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2005 KJ Powertrain

1. 245 DRIVEABILITY NGC Symptom P0O850 PAR K NEUTRAL SWITCH PERFORMANCE When Monitored and Set Condition P0850 PARK NEUTRAL SWITCH 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 DRB DISPLAYS P N amp D R NOT IN CORRECT POSITION TRS T41 SENSE P N SENSE CIRCUIT OPEN TRS T41 SENSE P N SENSE CIRCUIT SHORTED TO GROUND TRANSMISSION RANGE SENSOR PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the Park Neutral Position Switch input state While moving the gear selector through all gear positions Park to 1 and back to Park monitor the DRB display Did the DRB display show P N and D R in the correct gear positions Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 GoTo 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Transmission Range Sensor harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the TRS T41 Sense P N Sense circuit from the TRS har
2. 53 DRIVEABILITY NGC Symptom P0073 AMBIENT TEMP SENSOR CIRCUIT HIGH When Monitored and Set Condition P0073 AMBIENT TEMP SENSOR CIRCUIT HIGH When Monitored The ignition key on Set Condition TheAmbient Temperature Sensor voltage is greater than 4 94 volts at the PCM for 4 8 seconds Three good trips to clear 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 K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the Ambient Temperature Sensor voltage Is the voltage above 4 8 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the Ambient Temperature Sensor harness connector Connect a jumper wire between the G31 AAT Signal circuit and the K 900 Sensor ground circuit at the AAT Sensor harness connector Ignition on engine not running With the DRBIII read Ambient Temperature Sensor voltage Is the voltage below 1 0 volt Yes Replace the Ambient Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 54 DRIVEABILITY NGC P0073 AMBIENT TEMP SENSOR CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignit
3. GoTo 5 If there are no possible causes remaining view repair Repair Replace the Camshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 35 DRIVEABILITY NGC P0016 CRANKSHAFT CAMSHAFT TIMING MISALIGNMENT Continued ACTION APPLICABILITY Turn the ignition off Remove the lab scope probe WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 DRBIII 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 Yes Repair the wiring connector concerns as needed or replace the Camshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 7 Turn the ignition off All With the DRBII1 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 INA 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 ther
4. GoTo 9 No Repair the open in the T40 Starter Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Using a 12 volt test light connected to ground probe the A2 Fused B circuit at the Starter Relay terminal Does the test light illuminate brightly Yes GoTo 10 No Repair theopen or high resistancein the F used B circuit nspect related fuses and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 If there are no other possible causes remaining review repair Repair Replace the Starter Perform POWERTRAIN VERIFICATION TEST VER 1 303 STARTING Symptom NO RESPONSE FROM PCM WITH ANO START CONDITION POSSIBLE CAUSES PCM FUSED B CIRCUITS PCM NO RESPONSE PCM FUSED IGNITION SWITCH OUTPUT CIRCUITS Z81 Z82 PCM GROUND CIRCUITS THROTTLE POSISITON SENSOR 5 VOLT SENSOR OPEN OR SHORTED F855 5 VOLT SUPPLY CKT SHORT TO GROUND F856 5 VOLT CIRCUIT SUPPLY SHORTED TO GROUND PCM ACTION APPLICABILITY NOTE The DRBIII and cable must be operating properly for the results of All this test to be valid NOTE Ensure theignition switch was on while trying to communicate with the PCM Turn the ignition off Disconnect the PCM harness connectors Using a 12 volt test light connected to ground probethe PCM Fused B circuit in the PCM harness connector Does the test light illuminate brightly Yes GoTo 2 No Repair the open or short to
5. Repair the open in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the F855 5 volt Supply circuit at the CKP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 128 DRIVEABILITY NGC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 Turn the ignition off With the DRBII1 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 INA 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 lightly tap on the Crank Position Sensor Observe the lab scope screen Look for any pulses generated by the
6. Yes GoTo 10 No Repair the open in the Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 11 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the Sensor Signal circuit in the Temperature Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 12 Measure the resistance between the Signal circuit and the K 900 Sensor ground circuit at the Temperature Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground circuit and the Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 85 DRIVEABILITY NGC P0128 THERMOSTAT RATIONALITY Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All corrosion d
7. Yes GoTo 7 No Repair the open in the Z201 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 Measure the resistance between the K107 NVLD Switch Signal circuit and the All K106 NVLD Sol Control circuit in the NVLD electrical harness connector 162 DRIVEABILITY NGC Symptom P0456 E VAP SYSTEM SMALL LEAK When Monitored and Set Condition P0456 E VAP SYSTEM SMALL LEAK When Monitored Ignition off Fuel Level less than 88 Ambient Temperature between 4 C to 43 C 39 F to 109 F Set Condition Due to temperature changes a vacuum is created in the fuel tank and EVAP system With the EVAP system sealed the PCM monitors the NVLD switch If the NVLD switch does not close within a calibrated amount of time an error is detected POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO INTERMITTENT CONDITION VISUAL AND PHYSICAL INSPECTION EVAPORATIVE EMISSION LEAK DETECTION EVAP PURGE SOLENOID LEAKS STUCK OPEN ACTION APPLICABILITY Check for any related TSBs bef
8. 3 3 8 CLUTCH VOLUMES The LR clutch volume is updated when doing a 2 1 or 3 1 coast down shift The transmission tem perature must be between 21 49 C 70 120 F The clutch volume should be between 35 and 83 The 2 4 clutch volume is updated when doing a 1 2 shift The transmission temperature must be above 43 C 110 F The clutch volume should be between 20 and 77 The OD dutch volume is updated when doing a 2 3 shift The transmission temperature must be above 43 C 110 F The clutch volume should be between 40 and 150 13 GENERAL INFORMATION The UD clutch volume is updated when doing a 4 3 or 4 2 shift Thetransmission temperature must be above 43 C 110 F The clutch volume should be between 24 and 70 3 3 9 NO START INFORMATION POWERTRAIN IMPORTANT NOTE If the Powertrain Control Module has been pro grammed a DTC will set in the ABS and Air Bag modules In addition if the vehicleis equipped with a Sentry Key Immobilizer Module SKIM Secret Key data must be updated to enable starting 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 DRBIII to the data link connec tor 2 Go to Theft Alarm SKIM Misc and place the SKIM in secured access mode by using the appro priate PIN code for this vehicle 3 Select Update the Secret Key data data will be transferred from the SKIM to the PCM This i
9. Disconnect the vacuum hoses at the Evap Purge Solenoid Using a hand vacuum pump apply 10 in Hg to the CAN of the EVAP Purge Solenoid NOTE Monitor the vacuum gauge for at least 15 seconds Does the EVAP Purge Solenoid hold vacuum Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 6 154 DRIVEABILITY NGC Symptom P0443 EVAP PURGE SOLENOID CIRCUIT When Monitored and Set Condition P0443 EVAP PURGE SOLENOID CIRCUIT When Monitored The ignition on or engine running Battery voltage greater than 10 volts Set Condition ThePCM will set a trouble code if the actual state of the solenoid does not match the intended state POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO EVAP PURGE SOLENOID K52 EVAP PURGE SOL CONTROL CIRCUIT OPEN K52 EVAP PURGE SOL CONTROL CIRCUIT SHORTED TO GROUND K 70 EVAP PURGE SOL SIGNAL CIRCUIT OPEN K 70 EVAP PURGE SOL SIGNAL CIRCUIT SHORTED TO GROUND K 70 EVAP PURGE SOL SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE PCM ACTION APPLICABILITY Check for any related TSBs before continuing All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic
10. NOTE If one of the O2 Sensors Signal or Return circuit is shorted to ground the DRBIII 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 DRBIII 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 DRBIII monitor all the O2 Sensor voltage readings Is the voltage switching between 2 5 and 3 4 volts for all of the O2 Sensors Yes GoTo 4 No GoTo 10 101 DRIVEABILITY NGC P0O171 FUEL SYSTEM 1 1 LEAN Continued ACTION APPLICABILITY Turn the ignition off All 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 NOTE Perform the following test on all O2 Sensors Ignition on engine not running With the DRBIII actuate the O2 Heater Test With the DRBIII 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 GoTo 5 With the DRBIII read TP Se
11. Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Disconnect the Brake Switch harness connector Disconnect the C3 PCM harness connector Measure the resistance between ground and the V32 S C Supply circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 10 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If the there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 4 223 DRIVEABILITY NGC Symptom P0586 SPEED CONTROL VENT SOLENOID CIRCUIT E When Monitored and Set Condition P0586 SPEED CONTROL VENT SOLENOID CIRCUIT When Monitored Engine running the speed control switched on and learned and the brake pedal is not pressed No other fault has occured this trip Set Condition The PCM detects an open or short to ground in the Speed Control Vent Control circuit Cruise will be disabled for the remainder of that key on cycle One Trip Fault Three good trips to clear the MIL POSSIBLE CAUSES SPEED CONTROL SOLENOID OPERATION V32 S C SUPPLY CIRCUIT SPEED CONTROL VENT SOLENOID V32 S C SUPPLY SHORT TO GROUN
12. Remove special tool C4390 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 407 KPa 34 KPa 59 psi 5 psi Move special tool C4390 Hose Clamp Pliers from between the fuel pressure gauge and the engine to between the fuel pressure gauge and fuel pump module 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 drop Yes Replace the leaking fuel injectors Perform POWERTRAIN VERIFICATION TEST VER 2 No Check the fuel for contaminants Perform POWERTRAIN VERIFICATION TEST VER 2 296 STARTING Symptom ENGINE CRANKS BUT DOES NOT START POSSIBLE CAUSES NO START PRE TEST POWERTRAIN FUSES OPEN SECONDARY INDICATORS PRESENT NO CKP SENSOR SIGNAL WHEN CRANKING ENGINE NO CMP SENSOR SIGNAL WHEN CRANKING ENGINE ENGINE MECHANICAL PROBLEM A142 ASD RELAY OUTPUT CIRCUIT OPEN FUEL CONTAMINATION ACTION APPLICABILITY Note The following list of items must be checked before continuing with All any no start tests The battery must be fully charged and in good condition A low charged battery may produce invalid test results If the battery is low charge the battery and then attempt to start the vehicle by cranking the engine for 15 seconds 3 consecutive times This will allow any DTCs to set that may have been erased due to a dead battery Try to communi
13. Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 120 DRIVEABILITY NGC Symptom P0315 NO CRANK SENSOR LEARNED When Monitored and Set Condition PO315 NO CRANK SENSOR LEARNED When Monitored Under closed throttle decel and A C off ECT above 75 C 167 F Engine start time is greater than 50 seconds Set Condition One of the CKP sensor target windows has more than 2 86 variance from the reference One Trip Fault POSSIBLE CAUSES INTERMITTENT CONDITION TONE WHEEL PULSE RING INSPECTION CKP WIRE HARNESS INSPECTION CRANKSHAFT POSITION SENSOR ACTION APPLICABILITY NOTE Check for any TSBs that may apply to this symptom All Ignition on engine not running With the DRBIII clear DTCs PCM battery disconnect to reset the PCM Start the engine If the MIL has not yet illuminated test drive the vehicle to try to get the code to reset Does the code reset while cranking or during the test drive Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Visually inspect the CKP wire harness Look for any chafed pierced pinched or partially broken wires Visually inspect the CKP wire harness connectors Look for broken bent pushed out or corroded terminals Make sure the Crankshaft Position Sensor is properly installed and
14. Repair Replace the Camshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Ignition on engine not running Measure the voltage on the K 44 CMP Signal circuit Wiggle the related wire harness while taking this measurement Does the voltage ever increase above 5 5 volts Yes Repair the short to voltage in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 9 Measure the resistance between ground and the K44 CMP Signal circuit in the CMP Sensor harness connector Wiggle the related wire harness while monitoring the resistance value Does the resistance ever go below 100 ohms Yes Repair the short to ground in the K 44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 Measure the resistance between the F 856 5 volt Supply circuit and the K 44 CMP Signal circuit in the CMP harness connector Wiggle the related wire harness while taking this measurement Does the resistance ever go below 5 0 ohms Yes Repair the short between the F 856 5 volt Supply circuit and the K 44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 12 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL
15. Start the engine Warm the engine to operating temperature Measure the voltage between the Generator B Output Terminal and the Battery Post Is the voltage above 0 4 of a volt Yes Repair the high resistance in the Battery Positive circuit between the Generator and Battery Perform POWERTRAIN VERIFICATION TEST VER 3 GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE Make sure all wires are clear of the engine s moving parts Measure the voltage between the Generator Case and Battery ground post Is the voltage above 0 1 of a volt Yes Repair high resistance in the Generator Case Ground Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 4 Yes Replace the Generator Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 5 Turn the ignition off Using a 12 volt test connected to battery voltage probe the Z932 Generator Ground circuit in the Generator Field harness connector Does the test light illuminate brightly Yes GoTo 6 No Repair the open in the Z932 Generator Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 3 Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the K 125 Gen Field Control circuit at the Generator Field harness connector Is the voltage above 1 0 volt Yes Rep
16. perform the SRI Memory Test a third time All NOTE Retest the SRI Memory two more times Does the DRBIII 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 DRBIII perform the SRI Memory Test Does the DRBIII display SRI Mileage Invalid Yes Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 5 Compare the SRI Mileage stored with the Instrument Panel Odometer Is the mileage within the specified range displayed on the DRBII1 Yes Test Complete No Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER 1 257 DRIVEABILITY NGC Symptom List P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 P2097 DOWN STREAM FUEL TRIM RICH BANK 1 P2098 DOWN STREAM FUEL TRIM LEAN BANK 2 P2099 DOWN STREAM FUEL TRIM RICH BANK 2 Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 E ere When Monitored and Set Condition P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F altitude below 8500 ft and fuel level greater than 15 Set Condition IfthePCM multiplies short term compensation by long term adaptive
17. read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 3 207 DRIVEABILITY NGC P0562 BATTERY VOLTAGE LOW Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 NOTE Make sure all wires are clear of the engine s moving parts Start the engine Allow the engine to reach normal operating temperature Measure the voltage between the Generator B Terminal and the Battery Post Is the voltage above 0 4 of a volt Yes Repair the Battery Positive circuit for high resistance between the Generator and Battery Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE Make sure all wires are clear of the engine s moving parts Measure the voltage between the Generator case and Battery ground post Is the voltage above 0 1 of a volt Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 4
18. 0 0 cccceceeceeceeeueeuveues 13 3 3 8 CLUTCH VOLUMES si citcddiieansseandeebariusdaasadatanwes 13 3 3 9 NO START INFORMATION POWERTRAIN 0ee0 es 13 3 4 USING THE DRBIII 00 00 00 ccc cece eee cece eee eraa erraren 13 3 5 DRBIIl ERROR MESSAGES AND BLANK SCREEN 00000 13 3 5 1 DRBIII DOES NOT POWER UP 0 0 00cc eee e eee eees 14 3 5 2 DISPLAY ISNOTVISIBLE 0 ccc ceec eee ee eeeeeees 14 3 5 3 SOME DISPLAY ITEMS READ nuanua aanraai 14 3 6 TRANSMISSION SIMULATOR MILLER TOOL 8333 AND ELECTRONIC TRANSMISSION ADAPTER KIT MILLER TOOL 8333 1A 14 DISCLAIMERS SAFETY WARNINGS 0ccecceceeeeeceeeeeveuees 15 t WISCLANVE RS scrape fierce eO ArI EAEN 15 4 2 SAFETY 0 0 c cece cece cece eee aE EEEE EEEE EEr 15 4 2 1 TECHNICIAN SAFETY INFORMATION 0 00e0eeees 15 4 2 2 VEHICLE PREPARATION FOR TESTING 0 00e0es 15 4 2 3 SEVICING SUB ASSEMBLIES 0 0 cccceceeeeeeees 15 4 2 4 DRBIII SAFETY INFORMATION 0 00c0eeeee eee ees 15 4 3 WARNINGS AND CAUTIONS 0 ccceceeeeceeeeeeeeveeeeues 16 4 3 1 ROAD TEST WARNINGS 0 00 ccceeececeeeeeeeeeues 16 4 3 2 VEHICLE DAMAGE WARNINGS 0 00cc eee ee ees 16 4 3 3 ROAD TESTING A COMPLAINT VEHCILE TRANSMISSION 16 4 3 4 ELECTRONIC PINION FACTOR WARNINGS IF APPLICABLE 17 4 3 5 SERVICE BULLETINS AND RECALLS 00 0ee ees i7 REQUIRED TOOLS
19. Disconnect the Ambient Temp Sensor harness connector Ignition on engine not running Using a 12 volt test light connected to ground probe the G31 AAT Signal circuit at the Ambient Temp Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 49 DRIVEABILITY NGC P0071 AMBIENT TEMP SENSOR PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off Connect the C1 and C2 PCM harness connectors Ignition on engine not running With the DRBIII read the Ambient Temperature Sensor voltage Is the voltage above 4 6 volts Yes GoTo 4 No GoTo 7 Connect a jumper wire across the G31 AAT Signal circuit and the K900 Sensor ground circuit terminals of the Sensor harness connector With the DRBIII read the AAT Sensor voltage Is the voltage below 1 0 volt Yes Replace the Ambient Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE Remove the jumper wire before continuing Turn the ignition off All Disconnect the C1 and C2 PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the G31 AAT Signal circui
20. F855 5 VOLT SUPPLY CIRCUIT OPEN F855 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL CIRCUIT SHORTED GROUND K24 CKP SIGNAL CIRCUIT SHORTED TO F855 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN CRANKSHAFT POSITION SENSOR PCM ACTION APPLICABILITY Crank the engine All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No GoTo 14 Turn the ignition off Disconnect the CKP Sensor harness connector Ignition on engine not running Measure the voltage on the F 855 5 volt Supply circuit at the CKP Sensor harness connector Is the voltage between 4 8 and 5 2 volts Yes GoTo 3 No GoTo 10 126 DRIVEABILITY NGC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT Continued ACTION APPLICABILITY Measure the voltage on the K24 CKP Signal circuit at the CKP Sensor harness connector Is the voltage between 4 8 and 5 2 volts Yes GoTo 4 No GoTo 7 Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit
21. Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K106 NVLD Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between the Z201 Ground circuit and ground Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the Z201 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 5 182 DRIVEABILITY NGC Symptom PO501 VEHICLE SPEED SIGNAL PERFORMANCE When Monitored and Set Condition P0501 VEHICLE SPEED SIGNAL PERFORMANCE When Monitored With the engine running transmission not in park or neutral brakes not applied and engine rpm greater than 1500 Set Condition This code will set if no vehicle speed signal is received from the Body Control Module for more than 11 seconds for 2 consecutive trips POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO B22 VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO VOLTAGE B22 VEHICLE SPEED SIGNAL CIRCUIT OPEN B22 VEHICLE SPEED SIGNAL CIRCUIT SHORTED
22. Note Use the Freeze Frame Data to help duplicate the conditions that set the DTC Pay particular attention to the DTC set conditions such as VSS MAP ECT and Load Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary No Test Complete 318 TRANSMISSION 42RLE Symptom P0122 THROTTLE POSITION SENSOR APPS LOW M When Monitored and Set Condition P0122 THROTTLE POSITION SENSOR APPS LOW When Monitored Continuously with the ignition on and engine running Set Condition This DTC will set if the monitored TPS voltage drops below 078 volts for the period of 0 48 seconds POSSIBLE CAUSES RELATED TPS ENGINE DTC S PRESENT POWERTRAIN CONTROL MODULE INTERMITTENT WIRING AND CONNECTORS ACTION APPLICABILITY NOTE Low fluid level can be the cause of many transmission problems If All the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics
23. 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 intermit tent These codes require a set of parameters to be performed The DRBIII pretest 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 DRBIII refer to the On Board Diagnostic training booklet 81 699 97094 TRANSMISSION 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 compo nent 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 intermitte
24. Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 Turn the ignition off Disconnect the C3 PCM harness connector Measure the resistance between ground and the K107 NVLD Switch Signal circuit in the NVLD Assembly harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the K107 NVLD Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 8 Turn the ignition off Disconnect the C3 PCM harness connector Measure the resistance between ground and the K 52 Evap Purge Sol Control circuit at the EVAP Purge Solenoid harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the K52 Evap Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 8 Disconnect the NVLD electrical connector 159 DRIVEABILITY NGC P0452 NVLD PRESSURE SWITCH STUCK CLOSED Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 5 160 DRIVEABILITY NGC
25. Turn the ignition off Disconnect the Brake Switch harness connector Turn the ignition on Using the DRBIII actuate the S C Vacuum Solenoid Using a test light connected to ground probe the V32 S C Supply circuit in the Brake Switch harness connector Does the test light illuminate brightly Yes GoTo 4 No GoTo 8 Turn the ignition off Disconnect the S C Servo harness connector Measure the resistance of the Z212 S C Ground circuit at the S C Servo harness connector to ground Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the Z212 S C Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 6 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V36 S C Vacuum Sol Control circuit from the Speed Control Servo harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 Repair the open high resistance in the V36 S C Vacuum Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off All Disconnect the Speed Control Servo harness connector Ignition on engine no
26. With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis Continue GoTo 2 With the DRBIII check Engine DTC s this includes all one trip failures Are there any Engine TPS DTCs present Yes Refer to the Driveability category and perform the appropriate symptom Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 No GoTo 3 319 TRANSMISSION 42RLE P0122 THROTTLE POSITION SENSOR APPS LOW Continued ACTION APPLICABILITY With the DRBII1 record the EATX EVENT DATA to help identify the conditions in All which the DTC was set With the DRBIII erase Transmission DTCs NOTE To erase EATX EVENT DATA information a BATTERY DISCONNECT must be performed Performing a BATTERY DISCONNECT
27. 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 P0153 O2 SENSOR 2 1 SLOW RESPONSE When Monitored Vehicleis 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 P0159 O2 SENSOR 2 2 SLOW RESPONSE When Monitored Vehicleis 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 POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO 95 DRIVEABILITY NGC P0133 O2 SENSOR 1 1 SLOW RESPONSE Continued POSSIBLE CAUSES EXHAUST LEAK O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT O2 SENSOR ACTION APPLICABILITY 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 oper
28. err 0x1 User Requested COLD Boot Press MORE to switch between this display and the application screen Press F4 when done noting information If the DRBIII should display any other error message record the entire display and call the Star Center 3 5 1 DRBIII 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 con nection at DLC cavity A minimum of 11 volts is required to adequately power the DRBIII If all connections are proper between the DRBI 11 and the vehicle or other devices and the vehicle battery is fully charged an inoperative DRBIII 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 5 3 SOME DISPLAY ITEMS READ __ This is caused by scrolling the DRBIII display a single line up or down The line which was scrolled onto the screen might read _ Usethe page down or page up function to display the information DRB III DISPLAY REPLACEABLE LENS ENTER KEYS KEYS LEDs CONTRAST with YES key oe oe BACK ane 2 with YES key Doe SHIFT KEY LED 80b57566 3 6 TRANSMISSION
29. 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 71 DRIVEABILITY NGC Symptom PO118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH When Monitored and Set Condition P0O118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition TheEngine Coolant Temperature ECT sensor circuit voltage at the PCM is greater than 4 96 volts for more than 2 6 seconds One Trip Fault POSSIBLE CAUSES ECT SENSOR VOLTAGE ABOVE 4 96 VOLTS ECT SENSOR K2 ECT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K2 ECT SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the ECT Sensor voltage Is the voltage above 4 96 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the ECT Sensor harness connector Connec a jumper wire between the K2 ECT Signal circui
30. Continued ACTION APPLICABILITY Measure the resistance of the V37 S C Switch Signal circuit from the upper All Clockspring harness connector to the On Off switch harness connector Is the resistance below 5 0 ohms Yes GoTo 8 No Repair the open in the V37 S C Switch Signal circuit Clock spring to S C Switch Perform POWERTRAIN VERIFICATION TEST VER 4 Measure the resistance of the K900 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 Yes GoTo 9 No Repair the open in the K900 Sensor ground circuit between the Clockspring and S C Switch Perform POWERTRAIN VERIFICATION TEST VER 4 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 Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 4 220 DRIVEABILITY NGC Symptom P0582 SPEED CONTROL VACUUM SOLENOID CIRCUIT When Monitored and Set Condition P0582 SPEED CONTROL VACUUM SOLENOID CIRCUIT When Monitored Engine running the speed control switched on and learned and the brake pedal is not presse
31. ECT TPS ETC CRK Sensor DTCs nor any fuel system or injector DTCs Set Condition Engine speed is 100 RPM or more below idle speed for 7 seconds Two Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO AIR INDUCTION SYSTEM IAC OPERATION PCM ACTION APPLICABILITY NOTE If any other DTCs are present they must be diagnosed and repaired All before continuing this test Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Inspect the Air Induction System for the following problems Restrictions Dirty Air Cleaner Foreign material trap in the air intake tube etc Leaks Air Intake tube connection Air Cleaner housing etc Remove the IAC and inspect for foreign debris Check the MAP Sensor for proper installation Were any problems found Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 185 DRIVEABILITY NGC P0506 IDLE SPEED PERFORMANCE LOWER THAN EXPECTED Continued ACTION APPLICABILITY Inspect the throttle plate for carbon build up or other restrictions All Verify that the throttle cable between the Accelerator Pedal and the Throttle body is not binding Make sure the th
32. ECT SIGNAL CIRCUIT SHORTED TO GROUND K2 ECT SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the ECT Sensor voltage Is the voltage below 0 5 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the ECT harness connector Ignition on engine not running With the DRBIII read ECT Sensor voltage Is the voltage above 1 0 volt Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the C2 PCM harness connector Measure the resistance between ground and the K2 ECT Signal circuit at the ECT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 70 DRIVEABILITY NGC PO11L7 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW Continued ACTION APPLICABILITY Measure the resistance between the K2 ECT Signal circuit and the K900 Sensor All ground circuit at the ECT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground and the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE
33. F POSSIBLE CAUSES ENGINE COOLING SYSTEM MALFUNCTION TRANSMISSION OIL COOLER PLUGGED HIGH TEMPERATURE OPERATIONS ACTIVATED ACTION APPLICABILITY NOTE Low fluid level can be the cause of many transmission problems If All the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis Continue GoTo 2 Perform Engine Cooling System diagnostics per the Service Information Is the Engine Cool
34. GoTo 6 Repair the open in the N 201 Low Speed Rad Fan Relay Control 176 DRIVEABILITY NGC Symptom P0481 COOLING FAN NO 2 CONTROL CIRCUIT When Monitored and Set Condition P0481 COOLING FAN NO 2 CONTROL CIRCUIT When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition An open or shorted circuit is detected in the high speed radiator fan relay control circuit One Trip Fault POSSIBLE CAUSES HIGH SPEED RADIATOR FAN RELAY OPERATION HIGH SPEED RADIATOR FAN RELAY F1 FUSED IGNITION SWITCH OUTPUT CIRCUIT A16 FUSED B CIRCUIT N112 HIGH SPEED RAD FAN RELAY CONTROL CIRCUIT OPEN N112 HIGH SPEED RAD FAN RELAY CONTROL CIRCUIT SHORT TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the High Speed Radiator Fan Relay Is the High Speed Radiator Fan Relay operating Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 2 Turn the ignition off Remove the High Speed Radiator Fan Relay from the PDC Measure the resistance of the High Speed Radiator Fan Relay between the F 1 Fused Ignition Switch Output terminal and the N112 High Speed Rad Fan Relay Control terminal Is the resistance between 60 to 85 ohms Yes GoTo 3 No Replace the High Speed Radiator Fan Relay Perform POWERTRAIN VERIFICATION TEST VER 5 177 DRIVEABILITY NGC P0481 C
35. NOTE Before continuing check the PCM harness connector terminals for All 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 is no possible causes remaining view repair Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 306 STARTING Symptom START AND STALL CONDITION POSSIBLE CAUSES CHECKING DTCS CHECKING SKIM DTCS TP SENSOR SWEEP TP SENSOR VOLTAGE GREATER THAN 0 92 VOLTS WITH THROTTLE CLOSED ECT SENSOR OPERATION OTHER POSSIBLE CAUSES FOR START amp STALL FUEL CONTAMINATION ACTION APPLICABILITY Ignition on engine not running With the DRBIII read engine DTCs Are any DTCs present Yes Refer to the Driveability Category and perform the appropriate diagnostics Perform POWERTRAIN VERIFICATION TEST VER 1 GoTo 2 With the DRBIII read TP Sensor voltage While monitoring the DRBIII slowly open and close the Throttle Is the voltage change smooth Yes GoTo 4 No Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 1 With the DRBIII read TP Sensor voltage Throttle must be against stop Is the voltage 0 92 or less with the Throttle closed Yes GoTo 5 No Check for a binding throttle condition If OK replace the Throt
36. No GoTo 9 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 check the Ground circuits 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 Does the test light illuminate brightly for all the Ground circuits Yes GoTo 5 No Repair the Ground circuit and or circuits for an open or high resistance Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 328 TRANSMISSION 42RLE P0562 LOW BATTERY VOLTAGE Continued ACTION APPLICABILITY Turn the ignition off to the lock position All Disconnect the PCM harness connector Remove the Transmission Control Relay Note Check connectors Clean repair as necessary Connect a jumper wire between Fused B circuit and Transmission Control Relay Output circuit in the Transmission Relay connector Ignition on engine not running CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLE
37. Output circuit If the transmission system is in Limp in Relay open the simulator will not oper ate 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 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 1 DISCLAIMERS 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 SAFETY 4 2 1 TECHNICIAN SAFETY INFORMATION 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 pro tection and remove any metal jewelry such as watchbands or bracelets that
38. Perform the appropriate Powertrain verification test 314 TRANSFER CASE MECHANICAL Symptom P0838 4WD MODE SENSOR LOW When Monitored and Set Condition P0838 4WD MODE SENSOR LOW When Monitored Continuously with the ignition key on Set Condition When the 4WD Mode Sensor input circuit voltage falls below 0 3 volts for 5 72 seconds POSSIBLE CAUSES TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO GROUND TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO SENSOR RETURN CIRCUIT TRANSFER CASE POSITION SENSOR POWERTRAIN ENGINE CONTROL MODULE INTERMITTENT OPERATION ACTION APPLICABILITY With the DRBIII record and erase DTC s All Start the engine and cycle the Transfer Case through all positions With the DRBIII read Transfer Case DTCs Is the Good Trip Counter equal to zero Yes GoTo 2 No GoTo 6 Turn the ignition off to the lock position Disconnect the Powertrain Control Module harness connector CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Disconnect the Transfer Case Position Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Transfer Case Position Sensor Input circuit Is the resistance below 5 0 ohms Yes
39. Remove the jumper wire before continuing 197 DRIVEABILITY NGC P0517 BATTERY TEMPERATURE SENSOR HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 and C3 PCM harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 Using a 12 volt test light connected to ground probe the K25 Batt Temp Signal circuit at the Battery Temp Sensor harness connector Does the test light illuminate brightly Yes Repair the short tovoltagein the K 118 Batt Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 4 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 25 Batt Temp Signal circuit from the Battery Temp Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K25 Batt Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION I
40. Symptom P0453 NVLD PRESSURE SWITCH STUCK OPEN When Monitored and Set Condition P0453 NVLD PRESSURE SWITCH STUCK OPEN When Monitored Engine running Set Condition If the PCM does not see the NVLD switch close during test an error is detected One Trip Fault POSSIBLE CAUSES NVLD SWITCH OPERATION NVLD ASSEMBLY K107 NVLD SWITCH SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K107 NVLD SWITCH SIGNAL CIRCUIT OPEN K107 NVLD SWITCH SIGNAL CIRCUIT SHORTED TO THE K106 SOLENOID CONTROL CIR CUIT Z201 GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Check for any related TSBs before continuing All Start the engine Allow the engine to idle Using the DRBIII perform the NVLD FORCED MONITOR TEST Monitor the NVLD Switch state NOTE As the test runs the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the test is complete Did the NVLD Switch operate as described above Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 2 Turn the ignition off Disconnect the NVLD electrical harness connector Ignition on engine not running Monitor the NVLD Switch state on the DRBIII Connect a jumper wire between the K107 NVLD Switch Signal circuit and the Z201 Ground circuit in the NVLD harness connector Does the Switch change from OPEN to CLOSED Yes Replace the NVLD Assembly Perform PO
41. Turn the ignition off Disconnect the Generator Field harness connector Use a 12 volt test light and jump it across the Generator Field harness connector Ignition on engine not running With the DRBIII actuate the Generator Field Control circuit Does the test light illuminate brightly and flash on and off Yes Replace the Generator Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 5 Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 125 Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 208 DRIVEABILITY NGC P0562 BATTERY VOLTAGE LOW Continued ACTION APPLICABILITY Measure the resistance between ground and the K 125 Gen Field Control circuit in All the Generator Field harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 GoTo 7 Using a 12 volt test connected to 12 volts pro
42. V37 S C Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 5 MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V37 S C Switch Signal circuit from the lower Clockspring harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the V37 S C Switch Signal circuit between the PCM and Clockspring Perform POWERTRAIN VERIFICATION TEST VER 4 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 900 Sensor ground circuit from the lower Clock spring harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open K900 Sensor ground circuit between the PCM and Clockspring Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off All Disconnect the upper and lower Clockspring harness connectors per Service Infor mation Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL 219 DRIVEABILITY NGC P0581 SPEED CONTROL SWITCH NO 1 HIGH
43. When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition O2 Heater element input is below the minimum acceptable voltage P0057 O2 SENSOR 2 2 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition O2 Heater element input is below the minimum acceptable voltage POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER CONTROL CIRCUIT O2 HEATER CONTROL SHORTED TO GROUND PCM 38 DRIVEABILITY NGC P0031 02 SENSOR 1 1 HEATER CIRCUIT LOW Continued ACTION APPLICABILITY 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 DRBIII actuate the O2 Heater Test With the DRBIII monitor O2 Sensor voltage for at least 2 minutes Does the O2 Sensor voltage stay above 4 5 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 Is the resistance between 2 0 and 30 ohms Yes GoTo 3 No Replace the O2 Sensor Perform POWERTRAIN
44. _ _ _ ___S ee Sa Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be POO32 O2 SENSOR 1 1 HEATER CIRCUIT HIGH When Monitored and Set Condition P0032 O2 SENSOR 1 1 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition O2 Heater element input is above the maximum acceptable voltage P0038 02 SENSOR 1 2 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition O2 Heater element input is above the maximum acceptable voltage P0052 02 SENSOR 2 1 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition O2 Heater element input is above the maximum acceptable voltage P0058 O2 SENSOR 2 2 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition O2 Heater element input is above the maximum acceptable voltage POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER GROUND CIRCUIT OPEN O2 SENSOR O2 HEATER CONTROL SHORTED TO VOLTAGE O2 HEATER CONTROL CIRCUIT OPEN PCM 40 DRIVEABILITY NGC P0032 02 SENSOR 1 1 HEATER CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignition off All NOTE Wait a minimum of 8 minutes to allow the O2 Sensor to cool dow
45. engine not running Measure the voltage on the F 856 5 volt Supply circuit at the MAP Sensor harness connector Is the voltage between 4 5 to 5 2 volts Yes GoTo 3 No GoTo 6 87 DRIVEABILITY NGC P0129 BAROMETRIC PRESSURE OUT OF RANGE Continued ACTION APPLICABILITY With the DRBIII monitor 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 GoTo 4 Turn the ignition off Disconnect the C1 and C2 PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 1 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 GoTo 5 No Repair the open in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K1 MAP Signal circuit at the MAP All Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K 1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 9 Turn the ignition off Disconnect the C1 and C2 PCM harness connec
46. 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 64 DRIVEABILITY NGC Symptom PO113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH When Monitored and Set Condition P0O113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition ThelntakeAir Temperature IAT sensor circuit voltage at the PCM goes above 4 9 volts One Trip Failure POSSIBLE CAUSES IAT SENSOR VOLTAGE ABOVE 4 9 VOLTS IAT SENSOR K21 IAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K21 IAT SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the IAT Sensor voltage Is the voltage above 4 9 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the IAT harness connector Connect a jumper wire between the K21 IAT Signal circuit and the K 900 Sensor ground circuit at the IAT harness connector Ignition on engine not running With the DRBIII read the IAT Sensor voltage Is the voltage below 1 0 volt Yes Replace the IAT Sensor Perform POWERTRAIN VERIFICATION
47. tions necessary to meet the requirements of Cali fornia 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 pas senger 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 MIL Lamp Strategy I M Readiness OK totest 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 In order to meet mandated regulations a new feature has been added to engine control modules for 2002 to provide an OBDII I M In Field Inspection amp Maintenance readiness indicator When the engine controller is in in field mode turning the key on with the engine off will activate the MIL light for approximately 15 seconds After this time if the vehicle is ready for I M testing the MIL light will remain fully illuminated If the vehicle is not ready the MIL light will blink for approximately 5 seconds and then remain on until the first engine crank or the key is
48. 28 C 5 F Two Trip Fault POSSIBLE CAUSES LOW COOLANT LEVEL THERMOSTAT OPERATION ECT SENSOR ACTION APPLICABILITY NOTE If a Engine Coolant Temperature ECT DTC is set along with this All 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 Yes GoTo 2 No Inspect the vehicle for a coolant leak and add the necessary amount of coolant Perform POWERTRAIN VERIFICATION TEST VER 5 80 DRIVEABILITY NGC P0125 INSUFFICIENT COOLANT TEMP FOR CLOSED LOOP FUEL CON TROL Continued ACTION APPLICABILITY NOTE This test works best if performed on a cold engine cold soak All Ignition on engine not running With the DRBIII 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
49. Data 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 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 accor dance 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 22 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 ACTION APPLICABILITY Perform the symptom Checking PCM Power and Ground Circuits in the Driveability All category NOTE With the DRBIII in the generic scan tool mode attempt to commu nicate with the PCM NOTE If the DRBIII 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 t
50. IAC Current above 999 mA Yes GoTo 2 No RefertothelNTERMITTENT CONDITON Symptom Diagnostic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the IAC Motor harness connector With the DRBIII monitor the IAC Current Ignition on engine not running Does the DRBII display IAC Current at OmA Yes Replace the IAC Motor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 191 DRIVEABILITY NGC PO509 IAC VALVE SIGNAL CIRCUIT HIGH Continued ACTION APPLICABILITY With the DRBIII actuate the ASD Relay Measure the voltage on the K961 IAC Signal circuit in the IAC Motor harness connector Is the voltage above 0 5 of a volt Yes Repair the short to voltage in the K961 IAC Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Measure the voltage on the K61 IAC Control circuit in the IAC Motor harness connector Is the voltage above 0 5 of a volt Yes Repair the short to voltage in the K61 IAC Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE Stop the ASD Relay actuation before continuing Control circuit in the IAC Motor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K61 IAC Control circuit and the K961 IAC Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 6 NOTE Before continuing check the PCM ha
51. INA 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 lightly tap on the Cam Position Sensor Observe the lab scope screen Start the engine Observe the lab scope screen Are there any irregular or missing signals Yes Replace the Cam Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Turn the ignition off All Carefully disconnect the Battery Ground cable Remove the Crankshaft Position Sensor Inspect the Tone Wheel Flex Plate slots for damage foreign material or excessive movement Were any problems found 131 DRIVEABILITY NGC P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY If there are no possible causes remaining view repair Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C2 PCM harness connector Disconnect the CKP Sensor connector Ignition on engine not running Measure the voltage on the K 24 CKP Signal circuit in the Sensor harness connector Wiggle the related wire harness while taking this measurement Does the voltage ever increase above 5 5 volts Yes Repair the short to voltage in the K 24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 9 Measure the resistance between gro
