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    Engine El. Trouble 100psl

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    ELECTRONIC ENGINE CONTROL GM 2.2L TROUBLESHOOTING AND REPAIR H2.00-3.20XM (H40-65XM) SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load, Do not lift heavy parts by hand. Use a lif ing mechanism, Wear safety glasses, DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE section. Keep the unit and working area clean and in order. ‘Use the correct tools for the job. Keep the tools clean and in good condition, Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and. sparks away from the area, Make sure the area has ventilation. CONTENTS INTRODUCTION . GENERAL ‘TROUBLESHOOTING PROCEDURE HOW THIS SECTION IS ARRANGED . Where Do I Start? VISUAL/PHYSICAL INSPECTION KNOWLEDGE/TOOLS REQUIRED . . Damage From Static Discharge (Static Electricity) ‘TROUBLESHOOTING INFORMATION “Malfunction Indicator” Lamp (MIL) . .. Reading Diagnostic Trouble Codes (DTC) Clearing Diagnostic Trouble Codes (DTC's) . TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE Diagnostic Mode Field Service Mode ECM Leaming Ability ...... TABLE 2. “SCAN” TOOL INFORMATION On-Board DIAGNOSTIC (OBD) System Check . TROUBLESHOOTING CHARTS ..........- GENERAL .... TOOLS AND TEST EQUIPMENT... ; cette wee CHART A-1 NO “MALFUNCTION INDICATOR” LAMP .......+ seers 10 CIRCUIT DESCRIPTION . CHART A-2 -NO“SCAN" DATA, NO DIC 12,°MALFUNCTION INDICATOR” LAMP ON... 12 CIRCUIT DESCRIPTION . . cee 2 CHART A-3 -THE STARTER ROTATES THE ENGINE, ENGINE WILL NOTRUN .cssssccsssee 14 CIRCUIT DESCRIPTION . _— CHART A-S - FUEL PUMP RELAY CIRCUIT CIRCUIT DESCRIPTION . CHART A~7- FUEL SYSTEM TROUBLESHOOTING CIRCUIT DESCRIPTION ...... . DTC 14 - ENGINE COOLANT TEMPERATURI (HIGH TEMPERATURE INDICATED) ...... CIRCUIT DESCRIPTION . DTC 15 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED) CIRCUIT DESCRIPTION : DTC 21 - THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH) ...... CIRCUIT DESCRIPTION . DTC 22- THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW) ......-+ CIRCUIT DESCRIPTION DTC 31 - ENGINE GOVERNOR CIRCUIT . CIRCUIT DESCRIPTION ss 30 30 peered DTC 33- MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH - LOW VACUUM) CIRCUIT DESCRIPTION . DIC 34~ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE LOW - HIGH VACUUM) ...... CIRCUIT DESCRIPTION .... DTC 42 - IGNITION CONTROL (IC) CIRCUIT . CIRCUIT DESCRIPTION . - DTC 51- EEPROM OR ECM FAILURE... CIRCUIT DESCRIPTION ...... TROUBLESHOOTING, POOR OPERATION . GENERAL . Make A Careful Visual Check we FAULT: Codes Or Performance That Is Not Regular FAULT: Loss Of Diagnostic Trouble Code (DTC) Memory . FAULT: Engine Quits While Driving . FAULT: Engine Is Difficult To Start FAULT: Variation In Engine Power When The Throttle Is Held Steady FAULT: Decreased Engine Power .. FAULT: “Detonation” . FAULT: Engine Momentary Does Not Increase Power When Throttle Changes « - FAULT: One Or More Cylinders Do Not Operate Correctly. The Engine Does Not Ile Correct, . FAULT: Rough Idle Or Engine Stalls During Idle .......... = FAULT: Fuel Usage Too High . poseest42) SYSTEM TEST CHARTS Boo pee Sd) GENERAL . 52 ENGINE COOLANT TEMPERATURE (ECT) SENSOR TEST - $2 ‘THROTTLE POSITION (TP) SENSOR CHECK 33 MINIMUM IDLE SPEED .......... a) CHART C-1 ~ IDLE AIR CONTROL (IAC) SYSTEM CHECK, peeeneeeniensa SS) CIRCUIT DESCRIPTION . seeeeee 5S CHART C-2 - MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT TEST ..........++ 57 CIRCUIT DESCRIPTION ...... ceseeeeees -37 CHART C-3- ENGINE MISSES AT IDLE . eee eee = 59 CIRCUIT DESCRIPTION : 59) CHART C-4- ENGINE MISSES WITH A LOAD ... peeeenseseree roreseseset 2] CIRCUIT DESCRIPTION .....- 050005 - 2 CHECK THE PCV SYSTEM ........0.cscseeeseeeeeeeeeeeees - 64 CHECK THE GOVERNOR SYSTEM ... pee poets RESULTS OF INCORRECT OPERATION OF GOVERNOR SYSTEM . 