
LOW COOLANT LEVEL
THERMOSTAT OPERATION
ECT SENSOR
TEST
ACTION
APPLICABILITY
1
NOTE: If a Engine Coolant Temperature (ECT) DTC is set along with this
code, diagnose the ECT DTC first.
NOTE: Inspect the ECT terminals and related PCM terminals. Ensure the
terminals are free from corrosion and damage.
NOTE: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
NOTE: Extremely cold outside ambient temperatures may have caused this
DTC to set.
WARNING: Never open the cooling system when the engine is hot. The
system is under pressure. Extreme burns or scalding may result. Allow the
engine to cool before opening the cooling system.
Inspect the coolant system for proper level and condition.
Is the coolant level and condition OK?
All
Yes
→ Go To
No
→ Inspect the vehicle for a coolant leak and add the necessary
amount of coolant.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
530
DRIVEABILITY - NGC
P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL — Continued
TEST
ACTION
APPLICABILITY
2
NOTE: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Eng Coolant Tmp Deg value. If the engine was allowed
to sit overnight (cold soak), the temperature value should be a sensible value that is
somewhere close to the ambient temperature.
NOTE: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up monitor the Eng Coolant Tmp Deg value. The temp deg
value change should be a smooth transition from start up to normal operating temp
82°C (180°F) . Also monitor the actual coolant temperature with a thermometer.
NOTE: As the engine warms up to operating temperature, the actual coolant
temperature (thermometer reading) and the Eng Coolant Tmp Deg in the
DRB values should stay relatively close to each other.
Using the appropriate service information, determine the proper opening temperature of the thermostat.
Did the thermostat open at the proper temperature?
All
3
Yes
→ Go To
No
→ Replace the thermostat.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
3
Ignition on, engine not running.
With the DRBIIIt, read the Eng Coolant Tmp Deg value. If the engine was allowed
to sit overnight (cold soak), the temperature value should be a sensible value that is
somewhere close to the ambient temperature.
NOTE: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up monitor the Eng Coolant Tmp Deg value. The temp deg
value change should be a smooth transition from start up to normal operating temp
82°C (180°F) . Also monitor the actual coolant temperature with a thermometer.
NOTE: As the engine warms up to operating temperature, the actual coolant
temperature (thermometer reading) and the Eng Coolant Tmp Deg in the
DRB values should stay relatively close to each other.
Is the thermometer reading relatively close to the DRBIIIt ECT reading?
Yes
→ Test Complete.
No
→ Replace the Engine Coolant Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
531
All
DRIVEABILITY - NGC
Symptom:
P0128-THERMOSTAT RATIONALITY
When Monitored and Set Condition:
P0128-THERMOSTAT RATIONALITY
When Monitored:
Engine running.
Set Condition: The PCM predicts a coolant temperature value that it will compare to the
actual coolant temperature. A significant difference results in an error. Two Trip Fault.
Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
LOW COOLANT LEVEL
THERMOSTAT OPERATION
SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
TEMPERATURE SENSOR
SIGNAL CIRCUIT OPEN
(K4) SENSOR GROUND CIRCUIT OPEN
SIGNAL CIRCUIT SHORTED TO GROUND
SIGNAL CIRCUIT SHORTED TO (K4) SENSOR GROUND
OTHER POSSIBLE CAUSES
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: If any ECT, AAT, CMP or CKP sensor DTCs have set along with P0128,
diagnose them first before continuing.
NOTE: Ensure that Pinion Factor has been programmed correctly into the
PCM.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom in the
Driveability category.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
532
DRIVEABILITY - NGC
P0128-THERMOSTAT RATIONALITY —
Continued
TEST
ACTION
APPLICABILITY
2
NOTE: If a Engine Coolant Temperature (ECT) DTC is set along with this
code, diagnose the ECT DTC first.
NOTE: Inspect the ECT terminals and related PCM terminals. Ensure the
terminals are free from corrosion and damage.
NOTE: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
Note: Extremely cold outside ambient temperatures may have caused this
DTC to set.
WARNING: Never open the cooling system when the engine is hot. The
system is under pressure. Extreme burns or scalding may result. Allow the
engine to cool before opening the cooling system.
Check the coolant system to make sure that the coolant is in good condition and at
the proper level.
Is the coolant level and condition OK?
All
3
4
Yes
→ Go To
No
→ Inspect the vehicle for a coolant leak and add the necessary
amount of coolant.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
3
NOTE: This test works best if performed on a cold engine (cold soak).
Ignition on, engine not running.
With the DRBIIIt, read the ECT Deg value. If the engine was allowed to sit overnight
(cold soak), the temperature value should be a sensible value that is somewhere close
to the ambient temperature.
Note: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the ECT Deg value. The temp deg value change
should be a smooth transition from start up to normal operating temp 82°C (180°F)
. Also monitor the actual coolant temperature with a thermometer.
NOTE: As the engine warms up to operating temperature, the actual coolant
temperature (thermometer reading) and the ECT Deg in the DRB sensor
should stay relatively close to each other.
Using the appropriate service information, determine the proper opening temperature of the thermostat.
Did the thermostat open at the proper temperature?
Yes
→ Go To
No
→ Replace the thermostat.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
4
Ignition on, engine not running.
With the DRBIIIt, read and record the AAT Sensor Temperature value.
Using the DRB Temperature Probe #CH7050, measure the ambient air temperature
near the AAT sensor.
Is the AAT Sensor value with -15°C (5°F) of the temperature probe reading?
Yes
→ Go To
5
No
→ Go To
7
533
All
DRIVEABILITY - NGC
P0128-THERMOSTAT RATIONALITY —
Continued
TEST
ACTION
APPLICABILITY
5
WARNING: MAKE SURE THE ENGINE COOLING SYSTEM IS COOL BEFORE REMOVING THE PRESSURE CAP OR ANY HOSE. SEVERE PERSONAL INJURY MAY RESULT FROM ESCAPING HOT COOLANT. THE
COOLING SYSTEM IS PRESSURIZED WHEN HOT.