52. Is the resistance above 5 0 ohms Yes Repair the Transfer Case Position Sensor input circuit for an open No GoTo 3 317 TRANSFER CASE MECHANICAL P0839 4WD MODE SENSOR HIGH Continued ACTION APPLICABILITY Turn the ignition off to the lock position Disconnect the Powertrain Control Module harness connector CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Disconnect the Transfer Case Position Sensor harness connector Turn the ignition on Measure the voltage of the Transfer Case Position Sensor Input circuit Is there any voltage present Yes Repair the Transfer Case Position Sensor input circuit for a short to voltage No GoTo 4 Turn the ignition off to the lock position All Measure the resistance between the Transfer Case Position Sensor Input circuit and the Sensor Return circuit in the PCM ECM harness connector Is the resistance between 55 ohms and 1 3k ohms Yes GoTo 5 No Replace the Transfer Case Position Sensor If there are no possible causes remaining view repair Repair Replace and program the Powertrain E ngine Control Module per the Service Information Perform the appropriate Powertrain verification test The conditions to set this DTC are not present at this time
53. K1 MAP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K1 MAP SIGNAL CIRCUIT OPEN K1 MAP SIGNAL CIRCUIT SHORTED TO THE F856 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Start the engine All With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII read the MAP Sensor voltage Is the voltage above 4 93 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the MAP Sensor harness connector Connect a jumper wire between the K1 MAP Signal circuit and the K 900 Sensor ground circuit in the harness connector Ignition on engine not running With the DRBIII monitor the MAP Sensor voltage Is the voltage below 1 0 volt Yes Replace the MAP Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 58 DRIVEABILITY NGC P0108 MAP SENSOR CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Ignition on engine not running Using a 12 volt test light connected to ground probe the K1 MAP Signal circuit at the MAP Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VE
54. K52 Evap Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 70 Evap Purge Sol Signal circuit from the Evap Purge Solenoid harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K 70 Evap Purge Sol Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K 70 Evap Purge Sol Signal circuit at the Evap Purge Solenoid harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the K70 Evap Purge Sol Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Ignition on engine not running Using a 12 volt test light connected to ground probe the K 70 E vap Purge Sol Signal circuit in the Evap Purge Solenoid harness connector Does the test light illuminate brightly Yes Repair the short to battery voltage in the K 70 Evap Purge Sol Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 8 156 DRIVEABILITY NGC P0443 EVAP PURGE SOLENOID CIRCUIT Continued ACTION APPLICABILITY NOTE Before continuing check the
55. MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance in the K44 CMP Signal circuit from the CMP harness connector to the appropriate terminal of special tool 8815 Wiggle the related wire harness while taking this measurement Is the resistance below 5 0 ohms Yes GoTo 10 No Repair the excessive resistance in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 140 DRIVEABILITY NGC P0344 CAMSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 141 DRIVEABILITY NGC Symptom List P0420 CATALYST 1 1 EFFICIENCY P0430 CATALYST 2 1 EFFICIENCY a Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P0420 CATALYST 1 1 EFFI CIENCY When Monitored and Set Condition P0420 CATALYST 1 1 EFFICIENCY When Monitored After engine warm up to 70 C 158 F 180 seconds of open throttle operation at a speed greater than 18 mph and less than 55
56. NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 22 TP Sensor No 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 GoTo 5 No Repair the open in the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 7 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 Measure the resistance between the
57. 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 on the DRBIII screen should stay relatively close to each other Using the appropriate service information determine the proper opening tempera ture of the thermostat Did the thermostat open at the proper temperature Yes GoTo 3 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 Ignition on engine not running With the DRBIII 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 e
58. NOTE This code is enabled on engines with a plastic intake manifold and is All intended to shut down the engine if a large crack occurs 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 vacuum leaks Inspect the PCV system for proper operation or vacuum leaks Inspect the MAP Sensor for proper installation Were any vacuum leaks found Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 44 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED Continued ACTION APPLICABILITY Turn the ignition off Disconnect the TP Sensor harness connector Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F855 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 GoTo 6 No Repair the excessive resistance in the F 855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and F855 5 volt Supply dircuit at the TP Sensor harness connector Is the resistance
59. No GoTo 8 Measure the resistance between ground and the V32 S C Supply circuit in the Brake Switch harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 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 4 229 DRIVEABILITY NGC Symptom List PO600 SE RIAL COMMUNICATION LINK P0601 INTERNAL MEMORY CHECKSUM INVALID Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO60O0 SERIAL COMMUNICA TION LINK When Monitored and Set Condition PO600 SERIAL COMMUNICATION LINK When Monitored With the ignition on Set Condition Internal Bus communication failure between processors P0O601 INTERNAL MEMORY CHECKSUM INVALID When Monitored With the ignition on Set Condition Internal checksum for software failed does not match calculated value POSSIBLE CAUSES PCM INTERNAL OR SPI APPLICABILITY The Powertrain Control Module is reporting internal er
60. P0836 4WD MUX SWITCH STUCK 000 0 cece cece ee eeeeeeeeeeeeeees 310 P0837 4WD MUX SWITCH PERFORMANCE 0cceeeeeeeeseeeees 313 P0838 4WD MODE SENSOR LOW 00 0 annaa rnaar rraren 315 P0839 4WD MODE SENSOR HIGH 00 cece cece eeeeeeeeeeeeeeees 317 TRANSMISSION 42RLE P0122 THROTTLE POSITION SENSOR APPS LOW 0c 0cceeeeeeees 319 P0123 THROTTLE POSITION SENSOR APPS HIGH 0 0eceeeeeeees 321 P0124 THROTTLE POSITION SENSOR APPS INTERMITTENT 00 323 P0218 HIGH TEMPERATURE OPERATION ACTIVATED 00 0eeeee ees 325 P0562 LOW BATTERY VOLTAGE 0 ccccecceceeeeeeeeeueveseeeeees 327 P0602 CONTROL MODULE PROGRAMMING ERROR 0 00000 331 POGO4 INTERNAL TCM 0 0cc cece cece ee eeeeeeveuveeetevenereeness 332 GENERAL INFORMATION Important The Powertrain Control Module and Transmission Control Module have been combined into single control module on all vehicles equipped with a 2 4L and 3 7L engines This new module is the Next Generation Controller NGC New Diagnostics procedures along with new DTC s 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 D C1 BLK C2 ORANGE 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 8638 terminal
61. PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F856 5 volt Supply circuit from the A C Pressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open in the F 856 5 volt Supply circuit 202 DRIVEABILITY NGC Symptom P0533 A C PRESSURE SENSOR HIGH When Monitored and Set Condition P0533 A C PRESSURE SENSOR HIGH When Monitored Engine running A C is Learned and the AC Clutch Relay energized Set Condition The A C pressure sensor signal at the PCM goes above 4 92 volts for 2 6 seconds One trip Fault POSSIBLE CAUSES A C PRESSURE SENSOR VOLTAGE ABOVE 4 6 VOLTS A C PRESSURE SENSOR C18 A C PRESSURE SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE C18 A C PRESSURE SIGNAL CIRCUIT OPEN C18 A C PRESSURE SIGNAL CIRCUIT SHORTED TO THE K856 5 VOLT SUPPLY K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY NOTE Make sure the A C refrigerant System is properly charged per the All Service Information Start the engine With the DRBIII read the A C Pressure Sensor voltage Is the voltage above 4 6 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure
62. PCM harness connector terminals for All 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 5 157 DRIVEABILITY NGC Symptom P0452 NVLD PRESSURE SWITCH STUCK CLOSED E When Monitored and Set Condition P0452 NVLD PRESSURE SWITCH STUCK CLOSED When Monitored Immediately after the engine has been started Set Condition ThePCM activates the NLVD Solenoid If PCM does not see NVLD switch open an error is detected One Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO EVAP PURGE SOLENOID LEAKS STUCK OPEN K52 EVAP PURGE SOL CONTROL CIRCUIT SHORTED TO GROUND NVLD SWITCH OPERATION NVLD ASSEMBLY K107 NVLD SWITCH SIGNAL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Check for any related TSBs before continuing All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the EVAP Purge Solenoid harness connector
63. PDC Disconnect the A C Clutch harness connector Measure the voltage of the A C Clutch Relay Output circuit Is the voltage above 1 0 volt Yes Repair theA C Clutch Relay Output circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the A C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the BCM C1 harness connector Disconnect the A C Heater Control C1 harness connector Measure the resistance of the A C On Off Control circuit between the A C Heater Control C1 harness connector and ground Is the resistance below 10K ohms Yes Repair the A C On Off Control Circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Make sure that the BCM C1 harness connector is connected to the BCM Disconnect the A C Heater Control C1 harness connector Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while connecting a jumper wire between ground and theA C On Off Control circuit in the A C Heater Control C1 harness connector Does the A C Select Switch state change from Off to On when the jumper wire is connected Yes Replace the A C Heater Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Replace and program the Body Control Module in accordance with the Service Inform
64. PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measurethe resistance of the K 24 CKP Signal circuit from the CKP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 9 No Repair the open in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K 24 CKP Signal circuit at the CKP Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the K 24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 Turn the ignition off All Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the F 855 5 volt Supply circuit at the CKP Sensor harness connector Is the voltage above 5 5 volts Yes Repair the short to voltage in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F855 5 volt Supply circuit from the CKP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 12 No
65. PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS With a 12 volt test light connected to ground and with special tool 8815 installed probe the F11 Fused Ignition Switch Output circuit Perform the above check with the Ignition key in the off lock position Ignition on engine not running position and during cranking Wiggle the related wire harness while probing the special tool with the test light to try to interrupt the circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the open or excessive resistance in the F11 Fused Ignition Switch Offf Run Start circuit nspect the related fuse if the fuse is open check the circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 271 DRIVEABILITY NGC U0101 NO BUS MESSAGE FROM TRANS CONTROL MODULE Continued ACTION APPLICABILITY NOTE Determine which modules this vehicle is equipped with before All beginning NOTE When attempting to communicate with any of the modules on this vehicle the DRBIII will display 1 of 2 different communication errors a NO RESPONSE message or a BUS Y SIGNALS OPEN MESSAGE Ignition on engine not running Use the DRBIII attempt to communicate with the remaining control modules Was the DRBIII able to communicate with one or more of the Modules Yes Replace
66. Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the EVAP Purge Solenoid harness connector Ignition on engine not running Using a 12 volt test light jump across the K52 Evap Purge Sol Control circuit and K70 Evap Purge Sol Signal circuit in the EVAP Purge Solenoid harness connector With the DRBIII actuate the EVAP Purge Solenoid Does the test light flash on and off Yes Replace the EVAP Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 155 DRIVEABILITY NGC P0443 EVAP PURGE SOLENOID CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K52 Evap Purge Sol Control circuit from the Evap Purge Solenoid harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the K52 Evap Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K 52 Evap Purge Sol Control circuit at the Evap Purge Solenoid harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the
67. Purge Solenoid hold vacuum Yes GoTo 10 No Replace the EVAP Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Connect the vacuum hoses before continuing 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 GoTo 14 Ignition on engine not running NOTE Perform the following test on the O2 Sensors whose voltage was not switching properly in the previous step Disconnect the O2 Sensor harness connector With the DRBIII monitor the O2 Sensor voltage O2 Sensor voltage should read 5 0 volts on the DRBIII 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 wi
68. Repair all other Transfer Case DTCs before proceeding No GoTo 2 Verify proper Transfer Case Shifter adjustment per the Service Information Is the Transfer Case Shifter adjusted correctly Yes GoTo 3 No Adjust the Transfer Case shifter linkage per the Service Informa tion Turn the ignition off to the lock position Disconnect the PCM harness connector s CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Measure the resistance across the Transfer Case Position Sensor signal circuit and Sensor Ground circuit at the PCM harness connector Place the transfer case in each of the following positions 2H resistance should be between 1124 and 1243 ohms 4H resistance should be between 650 and 719 ohms N resistance should be between 389 and 431 ohms AL resistance should be between 199 and 221 ohms Were all resistance values in each transfer case position within the specified range Yes GoTo 4 No Replace the Transfer Case Position Sensor 313 TRANSFER CASE MECHANICAL P0837 4WD MUX SWITCH PERFORMANCE Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Engine Control Module per the Service Information
69. Repair the Transfer Case Position Sensor input circuit for a short to ground No GoTo 3 315 TRANSFER CASE MECHANICAL P0838 4WD MODE SENSOR LOW Continued ACTION APPLICABILITY Measure the resistance between the Transfer Case Position Sensor Input circuit and the Sensor Return circuit in the PCM ECM harness connector Is the resistance above 1000 0 ohms Yes GoTo 4 No Repair the Transfer Case Position Sensor Input circuit for a short to the Sensor Return circuit Measure the resistance between the Transfer Case Position Sensor Input circuit and the Sensor Return circuit in the PCM ECM harness connector Is the resistance between 55 ohms and 1 3k ohms Yes GoTo 5 No Replace the Transfer Case Position Sensor If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Engine Control Module per the Service Information Perform the appropriate Powertrain verification test The conditions to set this DTC are not present at this time Note Use the Freeze Frame Data to help duplicate the conditions that set the DTC Pay particular attention to the DTC set conditions such as VSS MAP ECT and Load Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Te
70. Return circuit at the O2 Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the O2 Return circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 Measure the voltage on the O2 Return circuit at the O2 Sensor harness connector All Is the voltage at 2 5 volts Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 91 DRIVEABILITY NGC Symptom List P0132 O2 SENSOR 1 1 CIRCUIT HIGH VOLTAGE P0138 O2 SENSOR 1 2 CIRCUIT HIGH VOLTAGE P0152 O2 SENSOR 2 1 CIRCUIT HIGH VOLTAGE P0158 O2 SENSOR 2 2 CIRCUIT HIGH VOLTAGE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO132 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 4 volts Set Condition The Oxygen Se
71. 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 accurately diagnose intermittent faults The transmission simulator simply put is an electronic device that simulates the electronic func tions of any EATX or NGC controlled transmission not The Simulators basic function is to aid the techni cian 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 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
72. SWITCH CLOCKSPRING V37 S C SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT V37 S C SIGNAL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY NOTE Do not press any of the Speed Control Switch buttons All Ignition on engine not running With the DRBIII read the Speed Control voltage Is the Speed Control voltage below 1 0 volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 With the DRBIII monitor the Speed Control Switch voltage Disconnect the Speed Control On Off Switch harness connector Did the voltage change to above 4 7 volts Yes Replace the Speed Control On Off Switch Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 3 With the DRBIII monitor the Speed Control Switch voltage Disconnect the Speed Control Resume Accel Switch harness connector Did the voltage change to above 4 7 volts Yes Replace the Speed Control Resume Accel Switch Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 4 216 DRIVEABILITY NGC P0580 SPEED CONTROL SWITCH NO 1 LOW Continued ACTION APPLICABILITY 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 DRBIII in Sensors read the S C Switch voltage Did the S C Switch volts change to 5 0 volts Yes Repl
73. 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 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 Yes GoTo 6 No Repair the PCI Bus circuit for an open Perform SKIS VERIFICATION 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 27 COMMUNICATION Symptom NO RESPONSE FROM TRANSMISSION CONTROL MODULE NGC 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 ACTION APPLICABILITY Turn the ignition on All 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 Yes GoTo 2 No Refer tothe Communications category and perform the appropri ate symptom Perfo
74. Sensor Temperature value Using the DRB Temperature Probe CH 7050 measure the engine coolant tempera ture Is the ECT Sensor value with 15 C 5 F of the temperature probe reading Yes GoTo 6 No GoTo 7 Inspect the Temperature sensors for any physical damage Inspect the engine coolant Make sure the coolant is at the proper level Refer to the Service Information COOLING Make sure the Temperature sensors are properly installed Make sure 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 INA 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 TERMI NALS 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 nece
75. TEST VER 1 Repair the A C On Off Control Circuit for an open Perform BODY VERIFICATION TEST VER 1 281 DRIVEABILITY NGC Symptom CHECKING PCM POWERS AND GROUNDS POSSIBLE CAUSES A209 PCM FUSED B CIRCUIT F1 F26 PCM FUSED IGNITION SWITCH OUTPUT CIRCUITS Z130 Z131 PCM GROUND CIRCUITS ACTION APPLICABILITY Turn the ignition off All Disconnect the C1 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 A209 PCM Fused B circuit in the appropriate terminals of special tool 8815 Does the test light illuminate brightly Yes GoTo 2 No Repair the open in the A209 Fused B circuit Inspect the related fuses and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Ignition on engine not running Using a 12 volt test light connected to ground probe the F 1 and F 26 PCM Fused Ignition Switch Output Off Run Start circuits in the appropriate terminals of special tool 8815 Does the test light illuminate brigh
76. Using a 12 volt test light connected to 12 volts probe the ground circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the ground circuit for an open Perform SKIS VERIFICATION Output circuit Does the test light illuminate brightly Yes GoTo 4 No Repair the Fused Ignition Switch Output circuit for an open Perform SKIS VERIFICATION Turn the ignition off Disconnect the SKIM harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform SKIS VERIFICATION Turn the ignition off All Disconnect the SKIM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch 26 COMMUNICATION NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE Continued ACTION APPLICABILITY Note E nsure there is PCI Bus communication with other modules on the All 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 CH 7058 Cable to Probe adapter CH 7062 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 DRBIII select Pep Module Tools
77. VER 4 No GoTo 4 Turn the ignition off NOTE The measurement must be taken from both Speed Control Switch harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V37 S C Signal circuit from the Speed Control harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms for both measurement Yes GoTo 5 No Repair the open in the V37 S C Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Measure the resistance between ground and the V37 S C Signal circuit at the Speed Control harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the V37 S C Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 6 251 DRIVEABILITY NGC P1593 SPEED CONTROL SWITCH NO 1 STUCK Continued ACTION APPLICABILITY Disconnect the C2 and C3 PCM harness connectors All Measure the resistance between the V37 S C Signal circuit and the K900 Sensor ground circuit in the Speed Control harness connector Is the resistance below 5 0 ohms Yes Repair the short between the V37 S C Signal circuit and the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 7 NOTE The mea
78. VERIFICATION TEST VER 1 329 TRANSMISSION 42RLE P0562 LOW BATTERY VOLTAGE Continued ACTION APPLICABILITY Turn the ignition off to the lock position All Install a substitute Relay in place of the Transmission Control Relay Start the engine Using a voltmeter measure the battery voltage With the DRBIII monitor the Transmission Switched Battery Voltage Compare the DRBIII Transmission Switched Battery voltage to the actual battery voltage Is the DRBIII voltage within 2 0 volts of the battery voltage Yes Replace the Transmission Control Relay Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 GoTo 8 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits Check for any Technical Service Bulletins TSB s and S T A R ON LINE for any possible causes that may apply If there are no possible causes remaining view repair Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorts and open circuits With the DRBIII check the EATX EVENT DATA to help identif
79. actuated Yes GoTo 5 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 6 Connect the previously disconnected vacuum hose Start the engine Allow the engine to idle Using the DRBIII perform the NVLD FORCED MONITOR TEST Monitor the NVLD Switch state NOTE As the test runs the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the test is complete Did the NVLD Switch operate as described above Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 6 Disconnect the vacuum supply hoses from the EVAP Purge Solenoid All Using a hand vacuum pump apply 10 in Hg to the CAN side of the EVAP Purge 145 DRIVEABILITY NGC P0440 GE NERAL EVAP SYSTEM FAILURE Continued ACTION APPLICABILITY To continue testing you will need Miller Tool 8404 Evaporative Emission Leak All 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 Connect the red power lead of EELD to the battery positive terminal and the black ground lead to battery negative terminal NOTE See Charts and Graph support material EELD Calibration Setup
80. 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 prob lems and some hydraulic problems When a prob lem is sensed the PCM stores a diagnostic trouble code Some of these codes cause the Transmission to go into Limp in mode Whilein this mode electrical power is taken away from the Transmission via the PCM de energizing the transmission control relay and taking power from the solenoid pack When this happens the only Transmission mechanical func tions are Park and Neutral Reverse Second Gear No upshifts or downshifts are possible The posi tion of the manual valve alone allows the three ranges that are available Although vehicle perfor mance is seriously degraded while in this mode it allows the owner to drive the vehicle in for service Once the DRBIII is in the Transmission portion of the diagnostic program it constantly monitors the transmission to see if the system is in Limp in mode If the Transmission is in Limp in mode the DRBIII will flash the red LED 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 de fault mode Once the DRBIII is
81. and the B15 Brake Switch No 1 Signal terminal at the Brake Lamp Switch Apply and release the brake pedal plunger while monitoring the ohmmeter Does the resistance change from below 5 0 ohms to an open circuit Yes GoTo 3 No Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Disconnect the C3 PCM harness connector Measure the resistance between ground and the B15 Brake Switch No 1 Signal circuit in the Brake Lamp Switch harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the B15 Brake Switch No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 4 212 DRIVEABILITY NGC P0572 BRAKE SWITCH NO 1 CIRCUIT LOW Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 4 213 DRIVEABILITY NGC Symptom P0573 BRAKE SWITCH NO 1 CIRCUIT HIGH ET a When Monitored and Set Condition P0573 BRAKE SWITCH NO 1 CIRCUIT HIGH When Monitored Ignition on Set Conditio
82. area well ventilated NOTE The fuel tank should have between 20 and 80 of fuel tank capacity to properly test the Evap system Connect the red power lead of the EELD 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 Block the vent hose of the EVAP Canister Connect shop air to the 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 if equipped or install the 8404 ADP service adapter in the NVLD filter line 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 lower fuel levels or if the vehicle is equipped with a Flow Management Valve may indicate high flow and will 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 th
83. below 8500 ft Set Condition IfthePCM multiplies short term compensation by long term adaptive and a purgefuel multiplier and the result is below a certain value for 30 seconds over twotrips a freeze frame is stored the MIL illuminates and a trouble code is stored PO175 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 Ifthe PCM multiplies short term compensation by long term adaptive and a purgefuel multiplier and the result is below a certain value for 30 seconds over twotrips a freeze frame is stored the MIL illuminates and a trouble code is stored POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO O2 SENSOR HEATER OPERATION O2 SENSOR O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT THROTTLE POSITION SENSOR VOLTAGE GREATER THAN 0 92 VOLTS WITH THROTTLE CLOSED THROTTLE POSITION SENSOR SWEEP MAP SENSOR ECT SENSOR EVAP PURGE SOLENOID OPERATION ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR HIGH PCM 106 DRIVEABILITY NGC P0O172 F UEL SYSTEM 1 1 RICH Continued ACTION APPLICABILITY 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 DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer
84. below the above specification Yes Replace the leaking Fuel njector s Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 Ignition on engine not running Using the DRBIII 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 Yes GoTo 9 No GoTo 10 NOTE Turn the ignition off remove the Fuel Pressure gauge and connect the fuel lines before continuing 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
85. 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 59 DRIVEABILITY NGC Symptom PO111 INTAKE AIR TEMPERATURE SENSOR PERFORMANCE When Monitored and Set Condition PO111 INTAKE AIR TEMPERATURE SENSOR PERFORMANCE When Monitored The engine off timeis 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 The AT Sensor value is not within 10 deg C 18 deg F of the other two temperature sensors Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO K21 IAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE IAT SENSOR K21 IAT SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN K21 IAT SIGNAL CIRCUIT SHORTED TO GROUND K21 IAT SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe I
86. cycle and noVSS MAF MAP ECT TPS ETC CRK Sensor DTCs nor any fuel system or injector DTCs Set Condition Engine speed is 200 RPM or more above idle speed for 7 seconds Two Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO AIR INDUCTION SYSTEM VACUUM LEAKS IAC OPERATION PCM ACTION APPLICABILITY NOTE If any other DTCs are present they must be diagnosed and repaired All before continuing this test Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Inspect the Air Induction System for the following problems Restrictions Dirty Air Cleaner Foreign material trap 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 5 No GoTo 3 187 DRIVEABILITY NGC P0507 IDLE SPEED PERFORMANCE HIGHER THAN EXPECTED Continued ACTION APPLICABILITY Start the engine All Inspect the vehicle for external vacuum leaks Inspect the engine for internal leaks Were any vacuum leaks found Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No
87. damaged e Do not use the test leads if the insulation is damaged or if metal is exposed e To avoid electrical shock do not touch the test leads tips or the circuit being tested e Choose the proper range and function for the measurement Do not try voltage or current mea surements that may exceed the rated capacity e Donot exceed the limits shown in the table below Volts 0 500 peak volts AC 0 500 volts DC Ohms resistance 0 1 12 megohms Temperature Frequency Measured 0 10kHz Frequency Generated 50 600 C 58 1100 F Ohms cannot be measured if voltage is present Ohms can be measured only in a non powered circuit e Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC e Use caution when measuring voltage above 25v DC or 25v AC e A 10A fuse or circuit breaker must protect the circuit being tested GENERAL INFORMATION e Usethe low current shunt to measure circuits up to 10A Use the high current clamp to measure circuits exceeding 10A e When testing for the presence of voltage or cur rent make sure the meter is functioning cor rectly Take a reading of a known voltage or current before accepting a zero reading e When measuring current connect the meter in series with the load e Disconnect the live test lead before disconnecting the common test lead e When using the meter function keep the DRBIII away from spark plug or coil wires to avoid measur
88. ground in the Fused B circuit Inspect and replace fuses as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Ignition on engine not running Using a 12 volt test light connected to ground probe the PCM Fused Ignition Switch Output circuit in the PCM harness connector Does the test light illuminate brightly Yes GoTo 3 No Repair the Ignition Switch Output circuits Inspect and replace fuses as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 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 GoTo 4 No Repair the Z81 282 PCM ground circuits Perform POWERTRAIN VERIFICATION TEST VER 1 304 STARTING NO RESPONSE FROM PCM WITH ANO START CONDITION Continued ACTION APPLICABILITY Connect the PCM harness connectors Disconnect the TP Sensor harness connector Ignition on engine not running Measure the voltage on the F 855 5 volt Supply circuit Is the voltage between 4 5 and 5 2 volts Yes GoTo 5 No GoTo 6 Turn the ignition off Disconnect the MAP Sensor harness connector NOTE Connect the TP Sensor harness connector Ignition on engine not running Measure the voltage on the MAP Sensor 5 Volt Supply circuit Is the voltage between 4 5 and 5 2 volts Yes If communication is available with a PCM on a l
89. have damaged the O2 Sensor and Catalytic Converter contaminated fuel unapproved silicone oil and cool ant repair necessary Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 GoTo 3 Inspect the exhaust for leaks between the engine and the appropriate rear O2 Sensor Are there any exhaust leaks Yes Repair or replace the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Check the exhaust for excessive smoke caused by an internal problem in the engine Is an engine mechanical condition present Yes Repair the engine mechanical condition as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 A new rear O2 Sensor along with an aging front O2 Sensor may cause the DTC to set Review the vehicles repai
90. ignition off All Disconnect the PCM harness connector Disconnect the DRBIII from the DLC CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 Yes GoTo 9 No Repair the PCM SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 25 COMMUNICATION Symptom NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE POSSIBLE CAUSES ATTEMPT TO COMMUNICATE WITH THE BCM GROUND CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN OPEN PCI BUS CIRCUIT SENTRY KEY IMMOBILIZER MODULE ACTION APPLICABILITY Turn the ignition on With the DRB enter Body then Body Computer Was the DRB able to I D or communicate with the BCM Yes GoTo 2 No Refer to the symptom list for problems related to no communica tion with the BCM Perform SKIS VERIFICATION Turn the ignition off Disconnect the SKIM harness connector
91. in the Transmission 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 DRBIII will flash the red LED GENERAL INFORMATION TRANSMISSION OPERATION AND SHIFT SCHEDULING AT VARIOUS OIL TEMPERATURES The transmission covered in this manual has unique shift schedules depending on the tempera ture 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 Temper ature Sensor on the 42RLE transmission The Tem perature Sensor is an integral component of the Transmission Range Sensor TRS If the Tempera ture Sensor is faulty the transmission will default to a calculated oil temperature Oil temperature will then be calculated through a complex heat transfer equation using engine coolant tempera ture battery ambient temperature and engine off time from the Body Control Module BCM These inputs are received from the PCI bus periodically and 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 us ing calculated oil temperature track oil tempera ture reasonably accurate during no
92. of a volt for 2 6 seconds One Trip Fault POSSIBLE CAUSES A C PRESSURE SENSOR VOLTAGE BELOW 0 6 OF A VOLT F856 5 VOLT SUPPLY CIRCUIT OPEN F856 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 THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY NOTE Make sure the A C refrigerant System is properly charged per the All Service Information Start the engine With the DRBIII read the A C Pressure Sensor voltage Is the voltage below 0 6 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit in the A C Pressure Sensor harness connector Is the voltage between 4 5 to 5 2 volts Yes GoTo 3 No GoTo 6 With the DRBIII monitor theA C Pressure Sensor voltage with the Sensor harness connector disconnected Is the voltage above 0 6 of a volt Yes Replace the A C Pressure Sensor Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 4 201 DRIVEABILITY NGC P0532 A C PRESSURE SENSOR LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C1 PCM harness connector Measure the resistance between g
93. off All Disconnect the PCM harness connectors Disconnect the SKIM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit from the SKIM harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the PCI Bus circuit between the PCM and the SKIM Perform SKIS VERIFICATION Connect the PCM harness connectors Replace the Sentry Key Immobilizer Module in accordance with the Service Infor mation 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 Yes Replace and program the Powertrain Control Moldule per service Information Perform SKIS VERIFICATION No Test Complete 275 DRIVEABILITY NGC Symptom A C OPERATES IN ALL MODE SWITCH POSITIONS POSSIBLE CAUSES CHECK FOR PCM DTCS POWERTRAIN CONTROL MODULE A C CLUTCH A C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE A C CLUTCH RELAY CHECK A C ON OFF CONTROL CIRCUIT FOR A SHORT TO GROUND A C HEATER CONTROL MODULE BODY CONTROL MODULE ACTION APPLICABILITY With the DRBII
94. 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 89 DRIVEABILITY NGC Symptom List P0131 O2 SENSOR 1 1 CIRCUIT LOW VOLTAGE P0137 O2 SENSOR 1 2 CIRCUIT LOW VOLTAGE P0O151 O2 SENSOR 2 1 CIRCUIT LOW VOLTAGE P0O157 O2 SENSOR 2 2 CIRCUIT LOW VOLTAGE ___ ____ _ E ee ee Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO131 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 4 volts Set Condition The oxygen sensor signal voltage is below 2 411 volts for 10 24 seconds after starting engine One Trip Fault 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 4 volts Set Condition The oxygen sensor signal voltage is below 2 411 volts for 10 24 seconds after starting engine One Trip Fault P0151 02 SENSOR 2 1 CIRCUIT LOW VOLTAGE When Monitored Engine running for less than 30 seconds and the O2 Sensor Heater
95. 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 lt 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 F or the monitor run conditions select the BANK 1 CAT MON PRE TEST in the DRB II1 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 ranges to allow the monitor to complete itself For the monitor run conditions select the EGR PRE TEST in the DRB III 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 PRE TEST in the DRB III OBD II Monitors Menu 3 2 3 TRANSMISSION CONTROL The 42RLE electronic Transmission has a fully adaptive control system The system performs it s functions based on continuous real time sensor feedback information The control system automat ically
96. the PCM harness connector terminals for All 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 Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 133 DRIVEABILITY NGC Symptom P0340 CAMSHAFT POSITION SENSOR CIRCUIT ETE When Monitored and Set Condition P0340 CAMSHAFT POSITION SENSOR CIRCUIT When Monitored Engine cranking running Battery voltage greater than 10 volts Set Condition At least 5 seconds or 2 5 engine revolutions have elapsed with crankshaft position sensor signals present but no camshaft position sensor signal POSSIBLE CAUSES INTERMITTENT CMP SIGNAL INTERMITTENT CKP SIGNAL F856 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE F856 5 VOLT SUPPLY CIRCUIT OPEN F856 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K44 CMP SIGNAL CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL CIRCUIT OPEN K44 CMP SIGNAL CIRCUIT SHORTED TO GROUND K44 CMP SIGNAL SHORTED TO THE F856 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN CAMSHAFT POSITION SENSOR PCM ACTION APPLICABILITY Crank the engine All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed an
97. the ignition off Disconnect the Fuel Injector harness connector Ignition on engine not running With the DRBIII actuate the ASD Relay Using a 12 volt test light connected to ground backprobe the F142 ASD Relay Output circuit at the Fuel Injector harness connector Does the test light illuminate brightly Yes GoTo 3 No Repair the open or short to ground in the F142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Using a 12 volt test light connected to 12 volts backprobe the Injector Control circuit With the DRBIII actuate the Fuel Injector What is the state of the test light during the actuation Brightly blinking Replace the Fuel Injector Perform POWERTRAIN VERIFICATION TEST VER 5 ON constantly GoTo 4 OFF constantly GoTo 5 112 DRIVEABILITY NGC P0201 FUEL INJ ECTOR NO 1 CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the C2 PCM harness connector Measure the resistance between ground and the Injector Control circuit at the Injector harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TER
98. to the Driveability category and perform the appropriate symptom Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 No GoTo 3 323 TRANSMISSION 42RLE P0O124 THROTTLE POSITION SENSOR APPS INTERMITTENT Continued ACTION APPLICABILITY With the DRBII1 record the EATX EVENT DATA to help identify the conditions in All which the DTC was set With the DRBIII erase Transmission DTCs NOTE To erase EATX EVENT DATA information a BATTERY DISCONNECT must be performed Performing a BATTERY DISCONNECT will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA With the DRBIII read Transmission DTCs Did the DTC P0124 THROTTLE POSITION SENSOR INTERMITTENT reset Yes GoTo 4 No GoTo 6 Ignition On Engine Not Running With the DRBIII under Transmission Sensors monitor the TPS voltage in the following step Slowly open and close the throttle while checking for erratic voltage changes Did the TPS voltage change smooth and consistent Yes GoTo 5 No Replace the Throttle Position Sensor per the Service Information Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 NOTE Due to the integration of the Powertrain and Transmission Control Modules communication between the modules is internal Using the schematics as a guid
99. to the INTERMITTENT CONDITION Symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 82 DRIVEABILITY NGC P0128 THERMOSTAT RATIONALITY Continued ACTION APPLICABILITY NOTE If a Engine Coolant Temperature ECT DTC is set along with this All code diagnose the ECT DTC first NOTE Inspect the ECT terminals and related PCM terminals Make sure 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 GoTo 3 No Inspect the vehicle for a coolant leak and add the necessary amount of coolant Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE This test works best if performed on a cold engine cold soak Ignition on engine not running With the DRBIII 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 engi
100. tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 6 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the A C Pressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 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 Measure the resistance between the C18 A C Pressure Signal circuit and the K 855 All 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 F 856 5 volt Supply circuit and the C18 A C Pres
101. tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 WARNING The fuel system is under a constant pressure even with the All 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 DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Turn the ignition off Choose a conclusion that best matches your fuel pressure reading Within Specification GoTo 3 Above Specification Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION Stop All Actuations 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 DRBIII monitor all of the O2 Sensor voltage readings Is the voltage switching between 2 5 and 3 4 volts Yes GoTo 4 No GoTo 11 Turn the igniti
102. vacuum value Is the DRB reading within 1 of the Vacuum Gauge reading Yes GoTo 8 No Replace the MAP Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Remove the vacuum gauge before continuing 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 DRBIII read the 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 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 GoTo 9 No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 108 DRIVEABILITY NGC P0O172 FUEL SYSTEM 1 1 RICH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the hoses at the Evap Purge Solenoid Using a hand vacuum pump apply 10 inches of vacuum to the E vap Purge Solenoid vacuum source port on the component side Did the E vap
103. 03 FUEL INJECTOR NO 3 CIRCUIT coctcssove es ceteadeades sande ere wew nes 111 PU204 FUEL INJECTOR NO 4 CIRCUIT o oes uktwsd ee ie been bowk G4 i eed aden 111 P0205 FUEL INJECTOR NO 5 CIRCUIT a3 sovavosenerivews ed s iv iu se eres feeds 111 P0206 FUEL INJECTOR NOG CIRCUIT 102226 oeteyeue sebet ete soe0ce4s eeeeed 111 P0300 MULTIPLE CYLINDER MISFIRE 26 4s2es2 0vus Bese wadee Seeue hes ewews 114 POCO GY UINDER NOT MISFIRE cuese sit oebeueee en pox hee diesen E seus 114 PO302 GYLINDER NO 2 MISFIRE sis cciscedeuvatocivetsacedoue bevewdagwses 114 Pus0s CYLINDER NOS IMISFIRE 20222 beeong se 648enede bowenk ets Keeeun seus 114 POS04 CYLINDER NO 4 MISFIRE 2s2ccec0e cersbovereus cause Sebetousadbees 114 PU305 CYLINDER NO 5 MISFIRE 2ccetceusewnew el eude lice teewetdawsaeee es 114 POS06 CYLINDER NO 6 MISFIRE wcccccatoseeta dee sete se Petateckeneeegeeas 114 P0315 NO CRANK SENSOR LEARNED 2 2cci32cd0 bal de ous eneS ences duce ce es 121 P0325 KNOCK SENSOR NO 1 CIRCUIT 2 2 0 22se cnagewbedenSdevaeedewks 123 P0330 KNOCK SENSOR NO 2 CIRCUIT 2 ish e2cere eo eat cadre bred en ede h eke 123 P0335 CRANKSHAFT POSITION SENSOR CIRCUIT 00000 126 P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT 130 P0340 CAMSHAFT POSITION SENSOR CIRCUIT 0 00000 134 P0344 CAMSHAFT POSITION SENSOR INTERMITTENT 0 138 P0420 CATALYST 1 1 EFFICIENCY o2csetesseeaniieviws ay hYeeeiie Yoeee es 142 P0430 CATALYST 2 1 EFFIC
