Er1 DSL PDF

TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2 FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.1 PCM On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.2 ECM Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.3 Monitored Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.1 Hard Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.2 Intermittent Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.4 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.5 Handling No Trouble Code Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.4 USING THE DRBIIIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . .5
3.5.1 DRBIIIT Does Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.5.2 Display is Not Visible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.0 SYSTEM COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 ENGINE CONTROL MODULE AND POWERTRAIN CONTROL MODULE . . . .7

4.2 CONTROLS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.4 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.5 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.6 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.7 LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.8 LAMPS, INDICATORS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.2.1 Technician Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.2.2 Vehicle Preparation for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.2.3 Servicing Sub-Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.2.4 DRBIIIT Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.3.1 Vehicle Damage Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.3.2 Road Testing a Complaint Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1 GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
TROUBLE CODE TEST

TEST DTC CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES
(DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
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TABLE OF CONTENTS - Continued
TC-1A REPAIRING - AC CONTROL OPEN CIRCUIT . . . . . . . . . . . . . . . . . .24
TC-2A REPAIRING - AC CONTROL SHORT CIRCUIT . . . . . . . . . . . . . . . . .30
TC-7A REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES . . . . . .36
TC-12A REPAIRING - AIR TEMP. SENSOR SRC HIGH EXCEEDED. . . . . . .46
TC-13A REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED . . . . . . .50
TC-16A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO
EARLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
TC-17A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO
LATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
TC-19A REPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED. . . . . . .64
TC-20A REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT
CONTACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
TC-22A REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH
EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
TC-23A REPAIRING - CONTROL SLEEVE SENSOR START END POS.
NOT ATTAINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
TC-24A REPAIRING - CONTROL SLEEVE SENSOR STOP END POS.
NOT ATTAINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
TC-33A REPAIRING - EGR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .90
TC-34A REPAIRING - EGR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . .94
TC-35A REPAIRING - ENGINE SPEED SENSOR DYN. PLAUSIBILITY . . . .98
TC-36A REPAIRING - ENGINE SPEED SENSOR OVERSPEED
RECOGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
TC-38A REPAIRING - ENGINE SPEED SENSOR STATIC
PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
TC-43A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV
DEVIATION COLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
TC-44A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV
DEVIATION WARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
TC-45A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV
DEVIATION COLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
TC-46A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV
DEVIATION WARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
TC-47A REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH
EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
TC-48A REPAIRING - FUEL TEMPERATURE SENSOR SRC LOW
EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
TC-49A REPAIRING - GLOW DISPLAY OPEN CIRCUIT. . . . . . . . . . . . . . . .132
TC-50A REPAIRING - GLOW DISPLAY SHORT CIRCUIT . . . . . . . . . . . . . .136
TC-51A REPAIRING - GLOW RELAY CONTROLLER OPEN CIRCUIT . . . .140
TC-53A REPAIRING - GLOW RELAY CONTROLLER SHORT CIRCUIT . . .144
TC-56A REPAIRING - INDUCTIVE AUX. SPEED SENSOR TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
TC-72A REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH
EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
TC-73A REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW
EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
TC-74A REPAIRING - REDUNDANT EMER. STOP PLAUSIBILITY IN
AFTER-RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
TC-75A REPAIRING - REDUNDANT EMER. STOP POWERSTAGE
DEFECTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
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TC-79A REPAIRING - SOLENOID VALVE CONTROLLER OPEN
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
TC-80A REPAIRING - SOLENOID VALVE CONTROLLER SHORT
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
TC-81A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC
HIGH EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
TC-82A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC
LOW EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
TC-84A REPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP. . .186
TC-85A REPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR
DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
TC-86A REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR
DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
TC-87A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL
HIGH EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
TC-88A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL
LOW EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
TC-89A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY
HIGH EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
TC-90A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY
LOW EXCEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
TC-91A REPAIRING - TURBOCHARGER BOOST SENSOR
PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
TC-96A REPAIRING - VEH. SPEED SENSOR TROUBLE CODES . . . . . . .224
TC-100A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH . . . .228
TC-101A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO LOW . . . .234
TC-102A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH . . . . . .238
TC-103A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW . . . . . . .244
TC-104A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . .250
TC-105A REPAIRING - ECT SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . .254
TC-107A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
TC-108A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
TC-109A REPAIRING - GENERATOR FIELD NOT SWITCHING
PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
TC-112A REPAIRING - NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . .274
TC-118A REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH . . . . . . . . . . .278
TC-119A REPAIRING - OIL PRESSURE VOLTAGE TOO LOW . . . . . . . . . . .284
NO TROUBLE CODE TESTS

NTC-1A NO TROUBLE CODE TEST MENU . . . . . . . . . . . . . . . . . . . . . . . . . .288
NTC-2A CHECKING THE GLOW PLUG OPERATION . . . . . . . . . . . . . . . . . .290
NTC-3A CHECKING THE FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . . . .294
NTC-4A CHECKING THE ECM AND PCM POWER AND GROUND
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
NTC-5A CHECKING THE ENGINE COOLANT SENSOR CALIBRATION . . .300
NTC-6A CHECKING THE ACCELERATOR PEDAL POSITION SENSOR
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
NTC-7A CHECKING THE BOOST PRESSURE SENSOR
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
NTC-8A CHECKING THE FUEL TEMPERATURE SENSOR
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
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NTC-9A CHECKING THE EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
NTC-10A CHECKING THE FUEL HEATER OPERATION. . . . . . . . . . . . . . . . .312
NTC-11A CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . .320
NTC-12A CHECKING THE LOW COOLANT LAMP OPERATION . . . . . . . . . .322
NTC-13A CHECKING THE WATER IN FUEL LAMP OPERATION . . . . . . . . .330
NTC-14A REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING
PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
NTC-15A CHECKING THE TACHOMETER OPERATION . . . . . . . . . . . . . . . .344
NTC-16A CHECKING THE WAIT TO START LAMP OPERATION. . . . . . . . . .348
NTC-17A CHECKING THE CHECK ENGINE LAMP OPERATION. . . . . . . . . .352
NTC-20A REPAIRING THE FUEL LEVEL GAUGE NOT OPERATING
PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
NTC-21A CHECKING VEHICLE COMMUNICATION . . . . . . . . . . . . . . . . . . . .360
NTC-24A CHECKING THE TURBOCHARGER OPERATION. . . . . . . . . . . . . .364
CHARGING TESTS
CH-1A CHECKING THE CHARGING SYSTEM OPERATION . . . . . . . . . . .368
NO START TESTS
NS- SEL NO START SELECTION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374
NS-1A REPAIRING A NO CRANK CONDITION . . . . . . . . . . . . . . . . . . . . . .376
NO RESPONSE TEST
NS-2A REPAIRING A NO RESPONSE CONDITION . . . . . . . . . . . . . . . . . .382
NO START TESTS
NS-3A REPAIRING A NO START CONDITION. . . . . . . . . . . . . . . . . . . . . . .390
NS-4A REPAIRING A START AND STALL CONDITION. . . . . . . . . . . . . . . .394
NS-5A CHECKING THE ENGINE MECHANICAL SYSTEM. . . . . . . . . . . . .396
VERIFICATION TEST
VER-1 NO START VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398
VER-2 ROAD TEST VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
VER-3 CHARGING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
8.0 MAINTENANCE AND SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
8.1 PROGRAMMING THE ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . .401
10.0 SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
10.1 ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402

10.2 POWERTRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
11.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
12.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
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1.0 INTRODUCTION G
E
The procedures contained in this manual include all the specifications, instructions, and graphics N
needed to diagnose engine control module (ECM) and powertrain control module (PCM) E
problems; they are no start, diagnostic trouble code, and no trouble code problems. The R
diagnostics in this manual are based on the trouble condition or symptom being present at the A
time of diagnosis. L
When repairs are required, refer to the appropriate volume of the service manual for the proper
removal and repair procedure. I
N
Diagnostic procedures change every year. New diagnostic systems may be added; carryover F
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE MANUAL O
TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. R
M
This manual is designed to begin all diagnosis at the DTC TEST, which is located at the beginning A
of Section 7.1. This will cover all the necessary requirements to begin a logical diagnostic path for T
each problem. If there is a diagnostic trouble code (DTC) detected, it will direct you to the trouble I
code test. If there are no trouble codes present, it will direct you by symptom to a no-trouble code O
test. N
1.1 System Coverage
This diagnostic procedures manual covers the 2000 R1 equipped with the 2.5L VM diesel engine.
1.2 Six-Step Troubleshooting Procedure

Diagnosis of the engine control module (ECM) and powertrain control module (PCM) is done in
six basic steps:
• verification of complaint
• verification of any related symptoms
• symptom analysis
• problem isolation
• repair of isolated problem
• verification of proper operation
2.0 IDENTIFICATION OF SYSTEM

The ECM is located behind the lower instrument panel cover and below the steering column.
The PCM is located in the engine compartment to the right of the air cleaner housing.
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
3.1 General Description

The 2.5L VM diesel engine system is equipped with the latest in technical advances. The
on-board diagnostics incorporated with the powertrain control module and engine control module
are intended to assist the field technician in repairing vehicle problems by the quickest means.
1
G 3.2 Functional Operation
E
N 3.2.1 PCM On-Board Diagnostics
E The PCM and ECM have been programmed to monitor many different circuits of the diesel fuel
R injection system. This monitoring is called “on-board diagnosis.”
A
L Certain criteria must be met for a trouble code to be entered into the PCM or ECM memory. The
criteria may be a range of: engine rpm, engine temperature, and/or input voltage. If all of the
I criteria for monitoring a system or circuit are met and a problem is sensed, then a trouble code
N will be stored in the PCM or the ECM.
F
O It is possible that a trouble code for a monitored circuit may not be entered into memory even
R though a malfunction has occurred. This may happen when the monitoring criteria have not been
M met.
A The PCM and ECM compare input signal voltages from each input device with specifications (the
T established high and low limits of the range) that are programmed into it for that device. If the input
I voltage is not within specifications and other trouble code criteria are met, a trouble code will be
O stored in the PCM or ECM memory.
N
3.2.2 ECM Operating Modes
As input signals to the ECM change, the ECM adjusts its response to output devices. For
example, the ECM must calculate a different fuel quantity and fuel timing for idle than it does for
wide open throttle. There are several different modes of operation that determine how the ECM
responds to the various input signals.
Ignition Switch On (Engine Off Mode)
When the ignition switch activates the diesel fuel injection system, the following actions occur:
1. The ECM determines atmospheric air pressure from the atmospheric pressure sensor
located in the ECM.
2. The ECM energizes the fuel quantity actuator and the fuel shutdown solenoid if no faults
are present.
If the engine is not started within 5 seconds of ignition on, the ECM deactivates the fuel quantity
actuator and the fuel shutdown solenoid to prevent overheating.
Engine Start-up Mode - The ECM uses the engine temperature sensor, fuel temperature sensor,
atmospheric pressure sensor, intake air temperature sensor and the engine speed sensor to
determine fuel delivery during this mode.
Normal Driving Modes - Engine idle, warm-up, acceleration, deceleration and wide open throttle
modes are all controlled based on the sensor inputs to the ECM and are modified based on
engine temperature, boost pressure, intake air temperature and engine speed.
Overheat Protection Mode - If engine temperature becomes too hot, the ECM limits fuel quantity
for engine protection.
Limp-In Modes - The ECM operates in limp-in mode when certain system faults are detected.
The ECM operates in one of the following modes based on the type and severity of the fault:
1. 10% torque reduction.
2. 50% torque reduction.
3. Engine speed set to 1100 rpm.
2
After-Run - When fused ignition switch output is removed from the ECM cavity C1-47, the ECM G
performs a self-diagnostic check in the following order: E
N
1. Electrical shut-off test. E
2. Fuel quantity actuator test. R
A
3. Monitoring module test. L
4. Voltage regulator test. I
5. Main relay test (if tests 1-4 pass). N
F
If any of tests 1-4 fail, the fault is stored in memory and can be retrieved during the next ignition O
cycle using the DRBIII. R
M
3.2.3 Monitored Circuits A
The PCM and ECM are able to monitor and identify most driveability related trouble conditions. Some T
circuits are directly monitored through feedback circuitry. In addition, the PCM and ECM monitor the I
voltage state of some circuits and compare those states with expected values. Other systems are O
monitored indirectly when the PCM and ECM conduct a rationality test to identify problems. N
Although most engine control subsystems are either directly or indirectly monitored, there may be
occasions when diagnostic trouble codes are not immediately identified. For a trouble code to set,
specific conditions must be met and unless these conditions are encountered, a code will not set.
3.3 Diagnostic Trouble Codes

Each diagnostic trouble code is diagnosed by following a specific testing procedure. The
diagnostic test procedures contain step-by-step instructions for determining the cause of trouble
codes as well as no trouble code problems. It is not necessary to perform all of the tests in this
book to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRBIII. This procedure begins
DTC TEST - Checking the System for Diagnostic Trouble Codes. This will direct you to the specific
test(s) that must be performed.
3.3.1 Hard Code
A diagnostic trouble code that comes back within one cycle of the ignition key is a ‘‘hard’’ code.
This means that the fault is there every time the powertrain control module/engine control module
checks that circuit or function. Procedures in this manual verify if the trouble code is a hard code
at the beginning of each test. When it is not a hard code, an ‘‘intermittent’’ test must be performed.
3.3.2 Intermittent Code
A diagnostic trouble code that is not there every time the powertrain control module/engine control
module checks the circuit is an ‘‘intermittent’’ code. Most intermittent codes are caused by wiring
or connector problems. Faults that come and go like this are the most difficult to diagnose; they
must be looked for under specific conditions that cause them. The following checks may assist
you in identifying 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 partially broken wire.
• Refer to any hotlines or technical service bulletins that may apply.
NOTE: Electro-magnetic (Radio) interference can cause intermittent system malfunction.
3
G 3.3.4 ECM Diagnostic Trouble Codes
E
N AC CONTROL OPEN CIRCUIT
E AC CONTROL SHORT CIRCUIT
R ACCEL. PEDAL SENSOR PLAUSIBILITY
A ACCEL. PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER
L ACCEL. PEDAL SENSOR SIGNAL HIGH EXCEEDED
ACCEL. PEDAL SENSOR SUPPLY HIGH EXCEEDED
I ACCEL. PEDAL SENSOR SUPPLY LOW EXCEEDED
N AIR TEMP. SENSOR SIGNAL HIGH EXCEEDED
F AIR TEMP. SENSOR SIGNAL LOW EXCEEDED
O ASD/DIESEL POWER RELAY SHUTS OFF TOO EARLY
R ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE
M ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED
A ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED
T BATTERY VOLTAGE SRC HIGH EXCEEDED
I BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
O CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
N CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED
CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED
EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ (EGR)
EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212
EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM
EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING
EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING
EEPROM PLAUSIBILITY VIN CHECKSUM ERROR
EGR OPEN CIRCUIT
EGR SHORT CIRCUIT
ENGINE SPEED SENSOR DYN. PLAUSIBILITY
ENGINE SPEED SENSOR OVER SPEED RECOGNITION
ENGINE SPEED SENSOR STATIC PLAUSIBILITY
FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD
FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM
FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD
FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM
FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED
FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED
GLOW DISPLAY OPEN CIRCUIT
GLOW DISPLAY SHORT CIRCUIT
GLOW RELAY CONTROLLER OPEN CIRCUIT
GLOW RELAY CONTROLLER SHORT CIRCUIT
INDUCTIVE AUX. SPEED SENSOR DYN. PLAUSIBILITY
INDUCTIVE AUX. SPEED SENSOR OVER SPEED RECOGNITION
INDUCTIVE AUX. SPEED SENSOR PLAUSIBILITY
INDUCTIVE AUX. SPEED SENSOR STATIC PLAUSIBILITY
MICROCONTROLLER GATE-ARRAY MONITORING
MICROCONTROLLER GATE-ARRAY WATCHDOG
MICROCONTROLLER PREPARE FUEL QUANTITY STOP
MICROCONTROLLER RECOVERY WAS OCCURRED
MICROCONTROLLER REDUNDANT OVERRUN MONITORING
NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED
NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED
REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN
REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE
REGULATOR LOWER REGULATOR LIMIT
REGULATOR UPPER REGULATOR LIMIT
4
SOLENOID VALVE CONTROLLER OPEN CIRCUIT G
SOLENOID VALVE CONTROLLER SHORT CIRCUIT E
TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED N
TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED E
TERMINAL 15 PLAUSIBILITY AFTER START-UP R
TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION A
TIMING GOVERNING POSITIVE GOVERNOR DEVIATION L
TURBOCHARGER BOOST SENSOR PLAUSIBILITY
TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED I
TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED N
TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED F
TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED O
U_REF (2.5V) R
VEHICLE SPEED SENSOR PEC FREQUENCY TOO HIGH M
VEHICLE SPEED SENSOR SRC HIGH EXCEEDED A
VEHICLE SPEED SENSOR PLAUSIBILITY T
I
3.3.5 Handling No Trouble Code Problems O
After reading Section 3.0 (System Description and Functional Operation), you should have a
N
better understanding of the theory and operation of the on-board diagnostics, and how this relates
to the diagnosis of a vehicle that may have a driveability-related symptom or complaint.
The ‘‘no code’’ system is broken down into three test methods:
– No Code Complete Test
– No Code Quick Individual Test
– No Code Quick Symptom Test
3.4 Using the DRBIIIT

Refer to the DRBIII user’s guide for instructions and assistance with reading trouble codes,
erasing trouble codes, and other DRBIII functions.
3.5 DRBIIIT Error Messages and Blank Screen
Under normal operation, the DRBIII will display one of only two error messages:
– User-Requested WARM Boot or User-Requested COLD Boot
This is a sample of such an error message display:
ver: 2.14
date: 26 Jul93
file: key—itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display

and the application screen.
Press F4 when done noting information.
5
G 3.5.1 DRBIIIT Does Not Power Up
E
N If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or
E a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11
R volts at DLC cavity 16 is required to adequately power the DRBIII. Check for proper ground
A connection at DLC cavities 4 and 5.
L If all connections are proper between the DRBIII and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIII may be the result of a faulty cable or vehicle wiring.
I For a blank screen, refer to the appropriate body diagnostics manual.
N
F 3.5.2 Display is Not Visible
O
R Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
M condition.
A
T
I
O
N
6
4.0 SYSTEM COMPONENT LOCATIONS G
E
4.1 Engine Control Module and Powertrain Control Module N
E
Engine Control Module R
A
L
I
N
F
O
R
M
A
T
I
O
N
CAV COLOR FUNCTION CAV COLOR FUNCTION
C1-1 Z12 BK/TN Ground C1-40 K21 BK/RD Turbocharger Boost Sensor Signal
C1-2 F142 DG/BR Fused ASD Relay Output Sense C1-42 K152 WT Glow Plug Relay Control
C1-4 K342 WT/LB Turbocharger Boost/Intake Air C1-45 D21 PK/DB K-Line for ISO Protocol
Temperature Sensor Return C1-47 F18 LG/BK Switched Ignition Input
C1-5 C13 DB/OR A/C Relay Control C1-51 G7 WT/OR Vehicle Speed Signal
C1-6 K159 VT/RD Engine Speed Output C2-53 K156 GY Fuel Temperature Sensor Signal
C1-8 C90 LG/WT A/C Request Input C2-54 K2 TN/BK ECM Coolant Temperature Sensor
C1-9 K29 WT/PK Brake Lamp Switch Sense Signal
C1-10 C20 BR A/C Pressure Switches Input C2-55 K68 LG/YL Needle Movement Sensor Return
C1-11 K7 OR Accelerator Pedal Position Sensor C2-56 K134 LB/BK Control Sleeve Position Sensor
5-Volt Supply Reference Coil
C1-12 K151 WT Low Idle Position Switch Input C2-57 K57 LG/OR Control Sleeve Position Sensor Middle
C1-13 K341 TN/WT Intake Air Temperature Sensor Signal Tap
C1-18 K44 WT/TN Fuel Computer Signal C2-58 K135 WT Control Sleeve Position Sensor
Measure Coil
C1-20 L50 WT/TN Brake Lamp Switch Output
C2-59 K140 TN Fuel Quantity Actuator Control
C1-23 K255 WT/DB Accelerator Pedal Position Sensor
Return C2-61 K167 BR/YL Low Idle Position Switch Return
C1-24 K22 OR/DB Accelerator Pedal Position Sensor C2-62 K67 BR/WT Needle Movement Sensor Signal
Signal C2-66 K140 TN Fuel Quantity Actuator Control
C1-27 Z12 BK/TN Ground C2-67 K24 GY/BK Engine Speed Sensor Signal
C1-28 F142 DG/BR Fused ASD Relay Output Sense C2-69 Z24 BK/RD Engine Speed Sensor Return
C1-29 K235 LG/PK Electric Vacuum Modulator C2-70 K3 BK/YL ECM Coolant Temperature Sensor
Control Return
C1-32 G85 OR/BK Wait To Start Lamp Control C2-76 K157 YL Fuel Temperature Sensor Return
C1-33 K51 DB/YL ASD Relay Control C2-77 K153 OR Fuel Shutdown Solenoid Control
C1-34 K48 OR/RD Check Engine Lamp Request Output C2-79 K126 LG Fuel Timing Solenoid Control
C1-39 K17 DB/TN Turbocharger Boost Sensor 5-Volt C2-80 K140 TN Fuel Quantity Actuator Control
Supply
7
G Powertrain Control Module
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O CAV CIRCUIT FUNCTION CAV CIRCUIT FUNCTION
N C1-2 F142 DG/BR Fused Ignition Switch Sense C2-27 G7 WT/OR Vehicle Speed Signal
C1-4 K4 BK/LB Sensor Return C3-1 C90 LG/WT AC Request Output
C1-8 K159 VT/RD Engine Speed Sensor Signal C3-12 F142 DG/BR Fused ASD Relay Output Sense
C1-12 G18 PK/BK Low Coolant Switch Signal C3-15 K118 PK/YL Ambient/Battery Temperature Sensor
C1-16 K222 TN PCM Coolant Temperature Sensor Signal
Signal C3-22 K48 OR/RD Check Engine Lamp Request Input
C1-17 K6 VT/WT Oil Pressure Sensor 5-Volt Supply C3-23 C103 DG AC Switch Input
C1-18 K44 WT/TN Fuel Computer Signal C3-25 K125 WT/DB Generator Source
C1-22 A71 DG/RD Battery Supply C3-26 G4 DB Fuel Level Sensor Signal
C1-27 G123 DG/WT Water In Fuel Sensor Signal C3-27 D21 PK/DB SCI Transmit
C1-31 Z12 BK/TN Ground C3-28 D2 WT/BK CCD–
C1-32 Z12 BK/TN Ground C3-29 D20 LG SCI Receive
C2-10 K20 DG Generator Field C3-30 D1 VT/BR CCD+
C2-23 G60 GY/YL Oil Pressure Sensor Signal
8
4.2 Controls and Solenoids G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
9
G 4.3 Data Link Connector
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N 4.4 Sensors
10
G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
11
G 4.4 Sensors (Continued)
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
12
G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
13
G 4.5 Relays
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
14
4.6 Switches G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
15
G 4.7 Lamps
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O 4.8 Lamps, Indicators and Gauges
N
The following components are controlled by the CCD BUS based on inputs from the powertrain
control module:
• Battery Voltage Gauge
• Fuel Level Gauge
• Oil Pressure Gauge
• Speedometer
• Water in Fuel Lamp
• Low Coolant Lamp
The following component is controlled by the engine control module directly:
• Wait to Start Lamp
The following components are controlled by the CCD BUS based on inputs from the engine
control module to the powertrain control module:
• Check Engine Lamp
• Speed Control Lamp
• Tachometer
5.0 DISCLAIMERS, SAFETY, WARNINGS
5.1 Disclaimers
All information, illustrations, and specifications contained in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any time
without notice.
5.2 Safety
5.2.1 Technician Safety Information
WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction
time, and can lead to serious injury. When the engine is operating, keep service areas
WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal
system.
16
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially G
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the E
drive wheels. N
E
When servicing a vehicle, always wear eye protection and remove any metal jewelry such as R
watchbands or bracelets that might make an inadvertent electrical contact. A
When diagnosing a powertrain system problem, it is important to follow approved procedures L
where applicable. These procedures can be found in Section 9.0 (Specifications) or in service
manual procedures. Following these procedures is very important to the safety of individuals I
performing diagnostic tests. N
F
5.2.2 Vehicle Preparation for Testing O
R
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic M
codes or error messages may occur. A
T
5.2.3 Servicing Sub-Assemblies I
Some components of the powertrain system are intended to be serviced in assembly only. O
Attempting to remove or repair certain system sub-components may result in personal injury N
and/or improper system operation. Only those components with approved repair and installation
procedures in the service manual should be serviced.
5.2.4 DRBIIIT Safety Information

WARNING: Exceeding the limits of the DRBIIIT 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 specifications at all times.
• Do not use the DRBIII if it has been damaged.
• Do not use the test leads if the insulation is damaged or if metal is exposed.
• To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
• Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
• Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT

Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated
Temperature -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 DC or 500v peak AC.
• Use caution when measuring voltage above 25v DC or 25v AC.
17
G • The circuit being tested must be protected by a 10A fuse or circuit breaker.
E
N • Use the low current shunt to measure circuits up to 10A. Use the high current clamp to
E measure circuits exceeding 10A.
R • When testing for the presence of voltage or current, make sure the meter is functioning
A correctly. Take a reading of a known voltage or current before accepting a zero reading.
L
• When measuring current, connect the meter in series with the load.
I
N • Disconnect the live test lead before disconnecting the common test lead.
F
O 5.3 Warnings
R
M 5.3.1 Vehicle Damage Warnings
A
T Before disconnecting any control module, make sure the ignition is “off” for at least 5 seconds.
I Failure to do so could damage the module.
O When testing voltage or continuity at any control module, use the terminal side (not the wire end)
N of the connector. Do not probe a wire through the insulation; this will damage it and eventually
cause it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis
of the original problem more difficult.
5.3.2 Road Testing a Complaint Vehicle

Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled.
During the test drive, do not try to read the DRBIIIT screen while in motion. Do not hang the
DRBIIIT from the rear view mirror or operate it yourself. Have an assistant available to
operate the DRBIIIT.
18
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES
7.1
GENERAL
TROUBLESHOOTING
19
T TEST DTC CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES (DTCs)
R
O
U NOTE: The battery must be fully charged for any test in this manual.
B
L 1. Attempt to start the engine. Crank for up to 10 seconds if necessary.
E
2. Connect the DRBIII to the data link connector. Write down the trouble codes that are displayed.
C 3. If the DRBIII displays ‘‘No Response’’, go to TEST NS-2A.
O
D 4. If the DRBIII screen is blank or has a DRBIII error message, go to General Information
E Section 3.5 in this manual.
T 5. If trouble code messages are displayed, refer to the trouble code list below and on the
E following pages for the appropriate test.
S 6. If there are no trouble codes displayed, refer to one of the following:
T
S For Charging problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CH
For Driveability problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC
For No Start problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS
NOTE: For all component locations see General Information Section 4.0 in this manual.
DIAGNOSTIC SCAN
ENGINE CONTROL MODULE DRBIIIT TROUBLE CODE (DTC) DISPLAYED TEST TOOL
AC Control Open Circuit TC-1 P1695
A/C Control Short Circuit TC-2 P1695
Accel. Pedal Sensor Supply High Exceeded TC-7 P1515
Accel. Pedal Sensor Supply Low Exceeded TC-7 P1515
Accel. Pedal Sensor High Exceeded TC-7 P1515
Accel. Pedal Sensor Plausibility TC-7 P1515
Accel. Pedal Sensor PWG Plaus With Potentiometer TC-7 P1515
Air Temp. Sensor SRC High Exceeded TC-12 P1110
Air Temp. Sensor SRC Low Exceeded TC-13 P1110
ASD/Diesel Power Relay Shuts Off Too Early TC-16 P1625
ASD/Diesel Power Relay Shuts Off Too Late TC-17 P1625
Atmosphere Pressure Sensor SRC High Exceeded * P1105
Atmosphere Pressure Sensor SRC Low Exceeded * P1105
Battery Voltage SRC High Exceeded TC-19 P1600
Brake Signal Plaus With Redundant Contact TC-20 P1703
Control Sleeve Sensor Signal High Exceeded TC-22 P1225
Control Sleeve Sensor Start End Pos. Not Attained TC-23 P1225
Control Sleeve Sensor Stop End Pos. Not Attained TC-24 P1225
EEPROM Plausibility Checksum Error For Adj ** P1680
EEPROM Plausibility Checksum Error in CC212 ** P1680
EEPROM Plausibility Communication with EEPROM ** P1680
EEPROM Plausibility Func Switch Wrong or Missing *** P1680
EEPROM Plausibility Ver Number Not Corresponding *** P1680
EEPROM Plausibility VIN Checksum Error **** P1680
EGR Open Circuit TC-33 P0400
EGR Short Circuit TC-34 P0400
Engine Speed Sensor Dyn. Plausibility TC-35 P0725
Engine Speed Sensor Over Speed Recognition TC-36 P0725
Engine Speed Sensor Static Plausibility TC-38 P0725
Fan Control Open Circuit TC-39 P1690
Fan Control Short Circuit TC-41 P1690
Fuel Quantity Actuator Neg Gov Deviation Cold TC-43 P1220
Fuel Quantity Actuator Neg Gov Deviation Warm TC-44 P1220
Fuel Quantity Actuator Pos Gov Deviation Cold TC-45 P1220
Fuel Quantity Actuator Pos Gov Deviation Warm TC-46 P1220
Fuel Temperature Sensor SRC High Exceeded TC-47 P0180
20
TEST DTC CONTINUED - CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES (DTCs) T
R
O
DIAGNOSTIC SCAN U
ECM DRBIIIT TROUBLE CODE (DTC) DISPLAYED (Continued) TEST TOOL B
Fuel Temperature Sensor SRC Low Exceeded TC-48 P0180 L
Glow Display Open Circuit TC-49 P1645 E
Glow Display Short Circuit TC-50 P1645
Glow Relay Controller Open Circuit TC-51 P1635
Glow Relay Controller Short Circuit TC-53 P1635 C
Inductive Aux. Speed Sensor Dyn. Plausibility TC-56 P1725 O
Inductive Aux. Speed Sensor Over Speed Recognition TC-56 P1725 D
Inductive Aux. Speed Sensor Plausibility TC-56 P1725 E
Inductive Aux. Speed Sensor Static Plausibility TC-56 P1725
Microcontroller Gate-array Monitoring * P1615
Microcontroller Gate-array Watchdog * P1615 T
Microcontroller Prepare Fuel Quantity Stop * P1615 E
Microcontroller Recovery Was Occurred * P1615 S
Microcontroller Redundant Overrun Monitoring * P1615 T
Needle Movement Sensor SRC High Exceeded TC-72 P1201
Needle Movement Sensor SRC Low Exceeded TC-73 P1201
S
Redundant Emer. Stop Plausibility in After-run TC-74 P1660
Redundant Emer. Stop Powerstage Defective TC-75 P1660
Regulator Lower Regulator Limit * P1610
Regulator Upper Regulator Limit * P1610
Solenoid Valve Controller Open Circuit TC-79 P1630
Solenoid Valve Controller Short Circuit TC-80 P1630
Temperature of Engine Coolant SRC High Exceeded TC-81 P0115
Temperature of Engine Coolant SRC Low Exceeded TC-82 P0115
Terminal #15 Plausibility After Start-up TC-84 P1605
Timing Governing Negative Governor Deviation TC-85 P1230
Timing Governing Positive Governor Deviation TC-86 P1230
Turbocharger Boost Sensor Signal High Exceeded TC-87 P0235
Turbocharger Boost Sensor Signal Low Exceeded TC-88 P0235
Turbocharger Boost Sensor Supply High Exceeded TC-89 P0235
Turbocharger Boost Sensor Supply Low Exceeded TC-90 P0235
Turbocharger Boost Sensor Plausibility TC-91 P0235
U−REF (2.5V) * P1620
Veh. Speed Sensor PEC Frequency Too High TC-96 P0500
Veh. Speed Sensor Plausibility TC-96 P0500
Veh. Speed Sensor SRC High Exceeded TC-96 P0500
* If this DTC is present, clear the DTC and perform several engine run cycles. If the DTC does not
return, no trouble can be found at this time. If the same DTC is present, replace the engine control
module.
** If this DTC is present, replace the engine control module.
*** If this DTC is present, download the latest DRBIII file and reprogram the DRBIII being used.
**** If this DTC is present, reprogram the ECM with the correct VIN. If the same DTC is present,
replace the engine control module.
NOTE: If trouble code TERMINAL 15 PLAUSIBILITY AFTER START-UP is present with other trouble
codes, perform TC-84 diagnosis first.
21
T TEST DTC CONTINUED - CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES (DTCs)
R
O
U DIAGNOSTIC SCAN
POWERTRAIN CONTROL MODULE DRBIII® TROUBLE CODE (DTC) DISPLAY
B TEST TOOL
L Ambient/Batt Temp Sen Volts Too High TC-100 P1492
E Ambient/Batt Temp Sen Volts Too Low TC-101 P1493
Charging System Voltage Too High TC-102 P1594
Charging System Voltage Too Low TC-103 P1682
C PCM Failure EEPROM Write Denied * P1696
O ECT Sensor Voltage Too High TC-104 P0118
D ECT Sensor Voltage Too Low TC-105 P0117
E Engine is Cold Too Long ** P1281
Fuel Level Sending Unit Volts Too High TC-107 P0463
Fuel Level Sending Unit Volts Too Low TC-108 P0462
T Generator Field Not Switching Properly TC-109 P0622
E Internal Controller Failure *** P0601
S No Cluster Bus Message TC-112 P1687
T Oil Pressure Voltage Too High TC-118 P0523
S Oil Pressure Voltage Too Low TC-119 P0522
* If this DTC is present, download the latest DRBIII file and reprogram the DRBIII being used. Clear
the DTC and perform several engine run cycles. If the same DTC returns, replace the powertrain
control module.
** If this DTC is present, the engine does not warm to 80°C (176°F) while driving for at least 20
minutes after start-up. See the service manual for cooling system repair (thermostat).
*** If this DTC is present, clear the DTC and perform several engine run cycles. If the DTC does not
return, no trouble can be found at this time. If the same DTC is present, replace the powertrain
control module.
22
TEST DTC CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES (DTCs)
T
R
O
NOTES U
B
L
E
C
O
D
E
T
E
S
T
S
23
T TEST TC-1A REPAIRING - AC CONTROL OPEN CIRCUIT
R
O Perform TEST DTC Before Proceeding
U
B
L
E
C
O
D
E
T
E
S
T
S
24
TEST TC-1A REPAIRING - AC CONTROL OPEN CIRCUIT
T
R
Perform TEST DTC Before Proceeding O
U
B
START TEST IS THE VEHICLE YES CONTINUE TEST
L
TC-1A. EQUIPPED WITH A/C? TC-1A ON THE E
NEXT PAGE.
C
NO O
D
E
USING THE DRB,
SELECT SELECT DOES THE DRB READ YES REPLACE THE ENGINE
T
"MISCELLANEOUS" "ENABLE/DISABLE "AC DEACTIVATED"? CONTROL MODULE.* E
FROM THE BOSCH AC".
CONTROLLER MENU. S
T
NO S
CLEAR CODES.
SELECT "PUSH 2 TO KEY OFF. DOES THE DRB YES REPLACE THE ENGINE
DISABLE (NON AC DISPLAY THIS CODE? CONTROL MODULE.*
VEH)". WAIT 10 SECONDS.
KEY ON. READ CODES.
NO
TEST COMPLETE.*
*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

25
T TEST TC-1A CONTINUED - REPAIRING - AC CONTROL OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
26
TEST TC-1A CONTINUED - REPAIRING - AC CONTROL OPEN CIRCUIT
T
R
O
U
B
TEST TC-1A
CONTINUED FROM
KEY ON.
IS THE A/C CLUTCH NO CONTINUE TEST
L
THE PREVIOUS USING THE DRB, RELAY CYCLING? TC-1A ON THE E
PAGE. ACTUATE THE A/C NEXT PAGE.
CLUTCH RELAY.
C
YES O
D
E
AT THIS TIME, THE
CONDITION REQUIRED
USING THE SCHEMATIC
AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
T
TO SET THE CODE IS THE WIRING AND FOUND? NECESSARY.* E
NOT PRESENT. CONNECTORS.
FIG.1 FIG.2 S
T
NO S
NOTE: THE DRB MUST REPAIR AS

WIGGLE THE WIRING STILL BE CYCLING DID THE WIGGLING YES NECESSARY WHERE
HARNESS FROM THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
RELAY TO THE ECM. RELAY. RELAY CYCLING? RELAY CYCLING TO
BE INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.*
INFORMATION ON
INTERMITTENT CODES.

