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TABLE OF CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2 FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2.1 PCM ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2.2 ECM OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.3 MONITORED CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.4 SKIS ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.5 SKIS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.6 SKIS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.3.1 HARD CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.3.2 INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.3.4 ECM DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . .43.3.5 HANDLING NO TROUBLE CODE PROBLEMS . . . . . . . . . . . . . . . . . . . .5

3.4 USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.5 DRBIII ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . . .5

3.5.1 DRBIII DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.2 VEHICLE PREPARATION FOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . .64.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.4 DRBIII SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . . .7

5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

CHARGING

P0622-GENERATOR FIELD NOT SWITCHING PROPERLY - DIESEL . . . . . . . . . . . .10P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH - DIESEL . . . . . . . . . . . . . . . .12P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW - DIESEL . . . . . . . . . . . . . . . . .15P1594-CHARGING SYSTEM VOLTAGE TOO HIGH - DIESEL . . . . . . . . . . . . . . . . . . .17P1600-BATTERY VOLTAGE SRC HIGH EXCEEDED - DIESEL . . . . . . . . . . . . . . . . . .19P1682-CHARGING SYSTEM VOLTAGE TOO LOW - DIESEL . . . . . . . . . . . . . . . . . . .21*CHECKING THE CHARGING SYSTEM OPERATION - DIESEL . . . . . . . . . . . . . . . . .21

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TABLE OF CONTENTS - Continued

COMMUNICATION

P-1685 INVALID SKIM KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25P-1686 NO SKIM BUS MESSAGE RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27P0600-PCM FAILURE SPI COMMUNICATIONS - DIESEL . . . . . . . . . . . . . . . . . . . . . .29P0601-PCM INTERNAL CONTROLLER FAILURE - DIESEL. . . . . . . . . . . . . . . . . . . . .29P1696-PCM FAILURE EEPROM WRITE DENIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29P1687-NO CLUSTER BUS MESSAGE - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

*NO RESPONSE FROM ECM AND PCM (DIESEL ONLY) . . . . . . . . . . . . . . . . . . . . . .32*NO RESPONSE FROM POWERTRAIN CONTROL MODULE (DIESEL ONLY) . . . . .35

DRIVEABILITY - DIESEL

P0115-TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED . . . . . . . . . .37P0115-TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED . . . . . . . . . .39P0117-ECT SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41P0118-ECT SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED . . . . . . . . . . . . . . . .45P0180-FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED . . . . . . . . . . . . . . . . .48P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . .51P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED . . . . . . . . . .53

P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED . . . . . . . . . .56P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED. . . . . . . . . .59P0235-TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED . . . . . . . . . .61P0400-EGR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63P0400-EGR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES. . . . . . . . . . . . . . . . . . . . . . . . .67P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW. . . . . . . . . . . . . . . . . . . . . . . .69P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH . . . . . . . . . . . . . . . . . . . . . . .71P0500-VEH. SPEED SENSOR PEC FREQUENCY TOO HIGH . . . . . . . . . . . . . . . . . .73P0500-VEH. SPEED SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73P0500-VEH. SPEED SENSOR SRC HIGH EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . .73P0522-OIL PRESSURE VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

P0523-OIL PRESSURE VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81P0725-ENGINE SPEED SENSOR DYN. PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . .84P0725-ENGINE SPEED SENSOR STATIC PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . .84P0725-ENGINE SPEED SENSOR OVERSPEED RECOGNITION . . . . . . . . . . . . . . . .87P1105-ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED . . . . . . . . . . . .89P1105-ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED . . . . . . . . . . . .89P1610-REGULATOR LOWER REGULATOR LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .89P1610-REGULATOR UPPER REGULATOR LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .89P1615-MICROCONTROLLER GATE-ARRAY MONITORING. . . . . . . . . . . . . . . . . . . . .89P1615-MICROCONTROLLER GATE-ARRAY WATCHDOG . . . . . . . . . . . . . . . . . . . . . .89P1615-MICROCONTROLLER PREPARE FUEL QUANTITY STOP. . . . . . . . . . . . . . . .89P1615-MICROCONTROLLER RECOVERY HAS OCCURRED . . . . . . . . . . . . . . . . . . .89P1615-MICROCONTROLLER REDUNDANT OVERRUN MONITORING . . . . . . . . . . .89P1620 - U-REF (2.5V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ (EGR) . . . . . . . . . . .89P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212 . . . . . . . . . . . . . . . .89P1680-EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM . . . . . . . . . . . . .89P1680-EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING . . . . . . . . . .89P1680-EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING . . . . . . . . .89P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR . . . . . . . . . . . . . . . . . . . . .89P1110-AIR TEMP. SENSOR SRC HIGH EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . .91P1110-AIR TEMP. SENSOR SRC LOW EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . .93

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P1201-NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED . . . . . . . . . . . . . . . . .95P1201-NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED . . . . . . . . . . . . . . . . .98P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD . . . . . . . . . . . . .100P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM . . . . . . . . . . . .102P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD . . . . . . . . . . . . .104P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM . . . . . . . . . . . .104P1225-CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED . . . . . . . . . . . . . . .106

P1225-CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDED . . . . . . . . . . . . . . .106P1225-CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED . . . . . . . .109P1225-CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED . . . . . . . . .109P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION . . . . . . . . . . . . . .111P1230-TIMING GOVERNING POSITIVE GOVERNOR DEVIATION . . . . . . . . . . . . . .113P1515-ACCEL. PEDAL SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115P1515-ACCEL. PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER . . . . . . . .115P1515-ACCEL. PEDAL SENSOR SIGNAL HIGH EXCEEDED . . . . . . . . . . . . . . . . . .115P1515-ACCEL. PEDAL SENSOR SUPPLY HIGH EXCEEDED . . . . . . . . . . . . . . . . . .115P1515-ACCEL. PEDAL SENSOR SUPPLY LOW EXCEEDED . . . . . . . . . . . . . . . . . .115P1520-VEHICLE SPEED GOV ANALOG CTRL - CONTROL CONTACT ALONE . . .123P1605-TERMINAL 15 PLAUSIBILITY AFTER START UP . . . . . . . . . . . . . . . . . . . . . .124

P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE. . . . . . . . . . . . . . . . . .126P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON . . . . . . . . . . . . . . . . .129P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . .131P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT . . . . . . . . . . . . . . . . . . .134P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . .136P1635-GLOW RELAY 1 CONTROLLER SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . .138P1645-GLOW DISPLAY OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140P1645-GLOW DISPLAY SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143P1660-REDUNDANT EMERG. STOP PLAUSIBILITY IN AFTER-RUN . . . . . . . . . . . .146P1660-REDUNDANT EMERG. STOP POWERSTAGE DEFECTIVE. . . . . . . . . . . . . .148P1685-VEHICLE THEFT ALARM IMMOBILIZER SIG LOST . . . . . . . . . . . . . . . . . . . .151P1685-VEHICLE THEFT ALARM INVALID SKIM MESSAGE. . . . . . . . . . . . . . . . . . . .151

P1690-FAN CONTROL OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154P1690-FAN CONTROL SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156P1703-BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT . . . . . . . . . . . . . . . .158P1725-INDUCTIVE AUX. SPEED SENSOR DYN. PLAUSIBILITY . . . . . . . . . . . . . . .162P1725-INDUCTIVE AUX. SPEED SENSOR OVERSPEED RECOGNITION. . . . . . . .162P1725-INDUCTIVE AUX. SPEED SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . .162P1725-INDUCTIVE AUX. SPEED SENSOR STATIC PLAUSIBILITY. . . . . . . . . . . . . .162*CHECKING THE A/C SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION . . .170*CHECKING THE CHECK ENGINE LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . .171*CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS. . . . . . . . . . .174*CHECKING THE EGR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176*CHECKING THE ELECTRIC RADIATOR FAN OPERATION . . . . . . . . . . . . . . . . . . .177*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION . .179*CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . .180*CHECKING THE FUEL COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181*CHECKING THE FUEL HEATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183*CHECKING THE FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185*CHECKING THE FUEL LEVEL GAUGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . .186*CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION . . . . . . . . . . . . . .188*CHECKING THE GLOW PLUG LAMP OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . .189*CHECKING THE GLOW PLUG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

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*CHECKING THE LOW COOLANT LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . .192*CHECKING THE OIL PRESSURE GAUGE OPERATION. . . . . . . . . . . . . . . . . . . . . .196*CHECKING THE SPEEDOMETER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .199*CHECKING THE TACHOMETER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202*CHECKING THE TURBOCHARGER BOOST PRESSURE SENSORCALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204*CHECKING THE TURBOCHARGER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .205

*CHECKING THE VEHICLE SPEED SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207*CHECKING THE WATER IN FUEL LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . .212

HEATING & A/C

P1655-AC CONTROL OPEN CIRCUIT - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214P1655-AC CONTROL SHORT CIRCUIT - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .216

SPEED CONTROL

P1596-SPEED CONTROL SWITCH ALWAYS HIGH - DIESEL . . . . . . . . . . . . . . . . . .218P1597-SPEED CONTROL SWITCH ALWAYS LOW - DIESEL. . . . . . . . . . . . . . . . . . .220*CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .222

STARTING*NO CRANK CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228*NO START CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

VEHICLE THEFT/SECURITY

ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234COP FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234INTERNAL FAULT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234

PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE . . . . . . . . . . . . .240TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

VERIFICATION TESTS

VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

8.1 ENGINE CONTROL MODULE, POWERTRAIN CONTROL MODULE ANDSENTRY KEY IMMOBILIZER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

8.2 CONTROLS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2488.3 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2488.4 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2498.5 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2508.6 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518.7 LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

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9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

A/C COMPRESSOR CLUTCH (DIESEL) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . .253A/C HIGH PRESSURE SWITCH - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253A/C LOW PRESSURE SWITCH - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY . . . . . . . .253BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . .254

BRAKE LAMP SWITCH - GRAY 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254CLOCKSPRING C1 - NATURAL 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254CLOCKSPRING C2 - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254CLUTCH INTERLOCK SWITCH - GREEN 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .254DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255EGR SOLENOID (DIESEL) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 51 WAY. . . . . . . . . . . . . . . . . .256ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 29 WAY. . . . . . . . . . . . . . . . . .257ENGINE COOLANT TEMPERATURE SENSOR NO. 1 (DIESEL ECM) - BLACK 2WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257ENGINE COOLANT TEMPERATURE SENSOR NO. 2 (DIESEL PCM) - BLACK 2WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258

ENGINE SPEED SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . .258FUEL HEATER (DIESEL) - 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258FUEL INJECTION PUMP (DIESEL) - BLACK 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . .258FUEL LEVEL SENSOR (DIESEL) - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .259GENERATOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259GENERATOR - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259GLOW PLUG RELAY (DIESEL) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259INSTRUMENT CLUSTER C2 - BLACK 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260LOW COOLANT SWITCH (DIESEL) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260MESSAGE CENTER (DIESEL) - BLACK 8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260NEEDLE MOVEMENT SENSOR (DIESEL) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .260FUSES (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

A/C COMPRESSOR CLUTCH RELAY (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . .262AUTOMATIC SHUT DOWN RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262ENGINE STARTER MOTOR RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263FUEL HEATER RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263RADIATOR FAN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263POWERTRAIN CONTROL MODULE C1 (DIESEL) - 32 WAY . . . . . . . . . . . . . . . . . . .264POWERTRAIN CONTROL MODULE C2 (DIESEL) - 32 WAY . . . . . . . . . . . . . . . . . . .265POWERTRAIN CONTROL MODULE C3 (DIESEL) - 32 WAY . . . . . . . . . . . . . . . . . . .266RADIATOR FAN MOTOR - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .266TURBO BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY . . . . . . . . . . . . . .267VEHICLE SPEED SENSOR (DIESEL) - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .267

10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269

10.1 ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26910.2 POWERTRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270

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1.0 INTRODUCTION

The procedures contained in this manual include

a ll t h e sp ecif ica t io n s, in st r u ct ion s, a n d g r a p h ics

needed to diagnose engine control module (EC M),

p ow e r t r a in con t r o l m o d u le (P CM) a n d se n t r y k ey

immobilizer m odule (SKIM) problems; they are no

start , diagnostic trouble code, and no trouble code

problems. The diagnostics in th is ma nua l a re basedon the trouble condition or symptom being present

at the t ime of diagnosis.

When repairs are required, refer to the appropri-

a t e vo lu m e o f t h e se r vice m a n u a l f o r t h e p r o p e r

removal an d repair procedure.

Dia gnostic procedures cha nge every year. New

d ia g n o st ic sy st e m s m a y be a d d e d ; ca r r y o ve r sy s-

t e m s m a y b e e n h a n c e d . I T I S R E C O M M E N D E D

THAT YOU REVIEW THE ENTIRE MANUAL TO

B E C O M E FAM I LI AR WI TH AL L N E W AN D

C H AN G E D D I AG N O S TI C P R O C E D U R E S .

Please follow the recommendations below when

choosing your diagn ostic path.

1. F i r st m a k e su r e t h e D R B I I I is communicating

with the a ppropriate modules; ie., if the DRB III d isp la y s a No Response condition, you must

diagnose this first before proceeding.

2. Read DTC’s (diagnostic trouble codes) with the

D R B I I I.

3. I f no DTC’s are present, identify the customer

complaint.

4. Once the DTC or customer complaint is identi-

f ie d , loca t e t h e m a t ch in g t e st in t h e Ta ble o f

Contents and begin to diagnose the symptom.

All component location views are in Section 8.0.

All connector pinouts a re in Section 9.0. All syst em

schematics are in Section 10.0.

An * placed before the symptom description indi-

cates a no DTC customer complaint .

1. 1 SYSTEM COVERAGE

Th is d ia g n ost ic p r oced u r es m a n u a l cover s t h e

2001 XJ equipped with the 2.5L VM diesel engine.

1. 2 SIX-STEP TROUBLESHOOTING

PROCEDURED ia g n o sis o f t h e e n g in e co n t r o l m o d u le (ECM)

and powertrain control module (PCM) is done in six

basic st eps:

• verification of complaint

• verificat ion of any related symptoms

• sy m p t om a n a ly sis

• problem isolation

• repair of isolated problem

• verifica tion of proper operat ion

2.0 IDENTIFICATION OFSYSTEM

LHD The ECM is located behind the lower instru-

ment panel to the right of the acceleratorpedal.

RHD The ECM is located behind the lower instru-

ment panel to the left of the clutch pedal.

The PCM for both LHD and RHD is located

in the engine compartment behind the aircleaner housing.

3.0 SYSTEM DESCRIPTION ANDFUNCTIONAL OPERATION

3. 1 GENERAL DESCRIPTION

The 2.5L VM diesel engine system is equipped

with the la test in t echnical a dvances. The on-board

diagnostics incorporated with the powertrain con-

trol module and engin e control module a re intended

t o a ssist t h e f ield t e ch n icia n in r e pa ir in g veh icle

problems by t he quickest means.

3. 2 FUNCTIONAL OPERATION

3. 2. 1 PCM ON-BOARD DIAGNOSTICS

T h e P C M a n d E C M h a v e b e e n p r o g r a m m e d t o

monitor many different circuits of the diesel fuel

in je ct ion sy st e m . Th is m on it or in g is ca l le d “on -

boar d diagnosis.”

Certa in criteria must be met for a trouble code to

b e e n t er ed i n t o t h e P C M or E C M m em or y. Th e

cr i t er ia m a y b e a r a n g e o f: e ng in e r p m , e ng in e

t e m pe r a t u r e , a n d /or in pu t volt a g e . I f a l l of t h e

criteria for monitoring a system or circuit are met

and a problem is sensed, then a trouble code will be

st or e d in t h e P CM o r t h e EC M.

It is possible that a trouble code for a monitored

ci r cu it m a y n ot b e en t e re d i n t o m e m or y ev enthough a malfunction has occurred. This may hap-

p en w h e n t h e m on it or in g cr i t er ia h a ve n ot bee n

met.

T h e PCM a n d ECM co m p a r e in p u t sig n a l vo lt -

ages from each input device with specifications (the

e st a blish e d h ig h a n d lo w l im it s of t h e r a n g e) t h a t

are programmed into it for tha t device. If th e input

voltage is not within specifications and other trou-

ble cod e cr i t er ia a r e m e t , a t r o uble cod e w ill be

stored in the PCM or ECM memory.

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3. 2. 2 ECM OPERATING M ODES

As i n pu t s ig n a l s t o t h e E C M ch a n g e, t h e E C M

a djusts it s response to output devices. For example,

t h e ECM m u st ca lcu la t e a d i f f e r e n t f u e l q u a n t i t y

and fuel t iming for idle than it does for wide open

throttle. There are several different modes of oper-

ation that determine how the ECM responds to the

various input signals.

Ignition Switch On (Engine Off Mode)When the ignition switch activates the diesel fuel

injection system, the following actions occur:

1. The ECM determines atmospheric air pressure

from the atmospheric pressure sensor located in

t h e E C M .

2. T h e ECM e n e r g iz e s t h e f u e l q u a n t i t y a ct u a t o r

a n d t h e f u e l sh u t d ow n solen oid i f n o f a u lt s a r e

present.

I f t h e e n g in e is n o t s t a r t e d w it h in 5 se co n d s o f

ig n it ion on , t h e ECM d e a ct iva t e s t h e f u el q u a n t i t y

actua tor an d t he fuel shutdown solenoid to prevent

overheating.Engine Start-up Mode - Th e E C M u s es t h e

engine temperature sensor, fuel temperature sen-

sor, at mospheric pressure sensor, inta ke air t emper-

at ure sensor a nd t he engine speed sensor t o deter-

mine fuel delivery during this mode.

Normal Driving Modes - Engine idle, warm-up,

acceleration, decelera tion a nd wide open thrott le

modes are all controlled based on the sensor inputs

t o t h e E C M a n d a r e m od if ied b a s ed on en g in e

t e m pe r a t u r e , bo ost p r essu r e, in t a k e a ir t e m pe r a -

ture a nd engine speed.

Overheat Protection Mode - If engine temper-

at ure becomes too hot , t he EC M limits fuel quan tity

for engine protection.

Limp-In Modes - The ECM operates in limp-in

mode when certa in system faults are detected. The

EC M opera tes in one of the following modes based

on the type and severity of the fault :

1. 10%t orque reduction.

2. 50%t orque reduction.

3. En gine speed set to 1100 rpm.

After-Run - When fused ignition sw itch output is

r em ov ed f r om t h e E C M ca v i t y C 1 -47, t h e E C M

performs a self-diagnostic check in the following

order:

1. Electrical shut-off test .

2. F u e l q u a n t i t y a ct u a t o r t e st .

3. Monitoring module test .

4. Volta ge regulat or test .

5. Main relay t est (if tests 1-4 pass).

I f a n y of t e st s 1-4 f a i l , t h e f a u lt i s s t o re d i n

memory a nd can be retrieved during the n ext igni-

tion cycle using the DRBIII.

3.2. 3 MONITORED CIRCUITS

Th e P C M a n d E C M a r e a b le t o m on it or a n d

id en t i f y m ost d r ivea bil it y r e la t e d t r o uble con d i-

tions. Some circuits are directly monitored through

f ee d ba ck cir cuit r y. I n a d d it ion , t h e P CM a n d ECM

m on i t or t h e v ol t a g e s t a t e of s om e ci r cu it s a n d

compare those states with expected values. Other

sy st e m s a r e m o n it o r e d in d ir e ct ly w h e n t h e PCM

a n d E C M con d u ct a r a t i on a l it y t e st t o i d en t i fy

problems.

Alt h ou g h m ost e n gin e con t r o l su bsy st e m s a r e

either directly or indirectly monitored, there ma y be

occa sion s w h e n d ia g n ost ic t r o uble cod e s a r e n ot

immediately identified. For a trouble code t o set ,

specific conditions must be met and unless these

conditions a re encountered, a code w ill not set .

3. 2. 4 SKIS ON-BOARD DIAGNOSTICS

The SKIS has been programmed to transmit and

monitor many different coded messages as well as

CC D B us messa ges. This monitoring is called “On-Board Diagnosis”.

C e r t a in cr i t er ia m u s t b e m e t f or a d ia g n os t i c

trouble code to be entered in to the SKIS memory.

The criteria m ay be a r ange of: input voltage, CC D

B us messages, or coded messages to the SKIS . If a ll

of the criteria for monitoring a circuit or function

a r e m e t a n d a f a u lt is se n se d, a d ia g n ost ic t r ou ble

code w ill be stored in the S KIS memory.

3.2. 5 SKIS OVERVIEW

The Sentry Key Im mobilizer S ystem (SKIS ) is a n

immobilizer system designed to prevent unautho-

rized vehicle operat ion. The sy stem consists of a

Sentry Key Immobilizer Module (SKIM), ignit ion

k ey (s) e q u ipp ed w it h a t r a n sp on d e r ch ip , e n gin e

controller an d powertra in controller . When the ig-

n it ion sw it ch is t u r n e d o n , t h e S K I M in t e rr og a t e s

the ignit ion key. If the ignit ion key is “Valid” the

SK I M se n d s a CCD B u s m e ssa g e t o t h e p ow e r t r a in

cont roller indicat ing th e presence of a va lid ignition

key. The PCM then supplies the ECM with a valid

immobilizer signa l a llowing the engine to continue

to operate.

3.2. 6 SKIS OPERATIONWhen ignit ion power is supplied to the S KI M, the

SKI M performs an internal self-test . After th e self-

test is completed, the S KIM energizes the a ntenna

(t h is a ct iva t e s t h e t r a n sp o n d e r ch ip ) a n d se n d s a

challenge to the transponder chip. The transponder

ch ip r e sp o n d s t o t h e ch a lle n g e by g e n e r a t in g a n

encrypted response message using the following:

Secret Key - This is an electronically stored value

(identification number) tha t is unique t o each S KIS .

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The secret key is stored in the SKIM, PCM and all

ignit ion key tra nsponders.

Challenge - Th is i s a r a n dom n u mb er t h a t i s

generated by the SKIM at each ignit ion key cycle.

T h e se cr e t k e y a n d ch a lle n g e a r e t h e t w o va r i-

a b les u sed i n t h e a l gor it h m t h a t pr od uces t h e

encrypted response message. The transponder uses

th e crypto a lgorithm t o receive, decode a nd respondto the message sent by SKIM. After responding to

t h e cod e d m e ssa g e, t h e t r a n sp on d e r se n d s a t r a n -

sponder ID message to the SKIM. The SKIM com-

pares the transponder ID to the available valid key

cod e s in SK I M m e m or y (8 k ey m a x im u m ). Af t er

va l id a t in g t h e ig n it ion k e y t h e SK I M se n d s a CCD

Bus message called a ‘‘Seed Request’’ to the power-

tra in controller th en wa its for a powertra in control-

ler response. If the powertrain controller does not

respond, the S KIM w ill send th e seed request a gain.

Af t er t h r ee f a i led a t t e m pt s t h e S K I M w i l l s t op

sending t he seed request a nd st ore a t rouble code. If

th e powertr a in cont roller sends a seed response, theS K I M s en d s a v a l id /i n va l i d k ey m es s a g e t o t h e

powert ra in contr oller. This is a n encrypted messa ge

that is generated using the following:

VIN - Vehicle Identificat ion Number

Seed - This is a random number that is generated

by the PCM at each ignit ion key cycle.

Th e V I N a n d se e d a r e t h e t w o va r ia bles u sed in

the rolling code algorithm tha t encrypts t he ‘‘valid/

invalid key’’ message. The powertra in controller

uses the rolling code algorithm to receive, decodean d r espond to t he va lid/invalid key message sent

by SKI M. After sending the valid/invalid key mes-

sa g e t h e SK I M w a it s 3.5 secon d s f or a P CM st a t u s

message from the powertrain controller . I f the P CM

d o e s n o t r e sp o n d w it h a va l id k e y m e ssa g e t o t h e

SK IM, a fault is detected and a trouble code stored.

Th e S K I S i n cor por a t e s a S K I S i n di ca t o r l a m p

l oca t e d i n t h e i n st r u m en t cl us t er. Th e l a m p i s

a ct u a t e d w h e n t h e SK I M sen d s a CC D B u s m essa g e

to th e electr o/mechan ical inst rument cluster (MIC)

requesting the la mp on. The MIC then provides the

p o w e r a n d g r o u n d f o r t h e l a m p . T h e S K I M w i l l

request la mp operat ion for the following:

– bulb check at ignit ion on

– t o a l e r t t h e v e h i c l e o p e r a t o r t o a S K I S m a l -

function

For all faults except transponder faults and VIN

misma tch, the lamp remains on steady. In the event

of a t ran sponder fault the light f lashes at the rat e of

1Hz (once per second). If a fa ult is present the la mp

will remain on or flashing for the complete ignition

cy cle . I f a f a u lt is s t o r e d in SK I M m e m o r y w h ich

prevents the system from operating properly, the

ECM w il l a l lo w t h e e n g in e t o st a r t a n d r u n ( f o r 2

seconds) up to six times. After th e sixth a tt empt, the

ECM d isa ble s f u e l d e live r y u n t i l t h e f a u lt is co r -

rected.

3. 3 DIAGNOSTIC TROUBLE CODES

E a c h d ia g n os t i c t r ou b le cod e i s d i a g nos ed b yfollowing a specific testing procedure. The dia gnos-

tic test procedures conta in st ep-by-step inst ructions

for determining t he cause of trouble codes as w ell as

n o t r o u ble cod e p r o blem s. I t is n ot n e ce ssa r y t o

perform a ll of the tests in th is book to dia gnose an

individual code.

Alw a y s beg in by r e a d in g t h e d ia g n ost ic t r o u ble

codes using t he DR B II I. This procedure begins in in

DTC TEST - Checking the System for Diagnostic

Trouble Codes. This will direct y ou t o th e specific

test(s) tha t must be performed.

3.3.1 HARD CODEA diagnostic tr ouble code th at comes ba ck with in

one cycle of the ignition key is a ‘‘hard’’ code. This

means that the fault is there every t ime the power-

tr a in cont rol module/engin e cont rol module/sent ry

key immobilizer system (SK IS) checks t ha t circuit

or function. Procedures in th is ma nua l verify if th e

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.

3.3. 2 INTERMITTENT CODE

A diagnostic trouble code th at is not there everytime th e powertra in cont rol module/engine control

m od u le /s en t r y k ey i m m ob il iz er s y t em (S K I S )

checks the circuit is an ‘ ‘ intermittent ’ ’ code. Most

intermittent codes a re caused by wiring or connec-

tor problems. Fa ults th at come and go like this ar e

the m ost difficult to diagnose; they must be looked

for under specific conditions t ha t cause t hem. The

f ollow in g ch eck s m a y a ssist y ou in id en t i f y in g a

possible intermittent problem:

• Visually inspect related wire harness connectors.

Look for broken, bent, pushed out, or corroded

terminals.

• Visually inspect the related harnesses. Look for

chafed, pierced, or part ially broken w ire.

• Refer to any hotlines or technical service bulle-

t in s t h a t m a y a p ply.

NOTE: Electro-ma gnetic (Ra dio) interference can

cause intermittent system malfunction.

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3. 3. 4 ECM DIAGNOSTIC TROUBLE CODES

AC CO N TRO L O PE N CI RC U I T

AC CONTROL SHORT CIRCUIT

ACCEL . PED AL SEN SO R PL AU SI B I L I T Y

ACCEL. PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER

AC C E L . P E D A L S E N S O R S I G N AL H I G H E X C E E D E D

A C C E L . P E D A L S E N S O R S U P P L Y H I G H E X C E E D E D

AC C E L . P E D A L S E N S O R S U P P L Y L OW E X C E E D E D

AI R T EMP. SEN SO R SI GN AL HI GH EX CEED ED

AI R TEMP. SE N SO R S I G N AL L O W EXCE ED E D

ATM OS P H E R E P R E S S U R E S E N S O R S R C H I G H E X C E E D E D

ATM OS P H E R E P R E S S U R E S E N S O R S R C L O W E X C E E D E D

B ATTERY VOLTAG E SRC HI G H EXCE ED ED

B RAKE SIG NAL P LAUS WITH RE DU NDANT CONTACT

C O N TR O L S L E E V E S E N S O R S I G N AL H I G H E X C E E D E D

CONTROL SL EE VE S EN SOR START E ND P OS. NOT ATTAINE D

CONTROL S LEE VE S ENS OR S TOP END P OS. NOT ATTAINE D

E E P R O M P L AU S I B I L I TY C H E C K S U M E R R O R F O R AD J (E G R )

E E P R O M P L AU S I B I L I TY C H E C K S U M E R R O R I N C C 2 12

EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROMEE P RO M PL AU SI B I L I TY F U N C SWI TCH WRO N G O R MI SS I N G

E E P R O M P L AU S I B I L I TY V E R N U M B E R N OT C O R R E S P O N D I N G

E E P R O M P L AU S I B I L I TY VI N C H E C K S U M E R R O R

E G R O P E N C I R C U I T

E G R S H O R T C I R C U I T

E N G I N E S P E E D S E N S O R D Y N. P L AU S I B I L I TY

E N G I N E S P E E D S E N S O R OVE R S P E E D R E C O G N I TI O N

EN G I N E S P EE D S EN SO R S TATI C P L AU S I B I L I TY

F AN C O N TRO L O PE N C I RCU I T

FAN C ONTROL S HORT CIRCU IT

FU EL QUANTITY ACTU ATOR NE G G OV DE VIATION COL D

FU E L QU ANTITY ACTUATOR NE G G OV DE VIATION WARM

FU EL QUANTITY ACTU ATOR P OS G OV DE VIATION COLDFU E L QU ANTITY ACTUATOR P OS G OV DE VIATION WARM

F U E L TE M P E R ATU R E S E N S O R S R C H I G H E X C E E D E D

F U EL T EMPERAT U RE SEN SO R SRC L O W EX CEED ED

G L O W D I S P L AY O P E N C I R C U I T

GL O W D I SP L AY SH O RT CI RCU I T

GL O W REL AY CO N TRO L L ER O PE N C I RCU I T

GLOW RELAY CONTROLLER SHORT CIRCUIT

I N D U CT I V E AU X . SPEED SEN SO R D YN . PL AU SI B I L I T Y

I N D U CT I V E AU X . SPEED SEN SO R O V ER SPEED RECO GN I T I O N

I N D U CT I V E AU X . SPEED SEN SO R PL AU SI B I L I T Y

INDU CTIVE AUX. SP EE D S ENS OR STATIC P LAUS IB ILITY

MIC ROC ONTROLLE R G ATE-ARRAY MONITORING

MIC ROC ONTROL LE R G ATE -ARRAY WATCH DOGMICROC ONTROLLER P REP ARE FU EL QUANTITY S TOP

MICROC ONTROLLER REC OVERY WAS OC CU RRE D

MICROC ONTROLLER RED UND ANT OVERR UN MONITORING

N E E D L E M OVE M E N T S E N S O R S R C H I G H E X C E E D E D

N EED L E MO V EMEN T SEN SO R SRC L O W EX CEED ED

REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN

RED UND ANT EME R. STOP P OWERS TAG E DE FE CTIVE

REG UL ATOR LOWER REG UL ATOR LI MIT

REG U L ATO R U P P ER REG U L ATO R L I MI T

SOLENOID VALVE CONTROLLER OPEN CIRCUIT

4

GENERAL INFORMATION

7/26/2019 01XJED


SOLENOID VALVE CONTROLLER SHORT CIRCUIT

T EMPERAT U RE O F EN GI N E CO O L AN T SRC HI GH EX CEED ED

TEMP ERATU RE O F E N GI N E CO O L AN T SRC L O W EX CEE D ED

TE RMI NAL 15 P LAUS IB IL ITY AFTE R S TART-U P

TIMING G OVER NING NEG ATIVE G OVER NOR D EVIATION

TIMING GOVERNING POSITIVE GOVERNOR DEVIATION

TU RB O CHARGER B O O ST SEN S O R P L AU S I B I L I TY

TU R B O C H AR G E R B O O S T S E N S O R S I G N AL H I G H E X C E E D E D

TU RB O CHARGER B O O ST SEN S O R SI G N AL L O W EX CEE D EDTU R B O C H AR G E R B O O S T S E N S O R S U P P LY H I G H E X C E E D E D

TU R B O C H AR G E R B O O S T S E N S O R S U P P L Y L O W E X C E E D E D

U_REF (2.5V)

VEHIC LE SP EE D G OV ANALOG CTRL CONTROL C ONTACT ALONE

VE H I C L E S P E E D S E N S O R P E C F R E Q U E N C Y TO O H I G H

VE H I C L E S P E E D S E N S OR S R C H I G H E X C E E D E D

VE H I C L E S P E E D S E N S O R P L A U S I B I L I TY

VEH I CL E THE F T AL ARM I MMO B I L I Z ER SI G N AL L O ST

VEHICLE THEFT ALARM INVALID SKIM MESSAGE

3. 3. 5 HANDLING NO TROUBLE CODE

PROBLEMS

After reading Section 3.0 (Syst em Description

a n d F u n ct i on a l O per a t i on ), y ou s h ou ld h a v e a

better understanding of the theory and operation of

t h e o n -boa r d d ia g n ost ics, a n d h ow t h is r e la t e s t o

t he d ia g nos is of a veh icle t ha t m a y h a ve a

driveability-related symptom or complaint.