104. 0330 KNOCK SENSOR NO 2 CIRCUIT When Monitored With the engine running gt 1312 RPM coolant temp gt 65 25 C 149 45 F MAF gt 250mg tdc and no ECT MAF or CAM Sensor DTCs Set Condition The Knock Sensor error program internal to the PCM is on the Knock Sensor voltage is lt 49 volt and the value of the Knock Sensor changes less than 06 volt for gt 11 seconds One Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE KNOCK SENSOR SIGNAL CIRCUIT OPEN KNOCK SENSOR RETURN CIRCUIT OPEN KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO GROUND KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO KNOCK SENSOR RETURN CIRCUIT KNOCK SENSOR ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 123 DRIVEABILITY NGC P0325 KNOCK SENSOR NO 1 CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Knock Sensor harness connector Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage of the Knock Sensor Signal circuit at the K nock Sensor harness connector Is the voltage above 2 0 volts Yes Repair the short to voltage in the Kno
105. 1 0 2 0 3 0 4 0 5 0 TABLE OF CONTENTS INTRODUCTION opsaicatiwecienadspsdmeacin EEO acu A EErEE 1 1 1 SYSTEM COVERAGE o an anona aonane aaeeea raoran rrena 1 1 2 SIX STEP TROUBLE SHOOTING PROCEDURE 0 0cseeeeeeees 1 IDENTIFICATION OF SYSTEM 0cccccecceceeceeeeeseueeeeueeueeues 1 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION a an nennen 2 314 GENERAL DESCRIPTION 0cceeceeceececeeceeceesuveavenres 2 3 2 FUNCTION OPERATION 0 ccceceeeeeceeeeeceeceeeevenveees 2 3 2 1 FUEL CONTROL GAS 0 0 ce cece ee ceeeeeeeeeeeeeees 2 3 2 2 ON BOARD DIAGNOSTICS 0 cece eee eee eeeeeeeeeees 2 3 2 3 TRANSMISSION CONTROL 0 0 0c c eee eeeeeeeeeeeeees 5 3 2 3 1 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT VARIOUS OIL TEMPERATURES 0c 0cseeeecseceeeees 5 3 2 4 O2 SENSOR NGC ccc cece eee eceeeeeeeeteeeeees 6 3 2 5 OTHER CONTROLS vacdveudaventievudesuvicavsetvasavetnerss 6 3 2 6 NON MONITORED CIRCUITS 0 0cceceeeeeeeeeees 10 3 3 DIAGNOSTIC TROUBLE CODES n on naonn naeron rran 10 3 3 1 HARD CODE ouuu aonn cece cece ee eaea earranan 11 3 3 2 ONE TRIP FAILURE nononono naaraana erranera 11 3 3 3 INTERMITTENT CODE ononon naonnaon erarnan 11 3 3 4 STARTS SINCE SET COUNTER 0ccecseeeeeeeeeeees 11 3 3 5 TROUBLE CODE ERASURE onun naana nnana 12 33 6 QUICK LEARN omig cause ruacwaaen diadann denon ndxaanoaaes 12 3 3 7 EATX DTC EVENT DATA
106. 254 DRIVEABILITY NGC P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the C1 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS With a 12 volt test light connected to ground and with special tool 8815 installed probe the F 1 F26 Fused Ignition Switch Output circuits Perform the above check with the Ignition key in the off lock position Ignition on engine not running position and during cranking Wiggle the related wire harness while probing the special tool with the test light to try to interrupt the circuit Does the test light illuminate brightly Yes GoTo 2 No Repair the open or excessive resistance in the F11 Fused Ignition Switch Off Run Start circuit Inspect the related fuse if the fuse is open check the circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 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 The Powertrain Control Module is reporting internal errors view repair to continue Repair Rep
107. 4 3 4 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 incor rectly 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 4 3 5 SERVICE BULLETINS AND RECALLS Always perform all Safety Recalls and Service Bulletins that are applicable to the problem Under the provisions of the warranty 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIII diagnostic read out box scan tool must use the latest release level 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 J umper wires Ohmmeter Oscilloscope Pressure gauge 0 2068 kPa 0 300 PSI Transmission simulator 8833 Electronic Transmission Adapter Kit Miller 8333 1A Vacuum gauge Voltmeter 17 GENERAL INFORMATION 12 volt test light minimum 25 ohms resistance with probe 6801 CAUTION A 12 volt test light should not be used for the following circuits damage to the powertrain controller will occur e 5 volt Supply e 1850 PCI Bus e CCD
108. 57 O2 SENSOR 2 2 CIRCUIT LOW VOLTAGE 00 2000 a ee P0132 O2 SENSOR 1 1 CIRCUIT HIGH VOLTAGE 2 2 2 2 ccc ceca eens P0138 02 SENSOR 1 2 CIRCUIT HIGH VOLTAGE 6 lt scec2eeeetereGees aaa dewtes P0152 02 SENSOR 2 1 CIRCUIT HIGH VOLTAGE w264 csccateee ceeaee easy bated P0158 02 SENSOR 2 2 CIRCUIT HIGH VOLTAGE 2 2200 cece see rede ees P0133 02 SENSOR 1 1 SLOW RESPONSE lt 2c320iecbicbarawaede de ened eae es TABLE OF CONTENTS Continued P0139 02 SENSOR 1 2 SLOW RESPONSE wii een da enw ei dadesaee eben aaees 95 P0153 02 SENSOR 2 1 SLOW RESPONSE s6ccctiveveves en seeuet are esauwa ees 95 P0159 02 SENSOR 2 2 SLOW RESPONSE si 2 4 sou hou 44 504 oieG aes o4 oss be 95 P0135 02 SENSOR 1 1 HEATER PERFORMANCE 2 0 000 ee 97 P0141 O2 SENSOR 1 2 HEATER PERFROMANCE cscicesasteveunucagdavesa 97 P0155 02 SENSOR 2 1 HEATER PERFORMANCE oc36 0 s0vseesese bes awes des 97 P0161 02 SENSOR 2 2 HEATER PERFORMANCE o ucs2024 600850 skees eve e es 97 P0171 FUEL SYSTEM 1 1 LEAN c0c0cb0d saad s Gre cdedbexuvats abun aed ees 100 Pul74 FUEL SYSTEM 2 1 LEAN o perendise heearess eee bekes ooearese KENES 100 P0172 FUEL SYSTEM 1 1 RICH 6 26d eit vansveesie eectiee eee ed ss eee sees RS 106 POl7S FUBL SY STEW 2 1 RICH s lt x 5 20 bs uses Ferme hess wee e EEE Keke ves 106 P0201 FUEL INJECTOR NO 1 CIRCUIT 22 s3ci00civerce te seded Hangs orsieurd 111 P0202 FUEL INJEC TOR NO 2 CIRCUIT 2062 0 seeeees ae Peeees soweaeie eoguau 111 PO2
109. 88 ASD RELAY SENSE CIRCUIT LOW Continued ACTION APPLICABILITY Measure the resistance between ground and the A142 ASD Relay Output circuit at All the Relay connection Is the resistance below 100 ohms Yes Repair the short to ground in the A142 ASD Reay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 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 5 244 DRIVEABILITY NGC Symptom P0700 TRANSMISSION CONTROL SYSTEM MIL REQUEST When Monitored and Set Condition P0O700 TRANSMISSION CONTROL SYSTEM MIL REQUEST When Monitored Ignition on Set Condition An active DTC is stored in the TCM ACTION APPLICABILITY This is an informational DTC letting you know that a DTC s is stored in the All Transmission Control Module Erase this DTC from the PCM after all Transmission DTC s have been repaired Using the DRBIII read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom PCM Diagnostic Information complete Continue Test Complete
110. AND EQUIPMENT 0 0cceeceeeeeeeceueeueeues 17 6 0 7 0 TABLE OF CONTENTS Continued ACRONYMS easier E E E E T E 6 2 DEFINITIONS o ccvaiadte Racdeudsaepeasesiky teaenaeguvtuddedaneins DIAGNOSTIC INFORMATION AND PROCEDURES 2 2eeeeeeees COMMUNICATION NO RESPONSE FROM POM PCI BUS NGO c2n2iestaveeen Mrsaeeeeds eames NO RESPONSE FROM PCM PCM SCI ONLY NGC 0 002 02 20850000s NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE NO RESPONSE FROM TRANSMISSION CONTROL MODULE NGC PGI BUS COMMUNICATION FAILURE o0stovesce ese dveravesac eet evEwaw ee wns DRIVEABILITY NGC INTERMITTENT CONDITMON i02cui se atan ne inersion edge ating ede hose e he P0016 CRANKSHAFT CAMSHAFT TIMING MISALIGNMENT P0031 02 SENSOR 1 1 HEATER CIRCUIT LOW wc ccisceueees ooeaes Ve eeeeeeus P0037 O2 SENSOR 1 2 HEATER CIRCUIT LOW cacsee cesses ee de nevrwevawues P0051 02 SENSOR 2 1 HEATER CIRCUIT LOW o26uhserubeev eee the eas wees P0057 O2 SENSOR 2 2 HEATER CIRCUIT LOW jaciccvtveceewawduowes Sa baa P0032 02 SENSOR 1 1 HEATER CIRCUIT HIGH 2224 seuoeters pesaebuesegdwweds P0038 O2 SENSOR 1 2 HEATER CIRCUIT HIGH 3c cs ccc cscs eeean eee eveedws P0052 02 SENSOR 2 1 HEATER CIRCUIT HIGH 460 vex ee peek ened ee idee e ed P0058 O2 SENSOR 2 2 HEATER CIRCUIT HIGH ccceccceansee van evawaus ee 08 P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED sc2siciaie 5u tes
111. AR 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 POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 37 DRIVEABILITY NGC Symptom List P0031 O2 SENSOR 1 1 HEATER CIRCUIT LOW P0037 O2 SENSOR 1 2 HEATER CIRCUIT LOW P0051 02 SENSOR 2 1 HEATER CIRCUIT LOW P0057 O2 SENSOR 2 2 HEATER CIRCUIT LOW ___ _ __ x xL __ ES Sea Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be POO31 O2 SENSOR 1 1 HEATER CIRCUIT LOW When Monitored and Set Condition P0031 O2 SENSOR 1 1 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition O2 Heater element input is below the minimum acceptable voltage P0037 O2 SENSOR 1 2 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition O2 Heater element input is below the minimum acceptable voltage P0051 O2 SENSOR 2 1 HEATER CIRCUIT LOW
112. Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive is detected after injector turn off P0204 FUEL INJ ECTOR NO 4 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive spike is detected after injector turn off and with no other injectors on P0205 FUEL INJ ECTOR NO 5 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive spike is detected after injector turn off 111 DRIVEABILITY NGC P0201 FUEL INJ ECTOR NO 1 CIRCUIT Continued SSS P0O206 FUEL INJ ECTOR NO 6 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive spike is detected after injector turn off POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO F142 ASD RELAY OUTPUT CIRCUIT FUEL INJ ECTOR INJ ECTOR CONTROL CIRCUIT OPEN INJ ECTOR CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn
113. 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 5 110 DRIVEABILITY NGC Symptom List PO201 FUEL INJ ECTOR NO 1 CIRCUIT P0O202 FUEL INJ ECTOR NO 2 CIRCUIT P0O203 F UEL INJ ECTOR NO 3 CIRCUIT P0O204 F UEL INJ ECTOR NO 4 CIRCUIT P0205 FUEL INJ ECTOR NO 5 CIRCUIT P0206 FUEL INJ ECTOR NO 6 CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P0201 FUEL INJ ECTOR NO 1 CIRCUIT je When Monitored and Set Condition P0201 FUEL INJ ECTOR NO 1 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive spike is detected after injector turn off P0202 FUEL INJ ECTOR NO 2 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts Auto Shutdown Relay energized Engine speed less than 3008 rpm Set Condition No inductive spike is detected after injector turn off P0203 FUEL INJ ECTOR NO 3 CIRCUIT When Monitored With battery voltage greater than 11 9981 volts
114. 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 55 DRIVEABILITY NGC Symptom P0O107 MAP SENSOR CIRCUIT LOW eT When Monitored and Set Condition P0107 MAP SENSOR CIRCUIT LOW When Monitored Enginespeed greater than 250 RPM Battery voltage greater than 10 3 volts Set Condition TheMAP sensor signal voltage is below 0 08 of a volt for 1 7 seconds One Trip Fault POSSIBLE CAUSES MAP SENSOR VOLTAGE BELOW 0 08 OF A VOLT F856 5 VOLT SUPPLY CIRCUIT OPEN F856 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND MAP SENSOR K1 MAP SIGNAL CIRCUIT SHORTED TO GROUND K1 MAP SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII read the MAP Sensor voltage Is the voltage below 0 08 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the MAP Sensor h
115. Bus e PCI Bus e CKP Sensor Signal e CMP Sensor Signal e Vehicle Speed Sensor Signal e O2 Sensor Signal 6 0 ACRONYMS A C Air Conditioning ABS Anti lock Brake System ASD Re Auto Shutdown Relay lay APPS Accelerator Pedal Position Sensor Baro Barometric Pressure BCM Body Control Module BTS Battery Temperature Sensor CAA Clean Air Act CAB Controller Antilock Brakes CARB California Air Resources Board CCD Chrysler Collision Detection Bus BUS CKP Crankshaft Position Sensor Sensor CKT Circuit CMP Camshaft Position Sensor Sensor CM840 Cummins Engine controller co Carbon Monoxide CVI Clutch Volume Index DCP So Duty Cycle Purge Solenoid lenoid DLC Data Link Connector DRBIII Diagnostic Readout Box 3rd Gen eration GENERAL INFORMATION DTC DVOM EATX EC ECT Sensor EE PROM EGR Valve EMCC EMI EOBD EPA EPP ETC EU EVAP EVR EWMA FEMCC FTP FSS HC HO2S Genera tor IAC Mo tor IAT Sen sor 10D IRT ISS 1 M JTEC Diagnostic Trouble Code Digital Volt Ohm Meter Electronic Automatic Transmission Controller European Community Engine Coolant Temperature Sensor Electrically Erasable Programmable Read Only Memory Exhaust Gas Recirculation Valve Electronically Modulated Converter Clutch Electro Magnetic Interference European OBD based upon Euro Stage III Environmental Protection Agency Engine Position Pulse Electronic Throttle Control Euro
116. CATION TEST VER 5 Measure the resistance between ground and the F 856 5 volt Supply circuit at the MAP Sensor harness connector Is the resistance above 100k ohms Yes GoTo 13 No Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 46 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED Continued ACTION APPLICABILITY Turn the ignition off Connect the C1 and C2 PCM harness connectors Ignition on engine not running With the DRBIII monitor the MAP Sensor voltage Connect a jumper wire between the K1 MAP Signal circuit and the K 900 Sensor ground circuit Cycle the ignition switch from off to on Does the DRBIII 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 GoTo 14 NOTE Remove the jumper wire before continuing Turn the ignition off All Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 1 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
117. CKP Sensor Allow the engine to idle Observe the lab scope screen Did the CKP Sensor generate any pulses Yes Inspect the related wire harness and replace the Crankshaft Position Sensor if no wiring problems were found Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 15 Turn the ignition off NOTE An intermittent condition with the CMP Sensor can set the P0335 DTC With the DRBII1 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 INA 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 lightly tap on the Cam Position Sensor Observe the lab scope screen Look for any pulses generated by the CMP Sensor Allow the engine to idle Observe the lab scope screen Did the CMP Sensor generate any erratic pulses Yes Inspect the related wire harness and replace the Camshaft Position Sensor if no wiring problems were found Perform POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 129 DRIVEABILITY NGC Symptom P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT When Monitored and Set Condition P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT When Monitored While cranking engine and engine running Set Condition When the CKP Sensor failure counte
118. CUIT E When Monitored and Set Condition P0685 ASD RELAY CONTROL CIRCUIT When Monitored With ignition on Battery voltage above 10 volts Set Condition An open or shorted condition is detected in the ASD relay control circuit for more than 2 7 seconds ASD Relay state does not equal the desired state P0688 will set along with P0685 POSSIBLE CAUSES ASD RELAY OPERATION A907 FUSED B CIRCUITS ASD RELAY K342 ASD RELAY CONTROL CIRCUIT OPEN K342 ASD RELAY CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the ASD Relay Is the ASD Relay operating Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 2 Turn the ignition off Remove the ASD Relay from the PDC Usinga 12 volt test light connect to ground probe the A907 Fused B circuits in the PDC Does the test light illuminate brightly Yes GoTo 3 No Repair the open or short to ground in the A907 Fused B circuits Inspect and replace any open fuses Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance of the ASD Relay Coil Is the resistance between 60 to 80 ohms Yes GoTo 4 No Replace theASD Relay Perform POWERTRAIN VERIFICATION TEST VER 5 240 DRIVEABILITY NGC P0685 ASD RELAY CONTROL CIRCUIT Continued ACTION APPLICABILITY Disconnect the C3 PCM harne
119. D V35 S C VENT SOL CONTROL CIRCUIT OPEN V35 S C VENT SOL CONTROL CIRCUIT SHORTED TO GROUND V32 S C SUPPLY CIRCUIT OPEN Z212 S C GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII actuate the Speed Control Vent Solenoid and note operation Does the Speed Control Vent Solenoid acutate properly Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 2 Turn the ignition off Disconnect the S C Servo harness connector Turn the ignition on Using the DRBIII actuate the S C Vent Solenoid Using a 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 and flash on and off Yes GoTo 5 No GoTo 3 224 DRIVEABILITY NGC P0586 SPEED CONTROL VENT SOLENOID CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Brake Switch harness connector Turn the ignition on Using the DRBIII actuate the S C Vent Solenoid Using a test light connected to ground probe the V32 S C Supply circuit in the Brake Switch harness connector Does the test light illuminate brightly and flash on and off Yes GoTo 4 No GoTo 8 Turn the ignition off Disconnect the S C Servo harness con
120. D FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the Low Speed Radiator Fan Relay Is the Radiator Fan Relay cycling on and off Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 2 Turn the ignition off Remove the Low Speed Radiator Fan Relay from the PDC Measure the resistance of the Low Speed Radiator Fan Relay Coil by measuring between the F1 Fused Ignition Switch terminal and the N201 Control circuit terminal at the Relay Is the resistance between 60 and 80 ohms Yes GoTo 3 No Replace the Low Speed Radiator Fan Relay Perform POWERTRAIN VERIFICATION TEST VER 5 175 DRIVEABILITY NGC P0480 COOLING FAN NO 1 CONTROL CIRCUIT Continued ACTION APPLICABILITY Ignition on engine not running Using a 12 volt test light connected to ground probe the F 1 Fused Ignition Switch Output circuit at the Relay connector in the PDC Does the test light illuminate brightly Yes GoTo 4 No Repair the open or short to ground in the F1 Fused Ignition Output Inspect the related fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Remove the Low Speed Radiator Fan Relay from the PDC Ignition on engine not running Measure the voltage on the A16 Fused B circuits in the PDC Is
121. D MONITOR TEST Monitor the NVLD Switch As the test runs the NVLD Switch should go from an OPEN state to CLOSED After the vacuum is released form the EVAP system the Switch state will return to OPEN Did the NVLD Switch operate as described above Yes GoTo 8 No Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Review the DRBIII Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply NOTE Make Ensure the gas cap meets OEM specifications Perform a visual and physical inspection of the entire Evaporative Emission system Check for the following conditions Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap gasket seal Were any of the above conditions found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No Test Complete 168 DRIVEABILITY NGC Symptom P0O461 F UEL LEVEL SENSOR NO 1 PERFORMANCE When Monitored and Set Condition P0461 FUEL LEVEL SENSOR NO 1 PERFORMANCE When Monitored TEST 1 With the ignition on the fuel level is compared to the previous key down after a 20 second delay TEST 2 T
122. DE FAILURE When Monitored At ignition on after ignition on during any rolling code handshake that occurs with the PCM due toa SKIM or PCM reset Set Condition When a PCM STATUS message with a Valid K ey status is not received by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the PCM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the PCM does not match the VIN stored in the SKIM s EEPROM POSSIBLE CAUSES VERIFYING ECM VIN REPLACE SKIM AND CHECK DTC S INTERMITTENT WIRING HARNESS PROBLEM ECM ACTION APPLICABILITY With the DRBIII erase the SKIM DTCs All Turn the ignition off Wait 10 seconds Turn the ignition on and wait 2 minutes With the DRBIII read the SKIM DTCs Does the DRBII1 display the DTC that was previously erased Yes GoTo 2 No GoTo 4 287 SENTRY KEY IMMOBILIZER ROLLING CODE FAILURE Continued ACTION APPLICABILITY Turn the ignition on All With the DRBIII select Engine system from the main menu Display and record the Vehicle Identification Number NOTE Ensure that a VIN has been programmed into the E CM Ifa VIN is not displayed attempt to program the ECM with the correct vehicle VIN before continuing Does the VIN recorded from the ECM match the VIN of the vehicle Yes GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perfo
123. Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 Internal engine component failures Were any of the above conditions present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the Ignition Coil harness connector and Fuel Injector harness connector of the cylinder being tested Ignition on engine not running With the DRBIII 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 the F142 ASD Relay Output circuit at the Fuel Injector harness connector Does the test light illuminate brightly Yes GoTo 4 No Repair the excessive resi
124. ER 5 Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the K44 CMP Signal circuit in the CMP Sensor harness connector Is the voltage above 5 2 volts Yes Repair the short to voltage in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 Measure the resistance between the K44 CMP Signal circuit and the F856 5 volt All Supply circuit in the CMP Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K44 CMP Signal circuit and the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 6 135 DRIVEABILITY NGC P0340 CAMSHAFT POSITION SENSOR CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K44 CMP Signal circuit from the CMP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 9 No Repair the open in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K44 CMP Signal circuit in the CMP Sensor harness connector Is the res
125. ERIFICATION TEST VER 1 Check the Battery Cables for high resistance using the service information proce dure Did either Battery Cable have a voltage drop greater than 0 2 of a volt Yes Repair the Battery circuit for high resistance Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 4 301 STARTING NO CRANK CONDITION Continued ACTION APPLICABILITY WARNING Place shifter in Neutral and set the Parking Brake All Disconnect the Clutch Interlock Switch If this vehicleis not equipped with a manual transmission answer NO tothis test and continue Connect a jumper wire between the two terminals of the Clutch Interlock Switch and attempt to start the engine Does the engine crank Yes Replace the Clutch Interlock Switch Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 5 NOTE Remove the jumper wire and connect the Switch before continuing Turn ignition off Remove the Starter Relay from PDC WARNING The Parking Brake must be on and the Transmission must be in park for a vehicle equipped with an automatic transmission or Neutral on a Manual transmission WARNING The engine may be cranked in the next step Keep away from moving engine parts Briefly connect a jumper wire between Starter Relay B circuit and the T 40 Starter Relay Output circuits Did the Starter Motor crank the engine Yes GoTo 6 No GoTo 8 NOTE Remove the jumper wire before continuing Ignition
126. FICATION TEST VER 2 No GoTo 3 NOTE Remove the jumper wire before continuing 205 DRIVEABILITY NGC P0551 POWER STEERING SWITCH PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure resistance of K66 P S Switch Signal circuit from the Power Steering Pressure Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the K66 P S Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Measure the resistance between ground and the K66 P S Pressure Switch Signal All circuit at the P S Pressure Switch connector Is the resistance below 100 ohms Yes Repair the short to ground in the K 66 P S Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 5 Measure the resistance between ground and the Z939 Ground circuit at the Power Steering Pressure Switch connector Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the Z939 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NOTE Before continuing check the PCM harness connector terminals for corrosion damag
127. FICATION TEST VER 3 GoTo 4 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 3 211 DRIVEABILITY NGC Symptom P0572 BRAKE SWITCH NO 1 CIRCUIT LOW EEN When Monitored and Set Condition P0572 BRAKE SWITCH NO 1 CIRCUIT LOW When Monitored Ignition on Set Condition When the PCM recognizes Brake Switch 1 is mechanically stuck in the low on position One Trip Fault Three Global Good Trips to Clear POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO BRAKE LAMP SWITCH OPERATION B15 BRAKE SWITCH NO 1 SIGNAL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY NOTE Verify battery voltage is greater than 10 volts All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Remove the Brake Lamp Switch and disconnect the harness connector Measure the resistance between the Z940 Ground circuit terminal
128. GoTo 4 Inspect the throttle body plate for carbon build up or other restrictions Verify that the throttle cable between the Accelerator Pedal and Throttle Body is not binding Make sure the throttle plate is resting on the stop at idle Remove the AC Motor and actuate the IAC Motor with the DRBIII to verify proper operation Install the IAC Motor WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING While the vehicleis running lightly tap on IAC Motor with your hand and listen for idle to raise Were any problems found Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 188 DRIVEABILITY NGC Symptom P0508 IAC VALVE SIGNAL CIRCUIT LOW When Monitored and Set Condition P0508 IAC VALVE SIGNAL CIRCUIT LOW When Monitored Engine running Battery voltage greater than 10 volts IAC motor operating Set Condi
129. GoTo 7 Are there multiple vehicle ignition keys available Yes GoTo 3 No GoTo 4 NOTE Perform the following steps using one of the vehicle ignition keys All When finished repeat the procedure using each of the other vehicle keys one at a time With the DRBIII erase the SKIM DTCs Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTCs Is the DTC present for all ignition keys Yes Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION No Replace the ignition key s that cause the SKIM DTC Perform SKIS VERIFICATION With the DRBIII attempt to reprogram the ignition keys to the SKIM With the DRBIII erase the SKIM DTCs Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTCs Does the DTC set again Yes GoTo 5 No Test Complete Replace the ignition key with a new key With the DRBIII program the new ignition key to the SKIM With the DRBIII erase the SKIM DTCs Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTCs Does the DTC set again Yes GoTo 6 No Test Complete 290 SENTRY KEY IMMOBILIZER TRANSPONDER COMMUNICATION FAILURE Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Sentry Key Immobilize
130. I check for PCM DTCs Are any DTCs present Yes Return tothe symptom list and choose the symptom s Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 2 Position the Mode switch on theA C Heater Control Module to the Panel position Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while pressing the A C mode switch on and off Does the A C Select Switch state change accordingly Yes GoTo 3 No GoTo 6 Does the A C Select Switch state change accordingly Yes GoTo 4 No Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the A C Clutch harness connector Start the engine and observe the A C Clutch and Compressor Does the A C Compressor run with the harness connector disconnected Yes Replace the A C Clutch per Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 5 Position the Mode switch on the A C Heater Control Module to the Panel position All Turn the ignition on With the DRBIII in Powertrain select Engine and select Inputs Outputs Monitor the A C Select Switch state while pressing the A C mode switch on and off 276 DRIVEABILITY NGC A C OPERATES IN ALL MODE SWITCH POSITIONS Continued ACTION APPLICABILITY Turn the ignition off All Remove the A C Clutch Relay from the
131. IENCY 2 20c 0c5e0eo 55 Bete ddat Sie deeed eur ede es 142 P0440 GENERAL EVAP SYSTEM FAILURE 00000 e ee eee eee 144 P0441 EVAP PURGE SYSTEM PERFORMANCE 000 eee eee 149 P0442 EVAP SYSTEM MEDIUM LEAK 0 0 e eee 151 P0455 EVAP SYSTEM LARGE LEAK ccienteictetece dite waai ip sdddoans 151 P0443 EVAP PURGE SOLENOID CIRCUIT 23 2000 see rdweicabgn enka eeew hs 155 P0452 NVLD PRESSURE SWITCH STUCK CLOSED 00 25 00000 2 eeu 158 P0453 NVLD PRESSURE SWITCH STUCK OPEN 2 2 2scsae2 0 venebiarresens 161 P0456 EVAP SYSTEM SMALL LEAK sccctcchstteeteatediestigebted eases ees 163 P0457 LOOSE FUEL CAP w2ceereisneg Sestieee oe Kioii e nan aori 3S eee eaee se 165 P0461 FUEL LEVEL SENSOR NO 1 PERFORMANCE 2 23228 cece s es ewes ees 169 P0462 FUEL LEVEL SENSOR NOAA LOW s u2ktardeeideeue oe vd bat nee ae eens 171 P0463 FUEL LEVEL SENSOR NO 1 HIGH acs2eeubeded ee aaaea 173 P0480 COOLING FAN NO 1 CONTROL CIRCUIT 2 000008 175 P0481 COOLING FAN NO 2 CONTROL CIRCUIT 00 000 00 00008 177 P0498 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW 179 P0499 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH 181 P0501 VEHICLE SPEED SIGNAL PERFORMANCE 2400 lt 0vs0 wseese eed eeades 183 P0506 IDLE SPEED PERFORMANCE LOWER THAN EXPECTED 185 P0507 IDLE SPEED PERFORMANCE HIGHER THAN EXPECTED 187 P0508 IAC VALVE SIGNAL CIRCUIT LOW 2 icc cia dnacdee be e
132. II parameters related to the DTC while wiggling the related 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 TERMI NALS 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 DRBIII 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 DRBIII to perform a System Test if one applies to failing component A co pilot da
133. IRCUIT A112 FUSED B CIRCUIT A C CLUTCH RELAY C13 A C CLUTCH RELAY CONTROL CIRCUIT OPEN C13 A C CLUTCH RELAY CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the A C Clutch Relay Is the A C Clutch Relay operating Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Ignition on engine not running Using a 12 volt test light connected to ground probe the F 1 Fused Ignition Switch Output circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the open or short to ground in the F1 Fused Ignition Switch Output circuit Inspect and replace any open fuses Perform POWERTRAIN VERIFICATION TEST VER 2 238 DRIVEABILITY NGC P0645 A C CLUTCH RELAY CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Using a 12 volt test light connected to ground probe the A112 Fused B circuit of the fuel pump relay in the PDC Does the test light illuminate brightly Yes GoTo 4 No Repair the open or short to ground in the A112 F used B circuit Inspect and replace any open fuses Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Measure the resistance of the A C Clutch Relay Coil Is the resistance between 60 to 80 ohms Y
134. IS VERIFICATION With the DRBIII attempt to communicate with the SKIM All Can the DRBIII communicate with the SKIM Yes GoTo 3 No Refer to symptom BUS SIGNAL OPEN FROM SKIM in the COMMUNICATION category Perform SKIS VERIFICATION 193 DRIVEABILITY NGC P0513 INVALID SKIM KEY Continued ACTION APPLICABILITY With the DRBIII display the VIN that is programmed in the PCM All Was the correct VIN programmed into the PCM Yes GoTo 6 No Replace and program the Powertrain Control Module per Service Information Perform SKIS VERIFICATION Turn the ignition off Replace and program the Sentry Key Immobilizer Module per Service Information Ignition on engine not running With the DRBIII erase all SKIM and PCM DTCs Attempt to start and idle the engine With the DRBIII read the PCM DTCs Does the DRBII1 display this code Yes NOTE Before continuing check the PCM harness connector termnals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module per Service nformation 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 Verify the correct VIN is
135. IT OPEN PCM ACTION APPLICABILITY Start the engine All With the DRBIII monitor each switch function for the Speed Control Switches Press and release each Speed Control Button Resume Accel Cancel Decel Coast Does each switch function change status when pressing and then depressing each switch Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 2 250 DRIVEABILITY NGC P1593 SPEED CONTROL SWITCH NO 1 STUCK Continued ACTION APPLICABILITY Turn the ignition off Remove the Speed Control Switches from the steering wheel Measure the resistance across each Switch Control Switch Monitor the onmmeter while pressing each function button on each switch Resume Accel 15 400 ohms Cancel 909 9 ohms Decel Coast 2940 30 ohms On Off 0 ohms Set 6650 66 ohms Does the function on the Speed Control Switches have the correct resistance value Yes GoTo 3 No Replace the Speed Control Switch that had the incorrect resis tance value Perform POWERTRAIN VERIFICATION TEST VER 4 Disconnect the C3 PCM harness connector All Ignition on engine not running Measure the voltage on the V37 S C Signal circuit at the Speed Control harness connector Is the is the voltage above 5 0 volts Yes Repair the short to battery voltage in the V37 S C Signal circuit Perform POWERTRAIN VERIFICATION TEST
136. ITY NGC P0586 SPEED CONTROL VENT SOLENOID CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the S C Servo harness connector Disconnect the C3 PCM harness connector Measure the resistance between ground and the V35 S C Vent Sol Control circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the V35 Speed Control Vent Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 10 Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V32 S C Supply circuit from the Brake Lamp Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 9 No Repair the open high resistance in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Disconnect the Brake Switch harness connector Disconnect the C3 PCM harness connector Measure the resistance between ground and the V32 S C Supply circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms Yes Repai
137. Ignition on engine not running Using a 12 volt test light jump across the EVAP Purge Solenoid harness connector With the DRBIII actuate the EVAP Purge Solenoid Does the test light flash on and off Yes GoTo 3 No GoTo 7 158 DRIVEABILITY NGC P0452 NVLD PRESSURE SWITCH STUCK CLOSED Continued ACTION APPLICABILITY Turn the ignition off Connect the Evap Purge Solenoid harness connector Disconnect the vacuum hoses at the Evap Purge Solenoid NOTE After disconnecting the Evap Purge Solenoid vacuum connections inspect the lines and solenoid for any signs of contamination from the E VAP Canister This may indicate a faulty rollover valve Replace repair as necessary Using a hand vacuum pump apply 10 in Hg to the CAN of the EVAP Purge Solenoid NOTE Monitor the vacuum gauge for at least 15 seconds Does the EVAP Purge Solenoid hold vacuum Yes GoTo 4 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 5 Ignition on engine not running Using the DRBIII monitor the NVLD Switch State with the vacuum pump still installed and holding vacuum Does the DRBIII display the NVLD state OPEN Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE Remove the vacuum pump and connect the vacuum hose before continuing Does the Switch change from CLOSED to OPEN Yes
138. K22 TP Sensor No 1 Signal circuit and the All F855 5 volt Supply circuit at the TP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the F 855 5 volt Supply circuit and the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 78 DRIVEABILITY NGC P0123 THROTTLE POSITION SENSOR NO 1 HIGH Continued ACTION APPLICABILITY Ignition on engine not running All With the DRBIII 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 tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 No Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 79 DRIVEABILITY NGC Symptom P0O125 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 engineis 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
139. 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 GoTo 16 118 DRIVEABILITY NGC PO0300 MULTIPLE CYLINDER MISFIRE Continued ACTION APPLICABILITY Turn the ignition off All 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 DRBIII erase DTCs Using a 12 volt test light connected to 12 volts probe the Injector Control circuit With the DRBIII actuate the Fuel Injector Does the test light blink flicker Yes Replace the Fuel Injector Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Check the Injector Control circuit for an open short to ground and short to voltage Was a problem found with the Injector Control circuit Yes Repair the excessive resistance or short to ground in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 16 Turn the ignition of
140. LEARN AND REPROGRAM PINION FACTOR Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 30 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 ACTION APPLICABILITY Note Determine which modules this vehicle is equipped with before begin All ning 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 Body Control Module MIC INSTRUMENT CLUSTER Was the DRBII1 able to communicate with one or more Module s Yes GoTo 2 No GoTo 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 Comple
141. LITY Check for any related TSBs before continuing All NOTE If any of the following DTCs are set P0443 P0452 P0453 P0498 or P0499 diagnose them first before continuing with P0441 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE After disconnecting the Evap Purge vacuum connections inspect the lines and solenoid for any signs of contamination or foreign materials Using a hand vacuum pump apply 10 in Hg to CAN side of the EVAP Purge Solenoid Ignition on engine not running Observe the vacuum gauge With the DRBIII actuate the EVAP Purge Solenoid Does the vacuum drop when the solenoid is actuated Yes GoTo 3 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 5 149 DRIVEABILITY NGC P0441 EVAP PURGE SYSTEM PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off All Carefully inspect the Evap Purge Solenoid vacuum supply hose for proper routing Check for a pinched or plugged hose from the throttle body to the Purge Solenoid Inspect the vacuum port at the throttle body for any damage or plugging Were any problems found Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAI
142. LITY NOTE Ensure the throttle is fully closed and free from binding or carbon All build up Start the engine With the DRBIII read DTCs and record the related Freeze Frame data NOTE Diagnose any IAC codes before continuing With the DRBIII read the TP Sensor voltage Is the voltage above 4 5 volts Yes GoTo 2 No GoTo 8 Turn the ignition off Disconnect the TP Sensor harness connector Connect a jumper wire between the K22 TP Sensor No 1 Signal circuit and the K900 Sensor ground circuit at the Sensor harness connector With the DRBIII 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 77 DRIVEABILITY NGC P0123 THROTTLE POSITION SENSOR NO 1 HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the K22 TP Sensor No 1 Signal circuit at the TP Sensor harness connector Is the voltage above 5 2 volts Yes Repair the short to voltage in the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI
143. M ACTION APPLICABILITY Check for any related TSBs before continuing All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the NVLD Assembly harness connector Measure the resistance of the NVLD Solenoid coil Is the resistance between 7 5 and 8 5 ohms Yes GoTo 3 No Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 Disconnect the C3 PCM harness connector Measure the voltage on the K 106 NVLD Sol Control circuit in the NVLD Assembly harness connector Is the voltage above 1 0 volt Yes Repair the short to voltage in the K106 NVLD Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 181 DRIVEABILITY NGC PO0499 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH Continued ACTION APPLICABILITY CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K106 NVLD Sol Control circuit from the NVLD Assembly harness connector to the appropriate terminal of special tool 8815
144. MI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the G6 Oil Pressure Signal circuit from the Oil Pressure Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the G6 Oil Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Measure the resistance between G6 Oil Pressure Signal circuit and ground at the Switch connector Is the resistance below 100 ohms Yes Repair the short to ground in the G6 Oil Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 2 200 DRIVEABILITY NGC Symptom P0532 A C PRESSURE SENSOR LOW When Monitored and Set Condition P0532 A C PRESSURE SENSOR LOW When Monitored Engine running A C is learned and the AC Clutch Relay energized Set Condition TheA C pressure sensor signal voltage at the PCM goes below 0 58
145. MINAL 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 GoTo 6 No Repair the open in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 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 5 113 DRIVEABILITY NGC Symptom List P0O300 MULTIPLE CYLINDER MISFIRE P0O301 CYLINDER NO 1 MISFIRE P0302 CYLINDER NO 2 MISFIRE P0303 CYLINDER NO 3 MISFIRE P0304 CYLINDER NO 4 MISFIRE P0305 CYLINDER NO 5 MISFIRE P0O306 CYLINDER NO 6 MISFIRE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be POSOO MULTIPLE CYLINDER MISFIRE When Monitored and Set Condition PO300 MULTIPLE CYLINDER MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rat
146. N VERIFICATION TEST VER 5 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 150 DRIVEABILITY NGC Symptom List P0442 EVAP SYSTEM MEDIUM LEAK P0455 EVAP SYSTEM LARGE LEAK Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P0442 E VAP SYSTEM MEDIUM LEAK E When Monitored and Set Condition P0442 E VAP SYSTEM MEDIUM LEAK When Monitored Engine Running Cold start test F uel Level greater than 12 Ambient Temperature between 4 C and 32 C 39 F and 89 F Close Loop fuel system Test runs when small leak test is maturing Set Condition ThePCM activates the E VAP Purge Solenoid to pull the E VAP system into a vacuum to close the NVLD switch Once the NVLD swtich is closed the PCM turns the EVAP Pugre solenoid off to seal the EVAP system If the NVLD switch reopens before the calibrated amount of time for a Medium leak an error is detected Two Trip Fault P0455 E VAP SYSTEM LARGE LEAK When Monitored EngineRunning Cold start test Fuel Level greater than 12 Ambient Temperature between 4 C and 32 C 39 F and 89 F Close Loop fuel system Test runs when small leak test is maturing Set Condition ThePCM activates the EVAP Purge Solenoid to pull the EVAP system into a vacuum to close the NVLD swtich Once the NVLD switch is closed the PCM turns the EVAP Purge solenoid off to seal the E
147. NECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 5 174 DRIVEABILITY NGC Symptom P0480 COOLING FAN NO 1 CONTROL CIRCUIT When Monitored and Set Condition P0480 COOLING FAN NO 1 CONTROL CIRCUIT When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition An open or shorted circuit is detected in the radiator fan relay control circuit POSSIBLE CAUSES LOW SPEED RADIATOR FAN RELAY OPERATION LOW SPEED RADIATOR FAN RELAY F1 FUSED IGNITION SWITCH OUTPUT CIRCUIT A16 FUSED B CIRCUIT N201 LOW SPEED RAD FAN RELAY CONTROL CIRCUIT OPEN N201 LOW SPEED RA
148. NECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K961 IAC Signal circuit from the IAC Motor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the K961 IAC Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K 961 IAC Signal circuit in the AC Motor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K 961 IAC Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K61 IAC Control circuit from the IAC Motor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K61 IAC Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K61 IAC Control circuit in thel AC Motor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K 61 IAC Control circuit Perf
149. NNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 73 DRIVEABILITY NGC Symptom P0122 THROTTLE POSITION SENSOR NO 1 LOW E When Monitored and Set Condition P0122 THROTTLE POSITION SENSOR NO 1 LOW 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 POSSIBLE CAUSES THROTTLE POSITION SENSOR SWEEP INTERMITTENT CONDITION F855 5 VOLT SUPPLY CIRCUIT OPEN F855 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND THROTTLE POSITION SENSOR K22 TP SENSOR
150. NO 1 SIGNAL CIRCUIT SHORTED TO GROUND K22 TP SENSOR NO 1 SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data NOTE Diagnose any IAC codes before continuing With the DRBIII read the TP Sensor voltage Is the voltage below 0 2 of a volt Yes GoTo 2 No GoTo 9 Turn the ignition off Disconnect the TP Sensor harness connector Ignition on engine not running Measure the voltage on the F855 5 volt Supply circuit at the TP Sensor harness connector Is the voltage between 4 5 to 5 2 volts Yes GoTo 3 No GoTo 6 With the DRBII1 monitor the TP Sensor voltage with the Sensor harness connector disconnected Is the voltage above 4 5 volts Yes Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 74 DRIVEABILITY NGC P0122 THROTTLE POSITION SENSOR NO 1 LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 PCM harness connector Measure the resistance between ground and the K 22 TP Sensor No 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 No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 Measure the resistance between the K22 TP Sensor No 1
151. NSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR HIGH PCM 100 DRIVEABILITY NGC P0O171 FUEL SYSTEM 1 1 LEAN Continued ACTION APPLICABILITY Diagnose all other trouble codes before continuing All NOTE Check for contaminants that may have damaged an O2 Sensor contaminated fuel unapproved silicone oil and coolant Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 WARNING The fuel system is under 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 DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Turn the ignition off Choose a conclusion that best matches your fuel pressure reading Within Specification GoTo 3 Above Specification Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 Below Specification GoTo 13 Caution Stop All Actuations Start the engine Allow the engine to reach normal operating temperature
152. NSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance in the K900 Sensor ground circuit from the Sensor connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 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 2 198 DRIVEABILITY NGC Symptom P0522 OIL PRESSURE VOLTAGE LOW When Monitored and Set Condition P0522 O1IL PRESSURE VOLTAGE LOW When Monitored With the ignition on and battery voltage above 10 4 volts Set Condition The switch reads closed at voltage below 0 942 of a volt The NGC must see a change in switch state at engine start One trip fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO OIL PRESSURE SWITCH G6 OIL PRESSURE SIGNAL CIRCUIT OPEN G6 OIL PRESSURE SIGNAL CIRCUIT SHORTED TO VOLTAGE G6 OIL PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII re
153. NTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the C2 PCM 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 Using a 12 volt test light connected to ground probe the K21 IAT Signal circuit in the IAT Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 60 DRIVEABILITY NGC PO1LLL INTAKE AIR TEMPERATURE SENSOR PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off Connect the C2 PCM harness connector Ignition on engine not running With the DRBIII read the IAT voltage Is the voltage above 4 6 volts Yes GoTo 4 No GoTo 7 Connect a jumper wire between the K21 IAT Signal circuit and K900 Sensor ground circuit in the IAT Sensor harness connector With the DRBIII read the IAT Sensor voltage Is the voltage below 1 0 volt Yes Replace the IAT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE Remove the jumper wire before continuing Turn the ignition off All Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE
154. O NOT WEAR LOOSE CLOTHING Ignition on engine not running Wiggle the related wire harness and lightly tap the Crank Position Sensor Observe the lab scope screen Allow the engine to idle Observe the lab scope screen Did the CKP Sensor generate any erratic pulses Yes Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 137 DRIVEABILITY NGC Symptom P0344 CAMSHAFT POSITION SENSOR INTERMITTENT a When Monitored and Set Condition P0344 CAMSHAFT POSITION SENSOR INTERMITTENT When Monitored While cranking the engine and engine running Set Condition When the failure counter reaches 20 One Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO CMP WIRE HARNESS INSPECTION F856 5 VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND TONE WHEEL PULSE RING INSPECTION CHECKING CKP SENSOR SIGNAL WITH THE DRBIII LAB SCOPE CAMSHAFT POSITION SENSOR K44 CMP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K44 CMP SIGNAL CIRCUIT OPEN K44 CMP SIGNAL CIRCUIT SHORTED TO GROUND K44 CMP SIGNAL CIRCUIT SHORTED TO THE F856 5 VOLT SUPPLY CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5
155. O THE K900 SENSOR GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C2 PCM harness connector 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 at the ECT Sensor harness connector Is the voltage above 5 2 volts Yes Repair the short to voltage in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 67 DRIVEABILITY NGC P0116 E NGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off Connect the C2 PCM harness connector Ignition on engine not running With the DRBIII read the ECT Sensor voltage Is the voltage above 4 6 volts Yes GoTo 4 No GoTo 7 Connect a jumper wire between the K2 ECT Signal circuit and the K 900 Sensor ground circuit at the ECT Sensor harness connector With the DRBIII read the ECT voltage Is the voltage below 1 0 volt Yes Repla
156. OLTAGE When Monitored With the engine running and the PCM has closed the Transmission Control Relay Set Condition If the battery voltage of the Transmission Control Relay Output Sense circuit s to the PCM is less than 10 0 volts for the period of 15 seconds Note P0562 generally indicates a gradually falling battery voltage or a resistive connection s to the PCM The DTC will also set if the battery voltage sensed at the PCM is less than 6 5v for 200ms or where Transmission Control Relay Output circuits is less than 7 2v for 200ms POSSIBLE CAUSES RELATED CHARGING SYSTEM DTC S GROUND CIRCUIT OPEN OR HIGH RESISTANCE FUSED B CIRCUIT TO PCM HIGH RESISTANCE TRANSMISSION CONTROL RELAY OUTPUT TO TCM OPEN OR HIGH RESISTANCE TRANSMISSION CONTROL RELAY POWERTRAIN CONTROL MODULE INTERMITTENT WIRING AND CONNECTORS ACTION APPLICABILITY NOTE Low fluid level can be the cause of many transmission problems If All the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect th
157. ON APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 Turn the ignition off With the DRBII1 lab scope probe and the Miller special tool 6801 backprobe the K44 CMP Signal circuit in the CMP harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 lightly tap on the Cam Position Sensor Observe the lab scope screen Allow the engine to idle Observe the lab scope screen Did the CMP Sensor generate any erratic pulses Yes Replace the Camshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 15 Turn the ignition off With the DRBIII lab scope probe and the Miller special tool 6801 back probe the K24 CKP Signal circuit in the CKP harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN D
158. ON TEST VER 5 42 DRIVEABILITY NGC Symptom List PO0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELA TION VACUUM LEAK DETECTED P2074 MAP SENSOR TP SENSOR CORRELATION VACUUM LEAK DETECTED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be POO68 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DE TECTED E When Monitored and Set Condition P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VAC UUM LEAK DETECTED When Monitored During all drive modes Set Condition If vacuum drops below 1 5 Hg with engine RPM greater than 2000 RPM and closed throttle P2074 MAP SENSOR TP SENSOR CORRELATION VACUUM LEAK DETECTED When Monitored During all drive modes Set Condition If vacuum drops below 1 5 Hg 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 F856 5 VOLT SUPPLY CIRCUIT F856 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND MAP SENSOR RESISTANCE IN THE K1 MAP SIGNAL CIRCUIT K1 MAP SIGNAL CIRCUIT SHORTED TO GROUND RESISTANCE IN THE K900 SENSOR GROUND CIRCUIT TP SENSOR OPERATION RESISTANCE IN THE F855 5 VOLT SUPPLY CIRCUIT F855 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND TP SENSOR RESISTANCE IN THE K22 TP SENSOR NO 1 SIGNAL CIRCUIT K22 TP SENSOR NO 1 SIGNAL CIRCUIT SHORTED TO GROUND 43 DRI
159. ON TEST VER 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 Yes Repair the short to voltage in the O2 Heater Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 41 DRIVEABILITY NGC P0032 02 SENSOR 1 1 HEATER CIRCUIT HIGH Continued ACTION APPLICABILITY CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 7 No Repair the open in the O2 Heater Control circuit Perform POWERTRAIN VERIFICATION TEST VER 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 VERIFICATI
160. OOLING FAN NO 2 CONTROL CIRCUIT Continued ACTION APPLICABILITY Ignition on engine not running Using a 12 volt test light connected to ground probe the F 1 Fused Ignition Switch Output circuit at the Relay connector in the PDC Does the test light illuminate brightly Yes GoTo 4 No Repair the open or short to ground in the F1 Fused Ignition Output Inspect the related fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 Using a 12 volt test light connected to ground probe the A16 F used B circuit in the PDC Does the test light illuminate brightly Yes GoTo 5 Repair the open or short to ground A16 F used B circuit I nspect the related fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the N 112 High Speed Rad Fan Relay Control circuit in the PDC Is the resistance below 5 0 ohms Yes Repair the short to ground in the N112 High Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 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 Servic
161. OTE 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 Disconnect the C3 PCM harness connector All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 31 Fuel Pump Relay Control circuit from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K31 Fuel Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 234 DRIVEABILITY NGC Symptom P0630 VIN NOT PROGRAMMED IN PCM When Monitored and Set Condition P0630 VIN NOT PROGRAMMED IN PCM When Monitored Ignition on Set Condition The VIN has not been programmed into the PCM POSSIBLE CAUSES PROGRAMMING VIN INTO PCM PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs Using the DRBIII program VIN into the PCM Start the engine NO
162. P0442 EVAP SYSTEM MEDIUM LEAK Continued ACTION APPLICABILITY To continue testing you will need Miller Tool 8404 Evaporative Emission Leak All 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 Connect the red power lead of the EELD 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 Block the vent hose of the EVAP Canister Connect shop air to the 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 flow meter is now calibrated 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 if equipped or install 8404 ADP service adaptor in the filter line Connect the Air supply hose from the EELD to the service port if equipped or 8404 ADP in t
163. PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 6 No Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 9 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C2 PCM harness connector 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 61 DRIVEABILITY NGC PO1LLL INTAKE AIR TEMPERATURE SENSOR PERFORMANCE Continued Xe fe A
164. PECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K107 NVLD Switch Signal circuit from the NVLD electrical harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 11 No Repair the open in the K107 NVLD Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 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 6 148 DRIVEABILITY NGC Symptom P0441 EVAP PURGE SYSTEM PERFORMANCE MMM When Monitored and Set Condition P0441 E VAP PURGE SYSTEM PERFORMANCE When Monitored Cold start test Engine Running Small Leak Test Passed Set Condition The PCM activates the EVAP Purge solenoid gradually increasing to maximum flow During flow the PCM looks for the NVLD switch to close If the PCM does not see the NVLD switch close at maximum flow an error is detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO INTERMITTENT CONDITION CHECKING EVAP PURGE SOLENOID FUNCTIONALITY EVAP PURGE SOLENOID VACUUM SUPPLY ACTION APPLICABI
165. PPLICABILITY Measure the resistance between the K 900 Sensor ground circuit and the K21 IAT All Signal circuit at the IAT Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K900 Sensor ground circuit and the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 62 DRIVEABILITY NGC Symptom PO112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW When Monitored and Set Condition P0O112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition ThelntakeAir Temperature IAT sensor circuit voltage at the PCM goes below 0 5 of a volt One Trip Failure POSSIBLE CAUSES IAT SENSOR VOLTAGE BELOW 0 5 OF A VOLT IAT SENSOR K21 IAT SIGNAL CIRCUIT SHORTED TO GROUND K21 IAT SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the IAT Se
166. Perform POWERTRAIN VERIFICATION TEST VER 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 K 900 Sensor ground circuit in the Sensor harness connector Ignition on engine not running With the DRBIII monitor the A C Pressure Sensor voltage Is the voltage below 1 0 volt Yes Replace the A C Pressure Sensor Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 3 NOTE Remove the jumper wire before continuing 203 DRIVEABILITY NGC P0533 A C PRESSURE SENSOR HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Ignition on engine not running Using a 12 volt test light connected to ground probe the C18 A C Pressure Signal circuit at the A C Pressure Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 GoTo 4 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the C18 A C Pressure Signal circuit from the A C Pressure Sensor harness connector to the appropriate terminal of special
167. Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 99 DRIVEABILITY NGC Symptom List PO171 FUEL SYSTEM 1 1 LEAN P0O174 FUEL SYSTEM 2 1 LEAN aa el Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO171 FUEL SYSTEM 1 1 LEAN E When Monitored and Set Condition P0171 FUEL SYSTEM 1 1 LEAN When Monitored With the engine running in dosed loop mode the ambient battery temperature above 20 deg F and altitude below 8500 ft Set Condition Ifthe PCM multiplies short term compensation by long term adaptive and a certain percentage is exceeded for two trips a freeze frameis stored the MIL illuminates and a trouble code is stored P0174 FUEL SYSTEM 2 1 LEAN When Monitored With the engine running in dosed loop mode the ambient battery temperature above 20 deg F and altitude below 8500 ft Set Condition Ifthe 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 RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED FUEL PUMP MODULE O2 SENSOR O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT O2 SENSOR HEATER OPERATION THROTTLE POSITION SENSOR VOLTAGE GREATER THAN 0 92 VOLTS WITH THROTTLE CLOSED THROTTLE POSITION SENSOR SWEEP MAP SENSOR ECT SE
168. R 5 No GoTo 4 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 1 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 GoTo 5 No Repair the open in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between the K1 MAP Signal circuit and the F856 5 volt All Supply circuit at the MAP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the F 856 5 volt Supply circuit and the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 6 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 7 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Before continuing check the PCM harness
169. R SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to ground check 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 Does the test light illuminate brightly Yes GoTo 6 No Repair the Fused B Circuit circuit for an open or high resistance Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 Turn the ignition off to the lock position Disconnect the PCM harness connector Remove the Transmission Control Relay Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Connect a jumper wire between F used B circuit and the Transmission Control Relay Output circuit Ignition on engine not running Using a 12 volt test light connected to ground check both Transmission Control Relay Output circuits 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 Does the test light illuminate brightly Yes GoTo 7 No Repair the Transmission Control Relay Output circuit for an open or high resistance Perform 42RLE NGC TRANSMISSION
170. RMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 900 Sensor ground circuit from the Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance above 5 0 ohms Yes Repair the excessive resistance in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 review repair Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 249 DRIVEABILITY NGC Symptom P1593 SPEED CONTROL SWITCH NO 1 STUCK E When Monitored and Set Condition P1593 SPEED CONTROL SWITCH NO 1 STUCK When Monitored Ignition on Set Condition S C Switche 1 is mechanically stuck in the On Off Resume Accel or Set position for too long One trip fault POSSIBLE CAUSES SPEED CONTROL SWITCH STATUS SPEED CONTROL SWITCHES V37 S C SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT V37 S C SIGNAL CIRCUIT SHORTED TO GROUND V37 S C SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE V37 S C SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCU
171. ST VER 2 196 DRIVEABILITY NGC Symptom P0517 BATTERY TEMPERATURE SENSOR HIGH When Monitored and Set Condition P0517 BATTERY TEMPERATURE SENSOR HIGH When Monitored Ignition on Set Condition Battery temperature voltage goes above 4 9412 volts for more than 4 8 seconds Three good trips to clear the MIL POSSIBLE CAUSES BATTERY TEMP SENSOR VOLTAGE ABOVE 4 9412 VOLTS BATTERY TEMPERATURE SENSOR K118 BATT TEMP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K25 BATT TEMP SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All Record all DTCs and the related Freeze Frame data With the DRBIII monitor the Battery Temperature Sensor voltage Is the voltage above 4 9412 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the Battery Temperature Sensor harness connector Ignition on engine not running With the DRBIII in sensors read the Battery Temp Voltage value Connect a jumper wire between the K25 Batt Temp Signal circuit and the K900 Sensor ground circuit at the Battery Temp Sensor harness connector Did the Battery Temp voltage value change from greater than 4 5 volts to less than 1 0 volt Yes Replace the Battery Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 3 NOTE
172. Signal circuit and the K900 Sensor ground circuit at the TP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K 900 Sensor ground and the K 22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 8 Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the F 855 5 volt Supply circuit at the TP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 Turn the ignition off All Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F855 5 volt Supply circuit from the TP Sensor harness connector to the appropr
173. T THROTTLE POSITION SENSOR POWERTRAIN CONTROL MODULE INTERMITTENT WIRING AND CONNECTORS ACTION APPLICABILITY NOTE Low fluid level can be the cause of many transmission problems If All the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis Continue GoTo 2 With the DRBIII check Engine DTC s this includes all one trip failures Are there any Engine TPS DTCs present Yes Refer
174. TE If the engine will not start crank the engine over for 15 seconds Crank at least 2 times with the ignition switch returning to the off position each time Allow the engine to reach normal operating temperature With the DRBIII read DTCs Does the DTC reset Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No TheVIN has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 235 DRIVEABILITY NGC Symptom P0632 ODOMETER NOT PROGRAMMED IN PCM E When Monitored and Set Condition P0632 ODOMETER NOT PROGRAMMED IN PCM When Monitored Ignition on Set Condition Odometer is not programed into the PCM POSSIBLE CAUSES PROGRAMMING MILEAGE INTO PCM PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs Using the DRBIII program the mileage into the PCM Start the engine Allow the engine to reach normal operating temperature With the DRBIII read DTCs Does the DTC reset Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 The mileage has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 236 DRIVEABILITY NGC Symptom P0633 SKIM KEY NOT PROGRAMMED IN PCM When Monitored and S
175. TENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 Disconnect the Brake Lamp Switch harness connector Start the engine Using a 12 volt test light connected to ground probe the V32 S C Supply circuit in the Switch harness connector while holding the Cruise Switch in the ON position Does the test light illuminate brightly Yes GoTo 3 No GoTo 7 227 DRIVEABILITY NGC P0594 SPEED CONTROL SERVO POWER CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect and remove the Brake Lamp Switch Measure the resistance across the V32 S C Supply circuit terminal and the V30 S C Brake Switch Output circuit terminal at the Brake Lamp Switch Push the Plunger of the Switch in and let it out Does the resistance change from below 5 0 ohms to an open circuit Yes GoTo 4 No Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off All Connect the Brake Lamp Switch harness connecter and install the Switch Disconnect the Speed Control Servo harness connector Ignition on engine not running NOTE It is necessary to PRESS and HOLD the Speed Control Switch in the ON position while checking for voltage Using a 12 volt test light connected to ground probe the V30 S C Brake Switch Output circuit in the Servo Harness connector Does the test light illuminate brightly Yes Replace the S C Servo Perfo
176. TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 65 DRIVEABILITY NGC PO113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Using a 12 volt test light connected to ground probe the K21 IAT Signal circuit at the IAT Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 5 No Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the IAT Sensor harness connector to the appr
177. TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All NOTE Any VSS DTCs in the BCM and CAB Module must be properly diagnosed before continuing Perform the diagnostic procedure for VSS faults using the Chassis Diagnostic book If those diagnostics lead to replacing a control module continue the diagnostics found here With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C1 PCM harness connector Disconnect the BCM harness connectors Ignition on engine not running Measure the voltage of the B22 Vehicle Speed Signal circuit at the BCM harness connector Is the voltage above 6 0 volts Yes Repair the short to voltage in the B22 Vehicle Speed Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 183 DRIVEABILITY NGC PO501 VEHICLE SPEED SIGNAL PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the B22 Vehicle Speed Signal circuit from the BCM
178. TY NGC P0132 O02 SENSOR 1 1 CIRCUIT HIGH VOLTAGE Continued ACTION APPLICABILITY Turn the ignition off Connect the PCM harness connectors Connect a jumper wire between the O2 Sensor Signal circuit and the O2 Sensor Return circuit in the O2 Sensor harness connector Ignition on engine not running With the DRBIII monitor the O2 Sensor voltage Is the voltage between 2 3 and 2 7 volts with the jumper wire in place Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 NOTE Remove the jumper wire before continuing Turn the ignition off All Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the O2 Sensor Signal circuit from the O2 Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance of the O2 Sensor Return circuit from the O2 Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open O2 Sensor Return circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Before c
179. Temperature is less than 251 C 484 F with battery voltage greater 10 4 volts Set Condition The oxygen sensor signal voltage is below 2 411 volts for 10 24 seconds after starting engine One Trip Fault P0O157 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 4 volts Set Condition The oxygen sensor signal voltage is below 2 411 volts for 10 24 seconds after starting engine One Trip Fault POSSIBLE CAUSES O2 SENSOR BELOW 2 52 VOLTS O2 SENSOR O2 RETURN CIRCUIT SHORTED TO GROUND PCM 90 DRIVEABILITY NGC P0131 02 SENSOR 1 1 CIRCUIT LOW VOLTAGE Continued ACTION APPLICABILITY Start the engine Allow the engine to reach normal operating temperature NOTE When diagnosing this DTC diagnose the O2 Sensor that set the DTC With the DRBIII read the O2 Sensor voltage Is the voltage below 2 52 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBIII monitor the O2 Sensor voltage Is the O2 Sensor voltage above 4 8 volts Yes GoTo 3 No GoTo 4 Turn the ignition off Disconnect the PCM harness connectors Measure the resistance between ground and the O2
180. To 15 No Repair the excessive resistance in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance above 100k ohms Yes GoTo 16 No Repair the short to ground in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 17 No Repair the excessive resistance in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 47 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 C
181. Turn the ignition off With the DRBIII lab scope probe and the Miller special tool 6801 backprobe the K44 CMP Signal circuit in the CMP harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 Observe the lab scope screen Start the engine Observe the lab scope screen Are there any irregular or missing signals Yes GoTo 3 No GoTo 8 138 DRIVEABILITY NGC P0344 CAMSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY Turn the ignition off Visually inspect the related wire harness including the ground circuit 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 Make sure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are tight Refer to any TSBs that may apply Were any of the above conditions present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Disconnect the CMP Sensor connector Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit Is the voltage between 4 5 and 5 2 volts Yes GoTo 5 No Repair the open or short to ground in the F856 5 vol
182. Two Consecutive Failure Most are Two Trip Faults Turns On The MIL and Sets DTC After Two Consecutive Failure Priority 1 or 3 Priority 2 or 4 Fuel Control Monitor Monitors Fuel Control System F or Fuel System Lean Fuel System Rich Requires 3 Consecutive Fuel Systen Good Trips to Extinguish the MIL Done Stop Testing Yes Oxygen Sensor H eater Oxygen Sensor Response Catalytic Converter Efficiency Except EWMA up to 6 tests per trip and a one trip fault SBEC and a two trip fault on J TEC Misfire Monitor Monitors for Engine Misfire EGR System Evaporative Emission System At Purge and Leak 4 X 1000 RPM Counter 4000 Non LDP Revs or Type B LDP 200 X 3 600 RPM Counter Type A Requires 3 Consecutive Good Trips to Extinguish the MIL Requires 3 Consecutive Good Trips To Extinguish the MIL 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 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 A Once the monitor run process has begun do not t
183. VAP system If the NVLD switch reopens before the calibrated amount of time for a Large leak an error is detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO INTERMITTENT CONDITION VISUAL AND PHYSICAL INSPECTION VERIFY EVAPORATIVE EMISSION SYSTEM LEAK EVAPORATIVE EMISSION LEAK DETECTION EVAP PURGE SOLENOID OPERATION 151 DRIVEABILITY NGC P0442 EVAP SYSTEM MEDIUM LEAK Continued ACTION APPLICABILITY Check for any related TSBs before continuing All NOTE Since a hot vehicle can conceal a leak it is best to perform this test at room temperature NOTE A loose gas cap could have caused this DTC to set Make sure gas cap is tight and in good condition E nsure the gas cap meets OE M specifications Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 Perform a visual and physical inspection of the entire Evaporative E mission system Check for the follow conditions Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap gasket seal Were any of the above conditions found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 3 152 DRIVEABILITY NGC
184. VEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED Continued POSSIBLE CAUSES RESISTANCE IN THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY NOTE Diagnose any TP Sensor or MAP Sensor component DTCs before continuing NOTE If the P0501 No Vehicle Speed Signal is set with this DTC refer to the P0501 diagnostics before continuing NOTE The throttle plate and linkage should be free from binding and carbon build up NOTE Make sure the throttle plate is at the idle position Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Start the engine With the DRBIII monitor the MAP Sensor voltage Snap the throttle Does the MAP Sensor voltage vary from below 2 0 volts at idle to above 3 5 volts at WOT Yes GoTo 4 No GoTo 11 Ignition on engine not running With the DRBIII monitor the TP Sensor voltage while slowly depressing the 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 tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 5
185. VEABILITY NGC P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 Continued ACTION APPLICABILITY Check for any of the following conditions mechanical problems All 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 ke 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 GoTo 4 Ignition on engine not running Disconnect the O2 Sensor harness connector With the DRBIII monitor the O2 Sensor voltage The O2 Sensor voltage should read 5 0 volts on the DRBIII with the connector disconnected Using a jumper wire jump the O2 Signal circuit to the O2 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 volts change from 5 0 volts to 2 5 volts Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 Remove the jump wire Igni
186. VERIFICATION TEST VER 5 No GoTo 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 Turn the ignition off All Disconnect the C1 and C2 PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F856 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 GoTo 7 No Repair the open in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 57 DRIVEABILITY NGC Symptom P0O108 MAP SENSOR CIRCUIT HIGH E When Monitored and Set Condition P0108 MAP SENSOR CIRCUIT HIGH When Monitored Engine RPM greater than 260 Battery voltage greater than 10 3 volts Set Condition The MAP sensor signal voltage is greater than 4 93 volts POSSIBLE CAUSES MAP SENSOR VOLTAGE ABOVE 4 93 VOLTS MAP SENSOR
187. VERIFICATION TEST VER 5 Turn the ignition off Disconnect the PCM harness connectors Measure the resistance between ground and the O2 Heater Control circuit at 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 POWERTRAIN VERIFICATION TEST VER 5 GoTo 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 Ignition on engine not running All With the DRBIII 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 at the O2 Sensor harness connector Does the test light illuminate brightly and flash on and off Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 39 DRIVEABILITY NGC Symptom List P0032 O02 SENSOR 1 1 HEATER CIRCUIT HIGH P0038 O2 SENSOR 1 2 HEATER CIRCUIT HIGH P0052 02 SENSOR 2 1 HEATER CIRCUIT HIGH P0058 O2 SENSOR 2 2 HEATER CIRCUIT HIGH
188. WERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 161 DRIVEABILITY NGC P0453 NVLD PRESSURE SWITCH STUCK OPEN Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C3 PCM harness connector Ignition on engine not running Measure the voltage on the K107 NVLD Switch Signal circuit in the NVLD electrical harness connector Is the voltage above 5 3 volts Yes Repair short to voltage in the K 107 NVLD Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K107 NVLD Switch Signal circuit from the NVLD electrical harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K107 NVLD Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Is the resistance below 5 0 ohms Yes Repair the short between the K107 NVLD Switch Signal circuit and the K106 NVLD Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 6 Measure the resistance between the Z201 Ground circuit and ground Is the resistance below 5 0 ohms
189. above 100k ohms Yes GoTo 7 No Repair the short to ground in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 volt Yes Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 NOTE Remove the jumper wire before continuing Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 22 TP Sensor No 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 GoTo 9 No Repair the excessive resistance in the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Connect the C2 PCM harness connector All Ignition on engine not running With the DRBIII monitor the TP Sensor voltage Connect a jumper wire between the K22 TP Sensor No 1 Signal circuit and the K900 Sensor ground circuit at the Sensor harness connector Does the TP Sensor voltage change from approximately 4 9 volts to below 0 5 of a 45 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION VACUUM LEAK DETECTED Continued ACTION APPLICABILITY Measure the resistance bet
190. ace the Clockspring Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 5 Turn the ignition off All Connect the Clockspring harness connector per Service Information Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between the K 900 Sensor ground circuit and the V37 S C Signal circuit at the Speed Control Switch Is the resistance below 5 0 ohms Yes Repair the V37 S C Signal circuit shorted to the K 900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 6 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the V37 S C Signal circuit at the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes Repair the short to ground in the V37 S C Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 7 NOTE Before continuing disconnect the PCM harness connector and check the related wiring terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect t
191. ach Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 Refer to the Instrument Category and perform the appropriate symptom Perform POWERTRAIN VERIFICATION TEST VER 1 273 DRIVEABILITY NGC Symptom U0168 NO SKIM BUS MESSAGE E When Monitored and Set Condition U0168 NO SKIM BUS MESSAGE When Monitored Ignition on or engine running Set Condition No J 1850 messages received from the Smart Key Immobilizer Module SKIM for 20 seconds One Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO NO RESPONSE FROM SKIM PCI BUS CIRCUIT OPEN FROM PCM TO SKIM SKIM PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform SKIS VERIFICATION With the DRBIII attempt to communicate with the SKIM NOTE This test will indicate if the bus is operational from the DLC to the SKIM Was the DRBIII able to communicate with the SKIM Yes GoTo 3 No Refer to Symptom BUS SIGNAL OPEN FROM SKIM in the COMMUNICATION category Perform SKIS VERIFICATION 274 DRIVEABILITY NGC U0168 NO SKIM BUS MESSAGE Continued ACTION APPLICABILITY Turn the ignition
192. ad DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the Oil Pressure Switch harness connector Ignition on engine not running Connect a jumper wire to the G6 Oil Pressure Signal circuit in the Sensor harness connector With the DRBIII monitor the Oil Pressure Switch state Touch the other end of the jumper wire to Ground at the Oil Pressure Switch harness connector 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 GoTo 3 NOTE Remove the jumper wire before continuing 199 DRIVEABILITY NGC P0522 OIL PRESSURE VOLTAGE LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C1 PCM harness connector Ignition on engine not running Using a 12 volt test light connected to ground probe the G6 Oil Pressure Signal circuit at the Switch harness connector Does the 12 volt test light illuminate brightly Yes Repair the short to voltage on the G6 Oil Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 4 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TER
193. 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 8404 CLL 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 NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister the smoke may not be as thick Introducing smoke into the filtered side of the canister may assist in locating the leak Was a leak found Yes Repair or replace the leaking component as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 5 NOTE After disconnecting the Evap Purge Solenoid vacuum connections inspect the lines and solenoid for any signs of contamination from the E VAP Canister This may indicate a faulty rollover valve Replace repair as necessary Turn the ignition off
194. air the short to voltage in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 GoTo 7 Turn the ignition off All Disconnect the Generator Field harness connector Using a 12 volt test light jump it across the Generator Field harness connector Ignition on engine not running With the DRBIII actuate the Generator Field Driver circuit Does the test light illuminate brightly and flash on and off 269 DRIVEABILITY NGC P2503 CHARGING SYSTEM OUTPUT LOW Continued ACTION APPLICABILITY Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 125 Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 8 No Repair the open in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 Measure the resistance between ground and the K 125 Gen Field Control circuit in the Generator Field harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 9 NOTE Before continuing check the PCM harnes
195. amage 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 86 DRIVEABILITY NGC Symptom P0129 BAROMETRIC PRESSURE OUT OF RANGE When Monitored and Set Condition P0129 BAROMETRIC PRESSURE OUT OF RANGE When Monitored With theignition key on NoCamor Crank signal within 75 ms Engine speed less than 250 RPM Set Condition ThePCM 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 POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO F856 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE F856 5 VOLT SUPPLY CIRCUIT OPEN F856 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND MAP SENSOR K1 MAP SIGNAL CIRCUIT OPEN K1 MAP SIGNAL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the MAP Sensor harness connector Ignition on
196. 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 P2097 DOWN STREAM FUEL TRIM RICH BANK 1 When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F and altitude below 8500 ft Set Condition If thePCM multiplies short term compensation by long term adaptive as well as 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 P2098 DOWN STREAM FUEL TRIM LEAN BANK 2 When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F altitude below 8500 ft and fuel level greater than 15 Set Condition Ifthe 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 P2099 DOWN STREAM FUEL TRIM RICH BANK 2 When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F and altitude below 8500 ft Set Condition If thePCM multiplies short term compensation by long term adaptive as well as a purge fuel multiplier and the resu
197. and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault Three good trips to turn off the MIL P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 2 4L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO A142 ASD RELAY OUTPUT CIRCUIT IGNITION COIL IGNITION COIL DRIVER CIRCUIT OPEN IGNITION COIL DRIVER CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Check for any related TSBs ENGINE 2 4L Ignition on engine not running POWER TECH With the DRBIII read DTCs and record the related Freeze Frame data DOHC l 4 Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 261 DRIVEABILITY NGC P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 2 4L Continued ACTION APPLICABILITY Turn the ignition off ENGINE 2 4L Disconnect the coil rail harness connector POWER TECH Ignition on engine not running DOHC l 4 With the DRBIII actuate the ASD Relay Using a 12 volt test light connected to g
198. and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 Refer to the COMMUNICATION category and perform the PCI BUS COMMUNICATION FAILURE Symptom Perform POWERTRAIN VERIFICATION TEST VER 1 272 DRIVEABILITY NGC Symptom U0155 NO CLUSTER BUS MESSAGE When Monitored and Set Condition U0155 NO CLUSTER BUS MESSAGE When Monitored Ignition key on and engine running Set Condition No messages received from the MIC Instrument Cluster for 20 seconds POSSIBLE CAUSES DTC RESET COMMUNICATE WITH CLUSTER INSTRUMENT CLUSTER OPERATION PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs Start the engine and shut if off several times allowing it to idle each time for 20 seconds With the DRBIII read DTCs Does the DTC reset Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 1 Ignition on engine not running With the DRBIII attempt to communicate with the Instrument cluster Can communication be established with the Instrument Cluster Yes GoTo 3 No Refer tothe Communication Category and perform the appropri ate symptom related to no communication with cluster Perform POWERTRAIN VERIFICATION TEST VER 1 Start the engine Allow the engine to idle Is the correct engine speed display in the instrument cluster T
199. arness connector Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit at the MAP Sensor harness connector Is the voltage between 4 5 to 5 2 volts Yes GoTo 3 No GoTo 6 With the DRBIII monitor the MAP Sensor voltage with the Sensor harness connector disconnected Is the voltage above 1 2 volts Yes Replace the MAP Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 56 DRIVEABILITY NGC P0107 MAP SENSOR CIRCUIT LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Measure the resistance between ground and the K 1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K 1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 Measure the resistance between the K 1 MAP Signal circuit and the K 900 Sensor ground circuit at the MAP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K 900 Sensor ground and the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 Measure the resistance between ground and the F 856 5 volt Supply circuit at the MAP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN
200. ate brightly Yes GoTo 7 No Repair the open in the Z212 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 3 NOTE Before continuing check the PCM connector terminals for corro sion 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 Measure the resistance between ground and K 125 Gen Field Control circuit in the All Generator Field harness connector 232 DRIVEABILITY NGC Symptom P0627 F UEL PUMP RELAY CIRCUIT When Monitored and Set Condition P0627 FUEL PUMP RELAY CIRCUIT When Monitored With the ignition on Battery voltage greater than 10 4 volts Set Condition An open or shorted condition is detected in the fuel pump relay control circuit POSSIBLE CAUSES FUEL PUMP RELAY OPERATION F1 FUSED IGNITION SWITCH OUTPUT CIRCUIT A209 FUSED B CIRCUIT FUEL PUMP RELAY K31 FUEL PUMP RELAY CONTROL CIRCUIT OPEN K31 FUEL PUMP RELAY CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the Fuel Pump Relay Is the Fuel Pump Relay operating Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic P
201. ation If all the O2 Sensor voltage readings have not returned to normal follow the diagnostic procedure for the remaining O2 Sensors With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 No Check the O2 Signal circuit for damage short to ground open or short to voltage If OK replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 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 damage short to ground open or short to voltage If OK replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 If there are no possible causes remaining view repair Repair Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off All Disconnect the O2 Sensor harness connector Ignition on engine not running Mea
202. ation Perform BODY VERIFICATION TEST VER 1 277 DRIVEABILITY NGC Symptom CHECKING A C SYSTEM OPERATION WITH NO DTCS POSSIBLE CAUSES CHECK FOR PCM DTCS REFRIGERATION SYSTEM NOT PROPERLY CHARGED HIGH PRESS CUT OFF SWITCH LOW PRESSURE SWITCH POWERTRAIN CONTROL MODULE A C CLUTCH COIL A C COMPRESSOR CLUTCH GROUND CIRCUIT OPEN C3 A C CLUTCH RELAY OUTPUT CIRCUIT OPEN A C REQUEST CIRCUIT OPEN A17 FUSED B CIRCUIT OPEN A C CLUTCH RELAY A C HEATER CONTROL MODULE BODY CONTROL MODULE A C ON OFF CONTROL CIRCUIT OPEN A C ON OFF CONTROL CIRCUIT OPEN ACTION APPLICABILITY With the DRBIII check for PCM DTCs All Are any DTCs present Yes Return tothe symptom list and choose the symptom s Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 2 Turn the ignition off Verify that the Refrigerant System is properly charged per Service Procedure Is the Refrigerant System properly charged Yes GoTo 3 No Properly charge the Refrigerant System per Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 Verify the High Pressure Cut Off Switch operation per Service Information Is the High Pressure Cut Off Switch OK Yes GoTo 4 No Replace the High Pressure Cut Off Switch Perform POWERTRAIN VERIFICATION TEST VER 2 278 DRIVEABILITY NGC CHECKING A C SYSTEM OPERATION WITH NO DTCS Continued ACTION APPLICABILITY Verify the Low Pressure Switch operation per Serv
203. be the Z932 Ground circuit in the Generator Field harness connector Does the test light illuminate brightly Yes GoTo 8 No Repair the open in the Z932 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 3 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 3 209 DRIVEABILITY NGC Symptom P0563 BATTERY VOLTAGE HIGH When Monitored and Set Condition P0563 BATTERY VOLTAGE HIGH When Monitored With the ignition on Engine RPM greater than 1000 RPM With no other charging system codes set Set Condition The battery sensed voltage is 1 volt above the charging goal for 13 47 seconds The PCM senses the battery voltage turns off the field driver and senses the battery voltage again If the voltages are the same the code is set POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO GENERATOR OPERATION K125 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE PCM ACTION APPLICABILITY NOTE Make sure the Battery is in good condition Using the Midtronics All Battery Tester test the Battery before continuing NOTE Insp
204. below 0 4 of a volt Yes Replace the Fuel Level Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 173 DRIVEABILITY NGC P0463 F VEL LEVEL SENSOR NO 1 HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 and C3 PCM harness connectors WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 N4 Fuel Level Signal circuit at the Fuel Pump Module harness connector Is the voltage above 5 3 volts Yes Repair the short to voltage in the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the N4 Fuel Level Signal circuit from the Fuel Pump Module harness connector to the appropriate terminal in special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CON
