2002 Chevrolet Malibu

Powertrain Diagnostics & Repair / Engine Performance / Fault Isolation / ENGINE CONTROL
SYSTEM TROUBLESHOOTING - NO CODES

INTRODUCTION
Before diagnosing symptoms or intermittent faults, perform appropriate DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS in
appropriate SELF-DIAGNOSTICS article. Use this article to diagnose driveability problems when a current DTC is not present.
Symptom checks are intended to direct the technician to malfunctioning component(s) so that further diagnosis may be performed. A
symptom should lead to further testing of specific components or systems, or verification of adjustment specifications.
Use intermittent test procedures to locate intermittent driveability problems that do not occur when the vehicle is being tested. These
problems may cause a noticeable driveability problem or cause the Malfunction Indicator Light (MIL) to illuminate on some vehicles.
It is also possible that certain driveability concerns have been rectified by the manufacturer through reprogramming the PCM. Check with
manufacturer for latest information on updated programs.

NOTE: For specific testing procedures, see appropriate SYSTEM & COMPONENT TESTING article. To verify specifications, see
appropriate ON-VEHICLE ADJUSTMENTS article, or SERVICE & ADJUSTMENT SPECIFICATIONS article.

PRELIMINARY INSPECTION
• Verify on-vehicle diagnostics are working by performing appropriate DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS in
appropriate SELF-DIAGNOSTICS article.
• Ensure PCM grounds are clean, tight, and properly located.
• Check vacuum hoses for splits, kinks, leaks, restrictions and proper connections. Ensure vacuum hoses are correctly routed as
shown on vehicle emission control information label.
• Check for air leaks at all intake manifold sealing surfaces.
• Check ignition wires for cracking, hardness, proper routing and carbon tracking.
• Check wiring for proper connections and routing, pinches, burns, cuts or other damage.
• Ensure PCM and MIL are functioning properly.
• Ensure there are no DTCs stored, or only intermittent DTCs are present.
• Ensure fuel control system is operating properly. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Perform fuel system pressure test. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Perform a careful visual inspection of all systems.

After all checks have been performed, verify customer complaint and locate correct symptom. Check items indicated under that symptom.
Not all items listed under each symptom apply to all models and systems. These procedures will normally recommend testing of a specific
system or component, such as EGR, ignition, TCC, etc. See appropriate SYSTEM & COMPONENT TESTING article for test procedures.

NOTE: If PCM displays data but engine fails to start, see NO-START DIAGNOSIS in appropriate BASIC DIAGNOSTIC
PROCEDURES article.

SYMPTOMS
Before proceeding with any symptom diagnosis, perform all steps under PRELIMINARY INSPECTION .

SYMPTOM DIAGNOSIS
Symptom checks should not be used unless symptom occurs while vehicle is being tested. To reduce diagnostic time, ensure steps in
appropriate BASIC DIAGNOSTIC PROCEDURES and SELF-DIAGNOSTICS articles were performed before diagnosing a symptom.
Symptoms available for diagnosis include:
• Cuts Out, Misses
• Detonation/Spark Knock
 • Engine Backfires
• Engine Dieseling/Run-On
• Hard Start
• Hesitation, Sag Or Stumble
• Lack Of Power, Sluggish Or Spongy
• Poor Fuel Economy
• Poor Fuel Fill Quality
• Rough, Unstable Or Incorrect Idle & Stalling
• Vehicle Surges Or Chuggles

CUTS OUT, MISSES

Symptom Definition
Cuts out or misses is a steady pulsation or jerking which follows engine speed and is usually more pronounced as engine load increases.
Exhaust may have a steady spitting sound at idle or low speed. Perform a careful visual inspection as described in appropriate BASIC
DIAGNOSTIC PROCEDURES article.