With the DRBIIIt, read and record the ECT Sensor Temperature value.
Using the DRB Temperature Probe #CH7050, measure the engine coolant temperature.
Is the ECT Sensor value with -15°C (5°F) of the temperature probe reading?
All
6
7
Yes
→ Go To
6
No
→ Go To
7
Inspect the Temperature sensors for any physical damage.
Inspect the engine coolant. Ensure the coolant is at the proper level. Refer to the
Service Information COOLING.
Ensure the Temperature sensors are properly mounted.
Ensure the CMP and CKP sensors are mounted properly. Check the connectors for
any signs of damage.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Refer to any Technical Service Bulletins (TSBs) that may apply.
With the engine running at normal operating temperature, monitor the Temperature
sensor parameters while wiggling the wire harness. Look for parameter values to
change.
Visually inspect the related wire harness. Look for any chafed, pierced, pinched,
partially broken wires and broken, bent, pushed out, or corroded terminals.
CAUTION: NEVER PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Inspect and clean all PCM, engine, and chassis grounds.
Were any problems found during the above inspections?
Yes
→ Repair as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Test Complete.
NOTE: Visually inspect both the component and the PCM connectors. Look
for damage, partially broken wires and backed out or corroded terminals
Turn the ignition off.
Disconnect the applicable Temperature Sensor harness connector.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage of the Signal circuit in the appropriate Temperature Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to battery voltage in the Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
8
534
All
All
DRIVEABILITY - NGC
P0128-THERMOSTAT RATIONALITY —
TEST
8
Continued
ACTION
Turn the ignition off.
Connect the PCM harness connectors.
Connect a jumper wire across the Temperature Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, read the Temperature voltage.
Is the voltage start at 5.0 volts and drop below 1.0 volt?
Yes
→ Replace the faulty Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
APPLICABILITY
All
9
NOTE: Disconnect the jumper wire before continuing.
9
10
11
12
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the Sensor Signal circuit from the Temperature Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the Sensor Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
10
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K4) Sensor ground circuit from the appropriate
Temperature Sensor harness connector to the appropriate terminal of special tool
#8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K4) Sensor ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
11
Measure the resistance between ground and the Sensor Signal circuit in the
Temperature harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
12
Measure the resistance between the Signal circuit and the (K4) Sensor ground circuit
in the Temperature Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K4) Sensor ground circuit and the
Sensor Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
13
535
All
DRIVEABILITY - NGC
P0128-THERMOSTAT RATIONALITY —
Continued
TEST
ACTION
APPLICABILITY
13
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
536
DRIVEABILITY - NGC
Symptom:
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE
When Monitored and Set Condition:
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE
When Monitored: With the ignition key on. No Cam or Crank signal within 75 ms. Engine
speed less than 250 RPM.
Set Condition: The PCM senses the voltage from the MAP sensor to be less than 2.2 volts
but above 0.04 of a volt for 300 milliseconds. One Trip Fault. Three good trips to turn off
the MIL. (5.7L ETC lamp will flash)
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(K6) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K6) 5-VOLT SUPPLY CIRCUIT OPEN
(K6) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MAP SENSOR
(K1) MAP SIGNAL CIRCUIT OPEN
(K1) MAP SIGNAL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the MAP Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the (K6) 5-volt Supply circuit in the MAP Sensor harness
connector.
Is the voltage between 4.5 to 5.2 volts?
Yes
→ Go To
3
No
→ Go To
6
537
All
DRIVEABILITY - NGC
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE —
Continued
TEST
ACTION
APPLICABILITY
3
With the DRBIIIt, monitor the MAP Sensor voltage with the Sensor harness
connector disconnected.
Is the voltage above 2.2 volts?
All
4
5
6
7
Yes
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K1) MAP Signal circuit from the MAP Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
5
Measure the resistance between ground and the (K1) MAP Signal circuit at the MAP
Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K1) MAP Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K6) 5-volt Supply circuit in the MAP Sensor harness
connector.
Is the voltage above 5.2 volts?
Yes
→ Repair the short to voltage in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
7
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K6) 5-volt Supply circuit from the MAP Sensor
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
8
538
All
DRIVEABILITY - NGC
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE —
Continued
TEST
ACTION
APPLICABILITY
8
Measure the resistance between ground and the (K6) 5-volt Supply circuit at the
MAP Sensor harness connector.
Is the resistance below 100 ohms?
All
9
Yes
→ Repair the short to ground in the (K6) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
539
All
DRIVEABILITY - NGC
Symptom List:
P0131-O2
P0137-O2
P0151-O2
P0157-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
LOW
LOW
LOW
LOW
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0131-O2 SENSOR 1/1 CIRCUIT
LOW VOLTAGE.
When Monitored and Set Condition:
P0131-O2 SENSOR 1/1 CIRCUIT LOW VOLTAGE
When Monitored: Engine running for less than 30 seconds and the O2 Sensor Heater
Temperature is less than 251°C (484°F) with battery voltage greater 10.99 volts.
Set Condition: The oxygen sensor signal voltage is below 2.5196 volts for 3 seconds after
starting engine. One Trip Fault. Three good trips to turn off the MIL.
P0137-O2 SENSOR 1/2 CIRCUIT LOW VOLTAGE
When Monitored: Engine running for less than 30 seconds and the O2 Sensor Heater
Temperature is less than 251°C (484°F) with battery voltage greater 10.99 volts.
Set Condition: The oxygen sensor signal voltage is below 2.5196 volts for 3 seconds after
starting engine. One Trip Fault. Three good trips to turn off the MIL.
P0151-O2 SENSOR 2/1 CIRCUIT LOW VOLTAGE
When Monitored: Engine running for less than 30 seconds and the O2 Sensor Heater
Temperature is less than 251°C (484°F) with battery voltage greater 10.99 volts.