3.4 USING THE DRBIII

Refer t o the DRB III user’s guide for instr uctions

and assistance with reading trouble codes, erasing

trouble codes, a nd other D RB III functions.

3.5 DRBI II ERROR MESSAGES ANDBLANK SCREEN

Und er norma l operat ion, the DRB III w ill display

one of only t wo error messa ges:

– U s er -R eq ues t ed WAR M B oot or U s er -

Requested COLD Boot

Th is is a sa m p le of su ch a n e r r or m e ssa g e d is-

play:

ver: 2.14da te: 26 J ul93

file: key —itf.ccdate: J ul 26 1993line: 548err: 0x1User-Requested COLD Boot

Press MORE to switch between this displayand the application screen.

P ress F4 w hen done noting informa tion.

3.5.1 DRBI II DOES NOT POWER UP

If the LE Ds do not light or no sound is emitted a t

sta rt up, check for loose ca ble connections or a ba dcable. Ch eck the vehicle bat tery voltage (data link

connector cavit y 16). Am inimum of 11 volts a t D LC

ca v i t y 16 i s r eq u ir ed t o a d e q ua t e l y p ow e r t h e

D RB I I I . Ch e ck f or p r op er g r ou n d con n e ct ion a t

D L C ca vit ie s 4 a n d 5.

If a ll connections a re proper betw een t he DRB III

and the vehicle or other devices, and the vehicle

b a t t e ry i s f u ll y ch a r g ed , a n i n op er a t i v e D R B I I I

ma y be the result of a fa ulty ca ble or vehicle wir ing.

For a blank screen, refer to the appropriate body

d ia g n ost ics m a n u a l .

3.5. 2 DISPLAY IS NOT VISIBLELow temperatures w ill affect t he visibility of the

display. Adjust t he contra st to compensate for this

condition.

5

GENERAL INFORMATION

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4.0 DISCLAIMERS, SAFETY,WARNINGS

4.1 DISCLAIMERS

All informat ion, illustra tions, a nd specificat ions

co n t a in e d in t h is m a n u a l a r e ba se d o n t h e la t e st

in f o r m a t io n a va i la ble a t t h e t im e o f p u blica t io n .The right is reserved to make changes at any t ime

without notice.

4.2 SAFETY

4. 2. 1 TECHNICIAN SAFETY INFORM ATION

WARNING: ENGINES PRODUCE CARBON

MONOXIDE THAT IS ODORLESS, CAUSES

SLOWER REACTION TIME, AND CAN LEAD

TO SERIOUS INJURY. WHEN THE ENGINE ISOPERATING, KEEP SERVICE AREAS WELL

VENTILATED OR ATTACH THE VEHICLE

EXHAUST SYSTEM TO THE SHOP EXHAUST

REMOVAL SYSTEM.S et t h e p a rk in g b ra k e a n d b lock t h e w h eel s

before testing or repairing the vehicle. I t is espe-

cially important to block the wheels on front-wheel

drive vehicles; the parking brake does not hold the

drive w heels.

When servicing a vehicle, always wear eye pro-

t e ct i on , a n d r em ov e a n y m et a l je w el r y s u ch a s

w a t ch ba n d s o r br a celet s t h a t m ig h t m a k e a n in a d -

vertent electrical conta ct .When dia gnosing a powertra in syst em problem,

i t i s i m por t a n t t o f ol low a p pr ov ed p roce du r es

wh ere applicable. These procedures can be found in

t h e ser vice m a n u a l p r oced u r es. F o llow in g t h e se

procedures is very importan t to the safety of indi-

viduals performing diagnostic tests.

4. 2. 2 VEHICLE PREPARATION FOR

TESTING

Ma k e su r e t h e ve h icle be in g t e st e d h a s a f u l ly

ch a r g ed b a t t e ry. I f i t d oes n ot , f a l se d ia g n os t i c

codes or error messages may occur.

4. 2. 3 SERVICING SUB-ASSEM BLIES

Some components of the powertrain system are

intended to be serviced in assembly only. Attempt-

i ng t o r em ov e or r epa i r cer t a i n s ys t em s ub -

components ma y result in personal injury and /or

im pr op er sy st e m op er a t io n . O n ly t h o se com p o-

nents w ith a pproved repair a nd insta llat ion proce-

dures in t he service ma nua l should be serviced.

4.2.4 DRBI II SAFETY INFORMATION

WARNING: EXCEEDING THE LIMITS OF THE

DRBIII MULTIMETER IS DANGEROUS. IT

CAN EXPOSE YOU TO SERIOUS OR

POSSIBLY FATAL INJURY. CAREFULLY

READ AND UNDERSTAND THE CAUTIONS

AND THE SPECIFICATION LIMITS.

Follow the vehicle manufacturer’s service speci-

fications at all t imes.

• D o n ot u se t h e D RB I I I i f it h a s be en d a m a g e d .

• D o n ot u s e t h e t e s t l ea d s i f t h e i n su la t i on i s

dam aged or if m etal is exposed.

• To a void electrical shock, do not touch the test

leads, t ips, or t he circuit being t ested.

• Ch o o se t h e p r o p e r r a n g e a n d f u n ct io n f o r t h e

m ea s u r em en t . D o n ot t r y v ol t a g e or cu r r en t

measurements that may exceed the rated capac-

ity.• D o n ot e xce ed t h e l im i t s s h ow n i n t h e t a b l e

below:

FUNCTION INPUT LIMIT

Volt s 0 - 500 pea k volt s AC

0 - 500 volts DC

O h m s (r es is t a n ce )* 0 - 1. 12 m eg oh m s

Frequency Measured

Frequency Generated

0 - 10 kH z

Tem pera ture -58 - 1100F

-50 - 600C

* Ohms cannot be measured if voltage is present.

Ohms can be measured only in a non-powered

circuit.

• Voltage between any terminal and ground must

not exceed 500v D C or 500v pea k AC.

• Use caution when measuring voltage above 25v

DC or 25v AC.

• The circuit being tested m ust be protected by a

10A fuse or circuit breaker.

• Use the low current shunt to measure circuits up

to 10A. Use the high current clamp to measurecircuits exceeding 10A.

• Wh en t e st i n g f or t h e p res en ce of v ol t a g e or

cu r r en t , m a k e s u r e t h e m et e r i s f un ct i on i ng

correctly. Take a reading of a known volta ge or

current before a ccepting a zero reading.

• When measuring current, connect the meter in

series with the load.

• D isconnect the live test lead before disconnect-

ing the common test lead.

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GENERAL INFORMATION

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4.3 WARNINGS

4. 3. 1 VEHICLE DAMAGE WARNINGS

Before disconnecting any control module, make

su r e t h e ig n it io n is “o f f ” . F a i lu r e t o d o so co u ld

damage the module.

When testing voltage or continuity at any control

module, use the terminal side (not the wire end) oft h e con n e ct o r. D o n o t p r obe a w ir e t h r ou g h t h e

i ns ul a t ion ; t h is w i ll d a m a g e i t a n d ev en t ua l ly

cause it to fail because of corrosion.

B e careful when performing electrical t ests so a s

to prevent accidental shorting of terminals. Such

mista kes can dam age fuses or components. Also, a

second code could be set , m aking diagnosis of t he

original problem more difficult.

4. 3. 2 ROAD TESTING A COMPLAINT

VEHICLE

Some complaints w ill require a t est drive as pa rt

of the repair verification procedure. The purpose of

t h e t e st d r ive is t o t r y t o d u p lica t e t h e d ia g n ost ic

code or sympt om 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 ASSISTANTAVAILABLE TO OPERATE THE DRBIII.

5.0 REQUIRED TOOLS ANDEQUIPMENT

a m m e t e r

D R B I I I (dia gnostic rea d-out box) scan

tool

high impedance 12-volt test light

jumper w ires a nd probes

ohmmeter

va cu u m g a u g evoltmeter

6.0 GLOSSARY OF TERMS

backfire,popback

fuel ignites in either t he inta ke or

t h e e x h a u st sy st e m

cuts out,misses

a steady pulsation or the inability

of the engine to maintain a consis-

tent rpm

DLC da ta link connector (previouslycalled ‘‘engine dia gnostic connec-

tor’’)

detona-tion,pre-ignition

a mild to severe ping, especially

under loaded engine conditions

ECM engine cont rol module (B osch

EDC15)

ECT engine coolant tempera tur e sensor

EGR exhaust gas recirculat ion valve an dsystem

EVM electric vacuum modulat or

genera-tor

previously called ‘‘alternator’’

hardstart

The engine ta kes longer tha n usua l

t o st a r t , e ven t h ou g h i t is a ble t o

crank normally.

hesita-tion,sag,stumble

There is a momenta ry la ck of re-

sponse w hen th e thr ott le is opened.

This can occur at all vehicle

speeds. If it is severe enough, th e

e n gin e m a y st a l l .

lack of power,sluggish

The engine has less than expected

power, with lit t le or no increase in

vehicle speed wh en th e thrott le is

opened.

MIC electro/mechan ical inst rument clus-

t er

MIL ma lfunction indicat or lamp

PCM powert ra in cont rol module (J TEC + )

PDC power distr ibution cent er

poor fueleconomy

There is significantly less fuel mile-

age than other vehicles of the same

design an d configurat ion.

7

GENERAL INFORMATION

7/26/2019 01XJED


rough,unstable,orerraticidle,stalling

The engine runs unevenly a t idle

a n d ca u ses t h e e n g in e t o sh a k e i f i t

is severe enough. The engine idle

rpm may vary (called ‘‘hunting’’).

This condition ma y ca use sta lling if

it is severe enough.

SKIM sentr y key immobilizer module

SKIS sentry key immobilizer system

start &stall

The engine star ts but imm ediately

dies.

surge engine rpm fluctua tion with out cor-

responding change in thrott le posi-

tion sensor

VSS vehicle speed sensor

8

GENERAL INFORMATION

7/26/2019 01XJED


7.0

DIAGNOSTIC INFORMATION AND

PROCEDURES

9

7/26/2019 01XJED


Symptom:P0622-GENERATOR FIE LD NOT SWITCHING PROPERLY - DIESEL

When Monitored and Set Condition:

P0622-GENER ATOR FIE LD NOT SWITC HING PROPERLY - DIE SEL

When Monitored: With th e engine speed greater t ha n 1500 RP M for a t least 25 seconds.

S e t C on d i t ion : Wh e n t h e P C M t r i es t o r e gu l a t e t h e g e n er a t or ou t p ut w i t h n o r es u lt

during monitoring.

POSSIBLE CAUSES

INTERMITTENT CONDITION

CH ECK F O R O THE R CH ARGI N G SYSTEM D TCS

G EN ERATO R F I EL D CI RC U I T O PE N

GEN ERAT O R SO U RCE CI RCU I T O PEN

POWERTRAIN CONTROL MODULE (INTERNAL DRIVER FAULT)

GENERATOR (FIELD OPEN)

POWERTRAIN CONTROL MODULE (GENERATOR SOURCE OPEN)

TEST ACTION APPLICABILITY

1 Tu rn t h e ig ni ti on on .

Wit h t he DR B , rea d P CM DTCs .

Are t here a ny ot her Cha rging S ys t em rela t ed DTCs ?

All

Yes → Refer to the symptom list for the related symptom(s).

Perform CHARGING VERIFICATION - VER-3.

No → G o To 2

2 NOTE: The battery must be fully charged and the generator belt must be ingood condition and tensioned properly before continuing.Turn the ignition on.

Wit h t he DR B , era s e P CM DTCs .

Turn t he ignition off for 10 seconds, then st ar t t he engine.


Did this DTC reset?

All

Yes → G o To 3

No → G o To 7

3 Tu r n t h e i g ni t i on o ff , t h e n on .

Measure the voltage of the Generator Field Driver circuit in PCM harness connector

C2 by back probing.

Is the voltage above 10.0 volts?

All

Yes → R epla ce a nd p rogra m t he P owert ra in C ont rol M odu le in a ccor-

da nce wit h t he S ervice I nforma t ion.


No → G o To 4

10

CHARGING

7/26/2019 01XJED



4 Tu r n t h e i gn it i on of f.

Disconnect the Generator Field harness connector.

Turn the ignition on.

M ea s u re t he volt a ge of t he G enera t or Sou rce circu it .Is the voltage above 10.0 volts?

All

Yes → G o To 5

No → G o To 6



Disconnect the PCM harness connectors.

M ea s u re t he res is t a nce of t he G enera t or Field circu it .

Is the resistance below 5.0 ohms?

All

Yes → Replace the Generat or.


No → Repair the G enerat or Field circuit for an open.Perform CHARGING VERIFICATION - VER-3.




Measure the resistance of the Generator Source circuit .


All




No → Repair the G enerat or Source circuit for an open.


7 WARNING: KEE P CL EAR OF THE ENGINE’S MOVING PARTS.NOTE : The conditions that set the DTC are not present at this time. T hefollowing list may help in identifying the intermittent condition.Wi t h t h e e n gi n e r u n n i n g a t n or m a l op er a t i n g t e m pe r a t u r e, m on i t or t h e D R B

p a ra met ers rela t ed t o t he D TC w hile wiggling t he wiring ha rnes s . L ook for p a ra m-

eter va lues to change a nd/or a DTC t o set.

Review the D TC When Monitored an d Set Conditions. If possible, try to duplicat e the

condit ions u nder which t he DTC wa s s et .

Refer to an y Technical S ervice B ulletins (TSB ) that ma y a pply.

Visually in spect t he relat ed wir ing ha rness. Look for an y cha fed, pierced, pinched, or

p a rt ia lly b roken w ires.

Visually inspect t he relat ed w iring ha rness connectors. Look for broken, bent, pushed

out, or corroded terminals.

Were any of the above conditions present?

All

Yes → R epa ir a s neces sa ry


No → Test Complete.

11

CHARGING

P0622-GENERATOR FIE LD NOT SWITCHING PROPERLY - DIE SEL —Continued

7/26/2019 01XJED


Symptom:P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH - DIE SEL


P1492-AMBIE NT/BATT TEMP SEN VOLTS TOO HI GH - DIE SEL

When Monitored: With the ignition on.

S e t C on d i t ion : Th e P C M d et e ct s v ol t a g e on t h e a m b i en t /b a t t e r y t e m pe r a t u r e s e n s or

signal circuit above 4.94 volts for more than 3 seconds.

POSSIBLE CAUSES

P OWER TRAIN C ONTROL MODU LE (SH ORTED TO VOLTAG E INTER NALLY)


AMB /B ATT TEM P SE NS OR S IG NAL CI RC U IT SH ORTED TO VOLTAG E

AMBI E NT/B ATTE RY TE MP E RATU RE SE NS OR

AMB IE NT/B ATTERY TEM P ER ATU RE SE NSOR SI G NAL CIRC U IT OP EN

AMB IE NT/B ATTERY TEMP ERATUR E SE NSOR G ROUND CIR CU IT OPE N

POWERTRAIN CONTROL MODULE (OPEN INTERNALLY)




Cycle the ignition on for five seconds, then off for five seconds, several t imes.Wit h t he DR B , rea d P CM DTCs .

Did this DTC reset?

All

Yes → G o To 2

No → G o To 8


Disconnect the Ambient/Ba tt ery Temperatur e S ensor ha rness connector.


Measure t he voltage betw een ground a nd t he Ambient/Ba tt ery Temperatur e Sensor

Signal circuit .


All

Yes → G o To 3

No → G o To 4

12

CHARGING

7/26/2019 01XJED






Remove the ASD /Diesel Pow er Relay from the P DC .Connect a jump er w ire b et ween ca vit y 30 a nd ca vit y 87 of t he A SD/Dies el P ower

Relay connector.


Measure t he voltage betw een ground a nd t he Amb/B at t Temp Sensor S igna l circuit .

Is the voltage below 0.5 volt?

All




No → Repair t he Ambient/B at tery Temperatur e Sensor Signa l circuit

for a short to voltage.


4 Tu r n t h e i gn it i on of f.Disconnect the Ambient/Ba tt ery Temperatur e S ensor ha rness connector.

Measure the resistan ce of th e Amb/Ba tt Temp S ensor.

Is the resistance above 100 kohms?

All

Yes → Replace the Ambient/B at tery Temperatu re S ensor.


No → G o To 5




Measure the resistan ce of the Amb/Ba tt Temp Sensor Signa l circuit .


All

Yes → G o To 6


for an open.





Measure the resistan ce of the Amb/Ba tt Temp Sensor Gr ound circuit .


All

Yes → G o To 7

No → Repair t he Ambient/B at tery Temperatur e Sensor G round circuit

for an open.Perform CHARGING VERIFICATION - VER-3.

7 I f t h ere a r e no possible ca u ses r em a in in g, view repa ir. All

Repair

R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-



13

CHARGING

P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH - DIESEL —Continued

7/26/2019 01XJED



8 WARNING: KEE P CL EAR OF THE ENGINE’S MOVING PARTS.NOTE : The conditions that set the DTC are not present at this time. T hefollowing list may help in identifying the intermittent condition.

Wi t h t h e e n gi n e r u n n i n g a t n or m a l op er a t i n g t e m pe r a t u r e, m on i t or t h e D R Bp a ra met ers rela t ed t o t he D TC w hile wiggling t he wiring ha rnes s . L ook for p a ra m-










All




14

CHARGING

P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH - DIESEL —Continued

7/26/2019 01XJED


Symptom:P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW - DIE SEL


P1493-AMBIE NT/BATT TEMP SEN VOLTS TOO LOW - DIE SEL


S e t C on d i t ion : Th e P C M d et e ct s v ol t a g e on t h e a m b i en t /b a t t e r y t e m pe r a t u r e s e n s or

signal circuit below 0.08 volt for more than 3 seconds.

POSSIBLE CAUSES


AMBI E NT/B ATTE RY TE MP E RATU RE SE NS OR

AMB IE NT/B ATTERY TEM P ER ATU RE SE NSOR SI G NAL CIRC U IT SH ORTE D TO G ROU ND

AMB /B ATT TEMP SE NSOR SI G NAL AND SE NSOR G ROUND CIR CU ITS SH ORTED TOGE THE R

POWERTRAIN CONTROL MODULE (SHORT TO GROUND INTERNALLY)



With the D RB , rea d t he voltage of the Ambient/B at tery Temperatur e Sensor.


All

Yes → G o To 2

No → G o To 6




With the D RB , rea d t he voltage of the Ambient/B at tery Temperatur e Sensor.


All

Yes → Replace the Ambient/B at tery Temperatu re S ensor.


No → G o To 3



Disconnect the PCM harness connectors.M ea s u re t he res is t a nce b et ween grou nd a nd t he A mb/B a t t Temp Sens or S igna l

circuit.


All

Yes → G o To 4


for a short to ground.


15

CHARGING

7/26/2019 01XJED






Measure t he resista nce betw een the Amb/B at t Temp Sensor Sign al circuit a nd S ensorGround circuit .


All

Yes → G o To 5

No → R e pa i r t h e Am b ie n t /B a t t e r y Te m pe r a t u r e S e n s or S i g n a l a n d

Sensor Ground circuits for a short together.


5 I f t h ere a r e no possible ca u ses r ema in in g, view repa ir. All

Repair















All




16

CHARGING

P1493-AMBIE NT/BATT TEMP SEN VOLTS TOO LOW- DIESEL — Continued

7/26/2019 01XJED


Symptom:P1594-CHARGING SYSTEM VOLTAGE TOO HI GH - DIE SEL


P1594-CHARGI NG SYSTEM VOLTAGE TOO HI GH - DIE SEL

When Monitored: With the engine running.

S e t C o nd i t ion : Th e v ol t a g e a t P C M c a v i t y C 1-22 i s 1 .0 v ol t or m or e a b ov e t h e t a r g et

char ging voltage for a t least 3 seconds.

POSSIBLE CAUSES


G EN ERATO R F I E L D D RI V ER C I RCU I T SH O RTED TO G RO U N D

P OWER TRAIN C ONTROL MODU LE (TARG ET CH ARGI NG VOLTAG E TOO LOW)

G ENE RATOR S HORTED TO G ROUND INTERNALLY

POWERTRAIN CONTROL MODULE (FIELD DRIVER SHORTED TO GROUND)


1 NOTE: The battery must be fully charged and the generator belt must be ingood condition and tensioned properly before continuing.Turn the ignition on.

Wit h t he DR B , a ct u a t e t he G enera t or Field.

Measure the voltage between ground and the Generator Field Driver circuit by back

probing the Generator Field harness connector with a voltmeter.Does the voltage cycle from B + to below 2.0 volts?

All

Yes → G o To 2

No → G o To 4

NOTE: With the DRB, stop the Generator Field actuation.

2 S ta rt t he en gin e.

Wit h t he D R B , rea d t he Ta rget Cha rging volt a ge

Is th e Tar get Ch ar ging voltage a bove 13.0 volts?

All

Yes → G o To 3

No → R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-

da nce wit h t he S ervice I nforma t ion.Perform CHARGING VERIFICATION - VER-3.

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All





Disconnect PCM harness connector C2.


M ea s u re t he res is t a nce b et ween ground a nd t he G enera t or Field Driver circu it .


All

Yes → G o To 5

No → R epa ir t he G enera t or Field Driver circu it for a s hort t o grou nd.




M ea s u re t he res ist a n ce bet ween grou nd a nd t he G enera t or Field D river t ermina l ont he b a ck of t he G enera t or .


All

Yes → G o To 6

No → R epa ir or rep la ce t he G enera t or a s neces s a ry.



Repair




18

CHARGING

P1594-CHARGING SYSTEM VOLTAGE TOO HIGH - DIE SEL — Continued

7/26/2019 01XJED


Symptom:P1600-BATTE RY VOLTAGE SRC HIGH E XCEEDE D - DIE SEL


P1600-BATTE RY VOLTAGE SRC HIGH EXCEE DED - DIE SEL


Set C ondit ion: The ECM detects t he system voltage ha s exceeded 20 volts for a t least 5

seconds.

POSSIBLE CAUSES

CH EC K THE CH ARG ING VOLTAG E AT 2000 RP M

CLE AR THE DTC AND RE TES T




Set the engine speed to 2000 RPM.

M ea s u re t he volt a ge a t t he b a t t ery.


All

Yes → R ef er t o s y m pt om l is t f or p r ob le m s r e l a t e d t o t h e c ha r g i n g

s ys t em.


No → G o To 2


Wit h t he DR B , era s e E CM D TCs .

St a rt t he engine a nd va ry t he engine s peed b et ween idle a nd 2500 R P M for s evera l

minutes. .

Wit h t he DR B , rea d E CM DTCs .

Did this DTC reset?

All

Yes → R epla ce a nd p rogra m t he E ngine Cont rol M odu le in a ccorda nce

wit h t he S ervice I nforma t ion.


No → G o To 3

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All




20

CHARGING

P1600-BATTE RY VOLTAGE SRC HI GH EXCEEDED - DIE SEL — Continued

7/26/2019 01XJED


Symptom List:P1682-CHARGING SYSTEM VOLTAGE TOO L OW - DIE SEL*CHECKI NG THE CHARGING SYSTEM OPERATION - DIESEL

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1682-CHARGING SYSTE MVOLTAGE TOO LOW - DIESEL .


P1682-CHARGI NG SYSTEM VOLTAGE TOO LOW - DIE SEL


S e t C o nd i t ion : Th e v ol t a g e a t P C M c a v i t y C 1-22 i s 0 .5 v ol t or m or e b e low t h e t a r g et

char ging voltage for a t least 3 seconds.

POSSIBLE CAUSES

CH ECK F O R CYCL I N G VO LTAG E O N THE GE N ERATO R F I EL D D RI V ER CI RCU I T


G ENE RATOR B ELT CONDITION OR TENS ION

HI G H RE SI STAN CE I N THE F U S ED B + CI RC U I T TO THE P CM

G ENE RATOR F IE LD DRI VER C IRC UI T SH ORTED TO VOLTAG E

G EN ERATO R F U SE D B + CI RCU I T HI G H RE SI STAN CEASD REL AY O U TP U T CI RCU I T OP EN

G EN ERATO R G RO U N D CI RCU I T HI G H RES I STAN CE

GEN ERAT O R F I EL D D RI V ER CI RCU I T O PEN

POWERTRAIN CONTROL MODULE


1 NOTE: Inspect the vehicle for aftermarket accessories that may exceed theGenerator capacity.NOTE : The battery must be fully charged before continuing.Inspect the generator belt condition and tension.

Is the generator belt in good condition and tensioned properly?

All

Yes → G o To 2

No → Repair as necessary.


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Wit h t he DR B , a ct u a t e t he G enera t or Field.

Measure the voltage between ground and the Generator Field Driver circuit by back

probing the Generator Field harness connector with a voltmeter.NOTE : The voltage should cycle from Battery voltage to below 2.0 voltsevery 1.4 seconds.While monitoring the voltmeter, wiggle the generator field harness and connectors

b et w een t he genera t or, P CM a nd t he ASD/Dies el P ower R ela y ( in t he P DC) .

Was t here an y int erruption of the normal volta ge cycling?

All

Yes → R epa ir t he ha rnes s a s neces s a ry w here t he wiggling ca u s ed t he

interruption.


No → G o To 3

NOTE: With the DRB, stop the Generator Field actuation.

3 Connect t he p os it ive lea d of a volt met er t o t he genera t or B + (12V) t ermina l a nd t he

negative lead to the battery positive (+ ) post.

WARNING: KEEP EVERYTHING CLEAR OF THE ENGINE’S MOVINGPARTS.S t a r t t h e e n g in e .

Is the voltage on the voltmeter below 0.4 volt?

All

Yes → G o To 4

No → R epa ir t he G enera t or Fu s ed B + circu it for high resis t a nce.


4 C on n e ct t h e p os i t iv e le a d of a v o lt m e t er t o t h e g en e r a t or c a s e (h ou s in g ) a n d t h e

negative lead to the battery negative (-) post.

WARNING: KEEP EVERYTHING CLEAR OF THE ENGINE’S MOVINGPARTS.S t a r t t h e e n g in e .

Is the voltage on the voltmeter below 0.4 volt?

All

Yes → G o To 5

No → R epa ir t he G enera t or G rou nd circu it for high res is t a nce.


5 Tu r n t h e i g ni t i on o ff , t h e n on .

Wit h t he DR B , rea d a nd record t he B a t t ery V olt a ge.

Wit h a volt met er, mea s u re a nd record t he volt a ge b et ween t he B a t t ery t ermina ls .

Compa re t he DR B B a t t ery Volt a ge rea ding t o t he volt met er rea ding.

I s t he dif ference b et ween t he t wo r ea dings les s t ha n 0.5 volt ?

All

Yes → G o To 6

No → G o To 7

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CHARGING

P1682-CHARGING SYSTEM VOLTAGE TOO LOW - DIE SEL — Continued

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All





Wit h a volt met er, mea s u re a nd record t he volt a ge b et ween t he B a t t ery t ermina ls .


M ea s u re t he volt a ge of t he Fu s ed B + circu it in t he P C M C1 ha rnes s connect or.

Are the voltage measurements within 0.5 volt of each other?

All

Yes → G o To 8

No → Repair the Fused B + circuit to the Powert ra in Control Module for

high resistance.



Disconnect the PCM harness connectors.Disconnect the Generator Field harness connector.


M ea s u re t he volt a ge of t he G enera t or Field Driver circu it .


All

Yes → G o To 9

No → R epa ir t he G enera t or Field Driver circu it for a s hort t o volt a ge.





Measure the voltage of the ASD Relay Output circuit in PCM harness connector C3,

cavity 12.Is the voltage above 10.0 volts?

All

Yes → G o To 1 0

No → Repair the ASD R elay Output circuit for an open.


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CHARGING


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1 0 Tu r n t h e i g ni t i on o ff .



M ea s u re t he res is t a nce of t he G enera t or Field Driver circu it .Is the resistance below 5.0 ohms?

All

Yes → G o To 11

No → Repair the G enerat or Field Driver circuit for an open.



Repair




24

CHARGING


7/26/2019 01XJED


Symptom:P-1685 INVALID SKIM KE Y


P-1685 INVALI D SKIM KEY


Set Condit ion: The PC M does not receive a va lid key message from the SK IM.

POSSIBLE CAUSES

I N CO RRECT V I N I N PCM

I N VAL I D SK I M K EY N O T P RESE N T

NO COMMUNICATION WITH SKIM

N O V I N PRO GRAMMED I N T HE PCM

P C M

S K I M TR O U B L E C O D E S S E T


1 Wi t h t h e D R B I I I , r e a d t h e P C M D TC s . L oo k f or P 16 85 .


I s t he St a rt s S ince Set cou nt er for DTC P 1685 dis pla yed a nd equ a l t o 0?

All

Yes → G o To 2

No → G o To 7


Wit h t he DR B I I I , a t t emp t t o commu nica t e wit h t he SKI M .

Ca n you commu nica t e wit h t he SKI M ?

All

Yes → G o To 3

No → R efer t o s ymp t om B U S + /- SI G N AL OP E N FR OM S KI M in t he

COMMUNICATION category.

Perform ROAD TEST VERIFICATION - VER-2.


With the DRB III , check for SKIM DTC’s.

Are t here a ny t rou b le codes s et in t he S KI M ?

All

Yes → Repair all SKIM DTC’s.


No → G o To 4

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COMMUNICATION

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4 NOTE: If a VIN has not been programmed into the PCM, program VIN intothe PCM and retest.Turn the ignition on.

Wit h t he DR B I I I , dis p la y t he V I N t ha t is p rogra mmed in t he P CM .I s t here a V I N p rogra mmed in t he P CM ?

All

Yes → G o To 5

No → P r ogra m t he correct VI N int o t he P C M a nd ret es t .



Wit h t he DR B I I I , dis p la y t he V I N t ha t is p rogra mmed in t he P CM .

I s t he correct V I N p rogra mmed in t he P CM ?

All

Yes → G o To 6

No → R e pl a ce a n d p r og r a m t h e P C M i n a cc or d a n c e w i t h t h e S e r v ice

I nforma t ion.



R ep la ce a nd p rogra m t he Sent ry Key I mmob iliz er M odu le in a ccorda nce wit h t he

Service Information.


Wit h t he D R B I I I , era s e a ll DTCs .

At t emp t t o s t a rt a nd idle t he engine.

Wit h t he DR B I I I , rea d t he P CM DTCs .

Does t he D R B I I I dis pla y t his code?

All





7 NOTE : This DTC could have been set if the SKI M harness connector wasdisconnected, or if the SKIM was replaced r ecently.NOTE : All keys that the customer uses for this vehicle must be tested toverify they are operating properly.Verify t he correct V I N is p rogra mmed in b ot h t h e P CM a nd SKI M modu les .

Turn the ignition off.

Wit h t he next cu s t omer key t u rn t he ignit ion key on a nd cra nk t he engine t o s t a rt .

Wit h t he DR B I I I , rea d t he P CM D TCs . L ook for P 1685

I s t he S t a rt s S ince Set C ou nt er for DTC P 1685 dis p la yed a nd equ a l t o 0?

All

Yes → Replace the Ignition Key.



NOTE: If thisDT C can not bereset,it may havebeen an actual theft attempt.

26

COMMUNICATION

P-1685 INVALI D SKIM KEY — Continued

7/26/2019 01XJED


Symptom:P-1686 NO SKIM BUS MESSAGE RE CEIVED


P-1686 NO SKI M BUS MESSAGE RE CE IVE D


S e t C o n d it i on : Th e P C M d oe s n ot r e ce iv e a C C D B u s m e ss a g e f r om t h e S K I M w h e n

expected.

POSSIBLE CAUSES

P C M


CCD B U S CI RCU I T (S) O PEN F RO M PCM T O SK I M

LOSS OF SKIM COMMUNICATION



Wit h t he DR B I I I , rea d P CM D TCs . L OOK for P 1686.

I s t he St a rt s S ince Set cou nt er for DTC P 1686 dis pla yed a nd equ a l t o 0?

All

Yes → G o To 2

No → G o To 4

2 Tu rn t h e ig ni ti on on .Wit h t he DR B I I I , a t t emp t t o commu nica t e wit h t he SKI M .

Wit h t he DR B I I I , s elect Theft Ala rm a nd rea d t he S KI M D TCs .

NOTE: This test will indicate if the Bus is operational from the DLC to theSKIM.C a n t h e D R B com m u n i ca t e w i t h t h e S K I M ?

All

Yes → G o To 3

No → R efer t o t he a p p rop ria t e s ymp t om in t he C OM M U N I CATI ON

category.




Disconnect the SKIM harness connector.

M ea s u re t he res is t a nce of b ot h CCD B u s circu it s b et ween t he P CM a nd t he SKI M .

Is the resistance below 5.0 ohms for each measurement?

All




No → Repair the CC D B us circuit(s) for an open.