Possible Cause & Correction

Check the following items:
• Check ignition wires for short or faulty insulation. Spray spark plug wires with a fine mist of water to check for shorts.
• Using Spark Tester (J-26792), check for available secondary voltage.
• Check ignition system for faulty ground and power feed circuits.
• Ensure ignition control wiring harness is not routed too close to wiring which may cause induced voltage signals.
• Check Transaxle Range (TR) switch input with vehicle in drive and shifter in drive or overdrive.
• Remove spark plugs and check for correct heat range, wear, cracks, wetness, improper gap or heavy deposits.
• Check for poor quality or alcohol contaminated fuel.
• Check for improper fuel pressure. Check for restricted fuel filter. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL
SYSTEM CHECKS in appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Check for plugged injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in
appropriate SYSTEM & COMPONENT TESTING article.
• Check PCM for proper ground circuits. Check for internal PCM intermittents.
• Check engine compression. Check for incorrect valve timing, bent push rods, broken valve springs or worn camshaft lobes.
• Check for sticking EGR valve.
• Check TP sensor for sticking and binding. Check for correct TP sensor voltage. See FUEL SYSTEMS in appropriate SERVICE &
ADJUSTMENT SPECIFICATIONS article.
• Using a scan tool, monitor the Knock Sensor (KS) system for any excessive spark retard activity.
• Check MAF sensor and connections.
• Check for proper Crankshaft Position (CKP) and Camshaft Position (CMP) sensor resistance.
• Check exhaust system for restrictions, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check for faulty motor mounts.
• Check injector drivers by disconnecting all injector harness connectors and connecting an injector test light (noid light) to each
injector's harness terminal. Light should flash while cranking.
• Check intake and exhaust manifold passages for casting flash.
• Check PCM and engine grounds for correct locations, tight and clean connections. See WIRING DIAGRAMS article.

DETONATION/SPARK KNOCK

Symptom Definition
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks which change with amount of
acceleration.

Possible Cause & Correction

Check the following items:
• Check TP sensor adjustment and operation.
• Check fuel system. Perform BASIC FUEL SYSTEM CHECKS. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Check fuel injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in appropriate
SYSTEM & COMPONENT TESTING article.
• Check Knock Sensor (KS) system for no retard.
• Check EGR system (insufficient).
• Check Torque Converter Clutch (TCC) system operation (applying too soon).
• Remove carbon from engine with top engine cleaner.
• If excessive carbon exists in combustion chamber, check for excessive oil burning due to leaking valve guide seals.
• Check for incorrect basic engine parts such as camshaft, cylinder heads and pistons.
• Ensure the installed PCM program is correct for the particular vehicle. Check with dealer for latest application information.
• Check for low engine coolant.
• Check cooling fan for proper operation.
• Check for restricted airflow to radiator or restricted coolant flow through radiator.
• Check for loose water pump belt.
• Check engine coolant sensor for shift in calibration. See appropriate SENSOR OPERATING RANGE CHARTS article.
• Check for rich or lean running conditions.
• Using Spark Tester (J-26792), check available output voltage of ignition coil.
• Check for crossfire between spark plugs and spark plug wires. Check for shorts and faulty insulation by spraying spark plug wires
with a fine water mist.
• Check spark plugs for proper application and heat range.
• Check engine compression.
• Check Transaxle Range (TR) switch. Ensure scan tool indicates proper gear range as selected.
• Check for alcohol contaminated or poor quality fuel.
• Check vehicle operation using a higher octane fuel (minimum 87 octane).

ENGINE BACKFIRES

Symptom Definition
Fuel ignites in intake manifold or in exhaust system, making a loud popping noise.

Possible Cause & Correction

Check the following items:
• Check for incorrect valve timing, bent push rods, broken valve springs or worn camshaft lobes.
• Check for sticking or leaking valves.
• Check EGR valve for leaking base gasket or valve hanging open.
• Check for engine vacuum leaks and/or engine not tuned to specifications.
• Check ignition module ground and power feed circuits for poor or loose connections.
• Check air induction system for restrictions or air leaks. Also check for air leaks between Mass Airflow (MAF) sensor and throttle
body. Check MAF sensor for proper operation.
• Check fuel injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in appropriate
SYSTEM & COMPONENT TESTING article.
• Check fuel system. Perform BASIC FUEL SYSTEM CHECKS. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Using Spark Tester (J-26792), check available output voltage of ignition coil.
• Check for crossfire between spark plugs and spark plug wires.
• Remove spark plugs and check for wet plugs, cracks, improper gap, burned electrodes or heavy carbon deposits. Also, check
condition of spark plug wires. Spray spark plug wires with a fine mist of water to check for shorts.
• Check for proper Crankshaft Position (CKP) and Camshaft Position (CMP) sensor resistance.
• Check ignition system for faulty ground and power feed circuits.
• Check exhaust system for restrictions, such as a damaged or collapsed pipe, muffler or catalytic converter.
 • Check intake and exhaust manifold passages for casting flash.
• Check harmonic balancer interrupter rings for missing, broken or bent vanes.
• Check for a low engine coolant level.
• Check the engine thermostat for the correct operation and heat range.
• Test the Torque Converter Clutch (TCC).
• Check the charging system. A bad diode in the alternator can allow A/C noise to enter the electrical system. This may affect the
engine controls system operation.
• Check the transaxle range switch circuit and be sure the scan tool indicates the vehicle is in drive with the gear selector in Drive or
in Overdrive.