27
T TEST TC-1A CONTINUED - REPAIRING - AC CONTROL OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2 FIG.3
28
TEST TC-1A CONTINUED - REPAIRING - AC CONTROL OPEN CIRCUIT
T
R
O
U
B
TEST TC-1A KEY OFF.
L
CONTINUED FROM
THE PREVIOUS REMOVE THE A/C
E
PAGE. CLUTCH RELAY.**
FIG.1
C
O
D
E
USING A VOLTMETER, REPAIR THE FUSED

T
MEASURE THE FUSED IS THE VOLTAGE NO ASD RELAY OUTPUT E
KEY ON. ASD RELAY OUTPUT
CIRCUIT.
ABOVE 10.0 VOLTS? CIRCUIT FOR AN
OPEN.* S
FIG.1 T
S
YES
KEY OFF. MEASURE THE

RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE A/C
USE AN OHMMETER IN A/C CLUTCH RELAY BETWEEN 70 AND 80 CLUTCH RELAY.*
THE FOLLOWING TERMINALS 1 AND 2. OHMS?
STEPS. FIG.2
YES
MEASURE THE REPAIR THE A/C

DISCONNECT THE ECM RESISTANCE BETWEEN IS THE RESISTANCE NO CLUTCH RELAY
HARNESS GROUND AND RELAY ABOVE 100K OHMS? CONTROL CIRCUIT
CONNECTORS.** CONNECTOR CAVITY 1. FOR A SHORT TO
FIG.1 GROUND.*
YES
MEASURE THE BETWEEN RELAY REPAIR THE A/C

RESISTANCE OF THE CONNECTOR CAVITY 1 IS THE RESISTANCE NO CLUTCH RELAY
A/C CLUTCH RELAY AND ECM CONNECTOR BELOW 5.0 OHMS? CONTROL CIRCUIT
CONTROL CIRCUIT... C1 CAVITY 5. FOR AN OPEN.*
FIG.3
YES
REPLACE THE ENGINE

CONTROL MODULE.*

29
T TEST TC-2A REPAIRING - AC CONTROL SHORT CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
30
TEST TC-2A REPAIRING - AC CONTROL SHORT CIRCUIT
T
R
U
B
START TEST IS THE VEHICLE YES CONTINUE TEST
L
TC-2A. EQUIPPED WITH A/C? TC-2A ON THE E
NEXT PAGE.
C
NO O
D
E
USING THE DRB,
SELECT SELECT DOES THE DRB READ YES REPLACE THE ENGINE
T
"MISCELLANEOUS" "ENABLE/DISABLE "AC DEACTIVATED"? CONTROL MODULE.* E
FROM THE BOSCH AC".
CONTROLLER MENU. S
T
NO S
CLEAR CODES.
SELECT "PUSH 2 TO KEY OFF. DOES THE DRB YES REPLACE THE ENGINE
DISABLE (NON AC DISPLAY THIS CODE? CONTROL MODULE.*
VEH)". WAIT 10 SECONDS.
KEY ON. READ CODES.
NO
TEST COMPLETE.*

31
T TEST TC-2A CONTINUED - REPAIRING - AC CONTROL SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
32
TEST TC-2A CONTINUED - REPAIRING - AC CONTROL SHORT CIRCUIT
T
R
O
U
B
TEST TC-2A
CONTINUED FROM
KEY ON.
IS THE A/C CLUTCH NO CONTINUE TEST
L
THE PREVIOUS USING THE DRB, RELAY CYCLING ON TC-2A ON THE E
PAGE. ACTUATE THE A/C AND OFF? NEXT PAGE.
CLUTCH RELAY.
C
YES O
D
E
AT THIS TIME, THE
CONDITION REQUIRED
USING THE SCHEMATIC
T
FIG.1 FIG.2 S
T
NO S
NOTE: THE DRB MUST REPAIR AS

WIGGLE THE WIRING STILL BE CYCLING DID THE WIGGLING YES NECESSARY WHERE
HARNESS FROM THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED
RELAY TO THE ECM. RELAY. RELAY CYCLING? RELAY CYCLING TO
BE INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

33
T TEST TC-2A CONTINUED - REPAIRING - AC CONTROL SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2 FIG.3
34
TEST TC-2A CONTINUED - REPAIRING - AC CONTROL SHORT CIRCUIT
T
R
O
U
B
TEST TC-2A
CONTINUED FROM
KEY OFF. L
THE PREVIOUS REMOVE THE A/C E
PAGE. CLUTCH RELAY.**
FIG.1
C
O
D
E
USING AN OHMMETER,
MEASURE THE 1 AND 2, 1 AND 3
IS THE RESISTANCE
BELOW 60 OHMS IN YES REPLACE THE A/C
T
RESISTANCE BETWEEN
A/C CLUTCH RELAY
THEN 1 AND 4. ANY OF THE
MEASUREMENTS?
CLUTCH RELAY.* E
TERMINALS... FIG.2 S
T
NO S
CONNECT A JUMPER
DISCONNECT THE ECM REMOVE THE ASD BETWEEN ASD RELAY
HARNESS RELAY FROM THE CONNECTOR CAVITIES
CONNECTORS.** PDC.** 3 AND 5.
FIG.3
KEY ON. MEASURE THE RELAY REPAIR A/C CLUTCH

CONTROL CIRCUIT AT IS THE VOLTAGE YES RELAY CONTROL
USE A VOLTMETER IN RELAY CONNECTOR ABOVE 0.5 VOLT? CIRCUIT FOR SHORT
THE FOLLOWING CAVITY 1. TO VOLTAGE.*
STEP. FIG.1
NO
REPLACE THE ENGINE

CONTROL MODULE.*

35
T TEST TC-7A REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
36
TEST TC-7A REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
T
R
U
B
START TEST
KEY OFF. CONNECT ONE END OF A
JUMPER WIRE TO ACCEL L
TC-7A. DISCONNECT THE ACCEL
PEDAL SENSOR HARNESS
PEDAL SENSOR HARNESS
CONNECTOR CAVITY 3. E
CONNECTOR.** FIG.1
C
O
D
KEY ON. USING THE THE JUMPER WIRE TO DOES THE DRB E
DRB, READ THE ACCEL PEDAL SENSOR CHANGE FROM "IDLE" NO PERFORM TEST
"LOW IDLE SWITCH" HARNESS CONNECTOR TO "ABOVE IDLE" TC-7B.
INPUT WHILE TAPPING
THE OTHER END OF...
CAVITY 5.
FIG.1
WHEN TAPPING THE
JUMPER WIRE? T
YES
E
S
T
S
REMOVE JUMPER WIRE. MEASURE BETWEEN
GROUND AND THE IS THE VOLTAGE NO PERFORM TEST
USE A VOLTMETER IN 5-VOLT SUPPLY BETWEEN TC-7C.
THE FOLLOWING STEPS. CIRCUIT. 4.7 AND 5.3 VOLTS?
FIG.1
YES
MEASURE BETWEEN CHECK THE SENSOR

SENSOR RETURN (CAV IS THE VOLTAGE NO RETURN CIRCUIT FOR
8) AND THE 5-VOLT BETWEEN AN OPEN.
SUPPLY CIRCUIT. 4.7 AND 5.3 VOLTS? IF OK, REPLACE THE
FIG.1 ECM.*
YES
MEASURE BETWEEN CHECK THE SIGNAL

GROUND AND THE IS THE VOLTAGE NO CIRCUIT FOR A
ACCEL PEDAL SENSOR BELOW 0.5 VOLT? SHORT TO VOLTAGE.
SIGNAL CIRCUIT. IF OK, REPLACE THE
FIG.1 ECM.*
YES
CONNECT A JUMPER CHECK THE ACCEL

BETWEEN THE 5-VOLT USING THE DRB, IS THE VOLTAGE NO PEDAL SENSOR SIGNAL
SUPPLY AND SENSOR READ THE ABOVE 4.5 VOLTS? CIRCUIT FOR AN OPEN.
SIGNAL CIRCUITS. "PEDAL OUTPUT VLT". IF OK, REPLACE THE
FIG.1 ECM.*
YES
REMOVE JUMPER. KEY ON. WITH THE IS THE VOLTAGE

KEY OFF. ACCEL PEDAL AT REST BETWEEN NO REPLACE THE
RECONNECT THE (IDLE), USE THE DRB 0.28 AND 0.38 ACCELERATOR PEDAL
ACCEL PEDAL SENSOR AND READ THE ACCEL VOLTS? POSITION SENSOR.*
HARNESS CONNECTOR. PEDAL SENSOR VOLTS.
YES
CONTINUE TEST
TC-7A ON THE
NEXT PAGE.

37
T TEST TC-7A CONTINUED - REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
38
TEST TC-7A CONTINUED - REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
T
R
O
U
B
TEST TC-7A
CONTINUED FROM
FULLY DEPRESS THE
ACCEL PEDAL. IS THE VOLTAGE NO REPLACE THE L
THE PREVIOUS
PAGE. USING THE DRB, READ
BETWEEN
4.1 AND 4.6 VOLTS?
ACCELERATOR PEDAL
POSITION SENSOR.* E
ACCEL PEDAL VOLTS.
YES C
O
D
USING AN ANALOG SLOWLY DEPRESS AND E
VOLTMETER, BACKPROBE RELEASE THE
ACCEL PEDAL SENSOR ACCELERATOR PEDAL
HARNESS CONN
CAVITY 7. FIG.1
SEVERAL TIMES WHILE
OBSERVING THE METER. T
E
S
T
S
NOTE: THE WITHOUT ANY SHARP DOES VOLTAGE
VOLTMETER NEEDLE INCREASE OR INCREASE AND NO REPLACE THE
SHOULD RESPOND DECREASE IN DECREASE SMOOTHLY ACCELERATOR PEDAL
SMOOTHLY TO ACCEL VOLTAGE. WITH ACCEL PEDAL POSITION SENSOR.*
PEDAL TRAVEL... TRAVEL?
YES
USING THE DRB WITH THE ACCEL PEDAL

CUSTOM DISPLAY, AND THE LOW IDLE AT FULL REST (IDLE) THE ACCEL PEDAL %
OBSERVE THE ACCEL SWITCH INPUT. SLOWLY DEPRESS THE AND THE LOW IDLE
PEDAL SENSOR ACCEL PEDAL WHILE SWITCH INPUT.
PERCENTAGE (%)... OBSERVING...
NOTE: THE LOW IDLE DID THE LOW IDLE

SWITCH INPUT BETWEEN 8% AND 21% SWITCH INPUT NO REPLACE THE
SHOULD SWITCH FROM OF ACCEL PEDAL CHANGE BETWEEN 8% ACCELERATOR PEDAL
"IDLE" TO POSITION TRAVEL. AND 21% OF ACCEL POSITION SENSOR
"ABOVE IDLE"... PEDAL TRAVEL?
YES
KEY OFF. INSPECT THE

DISCONNECT THE CONNECTORS FOR WERE ANY OF THESE YES REPAIR AS
ACCEL PEDAL SENSOR DAMAGE, CORROSION, CONDITIONS NECESSARY.*
AND ECM HARNESS TERMINAL PUSH-OUT PRESENT?
CONNECTORS. OR OTHER PROBLEMS.
NO
RECONNECT ALL WIGGLE THE WIRING REPAIR AS

CONNECTORS. AND CONNECTORS DOES THE DRB YES NECESSARY WHERE
KEY ON. ASSOCIATED WITH THE DISPLAY THIS CODE? WIGGLING CAUSED
USING THE DRB, CLEAR ACCEL PEDAL SENSOR. TROUBLE CODE TO
TROUBLE CODES. CHECK TROUBLE CODES. SET.*
NO
CONTINUE TEST
TC-7A ON THE
NEXT PAGE.

39
T TEST TC-7A CONTINUED - REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
40
TEST TC-7A CONTINUED - REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
T
R
O
U
B
TEST TC-7A
L
CONTINUED FROM
THE PREVIOUS
TEST DRIVE THE
VEHICLE.
E
PAGE.
C
O
D
E
DOES THE DRB T

USING THE DRB,
READ ENGINE
DISPLAY ANY
ACCELERATOR PEDAL
YES REPLACE THE ENGINE
CONTROL MODULE.*
E
TROUBLE CODES. CODE? S
T
NO S
TEST COMPLETE.

41
T TEST TC-7B REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
R
O Perform TEST TC-7A Before Proceeding
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
42
TEST TC-7B REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
T
R
Perform TEST TC-7A Before Proceeding O
U
B
START TEST
WITH JUMPER STILL
CONNECTED TO CAVITY
DOES THE DRB DISPLAY
CHANGE FROM "IDLE" YES
CHECK THE SENSOR
RETURN CIRCUIT FOR
L
TC-7B. 5, TAP THE OTHER END TO "ABOVE IDLE" WHEN AN OPEN. E
OF THE JUMPER TO TAPPING THE JUMPER IF OK,
CHASSIS GROUND. WIRE? REPLACE THE ECM*
C
NO O
D
E
USING A VOLTMETER,
MEASURE THE LOW IDLE IS THE VOLTAGE YES
REPAIR THE LOW
IDLE POSITION
T
POSITION SWITCH
SIGNAL CIRCUIT.
ABOVE 5.5 VOLTS? SWITCH SIGNAL
CIRCUIT FOR A
E
FIG.1 SHORT TO VOLTAGE.* S
T
NO S
KEY OFF. USING AN OHMMETER, REPAIR THE LOW

MEASURE BETWEEN IS THE RESISTANCE NO IDLE POSITION
DISCONNECT THE ECM GROUND AND THE LOW ABOVE 100K OHMS? SWITCH SIGNAL
HARNESS IDLE POS SW SIGNAL CIRCUIT FOR A
CONNECTORS.** CIRCUIT. FIG.1 SHORT TO GROUND.*
YES
USING AN OHMMETER, REPAIR THE LOW

MEASURE THE LOW IDLE IS THE RESISTANCE NO IDLE POSITION
POSITION SWITCH BELOW 5.0 OHMS? SWITCH SIGNAL
SIGNAL CIRCUIT. CIRCUIT FOR AN
FIG.2 OPEN.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

43
T TEST TC-7C REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
44
TEST TC-7C REPAIRING - ACCEL. PEDAL SENSOR TROUBLE CODES
T
R
U
B
KEY OFF. L
START TEST
TC-7C. DISCONNECT THE ECM E
HARNESS
CONNECTORS.**
C
O
D
E
MEASURE BETWEEN REPAIR THE 5-VOLT
USE AN OHMMETER IN GROUND AND THE IS THE RESISTANCE NO SUPPLY CIRCUIT FOR T
THE FOLLOWING
STEPS.
5-VOLT SUPPLY
CIRCUIT.
ABOVE 100K OHMS? A SHORT TO
GROUND.* E
FIG.1
S
YES T
S
EACH GROUND CIRCUIT REPAIR THE 5-VOLT

MEASURE BETWEEN AT ACCEL PEDAL IS THE RESISTANCE NO SUPPLY CIRCUIT FOR
THE 5-VOLT SUPPLY SENSOR HARNESS CONN ABOVE 100K OHMS? A SHORT TO SENSOR
CIRCUIT AND... CAVITIES 3 AND 8. GROUND.*
FIG.1
YES
WITH A JUMPER,
REMOVE THE ASD CONNECT ASD RELAY
RELAY.** CONNECTOR CAVITIES
3 AND 5 (IN PDC).
FIG.2
KEY ON. MEASURE THE VOLTAGE REPAIR THE 5-VOLT

ON THE 5-VOLT SUPPLY IS THE VOLTAGE YES SUPPLY CIRCUIT FOR
USE A VOLTMETER IN CIRCUIT. ABOVE 1.0 VOLT? A SHORT TO
THE FOLLOWING VOLTAGE.*
STEP. FIG.1
NO

RESISTANCE OF THE IS THE RESISTANCE NO REPAIR THE 5-VOLT
USE AN OHMMETER IN 5-VOLT SUPPLY BELOW 5.0 OHMS? SUPPLY CIRCUIT FOR
THE FOLLOWING CIRCUIT. AN OPEN.*
STEP. FIG.3
YES
REPLACE THE ENGINE

CONTROL MODULE.*

45
T TEST TC-12A REPAIRING - AIR TEMP. SENSOR SRC HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
46
TEST TC-12A REPAIRING - AIR TEMP. SENSOR SRC HIGH EXCEEDED T
R
U
B
START TEST
KEY ON. DOES THE DRB
DISPLAY "AIR TEMP. YES CONTINUE TEST
L
TC-12A. USING THE DRB, SENSOR SRC HIGH TC-12A ON THE E
CLEAR CODES. EXCEEDED"? NEXT PAGE.
C
NO O
D
E
USING THE SCHEMATIC
AS A GUIDE, WIGGLE MONITOR THE DRB
DOES THE DRB
DISPLAY "AIR TEMP. YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE INTAKE AIR TEMP FOR CODES. SENSOR SRC HIGH CAUSED THE CODE TO E
SENSOR CONNECTOR AND EXCEEDED"? SET.*
HARNESS. FIG.1 S
T
NO S
AT THIS TIME, THE USING THE SCHEMATIC

CONDITION REQUIRED AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
TO SET THE CODE IS THE WIRING AND FOUND? NECESSARY.*
FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

47
T TEST TC-12A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC HIGH EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
48
TEST TC-12A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC HIGH EXCEEDED T
R
O
U
B
TEST TC-12A
CONTINUED FROM
KEY OFF.
DISCONNECT THE ECM L
THE PREVIOUS
PAGE.
DISCONNECT THE BOOST
PRESSURE SENSOR
HARNESS
CONNECTORS.** E
HARNESS CONNECTOR.**
C
O
D
CONNECT A JUMPER KEY ON.
E
REMOVE THE ASD BETWEEN ASD RELAY
RELAY FROM THE CONNECTOR CAVITIES USE A VOLTMETER IN
PDC.** 3 AND 5.
FIG.1
THE FOLLOWING
STEP. T
E
S
T
S
MEASURE THE IAT REPAIR THE INTAKE
SENSOR SIGNAL IS THE VOLTAGE NO AIR TEMPERATURE
CIRCUIT. BELOW 1.0 VOLT? SENSOR SIGNAL
CIRCUIT FOR A
FIG.2 SHORT TO VOLTAGE.*
YES
USING AN OHMMETER, REPAIR THE INTAKE

KEY OFF. MEASURE THE IS THE RESISTANCE NO AIR TEMPERATURE
RESISTANCE OF THE BELOW 5.0 OHMS? SENSOR SIGNAL
REMOVE THE JUMPER. IAT SENSOR SIGNAL CIRCUIT FOR AN
CIRCUIT. FIG.3 OPEN.*
YES
CONNECT A JUMPER
RECONNECT THE ECM BETWEEN THE IAT
HARNESS SENSOR SIGNAL AND
CONNECTORS. SENSOR RETURN
CIRCUITS. FIG.2
DOES THE DRB

USING THE DRB, DISPLAY "AIR TEMP. YES REPLACE THE BOOST
CLEAR AND THEN SENSOR SRC LOW PRESSURE SENSOR.*
READ CODES. EXCEEDED"?
NO
MOVE THE JUMPER DOES THE DRB

FROM THE SENSOR MONITOR THE DRB DISPLAY "AIR TEMP. YES REPAIR THE SENSOR
RETURN TO AN FOR CODES. SENSOR SRC LOW RETURN CIRCUIT FOR
ENGINE GROUND. EXCEEDED"? AN OPEN.*
NO
REPLACE THE ENGINE

CONTROL MODULE.*

49
T TEST TC-13A REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
50
TEST TC-13A REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED T
R
U
B
START TEST
L
TC-13A. USING THE DRB, SENSOR SRC LOW TC-13A ON THE E
CLEAR CODES. EXCEEDED"? NEXT PAGE.
C
NO O
D
E
USING THE SCHEMATIC,
WIGGLE THE INTAKE MONITOR THE DRB
DOES THE DRB
DISPLAY "AIR TEMP. YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
AIR TEMP SENSOR FOR CODES. SENSOR SRC LOW CAUSED THE CODE TO E
CONNECTOR AND EXCEEDED"? SET.*
HARNESS. FIG.1 S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

51
T TEST TC-13A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
52
TEST TC-13A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED T
R
O
U
B
TEST TC-13A
CONTINUED FROM
KEY OFF. L
THE PREVIOUS DISCONNECT THE BOOST E
PAGE. PRESSURE SENSOR
CONNECTOR.**
C
O
D
E
USING THE DRB,

DOES THE DRB
T
CLEAR AND THEN
READ CODES.
SENSOR SRC HIGH
EXCEEDED"?
TC-13A ON THE
NEXT PAGE.
E
S
T
NO S
KEY OFF. USING AN OHMMETER, REPAIR THE INTAKE

MEASURE THE INTAKE IS THE RESISTANCE NO AIR TEMPERATURE
DISCONNECT THE ECM AIR TEMP SENSOR ABOVE 100K OHMS? SENSOR SIGNAL
HARNESS SIGNAL CIRCUIT TO CIRCUIT FOR A
CONNECTORS.** GROUND. FIG.1 SHORT TO GROUND.*
YES
USING AN OHMMETER, BOOST PRESSURE REPAIR THE IAT

MEASURE THE SENSOR HARNESS IS THE RESISTANCE NO SENSOR SIGNAL
RESISTANCE CONNECTOR CAVITIES ABOVE 100K OHMS? CIRCUIT SHORTED TO
BETWEEN... 1 AND 2. THE SENSOR RETURN
FIG.1 CIRCUIT.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

53
T TEST TC-13A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
54
TEST TC-13A CONTINUED - REPAIRING - AIR TEMP. SENSOR SRC LOW EXCEEDED T
R
O
U
B
TEST TC-13A NOTE: THE INTAKE
L
CONTINUED FROM
THE PREVIOUS
AIR TEMPERATURE
SENSOR
AT 25*C (77*F)
SHOULD BE 2.5K
E
PAGE. RESISTANCE... OHMS.
C
O
D
E
MEASURE THE T
RESISTANCE BETWEEN
BOOST PRESSURE
IS THE RESISTANCE
BETWEEN 500 OHMS
NO REPLACE THE BOOST
PRESSURE SENSOR.* E
SENSOR TERMINALS
1 AND 2.
AND 10K OHMS? S
T
YES S
REPAIR THE SENSOR

TERMINALS OR
HARNESS CONNECTOR
FOR A POOR
CONNECTION.*

55
T TEST TC-16A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO EARLY
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
56
TEST TC-16A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO EARLY T
R
U
B
START TEST
KEY ON.
ARE THERE OTHER YES DIAGNOSE OTHER
L
TC-16A. USING THE DRB, TROUBLE CODES CODES BEFORE E
CHECK FOR PRESENT? CONTINUING.
ADDITIONAL CODES.
C
NO O
D
E
USING THE DRB,

T
CLEAR CODES. E
S
T
S
PERFORM SEVERAL KEY ON.

IGNITION KEY CYCLES DOES THIS CODE YES CONTINUE TEST
PAUSING AT LEAST 10 USING THE DRB, APPEAR? TC-16A ON THE
SECONDS BETWEEN EACH READ CODES. NEXT PAGE.
CYCLE.
NO

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

57
T TEST TC-16A CONTINUED - REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO EARLY
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
58
TEST TC-16A CONTINUED - REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO EARLY T
R
O
U
B
TEST TC-16A KEY OFF. L
CONTINUED FROM
THE PREVIOUS
SUBSTITUTE A KNOWN
GOOD RELAY IN E
PAGE. PLACE OF THE ASD
RELAY. FIG.1
C
O
D
E
KEY CYCLES PAUSING DOES THIS CODE NO REPLACE THE T
FOR AT LEAST 10
SECONDS BETWEEN
USING THE DRB,
READ CODES.
APPEAR? INITIAL AUTOMATIC
SHUTDOWN RELAY.* E
EACH CYCLE.
S
YES T
S
KEY OFF.
DISCONNECT THE ECM
REMOVE THE ASD HARNESS
RELAY.** CONNECTORS.**
FIG.1
USING AN OHMMETER, WIGGLING THE WAS THE RESISTANCE REPAIR THE

MEASURE THE WIRING AND ABOVE 5.0 OHMS AT YES INTERMITTENT OPEN
RESISTANCE OF THE CONNECTORS BETWEEN ANY TIME WHILE IN THE AUTOMATIC
ASD RELAY CONTROL THE ECM AND PDC. WIGGLING? SHUTDOWN RELAY
CIRCUIT WHILE... FIG.2 CONTROL CIRCUIT.*
NO
REINSTALL THE ASD

RELAY.
RECONNECT THE ECM
HARNESS CONNECTORS.

KEY CYCLES PAUSING DOES THIS CODE YES REPLACE THE ENGINE
FOR AT LEAST 10 USING THE DRB, APPEAR? CONTROL MODULE.*
SECONDS BETWEEN READ CODES.
EACH CYCLE.
NO
TEST COMPLETE.*

59
T TEST TC-17A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
60
TEST TC-17A REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE T
R
U
B
START TEST
KEY ON.
ARE THERE OTHER YES DIAGNOSE OTHER
L
TC-17A. USING THE DRB, TROUBLE CODES CODES BEFORE E
CHECK FOR PRESENT? CONTINUING.
ADDITIONAL CODES.
C
NO O
D
E
USING THE DRB,

T
CLEAR CODES. E
S
T
S

IGNITION KEY CYCLES DOES THIS CODE YES CONTINUE TEST
PAUSING AT LEAST 10 USING THE DRB, APPEAR? TC-17A ON THE
SECONDS BETWEEN EACH READ CODES. NEXT PAGE.
CYCLE.
NO

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

61
T TEST TC-17A CONTINUED - REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
62
TEST TC-17A CONTINUED - REPAIRING - ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE T
R
O
U
B
TEST TC-17A
CONTINUED FROM
KEY OFF.
SUBSTITUTE A KNOWN L
THE PREVIOUS
PAGE.
GOOD RELAY IN
PLACE OF THE ASD E
RELAY. FIG.1
C
O
D
E
KEY CYCLES PAUSING DOES THIS CODE NO REPLACE THE
FOR AT LEAST 10 USING THE DRB, APPEAR? INITIAL AUTOMATIC
SECONDS BETWEEN
EACH CYCLE.
READ CODES. SHUTDOWN RELAY.*
T
E
YES
S
T
S
KEY OFF.
DISCONNECT THE ECM
REMOVE THE ASD HARNESS
RELAY.** CONNECTORS.**
FIG.1
USING AN OHMMETER, WHILE WIGGLING THE WAS THE RESISTANCE REPAIR THE
MEASURE THE WIRING AND BELOW 5.0 OHMS AT YES INTERMITTENT SHORT
RESISTANCE BETWEEN CONNECTORS BETWEEN ANY TIME WHILE TO GROUND IN THE
GROUND AND ASD RELAY THE ECM AND PDC. WIGGLING? ASD RELAY CONTROL
CONTROL CIRCUIT... FIG.1 CIRCUIT.*
NO
MEASURE THE REPAIR THE ASD

USE A VOLTMETER IN VOLTAGE AT ASD IS THE VOLTAGE NO RELAY OUTPUT
THE FOLLOWING RELAY CONNECTOR BELOW 0.5 VOLT? CIRCUIT FOR A
STEP. CAVITY 5. SHORT TO VOLTAGE.*
FIG.1
YES
REINSTALL THE ASD

RELAY.
RECONNECT THE ECM
HARNESS CONNECTORS.

KEY CYCLES PAUSING DOES THIS CODE YES REPLACE THE ENGINE
FOR AT LEAST 10 USING THE DRB, APPEAR? CONTROL MODULE.*
SECONDS BETWEEN READ CODES.
EACH CYCLE.
NO
TEST COMPLETE.*

63
T TEST TC-19A REPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
64
TEST TC-19A REPAIRING - BATTERY VOLTAGE SRC HIGH EXCEEDED T
R
U
B
START TEST KEY ON. USING THE ARE ANY PCM YES
PERFORM THE
APPROPRIATE
L
TC-14A. DRB, CHECK FOR PCM CHARGING SYSTEM TROUBLE CODE E
CODES. CODES PRESENT? TEST.
C
NO O
D
E
USING THE DRB,
CLEAR CODES. RUN MONITOR THE DRB
DOES THE DRB
DISPLAY "BATTERY YES REPLACE THE ENGINE
T
THE ENGINE AT IDLE FOR CODES. VOLTAGE SRC HIGH CONTROL MODULE.* E
AND 2500 RPM FOR EXCEEDED"?
SEVERAL MINUTES. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

65
T TEST TC-20A REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
66
TEST TC-20A REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT T
R
U
B
L
START TEST
TC-20A. KEY ON.
E
C
O
D
E
USING THE DRB, WHILE OBSERVING DOES THE DRB SHOW

T
MONITOR PRIMARY THE DISPLAY, PRESS PRIMARY BRAKE LAMP NO CONTINUE TEST E
AND SECONDARY
BRAKE SWITCH
AND RELEASE THE
BRAKE PEDAL
SWITCH "PRESSED"
AND "RELEASED"?
TC-20A ON THE
NEXT PAGE. S
INPUTS. SEVERAL TIMES. T
S
YES
DOES THE DRB SHOW

SECONDARY BRAKE NO PERFORM TEST
LAMP SWITCH TC-20B
"PRESSED" AND
"RELEASED"?
YES

FIG.1 FIG.2
NO
WHILE MONITORING DID THE DRB REPAIR THE HARNESS

THE DRB, WIGGLE TO THE ECM. DISPLAY A CHANGE YES OR CONNECTOR THAT
THE WIRING HARNESS IN THE PRIMARY OR CAUSED THE SWITCH
FROM THE BRAKE FIG.2 SECONDARY SWITCH STATUS TO CHANGE.*
LAMP SWITCH... STATE?
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

67
T TEST TC-20A CONTINUED - REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG. 2
68
TEST TC-20A CONTINUED - REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BRAKE E
PAGE. LAMP SWITCH HARNESS
CONNECTOR.**
C
O
D
E
USING A TEST BRAKE LAMP SWITCH
LIGHT, PROBE THE HARNESS CONNECTOR IS THE TEST LIGHT NO CONTINUE TEST T
FUSED BATTERY
SUPPLY CIRCUIT
CAVITY 6. ON? TC-20A ON THE
NEXT PAGE. E
AT... FIG.1
S
YES T
S
CONNECT A JUMPER
BETWEEN BRAKE LAMP DID THE DRB CHANGE YES ADJUST OR REPLACE
SWITCH HARNESS FROM "RELEASED" TO THE BRAKE LAMP
CONNECTOR CAVITIES "PRESSED"? SWITCH.*
5 AND 6. FIG.1
NO
REMOVE THE JUMPER

FROM THE BRAKE DISCONNECT THE ECM
LAMP SWITCH HARNESS KEY ON.
HARNESS CONNECTOR. CONNECTORS.**
USING A VOLTMETER, SIGNAL CIRCUIT AT REPAIR THE BRAKE

MEASURE THE BRAKE LAMP SWITCH IS THE VOLTAGE YES LAMP SWITCH SIGNAL
VOLTAGE ON THE HARNESS CONNECTOR ABOVE 1.0 VOLT? CIRCUIT FOR A
PRIMARY BRAKE LAMP CAVITY 5. SHORT TO VOLTAGE.*
SWITCH... FIG.1
NO
KEY OFF. MEASURE THE REPAIR THE PRIMARY

RESISTANCE OF THE IS THE RESISTANCE NO BRAKE LAMP SWITCH
USE AN OHMMETER IN PRIMARY BRAKE LAMP BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
THE FOLLOWING SWITCH SIGNAL AN OPEN.*
STEP. CIRCUIT. FIG.2
YES
REPLACE THE ENGINE

CONTROL MODULE.*

69
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
70
R
O
U
B
L
TEST TC-20A REMOVE AND INSPECT
CONTINUED FROM THE BRAKE LAMP NO CONTINUE TEST E
THE PREVIOUS SWITCH FUSE IS THE FUSE OK? TC-20A ON THE
PAGE. IN THE PDC. NEXT PAGE.
FIG.1 C
O
YES D
E
T
CONNECT THE TEST
LIGHT BETWEEN GROUND IS THE TEST LIGHT NO REPLACE THE POWER
E
AND THE FUSE’S ON? DISTRIBUTION S
BATTERY INPUT
CAVITY. FIG.1
CENTER.* T
S
YES
REPAIR THE BRAKE

LAMP SWITCH
BATTERY SUPPLY
CIRCUIT FOR AN
OPEN.*

71
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
72
R
O
U
B
TEST TC-20A LEAVE THE BRAKE
L
CONTINUED FROM
THE PREVIOUS
LAMP SWITCH AND
FUSE DISCONNECTED
E
PAGE. FOR THE FOLLOWING
STEPS.
C
O
D
E
USING AN OHMMETER, BRAKE LAMP SWITCH REPAIR THE FUSED

T
MEASURE THE HARNESS CONNECTOR IS THE RESISTANCE NO BRAKE LAMP SWITCH E
RESISTANCE BETWEEN
GROUND AND...
CAVITY 6. ABOVE 100K OHMS? BATTERY SUPPLY FOR
A SHORT TO GND AND S
FIG.1 REPLACE THE FUSE.* T
S
YES
MEASURE THE AND 4, FIRST IN THE IS THE RESISTANCE

RESISTANCE BETWEEN BRAKE "APPLIED" AND ABOVE 100K OHMS NO REPLACE THE BRAKE
BRAKE LAMP SWITCH THEN IN THE BRAKE FOR ALL LAMP SWITCH AND
TERMINAL 6 AND "RELEASED" SWITCH MEASUREMENTS? REPLACE THE FUSE.*
TERMINALS 1, 2, 3... POSITIONS. FIG.2
YES
MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE YES CONTINUE TEST
GROUND AND BRAKE BELOW 5.0 OHMS? TC-20A ON THE
LAMP SW CONNECTOR NEXT PAGE.
CAVITY 5. FIG.1
NO

CONDITION WHICH AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
CAUSED THE FUSE TO THE WIRING AND FOUND? NECESSARY AND
OPEN IS NOT CONNECTORS. REPLACE THE FUSE.*
PRESENT. FIG.3
NO
REFER TO GENERAL REPLACE THE FUSE.

INFORMATION 3.3.2
FOR ADDITIONAL
INFORMATION ON TEST COMPLETE.*
INTERMITTENT CODES.