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COMMUNICATION

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Wit h t he engine ru nning a nd a t norma l op era t ing t emp era t u re, monit or t he DR Bp a ra met ers rela t ed t o t he D TC w hile wiggling t he wiring ha rnes s . L ook for p a ra m-










All




28

COMMUNICATION

P-1686 NO SKIM BUS MESSAGE RE CEIVED — Continued

7/26/2019 01XJED


Symptom List:P0600-PCM FAIL URE SPI COMMUNICATIONS - DIE SELP0601-PCM INTERNAL CONTROLL ER FAILURE - DIESELP1696-PCM FAILURE EEPROM WRITE DENIED

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P0600-PCM FAILURE SPICOMMUNICATIONS - DIESEL.

POSSIBLE CAUSES



1 NOTE: This DTC indicates an internal PCM problem.View repair.

All

Repair




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COMMUNICATION

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Symptom:P1687-NO CL USTER BUS MESSAGE - DIE SEL


P1687-NO CL USTER BUS MESSAGE - DIE SEL


Set Condit ion: The PC M has not received an expected Cluster Sta tus B us message from

the instrument cluster w ithin t he last 20 seconds.

POSSIBLE CAUSES

C C D B U S C I R C U I T(S ) OP E N

CH ECK I N G CL U STER CO MMU N I CATI O N

P CM - INTERNAL FAILU RE




Wit h t he DR B I I I , era s e P CM DTCs .

Cycle t he ignit ion key on a nd off s evera l t imes , lea ving t he key on for a t lea s t 10

s econds a t a t ime.

Wit h t he DR B I I I , rea d P CM DTCs .

Did this DTC reset?

All

Yes → G o To 2

No → G o To 4


Wit h t he D R B I I I , a t t emp t t o commu nica t e wit h t he ins t ru ment clu s t er .

Ca n t he DR B commu nica t e wit h t he ins t ru ment clu s t er?

All

Yes → G o To 3

No → Refer to COMMUNI CATION for the rela ted sym ptom(s).




Disconnect the instrument cluster harness connector.

M ea s u re t h e r e s is t a n ce of b ot h C C D B u s ci rcu it s b et w e en t h e P C M a n d t h e

instrument cluster.

Is the resistance below 5.0 ohms for both measurements?

All




No → Repair the CC D B us circuit(s) tha t mea sured above 5.0 ohms for

an open.


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All




31

COMMUNICATION

P1687-NO CL USTER BUS MESSAGE - DIE SEL — Continued

7/26/2019 01XJED


Symptom:*NO RESPONSE FROM ECM AND PCM (DIE SEL ONLY)

POSSIBLE CAUSES

ATTEMPT TO COMMUNICATE WITH ANOTHER VEHICLE

C H E C K E C M P O WE R S AN D G R O U N D S

POWERTRAIN CONTROL MODULE - SCI TRANSMIT

CONTROLLER ANTILOCK B RAKE - SCI TRANSMIT

SC I TRANSMIT CIR CU IT SHOR TED TO VOLTAG E

SCI CI RCU I TS SH O RTED TO GETHE R

SC I TRANSMIT CIRC UI T SH ORTED TO G ROUND

SCI TRAN SMI T CI RCU I T OP EN

G RO U N D C I RCU I TS AT D L C O PE N

EN G I N E CO N TRO L MO D U L E



Connect the DRB to another vehicle.

Will the DRB communicate with this vehicle?

All

Yes → G o To 2

No → R epa ir or rep la ce t he DR B or DR B ca b le a s necess a ry.

P erform P OWERTRAIN VERI FIC ATION TES T VER - 1.

2 P e r for m t h e s y mp t om C h eck in g E C M a n d P C M P o w er a n d G r ou n d Ci r cu it s in t h e

Driveability category.

Did t he vehicle p a s s t his t es t ?

All

Yes → G o To 3




NOTE: Reconnect all previously disconnected components.Disconnect the PCM harness connectors.


Wit h t he DR B , a t t emp t t o commu nica t e wit h t he E CM .

Wa s t he DR B a b le t o commu nica t e wit h t he E C M ?

All

Yes → R epla ce t he P owert ra in C ont rol M odu le.

Perform POWERTRAIN VERIFICATION TEST VER - 1.

No → G o To 4

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COMMUNICATION

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Disconnect the CAB harness connector.


Wit h t he DR B , a t t emp t t o commu nica t e wit h t he E CM .Wa s t he DR B a b le t o commu nica t e wit h t he E C M ?

All

Yes → Replace the Controller Antilock Bra ke.

P erform P OWERTRAIN VERIFI CATION TES T VER - 1.

No → G o To 5


Dis connect t he DR B from t he DL C.


Disconnect the ECM harness connectors.



Measure th e volta ge of the S CI Tra nsmit circuit at the D LC connector.

Is the voltage above 1.0 volt?

All

Yes → Repair the SC I Tra nsmit circuit for a short to volta ge.

P erform P OWERTRAIN VERIFI CATION TES T VER - 1.

No → G o To 6






Measure th e resistance between the S CI Tra nsmit circuit and the S CI Receive circuit

a t t he P CM connect or .


All

Yes → R epa ir t he s hort b et ween t he SCI Tra ns mit a nd t he SC I R eceive

circuits.


No → G o To 7






M ea s u re t he res is t a nce b et ween grou nd a n d t he S CI Tra ns mit circu it a t t he DL C.


All

Yes →

Repair the SC I Tra nsmit circuit for a short to ground.Perform POWERTRAIN VERIFICATION TEST VER - 1.

No → G o To 8

33

COMMUNICATION

*NO RE SPONSE FROM ECM AND PCM (DIESEL ONLY) — Continued

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Measure th e resistance of the S CI Tra nsmit circuit between th e ECM connector an dt h e D L C .


All

Yes → G o To 9

No → Repair the SC I Tra nsmit circuit for an open.




Dis connect t he nega t ive b a t t ery ca b le.

M ea s u re t he res ist a nce b et ween grou nd a nd b ot h grou nd circu it s a t t he D L C.


All

Yes → G o To 1 0

No → R epa ir t he grou nd circu it t ha t m ea s u red a b ove 5.0 ohms for a n

open.



Repair

Replace the Engine Control Module.


34

COMMUNICATION

*NO RE SPONSE FROM ECM AND PCM (DIESEL ONLY) — Continued

7/26/2019 01XJED


Symptom:*NO RESPONSE FROM POWERTRAIN CONTROL MODULE (DIE-SEL ONLY)

POSSIBLE CAUSES

ATTEMPT TO COMMUNICATE WITH THE ECM

C H E C K P C M P O WE R S AN D G R O U N D S

SCI RECEI V E CI RCU I T SHO RT ED T O GRO U N D

S C I R E C E I V E C I R C U I T O P E N

SCI TRAN SMI T CI RCU I T OP EN


TEST ACTION APPLICABILITY 1 Tu rn t h e ig ni ti on on .

Wit h t he DR B a t t emp t t o commu nica t e wit h t he E CM .

Wa s t he DR B a b le t o commu nica t e wit h t he E C M ?

All

Yes → G o To 2

No → Refer to symptom list for problems related t o No Response From

E C M a n d P C M .


2 P e r for m t h e s y mp t om C h eck in g E C M a n d P C M P o w er a n d G r ou n d Ci r cu it s in t h e

Driveability category.

Did t he vehicle p a s s t his t es t ?

All

Yes → G o To 3




Disconnect the PCM C3 harness connector.


M ea s u re t he res is t a nce b et ween grou nd a nd t he S CI R eceive circu it .


All

Yes → Repair the SC I Receive circuit for a sh ort to ground.


No → G o To 4



Measure th e resistance of the SCI Receive circuit between the P CM C3 connector and

t h e D L C .


All

Yes → G o To 5

No → Repair the S CI Receive circuit for an open.


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COMMUNICATION

7/26/2019 01XJED





Measure th e resistance of the SC I Tra nsmit circuit between the P CM C3 connector

a n d t h e D L C .Is the resistance below 5.0 ohms?

All

Yes → G o To 6

No → Repair the SC I Tra nsmit circuit for an open.



Repair

R epla ce t he P owert ra in C ont rol M odu le.


36

COMMUNICATION

*NO RESPONSE FROM POWERTRAIN CONTROL MODULE (DIESELONLY) — Continued

7/26/2019 01XJED


Symptom:P0115-TEMPERATURE OF ENGINE COOLANT SRC HIGH EX-CEEDED


P0115-TEMPERATURE OF E NGINE COOLANT SRC HIGH EXCEEDE D


Set Condition: The volta ge on the ECM engine coola nt tempera tur e sensor signa l circuit

is above 4.9 volts for more than 3 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITIONE C M E C T S E N S O R G R O U N D C I R C U I T O P E N

EC M E CT SE NSOR S IG NAL CI RCU IT SH ORTED TO VOLTAG E

E C M E C T S E N S OR

E C M E C T S E N S OR S I G N AL C I R C U I T O P E N




With t he DRB , monitor the E CM E ngine Coolant Temperatur e (EC T) Sensor voltage.

I s t he E CM E CT Sens or volt a ge a b ove 4. 5 volt s ?

All

Yes → G o To 2

No → G o To 7


Disconnect the ECM ECT Sensor harness connector.


M ea s u re t he volt a ge on t he E CM E CT Sensor Signa l circu it .


All

Yes → Repair the EC M ECT Sensor Signa l circuit for a short to volta ge.


No → G o To 3



Connect a jumper wire between the ECM ECT Sensor harness connector cavities.


Wit h t he D R B , rea d t he E CM E CT Sens or volt a ge.


All

Yes → R ep la c e t h e E C M E C T S e n s or i n a c cor d a n c e w i t h t h e S e r vi ce

Information.


No → G o To 4

37


7/26/2019 01XJED





Connect a jump er wire b et ween grou nd a nd t he E CM E CT Sens or Signa l circu it .

Turn the ignition on.Wit h t he D R B , rea d t he E CM E CT Sens or volt a ge.


All

Yes → R epa ir t he E CM E CT Sens or G rou nd circu it for a n open.


No → G o To 5




M ea s u re t he res is t a nce of t he E C M E CT Sens or S igna l circu it .


All

Yes → G o To 6

No → R epa ir t he E CM E CT Sens or Signa l circu it for a n open.



Repair

R ep la ce a nd p rogra m t he E ngine Cont rol M odu le in a ccorda nce




p a ra met ers rela t ed t o t he D TC w hile wiggling t he wiring ha rnes s . L ook for p a ra m-eter va lues to change a nd/or a DTC t o set.









All



No →

Test Complete.

38


P0115-TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDE D —Continued

7/26/2019 01XJED


Symptom:P0115-TEMPERATURE OF ENGINE COOLANT SRC LOW EX-CEEDED


P0115-TEMPERATURE OF E NGINE COOLANT SRC LOW EXCEE DED


Set Condition: The volta ge on the ECM engine coola nt tempera tur e sensor signa l circuit

is below 0.5 volt for more than 3 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITIONE C M E C T S E N S OR

EC M EC T SE N SO R SI G N AL CI RC U I T SHO RTED TO G RO U N D

EC M EC T SE N SO R SI G N AL AN D G RO U N D CI RCU I TS SHO RTED TO GETHE R




With t he DRB , monitor the E CM E ngine Coolant Temperatur e (EC T) Sensor voltage.

I s t he E CM E CT Sens or volt a ge b elow 0. 3 volt ?

All

Yes → G o To 2

No → G o To 6




Wit h t he D R B , rea d t he E CM E CT Sens or volt a ge.


All

Yes → R ep la c e t h e E C M E C T S e n s or i n a c cor d a n c e w i t h t h e S e r vi ce

Information.


No → G o To 3

3 Tu r n t h e i gn it i on of f.Disconnect the ECM harness connectors.


M ea s u re t he res ist a nce b et ween grou nd a nd t he E C M E C T Sens or S igna l circu it .


All

Yes → G o To 4

No → R epa ir t he E CM E CT Sens or Signa l circu it for a s hort t o grou nd.


39


7/26/2019 01XJED






M ea s u re t he res is t a nce b et ween t he E CM E CT Sens or Signa l circu it a nd Sens orGround circuit .


All

Yes → G o To 5

No → R e pa i r t h e E C M E C T S e n sor S i g n a l a n d G r o u n d c ir cu i t s f or a

short together.



Repair















All




40


P0115-TEMPERATURE OF E NGINE COOLANT SRC LOW EXCEE DED —Continued

7/26/2019 01XJED


Symptom:P0117-ECT SENSOR VOLTAGE TOO LOW


P0117-ECT SENSOR VOLTAGE TOO LOW


Set Condition: The volta ge on the P CM engine coola nt tempera ture sensor signal circuit

is below 0.25 volt for more than 3 seconds.

POSSIBLE CAUSES


P C M E C T S E N S OR

P CM E CT SE N SO R SI G N AL CI RC U I T SHO RTED TO GRO U N D

P CM E CT SE N SO R SI G N AL AN D G RO U N D CI RCU I TS SHO RTED TO GETHE R




With t he DR B, m onitor the P CM E ngine Coolant Temperatur e (EC T) Sensor volta ge.

Is the PCM ECT Sensor voltage below 0.25 volt?

All

Yes → G o To 2

No → G o To 6


Disconnect the PCM ECT Sensor harness connector.


Wit h t he DR B , rea d t he P CM E CT Sens or volt a ge.


All

Yes → R ep la c e t h e P C M E C T S e n sor i n a cc or d a n c e w i t h t h e S e r vi ce

Information.


No → G o To 3


Disconnect the PCM harness connectors.Disconnect the PCM ECT Sensor harness connector.

M ea s u re t he res ist a nce b et ween grou nd a nd t he P CM E CT Sensor Signa l circu it .


All

Yes → G o To 4

No → R epa ir t h e P CM E CT Sensor Signa l circu it for a s hort t o ground.


41


7/26/2019 01XJED






M ea s u r e t h e r e si s t a n ce b et w e e n t h e P C M E C T S e n s or S i g n a l c ir cu i t a n d S e n s orGround circuit .


All

Yes → G o To 5

No → R e pa i r t h e P C M E C T S en s or S i g n a l a n d G r o u nd c i r cu i t s f or a

short together.



Repair















All




42


P0117-ECT SENSOR VOLTAGE TOO L OW — Continued

7/26/2019 01XJED


Symptom:P0118-ECT SENSOR VOLTAGE TOO HIGH


P0118-ECT SENSOR VOLTAGE TOO HIGH


Set Condition: The volta ge on the P CM engine coola nt tempera ture sensor signal circuit

is above 4.9 volts for more than 3 seconds.

POSSIBLE CAUSES


P C M E C T S E N S O R G R O U N D C I R C U I T O P E N

P CM E CT SE NSOR S IG NAL CI RCU IT SH ORTED TO VOLTAG E

P C M E C T S E N S OR

P C M E C T S E N S O R S I G N AL C I R C U I T O P E N




With t he DR B, m onitor the P CM E ngine Coolant Temperatur e (EC T) Sensor volta ge.

I s t he P CM E CT Sens or volt a ge a b ove 4. 98 volt s ?

All

Yes → G o To 2

No → G o To 7




M ea s u re t he volt a ge on t he P CM E CT Sens or S igna l circu it .


All

Yes → Repair the PC M ECT Sensor Signa l circuit for a short to volta ge.


No → G o To 3



Connect a jumper wire between the PCM ECT Sensor harness connector cavities.


Wit h t he DR B , rea d t he P CM E CT Sens or volt a ge.


All

Yes → R ep la c e t h e P C M E C T S e n sor i n a cc or d a n c e w i t h t h e S e r vi ce

Information.


No → G o To 4

43


7/26/2019 01XJED





Connect a jump er wire b et ween grou nd a nd t he P CM E CT Sensor Signa l circu it .

Turn the ignition on.Wit h t he DR B , rea d t he P CM E CT Sens or volt a ge.


All

Yes → R epa ir t he P C M E CT Sens or G rou nd circu it for a n op en.


No → G o To 5




M ea s u re t he res is t a nce of t he P CM E CT Sens or Signa l circu it .


All

Yes → G o To 6

No → R epa ir t he P C M E CT Sens or Signa l circu it for a n open.



Repair














All



No →

Test Complete.

44


P0118-ECT SENSOR VOLTAGE TOO HIGH — Continued

7/26/2019 01XJED


Symptom:P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED


P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED


Set C ondit ion: The fuel tempera ture sensor signal voltage is a bove 4.7 volts.

POSSIBLE CAUSES


F U E L TEMP ERATU RE SE N SO R (F U EL I N J ECTI O N P U MP ) O PEN I N TERN AL LY

F U EL T EMPERAT U RE SEN SO R GRO U N D CI RCU I T O PEN

F U EL T EMPERAT U RE SEN SO R SI GN AL CI RCU I T O PEN

INTERNAL FUEL INJ ECTION PUMP TEST

FU EL TEMP ERATUR E SE NSOR S IG NAL CI RCU IT SH ORTED TO VOLTAG E





Turn t he ignition off, wa it 10 seconds, then t urn t he ignition on.

Wit h t he DR B , rea d E CM DTCs .Did this DTC reset?

All

Yes → G o To 2

No → G o To 7


Disconnect the Fuel Injection Pump harness connector.

Connect a jumper wire between the Fuel Temperatur e Sensor Signa l circuit and t he

Sensor Ground circuit in the Fuel Injection Pump harness connector (vehicle side).


Wit h t he DR B , era s e E CM DTCs a nd t hen rea d E CM DTCs .

Did D TC P 0180-FU E L TE M P E R ATU R E SE N SOR S R C L OW E XCE E D E D s et ?

All

Yes → R epla ce t he Fu el I nject ion P u mp in a ccorda nce wit h t he Service

Information.


No → G o To 3

45


7/26/2019 01XJED





Connect a ju mp er wire b et ween grou nd a nd t he Fu el Temp era t u re Sens or Signa l

circuit in t he Fu el Injection P ump h ar ness connector (vehicle side).Turn the ignition on.


Did D TC P 0180-FU E L TE M P E R ATU R E SE N SOR S R C L OW E XCE E D E D s et ?

All

Yes → Repair the Fu el Temperatur e Sensor Ground circuit for a n open.


No → G o To 4




Measure th e resistance of the Fuel Temperatur e Sensor Signa l circuit .


All

Yes → G o To 5

No → Repair the Fuel Temperatur e Sensor Signa l circuit for an open.





Remove the ASD /Diesel Pow er Relay from the P DC .

Connect a jump er w ire b et ween ca vit y 30 a nd ca vit y 87 of t he A SD/Dies el P ower

Relay connector.


Measure th e volta ge of the Fuel Temperatur e Sensor Signa l circuit .


All

Yes → Repair the Fuel Temperatur e Sensor Signa l circuit for a sh ort to

voltage.


No → G o To 6

6 D i s con n e ct t h e F u e l I n je ct i on P u m p h a r n e s s c on n e ct o r.

M ea s u re t he res is t a nce b et ween t he following ca vit ies in t he Fu el I nject ion P u mp

connector (fuel pump side):

Cavity 1 to cavities 4, 5, 6, 7, 8, 9, and 10.

Cavity 4 to cavities 5, 6, 7, 8, 9, and 10.

Ca vit y 5 t o ca vit ies 6, 7, 8, a nd 9.


Ca vit y 8 t o ca vit ies 6 a nd 10.

NOTE : The resistance should be above 100 ohms for all measurements.Is the resistance above 100 ohms for each of the measurements?

All




No → R epla ce t he Fu el I nject ion P u mp in a ccorda nce wit h t h e Service

I nforma t ion.


46


P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEE DED — Continued

7/26/2019 01XJED














All




47


P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEE DED — Continued

7/26/2019 01XJED


Symptom:P0180-FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED


P0180-FUEL TEMPERATURE SENSOR SRC LOW EXCEE DED


Set C ondit ion: The fuel tempera ture sensor signal voltage is below 0.8 volt .

POSSIBLE CAUSES


F U E L TEMP ERATU RE SE N SO R (F U EL I N J ECTI O N P U MP ) SHO RTED TO G RO U N D I N TER-

NALLYF U E L TEMP ERATU RE SE N SO R SI GN AL CI RCU I T SHO RTED TO G RO U N D

F U E L TEMP ERATU RE SE N SO R SI GN AL AN D GRO U N D CI RCU I TS SHO RTED TO GETHE R








Did this DTC reset?

All

Yes → G o To 2

No → G o To 6





Did DTC P 0180 FU E L TE M P E R A TU R E SE N SOR SR C HI G H E XCE E DE D s et ?

All


Information.


No → G o To 3

48


7/26/2019 01XJED






M ea s u re t he res is t a nce b et ween grou nd a n d t he Fu el Temp era t u re Sens or Signa lcircuit.


All

Yes → G o To 4

No → Repair the Fuel Temperatur e Sensor Signa l circuit for a short t o

ground.





M ea s u re t he res is t a nce b et ween t he Fu el Temp era t u re S ens or Signa l circu it a nd

Sensor Ground circuit .


All

Yes → G o To 5

No → R epa ir t he Fu el Temp era t u re Sens or S igna l a nd G rou nd circu it s

for a short together.









Ca vit y 8 t o ca vit ies 6 a nd 10.NOTE : The resistance should be above 100 ohms for all measurements.Is the resistance above 100 ohms for each of the measurements?

All





I nforma t ion.


49


P0180-FUEL TEMPERATURE SENSOR SRC L OW EXCEEDE D — Continued

7/26/2019 01XJED














All




50


P0180-FUEL TEMPERATURE SENSOR SRC L OW EXCEEDE D — Continued

7/26/2019 01XJED


Symptom:P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY


P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY

When Monitored: With t he engine speed between 600 and 870 RPM.

Set Condit ion: When the engine is idling, the t urbochar ger boost pressure sensor input

does not a gree with the a tmospheric pressure sensor input for a t least 7 seconds.

POSSIBLE CAUSES


H I G H R E S I S TAN C E I N TH E B O O S T P R E S S U R E S E N S O R S I G N AL C I R C U I T

H I G H R E S I S TAN C E I N TH E B O O S T P R E S S U R E S E N S O R G R O U N D C I R C U I T

HI G H RESI STAN CE I N THE 5-VO LT SU P P LY CI RC U I T

TUR B OCHARGE R B OOST P RES SU RE/INTAKE AIR TEMP ERATUR E SE NSOR





Turn t he ignition off, wa it 30 seconds, then st ar t a nd idle the engine for at least 30

seconds.

NOTE: Engine idle speed must be below 870 RPM.Wit h t he DR B , rea d E CM DTCs .

Did this DTC reset?

All

Yes → G o To 2

No → G o To 6


Disconnect t he Turbocha rger B oost P ressur e/IAT Sen sor ha rness connector.


M ea s u re t he res is t a nce of t he B oost P res s u re Sens or S igna l circu it .


All

Yes → G o To 3

No → R epa ir t he B oos t P res s ure Sens or Signa l circu it for high res is-

t a nce.


51


7/26/2019 01XJED






M ea s u re t he res is t a nce of t he Sens or G rou nd circu it .Is the resistance below 5.0 ohms?

All

Yes → G o To 4

No → R epa ir t he B oos t P res su re Sens or G rou nd circu it for high res is-

t a nce.





Measure the resistance of the 5-volt Supply circuit .


All

Yes → G o To 5

No → Repair th e 5-volt Supply circuit for high resista nce.



Replace th e Turbocha rger B oost P ressure/Int ake Air Temperatu re Sensor.



Test dr ive the vehicle, pausing several t imes t o cycle the ignition.

M onit or t he DR B for E CM D TCs .

Did this DTC reset?

All




No → The repair is complete.









p a rt ia lly b roken w ires.Visually inspect t he relat ed w iring ha rness connectors. Look for broken, bent, pushed



All




52


P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY — Continued

7/26/2019 01XJED


Symptom:P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EX-CEEDED


P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED


Set C ondition: The turbocha rger boost pressure sensor signal volta ge exceeds 4.80 volts

for at least 2 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITION5-VOLT SU P P LY CIR CU IT SH ORTED TO VOLTAG E

B O O S T P R E S S U R E S E N S O R G R O U N D C I R C U I T O P E N

B O O ST PRES SU RE SE N SO R S I G N AL C I RCU I T SHO RTED TO V O LTAGE


P OOR C ONNE CTOR TER MINAL CONTACT

EN G INE CONTROL MOD U LE (5-VOLT SU P P LY SHOR TED TO VOLTAGE )

ENGINE CONTROL MODULE (INTERNAL)

ENG INE CONTROL MODU LE (SE NSOR S IG NAL SH ORTED TO VOLTAG E)



With t he DRB , read t he Turbocha rger B oost P ressure Sensor volta ge.


All

Yes → G o To 2

No → G o To 9




M ea s u re t he volt a ge b et ween grou nd a nd t he Tu rb ocha rger B oos t P r es su re S ens or

5-volt Supply circuit.Is the voltage above 5.2 volts?

All

Yes → G o To 3

No → G o To 4

53


7/26/2019 01XJED







Relay connector.


Measure the voltage between ground and the 5-volt Supply circuit .


All

Yes → Repair th e 5-volt S upply circuit for a short to volta ge.


No → R epla ce a nd p rogra m t he E ngine Cont rol M odu le in a ccorda nce




Disconnect t he Turbocha rger B oost P ressur e/IAT Sen sor ha rness connector.Turn the ignition on.

M ea s u re t he volt a ge b et ween grou nd a nd t he B oos t P res s ure Sens or Signa l circu it .


All

Yes → G o To 5

No → G o To 6






Relay connector.

Turn the ignition on.M ea s u re t he volt a ge b et ween grou nd a nd t he B oos t P res s ure Sens or Signa l circu it .


All

Yes → R ep a i r t h e B o os t P r e s s ur e S e n s or S i g n a l c ir cu i t f o r a s h or t t o

voltage.








M ea s u re t he res is t a nce of t he Sens or G rou nd circu it .Is the resistance below 5.0 ohms?

All

Yes → G o To 7

No → R epa ir t he B oost P res s ure Sens or G rou nd circu it for a n open.


54


P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED —Continued

7/26/2019 01XJED




NOTE: Ensure all harness connectors are connected.Turn the ignition on.

Measure the voltage of the Boost Pr essure Sensor Signal circuit by backprobing ECMharness connector C1, cavity 40.


All

Yes → Replace the Turbocha rger B oost P ressure/Int ake Air Tempera-

ture Sensor.


No → G o To 8



Did this DTC reset?

All




No → E ns u re good t ermina l cont a ct b et ween t he Tu rb ocha rger B oos t

P r es su re/I AT S ens or ha rn es s connect or a nd t he s ens or. The

repair is complete.






condit ions u nder which t he DTC wa s s et .Refer to an y Technical S ervice B ulletins (TSB ) that ma y a pply.






All




55


P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED —Continued

7/26/2019 01XJED


Symptom:P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EX-CEEDED


P0235-TURBOCHARGER BOOST SENSOR SIGNAL L OW EXCE EDE D


Set C ondit ion: The turbocha rger boost pressure sensor signa l voltage st ay s below 0.15

volt for at least 2 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITION5-VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND


B O O ST PRESSU RE SEN SO R SI GN AL CI RCU I T SHO RT ED T O GRO U N D

B O O ST PRESSU RE SEN SO R SI GN AL AN D GRO U N D CI RCU I T S SHO RT ED T O GET HER

B O O S T P R E S S U R E S E N S O R S I G N AL C I R C U I T O P E N






All

Yes → G o To 2

No → G o To 8






All

Yes → G o To 3

No → Repair t he 5-volt Supply circuit for an open or short to ground.Perform ROAD TEST VERIFICATION - VER-2.

56


7/26/2019 01XJED






Connect a jumper wire between the Boost Pressure Sensor Signal and 5-volt Supplycircuits.


Is the Boost Pressure Sensor voltage above 4.5 volts?

All


ture Sensor.


No → G o To 4




M ea s u r e t h e r e si s t a n ce b et w e e n g r o u n d a n d t h e B o os t P r e s su r e S e n sor S i g n a l

circuit.Is the resistance above 100 kohms?

All

Yes → G o To 5

No → R e pa i r t h e B oos t P r e s s ur e S e n s or S i g n a l c i rc ui t f o r a s h or t t o

ground.





Measure the resistance between the Boost Pressure Sensor Signal circuit and Sensor

Ground circuit .


All

Yes → G o To 6

No → Repair the Boost Pressure Sensor Signa l circuit for a short to the






M ea s u re t he res is t a nce of t he B oost P res s u re Sens or S igna l circu it .


All

Yes → G o To 7

No → R epa ir t he B oost P res s ure Sens or Signa l circu it for a n open.



Repair




57


P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED —Continued

7/26/2019 01XJED














All




58


P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED —Continued

7/26/2019 01XJED


Symptom:P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EX-CEEDED


P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED


Set C ondition: The tur bocharger boost pressure sensor supply voltag e exceeds 5.2 volts

for at least 2 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITION5-VOLT SU P P LY CIR CU IT SH ORTED TO VOLTAG E







Did this DTC reset?

All

Yes → G o To 2

No → G o To 3






Relay connector.




All






59


7/26/2019 01XJED














All




60


P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED —Continued

7/26/2019 01XJED


Symptom:P0235-TURBOCHARGER BOOST SENSOR SUPPLY LOW EX-CEEDED


P0235-TURBOCHARGER BOOST SENSOR SUPPLY L OW EXCEE DED


Set C ondition: The turbocha rger boost pressure sensor supply volta ge sta ys below 4.75

volts for at least 2 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITIONTUR B OCHARGE R B OOST P RES SU RE/INTAKE AIR TEMP ERATUR E SE NSOR

5-VOLT SU P P LY C IRC UI T SH ORTED TO G ROUND

5-VOLT SUPPLY AND SENSOR GROUND CIRCUITS SHORTED TOGETHER







Did this DTC reset?

All

Yes → G o To 2

No → G o To 6




M ea s u re t he volt a ge b et ween grou nd a nd t he Tu rb ocha rger B oos t P r es su re S ens or

5-volt Supply circuit.


All


ture Sensor.


No → G o To 3




Measure the resistance between ground and the 5-volt Supply circuit .


All

Yes → G o To 4

No → Repair th e 5-volt Supply circuit for a short to ground.


61


7/26/2019 01XJED






M ea s u re t he res is t a nce b et ween t he 5-volt Su p p ly circu it a nd t he Sens or G rou ndcircuit.


All

Yes → G o To 5

No → Repair th e 5-volt S upply and S ensor Ground circuits for a short

together.



Repair















All




62


P0235-TURBOCHARGER BOOST SENSOR SUPPLY L OW EXCEEDED —Continued

7/26/2019 01XJED


Symptom:P0400-EGR OPEN CIRCUIT


P0400-EGR OPEN CI RCUIT


S e t C o n di t ion : Th e E C M d et e ct s a n op en or s h or t t o g r o un d on t h e e l ect r i c v a cu u m

modulat or contr ol circuit.

POSSIBLE CAUSES


F U S ED ASD REL AY O U TP U T CI RCU I T OP EN

EG R S O L EN O I D C O N TRO L CI RC U I T SHO RTED TO G RO U N D

EGR SO L EN O I D CO N T RO L CI RCU I T O PEN

SU B S TI TU TE EG R S O L EN O I D





P erform s evera l ignit ion cycles, t u rning t he ignit ion off for a t lea s t 10 s econds

between each ignition cycle.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 7


Disconnect the EGR Solenoid harness connector.


Using a 12-volt test light connected to ground, check the Fused ASD Relay Output

circuit.

Does t he t es t l ight i l lu mina t e b right ly?

All

Yes → G o To 3

No → Repair the Fused ASD R elay Output circuit for an open.


63


7/26/2019 01XJED






M ea s u re t he res is t a nce b et ween ground a nd t he E G R Solenoid C ont rol circu it .Is the resistance above 100 kohms?

All

Yes → G o To 4

No → Repair the EG R Solenoid Control circuit for a short to ground.





Measure the resistance of the EGR Solenoid Control circuit .


All

Yes → G o To 5

No → Repair the E G R Solenoid Control circuit for an open.Perform ROAD TEST VERIFICATION - VER-2.


Install a substitute EGR Solenoid in place of the vehicle’s EGR Solenoid.

NOTE: Ensure the E CM and EGR Solenoid harness connectors are con-nected.Turn the ignition on.

With the DRB, check for this DTC to reset.

Did this DTC reset?

All

Yes → G o To 6

No → Replace the EG R Solenoid.



Repair




7 WARNING: KEE P CL EAR OF THE ENGINE’S MOVING PARTS.NOTE : The conditions that set the DTC are not present at this time.Thefollowing list may help in identifying the intermittent condition.Wi t h t h e e n gi n e r u n n i n g a t n or m a l op er a t i n g t e m pe r a t u r e, m on i t or t h e D R B











All




64


P0400-EGR OPEN CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P0400-EGR SHORT CIRCUIT


P0400-EGR SHORT CIRCUIT


Set Condition: The ECM detects excessive current dra w on the electric vacuum modula-

tor control circuit.

POSSIBLE CAUSES


E G R S O L E N O I D

EG R S OLE NOID CONTROL S HOR TED TO VOLTAG E

ENGINE CONTROL MODULE (INTERNAL)

EN G INE CONTROL MOD U LE (INTER NAL SH ORT TO VOLTAGE )




Test drive the vehicle and m onitor the DRB for ECM D TCs.

Did this DTC reset?