ENGINE DIESELING/RUN-ON

Symptom Definition
Engine continues to run after ignition is turned off but runs very rough. If engine runs smoothly, check ignition switch and adjustment.

Possible Cause & Correction

Check the following items:
• Check for leaking fuel injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in
appropriate SYSTEM & COMPONENT TESTING article.
• Check for alcohol contaminated fuel, correct fuel pressure or a restricted fuel injector.
• Check for fuel in pressure regulator vacuum hose. Replace pressure regulator if fuel is present.
• Check injector harness locations. Ensure injectors are connected to correct injector/cylinder according to firing order.
• Check for faulty PCV valve.
• Check Idle Air Control (IAC) system. Check for vacuum leak or high idle. Check for foreign material in IAC bore of throttle body.
Check for proper connection of IAC valve electrical connector.
• Check for short between battery voltage and ignition feed circuits. See WIRING DIAGRAMS article.

HARD START

Symptom Definition
Engine cranks okay, but does not start for a long time. Engine eventually starts, and may stall immediately or run okay.

Possible Cause & Correction

Check the following items:
• Check fuel pump relay by connecting test light between fuel pump relay connector ignition feed circuit and ground. Turn ignition on.
Light should illuminate for 2 seconds. If light does not illuminate for 2 seconds, see RELAYS under MODULES, RELAYS &
SOLENOIDS in appropriate SYSTEM & COMPONENT TESTING article. For location of fuel pump test connector, see
COMPONENT LOCATIONS in appropriate SYSTEM & COMPONENT TESTING article.
• Check for open injector fuse(s).
• Check for poor quality or alcohol contaminated fuel.
• Check for binding or sticking TP sensor, or high TP sensor voltage with throttle closed.
• Check EGR operation.
• Check for leaking fuel injector.
• Ensure resistance of Engine Coolant Temperature (ECT) sensor circuit is within specification. See appropriate SENSOR
OPERATING RANGE CHARTS article.
• Check resistance of ECT and Intake Air Temperature (IAT) sensors. On a cold engine, ECT and IAT sensor readings should be
within 5°F of each other.
• Check for proper spark output using Spark Tester (J-26792).
• Remove spark plugs and check for wet plugs, cracks, improper gap, burned electrodes or heavy carbon deposits.
• Check fuel pressure. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL SYSTEM CHECKS in appropriate BASIC
DIAGNOSTIC PROCEDURES article.
• Check for plugged injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEM in
appropriate SYSTEM & COMPONENT TESTING article.
 • Check for loose ignition coil ground and power feed circuit connections. Also check ignition coil fuse.
• Check for faulty in-tank fuel pump check valve (if equipped). A faulty in-tank fuel pump check valve will allow fuel to drain back to
tank after engine is stopped. To check this condition, turn ignition off, disconnect fuel pressure line at fuel rail and remove filler cap.
Using a radiator pressure tester, apply 15 psi (1.0 kg/cm2 ). If pressure holds for 60 seconds, check valve is okay.
• Ensure the installed PCM program is correct for the particular vehicle. Check with dealer for latest application information.
• Check for restricted exhaust system, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check Idle Air Control (IAC) system. Check for vacuum leak at high idle. Check for binding of throttle blade or linkage. Check for
foreign material in IAC bore of throttle body. Check for proper connection of IAC valve electrical connector. Check for failure of A/C
compressor or relay.
• Check Manifold Absolute Pressure (MAP) and/or Mass Airflow (MAF) sensor. Check air intake tube for air leaks, blockage or
damage.
• Inspect Crankshaft Position (CKP) sensor clearance and resistance. Check harmonic balancer interrupter rings for bent or missing
vanes.
• Check if PCV valve is stuck open.
• Using a scan tool, check the Idle Air Control (IAC) operation.
• Check basic engine mechanical problems (i.e., compression, head gasket(s), valves). Check for incorrect valve timing, bent push
rods, broken valve springs or worn camshaft lobes.
• Check PCM and engine grounds for correct locations, tight and clean connections. See WIRING DIAGRAMS article.