73
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
74
R
O
U
B
TEST TC-20A
L
CONTINUED FROM
THE PREVIOUS
DISCONNECT THE ECM
HARNESS
E
PAGE. CONNECTORS.**
C
O
D
E
MEASURE THE REPAIR THE PRIMARY T
RESISTANCE BETWEEN
GROUND AND BRAKE
IS THE RESISTANCE
ABOVE 100K OHMS?
NO BRAKE LAMP SWITCH
SIGNAL CIRCUIT FOR A E
LAMP SW CONNECTOR
CAVITY 5. FIG.1
SHORT TO GROUND AND
REPLACE THE FUSE.*
S
T
YES S
REPLACE THE ENGINE

CONTROL MODULE AND
THE FUSE.*

75
T TEST TC-20B REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
76
TEST TC-20B REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT T
R
U
B
L
START TEST
TC-20B. KEY OFF.
E
C
O
D
E
DISCONNECT THE KEY ON. USING A

T
BRAKE LAMP SWITCH VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST E
HARNESS
CONNECTOR.**
THE VOLTAGE AT BRAKE
LAMP SW CONNECTOR
ABOVE 9.0 VOLTS? TC-20B ON THE
NEXT PAGE. S
CAVITY 1. FIG.1 T
S
YES
CONNECT A 5 AMP REPAIR THE

FUSED JUMPER BETWEEN DID THE 5 AMP FUSE YES SECONDARY BRAKE
BRAKE SWITCH HARNESS OPEN? SWITCH SIGNAL
CONNECTOR CAVITIES 1 CIRCUIT FOR A
AND 2. FIG.1 SHORT TO VOLTAGE.*
NO
DID THE DRB

DISPLAY CHANGE YES ADJUST OR REPLACE
FROM "PRESSED" TO THE BRAKE LAMP
"RELEASED"? SWITCH.*
NO
USING AN OHMMETER, BRAKE LAMP SWITCH REPAIR THE

MEASURE THE CONNECTOR IS THE RESISTANCE NO SECONDARY BRAKE
RESISTANCE BETWEEN CAVITY 2. BELOW 5.0 OHMS? LAMP SWITCH GROUND
GROUND AND... CIRCUIT FOR AN
FIG.1 OPEN.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

77
T TEST TC-20B CONTINUED - REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
78
TEST TC-20B CONTINUED - REPAIRING - BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT T
R
O
U
B
TEST TC-20B
CONTINUED FROM
KEY OFF. L
THE PREVIOUS DISCONNECT THE ECM E
PAGE. HARNESS
CONNECTORS.**
C
O
D
E
USING AN OHMMETER,
OF THE SECONDARY
BRAKE LAMP SWITCH IS THE RESISTANCE NO
REPAIR THE
SECONDARY BRAKE
T
MEASURE THE SIGNAL CIRCUIT. BELOW 5.0 OHMS? LAMP SWITCH SIGNAL E
RESISTANCE... CIRCUIT FOR AN
FIG.1 OPEN.* S
T
YES S
MEASURE THE HARNESS CONNECTOR REPAIR THE

RESISTANCE BETWEEN CAVITY 1. IS THE RESISTANCE NO SECONDARY BRAKE
GROUND AND BRAKE ABOVE 100K OHMS? LAMP SWITCH SIGNAL
LAMP SWITCH... CIRCUIT FOR A
FIG.2 SHORT TO GROUND.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

79
T TEST TC-22A REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
80
TEST TC-22A REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED T
R
U
B
START TEST
KEY ON. L
TC-22A. USING THE DRB, E
CLEAR CODES.
C
O
D
E
KEY OFF.
MONITOR THE DRB
DOES THE DRB SHOW
"CONTROL SLEEVE YES CONTINUE TEST
T
WAIT 30 SECONDS. FOR CODES. SENSOR SIGNAL HIGH
EXCEEDED"?
TC-22A ON THE
NEXT PAGE.
E
KEY ON. S
T
NO S
USING THE SCHEMATIC, DOES THE DRB SHOW REPAIR THE HARNESS
WIGGLE THE CONTROL "CONTROL SLEEVE YES OR CONNECTOR THAT
SLEEVE POSITION SENSOR SIGNAL HIGH CAUSED THE TROUBLE
SENSOR CONNECTOR AND EXCEEDED"? CODE TO SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

81
T TEST TC-22A CONTINUED - REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
82
TEST TC-22A CONTINUED - REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED T
R
O
U
B
TEST TC-22A
CONTINUED FROM
KEY OFF.
L
THE PREVIOUS
PAGE.
DISCONNECT THE FUEL
INJECTION PUMP E
C
O
D
USE AN OHMMETER IN FUEL INJ. PUMP IS THE RESISTANCE E
THE FOLLOWING STEPS. CONNECTOR (PUMP BETWEEN 5.0 AND NO REPLACE THE FUEL
MEASURE THE SIDE) CAVITIES 1 7.0 OHMS FOR EACH INJECTION PUMP.*
RESISTANCE
BETWEEN...
AND 2 AND THEN 2
AND 3. FIG.1
MEASUREMENT?
T
YES
E
S
T
S
FUEL INJECTION IS THE RESISTANCE
MEASURE THE PUMP CONNECTOR BELOW 5.0 OHMS FOR YES REPLACE THE FUEL
RESISTANCE BETWEEN (PUMP SIDE) ANY OF THE INJECTION PUMP.*
GROUND AND... CAVITIES 1, 2 AND MEASUREMENTS?
3. FIG.1
NO
MEASURE RESISTANCE IS THE RESISTANCE REPAIR THE

DISCONNECT THE ECM BETWEEN GROUND AND BELOW 5.0 OHMS FOR YES CIRCUIT(S) THAT
HARNESS ECM CONNECTOR C2 ANY OF THE MEASURED BELOW 5.0
CONNECTORS.** CAVITIES 56, 57 MEASUREMENTS? OHMS FOR A SHORT
AND 58. FIG.2 TO GROUND.*
NO
MEASURE THE IS THE RESISTANCE REPAIR THE

RESISTANCE BETWEEN 56 AND 57, 56 AND BELOW 5.0 OHMS FOR YES CIRCUITS THAT HAD
ECM HARNESS 58, 57 AND 58. ANY OF THE RESISTANCE BELOW
CONNECTOR C2 MEASUREMENTS? 5.0 OHMS FOR A
CAVITIES... SHORT TOGETHER.*
NO
MEASURE THE TO THE FUEL

RESISTANCE OF THE INJECTION PUMP
FOLLOWING CIRCUITS HARNESS CONNECTOR.
FROM ECM HARNESS
CONNECTOR C2... FIG.2
ECM 56 TO INJ.PUMP 1 IS THE RESISTANCE REPAIR THE

ABOVE 5.0 OHMS FOR YES CIRCUIT(S)THAT
ECM 57 TO INJ.PUMP 2 ANY OF THE THE MEASURED ABOVE 5.0
MEASUREMENTS? OHMS FOR AN OPEN.*
ECM 58 TO INJ.PUMP 3
NO
CONTINUE TEST
TC-22A ON THE
NEXT PAGE.

83
T TEST TC-22A CONTINUED - REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
84
TEST TC-22A CONTINUED - REPAIRING - CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED T
R
O
U
B
TEST TC-22A REMOVE THE ASD CONNECT A JUMPER L
CONTINUED FROM
THE PREVIOUS
RELAY FROM THE
PDC.
BETWEEN ASD RELAY
CONNECTOR CAVITIES E
PAGE. 3 AND 5 (IN PDC).
FIG.1 FIG.1
C
O
D
E
KEY ON. MEASURE THE VOLTAGE REPAIR THE T
AT FUEL INJECTION IS THE VOLTAGE NO CIRCUIT(S) THAT
USE A VOLTMETER IN PUMP HARNESS BELOW 0.5 VOLT? MEASURED ABOVE 0.5 E
THE FOLLOWING
STEP.
CONNECTOR CAVITIES
1, 2 AND 3. FIG.2
VOLT FOR A SHORT
TO VOLTAGE.* S
T
YES S
REPLACE THE ENGINE

CONTROL MODULE.*

85
T TEST TC-23A REPAIRING - CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
86
TEST TC-23A REPAIRING - CONTROL SLEEVE SENSOR START END POS. NOT ATTAINED T
R
U
B
NOTE: IF OTHER KEY ON.
L
START TEST
TC-23A.
DTC’S ARE PRESENT,
DIAGNOSE OTHER USING THE DRB,
E
DTC’S BEFORE CLEAR CODES.
CONTINUING.
C
O
D
E
PERFORM SEVERAL
T
DRIVE CYCLES, BETWEEN EACH DRIVE E
TURNING THE IGNITION
OFF FOR AT LEAST 10
CYCLE.
S
SECONDS... T
S
DOES THE DRB

MONITOR THE DRB DISPLAY "CONTROL NO
FOR CODES. SLEEVE SENSOR TEST COMPLETE.*
START END POS. NOT
ATTAINED"?
YES
PERFORM SEVERAL
REPLACE THE FUEL DRIVE CYCLES, BETWEEN EACH DRIVE
INJECTION PUMP. TURNING THE IGNITION CYCLE.
OFF FOR AT LEAST 10
SECONDS...
DOES THE DRB

FOR CODES. SLEEVE SENSOR TEST COMPLETE.*
START END POS. NOT
ATTAINED"?
YES
REPLACE THE ENGINE

CONTROL MODULE.*

87
T TEST TC-24A REPAIRING - CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
88
TEST TC-24A REPAIRING - CONTROL SLEEVE SENSOR STOP END POS. NOT ATTAINED T
R
U
B
NOTE: IF OTHER KEY ON.
L
START TEST
TC-24A.
DTC’S ARE PRESENT,
DIAGNOSE OTHER USING THE DRB,
E
DTC’S BEFORE CLEAR CODES.
CONTINUING.
C
O
D
E
PERFORM SEVERAL
T
DRIVE CYCLES, BETWEEN EACH DRIVE E
TURNING THE IGNITION
OFF FOR AT LEAST 10
CYCLE.
S
SECONDS... T
S
DOES THE DRB

FOR CODES. SLEEVE SENSOR STOP TEST COMPLETE.*
END POS. NOT
ATTAINED"?
YES
PERFORM SEVERAL
REPLACE THE FUEL DRIVE CYCLES, BETWEEN EACH DRIVE
INJECTION PUMP. TURNING THE IGNITION CYCLE.
OFF FOR AT LEAST 10
SECONDS...
DOES THE DRB

FOR CODES. SLEEVE SENSOR STOP TEST COMPLETE.*
END POS. NOT
ATTAINED"?
YES
REPLACE THE ENGINE

CONTROL MODULE.*

89
T TEST TC-33A REPAIRING - EGR OPEN CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
90
TEST TC-33A REPAIRING - EGR OPEN CIRCUIT T
R
U
B
START TEST
KEY ON.
DOES THE DRB YES CONTINUE TEST
L
TC-33A. USING THE DRB, DISPLAY "EGR OPEN TC-33A ON THE E
CLEAR CODES. CIRCUIT"? NEXT PAGE.
C
NO O
D
E
WHILE MONITORING
THE DRB FOR CODES, DOES THE DRB YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
WIGGLE THE EVM DISPLAY "EGR OPEN CAUSED THE CODE TO E
HARNESS AND CIRCUIT"? SET.*
CONNECTORS. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

91
T TEST TC-33A CONTINUED - REPAIRING - EGR OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
92
TEST TC-33A CONTINUED - REPAIRING - EGR OPEN CIRCUIT T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE EVM E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
KEY ON. USING A REPAIR THE ASD
VOLTMETER, MEASURE IS THE VOLTAGE NO RELAY OUTPUT T
EVM HARNESS
CONNECTOR CAVITY 1.
OPEN.* E
FIG.1
S
YES T
S
KEY OFF.
USE AN OHMMETER IN
DISCONNECT THE ECM THE FOLLOWING
HARNESS STEPS.
CONNECTORS.**
MEASURE THE REPAIR THE EVM

RESISTANCE BETWEEN IS THE RESISTANCE NO CONTROL CIRCUIT
GROUND AND EVM ABOVE 100K OHMS? FOR A SHORT TO
CONNECTOR CAVITY 2. GROUND.*
FIG.1
YES
MEASURE THE EVM CONNECTOR

RESISTANCE BETWEEN CAVITY 2. IS THE RESISTANCE NO REPAIR THE EVM
ECM CONNECTOR C1 BELOW 5.0 OHMS? CONTROL CIRCUIT
CAVITY 29 AND... FIG.2 FOR AN OPEN.*
YES
REPLACE THE ELECTRIC RECONNECT THE ECM

VACUUM MODULATOR AND EVM HARNESS DOES THE EGR CODE NO REPLACE THE
WITH A KNOWN GOOD CONNECTORS. KEY RESET? ELECTRIC VACUUM
ELECTRIC VACUUM ON. USING THE DRB, MODULATOR.*
MODULATOR. CHECK FOR CODES.
YES
REPLACE THE ENGINE

CONTROL MODULE.*

93
T TEST TC-34A REPAIRING - EGR SHORT CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
94
TEST TC-34A REPAIRING - EGR SHORT CIRCUIT T
R
U
B
START TEST
KEY ON.
L
TC-34A. USING THE DRB, DISPLAY "EGR SHORT TC-34A ON THE E
CLEAR CODES. CIRCUIT"? NEXT PAGE.
C
NO O
D
E
WHILE MONITORING
THE DRB FOR CODES, DOES THE DRB YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
WIGGLE THE EVM DISPLAY "EGR SHORT CAUSED THE CODE TO E
HARNESS AND CIRCUIT"? SET.*
CONNECTORS. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

95
T TEST TC-34A CONTINUED - REPAIRING - EGR SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
96
TEST TC-34A CONTINUED - REPAIRING - EGR SHORT CIRCUIT T
R
O
U
B
TEST TC-34A KEY OFF.
L
CONTINUED FROM
THE PREVIOUS DISCONNECT THE EVM
E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
KEY ON.
T
DOES THE DRB NOW YES REPLACE THE E
USING THE DRB,
CLEAR CODES.
DISPLAY "EGR OPEN
CIRCUIT"?
ELECTRIC VACUUM
MODULATOR.* S
T
S
NO
MEASURE EVM
USE A VOLTMETER IN HARNESS CONNECTOR IS THE VOLTAGE YES REPLACE THE ENGINE
THE FOLLOWING CAVITY 2. BELOW 0.5 VOLTS? CONTROL MODULE.*
STEPS.
FIG.1
NO
KEY OFF. CONNECT A JUMPER

BETWEEN ASD RELAY
REMOVE THE ASD CONNECTOR CAVITIES
RELAY FROM THE 3 AND 5.
PDC.** FIG.2
KEY ON. REPAIR THE EVM

DISCONNECT THE ECM MEASURE EVM IS THE VOLTAGE NO CONTROL CIRCUIT
HARNESS HARNESS CONNECTOR BELOW 0.5 VOLTS? FOR A SHORT TO
CONNECTORS.** CAVITY 2. VOLTAGE.*
FIG.1
YES
REPLACE THE ENGINE

CONTROL MODULE.*

97
T TEST TC-35A REPAIRING - ENGINE SPEED SENSOR DYN. PLAUSIBILITY
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
98
TEST TC-35A REPAIRING - ENGINE SPEED SENSOR DYN. PLAUSIBILITY T
R
U
B
START TEST ATTEMPT TO START DOES THE ENGINE NO CONTINUE TEST
L
TC-35A. THE ENGINE. START? TC-35A ON THE E
NEXT PAGE.
C
YES O
D
E
USING THE SCHEMATIC
DOES THE DRB
DISPLAY "ENGINE YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE ENGINE SPEED FOR CODES. SPEED SENSOR DYN. CAUSED THE CODE TO E
SENSOR CONNECTOR AND PLAUSIBILITY"? SET.*
HARNESS. FIG.1 S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

99
T TEST TC-35A CONTINUED - REPAIRING - ENGINE SPEED SENSOR DYN. PLAUSIBILITY
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
100
TEST TC-35A CONTINUED - REPAIRING - ENGINE SPEED SENSOR DYN. PLAUSIBILITY T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE
DISCONNECT THE ECM
HARNESS E
PAGE. ENGINE SPEED SENSOR CONNECTORS.**
C
O
D
E
MEASURE BETWEEN REPAIR THE ENGINE
USE AN OHMMETER IN ENGINE SPEED IS THE RESISTANCE NO SPEED SENSOR T
THE FOLLOWING
STEPS.
SENSOR HARNESS
CONNECTOR CAVITY 3
ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
A SHORT TO E
AND GROUND. FIG.1 GROUND.*
S
YES T
S
ECM HARNESS REPAIR THE ENGINE

MEASURE THE CONNECTOR C2 IS THE RESISTANCE NO SPEED SENSOR
RESISTANCE CAVITIES 67 AND 69. ABOVE 100K OHMS? CIRCUITS FOR A
BETWEEN... SHORT TOGETHER.*
FIG.2
YES
MEASURE THE ENGINE SPEED REPAIR THE ENGINE

RESISTANCE BETWEEN SENSOR CONNECTOR IS THE RESISTANCE NO SPEED SENSOR
ECM HARNESS CAVITY 3. BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
CONNECTOR C2 AN OPEN.*
CAVITY 67 AND... FIG.2
YES
KEY ON. MEASURE THE VOLTAGE REPAIR THE ENGINE

AT ENGINE SPEED IS THE VOLTAGE NO SPEED SENSOR
USE A VOLTMETER IN SENSOR HARNESS BELOW 0.5 VOLTS? SIGNAL CIRCUIT FOR
THE FOLLOWING CONNECTOR CAVITY 3. A SHORT TO
STEP. FIG.1 VOLTAGE.*
YES
RECONNECT THE ECM USING A VOLTMETER TO WHILE CRANKING THE

AND ENGINE SPEED MEASURE FREQUENCY, ENGINE, IS THE YES REPLACE THE ENGINE
SENSOR HARNESS BACKPROBE ECM FREQUENCY BETWEEN 16 CONTROL MODULE.*
CONNECTORS. HARNESS CONNECTOR C2 AND 20HZ AT 270-300
CAVITY 67. FIG.2 CRANKING RPM?
NO
REPLACE THE ENGINE

SPEED SENSOR.*

101
T TEST TC-36A REPAIRING - ENGINE SPEED SENSOR OVERSPEED RECOGNITION
R
U
B
L
E
C
O
D
E
T
E
S
T
S
102
TEST TC-36A REPAIRING - ENGINE SPEED SENSOR OVERSPEED RECOGNITION T
R
U
B
NOTE: THIS CODE
L
START TEST
TC-36A.
INDICATES THE ENGINE
SPEED SENSOR HAS
E
SEEN AN ENGINE SPEED
ABOVE 5100 RPM.
C
O
D
E
USING THE DRB,

T
CHECK FOR OTHER DOES THE DRB YES REPAIR OTHER CODES E
KEY ON. ENGINE SPEED
SENSOR CODES.
DISPLAY OTHER
CODES?
BEFORE
CONTINUING.* S
T
S
NO
CHECK ENGINE SPEED

USING THE DRB, SENSOR WIRING FOR WERE ANY PROBLEMS YES REPAIR AS
CLEAR CODES. INCORRECT ROUTING FOUND? NECESSARY.*
AND CONNECTIONS
WHICH MAY CAUSE EMI.
NO
DOES THE DRB

TEST DRIVE MONITOR THE DRB DISPLAY "ENGINE NO
VEHICLE. FOR CODES. SPEED SENSOR TEST COMPLETE.*
OVER SPEED
RECOGNITION"?
YES
TEST DRIVE THE DOES THE DRB

REPLACE THE ENGINE VEHICLE. DISPLAY "ENGINE NO
SPEED SENSOR. SPEED SENSOR TEST COMPLETE.*
MONITOR THE DRB OVER SPEED
FOR CODES. RECOGNITION"?
YES
REPLACE THE ENGINE

CONTROL MODULE.*

103
T TEST TC-38A REPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
104
TEST TC-38A REPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY T
R
U
B
START TEST ATTEMPT TO START DOES THE ENGINE NO CONTINUE TEST
L
TC-38A. THE ENGINE. START? TC-38A ON THE E
NEXT PAGE.
C
YES O
D
E
USING THE SCHEMATIC
DOES THE DRB
DISPLAY "ENGINE YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE ENGINE SPEED FOR CODES. SPEED SENSOR CAUSED THE CODE TO E
SENSOR CONNECTOR AND STATIC SET.*
HARNESS. FIG.1 PLAUSIBILITY"? S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

105
T TEST TC-38A CONTINUED - REPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
106
TEST TC-38A CONTINUED - REPAIRING - ENGINE SPEED SENSOR STATIC PLAUSIBILITY T
R
O
U
B
CONTINUED FROM
DISCONNECT THE ECM
HARNESS E
PAGE. ENGINE SPEED SENSOR CONNECTORS.**
C
O
D
E
MEASURE BETWEEN REPAIR THE ENGINE
USE AN OHMMETER IN ENGINE SPEED IS THE RESISTANCE NO SPEED SENSOR T
THE FOLLOWING
STEPS.
SENSOR HARNESS
CONNECTOR CAVITY 3
ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
A SHORT TO E
AND GROUND. FIG.1 GROUND.*
S
YES T
S
ECM HARNESS REPAIR THE ENGINE

MEASURE THE CONNECTOR C2 IS THE RESISTANCE NO SPEED SENSOR
RESISTANCE CAVITIES 67 AND 69. ABOVE 100K OHMS? CIRCUITS FOR A
BETWEEN... SHORT TOGETHER.*
FIG.2
YES
MEASURE THE ENGINE SPEED REPAIR THE ENGINE

RESISTANCE BETWEEN SENSOR CONNECTOR IS THE RESISTANCE NO SPEED SENSOR
ECM HARNESS CAVITY 3. BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
YES
KEY ON. MEASURE THE VOLTAGE REPAIR THE ENGINE

AT ENGINE SPEED IS THE VOLTAGE NO SPEED SENSOR
USE A VOLTMETER IN SENSOR HARNESS BELOW 0.5 VOLTS? SIGNAL CIRCUIT FOR
THE FOLLOWING CONNECTOR CAVITY 3. A SHORT TO
STEP. FIG.1 VOLTAGE.*
YES
RECONNECT THE ECM USING A VOLTMETER TO WHILE CRANKING THE

AND ENGINE SPEED MEASURE FREQUENCY, ENGINE, IS THE NO REPLACE THE ENGINE
SENSOR HARNESS BACKPROBE ECM FREQUENCY BETWEEN 16 SPEED SENSOR.*
CONNECTORS. HARNESS CONNECTOR C2 AND 20HZ AT 270-300
CAVITY 67. FIG.2 CRANKING RPM?
YES
REPLACE THE ENGINE

CONTROL MODULE.*

107
T TEST TC-43A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
108
TEST TC-43A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
KEY OFF.
WAIT 30 SECONDS. MONITOR THE DRB
DOES THE DRB
DISPLAY "FUEL YES CONTINUE TEST
T
ATTEMPT TO START
AND IDLE THE
FOR CODES. QUANTITY ACTUATOR
NEG GOV DEVIATION
TC-43A ON THE
NEXT PAGE.
E
ENGINE. COLD"? S
T
NO S
USING THE DOES THE DRB REPAIR THE HARNESS

SCHEMATIC, WIGGLE DISPLAY "FUEL YES OR CONNECTOR THAT
THE FUEL INJECTION QUANTITY ACTUATOR CAUSED THE TROUBLE
PUMP CONNECTOR AND NEG GOV DEVIATION CODE TO SET.*
HARNESS. FIG.1 COLD"?
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

109
T TEST TC-43A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION
R COLD
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
110
TEST TC-43A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION T
COLD R
O
U
B
CONTINUED FROM
USE AN OHMMETER IN
THE FOLLOWING E
PAGE. FUEL INJECTION STEPS.
PUMP CONNECTOR.**
C
O
D
E
MEASURE THE CAVITY 8 AND IS THE RESISTANCE
RESISTANCE BETWEEN CAVITIES 4, 5, 6 ABOVE 100K OHMS NO REPLACE THE FUEL T
FUEL INJECTION
PUMP CONNECTOR
AND THEN GROUND. FOR EACH
MEASUREMENT?
INJECTION PUMP.*
E
(PUMP SIDE)... FIG.1
S
YES T
S
DISCONNECT THE ECM MEASURE THE

HARNESS RESISTANCE BETWEEN
CONNECTORS.** GROUND AND...
FUEL INJECTION REPAIR THE FUEL

PUMP HARNESS IS THE RESISTANCE NO QUANTITY ACTUATOR
CONNECTOR ABOVE 100K OHMS? CONTROL CIRCUIT
CAVITY 8. FOR A SHORT TO
FIG.2 GROUND.*
YES
MEASURE THE CAVITY 8 AND IS THE RESISTANCE REPAIR AS NECESSARY

RESISTANCE BETWEEN CAVITIES ABOVE 100K OHMS NO ANY CIRCUIT SHORTED
FUEL INJECTION 4, 5, AND 6. FOR EACH TO THE FUEL QUANTITY
PUMP HARNESS MEASUREMENT? ACTUATOR CONTROL
CONNECTOR... FIG.2 CIRCUIT.*
YES
NOTE: BEFORE
REPLACING AN ECM, DID THE FUEL NO REPLACE THE FUEL
PERFORM TEST NTC-3A INJECTION PUMP INJECTION PUMP.*
TO CHECK INTERNAL PASS TEST NTC-3A?
FUEL PUMP CIRCUITRY.
YES
REPLACE THE ENGINE

CONTROL MODULE.*

111
T TEST TC-44A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
112
TEST TC-44A REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
START
VARY
THE ENGINE.
THE ENGINE MONITOR THE DRB DOES THE DRB YES CONTINUE TEST
T
SPEED FROM IDLE TO FOR CODES. DISPLAY THIS CODE? TC-44A ON THE E
3500 RPM SEVERAL NEXT PAGE.
TIMES. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

113
T TEST TC-44A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION
R WARM
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
114
TEST TC-44A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR NEG GOV DEVIATION T
WARM R
O
U
B
CONTINUED FROM
USE AN OHMMETER IN
THE FOLLOWING E
PAGE. FUEL INJECTION STEPS.
PUMP CONNECTOR.**
C
O
D
E
MEASURE THE CAVITY 8 AND IS THE RESISTANCE
RESISTANCE BETWEEN CAVITIES 4, 5, 6 ABOVE 100K OHMS NO REPLACE THE FUEL T
FUEL INJECTION
PUMP CONNECTOR
AND THEN GROUND. FOR EACH
MEASUREMENT?
INJECTION PUMP.*
E
(PUMP SIDE)... FIG.1
S
YES T
S
DISCONNECT THE ECM MEASURE THE

HARNESS RESISTANCE BETWEEN
CONNECTORS.** GROUND AND...
FUEL INJECTION REPAIR THE FUEL

PUMP HARNESS IS THE RESISTANCE NO QUANTITY ACTUATOR
CONNECTOR ABOVE 100K OHMS? CONTROL CIRCUIT
CAVITY 8. FOR A SHORT TO
FIG.2 GROUND.*
YES
MEASURE THE CAVITY 8 AND IS THE RESISTANCE REPAIR AS NECESSARY

RESISTANCE BETWEEN CAVITIES ABOVE 100K OHMS NO ANY CIRCUIT SHORTED
FUEL INJECTION 4, 5, AND 6. FOR EACH TO THE FUEL QUANTITY
PUMP HARNESS MEASUREMENT? ACTUATOR CONTROL
CONNECTOR... FIG.2 CIRCUIT.*
YES
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

115
T TEST TC-45A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
116
TEST TC-45A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
START
VARY
THE ENGINE.
T
TIMES. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

117
T TEST TC-45A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION
R COLD
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
118
TEST TC-45A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION T
COLD R
O
U
B
TEST TC-45A
CONTINUED FROM
CHECK FOR RECENT
REPLACEMENT OR L
THE PREVIOUS
PAGE.
MOVEMENT OF THE
FUEL INJECTION E
PUMP.
C
O
D
NOTE: AN
E
IMPROPERLY TIMED WAS THE FUEL YES RESET FUEL
FUEL INJECTION INJECTION PUMP INJECTION PUMP TO
PUMP WILL CAUSE
THIS CODE TO SET.
MOVED OR REPLACED? ENGINE TIMING.*
T
E
NO
S
T
S
INSPECT THE FUEL
SYSTEM FOR AT THE FUEL TANK WAS A RESTRICTION YES REPAIR AS
RESTRICTIONS AT THE MODULE. FOUND? NECESSARY.*
DELIVERY LINES,
FILTER AND....
NO
NOTE: AN
INTERMITTENT SHORT CIRCUIT CAN ALSO
TO VOLTAGE ON THE SET THIS CODE.
FUEL QUANTITY
ACTUATOR CONTROL...
KEY OFF. CONNECT A TEST

DISCONNECT THE LIGHT BETWEEN THE AND GROUND.
FUEL INJECTION FUEL QUANTITY
PUMP HARNESS ACTUATOR CONTROL FIG.1
CONNECTOR.** CIRCUIT...
KEY ON. THE FUEL INJECTION DID THE TEST LIGHT REPAIR THE FUEL
PUMP HARNESS ILLUMINATE WHEN YES QUANTITY ACTUATOR
WIGGLE THE HARNESS CONNECTOR AND THE THE HARNESS WAS CONTROL CIRCUIT
AND CONNECTORS ECM WHILE MONITORING WIGGLED? FOR A SHORT TO
BETWEEN... THE TEST LIGHT. VOLTAGE.*
NO
REPLACE THE FUEL START AND OPERATE

INJECTION PUMP. THE ENGINE BETWEEN DOES THE DRB YES REPLACE THE ENGINE
IDLE AND 3500 RPM DISPLAY THIS CODE? CONTROL MODULE.*
USING THE DRB, WHILE MONITORING
CLEAR CODES. THE DRB DISPLAY.
NO
TEST COMPLETE.*

119
T TEST TC-46A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
120
TEST TC-46A REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
START
VARY
THE ENGINE.
T
TIMES. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

121
T TEST TC-46A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION
R WARM
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
122
TEST TC-46A CONTINUED - REPAIRING - FUEL QUANTITY ACTUATOR POS GOV DEVIATION T
WARM R
O
U
B
TEST TC-46A
CONTINUED FROM
CHECK FOR RECENT
REPLACEMENT OR L
THE PREVIOUS
PAGE.
MOVEMENT OF THE
FUEL INJECTION E
PUMP.
C
O
D
NOTE: AN
E
IMPROPERLY TIMED WAS THE FUEL YES RESET FUEL
FUEL INJECTION INJECTION PUMP INJECTION PUMP TO
PUMP WILL CAUSE
THIS CODE TO SET.
MOVED OR REPLACED? ENGINE TIMING.*
T
E
NO
S
T
S
INSPECT THE FUEL
SYSTEM FOR AT THE FUEL TANK WAS A RESTRICTION YES REPAIR AS
RESTRICTIONS AT THE MODULE. FOUND? NECESSARY.*
DELIVERY LINES,
FILTER AND....
NO
NOTE: AN
INTERMITTENT SHORT CIRCUIT CAN ALSO
TO VOLTAGE ON THE SET THIS CODE.
FUEL QUANTITY
ACTUATOR CONTROL...
KEY OFF. CONNECT A TEST

DISCONNECT THE LIGHT BETWEEN THE AND GROUND.
FUEL INJECTION FUEL QUANTITY
PUMP HARNESS ACTUATOR CONTROL FIG.1
CONNECTOR.** CIRCUIT...
KEY ON. THE FUEL INJECTION DID THE TEST LIGHT REPAIR THE FUEL
PUMP HARNESS ILLUMINATE WHEN YES QUANTITY ACTUATOR
WIGGLE THE HARNESS CONNECTOR AND THE THE HARNESS WAS CONTROL CIRCUIT
AND CONNECTORS ECM WHILE MONITORING WIGGLED? FOR A SHORT TO
BETWEEN... THE TEST LIGHT. VOLTAGE.*
NO
REPLACE THE FUEL START AND OPERATE

INJECTION PUMP. THE ENGINE BETWEEN DOES THE DRB YES REPLACE THE ENGINE
IDLE AND 3500 RPM DISPLAY THIS CODE? CONTROL MODULE.*
USING THE DRB, WHILE MONITORING
CLEAR CODES. THE DRB DISPLAY.
NO
TEST COMPLETE.*

123
T TEST TC-47A REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
124
TEST TC-47A REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED T
R
U
B
START TEST
L
TC-47A. USING THE DRB, TEMPERATURE SENSOR TC-47A ON THE E
CLEAR CODES. SRC HIGH NEXT PAGE.
EXCEEDED"?
C
NO O
D
E
USING THE SCHEMATIC
DOES THE DRB
DISPLAY "FUEL YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE FUEL TEMPERATURE FOR CODES. TEMPERATURE SENSOR CAUSED THE CODE TO E
SENSOR CONNECTOR AND SRC HIGH SET.*
HARNESS. FIG.1 EXCEEDED"? S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

125
T TEST TC-47A CONTINUED - REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
126
TEST TC-47A CONTINUED - REPAIRING - FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED T
R
O
U
B
CONTINUED FROM L
THE PREVIOUS
PAGE.
DISCONNECT THE
FUEL INJECTION E
PUMP CONNECTOR.**
C
O
D
E
CONNECT A JUMPER
BETWEEN THE FUEL
DISPLAY "FUEL YES REPLACE THE FUEL T
TEMP SENSOR SIGNAL
AND SENSOR RETURN
USING THE DRB,
CLEAR AND THEN
TEMPERATURE SENSOR
SRC LOW EXCEEDED"?
INJECTION PUMP.* E
CIRCUITS. FIG.1 READ CODES. S
T
NO
S
MOVE THE JUMPER DOES THE DRB REPAIR THE FUEL

FROM THE SENSOR MONITOR THE DRB DISPLAY "FUEL YES TEMPERATURE SENSOR
RETURN TO AN FOR CODES. TEMPERATURE SENSOR RETURN CIRCUIT FOR
ENGINE GROUND. SRC LOW EXCEEDED"? AN OPEN.*
NO
KEY OFF. USING AN OHMMETER, REPAIR THE FUEL

MEASURE THE FUEL IS THE RESISTANCE NO TEMPERATURE SENSOR
DISCONNECT THE ECM TEMPERATURE SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
HARNESS SIGNAL CIRCUIT AN OPEN.*
CONNECTORS.** FIG.2
YES
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

127
T TEST TC-48A REPAIRING - FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
128
TEST TC-48A REPAIRING - FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED T
R
U
B
START TEST
L
TC-48A. USING THE DRB, TEMPERATURE SENSOR TC-48A ON THE E
CLEAR CODES. SRC LOW EXCEEDED"? NEXT PAGE.
C
NO O
D
E
USING THE SCHEMATIC,
WIGGLE THE FUEL MONITOR THE DRB
DOES THE DRB
DISPLAY "FUEL YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
TEMPERATURE SENSOR FOR CODES. TEMPERATURE SENSOR CAUSED THE CODE TO E
CONNECTOR AND SRC LOW EXCEEDED"? SET.*
HARNESS. FIG.1 S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

129
T TEST TC-48A CONTINUED - REPAIRING - FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
130
TEST TC-48A CONTINUED - REPAIRING - FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED T
R
O
U
B
L
CONTINUED FROM
E
PAGE. FUEL INJECTION
PUMP CONNECTOR.**
C
O
D
E
KEY ON. KEY OFF. DOES THE DRB

T
WAIT 10 SECONDS. DISPLAY "FUEL YES REPLACE THE FUEL E
USING THE DRB,
CLEAR CODES.
KEY ON. TEMPERATURE SENSOR
SRC HIGH
INJECTION PUMP.*
S
READ CODES. EXCEEDED"? T
S
NO

MEASURE THE FUEL IS THE RESISTANCE NO TEMPERATURE SENSOR
DISCONNECT THE ECM TEMPERATURE SENSOR ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
HARNESS SIGNAL CIRCUIT TO A SHORT TO
CONNECTORS.** GROUND. FIG.1 GROUND.*
YES
USING AN OHMMETER, FUEL INJECTION PUMP REPAIR THE FUEL