205. bkeeoneddeeSevatepeswaueavers P2074 MAP SENSOR TP SENSOR CORRELATION VACUUM LEAK DETECTED cccttusecenpe reri ir Er AACA EEEE EET EEEE ERANA eared P0071 AMBIENT TEMP SENSOR PERFORMANCE i2c cceesteeaenseeeiwwnea P0072 AMBIENT TEMP SENSOR CIRCUIT LOW 0 00 00 e eee eee POG73 AMBIENT TEMP SENSOR CIRCUIT HIGH 4 0c0024nto0 ee sk ves esse os P0107 MAP SENSOR CIRCUIT LOW cs ctcuuesevavee be Orecaeee bores du s s ees PO108 MAP SENSOR CIRCUIT HIGH 2 2s 0t0r9 senbaenpeeepeoese ve edneeans P0111 INTAKE AIR TEMPERATURE SENSOR PERFORMANCE P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH P0116 ENGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH P0122 THROTTLE POSITION SENSOR NO 1 LOW 2 2 02 ce cence eee eee nes P0123 THROTTLE POSITION SENSOR NO 1 HIGH exci cca eiddeeeteweade ees P0125 INSUFFICIENT COOLANT TEMP FOR CLOSED LOOP FUEL CONTROL P0128 THERMOSTAT RATIONALITY idaccc octave eg er beeen euer tenet eae eee es P0129 BAROMETRIC PRESSURE OUT OF RANGE 000005 P0131 O2 SENSOR 1 1 CIRCUIT LOW VOLTAGE 06 2 eece eee se ce eee eee es P0137 O2 SENSOR 1 2 CIRCUIT LOW VOLTAGE 2 0 22 c ene eee ee ees P0151 02 SENSOR 2 1 CIRCUIT LOW VOLTAGE 2 20 scecevceweweee sowed aee es P01
206. cate with PCM if not able to communicate check fuses Ensure the Powers and Ground to the PCM are ok Make sure the PCM communicates with the DRBIII and that there are no DTCs stored in the PCM memory If the PCM reports a No Response condition refer to the Communication category for the proper tests Read the PCM DTCs with the DRBIII If any DTCs are present they must be repaired before continuing with any other No Start diagnostic tests Refer to the Symptom list for the related P code that is reported by the PCM Ensure that the PCI bus is functional Attempt to communicate with the Instrument Cluster and VTSS If you are unable to establish communicate refer to the Communication category for the proper symptoms The Sentry Key Immobilizer System must be operating properly Check for proper communication with the DRBIII and check for DTCs that may be stored in the Sentry Key Immobilizer Module SKIM Repair the DTC s before continuing If no DTCs are found using the DRBII1 select Clear PCM BATT Disconnect Crank the engine several times Using the DRBIII read DTCs If a DTC is present perform the DTC diagnostics before continuing Were any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 2 Check for any open fuses in the PDC or J unction Block that may be related tothe No Start condition Are any of the fuses open Yes Replace the open fuse and check the rela
207. ce between 2 0 and 30 ohms Yes GoTo 3 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 0 5 of an ohm Yes GoTo 4 No Repair the excessive resistance in the O2 Heater Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between an engine ground and the O2 Heater ground circuit at the O2 Sensor harness connector Is the resistance below 0 5 of an ohm Yes GoTo 5 No Repair the excessive resistance in the O2 Heater ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 98 DRIVEABILITY NGC P0135 O2 SENSOR 1 1 HEATER PERFORMANCE Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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
208. ce the ECT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 Turn the ignition off All Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 2 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 GoTo 6 No Repair the open in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 9 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C2 PCM harness connector Measure the resistance between ground and the K2 ECT Signal circuit at the ECT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K2 ECT Signal circu
209. ch Peripheral Expansion Port Park N eutral Proportional Purge Solenoid Power Steering PSP PTC PWM RAM REV RFI RKE RPM SAE SBEC SCW SKIM SRV SSV SW TCC TCCM TDC Power Steering Pressure Switch Positive Temperature Coefficient Pulse Width Modulation Random Access Memory Reverse Clutch Radio Frequency Interference Remote Keyless Entry Revolutions Per Minute Society of Automotive Engineers Single Board Engine Controller Similar Conditions Window Sentry Key Immobilizer Module Short Runner Valve Solenoid Switch Valve Switch Torque Converter Clutch Transfer Case Control Module Top Dead Center 19 GENERAL INFORMATION TP Throttle Position Sensor TRD Torque Reduction TRS Transmission Range Sensor TTS Transmission Temperature Sensor UD Underdrive Clutch vss Vehicle Speed Signal WOT Wide Open Throttle 2 4 2nd and 4th gear Clutch or Pres sure Switch 2C 2nd Clutch 4C 4th Clutch 6 2 DEFINITIONS OBDII EURO III Trip A vehicle start and drive cyde 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 DTC s may occur during the cycle NOTES 20 7 0 DIAGNOSTIC INFORMATION AND PROCEDURES COMMUNICATION S
210. chnical Service Bulletins that may apply Were there any problems found Yes Repair as necessary No Test Complete 316 TRANSFER CASE MECHANICAL Symptom P0839 4WD MODE SENSOR HIGH When Monitored and Set Condition P0839 4WD MODE SENSOR HIGH When Monitored Continuously with the ignition key on Set Condition When the 4WD Mode Sensor input circuit voltage raises above 4 78 volts for 5 72 seconds POSSIBLE CAUSES TRANSFER CASE POSITION SENSOR INPUT CIRCUIT OPEN TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO VOLTAGE TRANSFER CASE POSITION SENSOR POWERTRAIN ENGINE CONTROL MODULE INTERMITTENT OPERATION ACTION APPLICABILITY With the DRBIII record and erase DTC s All Start the engine and cycle the Transfer Case through all positions With the DRBIII read Transfer Case DTCs Is the Good Trip Counter equal to zero Yes GoTo 2 No GoTo 6 Turn the ignition off to the lock position Disconnect the Powertrain Engine Control Module harness connectors CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Disconnect the Transfer Case Position Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Transfer Case Position Sensor Input circuit
211. ck Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Knock Sensor Signal circuit from the Knock Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the Knock Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Knock Sensor Return circuit from the Knock Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the Knock Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the Knock Sensor Signal circuit at the Knock Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the Knock Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 Measure the resistance between the Knock Sensor Signal circuit and the Knock Sensor Return circuit at the Knock Sensor harness connector Is the resistance below 100 ohms Yes R
212. cle Another feature in the NVLD Assembly is a diaphragm that will open the seal with pressure in the evaporative system The seal will be opened at about 0 5 H2O 0 12 KPA pressure to permit the venting of vapors during refueling An added bene fit to this is that it will also allow the tank to breathe during increasing temperatures thus lim iting 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 alsoincludes 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 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 aspecial part of the controller stays alive and monitors for an NVLD switch closure This circuit within the PCM is very specific in its func tion 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 informa tion will be processed at the next key cycle NVLD Leak Detection Small Leak Test Passive If after a specif
213. connectors Disconnect the DRBIII 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 POWERTRAIN VERIFICATION TEST VER 1 No GoTo 6 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 POWERTRAIN VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Disconnect the PCM harness connector Disconnect the DRBIII from the DLC CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 8 No Repair the PCM SCI Receive circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the PCM harness connector Disconnect the DRBII from the DLC Measure the resistance between ground and the PCM SCI Receive circuit in the Data 24 COMMUNICATION NO RESPONSE FROM PCM PCM SCI ONLY NGC Continued ACTION APPLICABILITY Turn the
214. control switch to SMOKE NOTE The flow meter indicator ball will not move at this point Press the remote smoke air start button NOTE Make sure 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 8404 CLL 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 are 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 NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister the smoke or dye may or may not be visible Introducing smoke into the filtered side of the canister may assist in locating the leak Was a leak found Yes Repair or replace the leaking component as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 4 NOTE Aft
215. 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 3 3 5 TROUBLE CODE ERASURE 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 The Quick Learn function customizes adaptive parameters of the PCM to the transmission Char acteristics 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 consider ation gt 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 y
216. crocontroller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the write operation INTERNAL FAULT When Monitored With the ignition on Set Condition The SKIM has detected a fault during an internal self test RAM FAILURE When Monitored With the ignition on Set Condition The RAM fails a test that checks the RAM s ability to retain memory SERIAL LINK INTERNAL FAULT When Monitored With the ignition on Set Condition The SKIM fails an internal J 1850 communication self test STACK OVERFLOW FAILURE When Monitored With the ignition on Set Condition The micro controller has exceeded its stack space limit 283 SENTRY KEY IMMOBILIZER ANTENNA FAILURE Continued POSSIBLE CAUSES SKIM INTERNAL DTC FAILURE ACTION APPLICABILITY Note This trouble code indicates an internal SKIM fault All With the DRBIII1 read and record the SKIM DTCs and then erase the SKIM DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM DTCs Did the same SKIM DTC return Yes Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete 284 SENTRY KEY IMMOBILIZER Symptom List PCM STATUS FAILURE SERIAL LINK EXTERNAL FAULT Test No
217. ctors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the N4 Fuel Level Signal circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the N 4 Fuel Level Signal circuit at the Fuel Pump Module harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 WARNING The fuel system is under a constant pressure even with the engine off Before
218. cuit is operating properly Repair as neces sary Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 5 Disconnect the Ignition Coil harness connector All Remove the Fuel Pump Relay or ASD Relay Using a 12 volt test light connected to 12 volts probe the Ignition Coil Control circuit Crank the engine for 5 second while observing the test light NOTE Theresistance of the primary Ignition Coil on a 3 7L is 0 6 to 0 9 of an ohm at 77 F 25 C Does the test light brightly blink flicker Yes Replace the Ignition Coil Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 15 Turn the ignition off Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS 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 Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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
219. d No other fault has occured this trip Set Condition The PCM recognizes an open or short to ground in the speed control vacuum solenoid control circuit Cruise will be disabled for the remainder of that key on cycle One Trip fault Three good trips to clear the MIL POSSIBLE CAUSES SPEED CONTROL SOLENOID OPERATION V32 S C SUPPLY CIRCUIT SPEED CONTROL VACUUM SOLENOID V32 S C SUPPLY SHORT TO GROUND V36 S C VACUUM SOL CONTROL CIRCUIT SHORTED TO GROUND V32 S C SUPPLY CIRCUIT OPEN V36 S C VACUUM SOL CONTROL CIRCUIT OPEN Z212 S C GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII actuate the Speed Control Vacuum Solenoid and note operation Does the Speed Control Vacuum Solenoid actuate properly Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 2 Turn the ignition off Disconnect the S C Servo harness connector Turn the ignition on Using the DRBIII actuate the S C Vacuum Solenoid Using a 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 and flash on and off Yes GoTo 5 No GoTo 3 221 DRIVEABILITY NGC P0582 SPEED CONTROL VACUUM SOLENOID CIRCUIT Continued ACTION APPLICABILITY
220. d equal to zero Yes GoTo 2 No GoTo 14 Turn the ignition off Disconnect the CMP Sensor harness connector Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit in the CMP Sensor harness connector Is the voltage between 4 5 and 5 2 volts Yes GoTo 3 No GoTo 10 134 DRIVEABILITY NGC P0340 CAMSHAFT POSITION SENSOR CIRCUIT Continued ACTION APPLICABILITY Measure the voltage on the K44 CMP Signal circuit in the CMP Sensor harness connector Is the voltage between 4 5 and 5 0 volts Yes GoTo 4 No GoTo 7 Turn the ignition off Disconnect the C1 and C2 PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the CMP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Inspect the Camshaft sprocket for damage per the Service Informa tion If a problem is found repair as necessary If there are no possible causes remaining view repair Repair Replace the Camshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST V
221. dules communication between the modules is internal 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 Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits Pay particular attention to the TPS signal and sensor ground circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found Yes Repair as necessary Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 Test Complete 322 TRANSMISSION 42RLE Symptom P0124 THROTTLE POSITION SENSOR APPS INTERMITTENT When Monitored and Set Condition P0124 THROTTLE POSITION SENSOR APPS INTERMITTENT When Monitored Continuously with the ignition on and engine running Set Condition This DTC will set if the monitored TPS throttle angle between the angles of 6 and 120 and the degree change is greater than 5 within a period of less than 7 0 ms POSSIBLE CAUSES RELATED TPS ENGINE DTC S PRESEN
222. e Information Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off All Disconnect the C3 PCM harness connector Measure the resistance of the N112 High Speed Rad Fan Relay Control circuit from the PDC to the PCM harness connector Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the N 112 High Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 178 DRIVEABILITY NGC Symptom P0498 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW When Monitored and Set Condition P0498 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW When Monitored Engine running Set Condition ThePCM detects a short in the NVLD Canister vent solenoid circuits One trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO NVLD SOLENOID K106 NVLD SOL CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Check for any related TSBs before continuing All Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the NVLD electrical harness connector Measure the resistance of the NVLD Solenoid coil Is the resistance between 7 5 and 8 5 ohms Yes GoTo 3 No Replace the NVLD Assembly Perfo
223. e inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits Check for any Technical Service Bulletins TSB s and S T A R ON LINE for any possible causes that may apply If there are no possible causes remaining view repair Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits Pay particular attention to the TPS signal and sensor ground circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found Yes Repair as necessary Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 Test Complete 324 TRANSMISSION 42RLE Symptom P0218 HIGH TEMPERATURE OPERATION ACTIVATED When Monitored and Set Condition P0218 HIGH TEMPERATURE OPERATION ACTIVATED When Monitored Whenever the engine is running NOTE This is an informational DTC designed to aid the technician in diagnosing shift quality complaints Set Condition Immediately when a Overheat shift schedule is activated when the Transmission Oil Temperature reaches 155 C or 240
224. e 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 2 206 DRIVEABILITY NGC Symptom P0562 BATTERY VOLTAGE LOW When Monitored and Set Condition P0562 BATTERY VOLTAGE LOW When Monitored The engine running The engine speed greater than 380 RPM Set Condition Battery voltage is 1 volt less than desired system voltage POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO BATTERY POSITIVE CIRCUIT HIGH RESISTANCE GENERATOR GROUND HIGH RESISTANCE GENERATOR OPERATION K125 GEN FIELD CONTROL CIRCUIT OPEN K125 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND Z932 GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY NOTE Make sure the Battery is in good condition Using the Midtronics All Battery Tester test the Battery before continuing NOTE Inspect the vehicle for after market accessories that may exceed the Generator System output Turn the ignition off NOTE Make sure the generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse is found to be open use the wiring diagram schematic as a guide inspect the wiring and connectors for damage Ignition on engine not running With the DRBIII
225. e Information Start the engine Allow the engine to reach normal operating temperature With the DRBIII read DTCs Does the DTC reset Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No ThePCM has been successfully flashed Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 253 DRIVEABILITY NGC Symptom List P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION P1604 PCM INTERNAL DUAL PORT RAM READ WRITE INTEG RITY FAILURE P1607 PCM INTERNAL SHUTDOWN TIMER RATIONALITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION E E When Monitored and Set Condition P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION When Monitored Ignition off on and run start Set Condition Internal PCM failure detected Intermittent open on PCM Connector 1 pin 12 F11 Fused Ignition Switch Output circuit P1604 PCM INTERNAL DUAL PORT RAM READ WRITE INTEGRITY FAILURE When Monitored Ignition off on and run start Set Condition Internal PCM failure detected Intermittent open on PCM Connector 1 pin 12 F11 Fused Ignition Switch Output circuit P1607 PCM INTERNAL SHUTDOWN TIMER RATIONALITY When Monitored Ignition on Set Condition Internal PCM failure detected POSSIBLE CAUSES PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT PCM
226. e any irregular or missing signals Yes GoTo 8 No GoTo 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 Make sure 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 GoTo 10 36 DRIVEABILITY NGC P0016 CRANKSHAFT CAMSHAFT TIMING MISALIGNMENT Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 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 INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WE
227. e continues to blow it indicates a problem in the circuit that must be corrected 4 3 3 ROAD TESTING A COMPLAINT VEHCILE TRANSMISSION 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 CAUTION Before road testing a vehicle be sure that all components are reassembled During the test drive do not try to read DRBIII screen while in motion Do not hang the DRBIII from the rear view mirror or operate it yourself Have an assistant available to operate the DRBIII Road testing is an essential step in the diagnostic process that must not be overlooked Along with the diagnostic information obtained from the DRBIII 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 ac tual driving conditions J ust 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 e Delayed engagement e Poor shifting or erratic shifting e Excessive noise e Overheat
228. e is measured during two trips Above 3000 RPM 1 trip less than 3000 RPM 2 trip P0301 CYLINDER NO 1 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip P0302 CYLINDER NO 2 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip P0303 CYLINDER NO 3 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip P0304 CYLINDER NO 4 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip 114 DRIVEABILITY NGC PO0300 MULTIPLE CYLINDER MISFIRE Continued P0O305 CYLINDER NO 5 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is
229. e red flag indicates a sealed system Is the indicator ball above the red flag Yes GoTo 5 No GoTo 8 166 DRIVEABILITY NGC P0457 LOOSE FUEL CAP Continued ACTION APPLICABILITY NOTE A thorough visual inspection of the Evap system hoses tubes and All 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 in the smoke mode Press the remote smoke air start button NOTE Make sure 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 8404 CLL 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 sta
230. e steering wheel Measure the resistance across each Speed Control Switch Monitor the ohmmeter while pressing each function button on each switch Resume Accel 15 400 ohms Cancel 909 9 ohms Decel Coast 2940 30 ohms On Off 0 ohms Set 6650 H 66 ohms Does the function on the Speed Control Switches have the correct resistance value Yes GoTo 3 No Replace the Speed Control Switch that had the incorrect resis tance value Perform POWERTRAIN VERIFICATION TEST VER 4 218 DRIVEABILITY NGC P0581 SPEED CONTROL SWITCH NO 1 HIGH Continued ACTION APPLICABILITY Disconnect the upper and lower 6 way dockspring harness connectors per Service Information Measure the resistance of the K900 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 Yes Replace the clockspring Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 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
231. e the Generator Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 3 231 DRIVEABILITY NGC P0622 GENERATOR FIELD CONTROL CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the K 125 Gen Field Control circuit in the Generator Field harness connector Is the voltage above 1 0 volt Yes Repair the short to voltage in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 4 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K125 Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 Is the resistance below 100 ohms Yes Repair the short to ground in the K125 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 6 Using a 12 volt test connected to battery voltage probe the Z212 Ground circuit in the Generator Field harness connector Does the test light illumin
232. e wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis Continue GoTo 2 327 TRANSMISSION 42RLE P0562 LOW BATTERY VOLTAGE Continued ACTION APPLICABILITY With the DRBIII read the Engine DTC s All Are there any Charging System related DTC s present also Yes Refer to the Charging System category and repair any PCM Charging System DTC s before proceeding NOTE After repair ing the PCM Charging System DTC s perform the Transmission Verification test to verify the transmission was not damaged Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 No GoTo 3 NOTE Generator battery and charging system must be fully functional before performing this test With the DRBIII read Transmission DTC s With the DRBIII Check the STARTS SINCE SET counter for P0562 Note This counter only applies to the last DTC set Is the STARTS SINCE SET counter set at 0 Yes GoTo 4
233. ect the vehicle for after market accessories that may exceed the Generator System output Turn the ignition off NOTE Make sure the generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse is found to be open use the wiring diagram schematic as a guide inspect the wiring and connectors for damage Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 3 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt test light jump it across the Generator Field harness connector Ignition on engine not running With the DRBIII actuate the Generator Field Control circuit Does the test light illuminate brightly and flash on and off Yes Replace the Generator Perform POWERTRAIN VERIFICATION TEST VER 3 No GoTo 3 210 DRIVEABILITY NGC P0563 BATTERY VOLTAGE HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the C2 PCM harness connector Measure the voltage on the K125 Gen Field Control circuit at the Generator Field harness connector Is the voltage above 1 0 volt Yes Repair the short to voltage in the K125 Gen Field Control circuit Perform POWERTRAIN VERI
234. ector Is the resistance below 5 0 ohms Yes Repair the short to ground in the Coil Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Turn the ignition off ENGINE 3 7L Disconnect the C2 PCM harness connector POWER TECH V6 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Coil Control circuit from the Coil on plug connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open in the Coil Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Before continuing check the PCM harness connector terminals for ENGINE 3 7L corrosion damage or terminal push out Repair as necessary POWER TECH V6 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 POWERTRAIN VERIFICATION TEST VER 5 266 DRIVEABILITY NGC P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 3 7L Continued ACTION APPLICABILITY Turn the ignition off ENGINE 3 7L Remove the ASD Relay from
235. ed 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 1 H20 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 GENERAL INFORMATION The normally closed valve in the NVLD is in tended to maintain the seal on the evaporative system during the engine off condition If vacuumin the evaporative system exceeds 3 to 6 H 20 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 cy
236. eeak ec eeev ews oes 189 TABLE OF CONTENTS Continued P0509 IAC VALVE SIGNAL CIRCUIT HIGH 00 cece ese eeeeeeeeeeees PO513 INVALID SKIM KEY 0ccccceeeeceecseceeveueeeveueteseesees P0516 BATTERY TEMPERATURE SENSOR LOW 0 0eeeeeee eee ee P0517 BATTERY TEMPERATURE SENSOR HIGH 0 00ceeceeeeee ee P0522 OlIL PRESSURE VOLTAGE LOW n on aaoun naonnana orrae P0532 A C PRESSURE SENSOR LOW n on anonn aaan araara P0533 A C PRESSURE SENSOR HIGH nonono nanana arnan rnane P0551 POWER STEERING SWITCH PERFORMANCE 0 0 0 000s P0562 BATTERY VOLTAGE LOW 0c cece ccc cceeeeeeeceeeeeceeseeeees P0563 BATTERY VOLTAGE HIGH 0 0ccccceeeeeeeeeeeeeeeeceeeees P0572 BRAKE SWITCH NO 1 CIRCUIT LOW 0c cc cece eee eeeeeeeees P0573 BRAKE SWITCH NO 1 CIRCUIT HIGH onnaa 0c c cece eee eee ee P0580 SPEED CONTROL SWITCH NO 1 LOW onnaa nnana anran P0581 SPEED CONTROL SWITCH NO 1 HIGH 00 annann P0582 SPEED CONTROL VACUUM SOLENOID CIRCUIT 0 0 000 00 P0586 SPEED CONTROL VENT SOLENOID CIRCUIT 0 00 eee eee P0594 SPEED CONTROL SERVO POWER CIRCUIT onnaa annann nannaa P0600 SERIAL COMMUNICATION LINK nnaou anana aenaran P0601 INTERNAL MEMORY CHECKSUM INVALID n on nanana annann P0622 GENERATOR FIELD CONTROL CIRCUIT 0 cc cee eeeeeeeees P0627 FUEL PUMP RELAY CIRCUIT o on 00 0 cece eee eeceeeseeeeeeees P0630 VIN NOT PROGRAMMED IN PCM 0 0cceceeeeeeseeeeeee
237. 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 compres sion 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 NOTE Any of these conditions could result in arich 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 3 3 DIAGNOSTIC TROUBLE CODES Diagnostic trouble codes DTCs are codes stored by the Powertrain Control Module PCM that help us diagnose Powertrain Transmission and Trans fercase problems They are viewed using the DRBIII scan tool Always begin by performing a visual inspection of the wiring connectors fluid level cooler lines engine and the transmission Any obvious wiring problems or leaks should be repaired prior to performing any diagnostic test procedures Some engine driveability problems can be misinterpreted as a transmission problem En sure that the engine is running properly and that no engine DTCs are present that could cause a transmission complaint If there is a communica tion bus problem trouble codes will not be accessi ble until the problem is fixed The DRBIII will display an app
238. elow minimum or above maximum acceptable voltage POSSIBLE CAUSES TRANSFER CASE POSITION SENSOR INPUT CIRCUIT OPEN TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO GROUND TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO VOLTAGE TRANSFER CASE POSITION SENSOR INPUT CIRCUIT SHORT TO SENSOR RETURN CIRCUIT TRANSFER CASE POSITION SENSOR POWERTRAIN ENGINE CONTROL MODULE INTERMITTENT OPERATION ACTION APPLICABILITY With the DRBIII record and erase DTC s All Start the engine and cycle the Transfer Case through all positions With the DRBIII read Transfer Case DTCs Is the Good Trip Counter equal to zero Yes GoTo 2 No GoTo 8 Turn the ignition off to the lock position Disconnect the Powertrain Control Module harness connector CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Disconnect the Transfer Case Position Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Transfer Case Position Sensor Input circuit Is the resistance above 5 0 ohms Yes Repair the Transfer Case Position Sensor input circuit for an open No GoTo 3 310 TRANSFER CASE MECHANICAL P0836 4WD MUX SWITCH STUCK Continued ACTION APPLICABILITY Disconnect the Power
239. en Monitored At ignition on and during Key Programming M ode Set Condition When the SKIM does not receive a transponder response after 8 consec utive transponder read attempts within 2 0 seconds TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE When Monitored At ignition on and during Key Programming M ode Set Condition When 5 consecutive transponder signal transmissions are sent to the SKIM with the correct message format but with invalid data TRANSPONDER ID MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When the transponder ID read by the SKIM does not match any of the transponder D s stored in the SKIM s memory TRANSPONDER RESPONSE MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When thetransponder s crypto algorithm result fails to match the SKIM s result POSSIBLE CAUSES CHECKING MULTIPLE KEY OPERATION SKIM INTERMITTENT WIRING HARNESS PROBLEM REPLACE IGNITION KEY 289 SENTRY KEY IMMOBILIZER TRANSPONDER COMMUNICATION FAILURE Continued ACTION APPLICABILITY With the DRBIII read and record the SKIM DTCs With the DRBIII erase the SKIM DTCs NOTE Perform the following test several times to ensure the DTC is current Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTCs Does the DRBII1 display the DTC that was previously erased Yes GoTo 2 No
240. en 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 Start the engine Allow the engine to reach normal operating temperature With the DRBIII read the O2 Sensor voltage Is the voltage above 3 7 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the O2 Sensor harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 allow the engine to idle Measure the voltage on the O2 Sensor Signal circuit in the O2 Sensor harness connector NOTE Measure the voltage in reference to ground not the O2 Sensor Return circuit Is the voltage above 5 2 volts Yes Repair the short to voltage in the O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the PCM harness connectors Ignition on engine not running Measure the voltage on the O2 Sensor Return circuit in the O2 Sensor harness connector Is there any voltage present Yes Repair the short to voltage in the O2 Sensor Return circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 93 DRIVEABILI
241. epair the short between the Knock Sensor Signal circuit and Knock Sensor Return circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 7 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL 124 DRIVEABILITY NGC P0325 KNOCK SENSOR NO 1 CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Replace the Knock Sensor Ignition on engine not running With the DRBIII erase DTC Attempt to operate the vehicle using the information noted in the Freeze Frame With the DRBIII read DTCs Does the DRBII1 display the DTC that was previously erased 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 in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 125 DRIVEABILITY NGC Symptom P0335 CRANKSHAFT POSITION SENSOR CIRCUIT EE When Monitored and Set Condition P0335 CRANKSHAFT POSITION SENSOR CIRCUIT When Monitored Engine cranking Set Condition NoCKP signal is present during engine cranking and at least 8 camshaft position sensor signals have occurred POSSIBLE CAUSES INTERMITTENT CKP SIGNAL INTERMITTENT CMP SIGNAL F855 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
242. er disconnecting the Evap Purge Solenoid vacuum connections inspect the lines and solenoid for any signs of contamination from the E VAP 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 in Hg to the CAN side of the EVAP Purge Solenoid NOTE Monitor the vacuum gauge for at least 15 seconds Does the Evap Purge Solenoid hold vacuum Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 6 164 DRIVEABILITY NGC Symptom P0457 LOOSE FUEL CAP When Monitored and Set Condition P0457 LOOSE FUEL CAP When Monitored Ignition on Ambient temperature between 4 C and 32 C 39 F and 89 F Closed Loop fuel system Set Condition The PCM has detected an EVAP System leak after a fuel level increase Two Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO LOOSE OR MISSING FUEL FILL CAP INTERMITTENT CONDITION NVLD SERVICE TEST EVAPORATIVE EMISSION LEAK DETECTION EVAP PURGE SOLENOID OPERATION NVLD SWITCH OPERATION ACTION APPLICABILITY NOTE After the PCM has determined the leak test inconclusive and sees an All increase in fuel level the PCM will request the GAS CAP indicator on to in
243. erature 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 GoTo 9 No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 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 Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 12 Ignition on engine not running NOTE Perform the following test on the O2 Sensors whose voltage was not switc
244. erform POWERTRAIN VERIFICATION TEST VER 5 34 DRIVEABILITY NGC P0016 CRANKSHAFT CAMSHAFT TIMING MISALIGNMENT Continued ACTION APPLICABILITY Turn the ignition off With the DRBIII lab scope probe and the Miller special tool 6801 backprobe the K 44 CMP Signal circuit at the CMP harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 GoTo 3 No GoTo 6 Turn the ignition off All 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 Make sure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are torqued to the correct specification Refer to any TSBs that may apply Were any of the above conditions present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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
245. es GoTo 5 No Replace theA C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 Measure the resistance between ground and the C13 A C Clutch Relay Control circuit in the PDC Is the resistance below 5 0 ohms Yes Repair the short to ground in the C13 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 Disconnect the C3 PCM harness connector All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the C13 A C Clutch Relay Control circuit from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the C13 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 239 DRIVEABILITY NGC Symptom P0685 ASD RELAY CONTROL CIR
246. es P0632 ODOMETER NOT PROGRAMMED IN PCM 0 0eeeeeeeees P0633 SKIM KEY NOT PROGRAMMED IN PCM 0 0cseeseeeeeeees P0645 A C CLUTCH RELAY CIRCUIT o n 00 c cece cee ceeeeeeeeeeeeees P0685 ASD RELAY CONTROL CIRCUIT onnaa 0c c cee arnan nran P0688 ASD RELAY SENSE CIRCUIT LOW 0c cc cee seeeeeeeeeees P0700 TRANSMISSION CONTROL SYSTEM MIL REQUEST 0 P0850 PARK NEUTRAL SWITCH PERFORMANCE 00 0eceeeees P1115 GENERAL TEMPERATURE SENSOR PERFORMANCE P1593 SPEED CONTROL SWITCH NO 1 STUCK 0c ccceeseeeeeeees P1602 PCM NOT PROGRAMMED 0cccceeeeceeeseeseeeeeeees P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION 0 P1604 PCM INTERNAL DUAL PORT RAM READ WRITE INTEGRITY FAILURE P1607 PCM INTERNAL SHUTDOWN TIMER RATIONALITY 00000 P1696 PCM FAILURE EEPROM WRITE DENIED 0 0eeeseeeees P1697 PCM FAILURE SRI MILES NOT STORED 0c 0eseeeeeeees P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 00 0es eee eee ees P2097 DOWN STREAM FUEL TRIM RICH BANK 1 0c e eee eee eees P2098 DOWN STREAM FUEL TRIM LEAN BANK 2 0 0eceeeee ees P2099 DOWN STREAM FUEL TRIM RICH BANK 2 0c 0eseeeeeeees P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION CAD e reena err ina gearr Erna ieetauineeteeansed P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION CA repine a EE ase aden ette
247. est Yes GoTo 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Disconnect the DRBIII 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 POWERTRAIN VERIFICATION TEST VER 1 No GoTo 3 Turn the ignition off Disconnect the DRBIII 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 POWERTRAIN VERIFICATION TEST VER 1 No GoTo 4 23 COMMUNICATION NO RESPONSE FROM PCM PCM SCI ONLY NGC Continued ACTION APPLICABILITY Turn the ignition off Disconnect the DRBIII 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 Yes Repair the short between the PCM SCI Transmit and the PCM SCI Receive circuits Perform POWERTRAIN VERIFICATION TEST VER 1 GoTo 5 Turn the ignition off Disconnect the PCM harness
248. et Condition P0633 SKIM KEY NOT PROGRAMMED IN PCM When Monitored Ignition on Set Condition The SKIM Key information has not been programmed into the PCM POSSIBLE CAUSES PROGRAMMING SKIM KEY INTO PCM PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs Using the DRBIII program the SKIM Key information into the PCM Start the engine NOTE If the engine will not start crank the engine over for 15 seconds Crank at least 2 times with the ignition switch returning to the off position each time Allow the engine to reach normal operating temperature With the DRBIII read DTCs Does the DTC reset Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No TheSKIM KEY information has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 5 237 DRIVEABILITY NGC Symptom P0645 A C CLUTCH RELAY CIRCUIT When Monitored and Set Condition P0645 A C CLUTCH RELAY CIRCUIT When Monitored With theignition on Battery voltage greater than 10 volts A C Switch on Set Condition An open or shorted condition is detected in the A C clutch relay control circuit The desired A C state does not equal the actual A C clutch relay state Three good trips to clear the MIL POSSIBLE CAUSES A C CLUTCH RELAY OPERATION F1 FUSED IGNITION SWITCH OUTPUT C
249. f 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 vehicleon hoist and disconnect the fuel pressure line at the fuel pump module Install special tool 6539 5 16 6631 3 8 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 DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi H 5 psi Is the fuel pressure within specification Yes Repair or replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 119 DRIVEABILITY NGC PO300 MULTIPLE CYLINDER MISFIRE Continued ACTION APPLICABILITY 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 cir
250. for an example Block the vent hose of the EVAP Canister Connect shop air to the EELD Set the smoke air control switch to AIR Insert the tester s AIR supply tip clear hose into the 040 orifice on the tester s control panel 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 flow meter is now calibrated in liters per minute Install the service port adapter 8404 14 on the vehicle s service port if equipped or install the 8404 ADP into the filter line Connect theAir supply hose from the EELD tothe service port if equipped or to the 8404 ADP adapter Press the remote button to activate AIR flow NOTE Larger volume fuel tanks lower fuel levels or if the vehicle is equipped with a Flow Management Valve this may indicate high flow and will 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 GoTo 7 No GoTo 8 146 DRIVEABILITY NGC P0440 GE NERAL EVAP SYSTEM FAILURE Continued ACTION APPLICABILITY NOTE A thorough visual inspection of the Evap system hoses tubes and All connections may save time in your diagnosis Look for any physical damage or signs of wetness at connec
251. form the customer that the gas fill cap is loose or off Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 6 Perform a visual and physical inspection of the Fuel Fill Cap and the fill tube Check for the follow conditions Improper installation of Fuel Fill Cap Loose or missing Fuel Filler Cap Holes or cracks Damaged Locking tabs on Cap and or fill tube Damaged seal points on Cap and or fill tube Fuel Fill Cap gasket seal Were any of the above conditions found Yes Repair or replace the fuel fill cap as needed Ensure proper fuel fill cap installation Once the repair is complete continue to step 3 Perform POWERTRAIN VERIFICATION TEST VER 6 GoTo 3 165 DRIVEABILITY NGC P0457 LOOSE FUEL CAP Continued ACTION APPLICABILITY With the DRBIII perform the NVLD Service Test All Did the NVLD Service Test pass Yes Test Complete Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 4 To continue testing you will need Miller Tool 8404 Evaporative Emission Leak Detector EELD WARNING Keep lighted cigarettes sparks flames and other ignition sources away from the test area to prevent the ignition of explosive gases Keep the test
252. from the CKP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Measure the voltage on the K24 CKP 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 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 Measure the resistance between the K 24 CKP Signal circuit and the F 855 5 volt All Supply circuit at the CKP Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K24 CKP Signal circuit and the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 6 127 DRIVEABILITY NGC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO
253. g 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 STARTS SINCE SET COUNTER POWERTRAIN 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 DRBIII as STARTS since set When there are no trouble codes stored in memory the DRBIII will display NO TROUBLE CODES FOUND and the reset counter will show STARTS since set XXX OBDII vehi cles 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 consec utive Good Trips the MIL is extinguished and the good trip counter is replaced by a Warm Up Cycle counter 40 Warm Up Cycles will erasethe DTC and Freeze Frame information TRANSMISSION The Starts Since Set counter counts the number of times the vehicle has started since the most GENERAL INFORMATION recent DTC was set The counter will count up to 255 starts Note that this counter only applies tothe last code set When there are no diagnostic trouble codes stored in memory the DRBIII will display NO DTC s PRESENT and the reset
254. g 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 Tem perature 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 NGC 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 allow ing throttle position to decrease A special dump solenoid allows immediate release of throttle posi tion caused by braking cruise control turn off shifting into neutral excessive RPM tires spin ning or ignition key off 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 start ing in 2002 M Y This new system replaces the leak detection pump as the method of evaporative sys tem leak detection The current CARB requirement is to detect a leak equivalent to a 0 020 0 5 mm hole This
255. ge Sensor Input Speed Sensor and Output Speed Sensor are located on the left side of the transmission Refer to the Service Information for transmission D tag descriptions GENERAL INFORMATION 3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3 1 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 TRANSMISSION The 42RLE electronic Transmission is a conven tional Transmission in that it uses hydraulically applied clutches to shift a planetary gear train However the electronic control system replaces many of the mechanical and hydraulic components used in conventional transmission valve bodies 3 2 FUNCTION OPERATION 3 2 1 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 de pending 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 deter mined 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
256. ge turns off the field driver and senses the battery voltage again If the voltages are the same the code is set POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO BATTERY POSITIVE CIRCUIT HIGH RESISTANCE CASE GROUND HIGH RESISTANCE GENERATOR OPERATION Z932 GEN GROUND CIRCUIT OPEN K125 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K125 GEN FIELD CONTROL CIRCUIT OPEN K125 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY NOTE Inspect the vehicle for aftermarket accessories that may exceed the All Generator System output Ignition on engine not running NOTE The battery must be fully charged NOTE The Generator belt tension and condition must be checked before continuing With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII erase DTCs Start the engine Allow the idle to stabilize Ignition on engine not running With the DRBIII read DTCs Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 3 268 DRIVEABILITY NGC P2503 CHARGING SYSTEM OUTPUT LOW Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE Ensure all wires are clear of the engine s moving parts