HESITATION, SAG OR STUMBLE

Symptom Definition
Momentary lack of response when accelerator is pushed down. Condition occurs at all vehicle speeds or usually occurs when taking off
from a stop. If severe enough, may cause engine to stall.

Possible Cause & Correction

Check the following items:
• Visually check vacuum hoses for splits, kinks and proper connections as shown on vehicle emission control information label.
• Check ignition wires for cracking, hardness and proper connections at spark plugs. Spray spark plug wires with a fine mist of water
to check for shorts.
• Check wires for pinches, cuts and proper connections.
• Check fuel pressure. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL SYSTEM CHECKS in appropriate BASIC
DIAGNOSTIC PROCEDURES article.
• Check for poor quality or alcohol/water contaminated fuel.
• Check for fouled spark plugs.
• Ensure the installed PCM program is correct for that particular vehicle. Check with dealer for latest application information.
• Check for a binding or sticking TP sensor. Voltage should increase steadily as throttle is moved toward Wide Open Throttle (WOT).
Also check related wiring.
• Ensure PCM-controlled idle speed is correct.
• Check EGR operation.
• Check engine cooling system thermostat for proper operation and heat range.
• Check ignition control system ground and power feed circuits.
• Check canister purge system for proper operation.
• Check charging system output. Repair charging system if voltage is less than 9 volts or more than 16 volts.
• Check fuel injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in appropriate
SYSTEM & COMPONENT TESTING article.
• Check injector harness locations. Ensure injectors are connected to correct injector/cylinder according to firing order.
• Check for proper Crankshaft Position (CKP) and Camshaft Position (CMP) sensor resistance. Check for intermittent ignition feed or
ground circuits.
• Check Heated Oxygen Sensor (HO2S) ground (corroded threads in exhaust manifold or pipe).
• Check for air leaks between Mass Airflow (MAF) sensor and throttle body.
• Check air induction system for damage, restriction or air leaks.
• Check for intake valve deposits.
 • Check Manifold Absolute Pressure (MAP) and MAF sensor values and related wiring.
• Check for excessive exhaust system backpressure.
• Check for proper operation of the Transmission Fluid Pressure (TFP) manual valve switch.

LACK OF POWER, SLUGGISH OR SPONGY

Symptom Definition
Engine delivers less power than expected. Little or no increase in speed when accelerator is pushed down.

Possible Cause & Correction

Check the following items:
• Ensure air filter and fuel filter are not plugged. Replace if necessary. Check for incorrect fuel pressure. Also check for contaminated
fuel.
• Check shift solenoid system and Torque Converter Clutch (TCC) system for proper operation.
• Check Knock Sensor (KS) system for excessive retard.
• Check ignition control system for proper operation.
• Check the spark plugs.
• Check the fuel pressure. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL SYSTEM CHECKS in appropriate BASIC
DIAGNOSTIC PROCEDURES article.
• Check for plugged injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in
appropriate SYSTEM & COMPONENT TESTING article.
• Ensure EGR valve is not open all the time.
• Check exhaust system for restrictions, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check charging system output. Repair charging system if voltage is less than 9 volts or more than 16 volts.
• Check for A/C clutch cutout at Wide Open Throttle (WOT).
• Check Manifold Absolute Pressure (MAP) sensor.
• Using Spark Tester (J-26792), check for available secondary voltage.
• Check air induction system for restrictions or air leaks.
• Ensure the installed PCM program is correct for the particular vehicle. Check with dealer for latest application information.
• Check engine compression. Check for incorrect valve timing, bent push rods, broken valve springs or worn camshaft lobes.
• Check for excessive fuel additives.
• Check for binding accelerator cable.
• Check engine supercharger (if equipped).
• Check if engine is operating in torque management mode (if equipped).
• Check boost control system components and connections (if equipped).
• Check for proper operation of the Transmission Fluid Pressure (TFP) manual valve switch.
• Check PCM and engine grounds for correct locations, tight and clean connections. See WIRING DIAGRAMS article.