MEASURE THE HARNESS CONNECTOR IS THE RESISTANCE NO TEMP SENSOR SIGNAL
RESISTANCE CAVITIES 4 AND 7. ABOVE 100K OHMS? CIRCUIT SHORTED TO
BETWEEN... THE SENSOR RETURN
FIG.2 CIRCUIT.*
YES
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

131
T TEST TC-49A REPAIRING - GLOW DISPLAY OPEN CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
132
TEST TC-49A REPAIRING - GLOW DISPLAY OPEN CIRCUIT T
R
U
B
START TEST
KEY ON.
DOES THE DRB YES
REPAIR OTHER
TROUBLE CODES
L
TC-49A. USING THE DRB, DISPLAY OTHER BEFORE E
READ CODES. CODES? CONTINUING.
C
NO O
D
E
USING THE DRB,

IS THE WAIT TO
START LAMP NO CONTINUE TEST
T
ACTUATE THE WAIT
TO START LAMP.
FLASHING ON AND
OFF?
TC-49A ON THE
NEXT PAGE.
E
S
T
YES S

FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST DID THE WIGGLING REPAIR AS
HARNESS FROM THE STILL BE ACTUATING INTERRUPT THE WAIT YES NECESSARY WHERE
INSTRUMENT CLUSTER THE WAIT TO START TO START LAMP WIGGLING CAUSED
TO THE ENGINE LAMP. FLASHING? FLASHING TO BE
CONTROL MODULE. INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

133
T TEST TC-49A CONTINUED - REPAIRING - GLOW DISPLAY OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
134
TEST TC-49A CONTINUED - REPAIRING - GLOW DISPLAY OPEN CIRCUIT T
R
O
U
B
TEST TC-49A DISCONNECT THE ECM
L
CONTINUED FROM
THE PREVIOUS KEY OFF.
AND INSTRUMENT
CLUSTER HARNESS
E
PAGE. CONNECTORS.**
C
O
D
E
MEASURE THE REPAIR THE WAIT TO

T
USE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE NO START LAMP CONTROL E
THE FOLLOWING
STEPS.
WAIT TO START LAMP
CONTROL CIRCUIT.
BELOW 5.0 OHMS? CIRCUIT FOR AN
OPEN.* S
FIG.1 T
S
YES
MEASURE THE REPAIR THE WAIT TO

RESISTANCE BETWEEN IS THE RESISTANCE NO START LAMP CONTROL
ECM HARNESS ABOVE 100K OHMS? CIRCUIT FOR A
CONNECTOR C1 CAVITY SHORT TO GROUND.
32 AND GROUND. FIG.2
YES
RECONNECT THE KEY ON. CONNECT A

INSTRUMENT CLUSTER JUMPER WIRE BETWEEN DID THE WAIT TO YES REPLACE THE ENGINE
HARNESS ECM HARNESS START LAMP CONTROL MODULE.*
CONNECTORS. CONNECTOR C1 CAVITY ILLUMINATE?
32 AND GROUND. FIG.2
NO
REMOVE AND INSPECT NO REPLACE THE BULB

KEY OFF. WAIT TO START LAMP IS THE BULB OK? AND RETEST.*
BULB.
YES
REPLACE THE
ELECTRO/MECHANICAL
INSTRUMENT
CLUSTER.*

135
T TEST TC-50A REPAIRING - GLOW DISPLAY SHORT CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
136
TEST TC-50A REPAIRING - GLOW DISPLAY SHORT CIRCUIT T
R
U
B
START TEST
KEY ON.
DOES THE DRB YES
REPAIR OTHER
TROUBLE CODES
L
TC-50A. USING THE DRB, DISPLAY OTHER BEFORE E
READ CODES. CODES? CONTINUING.
C
NO O
D
E
USING THE DRB,

IS THE WAIT TO
START LAMP NO CONTINUE TEST
T
ACTUATE THE WAIT
TO START LAMP.
FLASHING ON AND
OFF?
TC-50A ON THE
NEXT PAGE.
E
S
T
YES S

FIG.1 FIG.2
NO
WIGGLE THE WIRING NOTE: THE DRB MUST DID THE WIGGLING REPAIR AS
HARNESS FROM THE STILL BE ACTUATING INTERRUPT THE WAIT YES NECESSARY WHERE
INSTRUMENT CLUSTER THE WAIT TO START TO START LAMP WIGGLING CAUSED
TO THE ENGINE LAMP. FLASHING? FLASHING TO BE
CONTROL MODULE. INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

137
T TEST TC-50A CONTINUED - REPAIRING - GLOW DISPLAY SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
138
TEST TC-50A CONTINUED - REPAIRING - GLOW DISPLAY SHORT CIRCUIT T
R
O
U
B
TEST TC-50A
CONTINUED FROM
L
THE PREVIOUS KEY OFF E
PAGE.
C
O
D
E
DISCONNECT THE
INSTRUMENT CLUSTER
T
HARNESS
CONNECTORS.**
KEY ON. E
S
T
S
USING A VOLTMETER, AT INSTRUMENT REPAIR THE WAIT TO

MEASURE THE WAIT CLUSTER HARNESS IS THE VOLTAGE YES START LAMP CONTROL
TO START LAMP CONNECTOR C1 ABOVE 1.0 VOLT? CIRCUIT FOR A
CONTROL CIRCUIT... CAVITY 8. SHORT TO VOLTAGE.*
FIG. 1
NO
USING THE DRB, DOES THE DRB

CLEAR CODES. KEY ON. DISPLAY "GLOW YES REPLACE THE ENGINE
DISPLAY SHORT CONTROL MODULE.*
KEY OFF FOR 30 READ CODES. CIRCUIT"?
SECONDS.
NO
CHECK FOR A SHORTED

WAIT TO START LAMP
BULB. IF OK, REPLACE
THE INSTRUMENT
CLUSTER.*

139
T TEST TC-51A REPAIRING - GLOW RELAY CONTROLLER OPEN CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
140
TEST TC-51A REPAIRING - GLOW RELAY CONTROLLER OPEN CIRCUIT T
R
U
B
START TEST
KEY ON.
IS THE GLOW PLUG NO CONTINUE TEST
L
TC-51A. USING THE DRB, RELAY CYCLING? TC-51A ON THE E
ACTUATE THE GLOW NEXT PAGE.
PLUG RELAY.
C
YES O
D
E
AT THIS TIME, THE
CONDITION REQUIRED
USING THE SCHEMATIC
T
FIG.1 FIG.2 S
T
NO S
USING THE SCHEMATIC NOTE: THE DRB MUST REPAIR AS

AS A GUIDE,WIGGLE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
THE WIRING HARNESS THE GLOW PLUG INTERRUPT THE WIGGLING CAUSED
FROM THE GLOW RELAY RELAY. CYCLING? THE CYCLING TO BE
TO THE ECM. FIG.2 INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

141
T TEST TC-51A CONTINUED - REPAIRING - GLOW RELAY CONTROLLER OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
142
TEST TC-51A CONTINUED - REPAIRING - GLOW RELAY CONTROLLER OPEN CIRCUIT T
R
O
U
B
L
CONTINUED FROM
E
PAGE. GLOW PLUG RELAY.**
C
O
D
E

T
MEASURE THE FUSED IS THE VOLTAGE NO ASD RELAY OUTPUT E
KEY ON. ASD RELAY OUTPUT
CIRCUIT.
OPEN.* S
FIG.1 T
S
YES

RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE GLOW
USE AN OHMMETER IN CAVITY 85 AND 86 OF BELOW 100.0 OHMS? PLUG RELAY.*
THE FOLLOWING THE GLOW PLUG RELAY.
STEPS. FIG.2
YES
KEY OFF. MEASURE THE REPAIR THE GLOW

RESISTANCE BETWEEN IS THE RESISTANCE NO PLUG RELAY CONTROL
DISCONNECT THE ECM GROUND AND CAVITY 85 ABOVE 100K OHMS? CIRCUIT FOR A
HARNESS OF THE RELAY HARNESS SHORT TO GROUND.*
CONNECTORS.** CONNECTOR. FIG.1
YES
MEASURE THE FROM RELAY HARNESS REPAIR THE GLOW

RESISTANCE OF THE CONNECTOR CAVITY IS THE RESISTANCE NO PLUG RELAY CONTROL
GLOW PLUG RELAY 85 AND ECM BELOW 5.0 OHMS? CIRCUIT FOR AN
CONTROL CIRCUIT... CONNECTOR C1 OPEN.*
CAVITY 42. FIG.3
YES
REPLACE THE ENGINE

CONTROL MODULE.*

143
T TEST TC-53A REPAIRING - GLOW RELAY CONTROLLER SHORT CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
144
TEST TC-53A REPAIRING - GLOW RELAY CONTROLLER SHORT CIRCUIT T
R
U
B
START TEST
KEY ON.
IS THE GLOW PLUG NO CONTINUE TEST
L
TC-53A. USING THE DRB, RELAY CYCLING? TC-53A ON THE E
ACTUATE THE GLOW NEXT PAGE.
PLUG RELAY.
C
YES O
D
E
AT THIS TIME, THE
CONDITION REQUIRED
USING THE SCHEMATIC
T
FIG.1 FIG.2 S
T
NO S
USING THE SCHEMATIC NOTE: THE DRB MUST REPAIR AS

AS A GUIDE, WIGGLE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE
THE WIRING HARNESS THE GLOW PLUG INTERRUPT THE WIGGLING CAUSED
FROM THE GLOW RELAY RELAY. CYCLING? CYCLING TO BE
TO THE ECM. FIG.2 INTERRUPTED.*
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

145
T TEST TC-53A CONTINUED - REPAIRING - GLOW RELAY CONTROLLER SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
146
TEST TC-53A CONTINUED - REPAIRING - GLOW RELAY CONTROLLER SHORT CIRCUIT T
R
O
U
B
L
CONTINUED FROM
THE PREVIOUS REMOVE THE GLOW
E
PAGE. PLUG RELAY.**
C
O
D
E
USING AN OHMETER, 85 AND 86, 85 AND IS THE RESISTANCE

T
MEASURE THE 87, 85 AND 30. BELOW 30.0 OHMS IN YES REPLACE THE GLOW E
RESISTANCE BETWEEN
GLOW PLUG RELAY
ANY OF THE
MEASUREMENTS?
PLUG RELAY.*
S
TERMINALS... FIG.1 T
S
NO
DISCONNECT THE ECM REMOVE THE ASD

HARNESS RELAY FROM THE
CONNECTORS.** PDC.**

BETWEEN ASD RELAY
CONNECTOR CAVITIES USE A VOLTMETER IN
3 AND 5. THE FOLLOWING
FIG.2 STEP.
MEASURE GLOW PLUG REPAIR THE GLOW

RELAY HARNESS IS THE VOLTAGE NO PLUG RELAY CONTROL
CONNECTOR CAVITY 85. BELOW 1.0 VOLT? CIRCUIT FOR A
SHORT TO VOLTAGE.*
FIG.3
YES
REPLACE THE ENGINE

CONTROL MODULE.*

147
T TEST TC-56A REPAIRING - INDUCTIVE AUX. SPEED SENSOR TROUBLE CODES
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1 FIG.2
FIG.3 FIG.4
FIG.5
148
TEST TC-56A REPAIRING - INDUCTIVE AUX. SPEED SENSOR TROUBLE CODES T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
START
VARY
THE ENGINE.
T
TIMES. S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

149
T TEST TC-56A CONTINUED - REPAIRING - INDUCTIVE AUX. SPEED SENSOR TROUBLE CODES
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
150
TEST TC-56A CONTINUED - REPAIRING - INDUCTIVE AUX. SPEED SENSOR TROUBLE CODES T
R
O
U
B
CONTINUED FROM
THE PREVIOUS
DISCONNECT THE
NEEDLE MOVEMENT E
PAGE. SENSOR HARNESS
CONNECTOR.**
C
O
D
E
INSPECT THE NEEDLE THE SENSOR HARNESS IS THERE ANY
MOVEMENT SENSOR AND ENGINE DAMAGE OR YES REPAIR AS T
CONNECTOR
TERMINALS AT
HARNESS. CORROSION AT
EITHER HARNESS
NECESSARY.*
E
BOTH.... FIG. 1 AND 2 CONNECTOR?
S
NO T
S
CHECK THE WIRING INTERFERENCE COULD

HARNESS FOR BE CAUSED BY LARGE IS THE WIRING YES REPAIR AS
MIS-ROUTING THAT CURRENT CARRYING HARNESS NECESSARY.*
COULD INDUCE WIRES OR THE MIS-ROUTED?
INTERFERENCE. ALTERNATOR.
NO
DISCONNECT THE ECM USE AN OHMMETER IN

HARNESS THE FOLLOWING
CONNECTORS.** STEP.
MEASURE THE AND NEEDLE MOVEMENT REPAIR THE NEEDLE

RESISTANCE BETWEEN SENSOR HARNESS IS THE RESISTANCE NO MOVEMENT SENSOR
ECM HARNESS CONNECTOR CAVITY 1. BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
CONNECTOR AN OPEN.*
CAVITY 62... FIG.3
YES
KEY OFF. REPLACE THE START AND OPERATE

NEEDLE MOVEMENT THE ENGINE FROM DOES THIS CODE YES REPLACE THE ENGINE
SENSOR. RECONNECT IDLE TO 3500 RPM. RESET? CONTROL MODULE.*
ALL CONNECTORS. KEY USING THE DRB,
ON. CLEAR CODES. READ CODES.
NO
TEST COMPLETE.*

151
T TEST TC-72A REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
152
TEST TC-72A REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED T
R
U
B
START TEST
KEY ON.
KEY OFF FOR 30
L
TC-72A. USING THE DRB, SECONDS. E
CLEAR CODES.
C
O
D
E
DISPLAY "NEEDLE YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
MOVEMENT SENSOR
SRC HIGH
TC-72A ON THE
NEXT PAGE.
E
EXCEEDED"? S
T
NO S
USING THE SCHEMATIC DOES THE DRB REPAIR THE HARNESS

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "NEEDLE YES OR CONNECTOR THAT
THE SENSOR CONNECTOR FOR CODES. MOVEMENT SENSOR CAUSED THE CODE TO
AND HARNESS. SRC HIGH SET.*
FIG.1 EXCEEDED"?
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

153
T TEST TC-72A CONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
154
TEST TC-72A CONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED T
R
O
U
B
TEST TC-72A
CONTINUED FROM
DISCONNECT THE
NEEDLE MOVEMENT L
THE PREVIOUS
PAGE.
KEY OFF. SENSOR HARNESS
CONNECTOR.** E
C
O
D
KEY OFF.
E
USE A VOLTMETER IN REMOVE THE ASD
DISCONNECT THE ECM THE FOLLOWING RELAY FROM THE
HARNESS
CONNECTORS.**
STEP. PDC.**
T
E
S
T
S
CONNECT A JUMPER KEY ON. MEASURE REPAIR THE NEEDLE
BETWEEN ASD RELAY THE NEEDLE IS THE VOLTAGE NO MOVEMENT SENSOR
CONNECTOR CAVITIES MOVEMENT SENSOR BELOW 0.5 VOLT? SIGNAL CIRCUIT FOR
3 AND 5. SIGNAL CIRCUIT. A SHORT TO
FIG.1 FIG.2 VOLTAGE.*
YES
CONNECT A JUMPER
RECONNECT THE ECM BETWEEN THE NEEDLE
HARNESS SENSOR SIGNAL AND
CONNECTORS. SENSOR RETURN
CIRCUITS. FIG.2
DOES THE DRB

MONITOR THE DRB DISPLAY "NEEDLE YES REPLACE THE NEEDLE
FOR CODES. MOVEMENT SENSOR MOVEMENT SENSOR.*
SRC LOW EXCEEDED"?
NO
MOVE THE JUMPER DOES THE DRB

FROM THE SENSOR MONITOR THE DRB DISPLAY "NEEDLE YES REPAIR THE SENSOR
RETURN TO AN FOR CODES. MOVEMENT SENSOR RETURN CIRCUIT FOR
ENGINE GROUND. SRC LOW EXCEEDED"? AN OPEN.*
NO
MEASURE THE REPAIR THE NEEDLE

USE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE NO MOVEMENT SENSOR
THE FOLLOWING NEEDLE MOVEMENT BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
STEP. SENSOR SIGNAL AN OPEN.*
CIRCUIT. FIG.3
YES
REPLACE THE ENGINE

CONTROL MODULE.*

155
T TEST TC-73A REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
156
TEST TC-73A REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED T
R
U
B
START TEST
KEY ON.
KEY OFF FOR 30
L
TC-73A. USING THE DRB, SECONDS. E
CLEAR CODES.
C
O
D
E
DISPLAY " NEEDLE YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
MOVEMENT SENSOR
SRC LOW EXCEEDED"?
TC-73A ON THE
NEXT PAGE.
E
S
T
NO S
USING THE SCHEMATIC, DOES THE DRB REPAIR THE HARNESS

WIGGLE THE NEEDLE MONITOR THE DRB DISPLAY "NEEDLE YES OR CONNECTOR THAT
MOVEMENT SENSOR FOR CODES. MOVEMENT SENSOR CAUSED THE CODE TO
CONNECTOR AND SRC LOW EXCEEDED"? SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

157
T TEST TC-73A CONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
158
TEST TC-73A CONTINUED - REPAIRING - NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED T
R
O
U
B
TEST TC-73A
CONTINUED FROM
KEY OFF.
DISCONNECT THE
DOES THE DRB
DISPLAY "NEEDLE YES REPLACE THE NEEDLE
L
THE PREVIOUS NEEDLE MOVEMENT MOVEMENT SENSOR MOVEMENT SENSOR.* E
PAGE. SENSOR.** SRC HIGH
KEY ON. EXCEEDED"?
C
NO O
D
E
KEY OFF.
USE AN OHMMETER IN
T
DISCONNECT THE ECM
HARNESS
THE FOLLOWING
STEPS.
E
CONNECTORS.** S
T
S
NEEDLE MOVEMENT REPAIR THE NEEDLE

MEASURE THE SENSOR SIGNAL IS THE RESISTANCE NO MOVEMENT SENSOR
RESISTANCE OF CIRCUIT TO GROUND. ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
THE... A SHORT TO
FIG.1 GROUND.*
YES
MEASURE THE REPAIR THE NEEDLE

RESISTANCE BETWEEN THE SENSOR RETURN IS THE RESISTANCE YES MOVEMENT SENSOR
THE NEEDLE MOVEMENT CIRCUIT. FIG.1 BELOW 5.0 OHMS? CIRCUITS FOR A
SENSOR SIGNAL SHORT TOGETHER.*
CIRCUIT AND...
NO
REPLACE THE ENGINE

CONTROL MODULE.*

159
T TEST TC-74A REPAIRING - REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
160
TEST TC-74A REPAIRING - REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
START AND TURN OFF
THE ENGINE SEVERAL
DISPLAY "REDUNDANT YES CONTINUE TEST
T
TIMES, PAUSING FOR
TEN SECONDS AT
MONITOR THE DRB
FOR CODES.
EMERG. STOP
PLAUSIBILITY IN
TC-74A ON THE
NEXT PAGE.
E
KEY OFF EACH TIME. AFTER-RUN"? S
T
NO S
AT THIS TIME, THE REVIEW THE CIRCUIT

CONDITION REQUIRED DESCRIPTION FOR A
TO SET THE CODE IS PROPER
NOT PRESENT. UNDERSTANDING OF
FIG. 1 THIS CODE. FIG.1
USING THE SCHEMATIC

THE WIRING AND FOUND? NECESSARY.*
CONNECTORS.
FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

161
T TEST TC-74A CONTINUED - REPAIRING - REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
162
TEST TC-74A CONTINUED - REPAIRING - REDUNDANT EMER. STOP PLAUSIBILITY IN AFTER-RUN T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE ECM
REMOVE THE ASD
RELAY FROM E
PAGE. HARNESS THE PDC.**
CONNECTORS.*
C
O
D
E
CONNECT A JUMPER USING A VOLTMETER, REPAIR THE FUEL
BETWEEN ASD RELAY MEASURE THE IS THE VOLTAGE NO SHUTDOWN SOLENOID T
CONNECTOR CAVITIES
3 AND 5.
VOLTAGE AT ECM
HARNESS CONNECTOR
BELOW 0.5 VOLTS? CONTROL CIRCUIT
FOR A SHORT TO E
FIG.1 CAVITY 77. FIG.2 VOLTAGE.*
S
YES T
S
REMOVE THE JUMPER REINSTALL THE ASD

FROM THE ASD RELAY RELAY.
CONNECTOR.
DISCONNECT THE KEY ON.

RECONNECT THE ECM FUEL INJECTION
HARNESS PUMP HARNESS USING THE DRB,
CONNECTORS. CONNECTOR.** ACTUATE THE FUEL
SHUTDOWN SOLENOID.
WITH THE DRB MEASURE THE VOLTAGE

ACTUATING THE AT FUEL INJECTION DOES VOLTMETER YES REPLACE THE FUEL
SOLENOID, USE A PUMP HARNESS CHANGE FROM B+ TO INJECTION PUMP.*
VOLTMETER TO... CONNECTOR CAVITY 6. 0 VOLTS?
FIG.3
NO
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

163
T TEST TC-75A REPAIRING - REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
164
TEST TC-75A REPAIRING - REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
CYCLE THE IGNITION
ON AND OFF SEVERAL KEY ON.
DOES THE DRB
DISPLAY "REDUNDANT YES CONTINUE TEST
T
TIMES, PAUSING FOR
TEN SECONDS AT KEY READ CODES.
EMERG. STOP
POWERSTAGE
TC-75A ON THE
NEXT PAGE.
E
ON AND OFF. DEFECTIVE"? S
T
NO S

FIG.1 THIS CODE.
USING THE SCHEMATIC

CONNECTORS.
FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

165
T TEST TC-75A CONTINUED - REPAIRING - REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
166
TEST TC-75A CONTINUED - REPAIRING - REDUNDANT EMER. STOP POWERSTAGE DEFECTIVE T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE FUEL
DISCONNECT THE ECM
HARNESS E
PAGE. INJECTION PUMP CONNECTORS.**
C
O
D
E
MEASURE THE REPAIR THE FUEL
USE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE NO SHUTDOWN SOLENOID T
THE FOLLOWING
STEPS.
FUEL SHUTDOWN
SOLENOID CONTROL
BELOW 5.0 OHMS? CONTROL CIRCUIT
FOR AN OPEN.* E
CIRCUIT. FIG.1
S
YES T
S
MEASURE THE CAVITY 6 AND REPAIR THE FUEL

RESISTANCE BETWEEN GROUND. IS THE RESISTANCE NO SHUTDOWN SOLENOID
FUEL INJECTION ABOVE 100K OHMS? CONTROL CIRCUIT
PUMP HARNESS FIG.2 FOR A SHORT TO
CONNECTOR... GROUND.*
YES
KEY ON.
RECONNECT THE ECM
HARNESS USING THE DRB,
CONNECTORS. ACTUATE THE FUEL
SHUTDOWN SOLENOID.
WITH THE DRB MEASURE THE VOLTAGE

ACTUATING THE AT FUEL PUMP HARNESS DOES VOLTMETER YES REPLACE THE FUEL
SOLENOID, USE A CONNECTOR CAVITY 6. CHANGE FROM B+ TO INJECTION PUMP.*
VOLTMETER TO... BELOW 1.0 VOLT?
FIG.2
NO
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

167
T TEST TC-79A REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
168
TEST TC-79A REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT T
R
U
B
START TEST
KEY ON.
USING THE DRB,
L
TC-79A. CLEAR CODES. E
KEY OFF. WAIT 30
SECONDS.
C
O
D
E
DISPLAY "SOLENOID YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
VALVE CONTROLLER
OPEN CIRCUIT"?
TC-79A ON THE
NEXT PAGE.
E
S
T
NO S

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "SOLENOID YES OR CONNECTOR THAT
THE SOLENOID VALVE FOR CODES. VALVE CONTROLLER CAUSED THE CODE TO
CONNECTOR AND OPEN CIRCUIT"? SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

169
T TEST TC-79A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
170
TEST TC-79A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT T
R
O
U
B
TEST TC-79A DISCONNECT THE L
CONTINUED FROM
FUEL INJECTION
PUMP HARNESS E
PAGE. CONNECTOR.**
C
O
D
E
KEY ON. MEASURE THE
USE A VOLTMETER IN VOLTAGE AT FUEL IS THE VOLTAGE NO CONTINUE TEST T
THE FOLLOWING
STEP.
INJECTION PUMP
HARNESS CONNECTOR
ABOVE 10.5 VOLTS? TC-79A ON THE
NEXT PAGE. E
CAVITY 10. FIG.1
S
YES T
S

MEASURE THE FUEL IS THE RESISTANCE NO TIMING SOLENOID
DISCONNECT THE ECM TIMING SOLENOID ABOVE 100K OHMS? CONTROL CIRCUIT
HARNESS CONTROL CIRCUIT TO FOR A SHORT TO
YES
MEASURE THE FUEL REPAIR THE FUEL

USE AN OHMMETER IN TIMING SOLENOID IS THE RESISTANCE NO TIMING SOLENOID
THE FOLLOWING CONTROL CIRCUIT. BELOW 5.0 OHMS? CONTROL CIRCUIT
STEPS. FOR AN OPEN.*
FIG.2
YES
MEASURE THE PUMP CONNECTOR (PUMP

RESISTANCE OF THE SIDE) BETWEEN IS THE RESISTANCE NO REPLACE THE FUEL
FUEL TIMING CAVITIES 5 AND 10. BETWEEN 12.0 AND INJECTION PUMP.*
SOLENOID AT THE 20.0 OHMS?
FUEL INJECTION... FIG.3
YES
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

171
T TEST TC-79A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
172
TEST TC-79A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER OPEN CIRCUIT T
R
O
U
B
TEST TC-79A REMOVE AND INSPECT REPAIR THE FUSED L
CONTINUED FROM
THE PREVIOUS
THE ASD RELAY
OUTPUT FUSE IS THE FUSE OK?
YES ASD RELAY OUTPUT
CIRCUIT FOR AN E
PAGE. IN THE PDC. OPEN.*
FIG.1
C
NO O
D
E
USING AN OHMMETER, CAVITY 10 AND REPAIR THE FUSED T
MEASURE THE GROUND. IS THE RESISTANCE NO ASD RELAY OUTPUT
RESISTANCE BETWEEN ABOVE 100K OHMS? CIRCUIT FOR A E
FUEL INJECTION PUMP
HARNESS CONNECTOR...
S
T
YES S
REPLACE THE FUEL

INJECTION PUMP.*

173
T TEST TC-80A REPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
174
TEST TC-80A REPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT T
R
U
B
START TEST
KEY ON.
USING THE DRB,
L
KEY OFF.
C
O
D
E
DISPLAY "SOLENOID YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
VALVE CONTROLLER
SHORT CIRCUIT"?
TC-80A ON THE
NEXT PAGE.
E
S
T
NO S

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "SOLENOID YES OR CONNECTOR THAT
THE SOLENOID VALVE FOR CODES. VALVE CONTROLLER CAUSED THE CODE TO
CONNECTOR AND SHORT CIRCUIT"? SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

175
T TEST TC-80A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
176
TEST TC-80A CONTINUED - REPAIRING - SOLENOID VALVE CONTROLLER SHORT CIRCUIT T
R
O
U
B
TEST TC-80A
CONTINUED FROM
KEY OFF. L
THE PREVIOUS DISCONNECT THE E
PAGE. FUEL INJECTION
PUMP CONNECTOR.**
C
O
D
E
KEY ON. KEY ON. DOES THE DRB
DISPLAY "FUEL YES REPLACE THE FUEL
T
USING THE DRB, MONITOR THE DRB
TIMING SOLENOID
CONTROLLER OPEN
INJECTION PUMP.* E
CLEAR CODES. FOR CODES. CIRCUIT"? S
T
NO S
KEY OFF. KEY ON. USING A REPAIR THE FUEL

VOLTMETER, MEASURE IS THE VOLTAGE NO TIMING SOLENOID
DISCONNECT THE ECM THE FUEL TIMING BELOW 0.5 VOLTS? CONTROL CIRCUIT
HARNESS SOLENOID CONTROL FOR A SHORT TO
CONNECTORS.** CIRCUIT. FIG.1 VOLTAGE.*
YES
NOTE: BEFORE
YES
REPLACE THE ENGINE

CONTROL MODULE.*

177
T TEST TC-81A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG. 2
FIG.3
178
TEST TC-81A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED T
R
U
B
START TEST
KEY ON. USING THE
DRB, READ THE
IS THE ENGINE
COOLANT YES CONTINUE TEST
L
TC-81A. ENGINE COOLANT TEMPERATURE SENSOR TC-81A ON THE E
TEMPERATURE SENSOR VOLTAGE ABOVE 4.7 NEXT PAGE.
VOLTAGE. VOLTS?
C
NO O
D
E
USING THE SCHEMATIC
AS A GUIDE, WIGGLE MONITOR THE DRB WAS THERE A YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE ECM ECT SENSOR FOR AN ECM ECT VOLTAGE CHANGE? CAUSED THE VOLTAGE E
CONNECTOR AND VOLTAGE CHANGE. CHANGE.*
HARNESS. FIG.1 AND 2 S
T
NO S

FIG.3 FIG.1 AND 2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

179
T TEST TC-81A CONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
180
TEST TC-81A CONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC HIGH T
EXCEEDED R
O
U
B
TEST TC-81A DISCONNECT THE ECM L
CONTINUED FROM
ENGINE COOLANT
TEMPERATURE SENSOR E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
MEASURE THE ECM REPAIR THE ECM ECT
USE A VOLTMETER IN ECT SIGNAL IS THE VOLTAGE YES SIGNAL CIRCUIT FOR T
THE FOLLOWING
STEP.
CIRCUIT. ABOVE 5.5 VOLTS? A SHORT TO
VOLTAGE.* E
FIG.1
S
NO T
S
CONNECT A JUMPER USING THE DRB, REPLACE THE ECM

BETWEEN ECM ECT READ THE ECM IS THE VOLTAGE YES ENGINE COOLANT
SENSOR HARNESS ENGINE COOLANT BELOW 1.0 VOLT? TEMPERATURE
CONNECTOR CAVITIES TEMPERATURE SENSOR SENSOR.*
1 AND 2. FIG.1 VOLTAGE.
NO
MOVE THE JUMPER FROM USING THE DRB, REPAIR THE ECM ECT
ECM ECT SENSOR READ THE ECM IS THE VOLTAGE YES SENSOR RETURN
HARNESS CONNECTOR ENGINE COOLANT BELOW 1.0 VOLT? CIRCUIT FOR AN
CAVITY 2 TO AN TEMPERATURE SENSOR OPEN.*
ENGINE GROUND. FIG.1 VOLTAGE.
NO
KEY OFF.
USE AN OHMMETER IN
HARNESS STEP.
CONNECTORS.**
MEASURE THE ECM HARNESS REPAIR THE ECM ECT

RESISTANCE BETWEEN CONNECTOR C2 IS THE RESISTANCE NO SENSOR SIGNAL
ECM ECT SENSOR CAVITY 54. BELOW 5.0 OHMS? CIRCUIT FOR AN
HARNESS CONNECTOR OPEN.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

181
T TEST TC-82A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
182
TEST TC-82A REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED T
R
U
B
START TEST
KEY ON. USING THE
DRB, READ THE ECM IS THE VOLTAGE YES CONTINUE TEST
L
TC-82A. ENGINE COOLANT BELOW 0.3 VOLT? TC-82A ON THE E
TEMPERATURE SENSOR NEXT PAGE.
VOLTAGE.
C
NO O
D
E
USING THE SCHEMATIC
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE ECM ECT SENSOR FOR AN ECM ECT VOLTAGE CHANGE? CAUSED THE VOLTAGE E
T
NO S

FIG.3 FIG.1 AND 2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

183
T TEST TC-82A CONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
184
TEST TC-82A CONTINUED - REPAIRING - TEMPERATURE OF ENGINE COOLANT SRC LOW T
EXCEEDED R
O
U
B
TEST TC-82A KEY OFF. DISCONNECT
L
CONTINUED FROM
THE PREVIOUS
THE ECM ENGINE
COOLANT TEMPERATURE
E
PAGE. SENSOR HARNESS
CONNECTOR.**
C
O
D
E
KEY ON. REPLACE THE ECM

T
IS THE ECM ECT YES ENGINE COOLANT E
USING THE DRB,
READ ECM ECT
SENSOR VOLTAGE
ABOVE 4.0 VOLTS?
TEMPERATURE
SENSOR.* S
SENSOR VOLTAGE. T
S
NO
KEY OFF.
USE AN OHMMETER IN
HARNESS STEPS.
CONNECTORS.**
MEASURE THE CAVITY 1 AND REPAIR THE ECM ECT

RESISTANCE BETWEEN GROUND. IS THE RESISTANCE NO SENSOR SIGNAL
ECM ECT SENSOR ABOVE 100K OHMS? CIRCUIT FOR A
HARNESS FIG.1 SHORT TO GROUND.*
CONNECTOR...
YES
MEASURE THE REPAIR THE ECM ECT

RESISTANCE BETWEEN CAVITIES 1 AND 2. IS THE RESISTANCE NO SENSOR CIRCUITS
ECM ECT SENSOR ABOVE 100K OHMS? FOR A SHORT
HARNESS FIG.1 TOGETHER.*
CONNECTOR...
YES
REPLACE THE ENGINE

CONTROL MODULE.*

185
T TEST TC-84A REPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
186
TEST TC-84A REPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
CYCLE THE IGNITION
ON AND OFF SEVERAL
KEY ON.
T
TIMES, PAUSING FOR
TEN SECONDS AT KEY
MONITOR THE DRB
FOR CODES.
DISPLAY "TERMINAL
15 PLAUSIBILITY"?
TC-84A ON THE
NEXT PAGE.
E
ON AND OFF. S
T
NO S

FIG. 1 THIS CODE.
USING THE SCHEMATIC

CONNECTORS.
FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

187
T TEST TC-84A CONTINUED - REPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
188
TEST TC-84A CONTINUED - REPAIRING - TERMINAL 15 PLAUSIBILITY AFTER START-UP T
R
O
U
B
L
CONTINUED FROM
E
PAGE. HARNESS
CONNECTORS.**
C
O
D
E
USING A VOLTMETER, NOTE: BE SURE TO IS THE VOLTAGE

T
MEASURE ALL ECM EXCLUDE CAVITIES ABOVE 2.0 VOLTS NO REPLACE THE ENGINE E
HARNESS CONNECTOR
CAVITIES EXCEPT 33
33 AND 45 FROM
THIS STEP.
FOR ANY OF THE
MEASUREMENTS?
CONTROL MODULE.*
S
AND 45. T
S
YES
IS VOLTAGE PRESENT REPAIR THE CIRCUIT

AT ECM HARNESS NO THAT MEASURED
CONNECTOR C1 ABOVE 2.0 VOLTS
CAVITIES 2 AND 28? FOR A SHORT TO
VOLTAGE.*
YES
USING A VOLTMETER, REPAIR THE ASD

REMOVE THE ASD MEASURE THE VOLTAGE IS THE VOLTAGE NO RELAY OUTPUT
RELAY FROM THE AT ECM HARNESS BELOW 2.0 VOLTS? CIRCUIT FOR SHORT
PDC.** CONNECTOR C1 TO VOLTAGE.*
CAVITY 2. FIG.1
YES
USING AN OHMMETER, CAVITY 2 AND REPAIR THE ASD

MEASURE THE GROUND. IS THE RESISTANCE NO RELAY CONTROL
RESISTANCE BETWEEN ABOVE 100K OHMS? CIRCUIT FOR SHORT
ASD RELAY TO GROUND.*
CONNECTOR... FIG.2
YES
REPLACE THE ASD

RELAY.*

189
T TEST TC-85A REPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
190
TEST TC-85A REPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION T
R
U
B
START TEST
KEY ON.
USING THE DRB,
L
KEY OFF FOR 30
SECONDS.
C
O
D
E
START THE ENGINE. DOES THE DRB
DISPLAY "TIMING YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
GOVERNING NEGATIVE
GOVERNOR
TC-85A ON THE
NEXT PAGE.
E
DEVIATION"? S
T
NO S

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "TIMING YES OR CONNECTOR THAT
THE SENSOR CONNECTOR FOR CODES. GOVERNING NEGATIVE CAUSED THE CODE TO
AND HARNESS. GOVERNOR SET.*
FIG.1 DEVIATION"?
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

191
T TEST TC-85A CONTINUED - REPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
192
TEST TC-85A CONTINUED - REPAIRING - TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION T
R
O
U
B
TEST TC-85A NOTE: THIS CODE REPAIR OTHER CODES L
CONTINUED FROM
THE PREVIOUS
WILL SET DUE TO
NOISE ON THE
ARE ANY OTHER
CODES SET?
YES FIRST.
CLEAR THIS CODE E
PAGE. NEEDLE MOVEMENT AND REPEAT
SENSOR CIRCUIT. DIAGNOSIS.*
C
NO O
D
E
TEST DRIVE THE T
REPLACE THE FUEL VEHICLE. DOES THE DRB NO
INJECTION PUMP. DISPLAY THIS CODE? TEST COMPLETE.* E
MONITOR THE DRB
FOR CODES. S
T
YES S
REPLACE THE ENGINE

CONTROL MODULE.*

193
T TEST TC-86A REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
194
TEST TC-86A REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION T
R
U
B
START TEST
KEY ON.
USING THE DRB,
L
KEY OFF FOR 30
SECONDS.
C
O
D
E
START THE ENGINE. DOES THE DRB
DISPLAY "TIMING YES CONTINUE TEST
T
MONITOR THE DRB
FOR CODES.
GOVERNING POSITIVE
GOVERNOR
TC-86A ON THE
NEXT PAGE.
E
DEVIATION"? S
T
NO S

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "TIMING YES OR CONNECTOR THAT
THE SENSOR CONNECTOR FOR CODES. GOVERNING POSITIVE CAUSED THE CODE TO
AND HARNESS. GOVERNOR SET.*
FIG.1 DEVIATION"?
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

195
T TEST TC-86A CONTINUED - REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
196
TEST TC-86A CONTINUED - REPAIRING - TIMING GOVERNING POSITIVE GOVERNOR DEVIATION T
R
O
U
B
TEST TC-86A
CONTINUED FROM
NOTE: THIS CODE
WILL SET DUE TO
L
THE PREVIOUS LOW FUEL VOLUME TO E
PAGE. THE FUEL INJECTION
PUMP.
C
O
D
E
CHECK THE FUEL WERE ANY PROBLEMS YES REPAIR AS

T
SYSTEM FOR FOUND? NECESSARY.* E
RESTRICTIONS.
S
T
NO S
TEST DRIVE THE

REPLACE THE FUEL VEHICLE. DOES THE DRB NO
INJECTION PUMP.* DISPLAY THIS CODE? TEST COMPLETE.*
MONITOR THE DRB
FOR CODES.
YES
REPLACE THE ENGINE

CONTROL MODULE.*

197
T TEST TC-87A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1
FIG. 2
198
TEST TC-87A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED T
R
U
B
START TEST
KEY ON.
USING THE DRB, IS THE VOLTAGE YES CONTINUE TEST
L
TC-87A. READ THE BOOST ABOVE 4.6 VOLTS? TC-87A ON THE E
PRESSURE SENSOR NEXT PAGE.
VOLTAGE.
C
NO O
D
E
USING THE SCHEMATIC
AS A GUIDE, WIGGLE MONITOR THE DRB WAS THERE ANY YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE BOOST PRESSURE DISPLAY. BOOST PRESSURE CAUSED THE VOLTAGE E
SENSOR CONNECTOR AND VOLTAGE CHANGE? CHANGE.*
HARNESS. FIG.1 S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
FOR ADDITIONAL TEST COMPLETE.
INFORMATION ON
INTERMITTENT CODES.