Set Condition: The oxygen sensor signal voltage is below 2.5196 volts for 3 seconds after
starting engine. One Trip Fault. Three good trips to turn off the MIL.
P0157-O2 SENSOR 2/2 CIRCUIT LOW VOLTAGE
When Monitored: Engine running for less than 30 seconds and the O2 Sensor Heater
Temperature is less than 251°C (484°F) with battery voltage greater 10.99 volts.
Set Condition: The oxygen sensor signal voltage is below 2.5196 volts for 3 seconds after
starting engine. One Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
O2 SENSOR BELOW 2.52 VOLTS
O2 SENSOR
O2 RETURN CIRCUIT SHORTED TO GROUND
O2 SIGNAL CIRCUIT SHORTED TO GROUND
540
DRIVEABILITY - NGC
P0131-O2 SENSOR 1/1 CIRCUIT LOW VOLTAGE —
Continued
POSSIBLE CAUSES
O2 SIGNAL CIRCUIT SHORTED TO SENSOR RETURN CIRCUIT
O2 SIGNAL SHORTED TO THE HEATER GROUND CIRCUIT
PCM
TEST
1
2
3
4
5
ACTION
Start the engine.
Allow the engine to reach normal operating temperature.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage below 2.52 volts?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
2
Turn the ignition off.
Disconnect the O2 Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage above 4.8 volts?
Yes
→ Go To
3
No
→ Go To
5
Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector.
Is the voltage at 2.5 volts?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
4
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the O2 Return circuit in the O2 Sensor
harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the O2 Return circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the O2 Signal circuit in the O2 Sensor
harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the O2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
6
541
All
DRIVEABILITY - NGC
P0131-O2 SENSOR 1/1 CIRCUIT LOW VOLTAGE —
Continued
TEST
ACTION
APPLICABILITY
6
Measure the resistance between the O2 Signal circuit and the O2 Return circuit in
the O2 Sensor harness connector.
Is the resistance below 100 ohms?
All
7
8
Yes
→ Repair the short between the O2 Return circuit and the O2 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
7
Measure the resistance between the O2 Signal circuit and the O2 Heater ground
circuit in the O2 Sensor harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the O2 Heater ground circuit and the
O2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
8
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
542
All
DRIVEABILITY - NGC
Symptom List:
P0132-O2
P0138-O2
P0152-O2
P0158-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
HIGH
HIGH
HIGH
HIGH
VOLTAGE
VOLTAGE
VOLTAGE
VOLTAGE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0132-O2 SENSOR 1/1 CIRCUIT
HIGH VOLTAGE.
When Monitored and Set Condition:
P0132-O2 SENSOR 1/1 CIRCUIT HIGH VOLTAGE
When Monitored: O2 Sensor Heater Temperature is greater than 496°C (925°F) and
battery voltage greater than 10.99 volts.
Set Condition: The Oxygen Sensor voltage is above 3.99 volts for 30 seconds. One Trip
Fault. Three good trips to turn off the MIL.
P0138-O2 SENSOR 1/2 CIRCUIT HIGH VOLTAGE
When Monitored: O2 Sensor Heater Temperature is greater than 496°C (925°F) and
battery voltage greater than 10.99 volts.
Set Condition: The Oxygen Sensor voltage is above 3.99 volts for 30 seconds. One Trip
Fault. Three good trips to turn off the MIL.
P0152-O2 SENSOR 2/1 CIRCUIT HIGH VOLTAGE
When Monitored: O2 Sensor Heater Temperature is greater than 496°C (925°F) and
battery voltage greater than 10.99 volts.
Set Condition: The Oxygen Sensor voltage is above 3.99 volts for 30 seconds. One Trip
Fault. Three good trips to turn off the MIL.
P0158-O2 SENSOR 2/2 CIRCUIT HIGH VOLTAGE
When Monitored: O2 Sensor Heater Temperature is greater than 496°C (925°F) and
battery voltage greater than 10.99 volts.
Set Condition: The Oxygen Sensor voltage is above 3.99 volts for 30 seconds. One Trip
Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
O2 SENSOR ABOVE 3.99 VOLTS
O2 SENSOR
O2 RETURN CIRCUIT OPEN
O2 SIGNAL CIRCUIT SHORTED TO VOLTAGE
543
DRIVEABILITY - NGC
P0132-O2 SENSOR 1/1 CIRCUIT HIGH VOLTAGE —
Continued
POSSIBLE CAUSES
O2 SIGNAL CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: The DRBIIIt will display all O2 Sensor voltage readings approximately 5.0 volts when only one O2 Sensor is shorted to voltage. When
diagnosing the DTC, diagnose the O2 Sensor that set the DTC.
Start the engine.
Allow the engine to reach normal operating temperature.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage above 3.99 volts?
All
2
3
4
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
Disconnect the O2 Sensor harness connector.
Ignition on, engine not running.
With the DRBIIIt, monitor the O2 Sensor voltage.
Is the O2 Sensor voltage below 4.8 volts?
Yes
→ Go To
3
No
→ Go To
5
Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector.
Is the voltage at 2.5 volts?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
All
4
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the O2 Return circuit from the O2 Sensor harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Return circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
544
All
DRIVEABILITY - NGC
P0132-O2 SENSOR 1/1 CIRCUIT HIGH VOLTAGE —
TEST
5
6
7
Continued
ACTION
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the O2 Signal circuit in the O2 Sensor harness connector.
Is the voltage above 5.0 volts?
Yes
→ Repair the short to voltage in the O2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
APPLICABILITY
All
6
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the O2 Signal circuit from the O2 Sensor harness connector
to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the O2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
7
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
545
All
DRIVEABILITY - NGC
Symptom List:
P0133-O2
P0139-O2
P0153-O2
P0159-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
SLOW
SLOW
SLOW
SLOW
RESPONSE
RESPONSE
RESPONSE
RESPONSE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0133-O2 SENSOR 1/1 SLOW
RESPONSE.