POOR FUEL ECONOMY

Symptom Definition
Fuel economy, as measured by an actual road test, is noticeably lower than expected. Fuel economy is noticeably lower than it was
previously on this vehicle.

Possible Cause & Correction

Check the following items:
• Visually check vacuum hoses for splits, kinks and proper connections as shown on vehicle emission control information label.
• Check for dirty or clogged air filter.
• Check coolant level. Check engine cooling system thermostat for proper heat range and operation.
• Check engine compression. Check for incorrect valve timing, bent push rods, broken valve springs or worn camshaft lobes.
• Check Engine Coolant Temperature (ECT) sensor for shift in calibration. See appropriate SENSOR OPERATING RANGE CHARTS
article.
 • Check A/C for "full time" operation.
• Ensure initial ignition timing is properly set, and check for proper operation of ignition control and knock sensor systems.
• Check Torque Converter Clutch (TCC) for proper operation.
• Check air intake system and crankcase for air leaks.
• Check exhaust system for restrictions, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check Heated Oxygen Sensor (HO2S) for silicone or lead contamination.
• Check for proper ignition voltage output. Check the ignition coils for cracks, or damage.
• Remove spark plugs and check for wet plugs, cracks, improper gap, burned electrodes or heavy carbon deposits.
• Ensure speedometer is properly calibrated.
• Check fuel pressure. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL SYSTEM CHECKS in appropriate BASIC
DIAGNOSTIC PROCEDURES article.
• Check for poor quality or alcohol contaminated fuel.
• Check fuel injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in appropriate
SYSTEM & COMPONENT TESTING article.
• Check injector harness locations. Ensure injectors are connected to correct injector/cylinder according to firing order.
• Check for fuel in pressure regulator vacuum hose. If fuel is present, replace regulator.
• Check Camshaft Position (CMP) and Crankshaft Position (CKP) sensors for proper operation.
• Check for air leaks between Mass Airflow (MAF) sensor and throttle body. Check air induction system for damage, restriction or air
leaks.
• Check boost control system (if equipped).
• Check engine compression.
• Check the exhaust system for possible restrictions.
• Check for dragging brakes.
• Check for conditions that cause the engine torque management system to reduce engine power.
• Check for incorrect tire pressure.
• Check for uneven or excessive tire wear from suspension misalignment.
• Check with operator to see if vehicle is operated under excessive acceleration or is heavily loaded.

POOR FUEL FILL QUALITY

Symptom Definition
Problem filling fuel tank.

Possible Cause & Correction

Check the following items:
• Fill limiter vent valve stuck closed.
• EVAP canister restricted.
• EVAP vent valve stuck closed.
• Restricted vapor lines.
• High reid vapor pressure or high fuel temperature.
• Fuel filler hose is pinched or kinked.
• Ignition switch on (EVAP vent valve closed).

Symptom Definition
Overfill tank.

Possible Cause & Correction

Check the following items:
• Pressure relief valve is stuck open or leaking.
• Fill limiter vent valve is stuck open or leaking.

Symptom Definition
Pre-mature shutoff of fuel dispensing nozzle.

Cause & Correction

Check the following items:
• Fill limiter vent valve stuck closed.
• EVAP canister restricted.
• EVAP vent valve stuck closed.
• Restricted vapor lines.
• High reid vapor pressure or high fuel temperature.
• Ignition switch on (EVAP vent valve closed).

Symptom Definition
Fuel spitback.

Possible Cause & Correction

Check the following items:
• The check valve is stuck open.
• The check valve is stuck closed.
• The check valve is leaking.
• High reid vapor pressure or high fuel temperature.
• Ignition switch on (EVAP vent valve closed).

Symptom Definition
Liquid to EVAP canister.

Possible Cause & Correction

Check the following items:
• Fill limiter vent valve stuck open or leaking.

Symptom Definition
Liquid leak to ground.

Possible Cause & Correction

Check the following items:
• The pressure relief valve in the fill limiter vent valve is stuck open or leaking.
• Fuel filler pipe loose or ruptured.
• The fill limiter vent valve is stuck open.

Symptom Definition
Fuel odor.

Possible Cause & Correction

Check the following items:
• The pressure relief valve in the fuel limiter vent valve is stuck open or leaking.
• The EVAP canister is saturated.