199
T TEST TC-87A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
200
TEST TC-87A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL HIGH T
EXCEEDED R
O
U
B
L
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BOOST
E
C
O
D
E
KEY ON. THE BOOST PRESSURE

T
SENSOR 5-VOLT IS THE VOLTAGE NO CONTINUE TEST E
USING A VOLTMETER,
MEASURE THE
SUPPLY CIRCUIT AND
GROUND.
NEXT PAGE. S
VOLTAGE BETWEEN... FIG.1 T
S
YES
KEY OFF.
REMOVE THE ASD
DISCONNECT THE ECM RELAY FROM THE
HARNESS PDC.**
CONNECTORS.**
CONNECT CONNECT A KEY ON.

JUMPER BETWEEN ASD
RELAY CONNECTOR USE A VOLTMETER IN
CAVITIES 3 AND 5. THE FOLLOWING
FIG.2 STEP.
MEASURE THE 5-VOLT

SUPPLY CKT AT THE IS THE VOLTAGE NO REPLACE THE ENGINE
BOOST PRESSURE ABOVE 1.0 VOLT? CONTROL MODULE.*
SENSOR HARNESS
CONNECTOR. FIG.1
YES
REPAIR THE 5-VOLT

SUPPLY CIRCUIT FOR
A SHORT TO
VOLTAGE.*

201
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
202
EXCEEDED R
O
U
B
TEST TC-87A
CONTINUED FROM
USING A VOLTMETER,
MEASURE THE BOOST IS THE VOLTAGE NO CONTINUE TEST
L
THE PREVIOUS PRESSURE SENSOR ABOVE 1.0 VOLT? TC-87A ON THE E
PAGE. SIGNAL CIRCUIT. NEXT PAGE.
FIG.1
C
YES O
D
E
KEY OFF.
REMOVE THE ASD
T
DISCONNECT THE ECM
HARNESS
RELAY FROM THE
PDC.**
E
CONNECTORS.** S
T
S

BETWEEN ASD RELAY
CONNECTOR CAVITIES USE A VOLTMETER IN
3 AND 5. THE FOLLOWING
FIG.2 STEP.
MEASURE THE BOOST

PRESSURE SENSOR IS THE VOLTAGE NO REPLACE THE ENGINE
SIGNAL CIRCUIT. ABOVE 1.0 VOLT? CONTROL MODULE.*
FIG.1
YES
REPAIR THE BOOST

PRESSURE SENSOR
SIGNAL CIRCUIT FOR
A SHORT TO
VOLTAGE.*

203
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
204
EXCEEDED R
O
U
B
TEST TC-87A
CONTINUED FROM
KEY OFF. L
PAGE. HARNESS
CONNECTORS.**
C
O
D
E
USE AN OHMMETER IN
MEASURE THE
RESISTANCE OF THE IS THE RESISTANCE NO
REPAIR THE BOOST
PRESSURE SENSOR
T
THE FOLLOWING
STEP.
BOOST PRESSURE
SENSOR RETURN
BELOW 5.0 OHMS? RETURN CIRCUIT FOR
AN OPEN.*
E
CIRCUIT. FIG.1 S
T
YES S
RECONNECT ALL USING A VOLTMETER,

CONNECTORS. BACKPROBE BOOST IS THE VOLTAGE YES REPLACE THE BOOST
PRESSURE SENSOR ABOVE 4.6 VOLTS? PRESSURE SENSOR.*
KEY ON. HARNESS CONNECTOR
CAVITY 4.
NO
MONITOR THE DRB DOES THE DRB YES REPLACE THE ENGINE
FOR CODES. DISPLAY THIS CODE? CONTROL MODULE.*
NO
TEST COMPLETE.*

205
T TEST TC-88A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
206
TEST TC-88A REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED T
R
U
B
START TEST
KEY ON. IS THE BOOST
PRESSURE SENSOR YES CONTINUE TEST
L
TC-88A. USING THE DRB, READ VOLTAGE BELOW 0.2 TC-88A ON THE E
THE BOOST PRESSURE VOLT? NEXT PAGE.
SENSOR VOLTAGE.
C
NO O
D
E
USING THE SCHEMATIC
WAS THERE ANY
BOOST PRESSURE YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE BOOST PRESSURE DISPLAY. SENSOR VOLTAGE CAUSED THE VOLTAGE E
SENSOR CONNECTOR AND CHANGE? CHANGE.*
HARNESS. FIG.1 S
T
NO S

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

207
T TEST TC-88A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
208
TEST TC-88A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW T
EXCEEDED R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BOOST E
C
O
D
E
USING A VOLTMETER,
MEASURE THE BOOST IS THE VOLTAGE NO CONTINUE TEST T
KEY ON. PRESSURE SENSOR
5-VOLT SUPPLY
NEXT PAGE. E
CIRCUIT. FIG.1
S
YES T
S
CONNECT A JUMPER READ THE BOOST IS THE BOOST

BETWEEN THE BOOST PRESSURE SENSOR PRESSURE SENSOR YES REPLACE THE BOOST
PRESSURE SENSOR VOLTAGE ON THE VOLTAGE ABOVE 4.5 PRESSURE SENSOR.*
SIGNAL CKT AND THE DRB. VOLTS?
5-VOLT CKT. FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR THE SENSOR

MEASURE THE BOOST IS THE RESISTANCE NO SIGNAL CIRCUIT FOR
DISCONNECT THE ECM PRESSURE SENSOR ABOVE 100K OHMS? A SHORT TO
HARNESS SIGNAL CKT TO GND. GROUND.*
CONNECTORS.** FIG.1
YES
MEASURE THE AND THE SENSOR REPAIR THE SENSOR

RESISTANCE BETWEEN RETURN CIRCUIT. IS THE RESISTANCE NO SIGNAL CIRCUIT
THE BOOST PRESSURE ABOVE 100K OHMS? SHORTED TO THE
SENSOR SIGNAL FIG.1 SENSOR RETURN
CIRCUIT... CIRCUIT.*
YES
MEASURE THE BOOST ECM CONNECTOR C1 REPAIR THE BOOST

PRESSURE SENSOR AND THE BOOST IS THE RESISTANCE NO PRESSURE SENSOR
SIGNAL CIRCUIT PRESSURE SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
BETWEEN... CONNECTOR. AN OPEN.*
FIG.2
YES
REPLACE THE ENGINE

CONTROL MODULE.*

209
T TEST TC-88A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
210
TEST TC-88A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SIGNAL LOW T
EXCEEDED R
O
U
B
TEST TC-88A
CONTINUED FROM
KEY OFF. L
PAGE. HARNESS
CONNECTORS.**
C
O
D
E
USE AN OHMMETER IN
MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE NO
REPAIR THE BOOST
PRESSURE SENSOR
T
THE FOLLOWING THE SENSOR 5-VOLT ABOVE 100K OHMS? 5-VOLT SUPPLY E
STEPS. SUPPLY AND GROUND. CIRCUIT FOR A
FIG.1 SHORT TO GROUND.* S
T
YES S
MEASURE THE ECM CONNECTOR C1 REPAIR THE BOOST

RESISTANCE OF THE AND THE BOOST IS THE RESISTANCE NO PRESSURE SENSOR
5-VOLT SUPPLY PRESSURE SENSOR BELOW 5.0 OHMS? 5-VOLT SUPPLY
CIRCUIT BETWEEN... CONNECTOR. CIRCUIT FOR AN
FIG.2 OPEN.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

211
T TEST TC-89A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
212
TEST TC-89A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED T
R
U
B
START TEST
KEY ON. DOES THE DRB DISPLAY
"TURBOCHARGER BOOST YES CONTINUE TEST
L
TC-89A. USING THE DRB, CLEAR SENSOR SUPPLY HIGH TC-89A ON THE E
CODES. CYCLE THE KEY EXCEEDED"? NEXT PAGE.
OFF, THEN ON.
C
NO O
D
E
WIGGLE THE BOOST
PRESSURE SENSOR MONITOR THE DRB
"TURBOCHARGER BOOST YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
CONNECTOR AND FOR CODES. SENSOR SUPPLY HIGH CAUSED THE CODE TO E
HARNESS WIRES. EXCEEDED"? SET.*
S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

213
T TEST TC-89A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
214
TEST TC-89A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY HIGH T
EXCEEDED R
O
U
B
TEST TC-89A
CONTINUED FROM
KEY OFF.
DISCONNECT THE ECM
L
THE PREVIOUS DISCONNECT THE BOOST HARNESS E
PAGE. PRESSURE SENSOR CONNECTORS.**
C
O
D
E
REMOVE THE ASD

CONNECT A JUMPER
BETWEEN ASD RELAY
KEY ON. T
RELAY FROM THE CONNECTOR CAVITIES USE A VOLTMETER IN E
PDC.** 3 AND 5. THE FOLLOWING
FIG.1 STEP. S
T
S
MEASURE THE BOOST

PRESSURE SENSOR IS THE VOLTAGE NO REPLACE THE ENGINE
5-VOLT SUPPLY ABOVE 1.0 VOLT? CONTROL MODULE.*
CIRCUIT.
FIG.2
YES
REPAIR THE BOOST

PRESSURE SENSOR
SUPPLY CIRCUIT FOR
A SHORT TO
VOLTAGE.*

215
T TEST TC-90A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
216
TEST TC-90A REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED T
R
U
B
START TEST
KEY ON. DOES THE DRB DISPLAY
"TURBOCHARGER BOOST YES CONTINUE TEST
L
TC-90A. USING THE DRB, CLEAR SENSOR SUPPLY LOW TC-90A ON THE E
CODES. CYCLE THE KEY EXCEEDED"? NEXT PAGE.
OFF, THEN ON.
C
NO O
D
E
WIGGLE THE BOOST
PRESSURE SENSOR MONITOR THE DRB
"TURBOCHARGER BOOST YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
CONNECTOR AND FOR CODES. SENSOR SUPPLY LOW CAUSED THE CODE TO E
HARNESS. EXCEEDED"? SET.*
S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

217
T TEST TC-90A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW
R EXCEEDED
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
218
TEST TC-90A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR SUPPLY LOW T
EXCEEDED R
O
U
B
L
CONTINUED FROM
THE PREVIOUS DISCONNECT THE BOOST
E
C
O
D
E
USING THE DRB, IS THE BOOST

T
MONITOR THE BOOST PRESSURE SUPPLY YES REPLACE THE BOOST E
KEY ON. PRESSURE SENSOR
SUPPLY VOLTAGE.
VOLTAGE ABOVE 4.0
VOLTS?
PRESSURE SENSOR.*
S
T
S
NO
KEY OFF.
USE AN OHMMETER IN
HARNESS STEPS.
CONNECTORS.**
MEASURE THE BOOST REPAIR THE BOOST

PRESSURE SENSOR IS THE RESISTANCE NO PRESSURE SENSOR
5-VOLT SUPPLY ABOVE 100K OHMS? SUPPLY CIRCUIT FOR
CIRCUIT TO GROUND. A SHORT TO
FIG.1 GROUND.*
YES
MEASURE THE AND THE SENSOR REPAIR THE 5-VOLT

RESISTANCE BETWEEN RETURN CIRCUIT. IS THE RESISTANCE NO SUPPLY CIRCUIT FOR
BOOST PRESSURE ABOVE 100K OHMS? A SHORT TO THE
SENSOR 5-VOLT SENSOR RETURN
SUPPLY CIRCUIT... FIG.1 CIRCUIT.*
YES
REPLACE THE ENGINE

CONTROL MODULE.*

219
T TEST TC-91A REPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
220
TEST TC-91A REPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
KEY OFF FOR 10 MONITOR THE DRB

DOES THE DRB
DISPLAY YES CONTINUE TEST
T
SECONDS, THEN
START THE ENGINE.
FOR CODES. "TURBOCHARGER
BOOST SENSOR
TC-91A ON THE
NEXT PAGE.
E
PLAUSIBILITY"? S
T
NO S
WIGGLE THE BOOST DOES THE DRB REPAIR THE HARNESS

PRESSURE SENSOR MONITOR THE DRB DISPLAY YES OR CONNECTOR THAT
CONNECTOR AND FOR CODES. "TURBOCHARGER CAUSED THE CODE TO
HARNESS. BOOST SENSOR SET.*
PLAUSIBILITY"?
NO

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

221
T TEST TC-91A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
222
TEST TC-91A CONTINUED - REPAIRING - TURBOCHARGER BOOST SENSOR PLAUSIBILITY T
R
O
U
B
TEST TC-91A L
CONTINUED FROM
THE PREVIOUS KEY OFF. E
PAGE.
C
O
D
E
DISCONNECT THE
DISCONNECT THE ECM BOOST PRESSURE T
HARNESS
CONNECTORS.**
SENSOR HARNESS
CONNECTOR.** E
S
T
S

USE AN OHMMETER IN PRESSURE SENSOR IS THE RESISTANCE NO PRESSURE SENSOR
THE FOLLOWING SIGNAL CIRCUIT. BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
STEPS. AN OPEN.*
FIG.1
YES

RETURN CIRCUIT. BELOW 5.0 OHMS? RETURN CIRCUIT FOR
AN OPEN.*
FIG.1
YES

5-VOLT SUPPLY BELOW 5.0 OHMS? 5-VOLT SUPPLY
CIRCUIT. CIRCUIT FOR AN
FIG.1 OPEN.*
YES
REPLACE THE BOOST TEST DRIVE THE

PRESSURE SENSOR.* VEHICLE AND PERFORM DOES THE DRB YES REPLACE THE ENGINE
KEY ON. SEVERAL KEY CYCLES. DISPLAY THIS CODE? CONTROL MODULE.*
USING THE DRB, MONITOR THE DRB FOR
CLEAR CODES. CODES.
NO
TEST COMPLETE.*

223
T TEST TC-96A REPAIRING - VEH. SPEED SENSOR TROUBLE CODES
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
224
TEST TC-96A REPAIRING - VEH. SPEED SENSOR TROUBLE CODES T
R
U
B
START TEST
KEY ON. L
TC-96A USING THE DRB, E
CLEAR CODES.
C
O
D
E
TEST DRIVE THE MONITOR THE DRB DOES THE DRB YES CONTINUE TEST
T
VEHICLE. FOR CODES. DISPLAY THIS CODE? TC-96A ON THE E
NEXT PAGE.
S
T
NO S

FIG.1 FIG.2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

225
T TEST TC-96A CONTINUED - REPAIRING - VEH. SPEED SENSOR TROUBLE CODES
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
226
TEST TC-96A CONTINUED - REPAIRING - VEH. SPEED SENSOR TROUBLE CODES T
R
O
U
B
PERFORM L
START TEST
TC-96A.
CHECK THE CAB
MODULE FOR DTC(S).
DOES THE CAB
MODULE HAVE ANY
YES APPROPRIATE
TEST IN CAB E
DTC(S)? DIAGNOSTIC
MANUAL.
C
NO O
D
E
KEY OFF. KEY ON. USING A REPAIR THE VEHICLE
VOLTMETER, MEASURE IS THE VOLTAGE YES SPEED SIGNAL T
DISCONNECT THE CAB
MODULE HARNESS
THE VEHICLE SPEED
SIGNAL CIRCUIT.
ABOVE 5.0 VOLTS? CIRCUIT FOR A
SHORT TO VOLTAGE.* E
CONNECTOR.** FIG. 1
S
NO T
S
KEY OFF. USING AN OHMMETER, REPAIR THE VEHICLE

DISCONNECT THE PCM MEASURE THE IS THE RESISTANCE NO SPEED SIGNAL
HARNESS RESISTANCE OF THE BELOW 5.0 OHMS? CIRCUIT FOR AN
CONNECTOR.** VEHICLE SPEED SIGNAL OPEN.*
CIRCUIT. FIG. 2
YES
USING AN OHMMETER, REPAIR THE VEHICLE

MEASURE THE IS THE RESISTANCE NO SPEED SIGNAL
RESISTANCE OF THE ABOVE 100K OHMS? CIRCUIT FOR A
VEHICLE SPEED SIGNAL SHORT TO GROUND.*
CKT TO GND. FIG. 1
YES
USING A JUMPER WIRE,

RECONNECT THE PCM CONNECT ONE END OF
HARNESS CONNECTOR. THE JUMPER TO THE
VEHICLE SPEED SIGNAL
CIRCUIT. FIG. 1
KEY ON. WHILE TAPPING THE REPLACE THE

OTHER END OF THE DOES THE DRB YES CONTROLLER
USING THE DRB, JUMPER WIRE TO DISPLAY KMH (MPH) ANTILOCK BRAKE
MONITOR THE VSS CHASSIS GROUND. GREATER THAN 0? MODULE.*
DISPLAY...
NO
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

227
T TEST TC-100A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
228
TEST TC-100A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
CYCLE THE KEY ON AND
OFF SEVERAL TIMES. DOES THE DRB YES CONTINUE TEST
T
KEY ON. DISPLAY THIS CODE? TC-100A ON THE E
MONITOR THE DRB NEXT PAGE.
FOR CODES. S
T
NO S

FIG.1 FIG.2
N0
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

229
T TEST TC-100A CONTINUED - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
230
TEST TC-100A CONTINUED - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH T
R
O
U
B
TEST TC-100A
CONTINUED FROM
DISCONNECT THE
AMBIENT/BATTERY
L
THE PREVIOUS KEY OFF. TEMPERATURE SENSOR E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
KEY ON. MEASURE THE VOLTAGE
AT AMBIENT/BATTERY IS THE VOLTAGE NO CONTINUE TEST
T
USE A VOLTMETER IN TEMP SENSOR HARNESS ABOVE 5.3 VOLTS? TC-100A ON THE E
THE FOLLOWING CONNECTOR CAVITY 1. NEXT PAGE.
STEP. FIG.1 S
T
YES S
KEY OFF. MEASURE THE VOLTAGE REPAIR THE

DISCONNECT THE PCM AT AMBIENT/BATTERY IS THE VOLTAGE NO AMBIENT/BATTERY
HARNESS TEMP SENSOR HARNESS BELOW 0.5 VOLT? TEMPERATURE SENSOR
CONNECTORS.** CONNECTOR CAVITY 1. SIGNAL CIRCUIT FOR A
KEY ON. FIG.1 SHORT TO VOLTAGE.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

231
T TEST TC-100A CONTINUED - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
232
TEST TC-100A CONTINUED - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO HIGH T
R
O
U
B
TEST TC-100A
L
CONTINUED FROM
USE AN OHMMETER IN
THE FOLLOWING
E
PAGE. STEPS.
C
O
D
E
MEASURE THE REPLACE THE

T
RESISTANCE OF THE IS THE RESISTANCE YES AMBIENT/BATTERY E
AMBIENT/BATTERY
TEMPERATURE
ABOVE 100K OHMS? TEMPERATURE
SENSOR.* S
SENSOR. FIG.1 T
S
NO
AMBIENT/BATTERY TEMP
MEASURE THE SENSOR HARNESS IS THE RESISTANCE NO REPAIR THE SENSOR
RESISTANCE CONNECTOR CAVITY 2 BELOW 5.0 OHMS? RETURN CIRCUIT FOR
BETWEEN... AND GROUND. AN OPEN.*
FIG.2
YES
MEASURE THE AMBIENT/BATTERY

DISCONNECT THE PCM RESISTANCE BETWEEN TEMPERATURE SENSOR
HARNESS PCM HARNESS HARNESS CONNECTOR
CONNECTORS.** CONNECTOR C3 CAVITY 1.
REPAIR THE
IS THE RESISTANCE NO AMBIENT/BATTERY
BELOW 5.0 OHMS? TEMPERATURE SENSOR
SIGNAL CIRCUIT FOR
AN OPEN.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

233
T TEST TC-101A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO LOW
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
234
TEST TC-101A REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO LOW T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
T
FOR CODES. S
T
NO S

FIG.1 FIG.2
N0
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

235
T TEST TC-101A CONTINUE - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
236
TEST TC-101A CONTINUE - REPAIRING - AMBIENT/BATT TEMP SEN VOLTS TOO LOW T
R
O
U
B
TEST TC-101A DISCONNECT THE
L
CONTINUED FROM
AMBIENT/BATTERY
TEMP SENSOR
E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
USING THE DRB, REPLACE THE

T
READ THE IS THE VOLTAGE YES AMBIENT/BATTERY E
KEY ON. AMBIENT/BATTERY
TEMPERATURE SENSOR
ABOVE 4.75 VOLTS? TEMPERATURE
SENSOR.* S
VOLTAGE. T
S
NO
KEY OFF.
USE AN OHMMETER IN
DISCONNECT THE PCM THE FOLLOWING
HARNESS STEPS.
CONNECTORS.**
AMBIENT/BATTERY REPAIR THE

MEASURE THE TEMPERATURE SENSOR IS THE RESISTANCE NO AMBIENT/BATTERY
RESISTANCE HARNESS CONNECTOR ABOVE 100K OHMS? TEMPERATURE SENSOR
BETWEEN... CAVITY 1 AND GROUND. SIGNAL CIRCUIT FOR A
YES
AMBIENT/BATTERY REPAIR THE AMB/BATT

MEASURE THE TEMPERATURE SENSOR IS THE RESISTANCE NO TEMP SENSOR SIGNAL
RESISTANCE HARNESS CONNECTOR ABOVE 100K OHMS? AND SENSOR RETURN
BETWEEN... CAVITIES 1 AND 2. CIRCUITS FOR A SHORT
FIG.1 TOGETHER.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

237
T TEST TC-102A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1 FIG.2
238
TEST TC-102A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH T
R
U
B
START TEST
TC-102A.
NOTE: BATTERY MUST
BE FULLY CHARGED.
L
E
C
O
D
E
NOTE: GENERATOR KEY ON.
BELT TENSION AND
CONDITION MUST BE USING THE DRB,
T
CHECKED BEFORE ACTUATE THE E
CONTINUING. GENERATOR FIELD.
S
T
S
BACKPROBE THE DOES THE VOLTAGE

USE A VOLTMETER IN GENERATOR FIELD SWITCH FROM YES PERFORM TEST
THE FOLLOWING CIRCUIT ON THE BACK BATTERY VOLTAGE TO TC-102B.
STEP. OF THE GENERATOR. BELOW 2.0 VOLTS?
FIG.1
NO
USING THE DRB,

STOP THE GENERATOR KEY OFF.
FIELD ACTUATION.
DISCONNECT THE
DISCONNECT PCM GENERATOR FIELD CONTINUE TEST
HARNESS HARNESS CONNECTOR TC-102A ON THE
CONNECTOR C2.** AT THE BACK OF THE NEXT PAGE.
GENERATOR.** FIG.2

239
T TEST TC-102A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
240
TEST TC-102A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH T
R
O
U
B
TEST TC-102A
CONTINUED FROM USE AN OHMMETER IN
L
THE PREVIOUS THE FOLLOWING E
PAGE. STEPS.
C
O
D
E
MEASURE THE
RESISTANCE BETWEEN AND GROUND. IS THE RESISTANCE NO
REPAIR THE
GENERATOR FIELD
T
PCM HARNESS ABOVE 100K OHMS? CIRCUIT FOR A E
CONNECTOR C2 FIG.1 SHORT TO GROUND.*
CAVITY 10... S
T
YES S
GENERATOR FIELD REPAIR OR REPLACE

MEASURE THE TERMINAL 2 AT THE IS THE RESISTANCE NO THE SHORTED
RESISTANCE BETWEEN REAR OF THE ABOVE 100K OHMS? GENERATOR AS
GROUND AND... GENERATOR. NECESSARY.*
FIG.2
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

241
T TEST TC-102B REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
242
TEST TC-102B REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH T
R
U
B
START TEST STOP THE GENERATOR
L
TC-102B. FIELD ACTUATION. E
C
O
D
E
START THE ENGINE.
IS THE TARGET NO REPLACE THE
T
READ THE TARGET
CHARGING VOLTAGE.
CHARGING VOLTAGE
ABOVE 13.0 VOLTS?
POWERTRAIN CONTROL
MODULE.*
E
S
T
YES S
USING THE DRB,

MANUALLY SET THE READ BOTH THE
ENGINE SPEED TO ACTUAL AND TARGET
1600 RPM. CHARGING VOLTAGES.
AFTER FIVE MINUTES

HAS ELAPSED, WAS THERE A NO PERFORM TEST
COMPARE THE ACTUAL DIFFERENCE OF MORE CH-1A.
AND TARGET THAN 1.0 VOLTS?
VOLTAGES.
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

243
T TEST TC-103A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
244
TEST TC-103A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW T
R
U
B
NOTE: BATTERY
L
START TEST
TC-103A.
CONDITION MUST BE
VERIFIED PRIOR TO
E
THIS TEST.
C
O
D
E
INSPECT THE IS THE GENERATOR

T
GENERATOR BELT BELT IN GOOD NO REPAIR AS E
TENSION AND
CONDITION.
CONDITION AND HAVE
THE PROPER
NECESSARY.*
S
TENSION? T
S
YES
KEY ON, ENGINE USING THE DRB,

OFF. ACTUATE THE
GENERATOR FIELD.
BACKPROBE GENERATOR NOTE: VOLTAGE

USE A VOLTMETER IN FIELD CONNECTOR SHOULD CYCLE FROM
THE FOLLOWING TERMINAL AT THE BACK BELOW 2.0 VOLTS TO
STEPS. OF THE GENERATOR. BATTERY VOLTAGE
FIG.1 EVERY 1.4 SECONDS.
WHILE MONITORING AND CONNECTORS WAS THERE ANY

THE VOLTMETER, BETWEEN THE INTERRUPTION OF NO CONTINUE TEST
WIGGLE THE GENERATOR, PCM AND THE NORMAL VOLTAGE TC-103A ON THE
GENERATOR FIELD ASD RELAY. CYCLING? NEXT PAGE.
HARNESS... FIG.2
YES
REPAIR THE HARNESS

WHERE THE WIGGLING
CAUSED THE
INTERRUPTION.*

245
T TEST TC-103A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
246
TEST TC-103A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW T
R
O
U
B
TEST TC-103A CAUTION: MAKE SURE
L
CONTINUED FROM
THE PREVIOUS
USE A VOLTMETER IN
THE FOLLOWING
ALL WIRES ARE
CLEAR OF MOVING
E
PAGE. STEPS. PARTS.
C
O
D
E
CONNECT THE POSITIVE AND THE NEGATIVE

T
LEAD OF THE LEAD OF THE E
VOLTMETER TO THE
GENERATOR (12V) B+
VOLTMETER TO THE
BATTERY POSITIVE S
TERMINAL... (+) POST. FIG.1 T
S
IS THE VOLTAGE NO REPAIR THE FUSED

START THE ENGINE. BELOW 0.4 VOLTS? B+ CIRCUIT FOR
HIGH RESISTANCE.*
YES
THE GENERATOR CASE

CONNECT THE AND THE VOLTMETER IS THE VOLTAGE NO REPAIR THE GROUND
VOLTMETER POSITIVE NEGATIVE LEAD TO THE BELOW 0.4 VOLTS? CIRCUIT FOR HIGH
LEAD TO... BATTERY NEGATIVE (-) RESISTANCE.*
POST. FIG.1
YES
TURN THE ENGINE USING A VOLTMETER, IS THE DIFFERENCE

OFF, THEN KEY ON. MEASURE AND RECORD BETWEEN THE TWO NO CONTINUE TEST
USING THE DRB, THE VOLTAGE ACROSS READINGS LESS THAN TC-103A ON THE
READ AND RECORD THE BATTERY 0.5 VOLT? NEXT PAGE.
BATTERY VOLTAGE. TERMINALS.
YES
TEST COMPLETE.*

247
T TEST TC-103A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
248
TEST TC-103A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW T
R
O
U
B
L
CONTINUED FROM
THE PREVIOUS DISCONNECT THE PCM
E
PAGE. HARNESS
CONNECTORS.**
C
O
D
E
MEASURE THE IS THE VOLTAGE

T
USE A VOLTMETER IN VOLTAGE AT PCM WITHIN 0.5 VOLT OF NO REPAIR THE FUSED E
THE FOLLOWING
STEPS.
HARNESS
CONNECTOR C1
THE READINGS
RECORDED EARLIER?
B+ CIRCUIT FOR
HIGH RESISTANCE.* S
CAVITY 22. FIG.1 T
S
YES
DISCONNECT THE KEY ON. REPAIR THE

GENERATOR FIELD MEASURE THE VOLTAGE IS THE VOLTAGE NO GENERATOR FIELD
HARNESS AT PCM HARNESS BELOW 0.5 VOLT? CIRCUIT FOR A
CONNECTOR.** CONNECTOR C2 SHORT TO VOLTAGE.*
CAVITY 10. FIG.2
YES
MEASURE THE REPAIR THE ASD

VOLTAGE AT PCM IS THE VOLTAGE NO RELAY OUTPUT
HARNESS CONNECTOR ABOVE 10.0 VOLTS? CIRCUIT FOR AN
C3 CAVITY 12. OPEN.*
YES
KEY OFF. REPAIR THE

USE AN OHMMETER IN MEASURE THE IS THE RESISTANCE NO GENERATOR FIELD
THE FOLLOWING RESISTANCE OF THE BELOW 5.0 OHMS? CIRCUIT FOR AN
STEP. GENERATOR FIELD OPEN.*
CIRCUIT. FIG 3
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

249
T TEST TC-104A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
250
TEST TC-104A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH T
R
U
B
START TEST
KEY ON.
IS THE PCM ECT YES CONTINUE TEST
L
TC-104A. USING THE DRB, SENSOR VOLTAGE TC-104A ON THE E
READ THE PCM ECT ABOVE 4.98 VOLTS? NEXT PAGE.
SENSOR VOLTAGE.
C
NO O
D
E
USING THE SCHEMATIC
AS A GUIDE, WIGGLE MONITOR THE DRB WAS THERE ANY PCM YES
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE PCM ECT SENSOR DISPLAY. ECT SENSOR VOLTAGE CAUSED THE VOLTAGE E
CONNECTOR AND CHANGE? CHANGE.*
T
NO S

FIG.3 FIG.1 AND 2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

251
T TEST TC-104A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
252
TEST TC-104A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO HIGH T
R
O
U
B
TEST TC-104A DISCONNECT THE
L
CONTINUED FROM
PCM ENGINE COOLANT
TEMPERATURE SENSOR
E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
CONNECT A JUMPER REPLACE THE PCM

T
BETWEEN PCM ECT USING THE DRB, IS THE VOLTAGE YES ENGINE COOLANT E
SENSOR HARNESS
CONNECTOR CAVITIES
READ THE PCM ECT
SENSOR VOLTAGE.
BELOW 1.0 VOLT? TEMPERATURE
SENSOR.* S
1 AND 2. FIG.1 T
S
NO
MOVE THE JUMPER FROM REPAIR THE PCM ECT

PCM ECT SENSOR USING THE DRB, IS THE VOLTAGE YES SENSOR RETURN
HARNESS CONNECTOR READ THE PCM ECT BELOW 1.0 VOLT? CIRCUIT FOR AN
CAVITY 2 TO AN SENSOR VOLTAGE. OPEN.*
ENGINE GROUND. FIG.1
NO
KEY OFF.
USE AN OHMMETER IN
DISCONNECT PCM THE FOLLOWING
HARNESS STEP.
CONNECTOR C1.**
MEASURE THE PCM HARNESS REPAIR THE PCM ECT

RESISTANCE BETWEEN CONNECTOR C1 IS THE RESISTANCE NO SENSOR SIGNAL
PCM ECT SENSOR CAVITY 16. BELOW 5.0 OHMS? CIRCUIT FOR AN
HARNESS CONNECTOR OPEN.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