All

Yes → G o To 2

No → G o To 5






Does t he DR B dis p la y P 0400 E G R OP E N CI R CU I T?

All

Yes → Replace the EG R Solenoid.


No → G o To 3

3 Tu r n t h e i gn it i on of f.Disconnect the EGR Solenoid harness connector.


Measure the voltage of the EGR Solenoid Control circuit .


All




No → G o To 4

65


7/26/2019 01XJED







Relay connector.


M ea s u re t he volt a ge of t he E G R Solenoid Cont rol circu it .


All




No → Repair the EG R Solenoid Control circuit for a short to volta ge.


5 WARNING: KEE P CL EAR OF THE ENGINE’S MOVING PARTS.

NOTE : The conditions that set the DTC are not present at this time. T hefollowing list may help in identifying the intermittent condition.Wi t h t h e e n gi n e r u n n i n g a t n or m a l op er a t i n g t e m pe r a t u r e, m on i t or t h e D R B











All




66


P0400-EGR SHORT CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES


P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES


Set Condition: The PC M receives a vehicle speed signal for an extended durat ion with out

a change in fuel level signal voltage.

POSSIBLE CAUSES

CH ECK F O R O THE R D TCS

F U E L TAN K O B STRU C TI N G THE F U E L L E VEL SE N SO R


F U E L L E VE L S E N S O R



Wit h t he DR B , check for a ddit iona l P CM D TCs .

Are other Fuel Level Sensor DTCs present?

All

Yes → R ef er t o t h e S y m p t om L i st f or d i a g n os i s o f o t h er F u e l L e ve l

Sensor related DTCs before continuing.


No → G o To 2


Disconnect the Fuel Level Sensor harness connector.


Wit h t he DR B , rea d a nd record t he F u el L evel S ens or volt a ge.

NOTE: The DRB should read 10.0 volts with the Fuel Level Sensor harnessconnector disconnected.Connect a 12-volt test light between Fuel Level Sensor harness connector cavities 3

a n d 4 .

Wit h t he DR B , rea d t he F u el L evel Sens or volt a ge.

Did t he volt a ge cha nge t o les s t ha n 10.0 volt s ?

All

Yes → G o To 3




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R emove t he Fu el L evel S ens or from t he F u el Ta nk in a ccorda nce wit h t he S ervice

Information.

Inspect the inside of the F uel Tan k for an y obstructions or deformities.I s t he Fu el Ta nk OK?

All

Yes → R epla ce t he Fu el L evel Sens or in a ccorda nce wit h t he S ervice

Information.


No → R epa ir or repla ce t he Fu el Ta nk in a ccorda nce wit h t h e Service

I nforma t ion.


68


P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES — Continued

7/26/2019 01XJED


Symptom:P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW


P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW


Set Condit ion: The fuel level sensor signal voltage on P CM cavity C3-26 is below 0.25

volt.

POSSIBLE CAUSES



F U EL L EV EL SEN SO R SI GN AL CI RCU I T SHO RT ED T O GRO U N D

F U E L L EV EL S EN SO R S I G N AL AN D G RO U N D C I RCU I TS S HO RTED TO GETHE R







Did this DTC reset?

All

Yes → G o To 2

No → G o To 6




Wit h t he DR B , rea d t he F u el L evel Sens or volt a ge.


All


Information.


No → G o To 3




M ea s u re t he res is t a nce b et ween ground a nd t he Fu el L evel Sens or Signa l circu it .


All

Yes → G o To 4

No → Repair the Fuel Level Sensor Signa l circuit for a short t o ground.


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M ea s u re t he res is t a nce b et ween t he Fu el L evel Sens or Signa l circu it a nd Sens orGround circuit .


All

Yes → G o To 5

No → R epa ir t he Fu el L evel Sens or S igna l a nd G rou nd circu it s for a

short together.



Repair















All




70


P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW — Continued

7/26/2019 01XJED


Symptom:P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH


P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH


Set Condit ion: The fuel level sensor signal voltage on P CM cavity C3-26 is a bove 9.50

volts.

POSSIBLE CAUSES


FU EL LEVEL S ENS OR SI G NAL CI RCU IT SH ORTED TO VOLTAG E

F U E L L E VE L S E N S O R S I G N AL C I R C U I T O P E N

F U E L L E VE L S E N S O R G R O U N D C I R C U I T O P E N








Did this DTC reset?

All

Yes → G o To 2

No → G o To 7





M ea s u re t he volt a ge on t he Fu el L evel Sens or Signa l circu it .


All

Yes → G o To 3

No → Repair the Fuel Level Sensor Signa l circuit for a short to volta ge.Perform ROAD TEST VERIFICATION - VER-2.




M ea s u re t he res is t a nce of t he Fu el L evel Sens or Signa l circu it .


All

Yes → G o To 4

No → Repair the Fuel Level Sensor Signal circuit for a n open.


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7/26/2019 01XJED






Measure the resistance of the Fuel Level Sensor Ground circuit .Is the resistance below 5.0 ohms?

All

Yes → G o To 5

No → Repair the Fuel Level Sensor Ground circuit for an open.





Wit h t he DR B , rea d a nd record t he F u el L evel S ens or volt a ge.

NOTE: The Fuel Level Sensor voltage should be 10.0 volts with the sensorharness connector disconnected.Connect a jumper wire between Fuel Level Sensor harness connector cavities 3 and

4.Wit h t he DR B , rea d t he F u el L evel Sens or volt a ge.

NOTE: The Fuel Level Sensor voltage should be less then 1.0 volt with the jumper wire connected.Are the voltage readings the expected voltages?

All


Information.


No → G o To 6


Repair















All




72


P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH — Continued

7/26/2019 01XJED


Symptom List:P0500-VEH. SPEED SENSOR PE C FRE QUENCY T OO HIGHP0500-VEH. SPEED SENSOR PLAUSIBI LITY P0500-VEH. SPEED SENSOR SRC HIGH EXCEEDE D

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P0500-VEH. SPEED SENSORPEC FREQUENCY TOO HIGH.


P0500-VEH. SPEE D SENSOR PEC FRE QUENCY TOO HIGH


Set C ondition: The EC M detects a vehicle speed great er tha n 220 km/h (137 MPH ).

P0500-VEH. SPEED SENSOR PLAUSIBI LI TY


S e t C on d it i on : Th e E C M com pa r e s t h e a m ou n t of f ue l t h e f uel q u a n t i t y a ct u a t or i s

delivering t o th e vehicle speed from t he vehicle speed sensor (VSS ). The VSS indica tes a

vehicle speed that cannot be achieved with the present amount of fuel being delivered.

P0500-VEH. SPEE D SENSOR SRC HIGH EXCEE DED


Set C ondition: The EC M detects a vehicle speed great er tha n 220 km/h (137 MPH ).

POSSIBLE CAUSES

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T S H O R TE D TO S E N S O R G R O U N D

P OWERTRAIN CONTROL MOD UL E - 5-VOLT SU P P LY H IG H

P OWER TRAIN CONTROL MODU LE - AFTER 5-VOLT SUP P LY SH ORTE D TO VOLTAG E

REPAI R THE 5-VO LT SU P P LY CI RCU I T AN D CHE CK THE P CM


5-VO LT SU P P LY CI RC U I T O PE NP OWER TRAIN C ONTROL MODU LE - SHOR TED TO VOLTAG E

SPEEDOMETER PINION AND DRIVE TEETH DAMAGED

VEH I CL E SP EE D S EN SO R S I G N AL CI RC U I T SH O RTED TO 5-VO LT SU P P LY CI RCU I T


EN G INE CONTROL MOD U LE - SH ORTED TO VOLTAG E

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T O P E N

5-VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND

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7/26/2019 01XJED


POSSIBLE CAUSES

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T S H O R TE D TO G R O U N D

VEH I CL E SP EE D SEN S O R SI G N AL CI RCU I T SH O RTED TO V OL TAGE

P OWERTRAIN CONTROL MOD UL E - 5-VOLT SU P P LY C IRC UI T LOW

S E N S O R G R O U N D C I R C U I T O P E N

VE H I C L E S P E E D S E N S OR

ENG INE CONTROL MODU LE - INTERNAL FAULT




Test d rive t he vehicle.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 2 1


Remove the Vehicle Speed Sensor.

I ns p ect t he S p eedomet er P inion a nd drive t eet h on t he Ou t p u t S ha ft (loca t ed in t he

transmission).

Are both components OK ?

All

Yes → G o To 3

No → Repair or replace the Speedometer P inion or interna l components

a s neces sa ry in a ccorda nce wit h t he Service I nforma t ion.



Disconnect the Vehicle S peed Sensor ha rness connector.

Check connectors - Clean/repair as necessaryTurn the ignition on.

Measure t he voltage of th e 5-volt Supply circuit in the Vehicle Speed Sensor h ar ness

connector.

Is the voltage between 4.8 and 5.5 volts?

All

Yes → G o To 4

Above

G o To 15

Below

G o To 17



Note: Check connectors - Clean/repair as necessary.Turn the ignition on.

Measure the voltage of the Vehicle Speed Sensor Signal circuit .


All

Yes → G o To 5

No → G o To 8

74


P0500-VEH. SPEED SENSOR PE C FRE QUENCY TOO HIGH — Continued

7/26/2019 01XJED






Note: Check connectors - Clean/repair as necessary.Turn the ignition on.



All

Yes → G o To 6







Note: Check connectors - Clean/repair as necessary.

Remove the ASD /Diesel Pow er Relay from the P DC .Connect a jumper w ire between ASD /Diesel Pow er Relay cavities 30 and 87 (in P DC ).




All

Yes → G o To 7





Repair

R ep a i r t h e Ve h icl e S p ee d S e n s or S i g n a l c ir cu i t f or a s h or t t o

voltage.




Dis connect t he P CM C 1 a nd C2 ha rnes s connect ors .

Check connectors - Clean/repair as necessaryM ea s u re t he res is t a nce b et ween t he V ehicle Sp eed Sens or Signa l circu it a nd t he



All

Yes → G o To 9

No → Repair th e Vehicle Speed Sensor Signa l circuit for a short t o the

5-volt Supply circuit.Perform ROAD TEST VERIFICATION - VER-2.




Note: Check connectors - Clean/repair as necessary.Measure the resistance of the Vehicle Speed Sensor Signal circuit .


All

Yes → G o To 1 0

No → Repair th e Vehicle Speed Sensor Signa l circuit for an open.


75



7/26/2019 01XJED






Note: Check connectors - Clean/repair as necessary.Measure th e resistance between ground a nd t he Vehicle Speed Sensor Signa l circuit .


All

Yes → G o To 11

No → R epa ir t he Vehicle Sp eed S ens or Signa l circu it for a s hort t o

ground.


11 Tu r n t h e i g ni t i on of f .



Note: Check connectors - Clean/repair as necessary.Measure the resistance of the Vehicle Speed Sensor Ground circuit .


All

Yes → G o To 1 2

No → Repair t he Vehicle Speed Sensor G round circuit for an open.




NOTE: Ensure the ECM and PCM harness connectors are connected beforecontinuing.Turn the ignition on.

Connect a jumper w ire to the Vehicle Speed Sensor Signa l circuit in t he VSS h ar ness

connector.

Wi t h t h e D R B , m on i t or t h e V E H I C L E S P E E D w h i l e t a p pi n g t h e o t h er e n d of t h e

jumper wire to ground.Does t he DR B dis pla y km/h (M P H ) grea t er t ha n 0?

All

Yes → Replace the Vehicle Speed Sensor.

P erform R OAD TES T VERI FI CATION - VER-2.

No → G o To 1 3







All

Yes → G o To 1 4





Repair




76



7/26/2019 01XJED









All

Yes → R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-



No → G o To 1 6


Repair the 5-volt Supply circuit for a short to voltage.

Reconnect all harness connectors except the Vehicle Speed Sensor harness connector.


Measure the voltage of the 5-volt Supply circuit .Is the voltage above 4.8 volts?

All

Yes → The repair is complete.








Check connectors - Clean/repair as necessaryMeasure the resistance of the 5-volt Supply circuit between the Vehicle Speed Sensor

ha rnes s connect or a nd t he P C M C 1 ha rnes s connect or.Is the resistance below 5.0 ohms?

All

Yes → G o To 1 8

No → Repair t he 5-volt Supply circuit for an open.





Check connectors - Clean/repair as necessaryMeasure the resistance between ground and the 5-volt Supply circuit .


All

Yes →

G o To 1 9No → Repair th e 5-volt Supply circuit for a short to ground.


77



7/26/2019 01XJED






Check connectors - Clean/repair as necessaryM ea s u re t he res is t a nce b et ween t he 5-volt Su p p ly circu it a nd t he Sens or G rou nd

circuit in t he Vehicle S peed Sensor h ar ness connector.


All

Yes → G o To 2 0

No → Repair the 5-volt Supply circuit for a sh ort to the Sensor Ground

circuit.



Repair













out, or corroded terminals.Were any of the above conditions present?

All

Yes → R ep a ir a s neces s a ry



78



7/26/2019 01XJED


Symptom:P0522-OIL PRESSURE VOLTAGE TOO LOW


P0522-OIL PRESSURE VOLTAGE TOO LOW


Set C ondition: The PC M detects voltage on the oil pressure sensor signa l circuit below 0.1

volt.

POSSIBLE CAUSES

C H E C K I N G TH E O I L P R E S S U R E S E N S O R

O I L P R E S S U R E S E N S O R S I G N AL C I R C U I T S H O RTE D TO G R O U N D

O I L P R E S S U R E S E N S O R S I G N AL C I R C U I T S H O R TE D TO S E N S O R G R O U N D

P C M - OI L P R E S S U R E S E N S O R S I G N AL S H O R T TO G R O U N D





Cycle t he ignit ion key on a nd off s evera l t imes , lea ving t he key on for a t lea s t 10

s econds a t a t ime.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 5


Disconnect the Oil Pressure Sensor harness connector.

M ea s u re t he volt a ge of t he Oil P res s ure S ens or S igna l circu it .


All

Yes → Replace the Oil Pressure Sensor.


No → G o To 3

3 Tu r n t h e i gn it i on of f.Disconnect the Oil Pressure Sensor harness connector.


M ea s u re t he res is t a nce b et ween grou nd a nd t he Oil P res s ure Sens or Signa l circu it .


All

Yes → G o To 4

No → R e pa i r t h e O i l P r e ss u r e S e n s or S i g n a l c i r cu i t f o r a s h or t t o

ground.


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7/26/2019 01XJED






M ea s u re t he res is t a nce b et ween S ens or G rou nd a nd t he Oil P res s u re Sens or S igna lcircuit.


All




No → Repair the Oil Pressure Sensor Signal circuit for a short to Sensor

G rou nd.













All




80


P0522-OIL PRE SSURE VOLTAGE TOO LOW — Continued

7/26/2019 01XJED


Symptom:P0523-OIL PRESSURE VOLTAGE TOO HIGH


P0523-OIL PRESSURE VOLTAGE TOO HIGH


Set C ondition: The PC M detects voltage on the oil pressure sensor signa l circuit above 4.8

volts.

POSSIBLE CAUSES

O I L P R E S S U R E S E N S O R F AI L U R E

O I L P R E S S U R E S E N S O R S I G N AL C I R C U I T O P E N

O I L P RESS U RE SE N SO R S I G N AL C I RCU I T SHO RTED TO V OL TAGE

P CM - O I L P RESS U RE SE N SO R SI GN AL CI RCU I T SHO RTED TO V OL TAGE

P C M - O I L P R E S S U R E S E N S O R S I G N AL O P E N






Cycle t he ignit ion key on a nd off s evera l t imes , lea ving t he key on for a t lea s t 10s econds a t a t ime.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 6





Select t he a p propria t e volt a ge rea ding.

All

Voltage is above 5.5 volts.G o To 3

Volta ge is betw een 4.7 and 5.4 volts.

G o To 4

Voltage is below 4.7 volts.

G o To 5

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7/26/2019 01XJED







Relay connector.




All




No → R e pa i r t h e O i l P r e ss u r e S e n s or S i g n a l c i r cu i t f o r a s h or t t o

voltage.


4 Tu r n t h e i gn it i on of f.Disconnect the Oil Pressure Sensor harness connector.


M ea s u re t he res is t a nce of t he Sens or G rou nd circu it .


All

Yes → Replace the Oil Pressure Sensor.


No → Repair the Sensor Gr ound circuit for an open.





M ea s u re t he res is t a nce of t he Oil P res su re S ens or Signa l circu it .Is the resistance below 5.0 ohms?

All




No → R epa ir t he Oil P res s u re Sens or S igna l circu it for a n open.


82


P0523-OIL PRESSURE VOLTAGE TOO HIGH — Continued

7/26/2019 01XJED














All




83


P0523-OIL PRESSURE VOLTAGE TOO HIGH — Continued

7/26/2019 01XJED


Symptom List:P0725-ENGINE SPEED SENSOR DYN. PLAUSIBIL ITY P0725-ENGINE SPEED SENSOR STATIC PLAUSIBILITY

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P0725-ENGINE SPEED SENSORDYN. PLAUSIBILI TY.


P0725-ENGI NE SPEED SENSOR DYN. PL AUSIBI LI TY

When Monitored: The engine speed is a bove 790 RP M.

Set Condition: The ECM detects a chan ge in engine speed tha t ha s occurred more ra pidly

tha n the engine is capable of changing speed.

P0725-ENGINE SPEED SENSOR STATIC PLAUSIBILITY

When Monitored: With t he engine speed a bove 700 RP M.

Set C ondition: The engine speed sensor signal indica tes engine speed below 75 RP M and

the needle movement sensor signa l (injector #1) indica tes engine speed a bove 700 RP M.

POSSIBLE CAUSES



E N G I N E S P E E D S E N S O R S I G N AL C I R C U I T S H O R TE D TO G R O U N D

EN GI N E SPEED SEN SO R CI RCU I T S SHO RT ED T O GET HER

E N G I N E S P E E D S E N S O R S I G N AL C I R C U I T O P E N

EN G I N E SP EE D SE N SO R SI GN AL CI RCU I T SH O RTED TO V OL TAGE

E N G I N E S P E E D S E N S OR


1 At t em pt t o s t a rt t h e en gi ne.

Did t he engine s t a rt ?

All

Yes → G o To 2

No → G o To 3

84


7/26/2019 01XJED














All





Disconnect the Engine Speed Sensor harness connector.


Measure the resistance between ground and the Engine Speed Sensor Signal circuit .


All

Yes → G o To 4

No → R e pa i r t h e E n g i ne S p e ed S e n s or S i g n a l c i rc ui t f o r a s h or t t o

ground.



Disconnect the Engine Speed Sensor harness connector.Disconnect the ECM harness connectors.

Measure the resistance between the Engine Speed Sensor Signal and Sensor Ground

circuits.


All

Yes → G o To 5

No → R ep a ir t h e E n g in e S p ee d S e ns or S i gn a l a n d S e ns or G r ou n d

circuits for a short together.





M ea s u re t he res is t a nce of t he E ngine S p eed S ens or Signa l circu it .Is the resistance below 5.0 ohms?

All

Yes → G o To 6

No → R epa ir t he E ngine Sp eed Sens or S igna l circu it for a n open.


85


P0725-ENGINE SPEED SENSOR DYN. PLAUSIBIL ITY — Continued

7/26/2019 01XJED






Turn the ignition on.M ea s u re t he volt a ge of t he E ngine Sp eed S ens or S igna l circu it .


All

Yes → G o To 7

No → R e pa i r t h e E n g i ne S p e ed S e n s or S i g n a l c i rc ui t f o r a s h or t t o

voltage.


7 NOTE: Ensure the EC M and Engine Speed Sensor harness connectors areconnected.Connect, by back probing, a voltmeter capable of reading frequency to ECM harness

connector C2 cavity 67.

Cra nk t he engine wh ile monit oring t he volt met er.

Is the frequency between 16 and 20 Hz at 270-300 cranking RPM?

All




No → Replace the En gine Speed Sensor in accorda nce wit h the Service

I nforma t ion.


86


P0725-ENGINE SPEED SENSOR DYN. PLAUSIBIL ITY — Continued

7/26/2019 01XJED


Symptom:P0725-ENGINE SPEED SENSOR OVERSPEED RECOGNITION


P0725-ENGINE SPEED SENSOR OVERSPEED RECOGNITION


Set C ondition: The engine speed sensor signa l indica tes engine speed is above 5100 RP M

for at least 500 milliseconds. NOTE: Engine dama ge is possible w hen the engine speed

exceeds 5100 RPM.

POSSIBLE CAUSES



R E P L AC E TH E E N G I N E S P E E D S E N S O R



1 CAUT ION: E ngine damage is possible when engine speed exceeds 5100RPM.NOTE : This DTC indicates the Engine Speed Sensor has seen an enginespeed above 5100 RPM.Turn the ignition on.

With the DRB, check for other Engine Speed Sensor DTCs.

Are other Engine Speed Sensor DTCs present?

All

Yes → Refer to symptom list for problems related to other DTCs before

continuing.


No → G o To 2



Test drive the vehicle and m onitor the DRB for ECM D TCs.

Did this DTC reset?

All

Yes → G o To 3

No → G o To 4

87


7/26/2019 01XJED



3 R ep la c e t h e E n g in e S pe ed S e n sor i n a c cor d a n c e w i t h t h e S e r v ice I n for m a t i on .


Perform several drive cycles, turning the ignition off for at least 10 seconds between

each d rive cycle.M onit or t he DR B for E CM D TCs .

Did this DTC reset?

All















Check t he E ngine Sp eed Sens or wiring ha rnes s for incorrect rou t ing which ma y

cause EMI interference.


All




88


P0725-ENGINE SPEE D SENSOR OVERSPEE D RECOGNITI ON — Continued

7/26/2019 01XJED


Symptom List:P1105-ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDEDP1105-ATMOSPHE RE PRESSURE SENSOR SRC L OW EXCEE DEDP1610-REGULATOR LOWER REGULATOR LIMITP1610-REGULATOR UPPER REGULATOR LIMIT

P1615-MICROCONTROLLER GATE-ARRAY MONITORINGP1615-MICROCONTROLLER GATE-ARRAY WATCHDOGP1615-MICROCONTROLLER PREPARE FUEL QUANTITY STOPP1615-MICROCONTROLLER RECOVERY HAS OCCURREDP1615-MICROCONTROL LER RE DUNDANT OVERRUN MONITOR-INGP1620 - U-REF (2.5V)P1680-EEPROM PLAUSIBIL ITY CHECKSUM ERROR FOR ADJ(EGR)P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212P1680-EEPROM PLAUSIBIL ITY COMMUNICATION WITH EE-PROMP1680-EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISS-INGP1680-EEPROM PLAUSIBILITY VER NUMBER NOT CORRE-SPONDINGP1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1105-ATMOSPHE RE PRES-SURE SENSOR SRC HIGH EXCEEDED.

POSSIBLE CAUSES




1 NOTE: This DTC indicates an internal ECM problem.

Turn the ignition on.Wit h t he DR B , era s e E CM D TCs .

P erform s evera l engine ru n cycles , t u rning t he ignit ion off for a t lea s t 20 s econds

between each engine run cycle.


Did this DTC reset?

All




No → G o To 2

89


7/26/2019 01XJED














All




90


P1105-ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEE DED —Continued

7/26/2019 01XJED


Symptom:P1110-AIR TEMP. SENSOR SRC HIGH E XCEE DED


P1110-AIR TE MP. SENSOR SRC HIGH EXCEE DED


Set C ondit ion: The intake air t emperature sensor signal goes a bove 4.7 volts for a t least

2 seconds.

POSSIBLE CAUSES


INTAKE AIR TEMP SE NSOR SI G NAL CIR CU IT SH ORTED TO VOLTAG E

I N TAK E AI R TEMP SE N SO R G RO U N D CI RCU I T O PE N

I N TAK E AI R TEMP SE N SO R S I G N AL C I RCU I T O PE N

TUR B OCHARGE R B OOST P RES SU RE/IAT SE NSOR






Did this DTC reset?

All

Yes → G o To 2

No → G o To 6






Relay connector.


Measure the voltage on the IAT Sensor Signal circuit .


All

Yes → G o To 3

No → R epa ir t he I nt a ke Air Temp era t u re Sens or Signa l circu it for a

short to voltage.


NOTE: Remove the jumper wire.

91


7/26/2019 01XJED






Measure th e resistance of the Int ake Air Temperatur e Sensor Signa l circuit .Is the resistance below 5.0 ohms?

All

Yes → G o To 4

No → R epa ir t he I nt a ke Air Temp era t u re Sens or Signa l circu it for a n

open.




Connect a jump er wire b et ween t he I AT Sensor Signa l a nd I AT Sensor G rou nd

circuits in t he Turbocha rger B oost P ressur e/IAT Sen sor ha rness connector.



Does t he DR B dis pla y P 1110 AI R TE M P . SE N S OR SR C L OW E XCE E DE D?

All


ture Sensor.


No → G o To 5




Connect a ju mp er w ire b et ween t he I n t a ke A ir Temp era t u re S ens or Signa l circu it

a nd grou nd.


Does t he DR B dis pla y P 1110 AI R TE M P . SE N S OR SR C L OW E XCE E DE D?

All

Yes → Repair the In ta ke Air Temperatur e Sensor Ground circuit for an

open.








Review the D TC When Monitored an d Set Conditions. If possible, try to duplicat e thecondit ions u nder which t he DTC wa s s et .







All




92


P1110-AIR TEMP. SENSOR SRC HIGH EXCEEDE D — Continued

7/26/2019 01XJED


Symptom:P1110-AIR TEMP. SENSOR SRC LOW EXCEEDED


P1110-AIR TE MP. SENSOR SRC LOW EXCEE DED


Set Condition: The inta ke a ir temperat ure sensor signal goes below 0.18 volt for a t least

2 seconds.

POSSIBLE CAUSES


INTAKE AIR TEMP SE NSOR S IG NAL CI RCU IT SH ORTED TO G ROUND

TUR B OCHARGE R B OOST P RES SU RE/IAT SE NSOR






Did this DTC reset?

All

Yes → G o To 2

No → G o To 5




M ea s u re t he res is t a nce b et ween grou nd a nd t he I nt a ke Air Temp era t u re S ens or

Signal circuit .


All

Yes → G o To 3

No → R epa ir t he I nt a ke Air Temp era t u re Sens or Signa l circu it for a

short to ground.






Does t he DR B dis p la y P 1110 A I R TE M P . SE N SOR SR C HI G H E XCE E DE D?

All


ture Sensor.


No → G o To 4

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Repair












Visually inspect t he relat ed w iring ha rness connectors. Look for broken, bent, pushedout, or corroded terminals.


All




94


P1110-AIR TEMP. SENSOR SRC LOW EXCEEDE D — Continued

7/26/2019 01XJED


Symptom:P1201-NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED


P1201-NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED


S e t C o nd i t ion : Th e E C M d et e ct s h i g h v ol t a g e o n t h e n e e dl e m ov em e n t s e n s or s i gn a l

circuit.

POSSIBLE CAUSES


N E E D L E M OVE M E N T S E N S O R G R O U N D C I R C U I T O P E N

NEE DLE MOVEME NT SE NSOR SIG NAL CI RCU IT SH ORTED TO VOLTAG E

N EED L E MO V EMEN T SEN S O R

N EED L E MO V EMEN T SEN SO R SI GN AL CI RCU I T O PEN







Did this DTC reset?

All

Yes → G o To 2

No → G o To 7



Disconnect t he Needle Movement S ensor ha rness connector.



Relay connector.


Measure the voltage on the Needle Movement Sensor Signal circuit .


All

Yes → G o To 3

No → Repair the Needle Movement S ensor Signa l circuit for a short to

voltage.



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3 NOTE : Ensure the EC M harness connectors are connected and the ASD/Diesel Power Relay is installed before continuing.Turn the ignition off.

Disconnect t he Needle Movement S ensor ha rness connector.Connect a ju mp er wire b et ween t he N eedle M ovement Sens or ha rnes s connect or

cavities.



Did DTC P 1201 N E E DL E M OV E M E N T SE N SOR SR C L OW E XCE E DE D s et ?

All

Yes → R epla ce t he N eedle M ovement Sens or in a ccorda nce wit h t he



No → G o To 4



Connect a ju mp er wire b et ween grou nd a nd t he N eedle M ovement Sens or Signa lcircuit.



Did DTC P 1201 N E E DL E M OV E M E N T SE N SOR SR C L OW E XCE E DE D s et ?

All

Yes → Repair the Needle Movement S ensor Ground circuit for an open.


No → G o To 5




Measure the resistance of the Needle Movement Sensor Signal circuit .


All

Yes → G o To 6

No → Repair the Needle Movement Sensor Signa l circuit for an open.



Repair




96


P1201-NEE DLE MOVEMENT SENSOR SRC HI GH EXCEEDED — Continued

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All




97


P1201-NEE DLE MOVEMENT SENSOR SRC HI GH EXCEEDED — Continued

7/26/2019 01XJED


Symptom:P1201-NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED


P1201-NEE DLE MOVEME NT SENSOR SRC L OW EXCE EDE D


Set Condition: The ECM detects th e volta ge on the needle movement sensor signa l circuit

below 0.141 volt.

POSSIBLE CAUSES


N EED L E MO V EMEN T SEN S O R

N EED L E MO VEMEN T SEN S O R SI G N AL CI RC U I T SHO RTED TO GR O U N D

N EED L E MO VEMEN T SEN SO R S I G N AL AN D GRO U N D CI RCU I TS SHO RTED TO GETHE R







Did this DTC reset?

All

Yes → G o To 2

No → G o To 6





D i d D TC P 1 20 1 NE E D L E M O VE M E N T S E N S O R S R C H I G H E X C E E D E D s et ?

All

Yes → R epla ce t he N eedle M ovement Sens or in a ccorda nce wit h t he



No → G o To 3




M ea s u re t he res is t a nce b et ween grou nd a nd t he N eedle M ovement Sens or Signa l

circuit.


All

Yes → G o To 4


ground.


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M ea s u re t he res is t a nce b et ween t he N eedle M ovement Sens or Signa l circu it a ndSensor Ground circuit .


All

Yes → G o To 5

No → R epa ir t he N eedle M ovement S ens or S igna l a nd G rou nd circu it s




Repair















All




99


P1201-NEE DLE MOVEMENT SENSOR SRC LOW EXCEEDED — Continued

7/26/2019 01XJED


Symptom:P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD


P1220-FUE L QUANTI TY ACTUATOR NEG GOV DEVIATION COL D


Set Condition: The EC M has at tempted to compensat e for a rich condition and the engine

coolant temperature is below 60° C (140° F). NOTE: An improperly timed fuel injection

pump may also set t his code.

POSSIBLE CAUSES


FUEL INJ ECTION PUMP SHORTED INTERNALLY

FUEL QUANTITY ACTUATOR CONTROL CIRCUIT SHORTED TO GROUND




1 NOTE: An improperly timed Fuel Injection Pump may also set this DTC.Turn the ignition on.


Tu rn t he ignit ion off , wa it 10 s econds, t hen a t t emp t t o s t a rt a nd idle t he engine.


All

Yes → G o To 2

No → G o To 5



M ea s u re t he res is t a nce b et ween grou nd a nd Fu el I nject ion P u mp connect or ( fu el

pump side) cavity 8.


All

Yes → G o To 3


I nforma t ion.


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M ea s u re t he res is t a nce b et ween grou nd a nd t he Fu el Qu a nt it y A ct u a t or Cont rolcircuit in ECM harness connector C2, cavities 59, 66, and 80.


All

Yes → G o To 4

No → R epa ir t he Fu el Qu a nt it y A ct u a t or Cont rol circu it for a s hort t o

ground.







Cavity 4 to cavities 5, 6, 7, 8, 9, and 10.Ca vit y 5 t o ca vit ies 6, 7, 8, a nd 9.




All





I nforma t ion.













All




101


P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD —Continued

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Symptom:P1220-FUE L QUANTITY ACTUATOR NEG GOV DEVIATI ON WARM


P1220-FUE L QUANTI TY ACTUATOR NE G GOV DEVI ATI ON WARM


Set Condition: The EC M has at tempted to compensat e for a rich condition and the engine

coolant temperature is above 60° C (140° F).

POSSIBLE CAUSES


FUEL INJ ECTION PUMP SHORTED INTERNALLY

FUEL QUANTITY ACTUATOR CONTROL CIRCUIT SHORTED TO GROUND






St a rt t he engine a nd va ry t he engine s p eed from idle t o 3500 R P M s evera l t imes .


Did this DTC reset?

All

Yes → G o To 2

No → G o To 5




pump side) cavity 8.


All

Yes → G o To 3


I nforma t ion.





M ea s u re t he res is t a nce b et ween grou nd a nd t he Fu el Qu a nt it y A ct u a t or Cont rol

circuit in ECM harness connector C2, cavities 59, 66, and 80.


All

Yes → G o To 4

No → R epa ir t he Fu el Qu a nt it y A ct u a t or Cont rol circu it for a s hort t o

ground.


102


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connector (fuel pump side):Cavity 1 to cavities 4, 5, 6, 7, 8, 9, and 10.






All





I nforma t ion.