When Monitored and Set Condition:
P0133-O2 SENSOR 1/1 SLOW RESPONSE
When Monitored: Vehicle is started and driven between 20 and 55 MPH with the Throttle
open for a minimum of 120 seconds. Coolant greater than 70°C (158°F). Catalytic
Converter Temp greater than 600°C (1112°F) and EVAP Purge is active.
Set Condition: The oxygen sensor signal voltage switches less than 16 times from lean to
rich within 20 seconds during monitoring. Two Trip Fault. Three good trips to turn off the
MIL.
P0139-O2 SENSOR 1/2 SLOW RESPONSE
When Monitored: Vehicle is started and driven between 20 and 55 MPH with the Throttle
open for a minimum of 120 seconds. Coolant greater than 70°C (158°F). Catalytic
Converter Temp greater than 600°C (1112°F) and EVAP Purge is active
Set Condition: The oxygen sensor signal voltage switches less than 16 times from lean to
rich within 20 seconds during monitoring. Two Trip Fault. Three good trips to turn off the
MIL.
P0153-O2 SENSOR 2/1 SLOW RESPONSE
When Monitored: Vehicle is started and driven between 20 and 55 MPH with the Throttle
open for a minimum of 120 seconds. Coolant greater than 70°C (158°F). Catalytic
Converter Temp greater than 600°C (1112°F) and EVAP Purge is active
Set Condition: The oxygen sensor signal voltage switches less than 16 times from lean to
rich within 20 seconds during monitoring. Two Trip Fault. Three good trips to turn off the
MIL.
P0159-O2 SENSOR 2/2 SLOW RESPONSE
When Monitored: Vehicle is started and driven between 20 and 55 MPH with the Throttle
open for a minimum of 120 seconds. Coolant greater than 70°C (158°F). Catalytic
Converter Temp greater than 600°C (1112°F) and EVAP Purge is active
Set Condition: The oxygen sensor signal voltage switches less than 16 times from lean to
rich within 20 seconds during monitoring. Two Trip Fault. Three good trips to turn off the
MIL.
546
DRIVEABILITY - NGC
P0133-O2 SENSOR 1/1 SLOW RESPONSE —
Continued
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
EXHAUST LEAK
O2 SIGNAL CIRCUIT
O2 RETURN CIRCUIT
O2 SENSOR
TEST
ACTION
APPLICABILITY
1
NOTE: Check for contaminants that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
NOTE: After the repairs have been made, verify proper O2 Sensor operation.
If all the O2 Sensor voltage readings have not returned to normal, follow the
diagnostic procedure for the remaining O2 Sensors.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
3
4
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Start the engine.
Inspect the exhaust system for leaks between the engine and the O2 Sensors.
Are there any exhaust leaks?
Yes
→ Repair or replace the leaking exhaust parts as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
3
Turn the ignition off
Disconnect the O2 Sensor harness connector.
Ignition on, engine not running.
Measure the voltage on the O2 Signal circuit in the O2 Sensor harness connector.
Is the voltage approximately 5.0 volts?
Yes
→ Go To
No
→ Check the O2 Signal circuit for a short to ground, open, or short
to voltage. If OK, replace and program the Powertrain Control
Module in per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
4
Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector.
Is the voltage at 2.5 volts?
Yes
→ Check the O2 Return circuit for a short to ground, open, or short
to voltage. If OK, replace and program the Powertrain Control
Module per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
547
All
DRIVEABILITY - NGC
P0133-O2 SENSOR 1/1 SLOW RESPONSE —
TEST
5
Continued
ACTION
If there are no possible causes remaining, view repair.
Repair
Replace the O2 Sensor
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
548
APPLICABILITY
All
DRIVEABILITY - NGC
Symptom List:
P0135-O2
P0141-O2
P0155-O2
P0161-O2
Test Note:
SENSOR
SENSOR
SENSOR
SENSOR
1/1
1/2
2/1
2/2
HEATER
HEATER
HEATER
HEATER
PERFORMANCE
PERFORMANCE
PERFORMANCE
PERFORMANCE
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0135-O2 SENSOR 1/1 HEATER
PERFORMANCE.
When Monitored and Set Condition:
P0135-O2 SENSOR 1/1 HEATER PERFORMANCE
When Monitored: During vehicle shutdown after vehicle had been driven greater than 10
miles with throttle open for a minimum of 3 minutes. Battery voltage greater than 11.0
volts.
Set Condition: No sensor output is received when the PCM powers up the sensor heater.
Two trip fault. Three good trips to turn off the MIL.
P0141-O2 SENSOR 1/2 HEATER PERFORMANCE
When Monitored: During vehicle shutdown after vehicle had been driven greater than 10
miles with throttle open for a minimum of 3 minutes. Battery voltage greater than 11.0
volts.
Set Condition: No sensor output is received when the PCM powers up the sensor heater.
Two trip fault. Three good trips to turn off the MIL.
P0155-O2 SENSOR 2/1 HEATER PERFORMANCE
When Monitored: During vehicle shutdown after vehicle had been driven greater than 10
miles with throttle open for a minimum of 3 minutes. Battery voltage greater than 11.0
volts.
Set Condition: No sensor output is received when the PCM powers up the sensor heater.
Two trip fault. Three good trips to turn off the MIL.
P0161-O2 SENSOR 2/2 HEATER PERFORMANCE
When Monitored: During vehicle shutdown after vehicle had been driven greater than 10
miles with throttle open for a minimum of 3 minutes. Battery voltage greater than 11.0
volts.
Set Condition: No sensor output is received when the PCM powers up the sensor heater.
Two trip fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
O2 SENSOR HEATER OPERATION
549
DRIVEABILITY - NGC
P0135-O2 SENSOR 1/1 HEATER PERFORMANCE —
Continued
POSSIBLE CAUSES
O2 HEATER ELEMENT
O2 HEATER CONTROL CIRCUIT OPEN
O2 HEATER GROUND CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
Turn the ignition off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize between
4.6 and 5.0 volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 4.5 volts?