65 REPAIRS .... peneeeeeeneeeet ie FUEL SYSTEM COMPONENTS Fuel Meter Body Fuel Injector .. Pressure Regulator - Throttle Position Sensor (TPS) . Idle Air Control (IAC) Valve . ‘Vacuum Port Module Throttle Body . ; Oil Pressure Switch, Replacement GOVERNOR SYSTEM . Govemor Module Replacement. Governor Motor Replacement ..... Throttle Cables, Installation and Adjustment IGNITION SYSTEM .. ECM Replacement . Function Check ...... ICM Replacement ....... Ignition Coil Replacement .... ‘Crankshaft Sensor Replacement Procedures For Spark Plugs, Spark Plug Wires, And Boots ‘TROUBLESHOOTING OF SPARK PLUGS FUEL PUMP REPLACEMENT ENGINE COOLANT SENSOR Replacement MAP SENSOR . Replacement . PCV SYSTEM Replacement .. WIRING Connectors And Terminals . ECM WIRING DIAGRAMS SPECIAL TOOLS This section is for the following models: H2,00-3.20XM (H40-65XM) © HYSTER COMPANY 1993 “THE QUALITY KEEPERS” HYSTER APPROVED PARTS INTRODUCTION GENERAL This section has the troubleshooting and repair proce- ures for the parts of the electronic engine controls. Us- ers of this section must know the components and opera- tion as described in the section ELECTRONIC EN- GINE CONTROL ~ Description and Operation, 2200 SRM 525. ‘The electronic engine control system is made of many parts. The main parts are the Throttle Body Injection (TBI) unit and the Electronic Control Module (ECM). ‘These parts and their sensors give information about en- zine operation and the systems it controls. The ECM has the ability to perform some troubleshooting of itself and of other parts of the system. When a problem is found, the ECM turns “ON” the “Malfunction Indicator” lamp that is in the instrument cluster. A diagnostic trouble code (DTC) is kept in the memory of the ECM. TROUBLESHOOTING PROCEDURE Before using this part of the manual, you need to know the information and the correct troubleshooting proce- dures. Ifthe correct troubleshooting procedures are not followed, as described in this section, it can result in re- placement of good parts. Troubleshooting charts use a “SCAN? tool where possible. The “SCAN” tool has the ability to save time in troubleshooting and preventing the replacement of good parts. HOW THIS SECTION IS ARRANGED This section is in five parts that describe the trouble- shooting and repair procedures. They are as follows. INTRODUCTION ‘TROUBLESHOOTING CHARI TROUBLESHOOTING - POOR OPERATION SYSTEM TEST CHARTS REPAIRS Where Do | Start? ‘There are three things to do to start troubleshooting. The first item is to become familiar with the electronic en- ‘gine control system. Secondly, always start your work with a good visual/ physical inspection. See the following paragraph for more explanation, ‘The last item on the "Where Do I Start” list is the "On— Board Diagnostic” (OBD) System Check. VISUAL/PHYSICAL INSPECTION A careful visual and physical inspection must be done as part of any diagnostic procedure. This can cause the re- pair of a problem without further steps, Inspect all vacu- uum hoses for correct routing, restrictions, cuts or bad connections. Be sure to inspect hoses that are difficult to see beneath the air filter. Inspect all the wires in the en- gine compartment for proper connections, damaged spots, or contact with sharp edges or the exhaust man- ifolds. This visual/physical inspection is very impor- tant. It must be done carefully. KNOWLEDGE/TOOLS REQUIRED To use this manual most effectively, 2 general under- standing of basic electrical circuits and circuit testing tools is required. One should be familiar with wiring diagrams, the meaning of voltage, ohms, amps, the basic theories of electricity, and understand what happens in an open or shorted wire. To perform the troubleshooting procedures, the use of a diagnostic “SCAN” tool is re- quired. A tachometer, test lamp, ohmmeter, digital volt- meter with 10 megohms impedance, vacuum gauge, and jumper wires are also required. Special tools that are re- quired for system service and the ones described above