All




103


P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM —Continued

7/26/2019 01XJED


Symptom List:P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLDP1220-FUE L QUANTITY ACTUATOR POS GOV DEVIATI ON WARM

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1220-FUEL QUANTITY ACTU-ATOR POS GOV DEVIATION COLD.


P1220-FUE L QUANTI TY ACTUATOR POS GOV DEVIATI ON COLD


Set Condition: The EC M ha s att empted to compensat e for a lea n condition and the engine

coolant temperature is below 60° C (140° F).

P1220-FUE L QUANTI TY ACTUATOR POS GOV DE VIATION WARM


Set Condition: The EC M ha s att empted to compensat e for a lea n condition and the engine

coolant temperature is above 60° C (140° F).

POSSIBLE CAUSES


CH ECK THE F U E L I N J EC TI O N PU MP TI MI N G

CH ECK F O R A F U E L RE STRI CTI O N

REP L ACE THE F U E L I N J ECTI O N PU MP







Did this DTC reset?

All

Yes → G o To 2

No → G o To 5

2 C h e ck t h e F u e l I n je ct i on P u m p t i m i ng u si n g t h e S e r v ic e I n f or m a t i on .

Is the Fuel Injection Pump timing correct?

All

Yes → G o To 3

No → S e t t h e F u el I n je ct i on P u m p t i mi ng i n a c cor d a n ce w i t h t h e



104


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Inspect the fuel system for restrictions in the delivery lines, filter an d/or at the fuel

level sensor module.

Was a restriction found?

All

Yes → Repair as necessary.


No → G o To 4


R epla ce t he Fu el I nject ion P u mp in a ccorda nce wit h t he S ervice I nforma t ion.





Did this DTC reset?

All











Refer to an y Technical S ervice B ulletins (TSB ) that ma y a pply.Visually in spect t he relat ed wir ing ha rness. Look for an y cha fed, pierced, pinched, or





All




105


P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD —Continued

7/26/2019 01XJED


Symptom List:P1225-CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDEDP1225-CONTROL SLEE VE SENSOR SIGNAL LOW EXCEEDED

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1225-CONTROL SLEEVE SEN-SOR SIGNAL HIGH EXCEEDED.


P1225-CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED

When Monitored: With t he ignition on a nd during a fter-run m ode (a t key-off).

Set Condition: The EC M does not receive a correct sign a l from the mea sure coil and/or

the sensor coil. NOTE: This fa ult w ill ca use t he engine t o stumble a nd/or sta ll.

P1225-CONTROL SLE EVE SENSOR SIGNAL LOW EXCE EDE D

When Monitored: With t he ignition on a nd during a fter-run m ode (a t key-off).

Set Condition: The EC M does not receive a correct sign a l from the mea sure coil and/or

the sensor coil.

POSSIBLE CAUSES


F U E L I N J EC TI O N P U MP - CO N TRO L SL EE VE P O SI TI O N SE N SO R O P EN

F U E L I N J EC TI O N P U MP - CO N TRO L SL E EV E P O SI TI O N SE N SO R S HO RTED TO G RO U N D

CONTROL SL EE VE P OSITION S ENS OR C IRC UI TS SH ORTED TO VOLTAG E

CO N TRO L SL E EV E P O SI TI O N SE N SO R C I RCU I T SH O RTED TO G RO U N D

CONTROL SLEEVE POSITION SENSOR CIRCUITS SHORTED TOGETHER

CO N TRO L SL EE VE P O SI TI O N SEN S O R CI RCU I TS O P EN



1 Tu rn t h e ig ni ti on on .Wit h t he DR B , era s e E CM D TCs .

Turn t he ignition off and w ait for at least 30 seconds.



Did this DTC reset?

All

Yes → G o To 2

No → G o To 9

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M ea s u re t he res is t a nce b et ween Fu el I nject ion P u mp connect or ( fu el p u mp s ide)

ca vit ies 1 a nd 2, t hen 2 a nd 3.I s t he res is t a nce b et ween 5.0 a nd 7.0 ohms for ea ch m ea s u rement ?

All

Yes → G o To 3


I nforma t ion.





pump side) cavities 1, 2 then 3.

Is the resistance above 100 kohms for each measurement?

All

Yes → G o To 4


I nforma t ion.







Relay connector.


M ea s u re t he volt a ge on E C M ha rnes s connect or C2 ca vit y 56.

M ea s u re t he volt a ge on E C M ha rnes s connect or C2 ca vit y 57.

M ea s u re t he volt a ge on E C M ha rnes s connect or C2 ca vit y 58.I s t he volt a ge a b ove 0. 5 volt for a ny of t he mea s u rement s ?

All

Yes → R epa ir t he C ont rol S leeve P osit ion Sens or circu it (s ) t ha t mea -

sured above 0.5 volt for a short to voltage.


No → G o To 5





Measure the resistance between ground and ECM harness connector C2 cavities 56,

57, and 58.Is the resistance above 100 kohms for each of the measurements?

All

Yes → G o To 6

No → R ep a ir t he Cont rol Sleeve P os it ion Sens or circu it ( s ) t ha t mea -

sured below 100 kohms for a short to ground.


107


P1225-CONTROL SLEE VE SENSOR SIGNAL HIGH EXCEEDED —Continued

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Measure the resistance between ECM harness connector C2 cavities 56 and 57, then56 and 58, then 57 and 58.

Is the resistance below 100 kohms for any of the measurements?

All

Yes → Repair the Control Sleeve P osition Sensor circuits that m easured

below 100 kohms for a short together.


No → G o To 7




M e a s u r e t h e r e s i s t a n c e b e t w e e n E C M h a r n e s s c o n n e c t o r C 2 c a v i t y 5 6 a n d F u e l

Injection Pump harness connector cavity 1.

M e a s u r e t h e r e s i s t a n c e b e t w e e n E C M h a r n e s s c o n n e c t o r C 2 c a v i t y 5 7 a n d F u e lInjection Pump harness connector cavity 2.

M e a s u r e t h e r e s i s t a n c e b e t w e e n E C M h a r n e s s c o n n e c t o r C 2 c a v i t y 5 8 a n d F u e l

Injection Pump harness connector cavity 3.

Is the resistance below 5.0 ohms for each of the measurements?

All

Yes → G o To 8

No → R ep a ir t he Cont rol Sleeve P os it ion Sens or circu it ( s ) t ha t mea -

sured above 5.0 ohms for an open.



Repair















All




108


P1225-CONTROL SLEE VE SENSOR SIGNAL HIGH EXCEEDED —Continued

7/26/2019 01XJED


Symptom List:P1225-CONTROL SLEE VE SENSOR START END POS. NOT AT-TAINEDP1225-CONTROL SLE EVE SENSOR STOP END POS. NOT AT-TAINED

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1225-CONTROL SLEEVE SEN-SOR START END POS. NOT ATTAINED.


P1225-CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED


Set C ondition: The control sleeve sensor signal indicates th e control sleeve did not reach

its sta rt posit ion.

P1225-CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED


Set C ondition: The control sleeve position sensor signa l indica tes th e control sleeve is not

at its ending position.

POSSIBLE CAUSESEN G I N E CO N TRO L MO D U L E




1 NOTE : If other C ontrol Sleeve Position Sensor or Fuel Quantity ActuatorDTCs are present, diagnose the other DTCs before continuing.Turn the ignition on.




Did this DTC reset?

All

Yes → G o To 2

No → G o To 3

109


7/26/2019 01XJED



2 R ep la c e t h e F ue l I n je ct i on P u m p in a c cor d a n c e w i t h t h e S er v ice I n for m a t i on .




Did this DTC reset?

All
















All




110


P1225-CONTROL SLEEVE SENSOR START END POS. NOT ATTAINE D —Continued

7/26/2019 01XJED


Symptom:P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION


P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION

When Monitored: With t he engine speed betw een 1000 and 4800 RPM.

Set C ondition: The ECM detects 3 degrees of excess timing reta rd for at least 10 seconds.

POSSIBLE CAUSES





F U E L I N J EC TI O N PU MP TI MI N G I N CO RRECT




Tu rn t he ignit ion off , wa it 30 s econds, t hen a t t emp t t o s t a rt t he engine.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 5

2 NOTE: T his DTC will set due to noise on the Needle Movement Sensorcircuit.Turn the ignition on.

With the DRB, check for additional DTCs.

Are other DTCs present?

All

Yes → Refer to the Symptom List for diagn osis of the other DTCs before

continuing.


No → G o To 3

3 C h e ck t h e F u e l I n je ct i on P u m p t i m i ng u si n g t h e S e r v ic e I n f or m a t i on .Is the Fuel Injection Pump timed correctly?

All

Yes → G o To 4

No → R e se t t h e F u e l I n j ec t io n P u m p t i m i n g i n a c cor d a n c e w i t h t h e



111


7/26/2019 01XJED







Did this DTC reset?

All
















All




112


P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION —Continued

7/26/2019 01XJED


Symptom:P1230-TIMING GOVERNING POSITIVE GOVERNOR DEVIATION


P1230-TIMING GOVERNING POSITIVE GOVERNOR DEVIATION

When Monitored: With t he engine speed betw een 1000 and 4800 RPM.

S e t C o nd i t ion : Th e E C M d et e ct s 3 d e g r ee s o f e xce ss t i m in g a d v a n c e f or a t l ea s t 10

seconds.

POSSIBLE CAUSES




FUEL SYSTEM RESTRICTIONS

F U E L I N J EC TI O N PU MP TI MI N G I N CO RRECT




Tu rn t he ignit ion off , wa it 30 s econds, t hen a t t emp t t o s t a rt t he engine.


Did this DTC reset?

All

Yes → G o To 2

No → G o To 5

2 NOTE: This DTC will set due to low fuel volume to the Fuel Injection Pump.Check the fuel system for restrictions.

Were a ny problems found?

All



No → G o To 3

3 C h e ck t h e F u e l I n je ct i on P u m p t i m i ng u si n g t h e S e r v ic e I n f or m a t i on .

Is the Fuel Injection Pump timed correctly?

All

Yes → G o To 4

No → R e se t t h e F u e l I n j ec t io n P u m p t i m i n g i n a c cor d a n c e w i t h t h e



113


7/26/2019 01XJED







Did this DTC reset?

All
















All




114


P1230-TIMING GOVERNING POSITI VE GOVERNOR DEVIATION —Continued

7/26/2019 01XJED


Symptom List:P1515-ACCEL. PEDAL SENSOR PLAUSIBIL ITY P1515-ACCEL. PEDAL SENSOR PWG PL AUS WITH POTENTI OME-TERP1515-ACCEL. PEDAL SENSOR SIGNAL HIGH EXCEEDED

P1515-ACCEL. PEDAL SENSOR SUPPLY HIGH E XCEEDEDP1515-ACCEL. PEDAL SENSOR SUPPLY LOW EXCEEDED

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1515-ACCEL. PEDAL SENSORPLAUSIBILITY.


P1515-ACCE L. PEDAL SENSOR PLAUSIBILI TY


Set C ondition: The accelera tor peda l position sensor signa l is below 0.2 volt (4%) or above

4.5 volts (90%) and the idle sw itch is not in the correct sta te. NOTE: The idle sw itch is

designed to transition when the accel position is approximately 16%(1.00 volt). This code

sets the ECM to Limp-in Mode, which includes a fixed engine speed of 1100 RPM.

P1515-ACCE L. PEDAL SENSOR PWG PL AUS WIT H POTE NTIOMET ER


Set C ondition: The accelerat or peda l position sensor signa l is below 0.20 volts, th e idle

switch transit ions at too high a percentage intermittently or the idle switch is not in thecorrect st a te int ermitt ently. NOTE: The idle swit ch is designed to tra nsition w hen t he a ccel

position is approximately 16%(1.00 volt). This code sets the ECM to Limp-in Mode, which

includes a fixed engine speed of 1100 RPM.

P1515-ACCEL . PEDAL SENSOR SIGNAL HIGH EXCEE DED


Set Condit ion: The a ccelerator pedal posit ion sensor signal voltage is above 4.5 volts.

NOTE: This code sets t he E CM to Lim p-in Mode, w hich includes a fixed engine speed of

1100 RPM.

P1515-ACCEL . PEDAL SENSOR SUPPLY HI GH EXCEE DED


Set C ondition: The EC M detects volta ge on th e accelera tor pedal position sensor 5-volt

supply circuit above 5.2 volts.

P1515-ACCEL . PEDAL SENSOR SUPPLY L OW EXCEE DED


Set Condit ion: The E CM detects voltage the accelerator pedal posit ion sensor 5-volt

supply circuit below 4.75 volts.

115


7/26/2019 01XJED


POSSIBLE CAUSES

5-VOLT SU P P LY CIR CU IT SH ORTED TO VOLTAG E

AP P SE NSOR CIR CU IT SH ORTED TO VOLTAG E

AP P SE NSOR ID LE VOLTAG E

AP P SE NSOR WID E OP EN THR OTTLE VOLTAG E

E C M S E N S O R G R O U N D C I R C U I T O P E N

LOW IDL E P OSITION S WITCH SE NSE CIR CU IT SH ORTED TO VOLTAG E

5-VO LT SU P P LY CI R CU I T SH O RTED TO THE SE N SO R G RO U N D CI RCU I T

APP SEN SO R SI GN AL CI RCU I T SHO RT ED T O T HE SEN SO R GRO U N D CI RCU I T


L O W I D L E P O SI TI O N SWI TCH SE N SE CI RCU I T SH O RTED TO THE SE N SO R G RO U N D CI R-

C U I T


AP P SEN S O R SI G N AL CI RC U I T SH O RTED TO GRO U N D

L O W I D L E P O SI TI O N SWI TCH SE N SE CI RCU I T SH O RTED TO G RO U N D

5-VO LT SU P P LY CI RC U I T O PE N

AP P S E N S O R S I G N AL C I R C U I T O P E N

L O W I D L E P O SI TI O N SWI TCH SE N SE CI RCU I T O PE N

EC M - 5-VO LT SU P P LY CI RCU I T

E C M - AP P S E N S O R S I G N AL C I R C U I T

P C M S E N S O R G R O U N D C I R C U I T O P E N

P C M - S E N S O R G R O U N D C I R C U I T

VERIFY LOW IDL E P OSITION S WITCH OPE RATION

VERIFY APP SENSOR OPERATION

E C M - S E N S O R G R O U N D O P E N

VERIFY CORRECT SWITCHING


1 Tu r n t h e i gn it i on of f.Disconnect the APP Sensor harness connector.

Connect one end of a jumper wire to APP Sensor harness connector cavity 4.


With th e DRB I II , monitor the Low Idle Position Switch input w hile tapping the other

end of the jumper wire to APP Sensor harness connector cavity 5.

Does t he DR B I I I cha nge b et ween I DL E a nd AB OV E I D L E w hen t a p p ing t he ju mp er

wire?

All

Yes → G o To 2

No → G o To 8

116


P1515-ACCEL. PEDAL SENSOR PL AUSIBIL ITY — Continued

7/26/2019 01XJED




Disconnect the APP Sensor harness connector.


Remove the ASD /Diesel Pow er Relay from the P DC .Connect a ju mp er w ire b et ween ca vit y 30 a nd ca vit y 87 ASD/Dies el P ower R ela y

connector.


M ea s u re t he volt a ge of t he L ow I dle P osit ion S wit ch S ens e circu it .


All

Yes → R epa ir t he L ow I dle P os it ion Swit ch Sens e circu it for a s hort t o

voltage.


No → G o To 3



Disconnect the ECM harness connectors.M ea s u re t he res ist a nce bet ween t he L ow I dle P os it ion S wit ch Sens e circu it a nd t he

Sens or G rou nd circu it s a t ca vit y 4 a nd 8 of t he AP P Sens or ha rnes s connect or .

Is the resistance above 100 kohms for both measurements?

All

Yes → G o To 4

No → R ep a ir t he L ow I dle P os it ion Swit ch Sens e circu it a nd Sens or

Ground circuit for a short together.





M ea s u r e t h e r e si st a n c e b e t w e en g r ou n d a n d t h e L ow I d l e P os it i on S w i t c h S e n s e

circuit.Is the resistance above 100 kohms?

All

Yes → G o To 5

No → R epa ir t he L ow I dle P os it ion Sw it ch Sens e circu it for a s hort t o

ground.





M ea s u re t he res is t a nce of t he L ow I dle P osit ion Sw it ch Sens e circu it .


All

Yes →

G o To 6No → Repair the Low Idle Position Swit ch Sense circuit for an open.


117



7/26/2019 01XJED






M ea s u re t he res is t a nce of t he Sens or G rou nd circu it b et ween A P P Sens or ha rnes sconnector cavity 4 and the PCM harness connector.


All

Yes → G o To 7

No → R epa ir t he P C M AP P Sens or G rou nd circu it for a n op en.



Repair




8 Tu rn t h e ig ni ti on on .Wit h t he DR B I I I obs erve t he L ow I dle P os it ion S wit ch inp u t .

P res s a nd relea s e t he a ccelera t or p eda l s evera l t imes while ob s erving t he DR B I I I

display.

NOTE: T he L ow Idle Position Switch input should change from IDL E toABOVE IDLE when pressing and releasing the accelerator pedal.Did L ow I dle P os it ion Swit ch inp u t cha nge b et ween I DL E a nd A B OV E I DL E ?

All

Yes → G o To 9

No → Replace the Accelerator P edal P osition Sensor in accorda nce with

the Service Information.



Disconnect the APP Sensor harness connector.Turn the ignition on.

Measure the voltage of the 5-volt Supply circuit in APP Sensor harness connector

cavity 10.


All

Yes → G o To 1 0

No → G o To 2 3



Connect a jumper wire between APP Sensor harness connector cavities 7 and 10.

Wit h t he DR B I I I , rea d t he P E D AL OU TP U T V OL TS.

Does t he DR B I I I dis pla y b et ween 4.0 a nd 5.5 volt s ?

All

Yes → G o To 11

No → G o To 1 8

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16 Tu r n t h e i gn it i on on .

With the DRB III , select Engine and with the custom display feature select Low Idle

Sw itch input a nd t he Accel Peda l %.

Slowly depress and release the accelerator pedal several t imes while monitoring theDR B I I I dis p la y.

NOTE : The Low I dle Switch state should change between 5% and 10% of Accelerator Pedal position.Did t he L ow I dle S wit ch s t a t e cha nge b et ween 5% a nd 10% of Accelera t or P eda l

position?

All

Yes → G o To 1 7

No → Replace the Accelerator P edal P osition Sensor.













All









Relay connector.


M ea s u re t he volt a ge of t he AP P Sens or Signa l circu it .


All

Yes → R epa ir t he AP P Sens or Signa l circu it for a s hort t o volt a ge.


No → G o To 1 9

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M ea s u r e t h e r e si s t a n ce b et w e e n t h e AP P S e n so r S i g n a l c ir cu i t a n d t h e S e n sorGround circuits at cavity 4 and 8 of the APP Sensor harness connector.

I s t he res is t a nce b elow 10 kohms for a ny of t he mea s u rement s ?

All

Yes → R epa ir t he AP P Sens or Signa l a nd Sens or G rou nd circu it s for a

short together.


No → G o To 2 0




M ea s u re t he res ist a nce b et ween grou nd a nd t he AP P Sens or S igna l circu it .

Is the resistance below 10 kohms?

All

Yes → R epa ir t he AP P Sens or Signa l circu it for a s hort t o grou nd.


No → G o To 2 1




M ea s u re t he res is t a nce of t he AP P Sens or S igna l circu it .


All

Yes → G o To 2 2

No → Repair the AP P S ensor Signal circuit for an open



Repair









Relay connector.


Measure the voltage of the 5-volt Supply circuit in the ECM harness connector.


All



No → G o To 2 4

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M ea s u re t he res is t a nce b et ween t he 5-volt Su p p ly circu it a nd t he Sens or G rou ndcircuits at cavities 4 and 8 of the APP Sensor harness connector.

Is the resistance above 100 kohms for both of the measurements?

All

Yes → G o To 2 5


circuit.





Measure the resistance between ground and the 5-volt Supply circuit .

Is the resistance below 10 kohms?

All

Yes → Repair th e 5-volt S upply circuit for a short to ground.


No → G o To 2 6




Measure the resistance of the 5-volt Supply circuit .


All

Yes → G o To 2 7




Repair




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Symptom:P1520-VEHICLE SPEED GOV ANALOG CTRL - CONTROL CON-TACT ALONE

POSSIBLE CAUSES

P ERF O RM S YMPTO M *CHEC K I N G THE SP EE D CO N TRO L O PE RATI O N








Did this DTC reset?

All

Yes → G o To 2

No → G o To 3

2 P e rf or m s y mpt om * C H E C KI NG TH E S P E E D C ON TR OL O P E R ATI ON i n t h e

Symp t om L is t .


All


Perform SPEED CONTROL VERIFICATION - VER-4.














All




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Symptom:P1605-TERMINAL 15 PLAUSIBI LITY AFTER START UP


P1605-TERMINAL 15 PLAUSIBIL ITY AFTER START UP

When Monitored: Dur ing power-up a nd in a fter-run mode.

Set C ondit ion: The switched ignit ion volta ge at EC M cavity C1-47 drops to 0 volt a nd

battery voltage is present at an ECM cavity other than cavities C1-33 and C1-45. NOTE:

The na me Term ina l 15 refers t o the internal t erminal on the B osch controller a nd not t o

the actual switched ignition cavity (cavity C1-47) in the ECM harness connector.

POSSIBLE CAUSES


ASD /DI ES EL P OWER R E LAY


EC M CIR CU IT SHORTED TO VOLTAG E

ASD RE LAY OU TP UT CIR CU IT SHOR TE D TO VOLTAG E

ASD RE LAY CONTROL CI RCU IT SH ORTED TO G ROUND



Wit h t he DR B , era s e E CM D TCs .Cycle the ignition switch on and off several t imes, pausing for at least 10 seconds at

each key off and key on.



Did this DTC reset?

All

Yes → G o To 2

No → G o To 6



M ea s u re t he volt a ge of a l l ca vit ies in t he E CM ha rnes s connect ors except ca vit ies

C1-33 a nd C1-45.

Is t he voltage a bove 2.0 volts on a ny of t he cavity termina ls except C1-33 and C1-45?

All

Yes → G o To 3




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Measure the voltage of ECM harness connector C1, cavities 2 and 28.

Is voltage present on ECM harness connector C1, cavities 2 and 28?

All

Yes → G o To 4

No → Repair the EC M circuit that measur ed above 2.0 volts for a short

to voltage.





M ea s u re t he volt a ge on E CM h a rnes s connect or C1 ca vit y 2.

Is the voltage below 2.0 volts?

All

Yes → G o To 5

No → R epa ir t he ASD R ela y Ou t p u t circu it for a s hort t o volt a ge.Perform ROAD TEST VERIFICATION - VER-2.




M ea s u re t he res is t a nce b et ween ground a nd t he ASD R ela y C ont rol circu it .


All

Yes → Replace the ASD /Diesel P ower Rela y.


No → Repair the ASD Relay C ontrol circuit for a sh ort to ground.













All




125


P1605-TERMINAL 15 PLAUSIBI LITY AFTER START UP — Continued

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Symptom:P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE


P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE

When Monitored: During after-run.

Set C ondit ion: The internal E CM t imer determines tha t t he ASD/Diesel P ower Relay

remains on too long when AFTER-RUN mode of operation has been completed.

POSSIBLE CAUSES



SU B STITU TE ASD/DI ES EL P OWER RE LAY

ASD /DI ES EL P OWER RE LAY CONTROL C IRC U IT SH ORTED TO G ROU ND INTER MITTE NTLY

ASD /DI ES EL P OWER RE LAY OU TP U T CI RC U IT SH ORTED TO VOLTAG E






All

Yes → Refer to the Symptom List for diagn osis of the other DTCs beforecontinuing.


No → G o To 2



P erform s evera l ignit ion key cycles , p a u s ing for a t lea s t 10 s econds b et ween ea ch

cycle.



Did this DTC reset?

All

Yes → G o To 3

No → G o To 7

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Insta ll a subst itute rela y in place of the ASD /Diesel Power R elay.


cycle.Turn the ignition on.


Did this DTC reset?

All

Yes → G o To 4

No → Replace the ASD /Diesel P ower Rela y.





M ea s u re t he res is t a nce b et ween ground a nd t he A SD/Dies el P ower R ela y Cont rol

circu it while w iggling t he wiring h a rnes s a nd connect ors .

Was t he resistance below 5.0 ohms at a ny time w hile wiggling the wiring h ar ness andconnectors?

All

Yes → Repair th e ASD /Diesel Power R elay C ontrol circuit for an int er-

mit t ent s hort t o grou nd.


No → G o To 5




Measure t he voltage of th e ASD /Diesel Power Relay Output circuit .


All

Yes → G o To 6

No → Repair th e ASD /Diesel Power Relay Output circuit for a short to

voltage.



Repair




127


P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE — Continued

7/26/2019 01XJED














All




128


P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE — Continued

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Symptom:P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON


P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON

When Monitored: During after-run.

Set Condition: The interna l EC M timer determines tha t the ASD /Diesel P ower Relay ha s

shut off before the AFTER -RU N mode of operat ion ha s been completed.

POSSIBLE CAUSES



SU B STITU TE ASD/DI ES EL P OWER RE LAY

ASD /DI ES EL P OWER RE LAY CONTROL C IRC U IT OP EN INTER MITTEN TLY






All


continuing.


No → G o To 2




cycle.



Did this DTC reset?

All

Yes → G o To 3

No → G o To 6


Insta ll a subst itute rela y in place of the ASD /Diesel Power R elay.


cycle.



Did this DTC reset?

All

Yes → G o To 4

No → Replace the ASD /Diesel P ower Rela y.


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Measure t he resista nce of the ASD /Diesel P ower Relay Control circuit w hile wigglingt he wiring ha rnes s a nd connect ors b et ween t he E CM a nd t he P DC.

Was t he resistance above 5.0 ohms at a ny time w hile wiggling the wiring h ar ness and

connectors?

All

Yes → Repair th e ASD /Diesel Power R elay C ontrol circuit for an int er-

mittent open.


No → G o To 5


Repair














All




130


P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON — Continued

7/26/2019 01XJED


Symptom:P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT


P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT


Set C ondit ion: The ECM detects a n open or short t o ground on the fuel t iming solenoid

control circuit.

POSSIBLE CAUSES

F U E L I N J EC TI O N P U MP


F U E L TI MI N G SO L EN O I D CO N TRO L CI RC U I T SHO RTED TO G RO U N D

F U S ED ASD REL AY O U TP U T CI RCU I T SHO RTED TO G RO U N D

F U S ED ASD REL AY O U TP U T OP EN

F U E L TI MI N G SO L EN O I D C O N TRO L CI RCU I T O PE N

F U E L TI MI N G SO L EN O I D (F U E L I N J ECTI O N P U MP ) I N TERN AL



TEST ACTION APPLICABILITY 1 Tu rn t h e ig ni ti on on .




Did this DTC reset?

All

Yes → G o To 2

No → G o To 9




M ea s u re t he volt a ge on t he Fu s ed ASD R ela y Ou t p u t circu it .


All

Yes → G o To 3

No → G o To 7

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M ea s u r e t h e r e si st a n c e b et w e e n g r ou n d a n d t h e F u e l Ti m in g S o le n oi d C o nt r o lcircuit.


All

Yes → G o To 4

No → R ep a ir t he Fu el Timing Solenoid Cont rol circu it for a s hort t o

ground.





Measure the resistance of the Fuel Timing Solenoid Control circuit .


All

Yes → G o To 5

No → Repair t he Fuel Timing S olenoid Control circuit for an open.




M ea s u re t he res is t a nce of t he Fu el Timing Solenoid a t t he Fu el I nject ion P u mp

connector (fuel pump side) between cavities 5 a nd 10.

Is the resistance between 12.0 and 20.0 ohms?

All

Yes → G o To 6


I nforma t ion.











All


wit h t he S ervice I nforma t ion.Perform ROAD TEST VERIFICATION - VER-2.


I nforma t ion.


7 R em ov e a n d in s pe ct t h e AS D R el a y Ou t p ut F u se f r om t h e P D C .

I s t he fu s e OK?

All

Yes → Repair the Fused ASD R elay Output circuit for an open.


No → G o To 8

132


P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT — Continued

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Remove the ASD Relay Output Fuse.

M ea s u re t he res is t a nce b et ween ground a nd t he Fu s ed A SD R ela y Ou t p u t circu it .


All


Information.


No → Repair the Fused ASD R elay Output circuit for a short to ground.





Review the D TC When Monitored an d Set Conditions. If possible, try to duplicat e thecondit ions u nder which t he DTC wa s s et .







All




133


P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT


P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT


S e t C on d i t ion : Th e E C M d et e ct s e xce ss i ve c u r r en t d r a w on t h e f u el t i m in g s ol en oi d

control circuit.

POSSIBLE CAUSES


FU EL TIMING SOLE NOID (FU EL INJ EC TION P UMP ) SHORTED TO VOLTAG E INTERNALLY

FU EL TIMING SOLE NOID CONTROL C IRC UI T SH ORTED TO VOLTAG E








Did this DTC reset?

All

Yes → G o To 2

No → G o To 5




Wit h t he DR B , era s e E CM DTCs a nd t hen rea d E CM DTCS.

Did DTC P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT set?

All


Information.


No → G o To 3

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Relay connector.


Measure the voltage of the Fuel Timing Solenoid Control circuit .


All

Yes → G o To 4

No → R ep a ir t he Fu el Timing Solenoid Cont rol circu it for a s hort t o

voltage.




connector (fuel pump side):Cavity 1 to cavities 4, 5, 6, 7, 8, 9, and 10.






All





I nforma t ion.












All




135


P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT — Continued

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I ns t a ll a s u b st it u t e rela y in p la ce of t he G low P lu g R ela y.


Wit h t he DR B , a ct u a t e t he G low P lu g R ela y.I s t he G low P lu g R ela y clicking?

All

Yes → R epla ce t he G low P lu g R ela y.


No → G o To 4


Disconnect t he E CM ha rness connector(s).

R emove t he G low P lu g R ela y from t he P DC.


Connect a jumper w ire between ASD /Diesel Pow er Relay cavities 30 and 87 (in P DC ).


M ea s u re t he volt a ge of t he G low P lu g R ela y C ont rol circu it .


All

Yes → Repair the Glow P lug Relay Control circuit for a short to volta ge.


No → G o To 5


Repair




139


P1635-GLOW RELAY 1 CONTROLL ER SHORT CI RCUIT — Continued

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All






Disconnect the Message Center harness connector.

M ea s u re t he res ist a nce b et ween grou nd a nd t he G low P lu g L a mp Cont rol circu it .


All

Yes → G o To 5

No → Repair the Glow P lug Lamp Control circuit for a short to ground.




Disconnect the Message Center harness connector.M ea s u re t he res is t a nce of t he G low P lu g L a mp Cont rol circu it .


All

Yes → G o To 6

No → R epa ir t he G low P lu g L a mp Cont rol circu it for a n op en.


6 NOTE : Ensure the Message Center harness connector is connected.Turn the ignition off.



Connect a jump er wire b et ween grou nd a nd t he G low P lu g L a mp C ont rol circu it in

ECM harness connector C1.

Did t he G low P lu g L a mp il lu mina t e?

All




No → G o To 7

141


P1645-GLOW DISPLAY OPEN CIRCUIT — Continued

7/26/2019 01XJED




R emove a nd check t he G low P lu g L a mp b u lb from t he I ns t ru ment Clu s t er.

I s t he b u lb OK?

All

Yes → Replace the Message Center.


No → R epla ce t he G low P lu g L a mp b u lb .


142


P1645-GLOW DISPLAY OPEN CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P1645-GLOW DISPLAY SHORT CIRCUIT


P1645-GLOW DISPLAY SHORT CI RCUIT

When Monitored: During wa it to sta rt lamp opera t ion.

Set Condit ion: The ECM detects excessive current dra w on the wa it to start lamp control

ci r cu i t w h e n a t t e m pt i n g t o a c t i va t e t h e w a i t t o s t a r t l a m p .

POSSIBLE CAUSES



G L O W P L U G L AMP CO N TRO L CI RC U I T SHO RTED TO G RO U N D

G L O W P L U G L AMP CO N TRO L CI RCU I T O PE N


C H E C K TH E G L O W P L U G L A MP B U L B

MESSAGE CEN T ER





All


continuing.


No → G o To 2


Wi t h t h e D R B , a c t u a t e t h e G l ow P l u g L a m p .

I s t he G low P lu g L a mp cycling on a nd off?

All

Yes → G o To 3

No → G o To 4

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R emove a nd check t he G low P lu g L a mp b u lb from t he I ns t ru ment Clu s t er.

I s t he b u lb OK?

All





145


P1645-GLOW DISPLAY SHORT CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P1660-REDUNDANT EMERG. STOP PLAUSIBI LITY IN AFTER-RUN


P1660-REDUNDANT EMER G. STOP PL AUSIBI LI TY I N AFTER-RUN

When Monitored: Dur ing aft er-run, w hen the engine speed is below 800 RP M and vehicle

speed is below 2.5 MPH.