All
2
3
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
Turn the ignition off.
NOTE: Allow the O2 sensor to cool down to room temperature.
Disconnect the O2 Sensor harness connector.
Measure the resistance across the O2 Heater element component side.
NOTE: O2 Heater Element resistance values should be measured at 70°F
(21.1°C). The resistance value will increase with temperature.
* 4.7L O2 Sensor Heater Element resistance value is 4.6 to 5.6 ohms for the
Upstream and Downstream Sensors.
* 5.7L Upstream O2 Sensor Heater Element resistance value is 3.3 to 4.1 ohms and
the resistance value for the Downstream Sensor’s is 4.0 to 5.0 ohms.
Is the resistance within the specifications?
Yes
→ Go To
No
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
3
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the O2 Heater Control circuit from the O2 harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 0.5 of an ohm?
Yes
→ Go To
No
→ Repair the excessive resistance in the O2 Heater Control circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
4
550
All
DRIVEABILITY - NGC
P0135-O2 SENSOR 1/1 HEATER PERFORMANCE —
Continued
TEST
ACTION
APPLICABILITY
4
Measure the resistance between ground and the O2 Heater ground circuit in the O2
Sensor harness connector.
Is the resistance below 0.5 of an ohm?
All
5
Yes
→ Go To
No
→ Repair the excessive resistance in the O2 Heater ground circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
5
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
551
All
DRIVEABILITY - NGC
Symptom List:
P0171-FUEL SYSTEM 1/1 LEAN
P0174-FUEL SYSTEM 2/1 LEAN
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0171-FUEL SYSTEM 1/1 LEAN.
When Monitored and Set Condition:
P0171-FUEL SYSTEM 1/1 LEAN
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20 deg. F and altitude below 8500 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a certain percentage is exceeded for two trips, a freeze frame is stored, the MIL illuminates
and a trouble code is stored. Two Trip Fault. Three good trips to turn off the MIL.
P0174-FUEL SYSTEM 2/1 LEAN
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20 deg. F and altitude below 8500 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a certain percentage is exceeded for two trips, a freeze frame is stored, the MIL illuminates
and a trouble code is stored. Two Trip Fault. Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
O2 SENSOR
O2 SIGNAL CIRCUIT
O2 RETURN CIRCUIT
O2 SENSOR HEATER OPERATION
MAP SENSOR OPERATION
ECT SENSOR OPERATION
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR (HIGH)
PCM
552
DRIVEABILITY - NGC
P0171-FUEL SYSTEM 1/1 LEAN —
Continued
TEST
ACTION
APPLICABILITY
1
Diagnose all other trouble codes before continuing.
NOTE: Check for contaminants that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge to the fuel rail.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49 psi +/- 5 psi).
Turn the ignition off.
Choose a conclusion that best matches your fuel pressure reading.
All
Within Specification
Go To 3
Above Specification
Replace the fuel filter/pressure regulator.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
Below Specification
Go To 12
CAUTION: Stop All Actuations.
3
Start the engine.
Allow the engine to reach normal operating temperature.
NOTE: If one of the O2 Sensors Signal or Return circuit is shorted to ground
the DRBIIIt will display all O2 Sensor voltage readings low. The O2 Sensor
that is shorted to ground will display a voltage reading near or at 0 volts.
NOTE: If one of the O2 Sensors Signal or Return circuit is shorted to
voltage, the DRBIIIt will display all O2 Sensor voltage readings high. It is
important to diagnose the O2 Sensor that set the DTC.
NOTE: After the repairs have been made, verify proper O2 Sensor operation.
If all the O2 Sensor voltage readings have not returned to normal, follow the
diagnostic procedure for the remaining O2 Sensors.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage switching between 2.5 and 3.4 volts for all the O2 Sensors?
Yes
→ Go To
4
No
→ Go To
8
553
All
DRIVEABILITY - NGC
P0171-FUEL SYSTEM 1/1 LEAN —
Continued
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0
volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 4.5 volts?
All
5
6
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
Turn the ignition off.
Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
NOTE: If engine will not idle, maintain a constant RPM above idle.
With the DRBIIIt in Sensors, read the MAP Sensor vacuum value.
Is the DRBIIIt reading within 19 of the Vacuum Gauge reading?
Yes
→ Go To
No
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
6
NOTE: For this test to be valid, the thermostat must be operating correctly.
NOTE: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Engine Coolant Temperature (ECT) Sensor value. If the
engine was allowed to sit overnight (cold soak), the temperature value should be a
sensible value that is somewhere close to the ambient temperature.
NOTE: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the ECT Sensor value. The temperature value
change should be a smooth transition from start up to normal operating temperature
82°C (180°F). The value should reach at least 82°C (180°F).
Did the ECT value increase smoothly and did it reach at least 180°F (82°C)?
Yes
→ Go To
No
→ Replace the Engine Coolant Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
554
All
DRIVEABILITY - NGC
P0171-FUEL SYSTEM 1/1 LEAN —
Continued
TEST
ACTION
APPLICABILITY
7
Turn the ignition off.
Check for any of the following conditions/mechanical problems.
AIR INDUCTION SYSTEM - must be free from leaks.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
ENGINE PCV SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?
All
8
Yes
→ Repair as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
11
Ignition on, engine not running.
NOTE: Perform the following test on all O2 Sensors.
Disconnect the O2 Sensor harness connector.
With the DRBIIIt, monitor the O2 Sensor voltage.
O2 Sensor voltage should read 5.0 volts on the DRBIIIt with the connector
disconnected.
Connect a jumper wire between the Signal circuit and the Return circuit in the O2
Sensor harness connector.
NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper
wire in place.
Did the O2 Sensor voltage change from 5.0 volts to 2.5 volts?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
9
NOTE: Remove the jumper wire before continuing.
9
Only have one Sensor disconnect at a time.