257. greater than 10 volts Set Condition No voltage sensed at the PCM when the ASD relay is energized for 3 075 seconds Three good trips to clear the MIL POSSIBLE CAUSES VERIFY ASD DTC ASD RELAY A907 FUSED B CIRCUITS A142 ASD RELAY OUTPUT CIRCUIT OPEN NO START A142 ASD RELAY OUTPUT CIRCUIT SHORTED TO GROUND A142 ASD RELAY OUTPUT CIRCUIT OPEN START PCM ACTION APPLICABILITY NOTE Diagnose P0685 Auto Shutdown Relay Control Circuit first if set All along with this DTC With the DRBIII erase the DTC Attempt to start the engine If the engine will not start crank the engine for at least 15 seconds It may be necessary to repeat several times Does the DTC reset Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Attempt to start the engine Does the engine start Yes GoTo 3 No GoTo 4 242 DRIVEABILITY NGC P0688 ASD RELAY SENSE CIRCUIT LOW Continued ACTION APPLICABILITY Turn the ignition off Remove the ASD Relay from the PDC Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the A142 ASD Relay Output circuit from the PDC to the appropriate terminals of special to
258. harness connector and the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the B22 Vehicle Speed Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the B22 Vehicle Speed Signal circuit in the BCM harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the B22 Vehicle Speed Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 is no possible causes remaining view repair Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 184 DRIVEABILITY NGC Symptom P0506 IDLE SPEED PERFORMANCE LOWER THAN EXPECTED TT When Monitored and Set Condition P0506 IDLE SPEED PERFORMANCE LOWER THAN EXPECTED When Monitored With the engine running at idle MAF lt 250 m g tdc air temp gt 17 8 C O F and lt 7 C 19 4 F enable after coolant temp gt 70 C 158 F or air temp gt 7 C 19 4 F coolant temp gt 7 C 19 4 F lt 130 C 266 F canister purge lt 100 duty cycle and noVSS MAF MAP
259. he DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Choose a conclusion that best matches your fuel pressure reading Below Specification GoTo 2 Within Specification GoTo 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 Raise vehicle on hoist and disconnect the fuel supply line at the fuel pump module Install special tool 6539 5 16 6631 3 8 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 DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Is the fuel pressure within specification Yes Visually and physically inspect the fuel supply lines between the fuel tank and the fuel rail Repair replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 GoTo 3 295 STARTING CHECKING HARD START FUEL DELIVERY SYSTEM Continued ACTION APPLICABILITY Turn the ignition off All 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 press
260. he Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Remove the Fuel Pump Relay from the PDC Using a 12 volt test light connected to ground backprobe the A14 Fuel Pump Relay Fused B circuit at the PDC Does the test light illuminate Yes GoTo 9 No Repair the open or short to ground in the A14 Fuel Pump Realy Fused B circuit Inspect the fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Disconnect the Fuel Pump Module harness connector Measure the resistance of the A141 Fuel Pump Relay Output circuit from the relay connector to the Fuel Pump Module connector Is the resistance below 5 0 ohms Yes Replace the Fuel Pump Relay Perform POWERTRAIN VERIFICATION TEST VER 1 No Repair the open in the A141 Fuel Pump Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 1 294 STARTING Symptom CHECKING HARD START FUEL DELIVERY SYSTEM POSSIBLE CAUSES RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED FUEL PUMP MODULE FAULTY FUEL PUMP MODULE FUEL INJ ECTOR S FUEL CONTAMINATION ACTION APPLICABILITY Turn the ignition off All 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 at the engine Ignition on engine not running With t
261. he PCM monitors the fuel level at ignition on Set Condition TEST 1 IfthePCM does not see a difference in fuel level of greater than 0 1 volt the test will fail TEST 2 If the PCM does not see a change in the fuel level of 1765 over a set amount of miles the test will fail POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO VISUALLY INSPECT FUEL TANK N4 FUEL LEVEL SIGNAL CIRCUIT OPEN N4 FUEL LEVEL SIGNAL CIRCUIT SHORTED TO GROUND K900 SENSOR GROUND CIRCUIT OPEN INTERNAL INSPECTION OF THE FUEL TANK FUEL LEVEL SENSOR ACTION APPLICABILITY NOTE Diagnose P0462 or P0463 first if set along with P0461 All NOTE Inspect the Fuel Pump Module harness connector for any corrosion or damage Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving Is the Fuel Tank OK Yes GoTo 3 No Replace the Fuel Tank as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 169 DRIVEABILITY NGC P0461 F VEL LEVEL SENSOR NO 1 PERFORMANCE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Fuel Pump Module harness connector Disconnect the C2 and C3 PCM harness conne
262. he filter line Press the remote button to activate AIR flow NOTE Larger volume fuel tanks lower fuel levels or if the vehicle is equipped with a Flow Management Valve may indicate high flow and will 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 GoTo 4 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 153 DRIVEABILITY NGC P0442 EVAP SYSTEM MEDIUM LEAK Continued ACTION APPLICABILITY NOTE A thorough visual inspection of the Evap system hoses tubes and All 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 if equipped or from the 8404 ADP adapter Connect the SMOKE supply tip black hose to the service port if equipped or to the 8404 ADP adapter Set the smoke air control switch to SMOKE NOTE The flow meter indicator ball will not move in the smoke mode Press the remote smoke air start button NOTE Make sure that smoke has filled the EVAP system by continuing to press the remote smoke
263. he fuel rail test port Ignition on engine not running With the DRBII I actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Choose a conclusion that best matches your fuel pressure reading Below Specification GoTo 3 Within Specification Test Complete Above Specification Replace the fuel filter fuel pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 1 Caution Stop All Actuations 292 STARTING CHECKING FUEL DELIVERY Continued ACTION APPLICABILITY Turn the ignition off All 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 DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Is the fuel pressure within specification now Yes Repair replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 4 Caution Stop All Actuati
264. he 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 4 217 DRIVEABILITY NGC Symptom P0581 SPEED CONTROL SWITCH NO 1 HIGH et When Monitored and Set Condition P0581 SPEED CONTROL SWITCH NO 1 HIGH When Monitored With the ignition key on Battery voltage above 10 volts Set Condition The PCM detects voltage above 4 8 volts in the Speed Control Switch Signal circuit One Trip Fault POSSIBLE CAUSES SPEED CONTROL SWITCH VOLTAGE HIGH SPEED CONTROL SWITCHES CLOCKSPRING V37 S C SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE V37 S C SWITCH SIGNAL CIRCUIT OPEN BETWEEN PCM AND CLOCKSPRING K900 SENSOR GROUND CIRCUIT OPEN BETWEEN PCM AND CLOCKSPRING V37 S C SWITCH SIGNAL CIRCUIT OPEN BETWEEN CLOCKSPRING AND S C SWITCH K900 SENSOR GROUND CIRCUIT OPEN BETWEEN CLOCKSPRING AND S C SWITCH PCM ACTION APPLICABILITY NOTE Do not press any of the Speed Control Switch buttons All Ignition on engine not running With the DRBIII read the Speed Control voltage Is the Speed Control voltage above 4 8 volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Remove the Speed Control Switches from th
265. hing properly in the previous step Disconnect the O2 Sensor harness connector With the DRBIII monitor the O2 Sensor voltage O2 Sensor voltage should read 5 0 volts on the DRBIII 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 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 NOTE Remove the jumper wire before continuing 103 DRIVEABILITY NGC P0O171 FUEL SYSTEM 1 1 LEAN Continued ACTION APPLICABILITY Only have one O2 Sensor disconnect at a time All With the DRBIII monitor all the O2 Sensor voltage readings NOTE The DRBIII will display all O2 Sensor voltage readings approxi mately 5 0 volts when only one O2 Sensor s Signal circuit is shorted to voltage NOTE The DRBIII will display one O2 Sensor voltage close to zero and the others will read lower than normal when one O2 Sensor Signal circuit contains excessive resistance Is the voltage above 4 8 volts Yes GoTo 12 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 Informati
266. hose fitting or line the fuel system pressure must be released Install a fuel pressure gauge Start the engine and observe the fuel pressure reading NOTE Fuel pressure specification is 407 KPa 34 KPa 59 psi 5 psi Choose a conclusion that best matches your fuel pressure reading Within Specification GoTo 7 Below Specification GoTo 12 Above Specification Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 117 DRIVEABILITY NGC PO300 MULTIPLE CYLINDER MISFIRE Continued ACTION APPLICABILITY NOTE Before continuing visually and physically inspect the fuel delivery All 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 16 or 6631 3 8 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 407 KPa 34 KPa 59 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 Upstream gauge fall
267. iate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open in the F855 5 volt Supply circuit 75 DRIVEABILITY NGC P0122 THROTTLE POSITION SENSOR NO 1 LOW Continued ACTION APPLICABILITY Ignition on engine not running All With the DRBIII 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 tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 No Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 76 DRIVEABILITY NGC Symptom P0123 THROTTLE POSITION SENSOR NO 1 HIGH When Monitored and Set Condition P0123 THROTTLE POSITION SENSOR NO 1 HIGH 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 POSSIBLE CAUSES THROTTLE POSITION SENSOR SWEEP INTERMITTENT CONDITION THROTTLE POSITION SENSOR K22 TP SENSOR NO 1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K22 TP SENSOR NO 1 SIGNAL CIRCUIT OPEN K22 TP SENSOR NO 1 SIGNAL CIRCUIT SHORTED TO THE F855 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABI
268. ice Information Is the Low Pressure Switch OK Yes GoTo 5 No Replace the Low Pressure Switch Perform POWERTRAIN VERIFICATION TEST VER 2 Ignition on engine not running Position the Mode switch on theA C Heater Control Module to the Panel position With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while pressing the A C mode switch on and off Does the A C Select Switch state change accordingly Yes GoTo 6 No GoTo 13 Position the Mode switch on theA C Heater Control Module to the Panel position With the DRBIII in Powertrain select Engine and select Inputs Outputs Monitor the A C Select Switch state while pressing the A C mode switch on and off Does the A C Select Switch state change accordingly Yes GoTo 7 Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 GoTo 9 No Repair the open in the A C Compressor Clutch ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Remove the A C Clutch Relay Note Check connectors Clean repair as necessary Measu
269. ide of the EVAP Canister Due to the filtering system in the canister the smoke or dye may or may not be visible Introducing smoke into the filtered side of the canister may assist in locating the leak Was a leak found Yes Repair or replace the leaking component as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 11 Turn the ignition off Disconnect the NVLD electrical harness connector Check connectors Clean repair as necessary Ignition on engine not running Connect a jumper wire between the K 107 NVLD Switch Signal circuit and the Z201 Ground circuit in the NVLD electrical harness connector Monitor the NVLD Switch state on the DRBIII Does the Switch change from OPEN to CLOSED Yes Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 9 NOTE Remove the jumper wire before continuing 147 DRIVEABILITY NGC P0440 GE NERAL EVAP SYSTEM FAILURE Continued ACTION APPLICABILITY Turn the ignition off All Measure the resistance between the Z201 Ground circuit and ground Is the resistance below 5 0 ohms Yes GoTo 10 No Repair the open in the Z201 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 6 Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER S
270. ied 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 closureis recorded as a Pass and the timers that are recording accumulated time are reset GENERAL INFORMATION This diagnostic test can take at least a week to maturea 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 0 020 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 bea limit on the amount of accrued run time during one specific drive that can be applied to the one week timer The enabling criteria to run this monitor are e Fuel level less than 85 e Ambient temperature greater than 40 F 4 4 C Rationality Tests 1 The rationality check of the switch solenoid and seal
271. ike vehide replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Disconnect PCM harness connectors Measure the resistance between ground and the F 855 5 volt Supply circuit with all the Sensor harness connectors disconnected Is the resistance below 100 ohms Yes Repair the short to ground in the F855 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 8 Disconnect all sensors that use the F856 5 volt Supply Measure the resistance between ground and the F 856 5 volt Supply circuit in the PCM harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 9 Turn the ignition off All Disconnect the TP Sensor harness connector Ignition on engine not running Measure the voltage on the F 855 5 volt Supply circuit Disconnect all the sensors that use F855 5 volt Supply circuit Did the voltage return to 4 5 to 5 2 volts when disconnecting any of the sensors Yes Replace the sensor that is pulling down the 5 volt supply Perform POWERTRAIN VERIFICATION TEST VER 1 305 STARTING NO RESPONSE FROM PCM WITH ANO START CONDITION Continued ACTION APPLICABILITY
272. ing The next step is to verify that the shift linkage is correctly adjusted If the shift linkage is incorrectly adjusted a number of complaints can result ThePCM monitors the Shift Lever Position SLP Sensor continuously If the linkage is incorrectly 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 e Delayed clutch engagement e Erratic shifts e Vehicle will drive in neutral e Engine will not crank in park or neutral e Gear shift linkage will be able to be shifted without the key in the ignition e Not able to remove the ignition key in park e 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 e Is the complaint or concern what you think the problem is based on the drivers description of the problem e Is the Transmission operating normally or is there a real problem e When does the problem occur e Is the problem only in one gear range e What temperature does the problem occur e Does the vehicle have to sit over night for the problem to occur e Does the transmission go into Limp in mode
273. ing System functioning properly Yes GoTo 3 No Repair the cause of the engine overheating Refer to the Service Information for the related symptoms or repair procedures Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 325 TRANSMISSION 42RLE P0218 HIGH TEMPERATURE OPERATION ACTIVATED Continued ACTION APPLICABILITY Perform Transmission Cooler Flow Check per the Service Information All Did the Transmission Cooler Flow Check test pass Yes GoTo 4 No Repair or replace the plugged Transmission Oil Cooler per the Service Information Repair the cause of the plugged Transmis sion Oil Cooler as necessary Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 This DTC is an informational DTC designed to aid the Technician in diagnosing shift quality complaints This DTC indicates that the transmission has been operating in the Overheat shift schedule which may generate a customer complaint The customer driving patterns may indicate the need for an additional transmission oil cooler With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set View repair options Repair Repair the cause of transmission overheating per the Service Information Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 326 TRANSMISSION 42RLE Symptom P0562 LOW BATTERY VOLTAGE SS When Monitored and Set Condition P0562 LOW BATTERY V
274. ing error from outside interference 4 3 WARNINGS AND CAUTIONS 4 3 1 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 DRBIII screen while in motion Do not hang the DRBIII from the rear view mirror or operate it yourself Have an assistant available to operate the DRBIII 4 3 2 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 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 over load If a properly rated fus
275. inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair as necessary Perform SKIS VERIFICATION No GoTo 3 NOTE Before proceeding it will be necessary to obtain the SKIM PIN Turn the ignition on With the DRBIII display and erase all ECM and SKIM DTCs Perform 5 ignition key cycles leaving theignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM DTCs Does the code appear Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete 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 wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 286 SENTRY KEY IMMOBILIZER Symptom List ROLLING CODE FAILURE VIN MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ROLLING CODE FAILURE When Monitored and Set Condition ROLLING CO
276. ion off Disconnect the C1 and C2 PCM harness connectors Ignition on engine not running Using a 12 volt test light connected to ground probe the G31 AAT Signal circuit at the AAT Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 5 No Repair the open in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE
277. ion passage Pressure then pushes the Diaphragm down unseating the Poppet Valve allow the EVAP pressure to exit to the Vent Filter Vacuum Relief The Poppet Valve is spring loaded closed up The Poppet Valve begins to open at 3 4 H2O Vacuum and is completely open at 6 H2O flows 70 Liters per Minute Vacuum acts on the bottom of the Poppet Valve amp draws it down to open the Purge Canister EVAP System to the Vent Filter NVLD Solenoid has a Resistance of 8 Ohms 0 5 Ohm at 68 Degrees F When Energized it pulls the Pintle down thus opening the Poppet Valve and connects the Purge Canister with the Vent Filter Atmosphere 80e6datd GENERAL INFORMATION TEST EQUIPMENT The Evaporative Emission Leak Detector EELD Miller Special Tool 8404 is capable of visually de tecting 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 3 2 6 NON MONITORED CIRCUITS The PCM does not monitor the following circuits systems and conditions even though they could have malfunctions that result in d
278. ir Repair Replace and program the Powertrain Engine Control Module per the Service Information Perform the appropriate Powertrain verification test 311 TRANSFER CASE MECHANICAL P0836 4WD MUX SWITCH STUCK Continued ACTION APPLICABILITY The conditions to set this DTC are not present at this time All Note Use the Freeze Frame Data to help duplicate the conditions that set the DTC Pay particular attention to the DTC set conditions such as VSS MAP ECT and Load Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary No Test Complete 312 TRANSFER CASE MECHANICAL Symptom P0837 4WD MUX SWITCH PERFORMANCE When Monitored and Set Condition P0837 4WD MUX SWITCH PERFORMANCE When Monitored Continuously with the ignition on Set Condition The 4WD muxed switch input detected in an invalid range or irrational switch state POSSIBLE CAUSES RELATED DTCS PRESENT TRANSFER CASE SHIFTER OUT OF ADJ USTMENT TRANSFER CASE POSITION SENSOR OUT OF TOLERANCE POWERTRAIN ENGINE CONTROL MODULE ACTION APPLICABILITY With the DRBIII read DTCs All Are any other Transfer Case DTCs present Yes
279. istance below 100 ohms Yes Repair the short to ground in the K 44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 Turn the ignition off All Disconnect the C1 and C2 PCM harness connectors Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit in the CMP Sensor harness connector Is the voltage above 5 3 volts Yes Repair the short to voltage in the F 856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F 856 5 volt Supply circuit between the CMP Sensor harness connector and the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 12 No Repair the open in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the F 856 5 volt Supply circuit in the CMP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 136 DRIVEABILITY NGC P0340 CAMSHAFT POSITION SENSOR CIRCUIT Continued ACTI
280. it Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 68 DRIVEABILITY NGC P0116 E NGINE COOLANT TEMPERATURE CIRCUIT PERFORMANCE Continued ACTION APPLICABILITY Measure the resistance between the K2 ECT Signal circuit and the K900 Sensor All ground circuit at the ECT Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K900 Sensor ground and the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 69 DRIVEABILITY NGC Symptom P0117 E NGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW NT When Monitored and Set Condition PO117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW When Monitored With the ignition on Battery voltage greater than 10 volts Set Condition TheEngine 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 POSSIBLE CAUSES ECT SENSOR VOLTAGE BELOW 0 5 OF A VOLT ECT SENSOR K2
281. ition on engine not running Measure the voltage between the A C On Off Control circuit and ground Is the voltage greater than 11 0 volts Yes GoTo 14 No GoTo 15 Turn the ignition off Disconnect the A C Heater Control C1 harness connector Ignition on engine not running With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while connecting a jumper wire between ground and theA C On Off Control circuit in the A C Heater Control C1 harness connector Does the A C Select Switch state change from Off to On when the jumper wire is connected Yes Replace the A C Heater Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Replace and program the Body Control Module per Service Information Perform BODY VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the A C Heater Control C1 harness connector 280 DRIVEABILITY NGC CHECKING A C SYSTEM OPERATION WITH NO DTCS Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the BCM C1 harness connector Disconnect the A C Heater Control C1 harness connector Measure the resistance of the A C On Off Control circuit between the BCM C1 harness connector and the A C Heater Control C1 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Body Control Module per Service Information Perform BODY VERIFICATION
282. iver circuit from the Ignition Coil connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the Ignition Coil Driver circuit Perform POWERTRAIN VERIFICATION TEST VER 5 262 DRIVEABILITY NGC P2302 IGNITION COIL NO 1L SECONDARY CIRCUIT INSUFFICIENT IONIZATION 2 4L Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for ENGINE 2 4L corrosion damage or terminal push out Repair as necessary POWER TECH Using the schematics as a guide inspect the wire harness and connectors Pay DOHC l 4 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 5 263 DRIVEABILITY NGC Symptom List P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L P2308 IGNITION COIL NO 3 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L P2311 IGNITION COIL NO 4 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L P2314 IGNITION COIL NO 5 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L P2317 IGNITION COIL NO 6 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 3 7L Test Note All symptoms listed above are diagnosed using the
283. l temperature gt Normal operation upshifts kickdowns and coastdowns gt Full EMCC No PEMCC except to engage FEMCC except at closed throttle at speeds above 113 133 Km h 70 83 MPH Overheat Oil temperature above 115 C 240 F or engine coolant temperature above 118 C 244 F gt Goes to a Hot below 110 C 230 F oil tempera ture or a Super Overheat above 115 C 240 F oil temperature gt Delayed 2 3 upshift 40 51 Km h 25 32 MPH gt Delayed 3 4 upshift 66 77 Km h 41 48 MPH gt 3rd gear FEMCC from 48 77 Km h 30 48 MPH gt 3rd gear PEMCC from 43 50 Km h 27 31 MPH Super Overheat Oil temperature above 127 C 260 F gt Goes back to a Overheat below 115 C 240 F oil temperature gt All a Overheat shift schedules features apply gt 2nd gear PEMCC above 35 Km h 22 MPH gt Above 35 Km h 22 MPH the torque converter will not unlock unless the throttleis closed i e at 80 Km h 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle or if a wide open throttle 2nd PEMCC to 1 kickdown is made Causes for operation in the wrong tempera ture shift schedule Extreme Cold or Cold shift schedule at start up gt Temperature Sensor circuit gt Overheat or Super Overheat shift schedule after extended operation gt Operation in city traffic or stop and go traffic gt E
284. lace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 255 DRIVEABILITY NGC Symptom List P1696 PCM FAILURE EEPROM WRITE DENIED P1697 PCM FAILURE SRI MILES NOT STORED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1696 PCM FAILURE EEPROM WRITE DENIED E When Monitored and Set Condition P1696 PCM FAILURE EEPROM WRITE DENIED When Monitored Ignition key on Continuous Set Condition An attempt to program write to the internal EEPROM failed Also checks at powerdown P1697 PCM FAILURE SRI MILES NOT STORED When Monitored Ignition key on Continuous Set Condition An attempt to program write to the internal EEPROM failed Also checks at powerdown POSSIBLE CAUSES DRB DISPLAYS WRITE FAILURE DRB DISPLAYS WRITE REFUSED 2ND TIME DRB DISPLAYS SRI MILEAGE INVALID COMPARE SRI MILEAGE WITH ODOMETER ACTION APPLICABILITY With the DRBIII perform the SRI Memory Test All Does the DRBII1 display Write Failure Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 2 With the DRBIII perform the SRI Memory Test Does the DRBIII display Write Refused Yes GoTo 3 No GoTo 4 256 DRIVEABILITY NGC P1696 PCM FAILURE EEPROM WRITE DENIED Continued ACTION APPLICABILITY With the DRBIII
285. lt 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 258 DRIVEABILITY NGC P2096 DOWN STREAM FUEL TRIM LEAN BANK 1 Continued POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO EXHAUST LEAK ENGINE MECHANICAL PROBLEM O2 SENSOR O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT FUEL CONTAMINATION ACTION APPLICABILITY NOTE Check the vehicle repair history If the O2 has been replace ensure All that the O2 sensor was properly installed and meets OEM specification 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 DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off WARNING To avoid personal injury from the exhaust system being hot allow the exhaust to cool down to a safe temperature before performing a physical inspection Visually and Physically inspect the for holes cracks and blockage in the exhaust system Is the exhaust system is good condition Yes GoTo 3 No Repair or Replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 259 DRI
286. measured during two trips or with a 10 to 30 misfire rate during one trip P0306 CYLINDER NO 6 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully updated Set Condition When more than a 2 2 5 LEV misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip POSSIBLE CAUSES INTERMITTENT MISFIRE VISUAL INSPECTION A142 F142 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 INJ ECTOR INJ ECTOR CONTROL CIRCUIT PCM 115 DRIVEABILITY NGC PO300 MULTIPLE CYLINDER MISFIRE Continued ACTION APPLICABILITY NOTE Check for any TSBs that apply to a Misfire condition Review the All 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 vehicleis operating in the SIMILAR CONDITIONS WINDOW refer tothe WHICH CYLINDER IS MISFIRING screen Observe the WHICH CYLINDER IS MISFIRING screen for at least one minute Is there a misfire present Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom
287. might make an inad vertent electrical contact 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 proce dures is very important to the safety of individuals performing diagnostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING 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 15 GENERAL INFORMATION 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 DRBIII Scan Tool passes without failure 4 2 3 SEVICING SUB ASSEMBLIES Some components of the powertrain system are intended to be serviced in assembly only Attempt ing to remove or repair certain system sub components 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 4 2 4 DRBIII SAFETY INFORMATION WARNING EXCEEDING THE LIMITS OF THE DRBIIIe 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 specifi cations at all times e Do not use the DRBIII if it has been
288. mph with the engine at 1200 1700 rpm and MAP vacuum between 15 0 and 21 0 inches of mercury Ho 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 P0430 CATALYST 2 1 EFFICIENCY When Monitored After engine warm up to 147 deg 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 Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO VISUALLY INSPECT CATALYTIC CONVERTER EXHAUST LEAK ENGINE MECHANICAL CONDITION AGING O02 SENSOR CATALYTIC CONVERTER 142 DRIVEABILITY NGC P0420 CATALYST 1 1 EFFICIENCY Continued ACTION APPLICABILITY NOTE A new rear O2 Sensor along with an aging front O2 Sensor may cause the DTC to set Review the repair history of the vehicle before continuing NOTE If a O2 Sensor DTC s set along with the Catalytic Converter Efficiency DTC diagnose the O2 Sensor DTC s before continuing NOTE Check for contaminants that may
289. n before continuing the test Allow the O2 Sensor voltage to stabilize at 5 0 volts Ignition on engine not running With the DRBIII actuate the O2 Heater Test With the DRBIII monitor O2 Sensor voltage for at least 2 minutes Does the O2 Sensor voltage stay above 4 5 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 Is the resistance between 2 0 and 30 ohms Yes GoTo 3 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 Ignition on engine not running With the DRBIII 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 at the O2 Sensor harness connector Does the test light illuminate brightly and flash on and off Yes GoTo 4 No GoTo 5 Turn the ignition off Measure the resistance between engine ground and the O2 Heater ground circuit at the O2 Sensor harness connector Is the resistance below 5 0 ohms Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Repair the open in the O2 Heater ground circuit Perform POWERTRAIN VERIFICATI
290. n When the PCM recognizes Brake Switch 1 is stuck in the high off position One Trip Fault Three good trips to turn off the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO BRAKE LAMP SWITCH OPERATION B15 BRAKE SWITCH NO 1 SIGNAL CIRCUIT OPEN Z940 GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Measure the resistance between the Ground circuit terminal and the B15 Brake Switch No 1 Signal circuit terminal in the Brake Lamp Switch Apply and release the brake pedal while monitoring the onmmeter Does the resistance change from below 5 0 ohms to an open circuit Yes GoTo 3 No Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 4 214 DRIVEABILITY NGC P0573 BRAKE SWITCH NO 1 CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Meas
291. n on engine not running With the DRBIII read AAT Sensor voltage Is the voltage above 4 6 volts Yes Replace the Ambient Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Measure the resistance between ground and the G31 AAT Signal circuit at the AAT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 52 DRIVEABILITY NGC P0072 AMBIENT TEMP SENSOR CIRCUIT LOW Continued ACTION APPLICABILITY Measure the resistance between the G31 AAT Signal circuit and the K900 Sensor All ground circuit at the AAT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground circuit and the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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
292. nated Perform BODY VERIFICATION TEST VER 1 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 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 32 DRIVEABILITY NGC Symptom INTERMITTENT CONDITION POSSIBLE CAUSES INTERMITTENT CONDITION ACTION APPLICABILITY NOTE The conditions that set the DTC are not present at this time The All following list may help in identifying the intermittent condition WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 DRBI
293. nd 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 2 247 DRIVEABILITY NGC Symptom P1115 GENERAL TEMPERATURE SENSOR PERFORMANCE When Monitored and Set Condition P1115 GENERAL TEMPERATURE SENSOR PERFORMANCE When Monitored With the ignition on and engine running Set Condition The PCM compares the ouputs of the ECT IAT and Ambient Temp sensors If one sensor does not corralate with the other two sensors the fault is set POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO TEMPERATURE SENSOR CIRCUT FAULTY SENSOR EXCESSIVE RESISTANCE IN THE SENSOR SIGNAL CIRCUIT EXCESSIVE RESISTANCE IN THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the DTCs and record the related Freeze Frame data NOTE All ECT Intake Air and Ambient Air Temperature Sensor codes must be diagnosed and repaired before continuing Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITENT CONDITION Symptom Diagnostic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 With the DRBIII in Sensors read the ECT Ambient Battery Temp and Intake Air Temp Sensor temp values Start the engine Allow the engine to reach normal operating temperature while monitoring the three Sensor temperature
294. ne 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 on the DRBIII screen should stay relatively close to each other Using the appropriate service information determine the proper opening tempera ture of the thermostat Did the thermostat open at the proper temperature Yes GoTo 4 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 Ignition on engine not running With the DRBIII read and record the AAT Sensor Temperature value Using the DRB Temperature Probe CH 7050 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 GoTo 5 No GoTo 7 83 DRIVEABILITY NGC P0128 THERMOSTAT RATIONALITY Continued ACTION APPLICABILITY WARNING MAKE SURE THE ENGINE COOLING SYSTEM IS COOL BE All FORE REMOVING THE PRESSURE CAP OR ANY HOSE SEVERE PER SONAL INJ URY MAY RESULT FROM ESCAPING HOT COOLANT THE COOLING SYSTEM IS PRESSURIZED WHEN HOT With the DRBIII read and record the ECT
295. nect the coil on plug harness connector POWER TECH V6 Ignition on engine not running With the DRBIII 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 when the Relay is actuating Yes GoTo 3 No GoTo 8 CAUTION Stop All Actuations 265 DRIVEABILITY NGC P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 3 7L Continued ACTION APPLICABILITY Turn the ignition off ENGINE 3 7L Note The following resistance measurement should be taken at 70 80 POWER TECH V6 degrees F Measure the primary resistance of the Coil on plug Is the resistance between 0 6 and 0 9 of an ohm Yes GoTo 4 No Replace the coil on plug Perform POWERTRAIN VERIFICATION TEST VER 5 Using a 12 volt test light connected toa 12 volt source probe the Ignition Coil Driver ENGINE 3 7L circuit POWER TECH V6 Crank the engine for 5 seconds while observing the test light What is the condition of the test light while cranking the engine Brightly blinking Replace the Ignition Coil Perform POWERTRAIN VERIFICATION TEST VER 5 ON constantly GoTo 5 OFF constantly GoTo 6 Turn the ignition off ENGINE 3 7L Disconnect the C2 PCM harness connector POWER TECH V6 Measure the resistance between the Coil Control circuit and ground in the Coil on plug harness conn
296. nector Measure the resistance of the Z212 S C Ground circuit at the S C Servo harness connector to ground Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the Z212 S C Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Yes Replace the Speed Control Servo Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 6 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V35 S C Vent Sol Control circuit from the Speed Control Servo harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 Repair the open high resistance in the V35 S C Vent Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Turn the ignition off All Disconnect the Speed Control Servo harness connector Ignition on engine not running With the DRBIII actuate the Speed Control Vent Solenoid Using a 12 volt test light connected to battery voltage probe the V35 Speed Control Vent Solenoid Control circuit in the Speed Control Servo harness connector Does the test light illuminate brightly and flash on and off 225 DRIVEABIL
297. nector Did the Batt Temp Sensor voltage change from below 1 0 volt to above 4 5 volts Yes Replace the Battery Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 3 Turn the ignition off Disconnect the C3 PCM harness connector Measure the resistance between ground and the K25 Batt Temp Signal circuit at the Battery Temp Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the K25 Batt Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 4 195 DRIVEABILITY NGC P0516 BATTERY TEMPERATURE SENSOR LOW Continued ACTION APPLICABILITY Measure the resistance between the K25 Batt Temp Signal circuit and the K900 All Sensor ground circuit at the Battery Temp Sensor harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K 900 Sensor ground and the K 25 Batt Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 TE
298. nes 283 INTERNAL FAULT x c aing cia ruperi reran Koad are EEES enon thins exe tae 283 PAM FAILURE ccicascrd diode cutaeantda omadaulendacnanrda ciabaauda weed opie dd 283 SERIAL LINK INTERNAL FAULT 0 0cccccceceeeeeeeeeueeeeeeeeeeen 283 STACK OVERFLOW FAILURE 0cceeceececeeeeeeeeveeeeeeeeeen 283 PCM STATUS FAILURE 0ccececceececcuveeesureutenttnreneenes 285 SERIAL LINK EXTERNAL FAULT 0 0ecceceecevcueeueeuvenceneen 285 ROLLING CODE FAILURE 0 00 cc cee ce eee eeeeeeeeeeeeeteseeeeees 287 VIN MISMATCH sansa crcuincens sade daha tincoimnede ESSren EEEE Vetik 287 TRANSPONDER COMMUNICATION FAILURE 0 0eceee cece eeee 289 TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE 289 TRANSPONDER ID MISMATCH 0 ccs eeceeeeeeeeeeeeeeeeeeeseeeen 289 TRANSPONDER RESPONSE MISMATCH n on nanona aonana rnan 289 STARTING CHECKING FUEL DELIVERY 0 0 0cceceeeceeeeveeeeeveueeeseeeen 292 CHECKING HARD START FUEL DELIVERY SYSTEM 0 00e0ee 295 ENGINE CRANKS BUT DOES NOT START o n naana aaran 297 FUEL PRESSURE LEAK DOWN 0 0ccceceeeeeeueeeeeeeeeeeeeen 300 NO CRANK CONDITION io 024 200 contewtna ede aA a EENES 301 NO RESPONSE FROM PCM WITH A NO START CONDITION 000 304 START AND STALL CONDITION 0 0ecceceeeeceeeeeceeeeeeeeeen 307 STARTS IN ALL GEARS WITH CLUTCH PEDAL RELEASED 309 TRANSFER CASE MECHANICAL
299. ness connector to the appropriate terminal of special tool 8815 installed Is the resistance below 5 0 ohms Yes GoTo 3 No Repair the open in the TRS T41 Sense P N Sense circuit Perform POWERTRAIN VERIFICATION TEST VER 2 246 DRIVEABILITY NGC P0850 PARK NEUTRAL SWITCH PERFORMANCE Continued ACTION APPLICABILITY Measure the resistance between ground and the TRS T41 Sense P N Sense circuit All at the TRS harness connector Is the resistance above 100k ohms Yes GoTo 4 No Repair the short to ground in the TRS T41 Sense P N Sense circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Connect the Transmission Range Sensor harness connector Move the Gear selector through all gear positions from Park to 1st and back While moving the gear selector through each gear measure the resistance between ground and the TRS T41 Sense P N Sense circuit using special tool 8815 NOTE The circuit is grounded in Park and Neutral and open in the other positions Did the resistance change from above 100 kohms open to below 10 0 ohms grounded Yes GoTo 5 No Replace the Transmission Range Sensor Perform POWERTRAIN VERIFICATION TEST VER 2 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 Grou
300. ness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH7058 Cable to Probe adapter CH 7062 and the red and black test probes Connec 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 DRBIII 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 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 GoTo 6 No Repair the PCI Bus circuit for an open Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 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 accor dance with the service information WITH THE DRBIII PER FORM QUICK
301. ngine idle speed too high gt Aggressive driving in low gear gt Trailer towingin OD gear position use 3 position or A S 3rd if frequent shifting occurs gt Cooling system failure causing engine to operate over 110 C 230 F gt Engine coolant temperature stays low too long If engine coolant temperature drops below 65 C 150 F the transmission will disengage EMCC Extended operation with the EMCC disengaged will cause the transmission to overheat gt Brake switch issue will cause the EMCC to disengage Extended operation with the EMCC disengaged will cause the transmission to over heat gt Transmission fluid overfilled gt Transmission cooler or cooler lines restricted gt Transmission Temperature Sensor circuit 3 2 4 02 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 DRBIII or measured with a high impedance voltmeter As the O2 sensor starts gen erating 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 O 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 5 OTHER CONTROLS Charging System NGC The chargin
302. ngine warms up to operating temperature the actual coolant temperature thermometer reading and the Eng Coolant Tmp Deg on the DRBIII screen should stay relatively close to each other Is the thermometer reading relatively close to the DRBIII ECT reading Yes Test Complete No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 81 DRIVEABILITY NGC Symptom P0128 THERMOSTAT RATIONALITY _ ees When Monitored and Set Condition P0128 THERMOSTAT RATIONALITY When Monitored Engine running Set Condition ThePCM predicts a coolant temperature value that it will compare to the actual coolant temperature A significant difference results in an error Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO OTHER POSSIBLE CAUSES LOW COOLANT LEVEL THERMOSTAT OPERATION SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO K900 SENSOR GROUND PCM ACTION APPLICABILITY NOTE If any ECT AAT CMP or CKP sensor DTCs have set along with P0128 All diagnose them before continuing NOTE Ensure that Pinion Factor has been programmed correctly into the PCM Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer
303. nsor voltage Is the voltage below 0 5 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the IAT harness connector Ignition on engine not running With the DRBIII read the IAT Sensor voltage Is the voltage above 1 0 volt Yes Replace the IAT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the C2 PCM harness connector 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 63 DRIVEABILITY NGC PO112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW Continued ACTION APPLICABILITY Measure the resistance between the K21 IAT Signal circuit and the K900 Sensor All ground circuit at the IAT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground and the K 21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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
304. nsor voltage NOTE The throttle must be against the stop Is the voltage 0 92 or less with the Throttle closed Yes GoTo 6 No Check for a binding throttle condition If OK replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 With the DRBIII read the TP Sensor voltage While monitoring the DRBIII slowly open and close the throttle Does the voltage increase and decrease smoothly Yes GoTo 7 No Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 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 DRBIII in Sensors read the MAP Sensor vacuum value Is the DRBIII reading within 1 of the Vacuum Gauge reading Yes GoTo 8 No Replace the MAP Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 102 DRIVEABILITY NGC P0O171 FUEL SYSTEM 1 1 LEAN Continued ACTION APPLICABILITY NOTE For this test to be valid the thermostat must be operating correctly All NOTE This test works best if performed on a cold engine cold soak Ignition on engine not running With the DRBIII 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 dose to the ambient temp
305. nsor voltage is above 3 99 volts for 66 56 seconds One trip fault 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 4 volts Set Condition The Oxygen Sensor voltage is above 3 99 volts for 76 8 seconds One trip fault 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 4 volts Set Condition The Oxygen Sensor voltage is above 3 99 volts for 66 56 seconds One trip fault P0158 02 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 4 volts Set Condition The Oxygen Sensor voltage is above 3 99 volts for 76 8 seconds One trip fault POSSIBLE CAUSES O2 SENSOR VOLTAGE ABOVE 3 7 VOLTS O2 SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE O2 SENSOR RETURN CIRCUIT SHORTED TO VOLTAGE O2 SENSOR 92 DRIVEABILITY NGC P0132 O02 SENSOR 1 1 CIRCUIT HIGH VOLTAGE Continued POSSIBLE CAUSES O2 SENSOR SIGNAL CIRCUIT OPEN O2 SENSOR RETURN CIRCUIT OPEN PCM ACTION APPLICABILITY NOTE If one of the O2 Sensors Signal or Return circuits are shorted to All voltage the DRBIII will display all O2 Sensor voltage readings high NOTE It is important to perform the diagnostics on the O2 Sensor that set the DTC NOTE After the repairs have be