Set C ondition: The fuel shutdown s olenoid is turned off and engine speed does not drop

below 500 RPM.

POSSIBLE CAUSES


FU EL SH UTDOWN S OLENOID CONTROL C IRC UI T SH ORTED TO VOLTAG E

FUEL SHUTDOWN SOLENOID (FUEL INJ ECTION PUMP) SHORTED INTERNALLY






Start and stop the engine several t imes, pausing for 10 seconds at key off each time.



All

Yes → G o To 2

No → G o To 5






Relay connector.


M ea s u re t he volt a ge on t he Fu el Shu t down S olenoid C ont rol circu it .


All

Yes → G o To 3

No → Repair the Fuel Shut down Solenoid Control circuit for a short to

voltage.


NOTE: Remove the jumper wire from theASD/Diesel Power Relay connec-tor, reinstall the ASD/Diesel Power Relay in the PDC , and reconnect theEC M harness connectors.

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2 Wit h t he DR B , s elect E N G I N E , t hen B OS CH 3. 1L V M DI E SE L CON TR OL L E R from

t he menu .

Display the Vehicle Ident ificat ion Number (VIN).

Compa re t he p rogra mmed V I N t o t h e vehicle V I N .Does t he p rogra mmed V I N m a t ch t he vehicle V I N ?

All

Yes → G o To 3




3 Wi t h t h e D R B , s el ect E N G I N E , t h en J TE C C O N TR O L LE R f r om t h e m e n u.

Display the Vehicle Ident ificat ion Number (VIN).

Compa re t he p rogra mmed V I N t o t h e vehicle V I N .

Does t he p rogra mmed V I N m a t ch t he vehicle V I N ?

All

Yes → G o To 4

No → R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-da nce wit h t he S ervice I nforma t ion.







Relay connector.


Measure the voltage of the Immobilizer Signal circuit .


All

Yes → G o To 5

No → Repair the Imm obilizer Signal circuit for a short to volta ge.


NOTE : Remove the jumper wire and install the ASD/Diesel Power R elay.




M ea s u re t he res is t a nce b et ween grou nd a nd t he I mmob iliz er Signa l circu it .


All

Yes → G o To 6

No → Repair the Imm obilizer Signal circuit for a short to ground.





Measure the resistance of the Immobilizer Signal circuit .


All

Yes → G o To 7

No → Repair the Imm obilizer Signal circuit for an open.


152


P1685-VEHICLE THEFT ALARM IMMOBILIZER SIG LOST — Continued

7/26/2019 01XJED




NOTE: Ensure the EC M harness connectors are connected.M ea s u re t he a mp era ge b et ween grou nd a nd t he I mmob iliz er S igna l circu it in P CM

harness connector C3.Turn the ignition on.

I s t he a mp era ge b et ween 1.0 a nd 1.4 mill ia mp s ?

All

Yes → G o To 8





NOTE: Ensure all connectors are connected.With the DRB oscilloscope function, select LAB SCOPE and set the oscilloscope to the

following specifications:

Voltage Ra nge to + 20.0V

Probe to X10Time Ra nge to 0.1s/Div


With the DRB oscilloscope lead, back probe PCM harness connector C3 cavity 16.

NOTE: A valid Immobilizer Signal voltage will cycle high and low.Does the DRB display show the 12-volt Immobilizer Signal voltage cycling high and

low?

All







153


P1685-VEHICLE THEFT ALARM IMMOBILIZER SIG LOST — Continued

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I ns t a ll a s u b s t it u t e rela y in p la ce of t he R a dia t or Fa n R ela y.


Wit h t he DR B , a ct u a t e t he R a dia t or Fa n R ela y.Does t he R a dia t or Fa n cycle on a nd off?

All

Yes → R epla ce t he R a dia t or Fa n R ela y.


No → G o To 4


R emove t he R a dia t or Fa n R ela y from t he P DC.



Relay connector.


M ea s u re t he volt a ge of t he R a dia t or Fa n R ela y Cont rol circu it .


All

Yes → G o To 5

No → R e pa i r t h e R a d i a t o r F a n R e la y C o nt r ol c i rc ui t f o r a s h or t t o

voltage.



Repair




157


P1690-FAN CONTROL SHORT CIRCUIT — Continued

7/26/2019 01XJED


Symptom:P1703-BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT


P1703-BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT


Set Condit ion: The ECM detects t he brake switch sense circuit an d brake lamp switch

output circuit inputs to th e EC M do not agree. NOTE: An out of adjustment bra ke lamp

switch ma y also cause a reduction in engine power.

POSSIBLE CAUSES


BRAKE LAMP SWITCH (SECONDARY OPEN)

B R A K E L AM P S WI TC H F U S E D B + C I R C U I T O P E N

SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND

BRAKE LAMP SWITCH (PRIMARY OPEN)

SE CO N D ARY B RAK E SWI TCH GR O U N D C I RCU I T O PE N

SE CO N D ARY B RAK E S WI TCH SI G N AL CI RCU I T O PE N

P RIMARY B RAKE SWITCH SIG NAL CIR CU IT SHORTED TO VOLTAG E

P RI MARY B RAK E S WI TCH SI G N AL C I RCU I T O PE N

ENGINE CONTROL MODULE (INTERNAL)EN G I N E CO N TRO L MO D U L E (P RI MARY B RAK E S I G N AL )

EN G I N E CO N TRO L MO D U L E (SEC O N D ARY B RAK E S I G N AL )



While ob s erving t he P R I M B R AKE SWI TCH s t a t u s on t h e DR B dis pla y, p res s a nd

relea s e t he b ra ke p eda l s evera l t imes .

Does t he DR B dis p la y P R I M B R A KE SWI TCH: P R E SSE D a nd R E L E A SE D for t he

appropriate pedal position?

All

Yes → G o To 2

No → G o To 11


While ob s erving t he SE C B R A KE SWI TCH s t a t u s on t he DR B dis p la y, p res s a nd

relea s e t he b ra ke p eda l s evera l t imes .

D o e s t h e D R B d i s p l a y S E C B R A K E S W I T C H : P R E S S E D a n d R E L E A S E D f o r t h e

appropriate pedal position?

All

Yes → G o To 3

No → G o To 4

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Dis connect t he B r a ke L a mp S wit ch h a rnes s connect or .


M e a s u r e t h e r e s i s t a n c e b e t w e e n g r o u n d a n d t h e S e c o n d a r y B r a k e S w i t c h S i g n a lcircuit.


All

Yes → G o To 9

No → R epa ir t he S econda ry B ra ke Sw it ch Signa l circu it for a s hort t o

ground.





M ea s u re t he res ist a nce of t he S econda ry B ra ke S wit ch Signa l circu it .


All

Yes → G o To 1 0

No → R epa ir t he S econda ry B ra ke Sw it ch Signa l circu it for a n op en.



Repair




11 D i s con n e ct t h e B r a k e L a m p S w i t c h h a r n e s s con n e ct o r.

Using a 12-volt test light connected to ground, check the F used B + circuit .


All

Yes → G o To 1 2

No → R epa ir t he B ra ke L a mp Sw it ch Fu sed B + circu it for a n op en.


1 2 D i s con n e ct t h e B r a k e L a m p S w i t c h h a r n e s s con n e ct o r.


Wh i le m o n it o r in g t h e P R I M B R AK E S WI TC H s t a t u s w i t h t h e D R B , con n e ct a

ju mp er wire b et ween t he P rima ry B ra ke Swit ch Signa l circu it a nd t he Fu s ed B ( + )

circuit.

D o es t h e D R B d i sp la y ch a n g e f r om R E L E AS E D t o P R E S S E D ?

All

Yes → Adjus t or repla ce t he B ra ke L a mp Sw it ch in a ccorda nce wit h t he



No → G o To 1 3

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P1703-BRAKE SIGNAL PLAUS WITH RE DUNDANT CONTACT — Continued

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Symptom List:P1725-INDUCTIVE AUX. SPEED SENSOR DYN. PLAUSIBIL ITY P1725-INDUCTIVE AUX. SPEED SENSOR OVERSPEED RE COGNI-TIONP1725-INDUCTIVE AUX. SPEED SENSOR PLAUSIBILITY

P1725-INDUCTIVE AUX. SPEED SENSOR STATIC PLAUSIBIL ITY

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be P1725-INDUCTIVE AUX. SPEEDSENSOR DYN. PLAUSIBI LITY.


P1725-INDUCTI VE AUX. SPEE D SENSOR DYN. PLAUSIBI LI TY


Set Condition: The EC M ha s determined tha t the inductive a uxilia ry speed sensor values

ar e incorrect during a n engine speed tra nsit ion.

P1725-INDUCTI VE AUX. SPEED SENSOR OVERSPEE D RE COGNITION


S e t C o nd i t ion : Th e E C M d et e ct s t h e e n gi n e s pe ed s i gn a l f r om t h e n e e dl e m o ve m en t

sensor ha s exceeded 6600 RP M.

P1725-INDUCTI VE AUX. SPEED SENSOR PLAUSIBI LITY


S e t C o nd i t ion : Th e E C M h a s d et e r m in e d t h a t t h e n e ed l e m ov em e n t s e n s or i n pu t i s

incorrect.

P1725-INDUCTI VE AUX. SPEED SENSOR STATI C PL AUSIBI LITY


Set Condition: The EC M ha s determined tha t the inductive a uxilia ry speed sensor values

are incorrect.

POSSIBLE CAUSES


CH ECK THE N EE D L E MO VEMEN T SEN SO R CO N N ECTO R TERMI N AL S

MIS-ROUTED WIRING HARNESS

N EED L E MO V EMEN T SEN SO R SI GN AL CI RCU I T O PEN

N E E D L E M OVE M E N T S E N S O R G R O U N D C I R C U I T O P E N


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M ea s u re t he res is t a nce b et ween grou nd a nd t he N eedle M ovement Sens or Signa lcircuit.


All

Yes → G o To 7


ground.



Replace the Needle Movement Sensor in accordance with the Service Information.





All








eter va lues to change a nd/or a DTC t o set.Review the D TC When Monitored an d Set Conditions. If possible, try to duplicat e the








All




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P1725-INDUCTIVE AUX. SPEED SENSOR DYN. PLAUSIBIL ITY —Continued

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2 Wit h t he DR B , s elect E ngine, B os ch Cont roller t hen I np u t s /Ou t p u t s .

St a rt t he engine a nd s et t he b lower t o P a nel.

Tur n t he A/C on.

With t he DR B, read the A/C S wit ch.Does the D RB display A/C S wit ch ON?

All

Yes → G o To 3

No → G o To 1 3


With t he DR B, select E ngine, B osch C ontroller t hen In puts/Outputs.

Rea d t he A/C H/L P ress S w

Does the D RB display A/C H/L P ress Sw ON?

All

Yes → G o To 4

No → G o To 8

4 Tu rn t h e ig ni ti on on .Wit h t he DR B I I I, a ctuat e t he A/C Compressor Clutch Relay.

Observe the A/C Compressor C lutch dur ing a ctuat ion.

Is t he A/C Compressor Clut ch clicking?

All

Yes → The electrical port ion of th e A/C S yst em is operat ing properly.


No → G o To 5

5 R em ov e t h e A/C C om p r es s or C l ut c h R e la y f r om t h e P D C .


I s t he t es t l ight on?

All

Yes → G o To 6

No → R epa ir t he Fu s ed B + circu it for a n open.Perform ROAD TEST VERIFICATION - VER-2.

6 R em ov e t h e A/C C om p r es s or C l ut c h R e la y f r om t h e P D C .

Disconnect t he A/C C ompressor Clu tch h a rness connector.

Connect a jumper wir e across the A/C C ompressor Clut ch Relay connector cavit ies 30

a n d 8 7 in t h e P D C .

Using a 12-volt test light connected t o ground, check t he A/C Compressor Clutch

Relay Output circuit in t he A/C Compressor C lutch h ar ness connector.


All

Yes → G o To 7

No → Repair t he A/C C ompressor Clutch Rela y Out put circuit for an

open.


7 Dis connect t he A/C Comp ress or Clu t ch ha rnes s connect or.

Using a 12-volt test light connected t o 12 volts, check t he A/C Compressor Clutch

Ground circuit .


All

Yes → R ep la c e t h e A/C C om p r es s or C l u t ch i n a c cor d a n c e w i t h t h e



No → Repair t he A/C C ompressor Clutch G round circuit for a n open.


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*CHECKING THE A/C SYSTEM — Continued

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Connect one end of a jumper wire t o ground an d ba ck probe the A/C P ressure Signa l

circuit at the ECM harness connector.

With t he DR B, select E ngine, B osch C ontroller t hen In puts/Outputs.Rea d t he A/C H/L P ress S w.


All

Yes → G o To 9

No → R e pl a ce a n d p r o gr a m t h e E C M i n a c cor d a n c e w i t h t h e S e r vi ce

I nforma t ion.


9 Dis connect t he A/C High P res s u re Sw it ch ha rnes s connect or.


Connect one end of a jumper wire t o ground an d ba ck probe the A/C P ressure Signa l

circuit a t t he A/C H igh P ressure Sw itch ha rness connector.


Rea d t he A/C H/L P ress S w.Does the D RB display A/C H/L P ress Sw ON?

All

Yes → G o To 1 0

No → Repair th e A/C P ressure Signa l circuit for an open betw een the

E CM a nd t he A/C High P r es su re Sw it ch.



Disconnect t he A/C High P ressure S wit ch ha rness connector.

Measure t he resista nce of the A/C H igh P ressure Sw itch.

Is the Resistance below 10.0 ohms?

All

Yes → G o To 11

No → Replace the A/C H igh P ressure Sw itch.Perform ROAD TEST VERIFICATION - VER-2.

11 Dis connect t he A/C L ow P res s u re Sw it ch ha rnes s connect or .


Connect one end of a jumper wire to ground a nd t he other end t o the A/C P ressure

Sense circuit at the A/C L ow P ressure Sw itch ha rness connector.


Rea d t he A/C H/L P ress S w.


All

Yes → G o To 1 2

No → Repair t he A/C P ressure Sense circuit for an open between t he

A/C H igh P ressure Sw itch a nd t he A/C L ow P ressure Sw itch.



Disconnect t he A/C Low P ressure S wit ch ha rness connector.

Measure t he resista nce of the A/C L ow P ressure Sw itch.

Is the Resistance below 10.0 ohms?

All

Yes → Repair the ground circuit at the A/C Low P ressure Sw itch for a n

open.


No → Replace the A/C Low P ressure Sw itch.


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*CHECKING THE A/C SYSTEM — Continued

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Symptom:*CHECKING THE CHECK ENGINE LAMP OPERATION

POSSIBLE CAUSES

ACTUATE CHECK ENGINE LAMP

CH EC K E NG INE CONTROL CI RCU IT SH ORTED TO VOLTAG E

C H E C K E N G I N E L AM P B U L B


INSTRUMENT CLUSTER

INSTRUMENT CLUSTER - LAMP NEVER ON

P OWER TRAIN C ONTROL MODU LE - CONTROL SH ORTED TO VOLTAG E

POWERTRAIN CONTROL MODULE - INTERNAL FAULT

CH ECK EN G I N E L AMP CO N TRO L CI RCU I T SH O RTED TO G RO U N D

CHECK EN GN I N E L AMP CO N T RO L CI RCU I T O PEN

POWERTRAIN CONTROL MODULE - CONTROL SHORTED TO GROUND


1 Tu r n t h e i g ni t i on on a n d ob s er v e t h e C h e ck E n g i n e L a m p .

Did the Check Engine Lamp illuminate for approximately 2 seconds then go out for

a bulb check?

All

Yes → G o To 2

No → G o To 1 0


Wit h t he D R B , a ct u a t e t he D ia g/G low P lu g L a mp .

Did t he Check E ngine L a mp il lu mina t e?

All

Yes → The Check Engine Lam p System is w orking properly.


No → G o To 3




M ea s u re t he volt a ge of t he C heck E ngine L a m p Cont rol circu it .


All

Yes → G o To 4

Above

G o To 6

Below

G o To 7

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Symptom:*CHECKING THE ECM AND PCM POWER AND GROUND CIR-CUITS

POSSIBLE CAUSES

ASD RE LAY OUTP UT CIRC UI T OPE N AT EC M

ASD RE LAY OU TP UT OPE N AT P CM

E C M G R O U N D C I R C U I T O P E N

F U S ED ASD B ATTERY SU P P LY CI RC U I T OP EN

F U S ED I G N I TI O N SWI TCH O U TP U T CI RCU I T O PE N

P CM B ATTERY SU P P LY CI RC U I T OP EN

P C M G R O U N D C I R C U I T O P E N




U s ing a 12-volt t es t l ight connect ed t o 12-volt s , check b ot h of t he E CM ground

circuits in ECM harness connector C1 cavities 1 and 27.

Did t he t es t l ight i l lu mina t e for b ot h ca vit ies ?

All

Yes → G o To 2

No → Repair the E CM G round circuit(s) for an open.



Disconnect the ECM harness connectors.Turn the ignition on.

U s ing a 12-volt t es t l ight connect ed t o grou nd, check t he Fu s ed I gnit ion Sw it ch

Output circuit in ECM harness connector C1 cavity 47.


All

Yes → G o To 3

No → R epa ir t he Fu s ed I gnit ion S wit ch Ou t p u t circu it for a n open.




Using a 12-volt test light connected to ground, check the F used ASD B at tery S upply

circuit in ASD/Diesel P ower R elay connector cavity 30.


All

Yes → G o To 4

No → R epa ir t he Fu s ed ASD B a t t ery S u p ply circu it for a n open.


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Connect a jump er wire b et ween ca vit y 30 a nd ca vit y 87 in t he A SD/Dies el P owerRelay connector.

Using a 12-volt test light connected to ground, check the ASD Relay Output circuit in

ECM harness connector C1 cavities 2 and 28.

Did t he t es t l ight i l lu mina t e for b ot h circu it s ?

All

Yes → G o To 5

No → Repair th e ASD Relay Out put circuit(s) for an open.


5 D i s con n e ct t h e P C M h a r n e s s c on n e ct o rs .

Using a 12-volt test light connected to ground, check the P CM B at tery S upply circuit

in PCM harness connector C1 cavity 22.


All

Yes → G o To 6

No → R epa ir t he P C M B a t t ery Su p p ly circu it (s ) for a n open.


6 D i s con n e ct t h e P C M h a r n e s s c on n e ct o rs .

Using a 12-volt test light connected to 12-volts, check both PCM Ground circuits in

PCM harness connector C1 cavities 31 and 32.

Did t he t es t l ight i l lu mina t e for b ot h ca vit ies ?

All

Yes → G o To 7

No → Repair the P CM G round circuit(s) for an open.


7 Tu r n t h e i gn it i on of f.Remove the ASD /Diesel Pow er Relay from the P DC .



Relay connector.

Using a 12-volt t est light connected to ground, check the ASD Relay Output circuit in

P C M ha rnes s connect ors C1 ca vit y 2 a nd C 3 ca vit y 12.

Did t he t es t l ight i l lu mina t e for b ot h circu it s ?

All

Yes → Test Complete.

No → Repair th e ASD Relay Out put circuit(s) for an open.


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*CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS —Continued

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Symptom:*CHECKING THE ELECTRIC RADIATOR FAN OPERATION

POSSIBLE CAUSES

ACTUATE THE RADIATOR FAN RELAY WITH THE DRB

CHECK FOR FAN CONTROL DTCS

RADIATOR FAN RELAY - SHORTED

RADIATOR FAN RE LAY OU TP U T CIRC U IT SH ORTED TO VOLTAGE

F U S E D B + C I R C U I T O P E N

SUBSTITUTE RADIATOR FAN RELAY

RADIATOR FAN REL AY OUTP UT CI RCU IT OPE N

RADIATOR FAN GROUND CIRCUIT OPEN

RADIATOR FAN - OPEN



Wit h t he DR B , check for E C M Fa n C ont rol DTCs .

Are a ny Fa n Cont rol DTCs p res ent ?

All

Yes → R efer t o s ymp t om lis t for p rob lems rela t ed t o t he F a n Cont rol

DTCs.


No → G o To 2

2 Tu rn t h e ig ni ti on on .Wit h t he DR B , a ct u a t e t he R a dia t or Fa n R ela y a nd ob s erve t he R a dia t or Fa n.

Did t he R a dia t or Fa n cycle on a nd off?

All

Yes → The test is complete.


R a dia t or Fa n inop era t ive

G o To 3

R a d i a t o r F a n a l w a y s o n

G o To 8


R emove t he R a dia t or Fa n R ela y from t he P DC.

Using a 12-volt test light connected to ground, check the Fu sed B+ circuit .

Did t he t es t l ight i l lu mina t e b right ly?

All

Yes → G o To 4

No → R epa ir t he Fu s ed B + circu it for a n open.


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Symptom:*CHECKING THE ENGINE COOLANT TEMPERATURE SENSORCALIBRATION

POSSIBLE CAUSES

EC T SE N SO R - CO L D

EC T SE N SO R - HO T


1 NOTE: The thermostat must be operating correctly for this test to be valid.Wit h t he DR B , rea d a nd not e t he engine coola nt t emp era t u re.

U s ing a t emp era t u re p rob e, mea s u re t he engine b lock t emp era t u re nea r t he E CT

Sensor.

Are t he rea dings w it hin 7° C (13° F) of ea ch ot her?

All

Yes → G o To 2

No → Replace the En gine Coolant Temperatur e Sensor.


2 NOTE: The thermostat must be operating correctly for this test to be valid.S t a r t t h e e n g in e .

U s ing a t emp era t u re p rob e, mea s u re t he engine b lock t emp era t u re nea r t he E CT

Sensor. When the engine temperature reaches 75°C (180°F), use the DRB and read

the engine coolant temperature.

Are t he rea dings w it hin 7° C (13° F) of ea ch ot her?

All


No → Replace the En gine Coolant Temperatur e Sensor.


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Symptom:*CHECKING THE FUEL COMPUTER

POSSIBLE CAUSES

E C M - F U E L C O MP U TE R O U TP U T C I R C U I T

FU EL COMP OUP UT CIRCU IT SH ORTED TO VOLTAG E

F U E L C O MP U TE R O U TP U T C I R C U I T O P E N

F U E L C O MPU TER O U TP U T CI RCU I T SH O RT TO G RO U N D

O VERH EAD C O N SO L E

P C M

P C M - F U E L C O MP U TE R O U TP U T C I R C U I T





M e a s u r e t h e v o l t a g e o f t h e F u e l C o m p u t e r O u t p u t c i r c u i t a t t h e E C M h a r n e s s

connector.


All

Yes → G o To 2

B elow 4.5 volts

G o To 4

Above 5.5 volts

Repair the Fuel Computer Output circuit for a short to voltage.





Connect a ju mp er wire b et ween grou nd a nd E CM ha rnes s connect or C1 ca vit y 18

while observing the Overhead Fuel Computer.

Did t he Overhea d Fu el Comp u t er s t a t u s cha nge?

All

Yes → R epla ce t he E CM in a ccorda nce wit h t he Service I nforma t ion.


No → G o To 3


Disconnect the ECM harness connectors.Turn the ignition on.

Connect one end of a ju mp er wire t o E CM ha rnes s connect or C1 ca vit y 18 while

observing the Overhead Fuel Computer.

Wit h t h e DR B , s elect B ody S ys t em a nd monit or P C I B u s I nfo while connect ing a nd

disconnecting the other end of the jumper wire to ground.

Does t he DR B dis p la y a cha nge in Fu el Comp u t er St a t u s ?

All

Yes → R ep la ce t he Overhea d Cons ole in a ccorda nce wit h t he Service

Information.



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Dis connect t he P CM a nd E CM h a rnes s connect ors .

M ea s u re t he res is t a nce of t he Fu el Compu t er Ou t p u t circu it b et ween t he E CM a nd

PCM harness connectors.Is the resistance below 10.0 ohms?

All

Yes → G o To 5

No → Repair the Fuel Computer Output circuit for an open.



Dis connect t he P CM a nd E CM h a rnes s connect ors .

M ea s u re t he res is t a nce b et ween ground a nd t he Fu el C ompu t er Ou t p u t circu it .


All

Yes → Repair the Fuel Computer Output circuit for a short to ground.


No → R epla ce t he P CM in a ccorda nce wit h t he Service I nforma t ion.Perform ROAD TEST VERIFICATION - VER-2.

182


*CHECKING THE FUEL COMPUTER — Continued

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Symptom:*CHECKING THE FUEL HEATER OPERATION

POSSIBLE CAUSES

FU EL HE ATER REL AY

F U E L HE ATER REL AY O U TP U T CI RCU I T OP EN

FU EL HE ATER RES IS TANCE


G R O U N D C I R C U I T O P E N

IGNITION SWITCH OUTPUT CIRCUIT OPEN

REL AY GRO U N D CI RCU I T O PE N



Disconnect the Fuel Heater harness connector.


Using a 12-volt test light connected to ground, check the Fuel Heater Relay Output

circuit at the Fuel Heater harness connector.


All

Yes → G o To 2

No → G o To 4




Using a 12-volt test light connected to 12-volts, check the G round circuit at the F uel

Heater harness connector.


All

Yes → G o To 3

No → Repair the G round circuit for an open.





With t he DRB , read the F uel Temperatur e Sensor.

NOTE : The Fuel temperature must be below 4.5°C (40°F).

M ea s u re t he res is t a nce of t he Fu el H ea t er .I s t he res is t a nce b et ween 0. 7 a nd 2.0 ohms ?

All


No → R epla ce t he Fu el Hea t er .


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I ns t a ll a s u b st it u t e rela y in p la ce of t he Fu el Hea t er R ela y.


Turn the ignition on.Using a 12-volt test light connected to ground, check the Fuel Heater Relay Output

circuit.


All

Yes → R epla ce t he init ia l Fu el Hea t er R ela y.


No → G o To 5


R emove t he Fu el Hea t er R ela y.



All

Yes → G o To 6






U s ing a 12-volt t es t l ight connect ed t o grou nd, check t he I gnit ion Swit ch Ou t p u t

circuit.


All

Yes → G o To 7

No → R epa ir t he I gnit ion S wit ch Ou t p u t circu it for a n open.





Using a 12-volt test light connected to 12-volts, check the G round circuit at the F uel

Heater Relay connector.


All

Yes → R epa ir t he Fu el Hea t er R ela y Ou t p u t circu it for a n op en.




184


*CHECKING THE FUEL HEATER OPERATION — Continued

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Symptom:*CHECKING THE FUEL I NJ ECTION PUMP

POSSIBLE CAUSES

CHECK I N G T HE F U EL I N J ECT I O N PU MP


1 NOTE : This test should beperformed before replacing theE CM during faultcode diagnostics.NOTE : This test checks for shorted circuits internal to the Fuel InjectionPump assembly.Turn the ignition off.

Disconnect the Fuel Injection Pump 10-way harness connector.

NOTE: The following resistance measurements are performed on the FuelInjection Pump 10-way harness connector (pump side). Resistanceon these

measurements should be greater than 100.0 ohms each.M ea s u re t he res is t a nce b et ween ca vit y 1 a nd ca vit ies 4, 5, 6, 7, 8, 9, 10 a nd ca s e

ground.

Measure the resistance between cavity 4 and cavities 5, 6, 8, 9, 10 and case ground.

M ea s u re t he res is t a nce b et ween ca vit y 5 a nd ca vit ies 6, 7, 8 a nd ca s e ground.

M ea s u re t he res is t a nce b et ween ca vit y 6 a nd ca vit ies 7, 8, 9 a nd 10.

M ea s u re t he res is t a nce b et ween ca vit y 7 a nd ca vit ies 8, 9, 10 a nd ca s e ground.

Is the resistance below 100.0 ohms for any of the measurements?

All

Yes → Replace the Fuel Injection Pum p Assembly in accordance with t he




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Symptom:*CHECKING THE FUEL LEVEL GAUGE OPERATION

POSSIBLE CAUSES


F U E L L E VE L S E N S O R S I G N AL C I R C U I T O P E N

F U EL L EV EL SEN SO R SI GN AL CI RCU I T SHO RT ED T O GRO U N D

F U EL L EV EL SEN SO R SI GN AL CI RCU I T SHO RT ED T O SEN SO R GRO U N D

INSTRUMENT CLUSTER



With t he DRB , perform t he Inst rument Cluster S elf Test.

NOTE: The 5 calibration points are: #1 Empty Stop, #2 Empty, #3 1/2 Full, #4Full, #5 Full Stop.Ob serve t he ga u ge du ring t he Self Tes t a nd compa re t he rea dings wit h t he rea dings

described in the NOTE.

NOTE: With the DRB ensure there are no PCM Fuel L evel Sensor DT Cs. If there are DTC s, they must be repaired before continuing.Did t he ga u ge rea ch t he p rop er ca lib ra t ion p oint s ?

All

Yes → G o To 2

No → R epla ce t he I ns t ru ment Clu s t er.





M ea s u re t he res is t a nce of t he Fu el L evel Sens or Signa l circu it .


All

Yes → G o To 3

No → Repair the Fuel Level Sensor Signal circuit for a n open.





M ea s u re t he res is t a nce b et ween ground a nd t he Fu el L evel Sens or Signa l circu it .

Is t he resista nce below 1000.0 ohms?

All

Yes → Repair the Fuel Level Sensor Signa l circuit for a short t o ground.Perform ROAD TEST VERIFICATION - VER-2.

No → G o To 4

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M ea s u re t he res is t a nce b et ween Sens or G rou nd a nd t he Fu el L evel Sens or Signa lcircuit.

Is t he resista nce below 1000.0 ohms?

All

Yes → Repair the Fuel Level Sensor Signa l circuit for a sh ort to Sensor

G rou nd.


No → G o To 5


Completely drain the fuel tank. Refer to Service Information for proper procedure.

NOTE: It is necessary to know the fuel tank capacity for this test.F i ll t h e f u e l t a n k t o 1 /4 o f i t s ca p a c it y t h e n t u r n t h e i g ni t i on on a n d n ot e t h e

ins t ru ment clu st er fu el ga u ge rea ding.

Turn the ignition off.F i ll t h e f u e l t a n k t o 3 /4 o f i t s ca p a c it y t h e n t u r n t h e i g ni t i on on a n d n ot e t h e

ins t ru ment clu st er fu el ga u ge rea ding.

Does t he Fu el G a u ge rea d t he fu el t a nk levels a ccu ra t ely?

All


No → Replace the Fuel Level Sensor.


187


*CHECKING THE FUEL LEVEL GAUGE OPERATION — Continued

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Symptom:*CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION

POSSIBLE CAUSES

F U E L TEMP ERATU RE SE N SO R - CO L D

F U E L TEMP ERATU RE SE N SO R - HO T


1 D i s con n e ct t h e F u e l H e a t e r h a r n e s s con n e ct o r.

Wit h t he DR B , monit or t he engine coola nt t emp era t u re a nd fu el t emp era t u re.

St a rt a nd idle t he engine u nt il engine t emp era t u re rea ches 70° C (160° F) .

NOTE: If the engine temperature is above 70°C (160°F), allow the engine tocool down to 70°C (160°F).Is the fuel temperature between 20°C (70°F) and 50°C (120°F)?

All

Yes → G o To 2

No → Replace the Fuel Injection Pum p Assembly in accorda nce with th e



2 D i s con n e ct t h e F u e l H e a t e r h a r n e s s con n e ct o r.

Wit h t he DR B , monit or t he engine coola nt t emp era t u re a nd fu el t emp era t u re.

St a rt a nd idle t he engine u nt il engine t emp era t u re rea ches 70° C (160° F) .

NOTE: If the engine temperature is above 70°C (160°F), allow the engine tocool down to 70°C (160°F).St a rt t he engine a nd a llow engine t o rea ch opera t ing t emp era t u re of 90° C (195° F) .

Does t he Fu el Tempera tur e increa se smoothly to 40-60°C (100-140° F)?

All


No → Replace the Fuel Injection Pum p Assembly in accorda nce with th e



188


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Connect a jump er wire b et ween grou nd a nd t he G low P lu g L a mp C ont rol circu it inthe ECM C1 harness connector.

I s t h e G l o w P l u g L a m p on ?

All




No → G o To 6





Connect a jum per wire betw een ASD/Diesel P ower Rela y connector cavit ies 30 and 87

(in PDC).Turn the ignition on.

M ea s u re t he volt a ge of t he G low P lu g L a mp Cont rol circu it .


All

Yes → G o To 7

No → Repair the Glow P lug Lamp Control circuit for a short to volta ge.





M ea s u re t he res is t a nce of t he G low P lu g L a mp Cont rol circu it .


All

Yes → G o To 8

No → R epa ir t he G low P lu g L a mp Cont rol circu it for a n op en.





Measure the voltage of the Ignition Feed circuit .


All

Yes → G o To 9

No → R ep a ir t he I gnit ion Feed circu it t o t he M es s a ge Cent er for a n

open.



R emove a nd ins pect t he G low P lu g L a mp b u lb from t he M es s a ge Cent er .

I s t he b u lb OK?

All





190


*CHECKI NG THE GLOW PLUG L AMP OPERATION — Continued

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7/26/2019 01XJED





Disconnect the Low Coolant Switch harness connector.