ROUGH, UNSTABLE OR INCORRECT IDLE & STALLING

Symptom Definition
Engine runs unevenly at idle. If severe enough, vehicle will shake. Idle may vary in RPM. Either problem may cause stalling. Engine idles
at incorrect RPM.
Possible Cause & Correction
Check the following items:
• Ensure throttle linkage and/or TP sensor is not sticking or binding. Ensure throttle bore is free of foreign material.
• Check for vacuum leaks.
• Check engine idle speed (both base idle and PCM idle).
• Check Idle Air Control (IAC) system. Check for vacuum leak or high idle. Check for alcohol contaminated fuel, incorrect fuel
pressure or a restricted injector. Check for foreign material in IAC bore of throttle body. Check for proper connection of IAC valve
electrical connector. Check for failure of A/C compressor or relay.
• Check for proper operation of EGR system.
• Check Transaxle Range (TR) switch circuit. Ensure TR switch is properly adjusted.
• Check Power Steering Pressure (PSP) switch operation.
• Check charging system output. Repair charging system if voltage is less than 9 volts or more than 16 volts.
• Check for fuel in pressure regulator vacuum hose. If fuel is present, replace regulator.
• Check evaporative emission control system.
• Check for proper spark plug gap.
• Check PCM grounds for clean and tight connections.
• Check A/C signal to PCM. If problem exists only when A/C is on, check A/C system operation and pressures.
• Ensure the installed PCM program is correct for the particular vehicle. Check with dealer for latest application information.
• Check Manifold Absolute Pressure (MAP) or Mass Airflow (MAF) sensors for proper operation.
• Check Heated Oxygen Sensor (HO2S) operation. Check for silicone contamination or incorrect RTV sealant.
• Check for excessive fuel additives.
• Check for shorted or open injector windings.
• Check for leaking injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in
appropriate SYSTEM & COMPONENT TESTING article.
• Check injector harness locations. Ensure injectors are connected to correct injector/cylinder according to firing order.
• If rough idle only occurs when engine is hot, check PCV valve operation. Check for manifold vacuum at inlet end of crankcase vent
tube assembly with engine idling.
• Using a scan tool, monitor the Knock Sensor (KS) system for any excessive spark retard activity.
• Test the crankcase ventilation valve for proper operation. Place a finger over the inlet hole of the valve end several times. The valve
should snap back. If not, replace the valve.
• Check ignition system. Check for moisture, dust, cracks, burns, etc. Check for shorts and faulty insulation by spraying spark plug
wires with a fine water mist.
• Using Spark Tester (J-26792), check for available secondary voltage.
• Check to see if condition is caused by engine running either rich or lean.
• Check engine compression. Check for incorrect valve timing, bent push rods, broken valve springs or worn camshaft lobes.
• Check Engine Coolant Temperature (ECT) sensor for proper temperature-to-resistance values.
• Check exhaust system for restrictions, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check the Torque Converter Clutch (TCC) operation. A scan tool should indicate an RPM drop when the TCC is commanded ON.
• Check the charging system. A bad diode in the alternator can allow A/C noise to enter the electrical system. This may affect the
engine controls system operation.
• Check the transaxle range switch circuit. Ensure the scan tool indicates the vehicle is in drive with the gear selector in Drive or in
Overdrive.
• Check for weak or broken motor mounts.

VEHICLE SURGES OR CHUGGLES

Symptom Definition
Engine power varies under steady throttle or cruise. Vehicle speeds up and slows down without changing position of accelerator pedal.