306. nt before attempt ing transmission diagnosis 3 3 2 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 illuminat ing the MIL GENERAL INFORMATION 3 3 3 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 proce dures may assist you in identifying a possible intermittent problem e Visually inspect related wire harness connectors Look for broken bent pushed out or corroded terminals e Visually inspect the related harnesses Look for chafed pierced or partially broken wire e Refer to any S T A R Hotline Newsletters Ser vice Information Tune ups SITs or Service Bul letins that may apply e Use the DRBIII 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 ra tio codes can be set by intermittent speed sensor circuitry or by line noise bein
307. ntained 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 EATX DTC EVENT DATA EATX DTC EVENT DATA can be used as a diagnostic aid when experiencing Electronic Trans missions with intermittent problems When a Diag nostic Trouble Code DTC is set the vehicles EATX inputs are stored in the controller memory and are retrievable with the DRBII1 This information can be helpful when a DTC can not be duplicated The EATX DTC EVENT DATA is located in the DRBIII 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 transmis sion 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 J anuary 2002 that explains many of the features of the EATX DTC EVENT DATA with several examples on how to interpret the information and suggested training material to help understand all the specif ics EATX DTC EVENT DATA can only be erased by 1 Disconnecting the battery 2 Performing a DRBIII QUICK LEARN proce dure 3 Reprogramming the EATX controller Erasing Transmission DTCs does not clear the EATX DTC EVENT DATA
308. ny problems found Yes Repair as necessary Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 Test Complete 320 TRANSMISSION 42RLE Symptom P0123 THROTTLE POSITION SENSOR APPS HIGH MMMM When Monitored and Set Condition P0123 THROTTLE POSITION SENSOR APPS HIGH When Monitored Continuously with the ignition on and engine running Set Condition This DTC will set if the monitored TPS voltage rises above 4 94 volts for the period of 0 48 seconds POSSIBLE CAUSES RELATED TPS ENGINE DTC S PRESENT POWERTRAIN CONTROL MODULE INTERMITTENT WIRING AND CONNECTORS ACTION APPLICABILITY NOTE Low fluid level can be the cause of many transmission problems If All the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC
309. of 5 minutes NOTE The pressure should not fall below 241 KPa 35 psi Does the fuel pressure drop Yes Replace the leaking fuel injectors Perform POWERTRAIN VERIFICATION TEST VER 2 No Test Complete 300 STARTING Symptom NO CRANK CONDITION POSSIBLE CAUSES MECHANICAL CONDITION TRANSMISSION RANGE SENSOR BATTERY CIRCUIT RESISTANCE TOO HIGH CLUTCH INTERLOCK SWITCH IGNITION SWITCH OUTPUT CIRCUIT TRS T41 SENSE P N SENSE CIRCUIT OPEN T40 STARTER RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN STARTER STARTER RELAY ACTION APPLICABILITY NOTE Check all fuses and verify the battery is fully charged and capable of All passing a load test before continuing WARNING MAKE SURE THE BATTERY IS DISCONNECTED THEN WAIT TWO MINUTES BEFORE PROCEEDING Turn the engine over by hand to ensure the engine is not seized Is the engine able to turn over Yes GoTo 2 No Repair the mechanical condition preventing the starter motor from cranking Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Disconnect the PCM harness connectors Move the Gear selector through all gear positions from Park to 1st and back While moving the gear selector through each gear measure the resistance between ground and the TRS T41 Sense P N Sense circuit Did the resistance change from above 10 0 ohms to below 10 0 ohms Yes GoTo 3 No Replace the Transmission Range Sensor Perform POWERTRAIN V
310. ol 8815 Is the resistance below 5 0 ohms Yes GoTo 8 No Repair the open in the A142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off All Install a substitute relay in place of the ASD Relay Ignition on engine not running With the DRBIII erase DTCs Attempt to start the engine With the DRBIII read DTCs Does the DTC reset Yes GoTo 5 No Replace theASD Relay Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Remove the ASD Relay from the PDC Usinga 12 volt test light connect to ground probe the A907 Fused B circuits in the PDC Does the test light illuminate brightly Yes GoTo 6 No Repair the open or short to ground in the A907 Fused B circuits Inspect the related fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the A142 ASD Relay Output circuit from the PDC tothe appropriate terminals of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the open in the A142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 243 DRIVEABILITY NGC P06
311. on Perform POWERTRAIN VERIFICATION TEST VER 5 Disconnect each O2 Sensor harness connector Measure the voltage on the O2 Return circuits in the O2 Sensor harness connector NOTE The DRBIII will display all O2 Sensor voltage readings approxi mately 5 0 volts when only one O2 Sensor s Return circuit is shorted to voltage NOTE The DRBIII will display one O2 Sensor voltage close to zero and the others will read lower than normal when one O2 Sensor Return circuit contains excessive resistance Is the voltage at 2 5 volts Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 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 POWERTRAIN VERIFICATION TEST VER 5 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 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
312. on engine not running For vehicles equipped with a Manual Transmission use a 12 volt test light connected to ground probe the T141 Clutch Interlock Relay Output circuit at the Relay connection While observing 12 volt test light hold ignition key in the start position For vehicles equipped with an Automatic Transmission use a 12 volt test light connected to ground and probe the F 45 Fused Ignition Switch Output circuit at the Relay connection Does the test light illuminate brightly Yes GoTo 7 No Repair the open or short to ground in the A41 Ignition Switch Output circuit Inspect related fuses and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Disconnect the PCM harness connectors Measure the resistance of the TRS T41 Sense P N Sense circuit from the Relay terminal to the PCM harness connector Is the resistance below 5 0 ohms Yes Replace the Starter Motor Relay Perform POWERTRAIN VERIFICATION TEST VER 1 No Repair the open in the TRS T41 Sense P N Sense circuit Perform POWERTRAIN VERIFICATION TEST VER 1 302 STARTING NO CRANK CONDITION Continued ACTION APPLICABILITY Turn the ignition off All Remove the Starter Relay Disconnect the Starter Relay Output connector from the Starter Solenoid Measure the resistance of the T40 Starter Relay Output circuit between the Relay and the Solenoid harness connector Is the resistance below 5 0 ohms Yes
313. on 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 DRBIII perform the O2 Heater Test for each of the O2 Sensors With the DRBIII monitor all O2 Sensor voltage readings 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 GoTo 5 107 DRIVEABILITY NGC P0O172 FUEL SYSTEM 1 1 RICH Continued ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the TP Sensor voltage NOTE The throttle must be against the stop Is the TP Sensor voltage 0 92 of a volt or less with the Throttle closed Yes GoTo 6 No Check for a binding throttle condition If OK replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 With the DRBIII read the TP Sensor voltage While monitoring the DRBIII slowly open and close the throttle Does the voltage increase and decrease smoothly Yes GoTo 7 No Replace the Throttle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 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 DRBIII in Sensors read the MAP Sensor
314. ons 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 1 No Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Disconnect the fuel pump module harness connector Ignition on engine not running With the DRBIII actuate the ASD Fuel System test Using a 12 volt test light connected to ground probe the A141 Fuel Pump Relay Output circuit at the Fuel Pump Module harness connector Does the test light illuminate brightly Yes GoTo 6 No GoTo 8 Caution Stop All Actuations Turn the ignition off Disconnect the Fuel Pump Module harness connector Using a test light connected to 12 volts probe the Z211 Fuel Pump ground circuit at the Fuel Pump Module harness connector Does the test light illuminate brightly Yes GoTo 7 No Repair the excessive resistance in the Z211 Fuel Pump Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 1 293 STARTING CHECKING FUEL DELIVERY Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace t
315. ontinuing 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 94 DRIVEABILITY NGC Symptom List P0133 O2 SENSOR 1 1 SLOW RESPONSE P0139 O2 SENSOR 1 2 SLOW RESPONSE P0153 O2 SENSOR 2 1 SLOW RESPONSE P0159 02 SENSOR 2 2 SLOW RESPONSE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO133 O2 SENSOR 1 1 SLOW RESPONSE When Monitored and Set Condition P0133 O2 SENSOR 1 1 SLOW RESPONSE When Monitored Vehicleis 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 P0139 O2 SENSOR 1 2 SLOW RESPONSE When Monitored Vehicleis 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
316. ontrol Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 48 DRIVEABILITY NGC Symptom P0071 AMBIENT TEMP SENSOR PERFORMANCE When Monitored and Set Condition P0071 AMBIENT TEMP SENSOR PERFORMANCE When Monitored Engine off timeis 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 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 POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO G31 AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE AAT SENSOR G31 AAT SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN G31 AAT SIGNAL CIRCUIT SHORTED TO GROUND G31 AAT SIGNAL CIRCUIT SHORTED TO K900 SENSOR GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 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 C1 and C2 PCM harness connectors
317. opening the fuel system the fuel pressure must be release Relieve the fuel pressure in accordance with the service information Remove the Fuel Tank per Service Information Remove the Fuel Pump Module Visually inspect the inside of the Fuel Tank for any obstructions or deformities Inspect the Fuel Pump Module Float arm for damage Were any problems found Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 If there are no possible causes remaining view repair Repair Replace the Fuel Level Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 170 DRIVEABILITY NGC Symptom P0462 FUEL LEVEL SENSOR NO 1 LOW When Monitored and Set Condition P0462 FUEL LEVEL SENSOR NO 1 LOW When Monitored Ignition on and battery voltage above 10 4 volts Set Condition The fuel level sensor signal voltage goes below 0 0196 of a volt for more than 90 seconds POSSIBLE CAUSES FUEL LEVEL SENSOR VOLTAGE BELOW 0 0196 OF A VOLT FUEL LEVEL SENSOR N4 FUEL LEVEL SIGNAL CIRCUIT SHORTED TO GROUND N4 FUEL LEVEL SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII read the Fuel Level Sensor voltage Is the Fuel Level Sensor voltage below 0 0196 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagn
318. opriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 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 66 DRIVEABILITY NGC Symptom PO11L6E ENGINE COOLANT TEMPERATURE CIRCUIT PERFOR MANCE ae When Monitored and Set Condition PO116 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 theAmbient Air Temp Sensor values If the AT Sensor valueis not within 10 deg C 18 deg F of the other two temperature sensors Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO K2 ECT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE ECT SENSOR K2 ECT SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN K2 ECT SIGNAL CIRCUIT SHORTED TO GROUND K2 ECT SIGNAL CIRCUIT SHORTED T
319. ore continuing All NOTE The difference in ambient temperature outside temp VS shop temp may conceal a leak it is best to perform this test after the vehicle s temperature has stabilized in the work area Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 Perform a visual and physical inspection of the entire Evaporative Emission system Check for the following conditions Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap gasket seal Were any of the above conditions found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 3 163 DRIVEABILITY NGC P0456 E VAP SYSTEM SMALL LEAK Continued ACTION APPLICABILITY NOTE A thorough visual inspection of the Evap system hoses tubes and All 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 Use the Miller Tool 8404 Evaporative Emissions Leak Detector EELD Connect the SMOKE supply tip black hose to the service port if equipped or 8404 ADP service adaptor in the filter line Set the smoke air
320. orm POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 190 DRIVEABILITY NGC Symptom P0509 IAC VALVE SIGNAL CIRCUIT HIGH When Monitored and Set Condition PO509 IAC VALVE SIGNAL CIRCUIT HIGH When Monitored Engine running Battery voltage greater than 10 volts IAC motor operating Set Condition ThePCM senses a short to ground or battery voltage on the Linear I dleAir Control LIAC control circuit for 2 75 seconds while the IAC motor is active POSSIBLE CAUSES IAC MOTOR OPERATION IAC MOTOR K961 IAC SIGNAL CIRCUIT SHORTED TO VOLTAGE K61 IAC CONTROL CIRCUIT SHORTED TO VOLTAGE K61 IAC CONTROL CIRCUIT SHORTED TO K961 IAC SIGNAL CIRCUIT PCM ACTION APPLICABILITY NOTE If the engine will not idle maintain an engine speed between 800 and All 1500 RPM Start the engine Allow the engine to idle Check for vacuum leaks proper PCV valve installation proper MAP Sensor instal lation and proper IAC installation With the DRBIII read the IAC Current Is the
321. os tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the Fuel Pump Module harness connector Ignition on engine not running With the DRBIII read the Fuel Level Sensor voltage Did the Fuel Level Sensor voltage change from below 0 4 of a volt to above 4 0 volts Yes Replace the Fuel Level Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 Turn the ignition off Disconnect the C2 and C3 PCM harness connectors Measure the resistance between ground and the N 4 Fuel Level Signal circuit at the Fuel Level Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 171 DRIVEABILITY NGC P0462 F UEL LEVEL SENSOR NO 1 LOW Continued ACTION APPLICABILITY Measure the resistance between the N4 Fuel Level Signal circuit and the K900 All Sensor ground circuit at the Fuel Pump Module harness connector Is the resistance below 5 0 ohms Yes Repair the short between the K900 Sensor ground and the N4 Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 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 atten
322. ou should try to relearn the value by performing the appropriate driving ma neuver 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 dutch circuits to prevent erroneous clutch volume val ues 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 gt 90 F gt If an unused PCM is installed on a vehicle witha HOT engine Quick Learn will cause the PCM to report a cold calculated oil temperature This requires monitoring the calculated oil tempera ture using the DRBIII 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 gt 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 Upon installation of a new service PCM After replacement or rebuild of internal trans mission components or the torque converter If one or mo
323. p the sensor heater O2 heater is out of control for 128 seconds after it has reached 300 deg C Two trip fault P0161 O2 SENSOR 2 2 HEATER PERFORMANCE When Monitored Engine running and heater duty cycle greater than 0 ASD Relay is energized Battery voltage greater than 10 4 volts Set Condition Nosensor output is received when the PCM powers up the sensor heater O2 heater is out of control for 128 seconds after it has reached 350 deg C Two trip fault POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER CONTROL CIRCUIT OPEN O2 HEATER GROUND CIRCUIT OPEN 97 DRIVEABILITY NGC P0135 O2 SENSOR 1 1 HEATER PERFORMANCE Continued POSSIBLE CAUSES ACTION APPLICABILITY 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 DRBIII actuate the O2 Heater Test With the DRBIII monitor O2 Sensor voltage for at least 2 minutes Does the voltage stay above 4 5 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off All 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 Is the resistan
324. pean Union Evaporative Emission System Electronic Voltage Regulator Exponentially Weighted Moving Av erage Fully Electronically Modulated Con verter Clutch Federal Test Procedure Fan Speed signal Hydrocarbons Heated Oxygen Sensor Previously called alternator Idle Air Control Motor Intake Air Temperature Sensor Ignition off draw Intelligent Recovery Timer Input Speed Sensor Inspection and Maintenance Testing J eep Truck Engine Controller LDP LED LPS LR LSIACV MAF MAP Sensor MDS MIL MS MTV NGC NTC NVLD O Sen 02S OBD I OBD IlI OD ORVR Oss PCI BUS PCM PCS PCV PDC PEMCC PEP P N PPS PS Leak Detection Pump Light Emitting Diode Line Pressure Sensor Low reverse Clutch Linear Solenoid Idle Air Control Valve Mass Air flow Manifold Absolute Pressure Sensor Mopar Diagnostic System 2nd Gen eration Malfunction Indicator Lamp Multi Select Manifold Tuning Valve Next Generation Controller Negative Temperature Coefficient Natural Vacuum Leak Detection Oxygen Sensor Oxygen Sensor On Board Diagnostics 1st Genera tion On Board Diagnostics 2nd Genera tion Overdrive Clutch On Board Refueling Vapor Recovery Output Speed Sensor Programmable Communications In terface BUS J 1850 Powertrain Control Module Pressure Control Solenoid Positive Crankcase Ventilation Power Distribution Center Partial Electronically Modulated Converter Clut
325. pleted 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 condi tions select the EVAP MON PRE TEST in the DRB II1 OBD II Monitors Menu The Purge mon itor 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 find ing a small leak If there are no faults and the conditions are correct this test will run and
326. 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 DRBIII read the PCM DTCs Look for P0513 Is the Good Trip Counter for DTC P0513 displayed and equal to 0 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 194 DRIVEABILITY NGC Symptom P0516 BATTERY TEMPERATURE SENSOR LOW MM When Monitored and Set Condition P0516 BATTERY TEMPERATURE SENSOR LOW When Monitored Ignition on Set Condition Battery temperature sensor voltage below 0 0392 of a volt for 4 8 seconds Three good trips to clear the MIL POSSIBLE CAUSES BATTERY TEMP VOLTS BELOW 0 0392 OF A VOLT BATTERY TEMPERATURE SENSOR K25 BATT TEMP SIGNAL CIRCUIT SHORTED TO GROUND K25 BATT TEMP SIGNAL CIRCUIT SHORTED TO THE K900 SENSOR GROUND CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII record all DTCs and the related Freeze F rame data With DRBIII monitor the Battery Temperature Sensor voltage Is the voltage below 0 0392 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 With the DRBIII in sensors read the Battery Temp Sensor Voltage value Disconnect the Battery Temperature Sensor harness con
327. r Module in accordance with the Service Information Perform SKIS VERIFICATION 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 wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 291 STARTING Symptom CHECKING FUEL DELIVERY POSSIBLE CAUSES FUEL PUMP RELAY FUEL PRESSURE OUT OF SPECIFICATION RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED FUEL PUMP A14 FUSED B CIRCUIT A141 FUEL PUMP RELAY OUTPUT CIRCUIT OPEN Z211 FUEL PUMP GROUND CIRCUIT EXCESSIVE RESISTANCE FUEL PUMP MODULE ACTION APPLICABILITY Ignition on engine not running All With the DRBIII actuate the ASD Fuel System test Note It may be necessary to use a mechanics stethoscope in the next step Listen for fuel pump operation at the fuel tank Does the Fuel Pump operate Yes GoTo 2 No GoTo 5 Caution Stop All Actuations 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 to t
328. r history Has the rear O2 Sensor been replace without replacing the front O2 Sensor Yes Replace the Front O2 Sensor as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 If there are no possible cause remaining view repair Repair Replace the Catalytic Converter Perform POWERTRAIN VERIFICATION TEST VER 5 Start the engine All Inspect the exhaust for leak between the engine and the O2 Sensor 143 DRIVEABILITY NGC Symptom P0440 GENERAL EVAP SYSTEM FAILURE When Monitored and Set Condition P0440 GE NE RAL EVAP SYSTEM FAILURE When Monitored Engine Running Fuel Level greater than 12 Ambient Temperature between 4 C and 32 C 39 F and 89 F Set Condition The PCM does not see the NVLD switch close during the medium large leak test The PCM then will increase the vacuum supply to the EVAP system by increasing flow through the EVAP Purge valve If the switch does not close with an increase in vacuum an error is detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO VISUAL AND PHYSICAL INSPECTION EVAP PURGE SOLENOID VACUUM SUPPLY INSPECTION EVAP PURGE SOLENOID NVLD SWITCH OPERATION Z201 GROUND CIRCUIT OPEN NVLD ASSEMBLY K107 NVLD SWITCH SIGNAL CIRCUIT OPEN EVAPORATIVE EMISSION LEAK DETECTION PCM ACTION APPLICABILITY Check for any related TSBs before continuing All NOTE If any of the following DTCs are set P0443 P0452 P0453 P0498 or P0499 diagnose them fi
329. r nantes EOE P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION FE eserse rerent rede CAER EREE EANES ENEE P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFICIENT NOI ZATIONS 7O asc ony cine eee tne EEEE OERS P2308 IGNITION COIL NO 3 SECONDARY CIRCUIT INSUFFICIENT ONG ZATION 97l os ch enrnttbanadaneanaacateaxcticensyaxnnswtapenacelcxd P2311 IGNITION COIL NO 4 SECONDARY CIRCUIT INSUFFICIENT DONA ZE TON A PE E E E caret cenewes TABLE OF CONTENTS Continued P2314 IGNITION COIL NO 5 SECONDARY CIRCUIT INSUFFICIENT JONI ZATIONS HS ces cea E E E wtoaess 264 P2317 IGNITION COIL NO 6 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 3 7 ccc cts tei asecncrcnarie tp he deer ienien EAE rane r rines 264 P2503 CHARGING SYSTEM OUTPUT LOW 0c ccseeseeseeeeeeeeees 268 U0101 NO BUS MESSAGE FROM TRANS CONTROL MODULE 271 U0155 NO CLUSTER BUS MESSAGE 0 0c cece ee cece cece eee een 273 U0168 NO SKIM BUS MESSAGE cccec cee eeeeeeeeeeeeeeseeeees 274 A C OPERATES IN ALL MODE SWITCH POSITIONS 00 0ec eee ees 276 CHECKING A C SYSTEM OPERATION WITH NO DTCS 0 00e eee ees 278 CHECKING PCM POWERS AND GROUNDS 0 0eseeseeeeeeeees 282 SENTRY KEY IMMOBILIZER ANTENNA FAILURE 4 g cc c0bs eeaxagcawsadduehesstubseuebeemiececsecwsiees 283 COP FAILURE 0 2 0 ccc cece cece cece cece eeeeteeveseuevetvetreeeeeen 283 EEPROM FAILURE 0 0cceccecevceeceesueeeeenrtavtaveneenea
330. r reaches 20 One Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO CKP WIRE HARNESS INSPECTION F855 5 VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND TONE WHEEL PULSE RING INSPECTION CHECKING CMP SENSOR SIGNAL WITH THE DRBIII LAB SCOPE CRANKSHAFT POSITION SENSOR K24 CKP SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORTED TO GROUND K24 CKP SIGNAL CIRCUIT SHORTED TO F855 5 VOLT SUPPLY CIRCUIT PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off With the DRBIII lab scope probe and the Miller special tool 6801 backprobe the K24 CKP Signal circuit at the Sensor harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 Observe the lab scope screen Start the engine Observe the lab scope screen Are there any irregular or missing signals Yes GoTo 3 No GoTo 8 130 DRIVEABILITY NGC P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY Turn the ignition off Vis
331. r the short to ground in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 10 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If the there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 4 226 DRIVEABILITY NGC Symptom P0594 SPEED CONTROL SERVO POWER CIRCUIT When Monitored and Set Condition P0594 SPEED CONTROL SERVO POWER CIRCUIT When Monitored Engine running the speed control switched on and learned and the brake pedal is not pressed No other fault has occured this trip Set Condition Thespeed control power supply circuit is either open or shorted to ground Cruise will be disabled for the remainder of that key on cycle One Trip Fault Three good trips to clear the MIL POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO V32 S C SUPPLY CIRCUIT OPEN V32 S C SUPPLY CIRCUIT SHORTED TO GROUND BRAKE LAMP SWITCH V30 S C BRAKE SWITCH OUTPUT V30 S C BRAKE SWITCH OUPUT CIRCUIT OPEN V30 S C BRAKE SWITCH OUTPUT CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter equal to zero Yes GoTo 2 No Refer tothe INTERMIT
332. re of the clutch volumes indexes CVI s contain skewed readings because of abnormal conditions The Quick Learn procedure is performed with the DRBIII by selecting Transmission system then Miscellaneous functions then Quick Learn Fol low the procedure instructions displayed on the DRBIII To perform the Quick Learn procedure the fol lowing conditions must be met 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 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 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 DRBII1 will prompt the operator to shift toOD Donot shift to OD until the engine idle speed stabilizes at 1600rpm Theshift lever must stay in OD after the Shift to Overdrive prompt until the DRBIII indi cates the procedure is complete NOTE The above conditions must be mai
333. re the resistance of the C3 A C Clutch Relay Output circuit between the Relay and the A C Clutch Coil Is the resistance below 5 0 ohms Yes GoTo 10 No Repair the open in the C3 A C Clutch Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Connect a test light between the ground circuit and the A C Clutch Relay Output All circuit With the DRBIII 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 2 279 DRIVEABILITY NGC CHECKING A C SYSTEM OPERATION WITH NO DTCS Continued ACTION APPLICABILITY Engine Running Turn the A C system on and the fan on high With the DRBIII in Inputs Outputs read the A C request state Does the A C request state change Yes GoTo 11 No Repair the open in the A C Request circuit Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Remove the A C Clutch Relay Note Check connectors Clean repair as necessary Measure the voltage of the A17 F used B circuit at the A C Clutch Relay connector Is the voltage above 11 0 volts Yes GoTo 12 No Repair the open in the A17 Fused B circuit Perform POWERTRAIN VERIFICATION TEST VER 2 If there are no possible causes remaining view repair Repair Replace the A C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 Ign
334. removal pick must be used to release the connector terminals or harness and connector damage will occur Also the Miller 8815 Pin Out Box was introduced You must use the Miller 8815 tool instead of probing the PCM terminals or harness and connector damage will occur There is also a new Verification test and module replacement procedure for the new PCM 1 0 INTRODUCTION The procedures contained in this manual include specifications instructions and graphics needed to diagnose the PCM Powertrain System The diag nostics in this manual are based on the failure condition or symptom being present at the time of diagnosis Please follow the recommenda tions below when choosing your diagnostic path 1 First make surethe DRBIII is communicating with the appropriate modules i e if the DRBIII displays a No Response condition you must diag nose this first before proceeding 2 Read DTCs diagnostic trouble codes with the DRBIII 3 If no DTCs are present identify the customer complaint 4 Once the DTC or customer complaint is iden tified 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 indi cates a customer complaint When repairs are required refer to
335. riveability prob lems 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 Engine Timing The PCM cannot detect an in correctly 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 ThePCM cannot detect a clogged fuel injector a sticking pintle or that an incorrect injector is installed Fuel Requirements Poor quality gasoline can cause problems such as hard starting stalling and stumble Use of methanol gasoline blends may re sult in starting and driveability problems See individual symptoms and their definitions in Sec tion 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 ThePCM cannot detect a clogged or restricted air cleaner inlet or filter
336. rm 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 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 TERMI NALS 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 GoTo 3 No Repair the Fused Ignition Switch Output circuit for an open Refer to the wiring diagrams located in the Service Information Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 28 COMMUNICATION NO RESPONSE FROM TRANSMISSION CONTROL MODULE NGC Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 ill
337. rm POWERTRAIN VERIFICATION TEST VER 4 No GoTo 5 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 Brake Lamp Switch harness connector to the S C Servo harness connector Is the resistance below 5 0 ohms Yes Repair the excessive resistance in the V30 S C Brake Switch Output circuit Perform POWERTRAIN VERIFICATION TEST VER 4 GoTo 6 Measure the resistance between ground and the V30 S C Brake Switch Output circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the V30 S C Brake Switch Output circuit Perform POWERTRAIN VERIFICATION TEST VER 4 No GoTo 9 228 DRIVEABILITY NGC P0594 SPEED CONTROL SERVO POWER CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V32 S C Supply circuit from the Brake Lamp Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance above 5 0 ohms Yes Repair the open in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4
338. rm POWERTRAIN VERIFICATION TEST VER 5 Disconnect the C3 PCM harness connector Measure the resistance between ground and the K 106 NVLD Sol Control circuit at the NVLD electrical harness connector Is the resistance below 5 0 ohms Yes Repair the short to ground in the K106 NVLD Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 4 179 DRIVEABILITY NGC P0498 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW Continued ACTION APPLICABILITY NOTE Before continuing check the PCM harness connector terminals for All 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 5 180 DRIVEABILITY NGC Symptom P0499 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH MMMM When Monitored and Set Condition P0499 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH When Monitored Engine running Set Condition The PCM detects an open in the NVLD Canister vent solenoid circuits One trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO NVLD SOLENOID K106 NVLD SOL CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K106 NVLD SOL CONTROL CIRCUIT OPEN Z201 GROUND CIRCUIT OPEN PC
339. rm SKIS VERIFICATION Turn the ignition off Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Turn the ignition on With the DRBIII display and clear all ECM and SKIM DTCs Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle With the DRBIII check for SKIM DTCs Does the DRBII1 display the same DTC Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SKIS VERIFICATION No Therepair is complete Perform SKIS VERIFICATION 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 wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 288 SENTRY KEY IMMOBILIZER Symptom List TRANSPONDER COMMUNICATION FAILURE TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE TRANSPONDER ID MISMATCH TRANSPONDER RESPONSE MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be TRANSPONDER COMMUNICA TION FAILURE E E When Monitored and Set Condition TRANSPONDER COMMUNICATION FAILURE Wh
340. rmal operation However if a transmission is overfilled a transmis sion oil cooler becomes restricted or if a customer drives aggressively in low gear the calculated oil temperature will be inaccurate Consequently the shift schedule sel ected may be inappropriate for the current conditions The key highlights of the vari ous shift schedules are as follows 3 2 3 1 Extreme Cold Oil temperature at start up below 26 6 C 16 F gt Goes to Cold schedule above 24 C 12 F oil temperature gt Park Reverse Neutral and 2nd gear only pre vents shifting which may fail a clutch with fre quent shifts Cold Oil temperature at start up above 24 C 12 F and below 2 2 C 36 F gt Goes to Warm schedule above 4 4 C 40 F oil temperature gt Delayed 2 3 upshift approximately 35 50 Km h 22 31 MPH gt Delayed 3 4 upshift 72 85 Km h 45 53 MPH gt Early 4 3 coastdown shift approximately 48 Km h 30 MPH gt Early 3 2 coastdown shift approximately 27 Km h 17 MPH GENERAL INFORMATION gt High speed 4 2 3 2 2 1 kickdown shifts are prevented gt No EMCC Warm Oil temperature at start up above 2 2 C 36 F and below 27 C 80 F gt Goes to a Hot schedule above 27 C 80 F oil temperature gt Normal operation upshifts kickdowns and coastdowns gt No EMCC Hot Oil temperature at start up above 27 C 80 F gt Goes toa Overheat schedule above 115 C 240 F oi
341. rness 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 Turn the ignition off All Disconnect the C2 PCM harness connector Measure the resistance across the K961 IAC Signal circuit and the K61 IAC 192 DRIVEABILITY NGC Symptom P0513 INVALID SKIM KEY er When Monitored and Set Condition P0513 INVALID SKIM KEY When Monitored Ignition on Set Condition The PCM detects an invalid SKIM key POSSIBLE CAUSES INCORRECT VIN IN PCM NO COMMUNICATION WITH SKIM NO VIN PROGRAMMED IN THE PCM SKIM TROUBLE CODES SET IGNITION KEY ACTION APPLICABILITY Ignition on engine not running With the DRBIII read the PCM DTCs Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No GoTo 7 With the DRBIII check for SKIM DTCs Are any DTCs present in the SKIM Yes Refer to BODY information for the related symptom s Perform SKIS VERIFICATION No GoTo 4 With the DRBIII display the VIN that is programmed in the PCM Has a VIN been programmed into the PCM Yes GoTo 5 No Program the correct VIN into the PCM and retest Perform SK
342. rocedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 2 Turn the ignition off Remove the Fuel Pump Relay from the PDC Ignition on engine not running Using a 12 volt test light connected to ground probe the F 1 Fused Ignition Switch Output circuit in the PDC Does the test light illuminate brightly Yes GoTo 3 No Repair the F1 Fused Ignition Switch Output circuit Inspect the related fuse An open fuse may have been caused by a short to ground Perform POWERTRAIN VERIFICATION TEST VER 5 233 DRIVEABILITY NGC P0627 F UEL PUMP RELAY CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Using a 12 volt test light connected to ground probe the A209 F used B circuit of the fuel pump relay in the PDC Does the test light illuminate brightly Yes GoTo 4 No Repair the open or short to ground in the A209 F used B circuit Inspect and replace any open fuses Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance of the Fuel Pump Relay Coil Is the resistance between 70 to 90 ohms Yes GoTo 5 No Replace the Fuel Pump Relay Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K31 Fuel Pump Relay Control circuit in the PDC Is the resistance below 5 0 ohms Yes Repair the short to ground in the K31 Fuel Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 7 N
343. ropriate message The following is a possible list of causes for a bus problem 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 diag nostic trouble code Possible sources of the code are checked and eliminated one by one It is not neces sary 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 re quest 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 consec utive successful OBDII EURO III trips or dearing the DTCs with a diagnostic tool DRBII or equiv alent 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 Transmis sion The PCM DTC 89 must also be erased in the PCM in order to extinguish the MIL 3 3 1 HARD CODE
344. rors view repair to continue All Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 230 DRIVEABILITY NGC Symptom P0622 GENERATOR FIELD CONTROL CIRCUIT When Monitored and Set Condition P0622 GE NERATOR FIELD CONTROL CIRCUIT When Monitored With the ignition on Engine speed greater than 1000 RPM Battery voltage greater than 10 4 volts ASD sense switch is on Set Condition When the PCM tries to regulate the generator field with no result during monitoring POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO GENERATOR OPERATION K125 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K125 GEN FIELD CONTROL CIRCUIT OPEN K125 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND Z212 GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 3 Turn the ignition off Disconnect the Generator Field harness connector J ump a 12 volt test light across the Generator Field harness connector Ignition on engine not running With the DRBIII actuate the Generator Field Control circuit Does the test light illuminate brightly and flash on and off Yes Replac
345. rottle plate is in the idle position Remove the AC Motor and actuate the IAC Motor with the DRBII1 to verify proper operation Install the IAC Motor WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING With the vehicleis running lightly tap on IAC Motor with your hand and listen for idle to raise Were any problems found Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 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 5 186 DRIVEABILITY NGC Symptom P0507 IDLE SPEED PERFORMANCE HIGHER THAN EXPECTED When Monitored and Set Condition P0507 IDLE SPEED PERFORMANCE HIGHER THAN EXPECTED When Monitored With the engine running at idle MAF lt 250 m g tdc air temp gt 17 8 C O F and lt 7 C 19 4 F enable after coolant temp gt 70 C 158 F or air temp gt 7 C 19 4 F coolant temp gt 7 C 19 4 F lt 130 C 266 F canister purge lt 100 duty
346. round Install a substitute relay in place of the Clutch Switch Override Relay Turn the ignition on With the vehiclein a gear other than first the Transfer Casein 2WD and the Clutch Pedal released Crank the Engine Does the engine crank Yes GoTo 3 No Replace the Clutch Switch Override Relay per Service Informa tion Perform POWERTRAIN VERIFICATION TEST VER 2 and the PCM Is the resistance above 5 0 ohms Yes Repair the short to ground in the K90 Clutch Override Relay Control Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 4 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 Turn the ignition off to the lock position All Disconnect the PCM harness connectors Measure the resistance of the K 90 Relay Control circuit from the Relay connection 309 TRANSFER CASE MECHANICAL Symptom P0836 4WD MUX SWITCH STUCK When Monitored and Set Condition P0836 4WD MUX SWITCH STUCK When Monitored When Transfer Case in 4WD Low Set Condition Four wheel drive 4WD muxed switch input detected b
347. round check the A142 ASD Relay Output circuit at the coil rail harness connector Does the test light illuminate brightly Yes GoTo 3 No Repair the open or short to ground in the A142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Stop All Actuations Turn the ignition off ENGINE 2 4L Disconnect the Ignition Coil harness connector POWER TECH Using a 12 volt test light connected to 12 volts probe the Ignition Coil Driver circuit DOHC l 4 Crank the engine for 5 second while observing the test light What is the state of the test light while cranking Brightly flashing Replace the Ignition Coil Perform POWERTRAIN VERIFICATION TEST VER 5 ON constantly GoTo 4 OFF constanly GoTo 5 Turn the ignition off ENGINE 2 4L Disconnect the C2 PCM harness connector POWER TECH Measure the resistance between the Ignition Coil Driver circuit and ground DOHC l 4 Is the resistance below 100 ohms Yes Repair the short to ground in the Ignition Coil Driver circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 Turn the ignition off ENGINE 2 4L Disconnect the C2 PCM harness connector POWER TECH CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING DOHC l 4 THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Ignition Coil Dr
348. round 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 GoTo 5 Measure the resistance between the C18 A C Pressure Signal circuit and the K 900 Sensor ground circuit in the A C Pressure Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground circuit and the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 GoTo 8 Perform POWERTRAIN VERIFICATION TEST VER 2 Measure the resistance between ground and the F 855 5 volt Supply circuit in the A C Pressure Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 Turn the ignition off All Disconnect the C1
349. rst before continuing with P0440 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 6 144 DRIVEABILITY NGC P0440 GE NERAL EVAP SYSTEM FAILURE Continued ACTION APPLICABILITY Perform a visual and physical inspection of the entire Evaporative E mission system Check for the following conditions Hoses disconnected or left off Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap left off or bad gasket seal Were any of the above conditions found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 3 Turn the ignition off Carefully inspect the Evap Purge Solenoid vacuum supply hose for proper routing Check for a pinched or plugged hose from the throttle body to the Purge Solenoid Make sure the vacuum port at the throttle body is free from any blockage Were any problems found Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 4 Solenoid Ignition on engine not running Observe the vacuum gauge With the DRBIII actuate the EVAP Purge Solenoid Does the vacuum drop when the solenoid is
350. rt 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 NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister the smoke may not be as thick Introducing smoke into the filtered side of the canister may assist in locating the leak Was a leak found Yes Repair or replace the leaking component as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 No GoTo 6 NOTE After disconnecting the Evap Purge Solenoid vacuum connections inspect the lines and solenoid for any signs of contamination from the E VAP Canister This may indicate a faulty vent 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 in Hg to the CAN of the EVAP Purge Solenoid NOTE Monitor the vacuum gauge for at least 15 seconds Does the EVAP Purge Solenoid hold vacuum Yes GoTo 7 No Replace the Evap Purge Solenoid Perform POWERTRAIN VERIFICATION TEST VER 6 167 DRIVEABILITY NGC P0457 LOOSE FUEL CAP Continued ACTION APPLICABILITY Reconnect all vacuum hoses All Start the engine Allow the engine to idle Using the DRBIII perform the NVLD FORCE
351. s 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 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 bet ter 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 driveability related symptom or complaint 3 4 USING THE DRBIII Refer to the DRBIII user s guide for instructions and assistance with reading trouble codes erasing trouble codes and other DRBIII functions 3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN Under normal operation the DRBIII will dis play one of only two error messages User Requested WARM Boot by pressing MORE and NO at the same time GENERAL INFORMATION ver 2 29 date 1 oct 93 file key_itf cc date J an 12 1994 line 544 err OxlUser Requested WARM Boot 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 ver 2 29 date 1 oct 99 file key HND1 CC date Mar 8 2000 line 1297
352. s 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 3 270 DRIVEABILITY NGC Symptom U0101 NO BUS MESSAGE FROM TRANS CONTROL MODULE When Monitored and Set Condition U0101 NO BUS MESSAGE FROM TRANS CONTROL MODULE When Monitored Equipped with automatic transmission The ignition on Battery voltage greater than 10 volts Set Condition An open circuit on the F 11 Fused I gniton Switch Output circuit No bus messages from the TCM for 20 seconds two trips required POSSIBLE CAUSES DTC RESET PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT PCI BUS UNABLE TO COMMUNICATE WITH DRBIII PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs Cycle the ignition key on and off several times Leaving the ignition on for at least 20 seconds With the DRBIII read DTCs Does the DTC reset Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS
353. s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis Continue GoTo 2 With the DRBIII check Engine DTC s this includes all one trip failures Are there any Engine TPS DTCs present Yes Refer to the Driveability category and perform the appropriate symptom Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 No GoTo 3 321 TRANSMISSION 42RLE P0123 THROTTLE POSITION SENSOR APPS HIGH Continued ACTION APPLICABILITY With the DRBII1 record the EATX EVENT DATA to help identify the conditions in All which the DTC was set With the DRBIII erase Transmission DTCs NOTE To erase EATX EVENT DATA information a BATTERY DISCONNECT must be performed Performing a BATTERY DISCONNECT will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA With the DRBIII read Transmission DTCs Did the DTC P0123 THROTTLE POSITION SENSOR HIGH reset Yes GoTo 4 No GoTo 5 NOTE Due to the integration of the Powertrain and Transmission Control Mo