With the DRBIIIt, monitor all the O2 Sensor voltage.
NOTE: The DRBIIIt will display all O2 Sensor voltage readings approximately 5.0 volts when only one O2 Sensor’s Signal circuit is shorted to
voltage.
NOTE: The DRBIIIt will display one O2 Sensor voltage close to zero and the
others will read lower than normal when the O2 Sensor Signal circuit has
excessive resistance or is open
Is the voltage above 4.8 volts?
Yes
→ Go To
No
→ Check all the O2 Signal circuits for a short to ground, open, or
short to voltage. Inspect the O2 Sensor connector and the PCM
harness connector. If OK, replace and program the Powertrain
Control Module per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
10
555
All
DRIVEABILITY - NGC
P0171-FUEL SYSTEM 1/1 LEAN —
Continued
TEST
ACTION
APPLICABILITY
10
Disconnect each O2 Sensor harness connector.
Measure the voltage on the O2 Return circuits in the O2 Sensor harness connector.
NOTE: The DRBIIIt will display all O2 Sensor voltage readings approximately 5.0 volts when only one O2 Sensor’s Return circuit is shorted to
voltage.
NOTE: The DRBIIIt will display one O2 Sensor voltage close to zero and the
others will read lower than normal when the O2 Sensor Return circuit has
excessive resistance or is open
Is the voltage at 2.5 volts?
All
11
Yes
→ Go To
No
→ Check all the O2 Return circuits for a short to ground, open, or
short to voltage. Inspect the O2 Sensor connector and the PCM
harness connector. If OK, replace and program the Powertriain
Control Module per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
11
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
12
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the T fitting on tool #6539.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49 psi +/- 5 psi).
Is the fuel pressure within specification?
Yes
→ Repair or replace fuel supply line as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
13
CAUTION: Stop All Actuations.
13
Turn the ignition off.
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
Yes
→ Replace the Fuel Pump Inlet Strainer.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
14
556
All
DRIVEABILITY - NGC
P0171-FUEL SYSTEM 1/1 LEAN —
TEST
14
Continued
ACTION
If there are no possible causes remaining, view repair.
Repair
Replace the Fuel Pump Module.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
557
APPLICABILITY
All
DRIVEABILITY - NGC
Symptom List:
P0172-FUEL SYSTEM 1/1 RICH
P0175-FUEL SYSTEM 2/1 RICH
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0172-FUEL SYSTEM 1/1 RICH.
When Monitored and Set Condition:
P0172-FUEL SYSTEM 1/1 RICH
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20 deg. F and altitude below 8500 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a purge fuel multiplier and the result is below a certain value for 30 seconds over two trips,
a freeze frame is stored, the MIL illuminates and a trouble code is stored. Two Trip Fault.
Three good trips to turn off the MIL.
P0175-FUEL SYSTEM 2/1 RICH
When Monitored: With the engine running in closed loop mode, the ambient/battery
temperature above 20 deg. F and altitude below 8500 ft.
Set Condition: If the PCM multiplies short term compensation by long term adaptive and
a purge fuel multiplier and the result is below a certain value for 30 seconds over two trips,
a freeze frame is stored, the MIL illuminates and a trouble code is stored. Two Trip Fault.
Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
O2 SENSOR HEATER OPERATION
O2 SENSOR
EVAP PURGE SOLENOID OPERATION
O2 SIGNAL CIRCUIT
O2 RETURN CIRCUIT
MAP SENSOR
ECT SENSOR
ENGINE MECHANICAL PROBLEM
FUEL FILTER/PRESSURE REGULATOR (HIGH)
PCM
558
DRIVEABILITY - NGC
P0172-FUEL SYSTEM 1/1 RICH —
Continued
TEST
ACTION
APPLICABILITY
1
NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
All
2
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge to the fuel rail.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339 KPa +/- 34 KPa (49 psi +/- 5 psi).
Turn the ignition off.
Choose a conclusion that best matches your fuel pressure reading.
All
Within Specification
Go To 3
Above Specification
Replace the fuel filter/pressure regulator.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
CAUTION: Stop All Actuations.
3
4
Start the engine.
Allow the engine to reach normal operating temperature.
NOTE: If one of the O2 Sensors Signal or Return circuit is shorted to ground
or voltage, all the other O2 Sensor voltage readings will be affected. It is
important to diagnose the O2 Sensor that set the DTC.
NOTE: After the repairs have been made, verify proper O2 Sensor operation.
If all the O2 Sensor voltage readings have not returned to normal, follow the
diagnostic procedure for the remaining O2 Sensors.
With the DRBIIIt, read the O2 Sensor voltage.
Is the voltage switching between 2.5 and 3.4 volts?
Yes
→ Go To
4
No
→ Go To
9
Turn the ignition off.
NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down
before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0
volts.
Ignition on, engine not running.
With the DRBIIIt, actuate the O2 Heater Test.
With the DRBIIIt, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 4.5 volts?
Yes
→ Replace the O2 Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
5
559
All
All
DRIVEABILITY - NGC
P0172-FUEL SYSTEM 1/1 RICH —
TEST
5
Continued
ACTION
Turn the ignition off.
Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
NOTE: If engine will not idle, maintain a constant RPM above idle.
With the DRBIIIt in Sensors, read the MAP Sensor vacuum value.
Is the DRB reading within 19 of the Vacuum Gauge reading?
Yes
→ Go To
No
→ Replace the MAP Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
APPLICABILITY
All
6
NOTE: Remove the vacuum gauge before continuing.
6
7
NOTE: For this test to be valid, the thermostat must be operating correctly.
NOTE: This test works best if performed on a cold engine (cold soak)
Ignition on, engine not running.
With the DRBIIIt, read the Engine Coolant Temperature Sensor value. If the engine
was allowed to sit overnight (cold soak), the temperature value should be a sensible
value that is somewhere close to the ambient temperature.