M ea s u re t he res ist a n ce bet ween grou nd a nd t he L ow Coola nt Sw it ch Signa l circu it .Is the resistance above 100 kohms?

All

Yes → G o To 4

No → R e pa i r t h e L o w C ool a n t S w i t c h S i g n a l c i r cu i t f or a s h or t t o

ground.





M ea s u re t he res is t a nce b et ween t he L ow Coola nt Swit ch Signa l circu it a nd Swit ch

Ground circuit .


All

Yes → G o To 5

No → R epa ir t he L ow Coola nt S wit ch Signa l a nd S wit ch G rou nd circu it





Turn t he ignition on a nd w ait 30 seconds.

I s t he L ow Coola nt L a mp on?

All

Yes → R epla ce t he L ow Coola nt S wit ch.


No → G o To 6


Repair






Turn t he ignition on and observe the Low Coolan t La mp.

Did t he L ow Coola nt L a mp il lu mina t e a nd s t a y on cont inu ou sly?

All

Yes → G o To 8

No →

G o To 9

193


*CHECKI NG THE LOW COOLANT LAMP OPERATION — Continued

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7/26/2019 01XJED




Connect a 8.3 B a r (120 P SI ) oil p res s u re ga u ge t o t he engine.

S t a r t t h e e n g in e .

Observe the mechanical oil pressure gauge.Is the engine oiling system functioning properly?

All

Yes → G o To 5

No → R epa ir t he engine oil ing s ys t em in a ccorda nce wit h t he S ervice

I nforma t ion.



Disconnect the Engine Oil Pressure Sensor harness connector.


Measure the voltage of the 5-volt Supply circuit in the Engine Oil Pressure Sensor

ha rness connector.


All

Yes → G o To 6

No → G o To 8



M ea s u re t he volt a ge on t he Sens or G rou nd circu it .


All

Yes → Replace the Eng ine Oil Pressure Sensor.


No → G o To 7


Disconnect the Engine Oil Pressure Sensor harness connector.Disconnect the PCM harness connectors.


M ea s u re t he volt a ge of t he S ens or G rou nd circu it .


All




No → R epa ir t he Sens or G rou nd circu it for a s hort t o volt a ge.




Disconnect the PCM harness connectors.Measure the resistance between ground and the 5-volt Supply circuit .


All

Yes → G o To 9



197


*CHECKING THE OIL PRESSURE GAUGE OPERATION — Continued

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M ea s u re t he res is t a nce b et ween t he 5-volt Su p p ly circu it a nd t he Sens or G rou ndcircuit in the Engine Oil Pressure Sensor harness connector.


All

Yes → G o To 1 0


circuit.





Measure the resistance of the 5-volt Supply circuit between the Engine Oil Pressure

Sens or ha rnes s connect or a nd t he P CM C1 ha rnes s connect or.


All

Yes → G o To 11




Repair




198


*CHECKING THE OIL PRESSURE GAUGE OPERATION — Continued

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7/26/2019 01XJED



4 Wi t h t h e D R B , m on i t or Ve h ic le S pe ed in t h e P C M S e n s or D i sp la y m e n u .

Test drive t he vehicle and observe the Vehicle Speed on t he D RB .

Compare the DRB reading with the vehicle’s Speedometer.

Are t he rea dings w ithin 5 km/h (3 MPH ) of each other?

All

Yes → The Speedometer Syst em is working properly.


No → G o To 5

5 Wi t h t h e D R B , s el ec t B O D Y f r om t h e S y s t e m s m e n u, E L E C TR O /M E C H I N S TR U -

M E N T CL U STE R , M ON I TOR DI S P L AY, t hen CC D B U S E N G I N E I N FO.

Monitor Vehicle S peed wh ile driving the vehicle.

Does the Vehicle Speed Sensor reading increase with vehicle speed?

All

Yes → R epla ce t he I ns t ru ment Clu s t er in a ccorda nce wit h t he S ervice

Information.


No → R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-da nce wit h t he S ervice I nforma t ion.





Measure t he voltage of th e 5-volt Supply circuit in the Vehicle Speed Sensor h ar ness

connector.


All

Yes → G o To 7

No → G o To 1 2






Measure the voltage between ground and Vehicle Speed Sensor harness connector

cavities 1, 2, and 3.

Is the voltage below 1.0 volt on each circuit?

All

Yes → G o To 8

No → R e pa i r t h e c i r cu i t t h a t m e a s u re d a b ov e 1 .0 v o lt f or a s h or t t o

voltage.


200


*CHECKING THE SPEEDOMETER OPERATION — Continued

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Disconnect the Vehicle S peed Sensor ha rness connector.Measure t he resista nce betw een ground a nd Vehicle Speed Sensor ha rness connector

cavities 1, 2, and 3.

Is the resistance above 100 kohms on each circuit?

All

Yes → G o To 9

No → Repair the circuit tha t mea sured below 100 kohms for a short to

ground.






M ea s u re t he res is t a nce b et ween V SS ha rnes s connect or ca vit y 1 a nd ca vit ies 2 a nd3, t hen b et ween ca vit y 2 a nd 3.

Is the resistance above 100 kohms for each measurement?

All

Yes → G o To 1 0

No → R ep a ir t he circu it t ha t mea s u red b elow 100 kohms for a s hort

together.





Measure the resistance of the Vehicle Speed Sensor Signal circuit .

Measure the resistance of the Vehicle Speed Sensor Ground circuit .


All

Yes → G o To 11

No → Repair the circuit that measur ed above 5.0 ohms for an open.



Yes → Replace the Vehicle Speed S ensor.





Check connectors - Clean/repair as necessary

Measure the resistance of the 5-volt Supply circuit between the Vehicle Speed Sensor

ha rnes s connect or a nd t he P C M C 2 ha rnes s connect or.


All






201


*CHECKING THE SPEEDOMETER OPERATION — Continued

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7/26/2019 01XJED


Symptom:*CHECKING THE TURBOCHARGER BOOST PRESSURE SENSORCALIBRATION

POSSIBLE CAUSES

TU RB O CHARGE R B O O ST P RESS U RE SEN S O R CAL I B RATI O N



With the DRB, select Engine, Bosch then Sensors. Read the Boost Pressure Voltage.

Is the Boost Pressure Voltage between 1.70 and 1.95 volts?

All


No → Replace the Turbocha rger B oost P ressure Sensor.


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Symptom:*CHECKI NG THE TURBOCHARGER OPERATION

POSSIBLE CAUSES

C H E C K I N G TH E TU R B O C H AR G E R H O S E S

CH EC KI NG THE WASTEG ATE H OSE

T U RB O CHARGER

WASTE G ATE ACTU ATOR ARM OP E RATIO N

WASTE G ATE RE S TRI C TIO N


1 NOTE: The exhaust system must befree from any restriction toperform thistest.

C h e ck t h e t u r b oc ha r g e r ou t l et h os e b e t w e en t h e t u r b oc ha r g e r a n d t h e i n t a k e

m a n i f o l d a n d t h e t u r b o c h a r g e r i n l e t h o s e b e t w e e n t h e t u r b o c h a r g e r a n d t h e a i r

clean er for loose connection, da ma ge or rest riction.

Are any of these conditions evident?

All

Yes → Repair or replace as necessary.


No → G o To 2

2 Check t he wa s t ega t e a ct u a t or s u p ply hose for loos e connect ion, da ma ge or res t r ict ion.

Are any of these conditions evident?

All



No → G o To 3

3 Dis connect t he Wa s t ega t e Act u a t or Su p p ly Hos e from t he int a ke ma nifold.

U s ing a n a ir p ress u re regu la t or, connect a n a ir hose t o t he dis connect ed end of t he

Wast egat e Actuat or Supply H ose.

S t a r t a t 0 k P a (0 P S I ) a n d s l ow l y i n c r ea s e a i r p r es s ur e t o 3 10 k P a (45 P S I ) w h i le

monitoring th e Wast egat e Actuat or Arm.

NOTE : The WastegateActuator Arm should remain closed until air pressurereaches 117-138 kPa (17-20 PSI) and fully open when the air pressurereaches 234-276 kPa (34-40 PSI).Did t he Wast egat e Actuat or unseat a nd fully open a s described?

All

Yes → G o To 4

No → G o To 5

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7/26/2019 01XJED



4 Connect a n a ir pres s ure ga u ge in-line wit h t he Wa s t ega t e Act u a t or Su p p ly Hos e.

NOTE: Air pressure gauge must be rated above 276 kPa (40 PSI).NOTE: The vehicle must be on flat level ground to perform this test.Failure

todrivevehicle on flat level ground could result in incorrect boost pressurereadings.NOTE: FIRST GEAR - The following numbers are a comparison of BoostPressure and E ngine Speed (PSI/RPM) for the First Gear test: 21 kPa (3PSI)/1500rpm - 28 kPa (4PSI)/2000rpm - 48 kPa (7 PSI)/2500rpm - 69 kPa (10PSI)/3000rpm - 90 kPa (13 PSI)/3500rpmNOTE: SECOND GEAR - The following numbers are a comparison of BoostPressure and Engine Speed (PSI/RPM) for the Second Gear test: 28 kPa (4PSI)/1500rpm - 28 kPa (4PSI)/2000rpm - 48 kPa (7PSI)/2500rpm - 76 kPa (11PSI)/3000rpm - 97 kPa (14 PSI)/3500rpmTes t drive t he vehicle in Firs t gea r . I ncrea s e engine R P M in 500 R P M increment s

slowly u ntil engine speed is 3500 RP M. Note the Air P ressure Ga uge reading a t ea ch

500 R P M increment . R ep ea t t his s t ep w it h t he vehicle in S econd G ea r.

Compa re t he t wo s et s of rea dings t o t he a p propria t e G E AR N OTE .

Do the Air P ressure Ga uge readings m at ch the values indicat ed in the NOTE [00b1]14 kP a (2 P S I )?

All


No → Replace the Turbocha rger Assembly in accorda nce with t he Ser-

vice Information.


5 R emove t he E -clip a nd dis connect t he Wa s t ega t e Act u a t or R od from t he Wa s t ega t e

Actuat or Arm.

Manu ally move the Wast egat e Actuat or Arm from closed to fully open.

Does the Wast egat e Actuat or Arm m ove easily wit hout restr iction?

All

Yes → R epla ce t he Wa s t ega t e Act u a t or in a ccorda nce wit h t he S ervice

Information.


No → Clea n Wa s t ega t e Act u a t or Arm or Wa s t ega t e Act u a t or Sha ft a s

necessar y. I f OK , r eplace Turbocha rger Assembly in accorda nce



206


*CHECKI NG THE TURBOCHARGER OPERATION — Continued

7/26/2019 01XJED


Symptom:*CHECKING THE VEHICLE SPEED SIGNAL

POSSIBLE CAUSES

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T S H O R TE D TO S E N S O R G R O U N D

CHECK F O R V SS D T C

P OWERTRAIN CONTROL MOD UL E - 5-VOLT SU P P LY H IG H

P OWER TRAIN CONTROL MODU LE - AFTER 5-VOLT SUP P LY SH ORTE D TO VOLTAG E

REPAI R THE 5-VO LT SU P P LY CI RCU I T AN D CHE CK THE P CM

5-VO LT SU P P LY CI RC U I T O PE N

P OWER TRAIN C ONTROL MODU LE - SHOR TED TO VOLTAG E

SPEEDOMETER PINION AND DRIVE TEETH DAMAGED

VEH I CL E SP EE D S EN SO R S I G N AL CI RC U I T SH O RTED TO 5-VO LT SU P P LY CI RCU I T


EN G INE CONTROL MOD U LE - SH ORTED TO VOLTAG E

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T O P E N

5-VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND

VE H I C L E S P E E D S E N S O R S I G N AL C I R C U I T S H O R TE D TO G R O U N D

VEH I CL E SP EE D SEN S O R SI G N AL CI RCU I T SH O RTED TO V OL TAGE

P OWERTRAIN CONTROL MOD UL E - 5-VOLT SU P P LY C IRC UI T LOW


VE H I C L E S P E E D S E N S OR

ENG INE CONTROL MODU LE - INTERNAL FAULT



With the DRB, select Engine, J TEC then Sensors.

Note the Vehicle Speed reading on the DRB while test driving the vehicle.

Does t he DR B dis pla y a n a ccura t e vehicle s peed rea ding?

All


No → G o To 2



Are any VSS DTCs present?

All

Yes → Refer to symptom list for problems relat ed to VSS DTCs.


No → G o To 3

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Note: Check connectors - Clean/repair as necessary.Remove the ASD /Diesel Pow er Relay from the P DC .





All

Yes → G o To 8





Repair

R ep a i r t h e Ve h icl e S p ee d S e n s or S i g n a l c ir cu i t f or a s h or t t o

voltage.




Dis connect t he P CM C 1 a nd C2 ha rnes s connect ors .




All

Yes → G o To 1 0







Note: Check connectors - Clean/repair as necessary.Measure the resistance of the Vehicle Speed Sensor Signal circuit .


All

Yes → G o To 11

No → Repair th e Vehicle Speed Sensor Signa l circuit for an open.


11 Tu r n t h e i g ni t i on of f .



Note: Check connectors - Clean/repair as necessary.Measure th e resistance between ground a nd t he Vehicle Speed Sensor Signa l circuit .


All

Yes → G o To 1 2

No → R epa ir t he Vehicle Sp eed S ens or Signa l circu it for a s hort t o

ground.


209


*CHECKING THE VEHICLE SPEED SIGNAL — Continued

7/26/2019 01XJED






Note: Check connectors - Clean/repair as necessary.Measure the resistance of the Vehicle Speed Sensor Ground circuit .


All

Yes → G o To 1 3

No → Repair t he Vehicle Speed Sensor G round circuit for an open.




NOTE: Ensure the ECM and PCM harness connectors are connected beforecontinuing.Turn the ignition on.

Connect a jumper w ire to the Vehicle Speed Sensor Signa l circuit in t he VSS h ar ness

connector.Wi t h t h e D R B , m on i t or t h e V E H I C L E S P E E D w h i l e t a p pi n g t h e o t h er e n d of t h e

jumper wire to ground.

Does t he DR B dis pla y km/h (M P H ) grea t er t ha n 0?

All

Yes → Replace the Vehicle Speed Sensor.


No → G o To 1 4





Sensor Ground circuit .Is the resistance above 100 kohms?

All

Yes → G o To 1 5





Repair










All

Yes → R ep la ce a nd p rogra m t he P owert ra in Cont rol M odu le in a ccor-



No → G o To 1 7

210



7/26/2019 01XJED




Repair the 5-volt Supply circuit for a short to voltage.

Reconnect all harness connectors except the Vehicle Speed Sensor harness connector.

Turn the ignition on.Measure the voltage of the 5-volt Supply circuit .


All

Yes → The repair is complete.








Check connectors - Clean/repair as necessary

Measure the resistance of the 5-volt Supply circuit between the Vehicle Speed Sensorha rnes s connect or a nd t he P C M C 1 ha rnes s connect or.


All

Yes → G o To 1 9






Check connectors - Clean/repair as necessaryMeasure the resistance between ground and the 5-volt Supply circuit .


All

Yes → G o To 2 0






Check connectors - Clean/repair as necessaryM ea s u re t he res is t a nce b et ween t he 5-volt Su p p ly circu it a nd t he Sens or G rou nd

circuit in t he Vehicle S peed Sensor h ar ness connector.


All

Yes → G o To 2 1

No → Repair the 5-volt Supply circuit for a sh ort to the Sensor Groundcircuit.



Repair




211



7/26/2019 01XJED


Symptom:*CHECKI NG THE WATER IN FUE L LAMP OPERATION

POSSIBLE CAUSES

MESSAGE CEN T ER

P C M

P CM - WATER I N F U E L S I G N AL C I RCU I T

S E N S O R G R O U N D O P E N

WATER IN F UE L LAMP B UL B

WATER I N F U E L S EN O R S I G N AL C I RCU I T O PE N

WATER IN FU EL SE NSOR

WATER IN FU EL S ENS OR SIG NAL CIR CU IT SH ORTED TO GR OUND

WATER I N F U E L S EN SO R SI G N AL C I RCU I T SHO RTED TO SE N SO R G RO U N D


1 NOTE: Be sure a water in fuel condition does not exist before continuing.Turn t he ignition on while monitoring th e Wat er In F uel Lam p.

Choos e t h e a p propria t e a ns w er.

All

The la mp t u rns on a nd s t a ys on.

G o To 2

The lamp turns on for 2 seconds then off

G o To 5

The la mp does not t u rn on a t a l l .G o To 8


Disconnect t he Wat er In Fuel S ensor ha rness connector.

Turn t he ignition on w hile observing th e Wat er In Fuel La mp.

Does t he Wa t er I n Fu el L a mp t u rn on a nd s t a y on?

All

Yes → G o To 3

No → Replace the Wat er In Fuel Sensor





Measure the resista nce between engine ground and t he Wat er In Fuel Sensor Signa l

circuit.


All

Yes → G o To 4

No → R e pa i r t h e Wa t e r I n F u el S e n sor S i g n a l c i rcu i t f o r a s h or t t o

ground.


212


7/26/2019 01XJED






M ea s u re t he res is t a nce b et w een t he Sens or G r ound circu it a nd t he Wa t er I n Fu elSensor Signal circuit .


All

Yes → R ep la c e a n d p r og r a m t h e P C M i n a c cor d a n c e w i t h t h e S e r v ice

Information.


No → R epa ir t he Wa t er I n Fu el Sens or S igna l circu it for a s hort t o t he






Connect a jumper w ire across the Wat er In F uel Sensor ha rness connector cavities 1a n d 2 .

Ob serve t he Wa t er I n Fu el L a m p .

I s t he la mp on?

All


No → G o To 6




M ea s u re t he res is t a nce of t he Wa t er I n Fu el Sens or Signa l circu it .


All

Yes → G o To 7

No → Repair the Wat er In Fuel Sensor Signa l circuit for an open.




M ea s u re t he res is t a nce of t he Sens or G rou nd circu it .


All

Yes → R ep la c e a n d p r og r a m t h e P C M i n a c cor d a n c e w i t h t h e S e r v ice

Information.


No → Repair the Sensor Gr ound circuit for an open.



Remove and inspect the Wat er In F uel Lam p bulb.

I s t he b u lb OK?

All



No → R epla ce t he Wa t er I n Fu el L a mp B u lb .


213


*CHECKI NG THE WATER I N FUEL LAMP OPERATION — Continued

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7/26/2019 01XJED




Remove the A/C Compressor C lutch Rela y from the P DC .


Using a 12-volt Test L ight connected t o ground, check th e ASD /Diesel P ower Rela yOutput circuit .

Did t he t es t l ight i l lu mina t e b right ly?

All

Yes → G o To 4

No → Repair t he ASD /Diesel Power R elay Out put circuit for a n open.



Insta ll a substitut e relay in place of the A/C C ompressor Clutch Rela y.


With the D RB , a ctuat e the A/C Compressor C lutch Rela y.

Is t he A/C Compressor Clut ch clicking?

All

Yes → Replace th e A/C C ompressor Clut ch Relay.


No → G o To 5




M ea s u re t he res is t a nce b et ween ground a nd t he A /C Compres s or Clu t ch R ela y

Control circuit .


All

Yes → G o To 6

No → R epa ir t he A /C Compres s or Clu t ch R ela y Cont rol circu it for a

short to ground.





Measure the resistan ce of the A/C Compressor Clutch Relay Control circuit .


All

Yes → G o To 7

No → Repair t he A/C C ompressor C lutch Relay Control circuit for a n

open.



Repair




215

HEATING & A/C

P1655-AC CONTROL OPEN CI RCUIT - DIESEL — Continued

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7/26/2019 01XJED




Insta ll a substitut e relay in place of the A/C C ompressor Clutch Rela y.


With the D RB , a ctuat e the A/C Compressor C lutch Rela y.Is t he A/C Compressor Clut ch clicking?

All

Yes → Replace th e A/C C ompressor Clut ch Relay.


No → G o To 4







Measure the volta ge of th e A/C Compressor C lutch Rela y Control circuit .


All

Yes → R epa ir t he A /C Comp res s or Clu t ch R ela y Cont rol circu it for a

short to voltage.


No → G o To 5


Repair




217

HEATING & A/C

P1655-AC CONTROL SHORT CI RCUIT - DIE SEL — Continued

7/26/2019 01XJED


Symptom:P1596-SPEED CONTROL SWITCH ALWAYS HIGH - DIESEL


P1596-SPEED CONTROL SWITCH ALWAYS HI GH - DIE SEL

When Monitored: With t he ignit ion on a nd ba t tery voltage a bove 10.4 volts.

Set C ondition: The P CM detects volta ge above 4.8 volts on the S/C sw itch signal circuit

for a t least 2 minutes.

POSSIBLE CAUSES

CH E CK IN G S/C ON /OFF -S E T S WITCH

P CM - S/C SI G N AL C I RCU I T O PE N

P CM - S/C SI G NAL CIR CU IT SH ORTED TO VOLTAG E

P C M - S E N S O R G R O U N D O P E N

S/C ON/OFF -SE T SWITCH SI G NAL CI RC U IT OPE N

S/C SWITCH SI G NAL CI RC U IT SHOR TED TO VOLTAG E

S E N S O R G R O U N D O P E N



Disconnect th e S /C O N/OFF -SE T butt on ha rness connector.

Turn the ignition on.Measure th e volta ge of the S/C S wit ch Signa l circuit .

Select t he a p propria t e volt a ge rea ding.

All

B elow 4.5 volts.

G o To 2

Between 4.5 and 5.5 volts.

G o To 3

Above 5.5 volts

G o To 5


Disconnect t he S /C ON /OFF -SE T Sw itch h ar ness connector.

Disconnect the PCM harness connectors.Measure th e resistance of the S/C S wit ch Signa l circuit .


All




No → Repair t he S/C ON/OFF-SET Switch S igna l circuit for a n open.


218

SPEED CONTROL

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7/26/2019 01XJED


Symptom:P1597-SPEED CONTROL SWITCH ALWAYS LOW - DIESEL


P1597-SPEED CONTROL SWITCH ALWAYS L OW - DIE SEL

When Monitored: With t he ignit ion on a nd ba t tery voltage a bove 10.4 volts.

Set C ondition: The P CM detects volta ge below 0.39 volt on the S/C sw itch signal circuit

for a t least 2 minutes.

POSSIBLE CAUSES


SP EE D CONTROL ON/OFF SWITCH

SP EE D CONTROL RE SU ME/ACC EL SWITCH

SPEED CONTROL SWITCH CONTROL CIRCUIT SHORTED TO SENSOR GROUND

SPEED CONTROL SWITCH CONTROL CIRCUIT SHORTED TO GROUND

P C M



Wit h t he DR B I I I, rea d t he S p eed Cont rol volt a ge.

Is the Speed Control voltage below 1.0 volts?

All

Yes → G o To 2

No → G o To 7


Wit h t he DR B I I I, monit or t he S p eed Cont rol Sw it ch volt a ge.

Disconnect t he S peed Control On /Off S wit ch ha rness connector.

Did the volt change to above 4.7 volts?

All

Yes → Replace the Speed Control On/Off Sw itch.


No → G o To 3


Wit h t he DR B I I I, monit or t he S p eed Cont rol Sw it ch volt a ge.

Disconnect the Speed Control Resume/Accel S wit ch h ar ness connector.

Did the volt change to above 4.7 volts?

All

Yes → Replace the S peed Control Resume/Accel Sw itch.


No → G o To 4

220

SPEED CONTROL

7/26/2019 01XJED






Disconnect the PCM harness connector.M ea s u re t he res is t a nce b et ween t he Sp eed Cont rol Swit ch circu it a nd t he Sens or

ground circuit in the PCM harness connector.


All

Yes → Repair the Speed Control Swit ch Signal circuit shorted to Sensor

ground circuit .


No → G o To 5




Disconnect the PCM harness connector.

M ea s u re t h e r es is t a n ce of t h e S p ee d C on t r ol S w i t ch ci rcu it i n P C M h a r n es sconnector t o ground.


All

Yes → Repair the Speed Control Swit ch Signal circuit shorted to ground.


No → G o To 6


Repair

R ep la ce t he P owert ra in Cont rol M odu le in a ccorda nce wit h t he














All




221

SPEED CONTROL

P1597-SPEED CONTROL SWITCH ALWAYS LOW - DIESEL — Continued

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Symptom:*CHECKI NG THE SPEED CONTROL OPERATION

POSSIBLE CAUSES

BRAKE LAMP SWITCH - PRIMARY CIRCUIT

BRAKE LAMP SWITCH - SECONDARY CKT

CHECKING BRAKE LAMP SWITCH ADJ USTMENT

CH EC KING THE S/C LAMP OPE RATION

C H E C K I N G TH E V E H I C L E S P E E D S I G N AL

EC M - B RAK E S WI TCH SI G N AL

EC M - PRI MARY B RAK E S WI TCH CI RCU I T

EC M - S/C LAMP CONTROL

EC M - S/C SI G NAL

EC M - SP EE D CO N TRO L


G R O U N D C I R C U I T O P E N

P CM - S/C LAMP CONTROL

P RI MARY B RAK E S WI TCH SI G N AL C I RCU I T O PE N

PRIMARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND

S/C LAMP SI G NAL OP EN

S/C LAMP SI G NAL S HORTED TO G ROUND

S /C L AMP S IG NAL SH ORTE D TO VOLTAGE

S/C SWITCH SIG NAL C IRC UI T OPE N

S/C SWITCH SIG NAL C IRC UI T SH ORTED TO G ROUND

S /C SWITCH E S

SE CO N D ARY B RAK E S WI TCH SI G N AL CI RCU I T O PE N

SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND



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With the DRB, select Engine, Bosch Controller then Sensor Display.

Ob serve t he cru ise s wit ch volt s on t he DR B while p ress ing a n d holding ea ch cru ise

button separately.NOTE : Pressing each cruise button should result in the following voltages:ON/OFF 0.55- 1.15v, SET 3.15 - 3.6v, RE SUME/ACCEL 3.9- 4.15v, CANCEL 1.55- 2.05v, COAST 2.5 - 3.0v, No Button Pressed 4.4 - 4.7vDoes each switch provide the correct voltage?

All

Yes → G o To 2

No → G o To 2 3


With t he DR B, select E ngine, B osch a nd I nputs/Outputs.

Observe the B ra ke Switch input wh ile pressing and releasing the bra ke pedal several

times.

Does t he DR B indica t e t he correct cha nge of s t a t e from R elea s ed t o P res s ed?

All

Yes → G o To 3

No → G o To 1 9


With t he DR B, select E ngine, B osch a nd I nputs/Outputs.

Observe the B ra ke Switch input wh ile pressing and releasing the bra ke pedal several

times.

Does t he DR B indica t e t he correct cha nge of s t a t e from R elea s ed t o P res s ed?

All

Yes → G o To 4

No → G o To 1 4

4 Wit h t he DR B , s elect E ngine, t hen B os ch Cont roller a nd monit or t he Vehicle Sp eed

Signa l while t es t driving t he vehicle.Does the DRB display accurate vehicle speed?

All

Yes → G o To 5

No → R efer t o s ymp t om lis t for p rob lems rela t ed t o Vehicle S p eed

Sens or S igna l .


5 Drive t he vehicle a nd genera t e a vehicle s p eed a b ove 55 Km/h (35 mp h).

Attempt to set the speed control.

Did vehicle speed control maintain set vehicle speed?

All

Yes → G o To 6

No → G o To 1 2

6 Drive t he vehicle a nd genera t e a vehicle s p eed a b ove 55 Km/h (35 mp h).

Set the speed control and observe the Speed Control Lamp.

Does the Speed Control Lamp illuminate when speed control is on?

All


No → G o To 7

223

SPEED CONTROL

*CHECKING THE SPEED CONTROL OPERATION — Continued

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12 R efer t o a ny Technica l Service B u llet ins (TSB ) t ha t ma y a p ply t o t his condit ion.



Visually inspect t he relat ed w iring ha rness connectors. Look for broken, bent, pushedout, or corroded terminals.


All



No → G o To 1 3

1 3 C h e ck t h e b r a k e l a m p s w i t ch for pr op er a d ju s t m en t .

I s t he b ra ke la mp s wit ch a dju s t ed p rop erly?

All




No → Adjust or replace the brake lamp swit ch as necessar y.Perform SPEED CONTROL VERIFICATION - VER-4.




M ea s u re t he volt a ge of t he Seconda ry B r a ke Sw it ch Signa l circu it .


All

Yes → G o To 1 5

No → G o To 1 7


Disconnect the Brake Switch harness connector.

Wit h t he DR B , monit or t he b ra ke s wit ch inp u t .Connect a ju mp er wire b et ween t he B ra ke L a mp Sw it ch ha rnes s connect or ca vit ies

1 a nd 2.

Did t he D R B dis pla y cha nge from P res s ed t o R elea s ed?

All

Yes → Adjus t or repla ce t he B ra ke L a mp S wit ch.


No → G o To 1 6


M ea s u re t h e r es is t a n ce b et w e en g r ou n d a n d t h e B r a k e L a m p S w i t ch h a r n es s

connector cavity 2.


All

Yes →

R ep la ce a nd p rogra m t he E CM in a ccorda nce wit h t he ServiceI nforma t ion.




225

SPEED CONTROL


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M ea s u r e t h e r e si st a n c e o f t h e S e con d a r y B r a k e S w i t c h S i g n a l b e t w e en t h e B r a k eL a m p S w i t c h a n d t h e P C M .


All

Yes → G o To 1 8

No → R epa ir t he S econda ry B ra ke Sw it ch Signa l circu it for a n op en.





M e a s u r e t h e r e s i s t a n c e b e t w e e n g r o u n d a n d t h e S e c o n d a r y B r a k e S w i t c h S i g n a l

circuit.


All

Yes → R epa ir t he S econda ry B r a ke Sw it ch Signa l circu it for a s hort t o

ground.



I nforma t ion.





M ea s u re t he res is t a nce b et ween grou nd a nd t he P rima ry B ra ke Swit ch Sens e circu it .


All

Yes → R e p a i r t h e P r i m a r y B r a k e S w i t c h S i g n a l c i r c u i t f o r a s h o r t t o

ground.


No → G o To 2 0




M ea s u re t he res is t a nce of t he P rima ry B ra ke Swit ch Sens e circu it .


All

Yes → G o To 2 1

No → R epa ir t he P rima ry B ra ke Sw it ch Signa l circu it for a n op en.




U s ing a 12-volt t es t l ight connect ed t o grou nd, check t h e Fu s ed B + circu it a t t he

B ra ke L a mp Sw it ch ha rnes s connect or ..


All

Yes → G o To 2 2



226

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4 WARNI NG: The transmission must be in Neutral and the parking break must be engaged for this test.WARNING: The engine may be cranked in this test. Keep away from moving

engine parts.B r i e fl y c on n e ct a ju m p er w i r e b e t w e en t h e S t a r t e r R e la y O u t pu t c ir cu i t a n d t h e

Fu s ed B + circu it a t t he s t a rt er rela y connect or in t he P DC.

Did t he engine cra nk?

All

Yes → G o To 5

No → G o To 8


R emove t he St a rt er R ela y From t he P DC.

I ns t a ll a s u b st it u t e rela y in p la ce of t he St a rt er R ela y.

At t emp t t o s t a rt t he engine.

Does t he engine cra nk?

All

Yes → R epla ce t he St a rt er R ela y.

P erform NO START VERI FI CATION - VER -1.

No → G o To 6


Disconnect the Clutch Interlock Switch harness connector.

C on n e ct a ju m pe r w i r e b et w e e n t h e C l u t ch I n t e r loc k S w i t ch S e n s e c ir cu i t a n d

ground.

At t emp t t o s t a rt t he engine.

Does t he engine cra nk?

All

Yes → Repair the Clutch Int erlock Sw itch Sense circuit for an open.

P erform NO START VERI FI CATION - VER -1.

No → G o To 7

7 Check t he s hif t er a nd a s s ocia t ed l inka ge for p rop er a dju s t ment b et w een s hif t er a nd

t ra ns mis s ion.


All


P erform NO S TART VERI FI CATION - VER -1.

No → R e pl a ce t h e C l u t ch I n t e r lo ck S w i t c h i n a c co rd a n c e w i t h t h e


Perform NO START VERIFICATION - VER-1.


R emove t he St a rt er R ela y from t he P DC.

Dis connect t he St a rt er R ela y Ou t p u t w ire from t h e St a rt er Solenoid.

M ea s u re t he resis t a nce of t he St a rt er R ela y Ou t p u t circu it b et ween t he P D C a nd t heSt a rt er S olenoid.


All

Yes → G o To 9

No → R epa ir t he S t a rt er R ela y Ou t p u t circu it for a n open.