253
T TEST TC-105A REPAIRING - ECT SENSOR VOLTAGE TOO LOW
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
254
TEST TC-105A REPAIRING - ECT SENSOR VOLTAGE TOO LOW T
R
U
B
START TEST
KEY ON. USING THE
DRB, READ THE PCM IS THE VOLTAGE YES CONTINUE TEST
L
TC-105A. ENGINE COOLANT BELOW 0.3 VOLT? TC-105A ON THE E
TEMPERATURE SENSOR NEXT PAGE.
VOLTAGE.
C
NO O
D
E
USING THE SCHEMATIC
REPAIR THE HARNESS
OR CONNECTOR THAT
T
THE PCM ECT SENSOR FOR AN PCM ECT VOLTAGE CHANGE? CAUSED THE VOLTAGE E
T
NO S

FIG.3 FIG.1 AND 2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

255
T TEST TC-105A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
256
TEST TC-105A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO LOW T
R
O
U
B
TEST TC-105A DISCONNECT THE PCM
L
CONTINUED FROM
THE PREVIOUS
ENGINE COOLANT
TEMPERATURE SENSOR
E
PAGE. HARNESS
CONNECTOR.**
C
O
D
E
REPLACE THE PCM

T
USING THE DRB, IS THE PCM ECT YES ENGINE COOLANT E
READ PCM ECT
SENSOR VOLTAGE.
SENSOR VOLTAGE
ABOVE 4.0 VOLTS?
TEMPERATURE
SENSOR.* S
T
S
NO
KEY OFF.
USE AN OHMMETER IN
HARNESS STEPS.
CONNECTORS.**
MEASURE THE CAVITY 1 AND REPAIR THE PCM ECT

RESISTANCE BETWEEN GROUND. IS THE RESISTANCE NO SENSOR SIGNAL
PCM ECT SENSOR ABOVE 100K OHMS? CIRCUIT FOR A
HARNESS FIG.1 SHORT TO GROUND.*
CONNECTOR...
YES
MEASURE THE REPAIR THE PCM ECT

RESISTANCE BETWEEN CAVITIES 1 AND 2. IS THE RESISTANCE NO SENSOR CIRCUITS
PCM ECT SENSOR ABOVE 100K OHMS? FOR A SHORT
HARNESS FIG.1 TOGETHER.*
CONNECTOR...
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

257
T TEST TC-107A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
258
TEST TC-107A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
KEY OFF.
USING THE DRB,
DOES THE DRB
T
WAIT 30 SECONDS. READ CODES. LEVEL SENDING UNIT
VOLTS TOO HIGH"?
TC-107A ON THE
NEXT PAGE.
E
KEY ON. S
T
NO S

AS A GUIDE, WIGGLE DISPLAY "FUEL YES OR CONNECTOR THAT
THE FUEL LEVEL LEVEL SENDING UNIT CAUSED THE CODE TO
SENSOR CONNECTOR AND VOLTS TOO HIGH"? SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

259
T TEST TC-107A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
260
TEST TC-107A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH T
R
O
U
B
TEST TC-107A KEY ON.
L
CONTINUED FROM
THE PREVIOUS USE A VOLTMETER IN
E
PAGE THE FOLLOWING
STEPS.
C
O
D
E
BACKPROBE PCM
T
HARNESS CONNECTOR IS THE VOLTAGE YES PERFORM TEST E
C3 CAVITY 26. WITHIN 0.5 VOLT OF
BATTERY VOLTAGE?
TC-107B.
S
FIG.1 T
S
NO
KEY OFF. KEY ON. MEASURE

THE VOLTAGE AT IS THE FUEL LEVEL NO CONTINUE TEST
DISCONNECT THE FUEL FUEL LEVEL SENSOR SENSOR VOLTAGE TC-107A ON THE
LEVEL SENSOR HARNESS HARNESS CONNECTOR ABOVE 8.0 VOLTS? NEXT PAGE.
CONNECTOR.** CAVITY 3. FIG.2
YES
KEY OFF. INSTALL A KEY ON. USING THE

JUMPER BETWEEN FUEL DRB, MONITOR THE IS THE VOLTAGE YES REPLACE THE FUEL
LEVEL SENSOR HARNESS FUEL LEVEL SENSOR BELOW 2.0 VOLTS? LEVEL SENSOR.*
CONNECTOR CAVITIES 3 VOLTAGE.
AND 4. FIG.2
NO
KEY OFF. INSTALL THE KEY ON. USING THE

JUMPER BETWEEN FUEL DRB, MONITOR THE IS THE VOLTAGE YES REPAIR THE SENSOR
LEVEL SENSOR HARNESS FUEL LEVEL SENSOR BELOW 1.0 VOLT? RETURN CIRCUIT FOR
CONNECTOR CAVITY 3 VOLTAGE. AN OPEN.*
AND GROUND. FIG.2
NO
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

261
T TEST TC-107A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
262
TEST TC-107A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE PCM E
PAGE HARNESS
CONNECTORS.**
C
O
D
E
USING AN OHMMETER, CAVITY 26 AND FUEL REPAIR THE FUEL T
MEASURE THE LEVEL SENSOR IS THE RESISTANCE NO LEVEL SENSOR
RESISTANCE BETWEEN HARNESS CONNECTOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR E
PCM HARNESS
CONNECTOR C3...
CAVITY 3.
FIG.1
AN OPEN.*
S
T
YES S
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

263
T TEST TC-107B REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
264
TEST TC-107B REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH T
R
U
B
KEY OFF. L
START TEST
TC-107B. DISCONNECT PCM E
HARNESS
CONNECTOR C3.**
C
O
D
E
USING A VOLTMETER, T
MEASURE THE VOLTAGE IS THE VOLTAGE NO REPLACE THE
KEY ON. PCM HARNESS ABOVE 6.0 VOLTS? POWERTRAIN CONTROL E
CONNECTOR C3
CAVITY 26. FIG.1
MODULE.*
S
T
YES S
REPAIR THE FUEL

LEVEL SENSOR
SIGNAL CIRCUIT FOR
A SHORT TO
VOLTAGE.*

265
T TEST TC-108A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
266
TEST TC-108A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
KEY OFF.
MONITOR THE DRB
DOES THE DRB
T
WAIT 30 SECONDS. FOR CODES. LEVEL SENDING UNIT
VOLTS TOO LOW"?
TC-108A ON THE
NEXT PAGE.
E
KEY ON. S
T
NO S

AS A GUIDE, WIGGLE MONITOR THE DRB DISPLAY "FUEL YES OR CONNECTOR THAT
THE FUEL LEVEL FOR CODES. LEVEL SENDING UNIT CAUSED THE CODE TO
SENSOR CONNECTOR AND VOLTS TOO LOW"? SET.*
HARNESS. FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

267
T TEST TC-108A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
FIG.3
268
TEST TC-108A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW T
R
O
U
B
CONTINUED FROM
THE PREVIOUS DISCONNECT THE FUEL E
PAGE. LEVEL SENSOR HARNESS
CONNECTOR.**
C
O
D
E
KEY ON. USING THE
DRB, MONITOR THE IS THE FUEL LEVEL YES REPLACE THE FUEL T
FUEL LEVEL SENSOR
VOLTAGE.
SENSOR VOLTAGE
ABOVE 1.0 VOLTS?
LEVEL SENSOR.*
E
S
NO T
S
KEY OFF.
USE AN OHMMETER IN
HARNESS STEPS.
CONNECTORS.**
MEASURE THE REPAIR THE FUEL

RESISTANCE BETWEEN IS THE RESISTANCE NO LEVEL SENSOR
PCM HARNESS ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
CONNECTOR C3 CAVITY A SHORT TO
26 AND GROUND. FIG.1 GROUND.*
YES
MEASURE THE IS THE RESISTANCE REPAIR THE

RESISTANCE BETWEEN CAVITIES 4 AND 6. ABOVE 100K OHMS NO CIRCUITS AFFECTED
FUEL LEVEL SENSOR FOR BOTH FOR A SHORT
HARNESS CONNECTOR FIG.2 MEASUREMENTS? TOGETHER.*
CAVITIY 3 AND...
YES
MEASURE THE IS THE RESISTANCE

RESISTANCE BETWEEN TERMINALS 4 AND 6. BELOW 5.0 OHMS FOR NO REPLACE THE
FUEL LEVEL SENSOR EITHER POWERTRAIN CONTROL
TERMINAL 3 AND... FIG.3 MEASUREMENT? MODULE.*
YES
REPLACE THE FUEL

LEVEL SENSOR.*

269
T TEST TC-109A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
270
TEST TC-109A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY T
R
U
B
START TEST
NOTE: IF ANY OTHER
CHARGING CODES ARE
NOTE: BATTERY MUST
BE FULLY CHARGED
L
TC-109A. SET, DIAGNOSE AND TO PERFORM THIS E
REPAIR OTHER CODES TEST.
FIRST.
C
O
D
E
KEY ON.
USING THE DRB,
KEY ON.
START THE ENGINE FOR
DOES THE DRB SHOW
"GENERATOR FIELD YES CONTINUE TEST
T
CLEAR CODES.
KEY OFF.
AT LEAST 10 SECONDS.
MONITOR THE DRB FOR
NOT SWITCHING
PROPERLY"?
TC-109A ON THE
NEXT PAGE.
E
WAIT 30 SECONDS. PCM CODES. S
T
NO S
USING THE SCHEMATIC DOES THE DRB SHOW REPAIR THE HARNESS
AS A GUIDE, WIGGLE "GENERATOR FIELD YES OR CONNECTOR THAT
THE WIRES AND NOT SWITCHING CAUSED THE CODE TO
CONNECTORS. PROPERLY"? SET.*
FIG.1
NO

FIG.2 FIG.1
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

271
T TEST TC-109A CONTINUED - REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
272
TEST TC-109A CONTINUED - REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY T
R
O
U
B
TEST TC-109A L
CONTINUED FROM
THE PREVIOUS
USE A VOLTMETER IN
THE FOLLOWING E
PAGE. STEP.
C
O
D
E
BACKPROBE PCM DOES THE VOLTMETER
HARNESS CONNECTOR DISPLAY 10.0-15.0 YES REPLACE THE T
C2 CAVITY 10. VOLTS AFTER THE
ENGINE HAS RUN FOR
POWERTRAIN CONTROL
MODULE.* E
FIG.1 1 MINUTE?
S
NO T
S
KEY OFF. DISCONNNECT THE

GENERATOR FIELD
DISCONNECT PCM HARNESS
CONNECTOR C2.**
MEASURE THE REPAIR THE

USE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE NO GENERATOR FIELD
THE FOLLOWING GENERATOR FIELD BELOW 5.0 OHMS? CIRCUIT FOR AN
STEPS. CIRCUIT. OPEN.*
FIG.2
YES
MEASURE THE
DISCONNECT PCM RESISTANCE BETWEEN
HARNESS CONNECTOR PCM HARNESS
C3.** CONNECTOR C3
CAVITY 25 AND...
GENERATOR FILED REPAIR THE

HARNESS CONNECTOR IS THE RESISTANCE NO GENERATOR SOURCED
CAVITY 1 BELOW 5.0 OHMS? CIRCUIT FOR AN
(GENERATOR SOURCE OPEN.*
CIRCUIT).
YES
REPLACE THE
GENERATOR.*

273
T TEST TC-112A REPAIRING - NO CLUSTER BUS MESSAGE
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
274
TEST TC-112A REPAIRING - NO CLUSTER BUS MESSAGE T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
T
FOR CODES. S
T
NO S

FIG.1 FIG.2
N0
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

275
T TEST TC-112A CONTINUED - REPAIRING - NO CLUSTER BUS MESSAGE
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
276
TEST TC-112A CONTINUED - REPAIRING - NO CLUSTER BUS MESSAGE T
R
O
U
B
TEST TC-112A L
CONTINUED FROM
DISCONNECT PCM
HARNESS E
PAGE. CONNECTOR C3.**
C
O
D
E
MEASURE THE
DISCONNECT USE AN OHMMETER IN RESISTANCE BETWEEN T
INSTRUMENT CLUSTER
CONNECTOR C1.**
THE FOLLOWING
STEPS.
PCM HARNESS
CONNECTOR C3 E
CAVITY 30 AND...
S
T
S
INSTRUMENT CLUSTER
HARNESS IS THE RESISTANCE NO REPAIR THE CCD+
CONNECTOR C1 BELOW 5.0 OHMS? CIRCUIT FOR AN
CAVITY 6. OPEN.*
FIG.1
YES
MEASURE THE INSTRUMENT CLUSTER

RESISTANCE BETWEEN HARNESS IS THE RESISTANCE NO REPAIR THE CCD-
PCM HARNESS CONNECTOR C1 BELOW 5.0 OHMS? CIRCUIT FOR AN
CONNECTOR C3 CAVITY 7. OPEN.*
YES
KEY ON.
REPLACE THE PERFORM SEVERAL KEY MONITOR THE DRB
INSTRUMENT CYCLES, WAITING AT FOR CODES.
CLUSTER. LEAST 30 SECONDS
BETWEEN EACH CYCLE.
DOES THE DRB YES REPLACE THE

DISPLAY THIS CODE? POWERTRAIN CONTROL
MODULE.*
NO
TEST COMPLETE.*

277
T TEST TC-118A REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
278
TEST TC-118A REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH T
R
U
B
START TEST
KEY ON. L
ERASE CODES.
C
O
D
E
T
FOR CODES. S
T
NO S

FIG.1 FIG.2
N0
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

279
T TEST TC-118A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
280
TEST TC-118A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH T
R
O
U
B
TEST TC-118A
CONTINUED FROM
DISCONNECT THE OIL
PRESSURE SENSOR
L
THE PREVIOUS KEY OFF. HARNESS E
PAGE. CONNECTOR.**
C
O
D
E
KEY ON. MEASURE THE
VOLTAGE AT OIL IS THE VOLTAGE NO CONTINUE TEST
T
USE A VOLTMETER IN PRESSURE SENSOR ABOVE 5.5 VOLTS? TC-118A ON THE E
THE FOLLOWING HARNESS CONNECTOR NEXT PAGE.
STEPS. CAVITY 2. FIG.1 S
T
YES S
KEY OFF. KEY ON. MEASURE REPAIR THE OIL

THE VOLTAGE AT OIL IS THE VOLTAGE NO PRESSURE SENSOR
DISCONNECT THE PCM PRESSURE SENSOR BELOW 0.5 VOLT? SIGNAL CIRCUIT FOR
HARNESS HARNESS CONNECTOR A SHORT TO
CONNECTORS.** CAVITY 2. FIG.1 VOLTAGE.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

281
T TEST TC-118A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
282
TEST TC-118A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO HIGH T
R
O
U
B
TEST TC-118A WAS THE VOLTAGE L
CONTINUED FROM
THE PREVIOUS
MEASURED IN THE
PREVIOUS STEP
YES
E
PAGE. BETWEEN 4.8 AND
5.3 VOLTS?
C
NO O
D
E
KEY OFF.
T
DISCONNECT PCM
HARNESS E
CONNECTOR C2.**
S
T
S
USING AN OHMMETER, OIL PRESSURE

MEASURE THE SENSOR HARNESS
RESISTANCE CONNECTOR CAVITY 3
BETWEEN... AND GROUND.
FIG.1
REPAIR THE OIL

IS THE RESISTANCE NO PRESSURE SENSOR
BELOW 5.0 OHMS? RETURN CIRCUIT FOR
AN OPEN.*
YES
KEY OFF. USING AN OHMMETER,

MEASURE THE REPLACE THE OIL
DISCONNECT PCM RESISTANCE PRESSURE SENSOR.*
HARNESS BETWEEN...
CONNECTOR C2.**
OIL PRESSURE SENSOR REPAIR THE OIL

HARNESS CONNECTOR IS THE RESISTANCE NO PRESSURE SENSOR
CAVITY 2 AND PCM BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
HARNESS CONNECTOR C2 AN OPEN.*
CAVITY 23. FIG.2
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

283
T TEST TC-119A REPAIRING - OIL PRESSURE VOLTAGE TOO LOW
R
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
284
TEST TC-119A REPAIRING - OIL PRESSURE VOLTAGE TOO LOW T
R
U
B
START TEST
KEY ON. L
CLEAR CODES.
C
O
D
E
T
FOR CODES. S
T
NO S

FIG.1 FIG.2
N0
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT CODES.

285
T TEST TC-119A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO LOW
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
286
TEST TC-119A CONTINUED - REPAIRING - OIL PRESSURE VOLTAGE TOO LOW T
R
O
U
B
L
CONTINUED FROM
THE PREVIOUS DISCONNECT THE OIL
E
C
O
D
E
KEY ON. MEASURE THE

T
VOLTAGE AT OIL IS THE VOLTAGE YES REPLACE THE OIL E
USE A VOLTMETER IN
THE FOLLOWING
PRESSURE SENSOR
HARNESS CONNECTOR
BETWEEN 4.8 AND
5.3 VOLTS?
PRESSURE SENSOR.*
S
STEP. CAVITY 2. FIG.1 T
S
NO
KEY OFF.
USE AN OHMMETER IN
HARNESS STEPS.
CONNECTORS.**
OIL PRESSURE REPAIR THE OIL

MEASURE THE SENSOR HARNESS IS THE RESISTANCE NO PRESSURE SENSOR
RESISTANCE CONNECTOR CAVITY 2 ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
BETWEEN... AND GROUND. A SHORT TO
FIG.1 GROUND.*
YES
OIL PRESSURE REPAIR THE OIL

MEASURE THE SENSOR HARNESS IS THE RESISTANCE NO PRESSURE SENSOR
RESISTANCE CONNECTOR CAVITIES ABOVE 100K OHMS? SIGNAL CIRCUIT FOR A
BETWEEN... 2 AND 3. SHORT TO THE SENSOR
FIG.1 RETURN CIRCUIT.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

287
N TEST NTC-1A NO TROUBLE CODE TEST MENU
O
Perform TEST DTC Before Proceeding
T First, check all Technical Service Bulletins that relate to this driveability problem. Perform corrective
R actions if indicated; otherwise continue.
O
U 1. NO TROUBLE CODE COMPLETE TEST (non-monitored & monitored circuits)
B
L Perform TESTS NTC-2A through NTC-24A in sequence until the driveability problem is found.
E NO TROUBLE CODE MENU
C CHECKING THE GLOW PLUG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-2A
O CHECKING THE FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-3A
D CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS . . . . . . . . . . . . . . . .NTC-4A
E
CHECKING THE ENGINE COOLANT SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . .NTC-5A
T CHECKING THE ACCELERATOR PEDAL SENSOR CALIBRATION . . . . . . . . . . . . . . . . . .NTC-6A
E CHECKING THE BOOST PRESSURE SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . .NTC-7A
S CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . .NTC-8A
T
S CHECKING THE EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-9A
CHECKING THE FUEL HEATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-10A
CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-11A
CHECKING THE LOW COOLANT LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-12A
CHECKING THE WATER IN FUEL LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-13A
REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY. . . . . . . . . . .NTC-14A
CHECKING THE TACHOMETER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-15A
CHECKING THE WAIT TO START LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-16A
CHECKING THE CHECK ENGINE LAMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-17A
CHECKING THE SPEEDOMETER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-19A
REPAIRING THE FUEL LEVEL GAUGE NOT OPERATING PROPERLY . . . . . . . . . . . . .NTC-20A
CHECKING VEHICLE COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-21A
CHECKING THE TURBOCHARGER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-24A
2. NO TROUBLE CODE QUICK INDIVIDUAL TEST (individual test only)

If you suspect any of the above items to be the cause of the vehicle’s driveability problem, perform
the associated test(s) individually. Return to No Trouble Code Menu if driveability problem still
exists, or perform No Trouble Code Complete Test.
3. NO TROUBLE CODE QUICK SYMPTOM TEST (symptom test only)
Symptom checks cannot be used properly unless the driveability problem characteristic actually
happens while the vehicle is being tested. To reduce diagnostic time, ensure that the DTC Test and
appropriate General Information sections have been reviewed before attempting to diagnose a
symptom.
Select the symptom that most accurately describes the vehicle’s driveability problem and then
perform the test routine that pertains to this symptom. Perform each routine test in sequence until
the problem is found. For definitions, see Section 12.0 in General Information section in this manual.
288
TEST NTC-1A NO TROUBLE CODE TEST MENU N
O
Perform TEST DTC Before Proceeding
SYMPTOM DIAGNOSTIC TEST ROUTINE

T
R
HARD START NTC-2A, 3A, 5A, 6A, 7A, 8A, 10A O
START AND STALL NTC-2A, 3A, 5A, 6A, 7A, 8A, 10A U
HESITATION/STUMBLE NO TROUBLE CODE COMPLETE TEST (STEP 1) B
SURGE NTC-3A, 4A, 5A, 6A, 7A, 9A, 11A, 12A, 16A L
LACK OF POWER/SLUGGISH NTC-3A, 4A, 5A, 6A, 7A, 8A, 9A, 10A, 24A E
PRE-IGNITION/DETONATION NO TROUBLE CODE COMPLETE TEST (STEP 1)
C
CUTS OUT/MISSES NTC-3A, 4A, 5A, 6A, 7A, 8A O
BACKFIRE/POPBACK NTC-3A, 4A, 5A, 6A, 7A, 8A, 11A D
RUNS ROUGH/UNSTABLE/ NO TROUBLE CODE COMPLETE TEST (STEP 1) E
ERRATIC IDLE
POOR FUEL ECONOMY NO TROUBLE CODE COMPLETE TEST (STEP 1) T
E
S
NOTE: For all component locations see General Information Section 4.0 in this manual.
T
NOTE: After replacement of the ECM, see GENERAL INFORMATION SECTION 8.0 for the S
programming procedure.
289
N TEST NTC-2A CHECKING THE GLOW PLUG OPERATION
O
Perform TEST NTC 1A Before Proceeding
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
290
TEST NTC-2A CHECKING THE GLOW PLUG OPERATION N
O
Perform TEST NTC 1A Before Proceeding
T
R
START TEST
O
NTC-2A. KEY OFF. U
B
L
E
C
O
DISCONNECT EACH
KEY ON. D
GLOW PLUG HARNESS USING THE DRB, E
CONNECTOR. ACTUATE THE GLOW
PLUG RELAY.
T
E
S
T
S
USING A VOLTMETER, DOES THE VOLTMETER
MEASURE EACH GLOW SWITCH FROM NO CONTINUE TEST
PLUG HARNESS BATTERY VOLTAGE TO NTC-2A ON THE
CONNECTOR. BELOW 1.0 VOLT NEXT PAGE.
FIG.1 DURING ACTUATION?
YES
GLOW PLUG
CIRCUITRY OK.
REFER TO SERVICE TEST COMPLETE.*
MANUAL FOR GLOW
PLUG TEST.

291
N TEST NTC-2A CONTINUED - CHECKING THE GLOW PLUG OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
292
TEST NTC-2A CONTINUED - CHECKING THE GLOW PLUG OPERATION N
O
T
R
TEST NTC-2A
CONTINUED FROM
DISCONNECT THE
GLOW PLUG RELAY
O
THE PREVIOUS HARNESS U
PAGE. CONNECTOR.**
B
L
E
C
O
USING A VOLTMETER,
MEASURE GLOW PLUG IS THE VOLTAGE NO REPAIR THE BATTERY
D
RELAY HARNESS ABOVE 11.0 VOLTS? SUPPLY CIRCUIT FOR E
CONNECTOR CAVITY 30. AN OPEN.*
FIG.1
T
YES E
S
T
S
CONNECT A JUMPER USING A VOLTMETER, IS THE VOLTAGE REPAIR THE GLOW
BETWEEN GLOW PLUG MEASURE THE VOLTAGE ABOVE 11.0 VOLTS NO PLUG RELAY OUTPUT
RELAY HARNESS AT EACH GLOW PLUG FOR EACH CIRCUIT FOR AN
CONNECTOR CAVITIES HARNESS CONNECTOR. MEASUREMENT? OPEN.*
30 AND 87. FIG.1 FIG.2
YES
REPLACE THE GLOW

PLUG RELAY.*
REFER TO SERVICE
MANUAL TO CHECK GLOW
PLUG OPERATION.

293
N TEST NTC-3A CHECKING THE FUEL INJECTION PUMP
O
Perform TEST NTC-1A Before Proceeding
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
294
TEST NTC-3A CHECKING THE FUEL INJECTION PUMP N
O
T
R
START TEST
THIS TEST SHOULD BE
PERFORMED BEFORE
O
NTC-3A. REPLACING THE ECM U
DURING FAULT CODE
DIAGNOSTICS. B
L
E
C
O
NOTE: THIS TEST
CHECKS FOR SHORTED
DISCONNECT THE
FUEL INJECTION
D
CIRCUITS INTERNAL
TO THE FUEL
PUMP HARNESS
CONNECTOR.**
E
INJECTION PUMP.
T
E
S
T
S
ON THE FUEL
USE AN OHMMETER INJECTION PUMP
FOR THE FOLLOWING CONNECTOR
MEASUREMENTS... (PUMP SIDE).
FIG.1
PERFORM THE IS THE RESISTANCE

RESISTANCE ABOVE 100 OHMS FOR NO REPLACE THE FUEL
MEASUREMENTS IN EACH OF THE INJECTION PUMP.*
FIG.2. MEASUREMENTS?
YES
THE FUEL INJECTION

PUMP INTERNAL
CIRCUITRY IS OK.
TEST COMPLETE.*

295
N TEST NTC-4A CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
296
TEST NTC-4A CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS N
O
T
R
O
START TEST
NTC-4A. KEY OFF.
U
B
L
E
C
O
USING AN OHMMETER,
D
DISCONNECT THE ECM
HARNESS
MEASURE ECM HARNESS
CONNECTOR C1
IS THE RESISTANCE
BELOW 5.0 OHMS FOR
NO REPAIR THE ECM
GROUND CIRCUIT(S)
E
CONNECTORS.** CAVITIES 1 AND 27 TO BOTH MEASUREMENTS? FOR AN OPEN.*
GROUND. FIG.1
T
YES
E
S
T
S
USING A VOLTMETER, REPAIR THE ASD
REMOVE THE ASD MEASURE THE IS THE VOLTAGE NO RELAY FUSED
RELAY FROM THE VOLTAGE AT ASD ABOVE 11.5 VOLTS? BATTERY SUPPLY FOR
PDC.** RELAY CONNECTOR AN OPEN.*
CAVITY 3. FIG.2
YES
CONNECT A JUMPER USING A VOLTMETER, IS THE VOLTAGE REPAIR THE ASD

BETWEEN ASD RELAY MEASURE ECM ABOVE 11.5 VOLTS NO RELAY OUTPUT
CONNECTOR CAVITIES HARNESS CONNECTOR FOR BOTH CIRCUIT FOR AN
3 AND 5. C1 CAVITIES MEASUREMENTS? OPEN.*
FIG.2 2 AND 28. FIG.1
YES

MEASURE THE VOLTAGE IS THE VOLTAGE NO IGNITION SWITCH
KEY ON. AT ECM HARNESS ABOVE 11.5 VOLTS? OUTPUT CIRCUIT FOR
CAVITY 47. FIG.1
YES
CONTINUE TEST
NTC-4A ON THE
NEXT PAGE.

297
N TEST NTC-4A CONTINUED - CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
298
TEST NTC-4A CONTINUED - CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS N
O
T
R
TEST NTC-4A KEY OFF.
O
CONTINUED FROM
THE PREVIOUS RECONNECT THE ECM
U
PAGE. HARNESS B
CONNECTORS.
L
E
C
O
USING AN OHMMETER,
D
DISCONNECT THE PCM MEASURE BETWEEN GND IS THE RESISTANCE NO REPAIR THE PCM E
HARNESS AND PCM CONNECTOR C1 BELOW 5.0 OHMS FOR GROUND CIRCUIT(S)
CONNECTORS.** CAVITIES 31 AND 32. BOTH MEASUREMENTS? FOR AN OPEN.*
FIG.1 T
E
YES
S
T
S
USE A VOLTMETER IN
THE FOLLOWING KEY ON.
STEPS.
MEASURE THE PCM HARNESS REPAIR THE ASD

VOLTAGE AT PCM CONNECTOR C1 IS THE VOLTAGE NO RELAY OUTPUT
HARNESS CONNECTOR CAVITY 2. ABOVE 10.0 VOLTS? CIRCUIT(S) FOR AN
C3 CAVITY 12 OPEN.*
AND... FIG.1
YES
MEASURE VOLTAGE AT
PCM HARNESS IS THE VOLTAGE NO REPAIR THE BATTERY
CONNECTOR C1 ABOVE 10.0 VOLTS? SUPPLY CIRCUIT FOR
CAVITY 22. AN OPEN.*
FIG.1
YES
POWER AND GROUNDS

ARE OK.
TEST COMPLETE.*

299
N TEST NTC-5A CHECKING THE ENGINE COOLANT SENSOR CALIBRATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
300
TEST NTC-5A CHECKING THE ENGINE COOLANT SENSOR CALIBRATION N
O
T
R
START TEST
NOTE: THIS TEST
WOULD BE INVALID IS THE THERMOSTAT NO REPLACE THE
O
NTC-5A. IF THE THERMOSTAT OPERATING THERMOSTAT.* U
IS STUCK OPEN, CORRECTLY?
CLOSED OR REMOVED. B
L
YES E
C
O
NOTE: MAKE SURE
THE KEY IS ON WITH ALLOW THE ENGINE
D
THE ENGINE OFF AT
THIS TIME.
TO COOL TO BELOW
71*C (160*F).
E
T
E
S
T
S
USING THE DRB, USING A IS THE DRB READING REPLACE THE ENGINE
READ THE ENGINE TEMPERATURE PROBE, WITHIN 7*C (13*F) NO COOLANT
COOLANT MEASURE THE ENGINE OF THE PROBE TEMPERATURE
TEMPERATURE BLOCK NEAR THE ECT READING? SENSOR.*
SENSOR. SENSOR.
YES
COMPARE THE ECT START THE ENGINE AND DOES THE DRB READING REPLACE THE ENGINE
READING ON THE DRB ALLOW IT TO REACH STAY WITHIN 7*C NO COOLANT
TO THE PROBE NORMAL OPERATING (13*F) OF THE PROBE TEMPERATURE
READING DURING THE TEMPERATURE ABOVE READING AT ALL SENSOR.*
FOLLOWING STEP. 82*C (180*F). TIMES?
YES
THE ENGINE COOLANT

SENSOR IS
OPERATING
NORMALLY.
TEST COMPLETE.*

301
N TEST NTC-6A CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
302
TEST NTC-6A CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION N
O
T
R
START TEST
O
NTC-6A. KEY ON. U
B
L
E
C
O
USING A VOLTMETER, NOTE: THROTTLE
IS THE VOLTAGE
BELOW 1.0 VOLT NO REPLACE THE
D
BACKPROBE ECM
HARNESS CONNECTOR
MUST BE FULLY
CLOSED.
WITH THE THROTTLE
FULLY CLOSED.
ACCELERATOR PEDAL
POSITION SENSOR.*
E
C1 CAVITY 24.
T
YES E
S
T
S
MONITOR THE
VOLTMETER WHILE WAS THE VOLTAGE NO REPLACE THE
SLOWLY OPENING THE CHANGE A SMOOTH ACCELERATOR PEDAL
THROTTLE TO WIDE TRANSITION? POSITION SENSOR.*
OPEN.
YES
WAS THE VOLTAGE AT NO REPLACE THE

WIDE OPEN THROTTLE ACCELERATOR PEDAL
ABOVE 4.0 VOLTS? POSITION SENSOR.*
YES
ACCEL PEDAL POSITION

SENSOR OPERATING
NORMALLY.
TEST COMPLETE.*

303
N TEST NTC-7A CHECKING THE BOOST PRESSURE SENSOR CALIBRATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
304
TEST NTC-7A CHECKING THE BOOST PRESSURE SENSOR CALIBRATION N
O
T
R
O
START TEST KEY ON, ENGINE U
NTC-7A. OFF.
B
L
E
C
O
USING THE DRB, IS THE VOLTAGE
D
READ BOOST BETWEEN NO REPLACE THE BOOST E
PRESSURE SENSOR 1.7 AND 1.95 PRESSURE SENSOR.*
VOLTAGE. VOLTS?
T
YES
E
S
T
S
BOOST PRESSURE
SENSOR OPERATING
NORMALLY.
TEST COMPLETE.*

305
N TEST NTC-8A CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
306
TEST NTC-8A CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION N
O
T
R
START TEST
KEY OFF. O
NTC-8A. DISCONNECT THE U
FUEL HEATER
HARNESS CONNECTOR. B
L
E
C
O
KEY ON. START AND IDLE THE
ENGINE UNTIL THE
D
USING THE DRB,
MONITOR THE ECM
ENGINE TEMPERATURE
REACHES 70*C
E
ECT SENSOR. (160*F).
T
E
S
T
S
NOTE: IF THE ENGINE USING THE DRB, IS THE FUEL
TEMP IS ABOVE 70*C MONITOR THE FUEL TEMPERATURE NO REPLACE THE FUEL
(160*F), ALLOW THE TEMPERATURE BETWEEN 20*C INJECTION PUMP.*
ENGINE TO COOL DOWN SENSOR. (70*F) AND 50*C
TO 70*C (160*F). (120*F)?
YES
COMPARE THE ECM START THE ENGINE DOES THE FUEL TEMP
ECT AND FUEL AND ALLOW IT TO SENSOR READING NO REPLACE THE FUEL
TEMPERATURE SENSOR REACH OPERATING INCREASE SMOOTHLY INJECTION PUMP.*
READINGS IN THE TEMPERATURE OF TO 40-60*C
FOLLOWING STEP. 90*C (195*F). (100-140*F)?
YES
THE FUEL
TEMPERATURE SENSOR
IS OPERATING
NORMALLY.
TEST COMPLETE.*

307
N TEST NTC-9A CHECKING THE EGR SYSTEM
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
308
TEST NTC-9A CHECKING THE EGR SYSTEM N
O
T
R
O
START TEST
NTC-9A. KEY OFF.
U
B
L
E
C
O
CONNECT A VACUUM REPAIR LEAKING OR
D
DISCONNECT THE
VACUUM SUPPLY HOSE
GAUGE TO THE
VACUUM SUPPLY
IS THE VACUUM
ABOVE 10" AT IDLE?
NO RESTRICTED VACUUM
SUPPLY HOSE OR
E
AT THE EVM. HOSE. START AND FAULTY VACUUM
IDLE THE ENGINE. SUPPLY PUMP.*
T
YES
E
S
T
S
KEY OFF. KEY ON. USING A REPAIR THE ASD
DISCONNECT THE EVM VOLTMETER, MEASURE IS THE VOLTAGE NO RELAY OUTPUT
HARNESS EVM HARNESS ABOVE 10.0 VOLTS? CIRCUIT FOR AN
CONNECTOR.** CONNECTOR CAVITY 1. OPEN.*
FIG.1
YES
CONNECT A THE EVM HARNESS

VOLTMETER BETWEEN CONNECTOR CAVITY 4. IS THE VOLTAGE NO REPAIR THE EVM
THE BATTERY ABOVE 10.0 VOLTS? GROUND CIRCUIT FOR
POSITIVE TERMINAL AN OPEN.*
AND... FIG.1
YES
DISCONNECT THE CONNECT THE EVM CHECK EGR VACUUM

VACUUM HOSE TO THE VACUUM SUPPLY HOSE IS THERE A NO HOSE FOR
EGR VALVE AT THE TO THE EGR VACUUM REDUCTION OF POWER RESTRICTIONS OR
EVM. START AND HOSE. TEST DRIVE ON ACCELERATION? LEAKS. IF OK,
IDLE THE ENGINE. THE VEHICLE. REPLACE EGR VALVE.*
YES
CONTINUE TEST
NTC-9A ON THE
NEXT PAGE.