NOTE: If engine coolant temperature is above 82°C (180°F), allow the engine
to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The temp
value change should be a smooth transition from start up to normal operating temp
82°C (180°F). The value should reach at least 82°C (180°F).
Did the ECT value increase smoothly and did it reach at least 180°F (82°C)?
Yes
→ Go To
No
→ Replace the Engine Coolant Temperature Sensor.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
All
7
Turn the ignition off.
Disconnect the hoses at the Evap Purge Solenoid.
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid
vacuum source port on the component side.
Did the Evap Purge Solenoid hold vacuum?
Yes
→ Go To
No
→ Replace the EVAP Purge Solenoid.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
8
NOTE: Connect the vacuum hoses before continuing.
560
All
DRIVEABILITY - NGC
P0172-FUEL SYSTEM 1/1 RICH —
Continued
TEST
ACTION
APPLICABILITY
8
Check for any of the following conditions/mechanical problems.
AIR INDUCTION SYSTEM - must be free from restrictions.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
ENGINE PCV SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - no internal vacuum leaks
FUEL - must be free of contamination
FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector
Are there any engine mechanical problems?
All
9
Yes
→ Repair as necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
12
Ignition on, engine not running.
Disconnect the O2 Sensor harness connector.
With the DRBIIIt, monitor the O2 Sensor voltage.
O2 Sensor voltage should read 5.0 volts on the DRBIIIt with the connector
disconnected.
Connect a jumper wire between the O2 Signal circuit and the O2 Return circuit in the
O2 Sensor harness connector.
NOTE: The voltage should drop from 5.0 volts down to 2.5 volts with the
jumper wire connected.
Did the O2 Sensor voltage drop from 5 volts to 2.5 volts?
Yes
→ Replace the O2 Sensor
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
10
NOTE: Remove the jumper wire before continuing.
10
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Ignition on, engine not running.
Measure the voltage on the O2 Signal circuit in the O2 Sensor harness connector.
Is the voltage above 4.8 volts?
Yes
→ Check the O2 Sensor Signal circuit for damage, short to ground,
open, or short to voltage. Inspect the O2 Sensor connector and the
PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
11
561
All
DRIVEABILITY - NGC
P0172-FUEL SYSTEM 1/1 RICH —
Continued
TEST
ACTION
APPLICABILITY
11
Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector.
Is the voltage at 2.5 volts?
All
Yes
→ Go To
No
→ Check the O2 Sensor Return circuit for damage, short to ground,
open, or short to voltage. Inspect the O2 Sensor connector and the
PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
12
NOTE: Turn the ignition off before continuing.
12
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
562
All
DRIVEABILITY - NGC
Symptom List:
P0201-FUEL
P0202-FUEL
P0203-FUEL
P0204-FUEL
P0205-FUEL
P0206-FUEL
P0207-FUEL
P0208-FUEL
Test Note:
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR
#1
#2
#3
#4
#5
#6
#7
#8
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0201-FUEL INJECTOR #1
CIRCUIT.
When Monitored and Set Condition:
P0201-FUEL INJECTOR #1 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
P0202-FUEL INJECTOR #2 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
P0203-FUEL INJECTOR #3 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive is detected after injector turn off. One Trip Fault. Three good
trips to turn off the MIL.
P0204-FUEL INJECTOR #4 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off, and with no other
injectors on. One Trip Fault. Three good trips to turn off the MIL.
563
DRIVEABILITY - NGC
P0201-FUEL INJECTOR #1 CIRCUIT —
Continued
P0205-FUEL INJECTOR #5 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
P0206-FUEL INJECTOR #6 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
P0207-FUEL INJECTOR #7 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
P0208-FUEL INJECTOR #8 CIRCUIT
When Monitored: With battery voltage greater than 10 volts. Auto Shutdown Relay
energized. Engine speed less than 3000 rpm.
Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
Three good trips to turn off the MIL.
POSSIBLE CAUSES
GOOD TRIP EQUAL TO ZERO
(A142) ASD RELAY OUTPUT CIRCUIT
FUEL INJECTOR
INJECTOR CONTROL CIRCUIT OPEN
INJECTOR CONTROL CIRCUIT SHORTED TO GROUND
PCM
TEST
1
ACTION
Ignition on, engine not running.
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
No
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
2
564
APPLICABILITY
All
DRIVEABILITY - NGC
P0201-FUEL INJECTOR #1 CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
2
Turn the ignition off.
Disconnect the Fuel Injector harness connector.
Ignition on, engine not running.
With the DRBIIIt, actuate the ASD Relay.
Using a 12-volt test light connected to ground, backprobe the (A142) ASD Relay
Output circuit at the Fuel Injector harness connector.
Does the test light illuminate brightly?
All
3
Yes
→ Go To
No
→ Repair the excessive resistance or short to ground in the (A142)
ASD Relay Output circuit. Inspect related fuses and repair as
necessary.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
3
Using a 12-volt test light connected to 12-volts, backprobe the Injector Control
circuit.
With the DRBIIIt, actuate the Fuel Injector.
What is the state of the test light during the actuation?
All
Brightly blinking.
Replace the Fuel Injector.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ON constantly.
Go To
4
OFF constantly.
Go To 5
4
5
Turn the ignition off.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the Injector Control circuit at the Fuel
Injector harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the Injector Control circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
All
6
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the Injector Control circuit from the Fuel Injector harness
connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the Injector Control circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
6
565
All
DRIVEABILITY - NGC
P0201-FUEL INJECTOR #1 CIRCUIT —
Continued
TEST
ACTION
APPLICABILITY
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
All
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
566
DRIVEABILITY - NGC
Symptom:
P0222-THROTTLE POSITION SENSOR #2 LOW
When Monitored and Set Condition:
P0222-THROTTLE POSITION SENSOR #2 LOW
When Monitored:
With the ignition on.
Set Condition: Throttle Position Sensor #2 Signal circuit voltage is less than 0.35 volt for
25 ms. One Trip Fault. ETC light will illuminate.