229

STARTING

*NO CRANK CONDITION — Continued

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Symptom:*NO START CONDITION

POSSIBLE CAUSES

CHECKING FUEL QUANTITY ACTUATOR

EC M - I MMO B I L I Z ER S I G N AL

EC M - I MMO B I L I Z ER S I G N AL O U TP U T

F U E L I N J EC TI O N P U MP TI MI N G

FU E L QU ANTITY ACTUATOR CI RC U IT SH ORT TO VOLTAGE

FU EL S U P P LY CONTAMINATION

F U E L S Y S TE M P R E S S U R E

FUEL SYSTEM RESTRICTION

I M M OB I L I Z E R S I G N AL C I R C U I T OP E N

I MMO B I L I Z ER S I G N AL C I RCU I T SH O RTED TO G RO U N D

IMMOBI LIZER SIG NAL C IRC UI T SH ORTED TO VOLTAG E

V ERI F YI N G I MMO B I L I Z ER SI GN AL


1 NOTE: Check for SKIM, ECM, and PCM DTCs. Return to the Symptom Listto diagnose any DTCs that are present before continuing.With the DRB, select Engine (J TEC), Miscellaneous and View SKIM Status.

While ob s erving t he D R B , a t t emp t t o s t a rt t he engine.

Does t he D R B dis pla y Fu el Shu t -Off Act iva t ed?

All

Yes → G o To 2

No → G o To 7



Disconnect the ECM harness connector.

R emove t he ASD R ela y from t he P DC.

Connect a jumper wire between ASD Relay connector cavity 30 and cavity 87 in the

P D C .


M ea s u re t he volt a ge of t he I mmob iliz er Signa l circu it .


All

Yes → Repair the Immobilizer Signa l circuit for a short to volta ge.P erform NO START VERI FI CATION - VER -1.

No → G o To 3

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STARTING

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M ea s u re t he res is t a nce of t he I mmob iliz er S igna l circu it b et ween t he P CM h a rnes sconnector and the ECM harness connector.


All

Yes → G o To 4

No → Repair the Imm obilizer Signal circuit for an open.





M ea s u re t he res is t a nce b et ween grou nd a nd t he I mmob iliz er Signa l circu it a t t he

PCM harness connector.


All

Yes → G o To 5

No → Repair the Imm obilizer Signal circuit for a short to ground.





M ea s u re t he a mp era ge b et ween P C M ha rnes s connect or C-3 ca vit y 16 a nd grou nd.

I s t he a mp era ge b et ween 1. 0 a nd 1.4 mill ia mp eres ?

All

Yes → G o To 6


I nforma t ion.


6 Wit h t he D RB I II, select the Lab Scope function.

Set t he volt a ge ra nge t o + 20.0V

Set the probe to X10.

Set the time ra nge t o 0.1S/Div.


Using the oscilloscope lead, backprobe the PCM harness connector C3 cavity 16.

NOTE: A valid immobilizer signal will cycle high and low similar to thepattern shown in Charts and Graphs.Does the DRB display show the 12-volt signal cycling high and low?

All

Yes → R epla ce a nd p rogra m t he E CM in a ccorda nce wit h t he Service

Information.

P erform NO S TART VERI FI CATION - VER -1.No → R epla ce t he P CM in a ccorda nce wit h t he Service I nforma t ion.


232

STARTING

*NO START CONDITION — Continued

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Symptom List:ANTENNA FAIL URECOP FAILUREEEPROM FAILUREINTERNAL FAULT

RAM FAILURESERIAL LINK INTERNAL FAULTSTACK OVERFLOW FAIL URE

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be ANTENNA FAILURE.


ANTENNA FAILURE

When Monitored: Every 250 milliseconds w ith th e ignition on.

Set Condit ion: The SKIM’s microcontroller determines that an ant enna circuit fault ha s

occurred for 2.0 consecutive seconds.

COP FAILURE


Set C ondition: The COP timer is not reset by the microcontr oller every 65.5 milliseconds

EEPROM FAILURE


S e t C o n d it i on : Wh e n t h e v a l u e w r i t t en t o E E P R O M m em or y d o es n o t e q u a l t h e v a l u e

read back after the write operat ion.

INTERNAL FAULT


Set Condit ion: The SKIM has detected a fault during an internal self test .

RAM FAILURE


Set C ondit ion: The RAM fails a test tha t checks the RAM’s a bili ty to reta in memory.

SERIAL LINK INTERNAL FAULT


Set C ondit ion: The SKI M fails a n interna l J 1850 communicat ion self test .

STACK OVERFL OW FAIL URE


Set C ondition: The microcontroller ha s exceeded its sta ck space limit.

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POSSIBLE CAUSES

SK IM INTERNAL DTC FAILU RE


1 Note: This trouble code indicates an internal SKIM fault.Wit h t he D R B I I I , rea d a nd record t he SKI M DTC’s a nd t hen era s e t he S KI M D TC’s

P erform 10 ignit ion key cycles , lea ving t he ignit ion key on for a minimu m of 90

seconds per cycle.

Wit h t he D R B I I I , rea d t he SK I M DTC’s .

Did t he s a me SKI M DTC ret u rn?

All

Yes → R ep la c e a n d p r og r a m t h e S e n t r y K e y I m m ob il iz er M od u le i n

a ccorda nce wit h t he Service I n forma t ion.

Perform SKIS VERIFICATION.


235


ANTENNA FAIL URE — Continued

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Symptom List:PCM STATUS FAILURESERIAL LINK EXTERNAL FAULT

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be PCM STATUS FAIL URE.


PCM STATUS FAILURE


Set Condition: This DTC exists when a P CM STATU S messa ge wa s not received from the

PCM for at least 20.0 consecutive seconds.

SERIAL LINK EXTERNAL FAULT

When Monitored: At ignition on, a fter ignition on during any rolling code ha ndsha ke tha t

occurs w ith the P CM due to a SK IM reset , or during SECRE T KE Y tra nsfers to the P CM.

S e t C o n d it i on : Wh e n t h e S K I M d o es n o t r e ce iv e a n e x pe ct e d P C I B U S m e ss a g e t r a n s -

mission acknowledgement from the PCM after 3 transmit a t tempts.

POSSIBLE CAUSES

INTERMITTENT WIRING HARNESS PROBLEM

WI RI N G HARNES S I N SP ECTI O N

SK IM/P CM


1 NOTE: Ensure the PCM has proper power and ground connections beforecontinuing.Wit h t he D R B I I I , rea d a nd record t he SKI M DTC’s t hen era s e t he SKI M DTC’ s.


Wait 2 minut es.



Does t he DR B I I I dis p la y t he DTC t ha t wa s p reviou s ly era s ed?

All

Yes → G o To 2

No → G o To 4

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Symptom List:ROLLING CODE FAILUREVIN MISMATCH

Test Note: All symptoms listed above are diagnosed using thesame tests.The title for the tests will be ROLLING CODE FAILURE.


ROLLING CODE FAILURE

When Monitored: At ignition on, a fter ignition on during any rolling code ha ndsha ke tha t

occu r s w i t h t h e P C M d u e t o a S K I M or P C M r e s et .

Set Condition: When a P CM STATU S messa ge with a Va lid Key sta tus is not received by

the SK IM w ithin 3.5 seconds of tra nsmitt ing t he last Valid Key C ode message to the P CM.

VIN MISMATCH


Set C ondit ion: When the VIN received from t he PC M does not ma tch the VIN stored in

t h e S K I M ’s E E P R O M.

POSSIBLE CAUSES

V ERI F YI N G PCM V I N

REPL ACE SK I M AN D CHECK D T C’S

INTERMITTENT WIRING HARNESS PROBLEM

P C M



Wit h t he D R B I I I , era s e t h e SKI M DTC’ s.


Wait 10 seconds.

Tu rn t he ignit ion on a nd w a it 2 minu t es .


Does t he DR B I I I dis p la y t he DTC t ha t wa s p reviou s ly era s ed?

All

Yes → G o To 2

No → G o To 4

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1 Wi t h t h e D R B I I I , r ea d a n d r ecor d th e S K I M D TC ’s .


NOTE: Perform the following test several times to ensure the DTC is

current.Turn the ignition off.

Wait 10 seconds.



Does t he D R B dis pla y t he DTC t ha t wa s p reviou s ly era s ed?

All

Yes → G o To 2

No → G o To 7

2 Ar e t her e mu lt iple vehicle ignit ion keys a va ila ble? All

Yes → G o To 3

No → G o To 4

3 NOTE: Perform the following steps using one of the vehicle ignition keys.When finished, repeat the procedure using each of the other vehicle keysone at a time.Wit h t he D R B I I I , era s e t h e SKI M DTC’ s.


Wait 10 seconds.



Is the DTC present for all ignition keys.

All

Yes → R epla ce t he Sent ry Key I mmob iliz er M odu le in a ccorda nce wit h

the Service Information.

Perform SKIS VERIFICATION.


4 Wi t h t h e D R B I I I , a t t e m pt t o r e pr og r a m t h e i g n it i on ke y s t o t h e S K I M .


Wait 10 seconds.



Does the DTC reset?

All

Yes → G o To 5


5 R ep la c e t h e i g n it i on k ey w i t h a ne w k ey.

Wit h t he DR B I I I , p rogra m t he new ignit ion key t o t he SKI M .

Wit h t he D R B I I I , era s e t h e SKI M DTC’ sTurn the ignition off.

Wait 10 seconds.



Does the DTC reset?

All

Yes → G o To 6


241


TRANSPONDER COMMUNICATION FAILURE — Continued

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Verification Tests

CHARGING VERIFICATION - VER-3 APPLICABILITY

1 . I n s p ec t t h e v eh i cl e t o e n su r e t h a t a l l e n gi n e c om p on e n t s a r e p r op er l y i n st a l l ed a n d

connected. Reassemble a nd reconnect components as necessar y.

2. If the PCM has been replaced, perform step 3. Otherwise, continue with step 4.

3. I f t he vehicle is equ ip p ed wit h a fa ct ory t heft a la rm, s t a rt t he engine a t lea s t 20 t imes in

order t o b e a b le t o a ct iva t e t he a la rm s ys t em when des ired.

4. With the DRB, erase all diagnostic trouble codes (DTCs).

5. St a rt t he engine.

6. Raise the engine speed to 2000 RPM for at least 30 seconds.

7. Allow the engine to idle.

8. Turn th e ignit ion off for 20 seconds.

9. Turn the ignition on.

10. Wit h t he DR B , rea d E CM a nd P CM DTCs .

11. I f t his D TC ha s res et , or a n ot her DTC ha s s et , look for a ny Technica l Service B u llet ins

(TSB s ) t ha t ma y rela t e t o t his condit ion. R et u rn t o t he Symp t om L is t i f neces s a ry.

12. I f t he cha rging s ys t em is fu nct ioning correct ly a nd t here a re n o DTCs , t he repa ir is now

complete.

Are a ny DTCs or s ymp t oms rema ining?

All

Yes → Repair is not complete, refer to appropriate symptom.

No → Repair is complete.

NO START VERIFICATION - VER-1 APPLICABILITY

1. NOTE: IMPORTANT! I f the Engine Control Module, Sentry Key ImmobilizerModule or Powertrain Control Module have been replaced, ensure the programmingprocedures for these modules have been performed in accordance with the ServiceInformation.2 . I n s p ec t t h e v eh i cl e t o e n su r e t h a t a l l e n gi n e c om p on e n t s a r e p r op er l y i n st a l l ed a n d


3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.

4. With the DRB, erase all diagnostic trouble codes (DTCs).

5. Turn the ign ition off for a t lea st 10 seconds.6. At t emp t t o s t a rt t he engine.

7. I f t he engine is u na b le t o s t a r t , look for a ny Technica l Service B u llet ins ( TSB s ) t ha t ma y

rela t e t o t his condit ion. R et u rn t o t he Symp t om L is t i f neces s a ry.

8. I f t he engine s t a rt s a nd cont inu es t o ru n, t he rep a ir is n ow comp let e.


All



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POWERTRAI N VERI FI CATION TEST VE R - 1 APPL ICABIL ITY



2. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.

3 . P e r f o r m t h e s t e p s 4 t h r o u g h 6 i f t h e P C M h a s b e e n r e p l a c e d . T h e n p r o c e e d w i t h t h everification. If the PCM has not been replaced skip those steps and continue verification.

4. I f P C M ha s b een cha nged a nd correct V I N a nd milea ge ha ve not b een p rogra mmed a DTC

will b e s et in AB S a nd A ir B a g modu les . I n a ddit ion, i f vehicle is equ ipp ed w it h a Sent ry Key

I mmob iliz er M odu le (SKI M ), Secret Key da t a mu s t b e u p da t ed t o ena b le s t a rt .

5. For ABS and Air Bag systems: Enter correct VIN and Mileage in PCM. Erase codes in ABS

a nd A ir B a g modu les .

6. For SK I M t heft a la rm: Connect D R B I I I to dat a link conn. G o to Theft Alarm , SK IM, Misc.

a nd p la ce S KI M in s ecu red a cces s mode, b y u s ing t he a p p rop ria t e P I N code for t h is vehicle.

Select U p da t e t he Secret Key da t a . Da t a will b e t ra ns ferred from SKI M t o P CM

7. At t emp t t o s t a rt t he engine.

8. I f t he engine is u na b le t o s t a rt , look for a ny Technica l Service B u llet ins t h a t ma y rela t e t o

this condition. Return to Symptom List if necessary.

9. I f t he engine s t a rt s a nd s t a ys ru nning, t he rep a ir is now complet e.

All

ROAD TEST VERIFICATION - VER-2 APPLICABILITY



2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and

4.

3. Check to see if the initia l symptom still exists. If th ere are no tr ouble codes an d th e symptom

no longer exists, the repair was successful and testing is now complete.

4. I f t he init ia l or a not her s ymp t om exis t s , t he rep a ir is not comp let e. Check a ll p ert inent

Technical S ervice B ulletins (TSB s) and r eturn to the S ymptom List if necessar y.

5. For p reviou s ly rea d DTCs t ha t ha ve not b een dea lt wit h, ret u rn t o t he Symp t om L is t a nd

follow the diagnostic path for that DTC; otherwise, continue.6. If the engine control module (EC M) has not been chan ged, perform st eps 7 and 8, otherw ise,

continue with step 9.

7. With the DRB, erase all diagnostic trouble codes (DTCs), then disconnect the DRB.

8. Turn the ign ition off for a t lea st 10 seconds.

9. Ensure no DTCs remain by performing steps 10 through 13.

10. Road t est th e vehicle. For some of the road test, go a t lea st 64 km/h (40 MP H). If th is test

is for a n A/C Relay Control Circuit , d rive the vehicle for a t least 5 minutes wit h t he A/C on.

11. At some point, stop the vehicle and t urn the engine off for at least 10 seconds, th en resta rt

t he engine a nd cont inu e.

12. U p on comp let ion of t he roa d t es t , t u rn t he engine off a nd check for DTCs wit h t he D R B .

13. If t he repaired DTC ha s reset, t he repair is not complete. Check for an y pertinent Technical

Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the repair was

successful an d is now complete.


All



244

VERIFICATION TESTS

Verification Tests — Continued

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SKIS VERIFICATION APPLICABILITY

1. Reconnect all previously disconnected components an d connectors.

2. Obtain the vehicle’s unique Personal Identification Number (PIN) assigned to it ’s original

SKIM. This number can be obtained from the vehicle’s invoice or Chrysler’s Customer Center

(1-800-992-1997).3. NOTE: When entering the PIN, care should be taken because the SKIM will onlyallow 3 consecutive attempts to enter the correct PI N. If 3 consecutive incorrectPIN’s are entered the SKIM will L ock Out the DRB II I for 1 hour.4. To exit Lock Out mode, the ign ition key must rema in in t he Run position continua lly for 1

hour. Turn off all accessories an d connect a bat tery charger if necessar y.

5. Wit h t he DR B I I I , s elect Theft A la rm, SKI M a nd M is cella neou s. Then s elect des ired

procedure and follow the steps that will be displayed.

6. If the SK IM ha s been replaced, ensure all of the vehicle ignition keys are program med to the

n e w S K I M .

7. NOTE: Prior to returning vehicle to the costumer, perform a module scan to besure that all DTC’s are erased. Erase any DTC’s that are found.8. With t he DRB III erase a ll DTC’s. Perform 5 ignition key cycles leaving the key on for at least

90 seconds per cycle.

9. Wit h t he D R B I I I , rea d t he SK I M DTC’ s.Are t here a ny SKI M DTC’s ?

All



245

VERIFICATION TESTS

Verification Tests — Continued

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8.4 SENSORSC

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COMPONENT LOCATIONS

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8.5 RELAYS

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COMPONENT LOCATIONS

8. 4 SENSORS (Continued)

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8.6 SWITCHES

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COMPONENT LOCATIONS

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8 . 7 LAM PS

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COMPONENT LOCATIONS

8. 6 SWITCHES (Continued)

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9.0 CONNECTOR PINOUTS

A/C COMPRESSOR CLUTCH (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION

1 C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT

2 Z1 16BK GROUND

A/C HIGH PRESSURE SWITCH - 4 WAY


1 C21 20DB/PK A/C SWITCH SENSE

2 C48 18TN RADIATOR FAN REQUEST

3 C90 20L G (GAS) A/C SWI TCH SENSE

3 Z1 18BK (DI ESEL) GROUND

4 C22 20DB/WT (DIESEL) A/C PRESSURE SWITCH SENSE

4 C90 20L G (GAS) A/C SWI TCH SENSE

A/C LOW PRESSURE SWITCH - 2 WAY


1 Z1 20BK (DI ESEL) GROUND

1 C22 18DB/WT (GAS) PRESSURE SWITCH OUTPUT

2 C21 20DB/PK A/C SWITCH SENSE

ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY


1 - -

2 - -

3 K4 20BK/LB SENSOR GROUND

4 - -

5 K151 20WT L OW I DL E P OSI TI ON SWI TCH SIGNAL

6 - -

7 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL

8 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND

9 - -

10 K6 20VT/WT 5V SUPPLY

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CONNECTOR PINOUTS

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BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION

1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL

2 K167 20BR/YL SENSOR GROUND

BRAKE LAMP SWITCH - GRAY 6 WAY


1 K29 18WT/PK (GAS) BRAKE LAMP SWITCH SENSE

1 K29 18WT/PK (DIESEL) SECONDARY BRAKE SWITCH SIGNAL

2 Z1 18BK GROUND

2 Z1 20BK (LHD BUILT UP

EXPORT)

GROUND

3 V32 20Y L/RD SPEED CONTROL SUPP LY

4 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT

5 L50 20WT/TN (LHD GAS) BRAKE LAMP SWITCH OUTPUT5 L50 20WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT

5 L50 20WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL

6 F32 20PK/DB FUSED B(+)

CLOCKSPRING C1 - NATURAL 4 WAY


1 X3 20BK/RD HORN RELAY CONTROL

2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL

3 K4 20BK/RD SENSOR GROUND

4 - -

CLOCKSPRING C2 - YELLOW 2 WAY


A R45 18DG/LB DRIVER AIRBAG LI NE 2

B R43 18BK/LB DRIVER AIRBAG LI NE 1

CLUTCH INTERLOCK SWITCH - GREEN 2 WAY

CAV CIRCUIT FUNCTION1 F45 20YL/RD (LHD DISEL) FUSED IGNITION SWITCH OUTPUT (START)

1 T141 20YL (EXCEPT LHD

DIESEL)

IGNITION SWITCH OUTPUT (START)

2 F45 20YL/RD (EXCEPT

LHD DIESEL)

FUSED IGNITION SWITCH OUTPUT (START)

2 T141 20YL (LHD DIESEL) IGNITION SWITCH OUTPUT (START)

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DATA LINK CONNECTOR - BLACK 16 WAY


1 - -

2 - -

3 D1 18VT/BR CCD BUS (+)

4 Z1 18BK GROUND

5 Z12 18BK/TN GROUND

6 D20 20LG/BK SCI RECEIVE

7 D21 20PK SCI TRANSMIT

8 - -

9 - -

10 - -

11 D2 18WT/BK CCD BUS (-)

12 - -

13 - -

14 - -

15 - -

16 F34 18TN/BK FUSED B(+)

EGR SOLENOID (DIESEL) - 4 WAY


A F142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT

B K35 18GY /Y L EGR SOL ENOI D CONTROL

C - -

D Z1 18BK GROUND

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CONNECTOR PINOUTS

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ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 51 WAY



2 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

3 - -

4 - -

5 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL

6 K159 18VT/RD ENGINE SPEED SENSOR SIGNAL

7 - -

8 C103 18DG A/C REQUEST INPUT

9 K29 20WT/P K BRAKE LAMP SWITCH SENSE

10 C22 20DB/WT A/C PRESSURE SWITCH SENSE

11 K6 20VT/WT 5V SUPPLY

12 K151 20WT L OW I DL E P OSI TI ON SWI TCH SI GNAL

13 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL

14 - -

15 - -

16 - -

17 C27 18DB/PK RADIATOR FAN RELAY CONTROL

18 G8 18L B/BK FUEL M ONI TOR OUTP UT SI GNAL

19 - -

20 L50 20WT/TN BRAKE L AM P SWI TCH OUTP UT21 - -

22 - -

23 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND

24 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL

25 - -

26 - -



29 K35 18GY /Y L EGR SOL ENOI D CONTROL

30 V66 18RD/LG SPEED CONTROL INDICATOR SIGNAL

31 - -

32 K185 20OR/LB WAIT TO START INDICATOR DRIVER

33 K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL

34 K48 18OR/RD FAULT INDICATOR REQUEST INPUT

35 - -

36 - -

37 - -

38 G55 18OR/BK ENGI NE DI SABL E SI GNAL

39 K9 20LB 5V SUPPLY

40 K1 20DG/RD BOOST PRESSURE SENSOR SIGNAL

41 - -

42 K152 18WT GLOW PLUG RELAY CONTROL

43 - -

44 - -

45 D21 20PK SCI TRANSMIT

46 - -

47 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)

48 C48 18TN RADIATOR FAN REQUEST

49 - -

50 - -

51 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL

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ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 29 WAY


52 - -

53 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL

54 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL

55 K68 18LG/YL NEEDLE MOVEMENT SENSOR GROUND

56 K134 20LB/BK CONTROL SLEEVE POSITION SENSOR SIGNAL

57 K57 20LG/OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP

58 K135 20WT/BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL

59 K140 18TN/WT FUEL QUANTITY ACTUATOR CONTROL

60 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL


62 K67 18BR/BK NEEDLE MOVEMENT SENSOR SIGNAL

63 - -

64 - -

65 - -


67 K24 20GY/BK ENGINE SPEED SENSOR SIGNAL

68 - -

69 K3 20L G/BK ENGI NE SPEED SENSOR GROUND

70 - -

71 - -72 - -

73 - -

74 - -

75 - -

76 - -

77 K153 18OR FUEL SHUTDOWN SOLENOID CONTROL

78 - -

79 K126 18L G FUEL TI MI NG SOLENOI D CONTR OL


ENGINE COOLANT TEMPERATURE SENSOR NO. 1 (DIESEL ECM) - BLACK 2 WAYCAV CIRCUIT FUNCTION

1 K2 18TN/BK ECM ENGINE COOLANT TEMPERATURE SENSOR SIGNAL


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ENGINE COOLANT TEMPERATURE SENSOR NO. 2 (DIESEL PCM) - BLACK 2 WAY


1 K222 18TN/RD PCM ENGINE COOLANT TEMPERATURE SENSOR SIGNAL


ENGINE SPEED SENSOR (DIESEL) - BLACK 3 WAY


1 K3 20L G/BK ENGI NE SPEED SENSOR GROUND

2 - -

3 K24 20GY /BK ENGI NE SPEED SENSOR SIGNAL

FUEL HEATER (DIESEL) - 2 WAY


1 A93 14R D/BK FUEL HEATER R EL AY OUTP UT

2 Z1 16BK GROUND

FUEL INJECTION PUMP (DIESEL) - BLACK 10 WAYCAV CIRCUIT FUNCTION

1 K134 20LB/BK CONTROL SLEEVE POSITION SENSOR SIGNAL

2 K57 20LG/OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP SIGNAL

3 K135 20WT/BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL


5 K126 18L G FUEL TI MI NG SOLENOI D CONTR OL

6 K153 18OR FUEL SHUT DOWN SOLENOID CONTROL

7 K156 20GY FUEL TEM PERATUR E SENSOR SIGNAL



10 F142 16DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT

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FUEL LEVEL SENSOR (DIESEL) - BLACK 6 WAYCAV CIRCUIT FUNCTION

1 A141 16DG/WT NOT USED

2 - -

3 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL


5 - -

6 Z1 16BK NOT USED

GENERATOR - BLACK 2 WAY


1 K72 16DG/OR (GAS) GENERATOR SOURCE

1 K72 18DG/OR (DIESEL) GENERATOR SOURCE

2 K20 16DG (GAS) GENERATOR FIELD

2 K20 18DG (DIESEL) GENERATOR FIELD

GENERATOR - 3 WAY


1 - FIELD WIRES

2 - FIELD WIRE CONNECTOR

3 - B(+) (OUTPUT TERMINALS)

GLOW PLUG RELAY (DIESEL) - 4 WAYCAV CIRCUIT FUNCTION

1 A54 10RD/GY FUSED B(+)

2 F142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT

3 K152 18WT GLOW PLUG RELAY CONTROL

4 K154 10GY GLOW PLUG RELAY OUTPUT

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INSTRUMENT CLUSTER C2 - BLACK 10 WAY


1 D2 20WT/BK CCD BUS(-)

2 D1 20VT/BR CCD BUS(+)

3 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL

4 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE

5 G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)

6 L60 20TN RIGHT TURN SIGNAL

7 G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME)

8 G26 20LB KEY- IN I GNITION SWITCH SENSE

9 Z2 18BK/LG GROUND

10 G10 20L G/RD SEAT BELT SWI TCH SENSE

LOW COOLANT SWITCH (DIESEL) - 2 WAY


1 G18 18PK/BK COOLANT LEVEL SWITCH SIGNAL


MESSAGE CENTER (DIESEL) - BLACK 8 WAY


1 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)

2 - -

3 - -

4 K185 20OR/LB WAIT TO START INDICATOR DRIVER

5 - -

6 - -

7 G86 20TN/OR WATER IN FUEL INDICATOR DRIVER

8 G154 20VT/LG LOW COOLANT INDICATOR DRIVER

NEEDLE MOVEMENT SENSOR (DIESEL) - 2 WAY


1 K67 18BR/BK NEEDLE MOVEMENT SENSOR (+)

2 K68 18L G/Y L NEEDLE M OVEM ENT SENSOR (- )

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CONNECTOR PINOUTS

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CONNECTOR PINOUTS

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FUSES (DIESEL)

FUSE

NO.

AMPS FUSED CIRCUIT FUNCTION

1 - - -

2 50A A54 12RD/GY FUSED B(+)

3 50A A54 12RD/GY FUSED B(+)

4 30A A16 12RD/LG FUSED B(+)

5 40A A1 12RD FUSED B(+)

6 30A A61 14LG/RD FUSED B(+)

7 20A A41 16YL FUSED B(+)

8 30A A3 14RD/WT FUSED B(+)

9 50A A7 10RD/BK FUSED B(+)

10 40A A2 12PK/BK FUSED B(+)

11 40A A111 12RD/LG FUSED B(+)

12 40A F141 12LG/RD FUSED B(+)

13 40A F141 12LG/RD FUSED B(+)

14 20A A20 12RD/DB FUSED B(+)

15 30A A4 12BK/PK FUSED B(+)

16 15A M1 20PK FUSED B(+)

16 15A M1 20PK FUSED B(+)

17 - - -

18 - - -

19 15A F32 20PK/DB FUSED B(+)



21 20A F142 16DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT

22 20A F75 16VT FUSED B(+)

23 15A L9 20BK/PK FUSED B(+)

24 10A F16 16RD/LG FUSED B(+)

25 15A F61 20WT/OR FUSED B(+)

26 20A F34 18TN/BK FUSED B(+)

27 10A F1 20DB/GY FUSED B(+)

A/C COMPRESSOR CLUTCH RELAY (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTIONB1 A17 16RD/BK FUSED B(+)

B2 C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT

B3 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL

B4 - -

B5 A142 18DG AUTOMATIC SHUT DOWN RELAY OUTPUT

AUTOMATIC SHUT DOWN RELAY (DIESEL)CAV CIRCUIT FUNCTION

C2 A16 12RD/LG FUSED B(+)

C4 A16 12RD/LG FUSED B(+)

C5 - -

C6 K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL

C8 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

C8 A142 18DG AUTOMATIC SHUT DOWN RELAY OUTPUT

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ENGINE STARTER MOTOR RELAY (DIESEL)


D10 A41 16YL FUSED B(+)

D11 T141 20YL IGNITION SWITCH OUTPUT (START)

D12 - -

D13 Z1 20BK GROUND

D13 Z1 20BK/YL GROUND

D14 T40 16BR ENGINE STARTER MOTOR RELAY OUTPUT

FUEL HEATER RELAY (DIESEL)


D2 A61 14LG/RD FUSED B(+)

D4 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)

D5 - -

D6 Z1 20BK GROUND

D8 A93 14RD/BK FUEL HEATER RELAY OUTPUT

RADIATOR FAN RELAY


C10 F141 12LG/RD FUSED B(+)



C12 - -

C13 C27 18DB/PK (RHD) RADIATOR FAN RELAY CONTROL

C13 C27 20DB/PK (LHD) RADIATOR FAN RELAY CONTROL

C14 C25 12L B R ADI ATOR FAN REL AY OUTP UT

D10 F141 12L G/RD FUSED B(+)

D11 F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN-START)

D11 F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN-START)

D12 - -

D13 C27 18DB/PK RADIATOR FAN RELAY CONTROL

D14 C25 12L B R ADI ATOR FAN REL AY OUTP UT

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POWERTRAIN CONTROL MODULE C1 (DIESEL) - 32 WAY


1 - -


3 - -


5 - -

6 - -

7 - -

8 K159 18VT/RD ENGINE SPEED SENSOR SIGNAL

9 - -

10 - -

11 - -

12 G18 18PK/BK COOLANT LEVEL SWITCH SIGNAL

13 - -

14 - -

15 - -

16 K222 18TN/RD ENGINE COOLANT TEMP SENSOR SIGNAL

17 K7 18OR 5V SUPPLY

18 G8 18L B/BK FUEL M ONI TOR OUTP UT SI GNAL

19 - -

20 - -21 - -

22 F16 16RD/LG FUSED B(+)

23 - -

24 - -

25 - -

26 - -

27 G123 18DG/WT WATER IN FUEL SENSOR SIGNAL

28 - -

29 - -

30 - -



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1 - -

2 - -

3 - -

4 - -

5 - -

6 - -

7 - -

8 - -

9 - -

10 K20 18DG GENERATOR FIELD

11 - -

12 - -

13 - -

14 - -

15 - -

16 - -

17 - -

18 V66 18RD/LG SPEED CONTROL INDICATOR SIGNAL

19 - -

20 - -21 - -

22 - -

23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL

24 - -

25 - -

26 - -

27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL

28 - -

29 - -

30 - -

31 - -

32 - -

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1 C103 18DG A/C REQUEST OUTPUT

2 - -

3 - -

4 - -

5 - -

6 - -

7 - -

8 G154 18VT/LG LOW COOLANT INDICATOR DRIVER

9 G86 18TN/OR WATER IN FUEL INDICATOR DRIVER

10 - -

11 - -

12 A142 16DG/OR AUTOMATIC HUT DOWN RELAY OUTPUT

13 - -

14 - -

15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL

16 G55 18OR/BK ENABLE DI SABL E SIGNAL

17 - -

18 - -

19 - -

20 - -21 - -

22 K48 18OR/RD FAULT INDICATOR REQUEST INPUT

23 C90 18LG A/C SWITCH SENSE

24 - -

25 K72 18DG/OR GENERATOR SOUR CE

26 K226 18DB/LG FUEL LEVEL SENSOR SIGNAL

27 D21 18BK SCI TRANSMIT

28 D2 18WT/BK CCD BUS (-)

29 D20 18LG/BK SCI RECEIVE

30 D1 18VT/BR CCD BUS (+)

31 - -

32 - -

RADIATOR FAN MOTOR - LT. GRAY 2 WAY


1 C25 12LB RADIATOR FAN RELAY OUTPUT

2 Z1 12BK GROUND

SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY


1 D1 20VT/BR CCD BUS(+)

2 D2 20WT/BK CCD BUS(-)

3 Z2 20BK/LG GROUND

4 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)

5 Z2 20BK/LG GROUND

6 F1 20DB/GY FUSED B(+)

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CONNECTOR PINOUTS

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TURBO BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY



2 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL

3 K9 20LB 5V SUPPLY

4 K1 20DG/RD BOOST P RESSURE SENSOR SI GNAL

VEHICLE SPEED SENSOR (DIESEL) - 3 WAY


1 K7 18OR 5V SUPPLY


3 G7 8WT/OR VEHI CL E SP EED SENSOR SIGNAL

WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION

1 G123 18DG/WT WATER IN FUEL SENSOR SIGNAL


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CONNECTOR PINOUTS

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NOTES

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10.0 SCHEMATIC DIAGRAMS

10. 1 ENGINE CONTROL MODULE

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SCHEMATIC DIAGRAMS

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10. 2 POWERTRAIN CONTROL M ODULE

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SCHEMATIC DIAGRAMS

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NOTES

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NOTES

01XJED

Documents

Transcript of 01XJED