309
N TEST NTC-9A CONTINUED - CHECKING THE EGR SYSTEM
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
310
TEST NTC-9A CONTINUED - CHECKING THE EGR SYSTEM N
O
T
R
TEST NTC-9A O
CONTINUED FROM
THE PREVIOUS
RECONNECT THE EGR
VACUUM HOSE AT THE U
PAGE. EVM. B
L
E
C
O
DISCONNECT THE START THE ENGINE. DOES THE VACUUM D
VACUUM HOSE AT THE WHILE MONITORING READING DROP BELOW NO REPLACE THE
EGR VALVE AND THE VACUUM GAUGE, 2" DURING THROTTLE ELECTRIC VACUUM E
INSTALL A VACUUM SNAP THE THROTTLE SNAP? MODULATOR.*
GAUGE IN THE HOSE. SEVERAL TIMES.
T
YES E
S
T
S
EGR SYSTEM
OPERATING
NORMALLY.
TEST COMPLETE.*

311
N TEST NTC-10A CHECKING THE FUEL HEATER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1 FIG.2
312
TEST NTC-10A CHECKING THE FUEL HEATER OPERATION N
O
T
R
KEY OFF. O
START TEST
NTC-10A.
DISCONNECT THE
FUEL HEATER KEY ON. U
HARNESS
CONNECTOR.** B
L
E
C
CONNECT A TEST OUTPUT CIRCUIT AT
O
LIGHT BETWEEN THE FUEL HEATER IS THE TEST LIGHT YES CONTINUE TEST D
GROUND AND FUEL
HEATER RELAY...
HARNESS CONNECTOR. ON? NTC-10A ON THE
NEXT PAGE. E
FIG. 1
NO T
E
S
T
KEY OFF. WITH TEST
LIGHT STILL
WITH A KNOWN GOOD
RELAY. IS THE TEST LIGHT YES REPLACE THE
S
CONNECTED, ON? INITIAL FUEL
SUBSTITUTE FUEL KEY ON. HEATER RELAY.*
HEATER RELAY...
NO
KEY OFF. USING A VOLTMETER,

MEASURE RELAY IS THE VOLTAGE NO PERFORM TEST
REMOVE THE FUEL CONNECTOR ABOVE 11.0 VOLTS? NTC-10B.
HEATER RELAY.** CAVITY 30.
FIG. 2
YES
MEASURE FUSED REPAIR THE

IGNITION SWITCH IS THE VOLTAGE NO IGNITION SWITCH
KEY ON. OUTPUT CIRCUIT, ABOVE 11.0 VOLTS? OUTPUT CIRCUIT FOR
CAVITY 86. AN OPEN.*
FIG. 2
YES
WITH IGNITION RELAY CONNECTOR

STILL ON, CONNECT CAVITIES 85 AND IS THE VOLTAGE NO REPAIR THE RELAY
A VOLTMETER 86. ABOVE 11.0 VOLTS? GROUND CIRCUIT FOR
ACROSS... AN OPEN.*
FIG. 2
YES
REPAIR THE FUEL

HEATER RELAY
OUTPUT CIRCUIT FOR
AN OPEN.*

313
N TEST NTC-10A CONTINUED - CHECKING THE FUEL HEATER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1
FIG. 2
314
TEST NTC-10A CONTINUED - CHECKING THE FUEL HEATER OPERATION N
O
T
R
TEST NTC-10A
CONTINUED FROM WITH THE IGNITION
O
THE PREVIOUS STILL ON... U
PAGE.
B
L
E
C
O
CONNECT THE TEST
LIGHT ACROSS THE IS THE TEST LIGHT NO
REPAIR THE FUEL
HEATER GROUND
D
FUEL HEATER
HARNESS CONNECTOR.
ON? CIRCUIT FOR AN
OPEN.*
E
FIG. 1
T
YES E
S
T
S
NOTE: FUEL
USING THE DRB, TEMPERATURE MUST
READ THE FUEL BE BELOW 4.5*C
TEMPERATURE. (40*F) TO CONTINUE
THIS TEST.
USING AN OHMMETER,
MEASURE THE IS THE RESISTANCE NO REPLACE THE FUEL
RESISTANCE OF THE BETWEEN HEATER.*
FUEL HEATER. 0.7 AND 2.0 OHMS?
FIG. 2
YES
FUEL HEATER SYSTEM

OPERATING
NORMALLY.
TEST COMPLETE.*

315
N TEST NTC-10B CHECKING THE FUEL HEATER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1
316
TEST NTC-10B CHECKING THE FUEL HEATER OPERATION N
O
T
R
REMOVE AND INSPECT
O
START TEST
NTC-10B.
THE FUEL HEATER
FUSE IN THE PDC. IS THE FUSE OK?
NO CONTINUE TEST
NTC-10B ON THE
U
FIG.1
NEXT PAGE. B
L
YES E
C
O
CONNECT THE TEST D
LIGHT BETWEEN GROUND
AND THE FUSE’S
IS THE TEST LIGHT
ON?
NO REPLACE THE POWER
DISTRIBUTION E
BATTERY INPUT CENTER.*
CAVITY. FIG.1
T
YES E
S
T
S
REPAIR THE FUEL
HEATER RELAY
BATTERY SUPPLY
CIRCUIT FOR AN
OPEN.*

317
N TEST NTC-10B CONTINUED - CHECKING THE FUEL HEATER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T FIG. 1 FIG. 2
S
FIG. 3 FIG.4
FIG.5
318
TEST NTC-10B CONTINUED - CHECKING THE FUEL HEATER OPERATION N
O
T
R
TEST NTC-10B LEAVE THE FUEL O
CONTINUED FROM
THE PREVIOUS
HEATER, FUEL HEATER
RELAY AND FUSE U
PAGE. DISCONNECTED FOR THE
FOLLOWING STEPS. B
L
E
C
USING AN OHMMETER, CAVITY 30 OF THE REPAIR THE FUSED
O
MEASURE THE FUEL HEATER RELAY IS THE RESISTANCE NO BATTERY CIRCUIT D
RESISTANCE BETWEEN
GROUND AND...
CONNECTOR. ABOVE 100K OHMS? FOR A SHORT TO
GROUND AND REPLACE E
FIG. 1 THE FUSE.*
YES T
E
S
T
MEASURE THE
RESISTANCE BETWEEN
MEASURE THE
RESISTANCE BETWEEN
IS THE RESISTANCE
ABOVE 100K OHMS NO
REPAIR THE SHORT
TO GROUND ON THE
S
GROUND AND RELAY THE FUEL HEATER FOR BOTH FUEL HEATER RELAY
CONNECTOR CAVITY 87. HARNESS CONNECTOR MEASUREMENTS? OUTPUT CIRCUIT AND
FIG.1 CAVITIES. FIG.2 REPLACE THE FUSE.*
YES
NOTE: THE FUEL MEASURE THE

TEMPERATURE MUST BE RESISTANCE OF THE IS THE RESISTANCE NO REPLACE THE FUEL
BELOW 4.5*C (40*F) FUEL HEATER. BETWEEN 0.7 AND HEATER AND THE
BEFORE TAKING THE 2.0 OHMS? FUSE.*
NEXT MEASUREMENT. FIG.3
YES
MEASURE THE
RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE FUEL
FUEL HEATER RELAY ABOVE 100K OHMS? HEATER RELAY AND
TERMINALS 30 AND THE FUSE.*
85. FIG.4
YES
AT THIS TIME, THE USING THE

SHORT TO GROUND SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS
THAT CAUSED THE GUIDE, INSPECT THE FOUND? NECESSARY AND
FUSE TO OPEN IS WIRING AND REPLACE THE FUSE.*
NOT PRESENT. CONNECTORS. FIG.5
NO
REPLACE THE FUSE.
TEST COMPLETE.*

319
N TEST NTC-11A CHECKING THE ENGINE MECHANICAL SYSTEMS
O
T At this point in the diagnostic test procedure, you have determined that all of the engine electrical
R systems are operating as designed; therefore, they are not the cause of the driveability problem.
O The following additional items should be checked as possible mechanical causes of the problem:
U
B 1. ENGINE VALVE TIMING - must be within specifications
L 2. ENGINE COMPRESSION - must be within specifications
E
3. CAMSHAFT LOBES - check for abnormal wear
C 4. ENGINE SPEED SENSOR PICK-UP - check crankshaft slots for debris/deterioration
O
D 5. ENGINE EXHAUST SYSTEM - must be free of any restrictions
E 6. ENGINE DRIVE SPROCKETS - must be properly positioned
7. POWER BRAKE BOOSTER - no internal vacuum leaks
T
E 8. FUEL - must be free of contamination
S 9. FUEL INJECTOR - plugged or restricted injector
T
S NOTE: Always look for any Technical Service Bulletins that may relate to the problem.
320
TEST NTC-11A CHECKING THE ENGINE MECHANICAL SYSTEMS N
O
NOTES T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
321
N TEST NTC-12A CHECKING THE LOW COOLANT LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1
322
TEST NTC-12A CHECKING THE LOW COOLANT LAMP OPERATION N
O
T
R
START TEST
NOTE: BE SURE
ENGINE COOLANT IS
O
NTC-12A. AT THE PROPER U
LEVEL BEFORE
CONTINUING. B
L
E
C
O
KEY ON.
DOES THE LOW YES CONTINUE TEST
D
MONITOR THE LOW
COOLANT LAMP.
COOLANT LAMP TURN
ON AND STAY ON?
NTC-12A ON THE
NEXT PAGE.
E
FIG.1
T
NO
E
S
T
S
PERFORM TEST
NTC-12B.

323
N TEST NTC-12A CONTINUED - CHECKING THE LOW COOLANT LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
324
TEST NTC-12A CONTINUED - CHECKING THE LOW COOLANT LAMP OPERATION N
O
T
R
TEST NTC-12A
CONTINUED FROM O
THE PREVIOUS
PAGE.
KEY OFF.
U
B
L
E
KEY ON. REPLACE THE

C
DISCONNECT THE PCM
HARNESS MONITOR THE LOW
DOES THE LOW
COOLANT LAMP TURN
YES ELECTRO/MECHANICAL
INSTRUMENT O
CONNECTORS.** COOLANT LAMP. ON AND STAY ON? CLUSTER.*
D
E
NO
T
E
KEY OFF.
DISCONNECT THE LOW USE AN OHMMETER IN
S
COOLANT SWITCH
HARNESS
THE FOLLOWING
STEPS.
T
CONNECTOR.**
S
MEASURE BETWEEN LOW REPAIR THE LOW

COOLANT SWITCH IS THE RESISTANCE NO COOLANT SWITCH
HARNESS CONNECTOR ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
CAVITY 1 AND GROUND. A SHORT TO
FIG.1 GROUND.*
YES
MEASURE BETWEEN REPAIR THE LOW

LOW COOLANT SWITCH IS THE RESISTANCE NO COOLANT SWITCH
HARNESS CONNECTOR ABOVE 100K OHMS? CIRCUITS FOR A
CAVITIES 1 AND 2. SHORT TOGETHER.*
FIG.1
YES
RECONNECT THE PCM CONNECT A HIGH

HARNESS IMPEDENCE TEST
CONNECTORS. LIGHT BETWEEN...
LOW COOLANT SWITCH

HARNESS CONNECTOR AFTER 20 SECONDS, YES REPLACE THE LOW
CAVITIES 1 AND 2. IS THE LOW COOLANT COOLANT SWITCH.*
KEY ON. LAMP ON STEADY?
FIG.1
NO
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

325
N TEST NTC-12B CHECKING THE LOW COOLANT LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
326
TEST NTC-12B CHECKING THE LOW COOLANT LAMP OPERATION N
O
T
R
KEY OFF. DOES THE LOW COOLANT O
START TEST
NTC-12B.
MONITOR THE
INSTRUMENT CLUSTER.
LAMP TURN ON FOR
APPROXIMATELY 2
YES CONTINUE TEST
NTC-12B ON THE U
KEY ON.
SECONDS, THEN TURN
OFF?
NEXT PAGE. B
L
NO E
C
O
D
REMOVE AND INSPECT NO REPLACE THE LOW
KEY OFF. THE LOW COOLANT IS THE LAMP OK? COOLANT LAMP.* E
LAMP.
T
YES E
S
T
S
REPLACE THE
ELECTRO/MECHANICAL
INSTRUMENT
CLUSTER.*

327
N TEST NTC-12B CONTINUED - CHECKING THE LOW COOLANT LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
328
TEST NTC-12B CONTINUED - CHECKING THE LOW COOLANT LAMP OPERATION N
O
T
R
TEST NTC-12B
CONTINUED FROM
KEY OFF.
DRAIN THE COOLANT DID THE LOW YES THE LOW COOLANT
O
THE PREVIOUS FROM THE COOLANT COOLANT LAMP TURN LAMP SYSTEM IS OK. U
PAGE. RESERVOIR.
KEY ON.
ON AND STAY ON?
TEST COMPLETE.* B
L
NO E
C
O
KEY OFF.
DISCONNECT THE LOW KEY ON. IS THE LOW COOLANT YES REPLACE THE LOW
D
COOLANT SWITCH LAMP ON? COOLANT SWITCH.* E
HARNESS WAIT 30 SECONDS.
CONNECTOR.**
T
NO E
S
T
S
KEY OFF. USING AN OHMMETER, REPAIR THE LOW
MEASURE THE LOW IS THE RESISTANCE NO COOLANT SWITCH
DISCONNECT THE PCM COOLANT SWITCH ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
HARNESS SIGNAL CIRCUIT TO A SHORT TO
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

329
N TEST NTC-13A CHECKING THE WATER IN FUEL LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
330
TEST NTC-13A CHECKING THE WATER IN FUEL LAMP OPERATION N
O
T
R
START TEST
NOTE: BE SURE A
WATER IN FUEL
O
NTC-13A. CONDITION DOES NOT U
EXISTING BEFORE
CONTINUING. B
L
E
C
O
KEY ON.
DOES THE WATER IN YES CONTINUE TEST
D
MONITOR THE WATER
IN FUEL LAMP.
FUEL LAMP TURN ON
AND STAY ON?
NTC-13A ON THE
NEXT PAGE.
E
FIG.1
T
NO
E
S
T
S
PERFORM TEST
NTC-13B.

331
N TEST NTC-13A CONTINUED - CHECKING THE WATER IN FUEL LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
332
TEST NTC-13A CONTINUED - CHECKING THE WATER IN FUEL LAMP OPERATION N
O
T
R
TEST NTC-13A O
CONTINUED FROM
THE PREVIOUS KEY OFF. U
PAGE.
B
L
E
C
KEY ON. REPLACE THE
O
DISCONNECT THE PCM DOES THE WATER IN YES ELECTRO/MECHANICAL D
HARNESS
CONNECTORS.**
MONITOR THE WATER
IN FUEL LAMP.
FUEL LAMP TURN ON
AND STAY ON?
INSTRUMENT
CLUSTER.* E
NO T
E
S
T
KEY OFF.
USE AN OHMMETER IN
S
DISCONNECT THE WATER THE FOLLOWING
IN FUEL SENSOR STEPS.
MEASURE BETWEEN REPAIR THE WATER

WATER IN FUEL IS THE RESISTANCE NO IN FUEL SENSOR
HARNESS CONNECTOR ABOVE 100K OHMS? SIGNAL CIRCUIT FOR
CAVITY 1 AND GROUND. A SHORT TO
FIG.1 GROUND.*
YES
MEASURE BETWEEN REPAIR THE WATER

WATER IN FUEL SENSOR IS THE RESISTANCE NO IN FUEL SENSOR
HARNESS CONNECTOR ABOVE 100K OHMS? CIRCUITS FOR A
CAVITIES 1 AND 2. SHORT TOGETHER.*
FIG.1
YES
RECONNECT THE PCM WITH WATER IN FUEL

HARNESS SENSOR HARNESS IS THE WATER IN NO REPLACE THE WATER
CONNECTORS. CONNECTOR FUEL LAMP ON IN FUEL SENSOR.*
DISCONNECTED, NOTE STEADY?
KEY ON. WATER IN FUEL LAMP.
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

333
N TEST NTC-13B CHECKING THE WATER IN FUEL LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
334
TEST NTC-13B CHECKING THE WATER IN FUEL LAMP OPERATION N
O
T
R
KEY OFF. DOES THE WATER IN O
START TEST
NTC-13B.
MONITOR THE
INSTRUMENT CLUSTER
FUEL LAMP TURN ON
FOR APPROXIMATELY
YES CONTINUE TEST
NTC-13B ON THE U
KEY ON.
2 SECONDS, THEN
TURN OFF?
NEXT PAGE. B
L
NO E
C
O
D
REMOVE AND INSPECT NO REPLACE THE WATER
KEY OFF. THE WATER IN FUEL IS THE LAMP OK? IN FUEL LAMP.* E
LAMP.
T
YES E
S
T
S
REPLACE THE
ELECTRO/MECHANICAL
INSTRUMENT
CLUSTER.*

335
N TEST NTC-13B CONTINUED - CHECKING THE WATER IN FUEL LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1
FIG.2
336
TEST NTC-13B CONTINUED - CHECKING THE WATER IN FUEL LAMP OPERATION N
O
T
R
TEST NTC-13B
CONTINUED FROM
KEY OFF.
REMOVE THE WATER DID THE WATER IN YES
THE WATER IN FUEL
LAMP SYSTEM IS OK.
O
THE PREVIOUS IN FUEL SENSOR AND FUEL LAMP TURN ON U
PAGE. PLACE THE PROBES AND STAY ON? TEST COMPLETE.*
IN WATER. KEY ON. B
L
NO E
C
O
KEY OFF.
DISCONNECT THE
KEY ON. CONNECT A
JUMPER BETWEEN WATER
AFTER WAITING 30
SECONDS,IS THE YES REPLACE THE WATER
D
WATER IN FUEL
SENSOR HARNESS
IN FUEL SENSOR
CONNECTOR CAVITIES 1
WATER IN FUEL LAMP
ON?
IN FUEL SENSOR.* E
CONNECTOR.** AND 2. FIG.1
T
NO E
S
T
S
WATER IN FUEL SENSOR REPAIR THE WATER
CONNECT THE JUMPER HARNESS CONNECTOR IS THE WATER IN YES IN FUEL SENSOR
BETWEEN GROUND CAVITY 1. FUEL LAMP ON? GROUND CIRCUIT FOR
AND... AN OPEN.*
FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR THE WATER

MEASURE THE WATER IS THE RESISTANCE NO IN FUEL SENSOR
DISCONNECT THE PCM IN FUEL SENSOR BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
HARNESS SIGNAL CIRCUIT. AN OPEN.*
CONNECTORS.** FIG.2
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

337
N TEST NTC-14A REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
338
TEST NTC-14A REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY N
O
T
R
START TEST
KEY ON. ARE ANY OIL
PRESSURE SENSOR YES
PERFORM THE
APPROPRIATE
O
NTC-14A. USING THE DRB, TROUBLE CODES TROUBLE CODE U
READ PCM CODES. PRESENT? TEST.
B
L
NO E
C
O
NOTE: MAKE SURE
THE ENGINE OIL IS
START THE ENGINE.
USING THE DRB, IS THE VOLTAGE NO CONTINUE TEST
D
AT THE PROPER
LEVEL.
MONITOR ENGINE OIL
PRESSURE SENSOR
READING BETWEEN
1.0 AND 4.0 VOLTS?
NTC-14A ON THE
NEXT PAGE.
E
VOLTS AND PRESSURE.
T
YES E
S
T
S
PERFORM THE PRESS AND HOLD THE WHEN "CHEC"
INSTRUMENT CLUSTER KEY OFF. TRIPOMETER RESET APPEARS IN THE
SELF TEST USING BUTTON. ODOMETER, RELEASE
THE FOLLOWING WAIT 30 SECONDS. THE TRIPOMETER
STEPS. KEY ON. RESET BUTTON.
WHEN "999" APPEARS OBSERVE THE OIL

IN THE ODOMETER, PRESSURE GAUGE AND DID THE GAUGE REACH NO REPLACE THE
PRESS AND RELEASE COMPARE THE TEST THE PROPER INSTRUMENT
THE TRIPOMETER RESET POINTS WITH THE CALIBRATION POINTS? CLUSTER.*
BUTTON AGAIN. CHART IN FIG.1.
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

339
N TEST NTC-14A CONTINUED - REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
340
TEST NTC-14A CONTINUED - REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY N
O
T
R
USING AN EXTERNAL IS THE ENGINE
O
START TEST
NTC-14A.
GAUGE, MAKE SURE
THE ENGINE HAS
OILING SYSTEM
FUNCTIONING
NO REPAIR ENGINE
OILING SYSTEM AS
U
PROPER OIL PROPERLY? NECESSARY.* B
PRESSURE.
L
YES
E
C
O
KEY OFF. USING A VOLTMETER,
D
DISCONNECT THE OIL MEASURE THE 5-VOLT IS THE VOLTAGE YES CONTINUE TEST E
PRESSURE SENSOR.* SUPPLY CIRCUIT. BETWEEN 5.0 AND NTC-14A ON THE
5.3 VOLTS? NEXT PAGE.
KEY ON. FIG.1 T
E
NO
S
T
S
KEY OFF. USING AN OHMMETER, REPAIR THE 5-VOLT
MEASURE THE 5-VOLT IS THE RESISTANCE NO SUPPLY CIRCUIT FOR
DISCONNECT THE PCM SUPPLY CIRCUIT TO ABOVE 100K OHMS? A SHORT TO
HARNESS GROUND. GROUND.*
CONNECTORS.** FIG.1
YES
MEASURE THE
RESISTANCE OF THE IS THE RESISTANCE NO REPAIR THE 5-VOLT
5-VOLT SUPPLY BELOW 5.0 OHMS? SUPPLY CIRCUIT FOR
CIRCUIT. AN OPEN.*
FIG.2
YES
THE 5-VOLT SUPPLY REPAIR THE 5-VOLT

MEASURE THE AND SENSOR RETURN IS THE RESISTANCE NO SUPPLY AND SENSOR
RESISTANCE CIRCUITS. ABOVE 100K OHMS? RETURN CIRCUITS
BETWEEN... FOR A SHORT
FIG.1 TOGETHER.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

341
N TEST NTC-14A CONTINUED - REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
342
TEST NTC-14A CONTINUED - REPAIRING THE OIL PRESSURE GAUGE NOT OPERATING PROPERLY N
O
T
R
TEST NTC-14A
CONTINUED FROM USE A VOLTMETER IN
O
THE PREVIOUS THE FOLLOWING U
PAGE. STEP.
B
L
E
C
O
MEASURE THE SENSOR
RETURN CIRCUIT FOR IS THE VOLTAGE YES REPLACE THE OIL
D
VOLTAGE. BELOW 0.5 VOLT? PRESSURE SENSOR.* E
FIG.1
T
NO E
S
T
S
KEY OFF. MEASURE THE SENSOR REPAIR THE SENSOR
DISCONNECT THE PCM RETURN CIRCUIT FOR IS THE VOLTAGE NO RETURN CIRCUIT FOR
HARNESS CONNECTORS. VOLTAGE. BELOW 0.5 VOLT? A SHORT TO
VOLTAGE.*
KEY ON. FIG.1
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

343
N TEST NTC-15A CHECKING THE TACHOMETER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
344
TEST NTC-15A CHECKING THE TACHOMETER OPERATION N
O
T
R
KEY ON.
O
START TEST
NTC-15A. NOTE GAUGE AND
DO THE OTHER
GAUGES WORK
NO PERFORM TEST
NTC-21A.
U
BULB OPERATION PROPERLY? B
DURING BULB CHECK.
L
YES
E
C
O
KEY OFF. KEY ON. USING A
D
VOLTMETER, MEASURE IS THE VOLTAGE YES CONTINUE TEST E
DISCONNECT THE ECM THE VOLTAGE AT ECM BETWEEN 4.0 AND NTC-15A ON THE
HARNESS HARNESS CONNECTOR 6.0 VOLTS? NEXT PAGE.
CONNECTORS.** C1 CAVITY 6. FIG.1 T
E
NO
S
T
S
KEY OFF. KEY ON. USING A REPAIR THE TACH
VOLTMETER, MEASURE IS THE VOLTAGE YES SIGNAL CIRCUIT FOR
DISCONNECT THE PCM ECM HARNESS ABOVE 6.0 VOLT? A SHORT TO
HARNESS CONNECTOR C1 VOLTAGE.*
CONNECTORS.** CAVITY 6. FIG.1
NO
KEY OFF. ECM HARNESS REPAIR THE TACH

USING AN OHMMETER, CONNECTOR C1 CAVITY IS THE RESISTANCE NO SIGNAL CIRCUIT FOR
MEASURE THE 6 AND GROUND. ABOVE 100K OHMS? A SHORT TO
RESISTANCE GROUND.*
BETWEEN... FIG.1
YES
USING AN OHMMETER,
MEASURE THE IS THE RESISTANCE NO REPAIR THE TACH
RESISTANCE OF THE BELOW 5.0 OHMS? SIGNAL CIRCUIT FOR
TACH SIGNAL CIRCUIT. AN OPEN.*
FIG.2
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

345
N TEST NTC-15A CONTINUED - CHECKING THE TACHOMETER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
346
TEST NTC-15A CONTINUED - CHECKING THE TACHOMETER OPERATION N
O
T
R
TEST NTC-15A KEY OFF.
O
CONTINUED FROM
THE PREVIOUS RECONNECT THE ECM
U
PAGE. HARNESS B
CONNECTORS.
L
E
C
O
USE A VOLTMETER BACKPROBE ECM
D
SET TO MEASURE HARNESS CONNECTOR E
FREQUENCY (HZ) IN C1 CAVITY 6.
THE NEXT STEP. FIG.1
T
E
S
T
S
IS THE READING NO REPLACE THE ENGINE

START THE ENGINE. BETWEEN 26.0 AND CONTROL MODULE.*
34.0 HZ AT IDLE?
YES
USING THE DRB, ON THE DRB, IS THE

MONITOR ENGINE RPM RPM APPROX 850 RPM NO REPLACE THE
WITH THE ENGINE AT IDLE AND DOES POWERTRAIN CONTROL
IDLING. THE RPM INCREASE MODULE.*
WITH ENGINE SPEED?
YES
DOES THE DRB REPLACE THE

READING MATCH THE NO ELECTRO/MECHANICAL
INSTRUMENT CLUSTER INSTUMENT
TACHOMETER CLUSTER.*
READING?
YES
TACHOMETER
OPERATION OK.
TEST COMPLETE.

347
N TEST NTC-16A CHECKING THE WAIT TO START LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG. 1 FIG.2
FIG.3
348
TEST NTC-16A CHECKING THE WAIT TO START LAMP OPERATION N
O
T
R
DOES THE WAIT TO O
START TEST
NTC-16A. KEY ON.
START LAMP TURN ON
AND STAY ON LONGER
YES CONTINUE TEST
NTC-16A ON THE U
THAN 20 SECONDS? NEXT PAGE.
B
L
NO E
C
THE WAIT TO START
O
USING THE DRB, DOES THE WAIT TO YES LAMP SYSTEM IS OK. D
ACTUATE THE WAIT
TO START LAMP.
START LAMP CYCLE
ON AND OFF? TEST COMPLETE.* E
NO T
E
S
T
KEY OFF. KEY ON. S
DISCONNECT THE ECM CONNECT A JUMPER
HARNESS BETWEEN GROUND
CONNECTORS.** AND...
ECM HARNESS
CONNECTOR C1 DID THE WAIT TO YES REPLACE THE ENGINE
CAVITY 32. START LAMP TURN CONTROL MODULE.*
ON?
FIG.1
NO
KEY OFF. USING AN OHMMETER, REPAIR THE WAIT TO

DISCONNECT THE MEASURE THE WAIT IS THE RESISTANCE NO START LAMP CONTROL
INSTRUMENT CLUSTER TO START LAMP BELOW 5.0 OHMS? CIRCUIT FOR AN
FROM THE HARNESS CONTROL CIRCUIT. OPEN.*
CONNECTORS.** FIG.2
YES
USING A VOLTMETER, REPAIR THE

MEASURE INST CLUSTER IS THE VOLTAGE NO IGNITION FEED TO
KEY ON. HARNESS CONNECTOR C1 ABOVE 10.0 VOLTS? THE INSTRUMENT
CAVITY 4. CLUSTER FOR AN
FIG.3 OPEN.*
YES
CHECK THE WAIT TO

START LAMP. IF OK,
REPLACE THE
ELECTRO/MECHANICAL
INSTRUMENT CLUSTER.*

349
N TEST NTC-16A CONTINUED - CHECKING THE WAIT TO START LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
350
TEST NTC-16A CONTINUED - CHECKING THE WAIT TO START LAMP OPERATION N
O
T
R
TEST NTC-16A
CONTINUED FROM
O
THE PREVIOUS KEY OFF. U
PAGE.
B
L
E
C
O
DISCONNECT THE ECM IS THE WAIT TO NO REPLACE THE ENGINE
D
HARNESS
CONNECTORS.**
KEY ON. START LAMP ON? CONTROL MODULE.* E
T
YES E
S
T
S
KEY OFF.
DISCONNECT THE USE AN OHMMETER IN
INSTRUMENT CLUSTER THE FOLLOWING
FROM THE HARNESS STEP.
CONNECTORS.**
INSTRUMENT CLUSTER REPAIR THE WAIT TO

MEASURE THE HARNESS CONNECTOR IS THE RESISTANCE NO START LAMP CONTROL
RESISTANCE CAVITY 8 AND GROUND. ABOVE 100K OHMS? CIRCUIT FOR A
BETWEEN... SHORT TO GROUND.*
FIG.1
YES
REPLACE THE
ELECTRO/MECHANICAL
INSTRUMENT
CLUSTER.*

351
N TEST NTC-17A CHECKING THE CHECK ENGINE LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
352
TEST NTC-17A CHECKING THE CHECK ENGINE LAMP OPERATION N
O
T
R
START TEST
O
NTC-17A. KEY OFF. U
B
L
E
C
O
MONITOR THE CHECK
ENGINE LAMP DURING
DID THE CHECK ENGINE
LAMP TURN ON FOR YES
THE CHECK ENGINE
LAMP SYSTEM IS OK.
D
KEY ON. BULB CHECK. APPROXIMATELY 2
SECONDS, THEN TURN TEST COMPLETE.*
E
FIG.1 OFF?
T
NO E
S
T
S
KEY OFF. KEY ON.
DISCONNECT THE ECM USE A VOLTMETER IN

HARNESS THE FOLLOWING
CONNECTORS.** STEP.
MEASURE THE
VOLTAGE AT ECM IS THE VOLTAGE NO CONTINUE TEST
HARNESS CONNECTOR BETWEEN NTC-17A ON THE
C1 CAVITY 34. 4.5 AND 5.5 VOLTS? NEXT PAGE.
FIG.2
YES
PERFORM TEST
NTC-17B.

353
N TEST NTC-17A CONTINUED - CHECKING THE CHECK ENGINE LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
354
TEST NTC-17A CONTINUED - CHECKING THE CHECK ENGINE LAMP OPERATION N
O
T
R
TEST NTC-17A
CONTINUED FROM IS THE VOLTAGE IN
CHECK THE CHECK
YES ENGINE LAMP CONTROL
O
THE PREVIOUS THE PREVIOUS STEP CIRCUIT FOR A SHORT U
PAGE. ABOVE 5.5 VOLTS? TO VOLTAGE. IF OK,
REPLACE THE PCM.* B
L
NO E
C
O
MEASURE RESISTANCE IS THE RESISTANCE NO
REPAIR THE CHECK
ENGINE LAMP
D
DISCONNECT THE PCM OF THE CHECK ENGINE BELOW 5.0 OHMS? CONTROL CIRCUIT E
HARNESS LAMP CONTROL FOR AN OPEN.*
CONNECTORS.** CIRCUIT. FIG.1
T
YES E
S
T
S
USING AN OHMMETER, PCM HARNESS REPAIR THE CHECK
MEASURE THE CONNECTOR C3 CAVITY IS THE RESISTANCE NO ENGINE LAMP
RESISTANCE 22 AND GROUND. ABOVE 100K OHMS? CONTROL CIRCUIT
BETWEEN... FOR A SHORT TO
FIG.2 GROUND.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

355
N TEST NTC-17B CHECKING THE CHECK ENGINE LAMP OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
356
TEST NTC-17B CHECKING THE CHECK ENGINE LAMP OPERATION N
O
T
R
START TEST WITH IGNITION
O
NTC-17B. STILL ON... U
B
L
E
C
O
CONNECT A JUMPER
ECM HARNESS
CONNECTOR C1 DID THE CHECK YES REPLACE THE ENGINE
D
BETWEEN GROUND
AND...
CAVITY 34. ENGINE LAMP TURN
ON?
CONTROL MODULE.* E
FIG.1
T
NO E
S
T
S
PERFORM THE PRESS AND HOLD THE
INSTRUMENT CLUSTER KEY OFF. TRIPOMETER RESET
SELF TEST USING BUTTON.
THE FOLLOWING WAIT 30 SECONDS.
STEPS. KEY ON.
WHEN "CHEC" WHEN "999" APPEARS DOES THE CHECK INSPECT CHECK ENGINE
APPEARS IN THE IN THE ODOMETER, ENGINE LAMP NO LAMP BULB. IF OK,
ODOMETER, RELEASE PRESS AND RELEASE ILLUMINATE DURING REPLACE THE
THE TRIPOMETER THE TRIPOMETER RESET THE BULB CHECK? ELECTRO/MECHANICAL
RESET BUTTON. BUTTON AGAIN. INSTRUMENT CLUSTER.*
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

357
N TEST NTC-20A REPAIRING THE FUEL LEVEL GAUGE NOT OPERATING PROPERLY
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
358
TEST NTC-20A REPAIRING THE FUEL LEVEL GAUGE NOT OPERATING PROPERLY N
O
T
R
PERFORM THE
O
START TEST
NTC-20A.
INSTRUMENT CLUSTER
SELF TEST USING
KEY OFF. U
THE FOLLOWING WAIT 30 SECONDS. B
STEPS.
L
E
C
O
PRESS AND HOLD THE WHEN "CHEC"
D
TRIPOMETER RESET APPEARS IN THE E
BUTTON. ODOMETER, RELEASE
THE TRIPOMETER
KEY ON. RESET BUTTON. T
E
S
T
S
WHEN "999" APPEARS OBSERVE THE FUEL REPLACE THE
IN THE ODOMETER, LEVEL GAUGE AND DID THE GAUGE REACH NO ELECTRO/MECHANICAL
PRESS AND RELEASE COMPARE THE TEST THE PROPER INSTRUMENT
THE TRIPOMETER RESET POINTS WITH THE CALIBRATION POINTS? CLUSTER.*
BUTTON AGAIN. CHART. FIG.1
YES
USING THE DRB, PERFORM THE

SELECT "ENGINE" READ PCM TROUBLE ARE ANY FUEL LEVEL YES APPROPRIATE
FROM THE SYSTEM CODES. SENSOR CODES TROUBLE CODE
MENU. PRESENT? TEST.*
NO
KEY OFF.
DISCONNECT THE KEY ON. DOES THE FUEL YES REPLACE THE FUEL
FUEL LEVEL SENSOR GAUGE DROP TO LEVEL SENSOR.*
HARNESS WAIT 30 SECONDS. EMPTY?
CONNECTOR.**
NO
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

359
N TEST NTC-21A CHECKING VEHICLE COMMUNICATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
360
TEST NTC-21A CHECKING VEHICLE COMMUNICATION N
O
T
R
START TEST
NOTE: PERFORM TEST
NTC-4A TO CHECK DID VEHICLE PASS NO REPAIR AS
O
NTC-21A. POWER AND GROUNDS TEST NTC-4A? NECESSARY.* U
BEFORE CONTINUING.
B
L
YES E
C
O
INSTALL THE DRB
AND ATTEMPT TO CAN YOU YES CONTINUE TEST
D
KEY ON. COMMUNICATE WITH COMMUNICATE WITH NTC-21A ON THE E
THE PCM. THE PCM? NEXT PAGE.
T
NO E
S
T
S
KEY OFF. CHECK PCM HARNESS ARE PCM HARNESS
CONNCTOR C3 CAVITIES CONNECTOR C3 NO REPAIR AS
DISCONNECT PCM 27 AND 29 FOR PROPER CAVITIES 27 AN 29 NECESSARY.*
HARNESS CONNECTION TO WIRING PROPERLY
CONNECTOR C3.** HARNESS. FIG.1 CONNECTED?
YES
REFER TO SERVICE
MANUAL WIRING
DIAGRAM TO DIAGNOSE TEST COMPLETE.*
SCI TRANSMIT AND SCI
RECEIVE CIRCUITS.