POSSIBLE CAUSES
TP SENSOR #2 SWEEP
INTERMITTENT CONDITION
(K7) 5-VOLT SUPPLY CIRCUIT OPEN
(K7) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
TP SENSOR
(K122) TP SENSOR #2 SIGNAL CIRCUIT OPEN
(K122) TP SENSOR #2 SIGNAL CIRCUIT SHORTED TO GROUND
(K122) TP SENSOR #2 SIGNAL CIRCUIT SHORTED TO (K101) SENSOR RETURN CIRCUIT
PCM
TEST
1
2
ACTION
Ignition on, engine not running.
With the DRBIIIt, read the TP Sensor #2 voltage value.
Is voltage readings below 0.35 of a volt?
Yes
→ Go To
2
No
→ Go To
10
Turn the ignition off.
Disconnect the Throttle Body harness connector.
Ignition on, engine not running.
Measure the voltage on the (K7) 5-volt Supply circuit.
Is the voltage between 4.8 and 5.2 volts?
Yes
→ Go To
3
No
→ Go To
7
567
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0222-THROTTLE POSITION SENSOR #2 LOW —
Continued
TEST
ACTION
APPLICABILITY
3
Connect a jumper wire between the (K7) 5-volt supply circuit and the (K122) TP
Sensor #2 Signal circuit.
With the DRBIIIt, monitor the TP Sensor #2 voltage.
Is the voltage between 4.8 and 5.2 volts?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
Yes
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select LEARN
ETC.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
NOTE: Remove the jumper wire before continuing.
4
5
6
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K122) TP Sensor #2 Signal circuit from the Throttle
Body harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K122) TP Sensor #2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
Measure the resistance between ground and the (K122) TP Sensor #2 Signal circuit
between the appropriate terminals of Special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K122) TP Sensor #2 Signal.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
6
Measure the resistance between the (K122) TP Sensor #2 Signal circuit and the
(K101) Sensor Return circuit between the appropriate terminals of Special tool
#8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K101) Sensor Return circuit and
the (K122) TP Sensor #2 Signal circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
9
568
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0222-THROTTLE POSITION SENSOR #2 LOW —
Continued
TEST
ACTION
APPLICABILITY
7
Turn the ignition off.
Disconnect the PCM harness connectors.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K7) 5-volt Supply circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
8
9
Yes
→ Go To
No
→ Repair the open in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
8
Measure the resistance between ground and the (K7) 5-volt Supply circuit between
the appropriate terminals of Special tool #8815.
Is the resistance below 100 ohms?
Yes
→ Repair the short to ground in the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
9
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
10
Ignition on, engine not running..
With the DRBIIIt, perform the Pedal Follower Test.
Monitor the TP Sensor #2 voltage while pressing the Throttle pedal down.
Is there a smooth voltage change from high to low?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select the
LEARN ETC function.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
569
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
Symptom:
P0223-THROTTLE POSITION SENSOR #2 HIGH
When Monitored and Set Condition:
P0223-THROTTLE POSITION SENSOR #2 HIGH
When Monitored:
With the ignition on.
Set Condition: Throttle Position Sensor #2 Signal circuit voltage is greater than 4.9 volts
for 25 ms. One Trip Fault. 5.7L ETC light will illuminate.
POSSIBLE CAUSES
TP SENSOR #2 SWEEP
INTERMITTENT CONDITION
TP SENSOR
(K122) TP SENSOR #2 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K122) TP SENSOR #2 SIGNAL CIRCUIT SHORTED TO (K7) 5-VOLT SUPPLY CIRCUIT
(K101) SENSOR RETURN CIRCUIT OPEN
PCM
TEST
1
2
ACTION
With the DRBIIIt, read DTCs and record the related Freeze Frame data.
Ignition on, engine not running.
Is the Good Trip Counter displayed and equal to zero?
Yes
→ Go To
2
No
→ Go To
7
Turn the ignition off.
Disconnect the Throttle Body Assembly harness connector.
Ignition on, engine not running.
With the DRBIIIt monitor the TP Sensor #2 voltage.
Is the voltage below 0.5 volt?
Yes
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the DRBIIIt under the Misc. Menu select the
LEARN ETC function.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
3
570
APPLICABILITY
ENGINE - 9MAGNUM9 5.7L SMPI
V8
ENGINE - 9MAGNUM9 5.7L SMPI
V8
DRIVEABILITY - NGC
P0223-THROTTLE POSITION SENSOR #2 HIGH —
Continued
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the PCM harness connectors.
Ignition on, engine not running.
Measure the voltage on the (K122) TP Sensor #2 Signal circuit in the Throttle Body
harness connector.
Is the voltage above 5.2 volts?
ENGINE - 9MAGNUM9 5.7L SMPI
V8
4
5
6
Yes
→ Repair the short to voltage in the (K122) TP Sensor #2 Signal
circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
4
Measure the resistance between the (K122) TP Sensor #2 Signal circuit and the (K7)
5-volt Supply circuit at the Throttle Body harness connector.
Is the resistance below 100 ohms?
Yes
→ Repair the short between the (K122) TP Sensor #2 Signal circuit
and the (K7) 5-volt Supply circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Go To
ENGINE - 9MAGNUM9 5.7L SMPI
V8
5
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K101) Sensor Return circuit from the Throttle Body
harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
Yes
→ Go To
No
→ Repair the open in the (K101) Sensor Return circuit.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
6
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay
particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
ENGINE - 9MAGNUM9 5.7L SMPI
V8
Repair
Replace and program the Powertrain Control Module per Service
Information.
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
7
With the DRBIIIt, perform the Pedal Follower Test.
Monitor the TP Sensor #2 voltage.
Is there a smooth voltage change from high to low?
Yes
→ Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.
No
→ Disconnect the Battery when replacing the Throttle Body Assembly. Replace the Throttle Body Assembly. After installation is
complete, with the D