354. same tests The title for the tests will be P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 3 7L eee eS eee When Monitored and Set Condition P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault Three good trips to turn off the MIL P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault Three good trips to turn off the MIL P2308 IGNITION COIL NO 3 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn timeis incorrect to short or not present an error is detected One Trip Fault Three good trips to turn off the MIL P2311 IGNITION COIL NO 4 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect to short or not present an error is detected One Trip Fault Three good trips to turn off
355. ss connector All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K 342 ASD Relay Control circuit from the PDC tothe appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the K342 ASD Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the K342 ASD Relay Control circuit in the PDC Is the resistance below 5 0 ohms Yes Repair the short to ground in the K342 ASD Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 241 DRIVEABILITY NGC Symptom P0688 ASD RELAY SENSE CIRCUIT LOW ETE ee When Monitored and Set Condition P0688 ASD RELAY SENSE CIRCUIT LOW When Monitored With ignition key on Battery voltage
356. ssary Perform 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 POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 84 DRIVEABILITY NGC P0128 THERMOSTAT RATIONALITY Continued ACTION APPLICABILITY Connect a jumper wire across the Temperature Sensor harness connector With the DRBIII read the Temperature voltage Does the voltage start at 5 0 volts and drop below 1 0 volt Yes Replace the suspected Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 9 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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
357. stance or short to ground in the A142 F142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 116 DRIVEABILITY NGC P0300 MULTIPLE CYLINDER MISFIRE Continued ACTION APPLICABILITY Turn the ignition off All Remove the Ignition Coil Connect the Ignition Coil harness connector NOTE Before continuing inspect the Ignition Coil for the following condi tions If a problem is found replace the Ignition Coil Damage or Carbon Tracking on the Coil or the spark plug insulator boot Install a spark tester on the Ignition Coil 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 GoTo 5 No GoTo 14 NOTE Connect the Fuel Injector harness connector before continuing 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 Yes Replace the Spark Plug Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 Warning The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system
358. start and stall condition Refer to any Technical Service Bulletins TSB s that may apply to the symptom The exhaust system must be free of any restrictions The engine compression must be within specifications The engine valve timing must be within specifications The engine must be free from vacuum leaks The throttle body must be free of carbon buildup and dirt Do any of the above conditions exist Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 No GoTo 7 Verify that the Fuel tank is not empty before continuing Follow the diagnostics for Checking Fuel Delivery under the Driveability section of this manual Was the No Start condition solved after following the above diagnostic test Yes Test Complete No Check for contamination water in the fuel Ensure the fuel being used in this vehicle meets manufactures Fuel Requirement refer to the service manual Perform POWERTRAIN VERIFICATION TEST VER 1 308 STARTING Symptom STARTS IN ALL GEARS WITH CLUTCH PEDAL RELEASED POSSIBLE CAUSES CLUTCH SWITCH OVERRIDE RELAY CLUTCH OVERRIDE RELAY CONTROL CIRCUIT SHORT TO GROUND PCM ACTION APPLICABILITY NOTE J eep uses a clutch override system that allows the engine to crank in any gear when the transfer case is in the 4wd low position Is the transfercase in the 4wd low position Yes Test Complete No GoTo 2 Raise the vehicle so that the drive wheels are off the g
359. sure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 204 DRIVEABILITY NGC Symptom P0551 POWER STEERING SWITCH PERFORMANCE When Monitored and Set Condition P0551 POWER STEERING SWITCH PERFORMANCE 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 K66 P S SWITCH SIGNAL CIRCUIT OPEN K66 P S SWITCH SIGNAL CIRCUIT SHORTED TO GROUND Z939 GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 Turn the ignition off Disconnect the Power Steering Pressure Switch harness connector Ignition on engine not running Connect a jumper wire to the K 66 P S Switch Signal circuit in harness connector Using the DRBIII monitor the Power Steering Pressure Switch Touch the jumper wire to the Z939 Ground circuit in the Power Steering Pressure Switch harness connector several times Did the Power Steering Pressure Switch status change from High to Low Yes Replace the Power Steering Pressure Switch Perform POWERTRAIN VERI
360. sure the voltage on the O2 Signal circuit in the O2 Sensor harness connector Is the voltage between 4 5 and 5 0 volts Yes GoTo 4 96 DRIVEABILITY NGC Symptom List P0135 O2 SENSOR 1 1 HEATER PERFORMANCE P0141 O2 SENSOR 1 2 HEATER PERFROMANCE P0155 O2 SENSOR 2 1 HEATER PERFORMANCE P0161 O2 SENSOR 2 2 HEATER PERFORMANCE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO135 O2 SENSOR 1 1 HEATER PERFORMANCE E When Monitored and Set Condition P0135 02 SENSOR 1 1 HEATER PERFORMANCE When Monitored Engine running and heater duty cycle greater than 0 ASD Relay is energized Battery voltage greater than 10 4 volts Set Condition Nosensor output is received when the PCM powers up the sensor heater O2 heater is out of control for 128 seconds after it has reached 300 deg C Two trip fault P0141 O2 SENSOR 1 2 HEATER PERFROMANCE When Monitored Engine running and heater duty cycle greater than 0 ASD Relay is energized Battery voltage greater than 10 4 volts Set Condition Nosensor output is received when the PCM powers up the sensor heater O2 heater is out of control for 128 seconds after it has reached 350 deg C Two trip fault P0155 O2 SENSOR 2 1 HEATER PERFORMANCE When Monitored Engine running and heater duty cycle greater than 0 ASD Relay is energized Battery voltage greater than 10 4 volts Set Condition Nosensor output is received when the PCM powers u
361. surement must be taken from both Speed Control Switch harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 Sensor ground circuit from the Speed Control harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms for both measurements Yes GoTo 8 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 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 4 252 DRIVEABILITY NGC Symptom P1602 PCM NOT PROGRAMMED When Monitored and Set Condition P1602 PCM NOT PROGRAMMED When Monitored Ignition on Set Condition The PCM has not been programmed POSSIBLE CAUSES PCM NOT FLASHED PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII erase DTCs With the DRBIII flash the PCM per Servic
362. 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 tem perature of the gas in the vessel changes The vessel will only see this effect if it is indeed sealed Even 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 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 ambi ent temperature cycling The diurnal effect is con sidered one of the primary contributors to the leak determination by this diagnostic When the vacuum in the system exceeds about 1 H20 0 25 KPA a vacuum switch closes The switch closure sends a signal tothe 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 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 actuat
363. t Supply circuit Use Miller special tool 8815 when checking for an open circuit to prevent PCM harness connector terminal damage Perform POWERTRAIN VERIFICATION TEST VER 5 Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 NOTE An intermittent condition with the Crank Position Sensor can cause the P0344 to set Install the CMP Sensor With the DRBIII lab scope probe and the Miller special tool 6801 backprobe the K24 CKP Signal circuit in the CKP harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA 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 lightly tap on the Crank Position Sensor Observe the lab scope screen Start the engine Observe the lab scope screen Are there any irregular or missing signals Yes Replace the Crank Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Turn the ignition off All Carefully disconnect the Battery Ground cable 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 139 DRIVEABILITY NGC P0344 CAMSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY If there are no possible causes remaining view repair
364. t and the K900 Sensor ground circuit at the ECT harness connector Ignition on engine not running With the DRBIII read the ECT Sensor voltage Is the voltage below 1 0 volt Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 NOTE Remove the jumper wire before continuing 72 DRIVEABILITY NGC P0118 E NGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the C2 PCM harness connector Ignition on engine not running Using a 12 volt test light connected to ground probe the K2 ECT Signal circuit at the ECT Sensor harness connector Does the test light illuminate brightly Yes Repair the short to voltage in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 GoTo 5 No Repair the open in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CO
365. t from the AAT Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 6 No Repair the open in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 9 No Repair the open in the K900 Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the C1 and C2 PCM harness connectors Measure the resistance between ground and the G31 AAT Signal circuit at the AAT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 8 50 DRIVEABILITY NGC P0071 AMBIENT TEMP SENSOR PERFORMANCE Continued ACTION APPLICABILITY Measure the resistance between the G31 AAT Signal circuit and the K900 Sensor All ground circuit at the AAT Sensor harness connector Is the resistance below 100 ohms Yes Repair the short between the K900 Sensor ground circ
366. t running With the DRBIII actuate the Speed Control Vacuum Solenoid Using a 12 volt test light connected to battery voltage probe the S C Vacuum Control circuit Does the test light illuminate brightly and flash on and off Yes Replace the Speed Control Servo Perform POWERTRAIN VERIFICATION TEST VER 4 222 DRIVEABILITY NGC P0582 SPEED CONTROL VACUUM SOLENOID CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the S C Servo harness connector Disconnect the C3 PCM harness connector Measure the resistance between ground and the V36 S C Vacuum Solenoid Control circuit at the Speed Control Servo 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 GoTo 10 Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Disconnect the C3 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V32 S C Supply circuit from the Brake Lamp Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 9 No Repair the open high resistance in the V32 S C Supply circuit
367. ta recorder and or lab scope should be used to help diagnose intermit tent conditions Were any problems found during the above inspections Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 33 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 POSSIBLE CAUSES INTERMITTENT CONDITION CMP WIRE HARNESS INSPECTION TONE WHEEL PULSE RING INSPECTION INTERMITTENT CMP SIGNAL CKP WIRE HARNESS INSPECTION TONE WHEEL PULSE RING INSPECTION INTERMITTENT CKP SIGNAL CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All 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 DRBIII read DTCs and record the related Freeze Frame data With the DRBIII erase DTCs 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 reset Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure P
368. te Turn the ignition off Disconnect the BCM C1 harness connector 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 BCM harness connector Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 31 COMMUNICATION PCI BUS COMMUNICATION FAILURE Continued ACTION APPLICABILITY NOTE Reconnect the BCM harness connector and the negative battery All 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 GoTo 5 No GoTo 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 elimi
369. te All symptoms listed above are diagnosed using the same tests The title for the tests will be PCM STATUS FAILURE When Monitored and Set Condition PCM STATUS FAILURE When Monitored With the ignition on Set Condition This DTC exists when a PCM STATUS message was not received from the PCM for at least 20 0 consecutive seconds SERIAL LINK EXTERNAL FAULT When Monitored At ignition on after ignition on during any rolling code handshake that occurs with the PCM due toa SKIM reset or during SECRET KEY transfers tothe PCM Set Condition When the SKIM does not receive an expected PCI BUS message trans mission acknowledgement from the PCM after 3 transmit attempts POSSIBLE CAUSES INTERMITTENT WIRING HARNESS PROBLEM WIRING HARNESS INSPECTION SKIM ECM ACTION APPLICABILITY NOTE Ensure the ECM has proper power and ground connections before All continuing With the DRBIII read and record the SKIM DTCs then erase the SKIM DTCs Turn the ignition off Wait 2 minutes Turn the ignition on With the DRBIII read the SKIM DTCs Does the DRBIII display the DTC that was previously erased Yes GoTo 2 No GoTo 4 285 SENTRY KEY IMMOBILIZER PCM STATUS FAILURE Continued ACTION APPLICABILITY Turn the ignition off All NOTE Visually inspect the related wiring harness and CCD PCI Bus whichever applicable circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually
370. ted circuit s for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 3 297 STARTING ENGINE CRANKS BUT DOES NOT START Continued ACTION APPLICABILITY Ignition on engine not running With the DRBIII under DTCs amp Related Functions read the Secondary Indicators while cranking the engine Are there any Secondary Indicators present while cranking the engine Yes Refer to symptom list and perform tests related to the secondary indicator that is reported by the DRBIII Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 4 With the DRBIII in Sensors check the Current CKP Count while cranking the engine Does the CKP Counter change while cranking the engine Yes GoTo 5 Refer to Driveability Symptom P0320 NO CRANK REFERENCE SIGNAL AT PCM Perform POWERTRAIN VERIFICATION TEST VER 5 With the DRBIII in Sensors check the Current CMP Count while cranking the All engine Does the Current CMP Count change while cranking the engine Yes GoTo 6 No Refer to Driveability Symptom P0340 NO CAM SIGNAL AT PCM Perform POWERTRAIN VERIFICATION TEST VER 5 Check for any of the following conditions mechanical problems ENGINE VALVE TIMING must be within specifications ENGINE COMPRESSION must be within specifications ENGINE EXHAUST SYSTEM must be free of any restrictions or leaks FUEL must be free of contamination FUEL INJECTOR plugged or restricted injector control
371. ter vent e Activate purge shortly after closed loop Pull the tank vacuum past the vacuum switch point 1 H20 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 impor tant determining factor e 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 MANIFOLD VACUUM PURGE SOLENOID LJ FUEL TANK CANISTER aa NATURAL VACUUM LEAK DETECTION SYSTEM 80dceb8e GENERAL INFORMATION NGC Switch Common Ground Diaphragm Sense 12v 2 NVLD Switch N O Diaphragm Button From Vent Filter Poppet Pintle Valve N C Spring Communication Passage NGC Solenoid NVLD i Vacuum amp Pressure 12v Feed ommon Solenoid Coil Ground To Purge Canister EVAP System NVLD Switch Closure happens at 1 H20 Water Vacuum 12 when new Vacuum draws the Diaphragm up closing the Switch Pressure Relief The Poppet Valve is spring loaded closed up It opens at 1 H2O Pressure Pressure from the Purge Canister EVAP System enters the top of the diaphragm chamber via an internal communicat
372. ternal 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 16 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 407 KPa 34 KPa 59 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 drop Yes Replace Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 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 Remove special tool C4390 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 407 KPa 34 KPa 59 psi 5 psi Move special tool C4390 Hose Clamp Pliers from between the fuel pressure gauge and the engine to between the fuel pressure gauge and fuel pump module Monitor the fuel pressure gauge for a minimum
373. th the jumper wire connected Did the O2 Sensor voltage drop from 5 0 volts to 2 5 volts Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 12 NOTE Remove the jumper wire before continuing 109 DRIVEABILITY NGC P0O172 FUEL SYSTEM 1 1 RICH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine Measure the voltage on the O2 Sensor Signal circuit in the O2 Sensor harness connector with the Sensor harness connector disconnected Is the voltage above 4 8 volts Yes Check the O2 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 the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 13 Engine still running Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector Is the voltage at 2 5 volts Yes GoTo 14 No Check the O2 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 the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Turn the ignition off before continuing NOTE
374. the DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 407 KPa 34 KPa 59 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 GoTo 14 CAUTION Stop All Actuations 104 DRIVEABILITY NGC P0O171 FUEL SYSTEM 1 1 LEAN Continued ACTION APPLICABILITY Turn the ignition off All 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 GoTo 15 If there are no possible causes remaining view repair Repair Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 5 105 DRIVEABILITY NGC Symptom List P0O172 FUEL SYSTEM 1 1 RICH P0O175 FUEL SYSTEM 2 1 RICH _ oan Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO172 FUEL SYSTEM 1 1 RICH B Ee When Monitored and Set Condition PO172 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
375. the MIL DRIVEABILITY NGC P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 3 7L Continued P2314 IGNITION COIL NO 5 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect to short or not present an error is detected One Trip Fault Three good trips to turn off the MIL P2317 IGNITION COIL NO 6 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 3 7L When Monitored Engine running and battery voltage greater than 10 volts Set Condition If PCM detects that the secondary ignition burn time is incorrect to short or not present an error is detected One Trip Fault Three good trips to turn off the MIL 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 IGNITION COIL COIL CONTROL CIRCUIT OPEN COIL CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Ignition on engine not running ENGINE 3 7L With the DRBIII read DTCs and record the related Freeze Frame data POWER TECH V6 Is the Good Trip Counter displayed and equal to zero Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off ENGINE 3 7L Discon
376. the PDC POWER TECH V6 Measure the resistance of the A142 ASD Relay Output circuit between the Relay Output terminal of the PDC and the Coil on Plug harness connector Is the resistance below 5 0 ohms Yes GoTo 9 No Repair the open in the A142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NOTE Repeat the following test for both capacitors ENGINE 3 7L NOTE The Capacitors are attached to the side of each valve cover POWER TECH V6 Turn the ignition off Disconnect the Capacitor harness connector Install a good INJ COIL fuse With the DRBIII actuate the ASD Relay NOTE If the above test result is 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 5 267 DRIVEABILITY NGC Symptom P2503 CHARGING SYSTEM OUTPUT LOW When Monitored and Set Condition P2503 CHARGING SYSTEM OUTPUT LOW When Monitored The engine running The engine speed greater than 1157 RPM Set Condition The battery sensed voltage is 1 volt below the charging goal for 13 47 seconds The PCM senses the battery volta
377. the appropri ate 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 diag nostic 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 1 1 SYSTEM COVERAGE This diagnostic procedure manual covers Power train Transmission and Transfer Case diagnostics for 2005 KJ vehicles equipped with the Next Gen eration Control Module NGC 1 2 SIX STEP TROUBLE SHOOTING PROCEDURE Diagnosis of the Powertrain Control Module PCM is done in six basic steps e verification of complaint e verification of any related symptoms e symptom analysis e problem isolation e repair of isolated problem e verification of proper operation 2 0 IDENTIFICATION OF SYSTEM The Powertrain Control Module PCM monitors and controls e fuel system e ignition system e charging system e speed control system e The NGC control module is used on the 2 4L and 3 7L engines with an automatic or manual trans mission e The 42RLE transmission can be identified by confirming a Solenoid Pressure Switch Assembly located on the right side of the transmission The Transmission Ran
378. the mounting bolt s is properly torqued to specification Were any of the above conditions present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 3 121 DRIVEABILITY NGC P0315 NO CRANK SENSOR LEARNED Continued ACTION APPLICABILITY Remove the Crankshaft Position Sensor All Inspect the Tone Wheel F lex Plate slots for damage foreign material or excessive movement Were any problems found Yes Repair or replace the Tone Wheel F lex Plate as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 If there are no possible causes remaining view repair Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 122 DRIVEABILITY NGC Symptom List P0325 KNOCK SENSOR NO 1 CIRCUIT P0330 KNOCK SENSOR NO 2 CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO325 KNOCK SENSOR NO 1 CIRCUIT When Monitored and Set Condition P0325 KNOCK SENSOR NO 1 CIRCUIT When Monitored With the engine running gt 1312 RPM coolant temp gt 65 25 C 149 45 F MAF gt 250mg tdc and no ECT MAF or CAM Sensor DTCs Set Condition The Knock Sensor error program internal to the PCM is on the Knock Sensor voltage is lt 49 volt and the value of the Knock Sensor changes less than 06 volt for gt 11 seconds One Trip Fault Three good trips to turn off the MIL P
379. the voltage above 11 0 volts Yes GoTo 5 Repair the open or short to ground in the A16 Fused B circuits Inspect the related fuse and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the resistance between ground and the N201 Low Speed Rad Fan Relay Control circuit at the PDC Is the resistance below 100 ohms Yes Repair the short to ground in the N201 Low Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 Disconnect the C3 PCM harness connector All CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the N201 Low Speed Rad Fan Relay Control circuit from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes
380. tion ThePCM senses a short to ground or battery voltage on the Linear I dleAir Control LIAC control circuit for 2 75 seconds while the IAC motor is active POSSIBLE CAUSES IAC MOTOR OPERATTION IAC MOTOR K61 IAC CONTROL CIRCUIT SHORTED TO GROUND K961 IAC SIGNAL CIRCUIT OPEN K961 IAC SIGNAL CIRCUIT SHORTED TO GROUND K61 IAC CONTROL CIRCUIT OPEN PCM ACTION APPLICABILITY NOTE If the engine will not idle maintain an engine speed between 800 and All 1500 RPM Start the engine Allow the engine to idle Check for vacuum leaks proper PCV valve installation proper MAP Sensor instal lation and proper IAC installation With the DRBIII read the IAC Current Is the IAC Current below 146 mA Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the IAC Motor harness connector Remove the IAC Motor NOTE Inspect the IAC air passages for restriction and damage to the IAC valve Measure the resistance across the IAC Motor pin terminals component Is the resistance 9 7 1 0 ohms Yes GoTo 3 No Replace the lAC Motor Perform POWERTRAIN VERIFICATION TEST VER 5 189 DRIVEABILITY NGC P0508 IAC VALVE SIGNAL CIRCUIT LOW Continued ACTION APPLICABILITY Disconnect the C2 PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CON
381. tion on engine not running With the DRBIII monitor the O2 Sensor voltage Is the voltage above 4 8 volts Yes GoTo 6 No Check the O2 Signal circuit for a short to ground open or short to voltage nspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector Is the voltage at 2 5 volts Yes Check the fuel system for contaminants Perform POWERTRAIN VERIFICATION TEST VER 5 No Check the O2 Return circuit for a short to ground open or short to voltage nspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 260 DRIVEABILITY NGC Symptom List P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 2 4L P2305 IGNITION COIL NO 2 SECONDARY CIRCUIT INSUFFI CIENT IONIZATION 2 4L Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 2 4L SS ee When Monitored and Set Condition P2302 IGNITION COIL NO 1 SECONDARY CIRCUIT INSUFFICIENT IONIZA TION 2 4L When Monitored Engine running
382. tion 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 5 172 DRIVEABILITY NGC Symptom P0463 F UEL LEVEL SENSOR NO 1 HIGH When Monitored and Set Condition P0463 F UEL LEVEL SENSOR NO 1 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 9 volts for more than 90 seconds POSSIBLE CAUSES FUEL LEVEL SENSOR VOLTAGE ABOVE 4 9 VOLTS FUEL LEVEL SENSOR N4 FUEL LEVEL SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE N4 FUEL LEVEL SIGNAL CIRCUIT OPEN K900 SENSOR GROUND CIRCUIT OPEN PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the Fuel Level Sensor voltage Is the Fuel Level Sensor voltage above 4 9 volts Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the Fuel Pump Module electrical harness connector Connect a jumper wire between the N4 Fuel Level Signal circuit and the K 900 Sensor ground circuit at the Fuel Pump Module harness connector Ignition on engine not running With the DRBIII read the Fuel Level Sensor voltage Did the Fuel Level Sensor voltage change from above 4 8 volts to
383. tions 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 or the 8404 ADP adapter Connect the SMOKE supply tip black hose to the service port if equipped or to the 8404 ADP adapter 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 Make sure 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 8404 CLL 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 are 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 NOTE Carefully inspect the vent s
384. tle Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 1 NOTE If you are unable to communicate with the SKIM refer to the All Communication Category and perform the appropriate symptom With the DRBIII read the SKIM codes Are there any SKIM DTCs Yes Refer to the Vehicle Theft category and perform the appropriate diagnostics Perform POWERTRAIN VERIFICATION TEST VER 1 GoTo 3 307 STARTING START AND STALL CONDITION Continued ACTION APPLICABILITY Note For this test to be valid the thermostat must be operating correctly All Note This test works best if performed on a cold engine cold soaked NOTE If the vehicle was allowed to sit over night with no engine start coolant temperature should be near ambient temperatures With the DRBIII read the ECT value 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 temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Temperature value increase smoothly and did it reach at least 82 C 180 F Yes GoTo 6 No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 1 The following additional items should be checked as a possible cause for a
385. tly Yes GoTo 3 No Repair the open in the F1 and F26 Fused Ignition Switch Output Off Run Start circuit s Inspect the related fuses and and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to battery voltage probe the Z130 and Z131 PCM Ground circuits in the appropriate terminals of special tool 8815 Does the test light illuminate brightly Yes Test Complete No Repair the open in the Z130 and Z131 PCM Ground circuit s Perform POWERTRAIN VERIFICATION TEST VER 1 282 SENTRY KEY IMMOBILIZER Symptom List ANTENNA FAILURE COP FAILURE EEPROM FAILURE INTERNAL FAULT RAM FAILURE SERIAL LINK INTERNAL FAULT STACK OVERFLOW FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ANTENNA FAILURE EE When Monitored and Set Condition ANTENNA FAILURE When Monitored Every 250 milliseconds with the ignition on Set Condition TheSKIM s microcontroller determines that an antenna circuit fault has occurred for 2 0 consecutive seconds COP FAILURE When Monitored With the ignition on Set Condition TheCOP timer is not reset by the mi
386. tors Ignition on engine not running Measure the voltage on the F 856 5 volt Supply circuit at the MAP Sensor harness connector Is the voltage above 5 2 volts Yes Repair the short to voltage in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Turn the ignition off CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F856 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 GoTo 8 No Repair the open in the F 856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 88 DRIVEABILITY NGC P0129 BAROMETRIC PRESSURE OUT OF RANGE Continued ACTION APPLICABILITY Measure the resistance between ground and the F 856 5 volt Supply circuit at the All MAP Sensor harness connector Is the resistance below 100 ohms Yes Repair the short to ground in the F856 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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
387. train Control Module harness connector All Measurethe resistance between ground and the Transfer Case Position Sensor nput circuit Is the resistance below 5 0 ohms Yes Repair the Transfer Case Position Sensor input circuit for a short to ground No GoTo 4 Turn the ignition on Measure the voltage of the Transfer Case Position Sensor Input circuit Is there any voltage present Yes Repair the Transfer Case Position Sensor input circuit for a short to voltage No GoTo 5 Turn the ignition off to the lock position NOTE Check connectors Clean repair as necessary Measure the resistance between the Transfer Case Position Sensor Input circuit and the Sensor Return circuit in the PCM harness connector Is the resistance above 1000 0 ohms Yes GoTo 6 No Repair the Transfer Case Position Sensor Input circuit for a short to the Sensor Return circuit CAUTION IF EQUIPPED WITH NGC CONTROLLER DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNEC TORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TER MINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815TO PERFORM DIAGNOSIS Measure the resistance between the Transfer Case Position Sensor Input circuit and the Sensor Return circuit in the PCM harness connector Is the resistance between 55 ohms and 1 3k ohms Yes GoTo 7 No Replace the Transfer Case Position Sensor If there are no possible causes remaining view repa
388. turned off This differs from the previous behavior of the MIL light which was only activated with a failure in the system For in plant mode the MIL light will function as in previous model years Below are diagrams of how the MIL light will operate IN PLANT MODE IN FIELD MODE Key On Ignition Off Key On Ignition Off MIL Light On 15 seconds MIL Light Off MIL Flash MIL On MIL Flash 5 seconds OBD readiness bits not cleared Tests In Progress OBD readiness bits cleared MIL On MIL Off Test Failed Tests Passed 80e93c7e The following table summarizes the various OBDII monitors operation GENERAL INFORMATION OBD II Monitor Operation Comprehensive Components Monitor Run constantly Includes All Engine Hardware Sensors Switches Solenoids etc Most are One Trip Faults Usually Turns On The MIL and Sets DTC After One Failure Priority 3 All Checked For Continuity Open Short To Ground Short To Voltage Inputs Checked For Rationality Outputs Checked For Functionality Requires 3 Consecutive Good Trips to Extinguish the MIL 40 Warm Up Cycles are required to erase DTCs after the MIL has been extinguished Major Monitors Fuel Control amp Misfire Major Monitors Non Fuel Control amp Non Misfire Run Once Per Trip Run constantly Monitors Entire Emission System Monitors Entire System Two Trip Faults Turns On The MIL and Sets DTC After
389. ually inspect the related wire harness including the ground circuit 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 Make sure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are tight Refer to any TSBs that may apply Were any of the above conditions present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Disconnect the CKP Sensor connector Ignition on engine not running Measure the voltage on the F855 5 volt Supply circuit in the Sensor harness connector Is the voltage between 4 5 and 5 3 volts Yes GoTo 5 No Repair the open or short to ground in the F855 5 volt Supply circuit Use Miller special tool 8815 when checking for an open circuit to prevent PCM harness connector terminal damage Perform POWERTRAIN VERIFICATION TEST VER 5 Yes Repair or replace the Tone Wheel F lex Plate as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 6 NOTE An intermittent condition in the Cam Position Sensor can cause the P0339 to set Install the Crankshaft Position Sensor With the DRBIII lab scope probe and the Miller special tool 6801 backprobe the K44 CMP Signal circuit at the Sensor harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND
390. uit and the G31 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 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 5 51 DRIVEABILITY NGC Symptom P0072 AMBIENT TEMP SENSOR CIRCUIT LOW mT When Monitored and Set Condition P0072 AMBIENT TEMP SENSOR CIRCUIT LOW When Monitored The ignition key on Set Condition Ambient Temperature Sensor is less than 0 039 of a volt at the PCM for 4 8 seconds Three good trips to clear 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 K900 SENSOR GROUND PCM ACTION APPLICABILITY Ignition on engine not running All With the DRBIII read the Ambient Temperature Sensor voltage Is the voltage below 0 3 of a volt Yes GoTo 2 No Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off Disconnect the Ambient Temperature Sensor harness connector Ignitio
391. uminate brightly Compare the brightness to that of a direct connection to the battery Is the test light illuminated Yes GoTo 4 No Repair the Fused B circuit for an open Refer to the wiring diagrams located in the Service Information Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 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 TERMI NALS 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 GoTo 5 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 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 29 COMMUNICATION NO RESPONSE FROM TRANSMISSION CONTROL MODULE NGC Continued ACTION APPLICABILITY Note E nsure there is PCI Bus communication with other modules on the All vehicle before proceeding If not refer to the symptom list from the menu and repair as necessary Disconnect the PCM har
392. und and the K 24 CKP Signal circuit at the CKP Sensor harness connector Wiggle the related wire harness while monitoring the resistance value Does the resistance ever go below 100 ohms Yes Repair the short to ground in the K 24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 11 Measure the resistance between the F 855 5 volt Supply circuit and the K24 CKP Signal circuit at the CKP harness connector Wiggle the related wire harness while taking this measurement Does the resistance ever go below 5 0 ohms Yes Repair the short between the F 855 5 volt Supply circuit and the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 12 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING All THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance in the K 24 CKP Signal circuit between the CKP harness connector and the appropriate terminal of special tool 8815 Wiggle the wire harness while taking this measurement Is the resistance below 1 0 ohm Yes GoTo 10 No Repair the open high resistance in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 132 DRIVEABILITY NGC P0339 CRANKSHAFT POSITION SENSOR INTERMITTENT Continued ACTION APPLICABILITY NOTE Before continuing check
393. upon the state of the O2 sensors engine speed MAP throttle posi tion air temperature battery voltage and coolant temper ature 3 2 2 ON BOARD DIAGNOSTICS The PCM has been programmed to monitor any circuit or system that has an effect on vehicle emissions or is used by the PCM to determine the proper functionality of these systems This monitor ing is called on board diagnosis Certain criteria or arming conditions must be met before a trouble code will be entered into the PCM memory The criteria range from engine rpm engine temperature and or input voltage to the PCM 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 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 compares input signal voltage from each input component to specifications the estab lished high and low limits of the range that are preprogrammed for that component If the input voltage is not within specifications and other trou ble code criteria arming conditions are met a trouble code will store in the PCM memory The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII These OBDII Diagnostics control the func
394. ure 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 2 No Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 2 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 16 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 407 KPa 34 KPa 59 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 drop Yes Replace Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 2 No GoTo 5 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
395. ure the resistance of the B15 Brake Switch No 1 Signal circuit from the Brake Lamp Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms Yes GoTo 4 No Repair the open in the B15 Brake Switch No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 4 Measure the resistance between the Z940 Ground circuit and ground at the Brake Lamp Switch harness connector Is the resistance below 5 0 ohms Yes GoTo 5 No Repair the open in the Z940 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 4 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 4 215 DRIVEABILITY NGC Symptom P0580 SPEED CONTROL SWITCH NO 1 LOW E When Monitored and Set Condition P0580 SPEED CONTROL SWITCH NO 1 LOW When Monitored With the ignition key on Battery voltage above 10 volts Set Condition When switch voltage is less than 0 60 of a volt for 2 minutes POSSIBLE CAUSES SPEED CONTROL SWITCH VOLTAGE LOW SPEED CONTROL ON OFF SWITCH SPEED CONTROL RESUME ACCEL
396. urn off the ignition By turning the ignition key off monitor enabling conditions will be lost NVLD Monitor runs after key off B By performing a Battery Disconnect or Selecting Erase DTCs the CARB Readiness and all additional OBD II information will be cleared Monitor Preliminary Checks 1 Plug a DRB II1 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 On the DRB III Select 1 DRBIII Stand alone 4 Select 1 1998 2003 Diagnostics 5 Select 1 Engine 6 Select 2 DTCs and Related Functions 7 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 8 Return to Engine Select Function Menu and Select 9 OBD II Monitors 9 Select 3 CARB Readiness Status Doall 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 NOTE A Only the monitors which are not YES in the CARB Readiness Status need to be com
397. values Is the temperature for each of the Sensors increasing properly Yes Refer tothe INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 GoTo 3 248 DRIVEABILITY NGC P1115 GENERAL TEMPERATURE SENSOR PERFORMANCE Continued ACTION APPLICABILITY Ignition on engine not running Disconnect the suspected faulty sensor Connect a jumper wire between the Sensor Signal circuit and the K900 Sensor ground circuit With the DRBIII in Sensors read the voltage of the suspected Sensor Did the voltage reading start at 4 8 to 5 0 volts and decrease to 0 volts Yes Replace the faulty Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 4 Turn the ignition off All Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS 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 Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance above 5 0 ohms Yes Repair the excessive resistance in the Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TE
398. ween ground and the K 22 TP Sensor No 1 Signal circuit at the TP Sensor harness connector Is the resistance above 100k ohms Yes GoTo 10 No Repair the short to ground in the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K900 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 GoTo 17 No Repair the excessive resistance in the K900 Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 Turn the ignition off All Disconnect the MAP Sensor harness connector Disconnect the C1 and C2 PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the F856 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 GoTo 12 No Repair the excessive resistance in the F 856 5 volt Supply circuit Perform POWERTRAIN VERIFI
399. will be performed as follows e 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 e The solenoid will be deenergized 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 e The solenoid is then re energized for the remain der of the drive cycle e If the switch events are not seen in a certain period of time the rationality check will have failed 2 trip rule N C SOLENOID VACUUM RELIEF FILTER SWITCH NVLD ASSEMBLY p PRESSURE RELIEF VACUUM 2 Purge Flow The above rationality check is considered suffi cient to confirm purge solenoid function and con formance 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 e 40 F to 90 F e Engine temperature at startup within 10 F of the ambient temperature e Fuel level less than 85 The intrusive Medium and Large leak are con ducted as follows e De energize the NVLD solenoid to seal the can is
400. will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA With the DRBIII read Transmission DTCs Did the DTC P0122 THROTTLE POSITION SENSOR LOW reset Yes GoTo 4 No GoTo 5 NOTE Due to the integration of the Powertrain and Transmission Control Modules bus communication between the modules is internal Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits Verify the flash level of the controller and update the controller if available With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set If there are no possible causes remaining view repair Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits Pay particular attention to the TPS signal and sensor ground circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there a
401. wire not connected to correct injector Are there any engine mechanical problems Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No GoTo 7 Turn the ignition off Remove the ASD relay from the PDC Disconnect the PCM harness connectors Verify the ASD Relay is getting Fused B voltage before continuing Measure the resistance of the A142 ASD Relay output circuit from the ASD Relay connector to the PCM harness connector Ignition coil and the fuel injectors Is the resistance below 5 0 ohms Yes GoTo 8 No Repair the open ASD Relay output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 298 STARTING ENGINE CRANKS BUT DOES NOT START Continued ACTION APPLICABILITY Verify that the Fuel tank is not empty before continuing All Follow the diagnostics for Checking Fuel Delivery under the Driveability section of this manual Was the No Start condition solved after following the above diagnostic procedure Yes Test Complete No Check for contamination water in the fuel Ensure the fuel being used in this vehicle meets manufactures Fuel Requirement refer to the service manual Perform POWERTRAIN VERIFICATION TEST VER 5 299 STARTING Symptom FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES FAULTY FUEL PUMP MODULE FUEL INJ ECTOR S ACTION APPLICABILITY NOTE Before continuing visually and physically inspect the fuel delivery All system for ex
402. y the conditions in which the DTC was set Were there any problems found Yes Repair as necessary Perform 42RLE NGC TRANSMISSION VERIFICATION TEST VER 1 Test Complete 330 TRANSMISSION 42RLE Symptom P0602 CONTROL MODULE PROGRAMMING ERROR When Monitored and Set Condition P0602 CONTROL MODULE PROGRAMMING ERROR When Monitored Continuously Set Condition The DTC will always light the MIL and is designed to signal the technician that the controller still has generic software installed ACTION APPLICABILITY NOTE Controller is programmed with generic software and will not allow All the correct vehicle Powertrain management Record the vehicles controller part number Select Use Controller Part Number under the Flash Tab Flash the controller with the correct software Test complete Yes Test Complete 331
403. ymptom NO RESPONSE FROM PCM PCI BUS NGC POSSIBLE CAUSES PCM PCI NO RESPONSE POWERTRAIN CONTROL MODULE PCI BUS CIRCUIT OPEN ACTION APPLICABILITY Turn the ignition on All NOTE As soon as one or more module communicates with the DRB answer the question With the DRB enter Anti Lock Brakes With the DRB enter Electro Mechanical Cluster MIC With the DRB enter Passive Restraints then Airbag Were you able to establish communications with any of the modules Yes GoTo 2 No Refer to symptom PCI Bus Communication Failure in the Com munications category Perform POWERTRAIN VERIFICATION TEST VER 1 With the DRB read the Powertrain DTC s This is to ensure power and grounds tothe 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 TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH 7058 Cable to Probe adapter CH 7062 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 DRBIII select Pep Module Tools Select lab scope Select Live

2005 KJ Powertrain

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