Possible Cause & Correction

Check the following items:
• Visually check vacuum hoses for splits, kinks and proper connections as shown on vehicle emission control information label.
 • Check canister purge system for proper operation.
• Check ignition control system for proper operation.
• Check EGR system for proper operation.
• Ensure the installed PCM program is correct for that particular vehicle. Check with dealer for latest application information.
• Check for proper ignition voltage output using Spark Tester (J-26792).
• Check Heated Oxygen Sensor (HO2S) for contamination. This will cause a false high voltage signal to PCM. PCM will respond by
leaning out air/fuel ratio.
• Check in-line fuel filter, and replace if dirty or clogged.
• Check fuel pressure while condition exists. See FUEL SYSTEM PRESSURE TEST under BASIC FUEL SYSTEM CHECKS in
appropriate BASIC DIAGNOSTIC PROCEDURES article.
• Check for poor quality or alcohol contaminated fuel.
• Check Mass Airflow (MAF) sensor for proper operation. Check air induction system for damage, restriction or air leaks. See
DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.
• Remove spark plugs and check for wet plugs, cracks, improper gap, burned electrodes or heavy carbon deposits. Also, check
condition of spark plug wires. Spray spark plug wires with a fine mist of water to check for shorts.
• Check charging system output. Repair charging system if voltage is less than 9 volts or more than 16 volts.
• Check for restricted exhaust system, such as a damaged or collapsed pipe, muffler or catalytic converter.
• Check transmission shift solenoid system and Torque Converter Clutch (TCC) system for proper operation.
• Ensure owner understands operation of TCC and A/C clutch operation, as stated in owners manual.
• Check injector harness locations. Ensure injectors are connected to correct injector/cylinder according to firing order.
• Check for rich or lean conditions. Drive vehicle at speed when complaint occurs. See appropriate HO2S DTCs for diagnostic aids.
See appropriate SELF-DIAGNOSTICS article.
• Check for plugged injectors. Perform injector balance test. See FUEL INJECTOR BALANCE TEST under FUEL SYSTEMS in
appropriate SYSTEM & COMPONENT TESTING article.
• Ensure PCM grounds are clean and tight.
• Check for excessive use of additives in fuel.
• Ensure that the engine coolant temperature is not above 266°F (130°C). This condition causes the PCM to operate in Engine
Coolant Over Temperature-Fuel Disabled Mode. While in Engine Coolant Over Temperature-Fuel Disabled Mode, the PCM turns
fuel OFF to 4 cylinders at a time in order to keep engine temperatures from reaching damaging levels. The system perceives Engine
Coolant Over Temperature-Fuel Disabled Mode as a lack of power, a miss, or a rough idle.

INTERMITTENTS

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in
GENERAL INFORMATION before disconnecting battery.

PRELIMINARY
Perform the Diagnostic System Check-Engine Controls before starting. See DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS in
appropriate SELF-DIAGNOSTICS article.

HARNESS OR CONNECTOR INTERMITTENTS

Many intermittent open or shorted circuits come and go with harness or connector movement caused by the following type conditions:
• Vibration.
• Engine torque.
• Bumps or rough pavement.

Test for intermittents by performing the applicable procedure from the following list:
• Move related connectors and wiring while monitoring the appropriate scan tool data.
• Move related connectors and wiring with the component commanded ON and OFF, with the scan tool. Observe the component
operation.
• With the engine running, move related connectors and wiring while monitoring engine operation.
Verify whether the harness or connector movement affects any of the following systems:
• Data displayed.
• Component or system operation.
• Engine operation.

Repair the components as necessary.

ELECTRICAL CONNECTIONS OR WIRING

1. Intermittents are usually caused by one or more of the following conditions:
• Poor electrical connections.
• Terminal tension.
• Wiring problems.

2. Carefully inspect the suspected circuit for the following conditions:

• Poor mating of the connector halves.
• Terminals backed out or not fully seated in the connector body.
• Improperly formed or damaged terminals. Test for poor terminal tension.
• Poor terminal-to-wire connections including terminals crimped over insulation. This requires removing the terminal from the
connector body.
• Corrosion or water intrusion. Pierced or damaged insulation can allow moisture to enter the wiring. The conductor can
corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wires that are broken inside the insulation.
• Pinched, cut, or rubbed through wiring in the harness.
• Wiring that is in contact with hot exhaust components.

3. Repair the condition as necessary.

CONTROL MODULE POWER & GROUNDS, & COMPONENT POWER & GROUNDS
Poor power or ground connections can cause widely varying symptoms.
• Test all control module power circuits. Many vehicles have multiple circuits supplying power to the control module. Other
components in the system may have separate power circuits that may also need to be tested. Inspect connections at the module or
component connectors, fuses, and any intermediate connections between the power source and the module or component. A test
lamp or a Digital Multimeter (DMM) may indicate that voltage is present, but neither tests the ability of a circuit to carry sufficient
current. Ensure that the circuit can carry the current necessary to operate the component. See POWER DISTRIBUTION article in
WIRING DIAGRAMS.
• Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other
components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that
the circuit can carry the current necessary to operate the component. See GROUND DISTRIBUTION article in WIRING
DIAGRAMS.