361
N TEST NTC-21A CONTINUED - CHECKING VEHICLE COMMUNICATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
362
TEST NTC-21A CONTINUED - CHECKING VEHICLE COMMUNICATION N
O
T
R
TEST NTC-21A KEY ON. REFER TO THE BODY O
CONTINUED FROM
THE PREVIOUS MONITOR THE
DID THE INSTRUMENT
CLUSTER PERFORM
NO DIAGNOSTIC MANUAL
TO DIAGNOSE U
PAGE. INSTRUMENT CLUSTER
DURING BULB CHECK.
THE BULB CHECK? INSTRUMENT CLUSTER
MALFUNCTION.*
B
L
YES E
C
O
NOTE: A FAULT IN D
THE CCD CIRCUITS OIL PRESSURE GAUGE
WILL DISABLE THE AND SPEEDOMETER. E
TACHOMETER,
VOLTMETER,...
T
E
S
T
S
TEST DRIVE THE IF ALL OF THESE TO DIAGNOSE THE
VEHICLE AND NOTE GAUGES ARE INSTRUMENT CLUSTER
THE INSTRUMENT INOPERATIVE, REFER AND CCD BUS
CLUSTER OPERATION. TO BODY DIAGNOSTIC CIRCUITS.
MANUAL...

363
N TEST NTC-24A CHECKING THE TURBOCHARGER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
FIG.2
364
TEST NTC-24A CHECKING THE TURBOCHARGER OPERATION N
O
T
R
NOTE: THE EXHAUST CHECK THE O
START TEST SYSTEM MUST BE TURBOCHARGER OUTLET
NTC-24A. FREE FROM ANY HOSE BETWEEN THE U
RESTRICTIONS TO
PERFORM THIS TEST.
TURBOCHARGER AND THE
INTAKE MANIFOLD... B
L
E
C
AND THE FOR LOOSE
O
TURBOCHARGER INLET
HOSE BETWEEN THE
CONNECTION, DAMAGE
OR RESTRICTIONS.
ARE ANY OF THESE
CONDITIONS
YES REPAIR OR REPLACE
AS NECESSARY.
D
TURBOCHARGER AND
THE AIR CLEANER... FIG.1
EVIDENT? E
NO T
E
S
T
CHECK THE WASTEGATE
ACTUATOR SUPPLY HOSE ARE ANY OF THESE YES REPAIR OR REPLACE
S
FOR LOOSE CONDITIONS AS NECESSARY.
CONNECTION, DAMAGE EVIDENT?
OR RESTRICTIONS.
NO
CONNECT AN AIR NOTE: AIR PRESSURE NOTE: VEHICLE MUST

PRESSURE GAUGE GAUGE MUST BE BE ON FLAT LEVEL
IN-LINE WITH THE RATED TO AT LEAST ROAD TO PERFORM
ACTUATOR SUPPLY 50 PSI. THE FOLLOWING
HOSE. FIG.1 STEPS.
FAILURE TO DRIVE WITH THE VEHICLE IN MAINTAIN EACH

VEHICLE ON LEVEL FIRST GEAR, INCREASE INDICATED ENGINE RPM
ROAD COULD RESULT ENGINE SPEED TO RPM FOR SEVERAL SECONDS
IN INCORRECT BOOST INDICATED IN UNTIL BOOST PRESSURE
PRESSURE READINGS. FIGURE 2. STABILIZES.
RECORD BOOST DO RECORDED READINGS

PRESSURE AT ALL REPEAT PREVIOUS MATCH CHART READINGS YES TURBOCHARGER OK,
INDICATED ENGINE STEP FOR SECOND +OR- 2 PSI FOR EACH
SPEEDS. GEAR. GEAR INDICATED? TEST PASSED.
FIG. 2
NO
CONTINUE TEST
NTC-24A ON THE
NEXT PAGE.

365
N TEST NTC-24A CONTINUED - CHECKING THE TURBOCHARGER OPERATION
O
T
R
O
U
B
L
E
C
O
D
E
T
E
S
T
S
FIG.1
366
TEST NTC-24A CONTINUED - CHECKING THE TURBOCHARGER OPERATION N
O
T
R
TEST NTC-24A
CONTINUED FROM
DISCONNECT THE
ACTUATOR SUPPLY
O
THE PREVIOUS HOSE FROM THE U
PAGE. INTAKE MANIFOLD.
FIG.1 B
L
E
C
O
USING AN AIR
PRESSURE REGULATOR,
THE WASTEGATE
ACTUATOR SUPPLY
START AT 0 PSI AIR
PRESSURE AND SLOWLY
D
CONNECT AN AIR HOSE
TO THE DISCONNECTED
HOSE. INCREASE TO 45 PSI
WHILE MONITORING THE
E
END OF... FIG.1 ACTUATOR ARM. FIG.1
T
E
S
T
S
NOTE: THE ACTUATOR DID THE WASTEGATE
ARM SHOULD REMAIN FULLY OPEN AT ACTUATOR UNSEAT YES REPLACE THE
CLOSED UNTIL AIR 34-40 PSI. AND FULLY OPEN AS TURBOCHARGER.
PRESSURE REACHES DESCRIBED?
17-20 PSI...
NO
DISCONNECT THE SHOP MANUALLY MOVE DOES THE WASTEGATE

AIR SUPPLY. REMOVE WASTEGATE ARM FROM ARM MOVE EASILY YES REPLACE THE
E-CLIP AND CLOSED TO FULLY WITHOUT WASTEGATE
DISCONNECT ACTUATOR OPEN POSITION. RESTRICTION? ACTUATOR.
ROD FROM ARM. FIG.1 FIG.1
NO
CLEAN WASTEGATE ARM

OR WASTEGATE SHAFT
AS NECESSARY.
IF OK, REPLACE
TURBOCHARGER.

367
C TEST CH-1A CHECKING THE CHARGING SYSTEM OPERATION
H
A Perform TEST DTC Before Proceeding
R
G
I
N
G
T
E
S
T
S
FIG.1
FIG.2
368
TEST CH-1A CHECKING THE CHARGING SYSTEM OPERATION
C
H
Perform TEST DTC Before Proceeding A
R
G
START TEST
NOTE: BATTERY
CONDITION MUST BE I
CH-1A. VERIFIED PRIOR TO
THIS TEST. N
G
T
E
INSPECT THE IS THE GENERATOR S
GENERATOR BELT
TENSION AND
BELT IN GOOD
CONDITION AND
NO REPAIR AS
NECESSARY.* T
CONDITION. TENSIONED
PROPERLY? S
YES
START THE ENGINE. USING THE DRB,

USING THE DRB, SET RETURN THE ENGINE ARE THERE ANY YES PERFORM THE
THE ENGINE SPEED SPEED TO IDLE AND CHARGING SYSTEM DTC TEST.
TO 1600 RPM FOR 30 READ CODES. TROUBLE CODES?
SECONDS.
NO
KEY ON, ENGINE USING THE DRB,

OFF. ACTUATE THE
GENERATOR FIELD.
BACKPROBE GENERATOR
USE A VOLTMETER IN FIELD HARNESS
THE FOLLOWING CONNECTOR CAVITY 2
STEPS. AT THE BACK OF THE
GENERATOR. FIG.1
NOTE: THE VOLTAGE WHILE MONITORING THE WAS THERE ANY REPAIR THE HARNESS
SHOULD CYCLE FROM VOLTMETER, WIGGLE INTERRUPTION OF YES OR CONNECTOR WHERE
APPROXIMATELY B+ THE GENERATOR FIELD THE NORMAL CYCLING WIGGLING CAUSED
TO 0.6 VOLTS EVERY HARNESS BACK TO THE BETWEEN 0.6 VOLTS THE INTERRUPTION.*
1.4 SECONDS. PCM. FIG.2 AND B+?
NO
DISCONTINUE THE
DRB ACTUATION OF ARE THERE ANY YES PERFORM THE
THE CHARGING CHARGING SYSTEM DTC TEST.
SYSTEM AND READ TROUBLE CODES?
CODES.
NO
CONTINUE TEST
CH-1A ON THE
NEXT PAGE.

369
C TEST CH-1A CONTINUED - CHECKING THE CHARGING SYSTEM OPERATION
H
A
R
G
I
N
G
T
E
S
T
S
FIG.1
370
TEST CH-1A CONTINUED - CHECKING THE CHARGING SYSTEM OPERATION
C
H
A
R
G
TEST CH-1A USE A VOLTMETER IN THE GENERATOR B+
I
CONTINUED FROM
THE PREVIOUS
THE FOLLOWING STEP. TERMINAL AND THE
BATTERY B+
N
PAGE. CONNECT THE TERMINAL. G
VOLTMETER BETWEEN... FIG.1
T
E
S
T
CAUTION: MAKE SURE
S
ALL WIRES ARE IS THE VOLTAGE YES REPAIR THE FUSED
CLEAR OF MOVING START THE ENGINE. ABOVE 0.4 VOLTS? B+ CIRCUIT FOR
PARTS. HIGH RESISTANCE.*
NO
KEY OFF. THE GENERATOR CASE

AND THE BATTERY
CONNECT THE NEGATIVE (-)
VOLTMETER TERMINAL.
BETWEEN... FIG.1
CAUTION: MAKE SURE REPAIR THE

ALL WIRES ARE IS THE VOLTAGE YES GENERATOR GROUND
CLEAR OF MOVING START THE ENGINE. ABOVE 0.4 VOLTS? CIRCUIT FOR HIGH
PARTS. RESISTANCE.*
NO
KEY ON, ENGINE USING A VOLTMETER, IS THE DIFFERENCE

OFF. USING THE MEASURE AND RECORD BETWEEN THE TWO YES
DRB, READ AND THE VOLTAGE READINGS LESS THAN TEST COMPLETE.*
RECORD BATTERY BETWEEN THE 1.0 VOLT?
VOLTAGE. BATTERY TERMINALS.
NO
CONTINUE TEST
CH-1A ON THE
NEXT PAGE.

371
C TEST CH-1A CONTINUED - CHECKING THE CHARGING SYSTEM OPERATION
H
A
R
G
I
N
G
T
E
S
T
S
FIG.1
372
TEST CH-1A CONTINUED - CHECKING THE CHARGING SYSTEM OPERATION
C
H
A
R
G
TEST CH-1A KEY OFF.
I
CONTINUED FROM
THE PREVIOUS DISCONNECT PCM
N
PAGE. HARNESS
CONNECTOR C1.**
G
T
E
S
T
USING A VOLTMETER, IS THE VOLTAGE S
MEASURE THE VOLTAGE WITHIN 1.0 VOLT OF NO REPAIR THE BATTERY
AT PCM HARNESS THE READINGS SUPPLY CIRCUIT FOR
CONNECTOR C1 RECORDED EARLIER? HIGH RESISTANCE.*
CAVITY 22. FIG.1
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

373
N TEST NS-SEL NO START SELECTION MENU
O
S NOTE: The battery must be fully charged before performing any test in this manual.
T
A NOTE: With the DRBIII, attempt to read ECM and PCM trouble codes. If the DRBIII is unable
R to communicate with the ECM, perform Test NS-2A. If there are any trouble codes present
T they must be repaired before continuing with the No Start Symptom diagnostics.
T NOTE: A failed ECM engine coolant temperature (ECT) sensor can cause a cranks but will not
E run or extended cranking before start condition. This occurs when the ECM ECT sensor
S calibration fails (sensor indicates engine temperature is warmer than actual engine temper-
T ature) and the ECM cannot command proper fuel quantity to the injection pump.
S Below you will find a recommended procedure to correct a No Start Problem by symptom. They
should be performed in the order that they are listed.
Repairing a No Crank Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-1A

Repairing a No Response Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-2A
Repairing a No Start Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-3A
Repairing a Start and Stall Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-4A
Checking the Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-8A
NOTE: For all component locations see GENERAL INFORMATION SECTION 4.0 in this manual.
374
TEST NS-SEL NO START SELECTION MENU N
O
NOTES S
T
A
R
T
T
E
S
T
S
375
N TEST NS-1A REPAIRING A NO CRANK CONDITION
O
Perform TEST NS-SEL Before Proceeding
S
T
A
R
T
T
E
S
T
S
FIG.1
376
TEST NS-1A REPAIRING A NO CRANK CONDITION
N
O
S
T
START TEST
NOTE: BATTERY MUST
BE FULLY CHARGED
A
NS-1A. BEFORE DIAGNOSING R
A NO-START
CONDITION. T
T
E
S
T
INSPECT BATTERY
CABLES FOR WERE ANY PROBLEMS YES REPAIR AS
S
KEY OFF. CORROSION, FOUND? NECESSARY.*
LOOSENESS OR OTHER
PROBLEMS.
NO

REMOVE THE MEASURE THE VOLTAGE IS THE VOLTAGE NO BATTERY SUPPLY
STARTER RELAY AT STARTER RELAY ABOVE 11.6 VOLTS? CIRCUIT FOR AN
FROM THE PDC.** CONNECTOR CAVITY 3. OPEN.*
FIG.1
YES
WARNING: THE TRANS WARNING: THE ENGINE BRIEFLY CONNECT A

MUST BE IN NEUTRAL MAY BE CRANKED IN JUMPER BETWEEN CONTINUE TEST
AND THE PARKING THE NEXT STEP. KEEP STARTER RELAY NS-1A ON THE
BRAKE MUST BE SET AWAY FROM MOVING CONNECTOR CAVITIES NEXT PAGE.
BEFORE CONTINUING. ENGINE PARTS. 3 AND 5. FIG.1

377
N TEST NS-1A CONTINUED - REPAIRING A NO CRANK CONDITION
O
S
T
A
R
T
T
E
S
T
S
FIG.1
FIG.2
378
TEST NS-1A CONTINUED - REPAIRING A NO CRANK CONDITION
N
O
S
T
TEST NS-1A A
CONTINUED FROM
THE PREVIOUS
DID THE STARTER
MOTOR CRANK THE
YES CONTINUE TEST
NS-1A ON THE R
PAGE. ENGINE? NEXT PAGE.
T
NO T
E
S
DID THE STARTER
T
SOLENOID CLICK NO S
WHEN THE JUMPER REMOVE THE JUMPER.
WAS CONNECTED?
YES
USING AN OHMMETER, DISCONNECT THE

MEASURE THE STARTER RELAY OUTPUT
RESISTANCE OF THE WIRE FROM THE
STARTER RELAY OUTPUT STARTER SOLENOID.**
CIRCUIT. FIG.1 AND 2 FIG.1
REPAIR THE STARTER

IS THE RESISTANCE NO RELAY OUTPUT
BELOW 5.0 OHMS? CIRCUIT FOR AN
OPEN.*
YES
CHECK THE BATTERY DID EITHER BATTERY

REINSTALL THE CABLES FOR HIGH CIRCUIT HAVE A YES REPAIR THE BATTERY
STARTER RELAY. RESISTANCE. (USE VOLTAGE DROP CIRCUIT FOR HIGH
SERVICE MANUAL GREATER THAN 0.2 RESISTANCE.*
PROCEDURE) VOLT?
NO
ATTEMPT TO
MANUALLY ROTATE IS THE CRANKSHAFT NO REPAIR THE ENGINE
THE CRANKSHAFT AT ABLE TO ROTATE 360 MECHANICAL PROBLEM
LEAST 360 DEGREES. DEGREES? AS NECESSARY.*
YES
REPLACE THE
STARTER MOTOR.*

379
N TEST NS-1A CONTINUED - REPAIRING A NO CRANK CONDITION
O
S
T
A
R
T
T
E
S
T
S
FIG.1
FIG. 2
380
TEST NS-1A CONTINUED - REPAIRING A NO CRANK CONDITION
N
O
S
T
TEST NS-1A
CONTINUED FROM
KEY OFF. USING AN
OHMMETER, MEASURE IS THE RESISTANCE NO REPLACE THE
A
THE PREVIOUS BETWEEN STARTER BETWEEN 60.0 AND STARTER RELAY.* R
PAGE. RELAY TERMINALS 1
AND 2. FIG.1
90.0 OHMS?
T
YES T
E
S
T
USING AN OHMMETER,
MEASURE THE
STARTER RELAY
CONNECTOR CAVITY 2 IS THE RESISTANCE NO
REPAIR THE STARTER
RELAY GROUND
S
RESISTANCE AND GROUND. BELOW 5.0 OHMS? CIRCUIT FOR AN
BETWEEN... OPEN.*
FIG.2
YES
KEY ON. USING A CAVITY 1 WHILE

VOLTMETER, MEASURE TURNING THE IGNITION IS THE VOLTAGE YES REPLACE THE
THE VOLTAGE AT KEY TO START. ABOVE 10.0 VOLTS? STARTER RELAY.*
STARTER RELAY
CONNECTOR... FIG.2
NO
REPAIR THE
IGNITION SWITCH
START OUTPUT
CIRCUIT FOR AN
OPEN.*

381
N TEST NS-2A REPAIRING A NO RESPONSE CONDITION
O
R
E
S
P
O
N
S
E
T
E
S
T
FIG.1
FIG.2
382
TEST NS-2A REPAIRING A NO RESPONSE CONDITION
N
O
R
E
START TEST
KEY ON.
USING THE DRB, WILL THE DRB NO CONTINUE TEST
S
NS-2A. ATTEMPT TO COMMUNICATE WITH NS-2A ON THE P
COMMUNICATE WITH
THE ECM.
THE ECM? NEXT PAGE.
O
N
YES S
E
T
ATTEMPT TO WILL THE DRB NO PERFORM TEST
E
COMMUNICATE WITH COMMUNICATE WITH NS-2B. S
THE PCM. THE PCM?
T
YES
AT THIS TIME, THE USING THE SCHEMATICS

CONDITION WHICH AS A GUIDE, INSPECT WERE ANY PROBLEMS YES REPAIR AS
CAUSES THIS FAULT THE WIRES AND FOUND? NECESSARY.*
IS NOT PRESENT. CONNECTORS.
FIG.1 AND 2
NO
REFER TO GENERAL
INFORMATION 3.3.2
INFORMATION ON
INTERMITTENT FAULTS.

383
N TEST NS-2A CONTINUED - REPAIRING A NO RESPONSE CONDITION
O
R
E
S
P
O
N
S
E
T
E
S
T
FIG.1
384
TEST NS-2A CONTINUED - REPAIRING A NO RESPONSE CONDITION
N
O
R
E
TEST NS-2A
S
CONTINUED FROM
THE PREVIOUS
CONNECT THE DRB TO
ANOTHER VEHICLE.
WILL THE DRB
COMMUNICATE WITH
NO REPAIR OR REPLACE
THE DRB OR DRB
P
PAGE. THIS VEHICLE? INTERFACE CABLE.* O
N
YES S
E
T
E
PERFORM TEST
NTC-4A.
DID THE VEHICLE
PASS TEST NTC-4A?
NO REPAIR AS
NECESSARY.* S
T
YES
KEY ON. USING A

VOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST
THE VOLTAGE AT DLC ABOVE 5.0 VOLTS? NS-2A ON THE
CAVITY 7. NEXT PAGE.
FIG.1
YES
IS THE VOLTAGE NO REPLACE THE ENGINE

ABOVE 12.0 VOLTS? CONTROL MODULE.*
YES
REPAIR THE SCI

TRANSMIT CIRCUIT
FOR A SHORT TO
VOLTAGE.*

385
N TEST NS-2A CONTINUED - REPAIRING A NO RESPONSE CONDITION
O
R
E
S
P
O
N
S
E
T
E
S
T
FIG.1
FIG.2
386
TEST NS-2A CONTINUED - REPAIRING A NO RESPONSE CONDITION
N
O
R
E
TEST NS-2A KEY OFF.
S
CONTINUED FROM
DISCONNECT THE PCM
HARNESS
P
PAGE. HARNESS CONNECTORS.** O
CONNECTORS.**
N
S
E
T
USING AN OHMMETER, DLC CAVITY 7 AND REPAIR THE SCI
E
MEASURE THE DLC CAVITIES IS THE RESISTANCE NO TRANSMIT CIRCUIT S
RESISTANCE
BETWEEN...
4 AND 5 (GROUND). ABOVE 100K OHMS? FOR A SHORT TO
GROUND.* T
FIG.1
YES
MEASURE THE REPAIR THE SCI

RESISTANCE BETWEEN IS THE RESISTANCE NO TRANSMIT CIRCUIT
DLC CAVITY 7 AND ABOVE 100K OHMS? FOR A SHORT TO THE
DLC CAVITY 11. CCD- CIRCUIT.*
FIG.1
YES
ECM HARNESS
MEASURE THE CONNECTOR C1 CAVITY IS THE RESISTANCE NO REPAIR THE SCI
RESISTANCE 45 AND DLC CONNECTOR BELOW 5.0 OHMS? TRANSMIT CIRCUIT
BETWEEN... CAVITY 7. FOR AN OPEN.*
FIG.2
YES
MEASURE THE
RECONNECT THE PCM RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE ENGINE
HARNESS DLC CAVITY 7 AND BELOW 5.0 OHMS? CONTROL MODULE.*
CONNECTORS. GROUND.
FIG.1
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

387
N TEST NS-2B REPAIRING A NO RESPONSE CONDITION
O
Perform TEST NS-2A Before Proceeding
R
E
S
P
O
N
S
E
T
E
S
T
FIG.1
388
TEST NS-2B REPAIRING A NO RESPONSE CONDITION
N
O
Perform TEST NS-2A Before Proceeding
R
E
START TEST
PERFORM TEST
NTC-4A FOR PCM DID THE VEHICLE NO REPAIR AS
S
NS-2B. POWER AND GROUND PASS NTC-4A? NECESSARY.* P
CONNECTIONS BEFORE
CONTINUING. O
N
YES S
E
T
MEASURE THE
E
DISCONNECT THE PCM RESISTANCE S
HARNESS BETWEEN...
CONNECTORS.** T
PCM HARNESS
CONNECTOR C3 IS THE RESISTANCE NO REPAIR THE SCI
CAVITY 27 AND DLC BELOW 5.0 OHMS? TRANSMIT CIRCUIT
CAVITY 7. FOR AN OPEN.*
FIG.1
YES
REPLACE THE
POWERTRAIN CONTROL
MODULE.*

389
N TEST NS-3A REPAIRING A NO START CONDITION
O
S
T
A
R
T
T
E
S
T
S
FIG.1
FIG.2 FIG.3
390
TEST NS-3A REPAIRING A NO START CONDITION
N
O
S
T
KEY ON.
A
START TEST
NS-3A. USING THE DRB,
ARE ANY CODES
PRESENT?
YES REFER TO THE
APPROPRIATE
R
READ CODES. TROUBLE CODE T
TEST.
T
E
S
T
S
MEASURE BETWEEN IS THE RESISTANCE NO REPLACE THE FUEL
DISCONNECT THE FUEL FUEL INJ. PUMP BETWEEN 0.9 AND INJECTION PUMP.*
INJECTION PUMP TERMINALS 8 AND 9. 1.5 OHMS?
HARNESS CONNECTOR.** FIG.1
YES
KEY ON. USING A REPAIR THE FUEL

DISCONNECT THE ECM VOLTMETER, MEASURE IS THE VOLTAGE NO QUANTITY ACTUATOR
HARNESS ECM HARNESS BELOW 1.0 VOLT? CONTROL CIRCUIT
CONNECTORS.** CONNECTOR C2 FOR A SHORT TO
CAVITY 80. FIG.2 VOLTAGE.*
YES
RECONNECT THE FUEL REMOVE THE ASD

KEY OFF. INJECTION PUMP RELAY FROM THE
HARNESS CONNECTOR. PDC.
CONNECT A JUMPER USING A VOLTMETER, IS THE VOLTAGE

BETWEEN ASD RELAY MEASURE ECM ABOVE 10.0 VOLTS NO REPAIR THE
CONNECTOR CAVITIES HARNESS CONNECTOR FOR EACH AFFECTED CIRCUIT
3 AND 5. C2 CAVITIES 59, 66 MEASUREMENT? FOR AN OPEN.*
FIG.3 AND 80. FIG 2
YES
CONTINUE TEST
NS-3A ON THE
NEXT PAGE.

391
N TEST NS-3A CONTINUED - REPAIRING A NO START CONDITION
O
S
T
A
R
T
T
E
S
T
S
392
TEST NS-3A CONTINUED - REPAIRING A NO START CONDITION
N
O
S
T
TEST NS-3A INSPECT ALL FUEL
A
CONTINUED FROM
THE PREVIOUS
SYSTEM LINES FOR
RESTRICTIONS,
WERE ANY PROBLEMS
EVIDENT?
YES REPAIR AS
NECESSARY.*
R
PAGE. LEAKS OR OTHER
PROBLEMS.
T
NO T
E
S
T
REFER TO THE CHECK FUEL S
SERVICE MANUAL AND IS THE FUEL YES INJECTION PUMP
PERFORM THE FUEL PRESSURE OK? TIMING. CHECK FUEL
SYSTEM PRESSURE SUPPLY FOR
TEST. CONTAMINATION.*
NO
CHECK THE FUEL

PUMP DRIVE. IF OK,
REPLACE THE FUEL
INJECTION PUMP.*

393
N TEST NS-4A REPAIRING A START AND STALL CONDITION
O
S NOTES
T
A
R
T
T
E
S
T
S
394
TEST NS-4A REPAIRING A START AND STALL CONDITION
N
O
At this point in the diagnostic test procedure, it is assumed that all of the engine electrical systems S
are operating as designed and are not the cause of a start and stall, or a no start problem. The T
following additional items should be checked as possible mechanical problems. Any of one of these A
items can produce a start and stall, or no start condtion; none can be overlooked as a possible R
cause. T
1. ENGINE VALVE TIMING - must be within specifications T
2. ENGINE COMPRESSION - must be within specifications E
S
3. ENGINE EXHAUST SYSTEM - must be free of any restrictions T
4. FUEL - must be free of contamination S
5. THROTTLE BODY - must be free of any choking conditions
6. INTAKE AIR DUCT - passages must be free of any debris
Always look for any Technical Service Bulletins that may relate to this condition.
395
N TEST NS-5A CHECKING THE ENGINE MECHANICAL SYSTEM
O
S NOTES
T
A
R
T
T
E
S
T
S
396
TEST NS-5A CHECKING THE ENGINE MECHANICAL SYSTEM
N
O
S
T
KEY OFF. USING
A
START TEST
NS-5A.
SERVICE MANUAL
PROCEDURES, CHECK
IS THE VALVE
TIMING WITHIN
NO REPAIR VALVE
TIMING AS
R
ENGINE VALVE
TIMING.
SPECIFICATIONS? NECESSARY.* T
YES T
E
S
T
USING SERVICE S
MANUAL PROCEDURES, IS ENGINE NO REPAIR THE ENGINE
CHECK ENGINE COMPRESSION WITHIN AS NECESSARY.*
COMPRESSION. SPECIFICATIONS?
YES
USING SERVICE IS THE FUEL REPAIR FUEL

MANUAL PROCEDURES, INJECTION PUMP NO INJECTION PUMP
CHECK FUEL TIMING WITHIN TIMING AS
INJECTION PUMP SPECIFICATIONS? NECESSARY.*
TIMING.
YES
TEST COMPLETE.*

397
V TEST VER-1 NO START VERIFICATION
E
R
I Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect
F components as necessary.
I
C Inspect the engine for contamination. If it is contaminated, change the oil and filter.
A
T Clear the diagnostic trouble codes (DTC’s).
I Turn the ignition off for 10 seconds.
O
N Attempt to start the engine.
T If the engine is unable to start, look for any Technical Service Bulletins that may relate to this
E condition. Return to DTC TEST if necessary.
S The repair is now complete.
T
398
TEST VER-2 ROAD TEST VERIFICATION
V
E
R
Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect I
all components as necessary. F
I
If this verification procedure is being performed after a NO TROUBLE CODE test, do the C
following: A
T
1. Check to see if the initial symptom still exists. I
2. If the initial or another symptom exists, the repair is not complete. Check all pertinent Technical O
Service Bulletins and return to TEST NTC-1A if necessary. N
For previously read trouble codes that have not been dealt with, return to DTC TEST and follow the T
path specified; otherwise continue. E
S
If the powertrain control module has not been changed: T
1. Connect the DRBIII to the PCM data link connector and erase trouble codes.
2. With DRBIII, reset all values in the adaptive memory.
3. Disconnect the DRBIII.
4. Turn the ignition off for at least 10 seconds.
Ensure no trouble code remains by doing the following:
1. If this test is for any A/C Relay Control Circuit Code, drive the vehicle for at least five minutes
with the A/C on. For some of the drive, go at least 40 mph; at some point stop the car and turn
the engine off for 10 seconds or more; then restart and continue. Ensure the transmission shifts
through all gears. Upon completion of the road test, turn the engine off, and read trouble codes
with the DRBIII.
2. If the repaired code has reset, the repair is not complete. Check all related Technical Service
Bulletins and return to DTC TEST if necessary. If another trouble code has set, return to DTC
TEST and follow the path specified for that trouble code. If there are no trouble codes, the
repair was successful and is now complete.
399
V TEST VER-3 CHARGING VERIFICATION
E
R
I Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect
F components as necessary.
I
C If the powertrain control module has been changed, do the following:
A
T Connect the DRBIII to the data link connector and erase the codes.
I Ensure no other charging system problems remain by doing the following:
O
N 1. Start the engine.
T 2. Raise the engine speed to 2000 rpm for at least 30 seconds.

E 3. Allow the engine to idle.
S
T 4. Turn the engine off.
5. Turn the ignition switch on.
6. With the DRBIII, read trouble code messages.
If the repaired code as reset, or another one has set, check all pertinent Technical Service Bulletins
and return to DTC TEST if necessary.
If there are no codes, the repair is now complete.
400
8.0 MAINTENANCE AND SERVICE INFORMATION G
E
Refer to the appropriate service manual for information about repair and replacement procedures. N
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. E
The use of a fuse with a rating other than indicated may result in a dangerous electrical system R
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must A
be corrected. L
I
8.1 Programming the Engine Control Module N
NOTE: A new engine control module (ECM) has no VIN programmed into it and air conditioning F
is set to “AC ACTIVATED”. O
R
1. Turn the ignition switch on (transmission in park/neutral). M
A
2. Use the DRBIII and select “ENGINE”, “BOSCH VM DIESEL CONTROLLER”. T
3. Enter the VIN.
I
O
4. Select “ENGINE”, “BOSCH VM DIESEL CONTROLL” then “MISCELLANEOUS” to program N
the ECM for air conditioning options.
5. If the vehicle is not equipped with a/c, select “ENABLE/DISABLE AC” and select “PUSH 2 TO
DISABLE (NON AC VEHICLES)”.
6. Turn the ignition switch off for 5 seconds to enable the charge to take place.
401
G 10.0 SCHEMATIC DIAGRAM
E
N 10.1 ENGINE CONTROL MODULE
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
402
10.2 Powertrain Control Module G
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
403
G 11.0 REQUIRED TOOLS AND EQUIPMENT
E
N ammeter
E DRBIIIT (diagnostic read-out box) scan tool
R high impedance 12-volt test light
A jumper wires and probes
L ohmmeter
vacuum gauge
I voltmeter
N
F 12.0 GLOSSARY OF TERMS
O
R backfire, fuel ignites in either the intake or the exhaust system
M popback
A CAB controller antilock brake
T
I cuts out,
O misses a steady pulsation or the inability of the engine to maintain a
N consistent rpm
DLC data link connector (previously called ‘‘engine diagnostic connector’’)

detonation, a mild to severe ping, especially under loaded engine conditions
pre-ignition
ECM engine control module (Bosch EDC15)
ECT engine coolant temperature sensor
EGR exhaust gas recirculation valve and system
EVM electric vacuum modulator
generator previously called ‘‘alternator’’
hard start The engine takes longer than usual to start, even though it is able to
crank normally.
hesitation, There is a momentary lack of response when the throttle is opened.
sag, stumble This can occur at all vehicle speeds. If it is severe enough, the engine
may stall.
lack of power, The engine has less than expected power, with little or no increase in
sluggish vehicle speed when the throttle is opened.
MIC electro/mechanical instrument cluster
MIL malfunction indicator lamp

PCM powertrain control module (JTEC+)
PDC power distribution center
poor fuel There is significantly less fuel mileage than other vehicles of the same
economy design and configuration.
404
rough, The engine runs unevenly at idle and causes the engine to shake if it G
un-stable or is severe enough. The engine idle rpm may vary (called ‘‘hunting’’). E
erratic idle, This condition may cause stalling if it is severe enough. N
stalling E
start and The engine starts but immediately dies.
R
stall
A
L
surge engine rpm fluctuation without corresponding change in throttle
position sensor I
N
F
O
R
M
A
T
I
O
N
405
G NOTES
E
N
E
R
A
L
I
N
F
O
R
M
A
T
I
O
N
406

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TABLE OF CONTENTS

1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4.0 SYSTEM COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.1 ENGINE CONTROL MODULE AND POWERTRAIN CONTROL MODULE . . . .7

5.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.1 GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

TROUBLE CODE TEST

NO TROUBLE CODE TESTS

8.0 MAINTENANCE AND SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

8.1 PROGRAMMING THE ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . .401

10.0 SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402

10.1 ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402

11.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404

12.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404

1.2 Six-Step Troubleshooting Procedure

2.0 IDENTIFICATION OF SYSTEM

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION

3.1 General Description

3.3 Diagnostic Trouble Codes

3.4 Using the DRBIIIT

Press MORE to switch between this display

CAV COLOR FUNCTION CAV COLOR FUNCTION

5.0 DISCLAIMERS, SAFETY, WARNINGS

5.2.4 DRBIIIT Safety Information

FUNCTION INPUT LIMIT

* Ohms cannot be measured if voltage is present.

5.3.2 Road Testing a Complaint Vehicle

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

NOTE: THE DRB MUST REPAIR AS

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

USING A VOLTMETER, REPAIR THE FUSED

KEY OFF. MEASURE THE

MEASURE THE REPAIR THE A/C

MEASURE THE BETWEEN RELAY REPAIR THE A/C

REPLACE THE ENGINE

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

NOTE: THE DRB MUST REPAIR AS

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

KEY ON. MEASURE THE RELAY REPAIR A/C CLUTCH

REPLACE THE ENGINE

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

MEASURE BETWEEN CHECK THE SENSOR

MEASURE BETWEEN CHECK THE SIGNAL

CONNECT A JUMPER CHECK THE ACCEL

REMOVE JUMPER. KEY ON. WITH THE IS THE VOLTAGE

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

USING THE DRB WITH THE ACCEL PEDAL

NOTE: THE LOW IDLE DID THE LOW IDLE

KEY OFF. INSPECT THE

RECONNECT ALL WIGGLE THE WIRING REPAIR AS

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

DOES THE DRB T

*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.