TEMPERATURE SENSITIVITY
1. An intermittent condition may occur when a component or connection reaches normal operating temperature. The condition may
occur only when the component or connection is cold, or only when the connection is hot.
2. The following data may help to diagnose this type of intermittent condition:
• Freeze Frame/Failure Records.
• Scan tool snapshot.
• Vehicle data recorder.

3. If the intermittent is related to heat, review the following data:

• High ambient temperatures.
• Underhood or engine generated heat.
• Circuit generated heat due to a poor connection, or high electrical load.
• Higher than normal load conditions, such as towing.
 4. If the intermittent is related to cold, review the following data:
• Low ambient temperatures. In extremely low temperatures, ice may form in a connection or component. Test for water
intrusion.
• The condition only occurs on a cold start.
• The condition is not present after the vehicle warms up.

5. Information from the customer may help to determine if the trouble follows a pattern that is temperature related.

ELECTROMAGNETIC INTERFERENCE (EMI) & ELECTRICAL NOISE

Some electrical components or circuits are sensitive to Electromagnetic Interference (EMI) or other types of electrical noise. Perform the
following procedures:

1. Inspect for a misrouted harness that is too close to a high voltage or high current device. This condition may induce electrical noise
on a circuit that could interfere with normal circuit operation. Inspect for wires that are too close to the following devices:
• Secondary ignition components.
• Motors.
• The generator.

2. Determine whether the electrical system interference is caused by a malfunctioning relay, PCM driven solenoid or switch. These
components may cause a sharp electrical surge. Normally, the problem will occur when the malfunctioning component is operating.
3. Determine whether non-factory or aftermarket add-on accessories are installed in the vehicle. These accessories may lead to an
emission related OBD-II failure. Determine if any of the following non-factory or aftermarket add-on accessories is causing the
intermittent:
• Lights.
• 2-way radios.
• Amplifiers.
• Electric motors.
• Remote starters.
• Alarm systems.
• Cell phones.

4. Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.
5. Test for proper performance of the generator. See ON-VEHICLE TESTING in appropriate GENERATORS & REGULATORS article
in STARTING & CHARGING SYSTEMS.
6. If a DTC is determined to be intermittent, and the tests in this section do not reveal a problem, see VEHICLE DATA RECORDER .

INCORRECT PCM PROGRAMMING

1. There are only a few situations when reprogramming a PCM is appropriate, such as the following:
• A new service PCM is installed.
• A PCM from another vehicle is installed.
• Revised software or calibration files have been released for this vehicle.

NOTE: DO NOT re-program the PCM with the SAME software or calibration files that are already present in the PCM. This
is not an effective repair for any type of driveability problem.

2. Verify that the PCM contains the correct software or calibration. If incorrect programming is found, reprogram the PCM with the most
current software or calibration. See POWERTRAIN CONTROL MODULE under PROGRAMMING in appropriate SELF-
DIAGNOSTICS article.

DUPLICATING FAILURE CONDITIONS

1. If none of the previous tests are successful, attempt to duplicate or capture the failure conditions.
2. Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. Perform the
following procedure:
 • Review and record Freeze Frame/Failure Records data.
• Clear the DTCs using the scan tool.
• Turn the key to OFF and wait 15 seconds.
• Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as
possible. The vehicle must also be operating within the Conditions for Running DTC.
• Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been
satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.

3. An alternate method is to drive the vehicle with the Digital Multimeter (DMM) connected to a suspected circuit. An abnormal reading
on the DMM when the problem occurs, may help you locate the problem.

SCAN TOOL SNAPSHOT

The scan tool can be set up to take a snapshot of the parameters available via serial data. The snapshot function records live data over a
period of time. The recorded data can be played back and analyzed. The scan tool can also graph parameters singly or in combinations of
parameters for comparison. The snapshot can be triggered manually at the time the symptom is noticed, or set up in advance to trigger
when a DTC sets. An abnormal value captured in the recorded data may point to a system or component that needs to be investigated
further. Refer to the scan tool user instructions for more information on the Snapshot function.

VEHICLE DATA RECORDER

The Vehicle Data Recorder (J 42598) is connected to the Data Link Connector (DLC) and sent with the customer. The J 42598 captures
data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information.

Created/Modified Date: 2/2/2012 8:31:26 PM