are shown at the end of this section. DAMAGE FROM STATIC DISCHARGE (STATIC ELECTRICITY) Electronic components used in control systems use a very low voltage, and can be easily damaged by static discharge or static electricity. Less than 100 volts of stat~ ic electricity can cause damage to some electronic com- ponents. There are several ways for a person to become statically charged. The most common methods of charg- ing are by friction and by induction. An example of charging by friction is a person sliding across a car seat; in which a charge of as much as 2 to 5,000 volts can build up. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off, leaving the person highly charged with the opposite polarity Static charges of ei- ther type can cause damage, therefore, itis important to use care when handling and testing electronic compo- nents. NOTE: To prevent damage by static electricity, DO NOT touch the ECM connector pins. FIGURE 1.ECM TROUBLESHOOTING INFORMATION ‘The troubleshooting charts ard function checks in this section are designed to find a bad circuit or component through logic based on the process of elimination. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are no multiple failures. The ECM does constant testing on certain control functions. The ECM commu- nicates the source of a malfunction with Diagnostic Trouble Codes (DTC). The DTC’s are two digit num- bers that can range from 12 t0 99. When a malfunction is found by the ECM, a DTC is set and the “Malfunction Indicator” lamp is tured “ON”. “Malfunction Indicator” Lamp (MIL) ‘This lamp is on the instrument cluster and has the fol- lowing functions. It lets the operator know that a problem has occurred and that the vehicle must be taken for service as soon as possible It displays Diagnostic Trouble Codes (DTC's) kept by the ECM which help the technician troubleshoot system problems. Asa bulb and system check, the lamp will come “ON” ‘with the ignition switch ON and the engine not running. ‘When the engine is started, the lamp will turn “OFF. If the lamp remains “ON”, the system has found a prob- Jem. This problem is referred to as a "current” DTC. If the problem goes away, the amp will go out after 10 se- cconds. In either condition a DTC” will remain in the ECM. ‘When the lamp remains “ON” while the engine is run- ning, or when there is a malfunction, the “On-Board Diagnostic” (OBD) System Check must be done. ‘When a problem is not regular or constant, the “Mal- function Indicator” lamp will turn “ON” for approxi- mately ten (10) seconds and then will go tum “OFF”. However, the diagnostic trouble code (DTC) will be kept in the memory of the ECM until the DTC’s are cleared (see DTC clearing in this section). An DTC that is not constant can reset. If itis a problem that is not constant a DTC Chart is not used. However you can use the “Other Troubleshooting Checks” on the page facing the troubleshooting chart for that DTTC to help locate the problem. Reading Diagnostic Trouble Codes (DTC) ‘The Diagnostic Link Connector (DLC) is used to com- municate with the ECM. See FIGURE 2. The DLC is installed on the bracket on top of the valve cover. It is used in the assembly plant to receive information in cchecking that the engine is operating correctly before it leaves the plant, The DT'C(s) kept in the ECM’s memory ccan be read with a "SCAN" tool connected to the DLC. ‘They can also be read by counting the number of flashes of the “Malfunction Indicator” lamp when terminal “B™ of the DLC connector is connected to ground. ‘The ter- minal can be connected to ground at terminal “A” (ex- teal ECM ground), DIAGNOSTIC KEY B = FAULT ANALYSIS TERMINAL M = SERIAL DATA FOR “SCAN” TOOL, FIGURE 2. DIAGNOSTIC LINK CONNECTOR (DLC) The ignition switch must be moved to the ON position, with the engine not running, and terminals “A” and “B” connected. At this point, the “Malfunction Indicator” lamp will flash DTC 12 three times consecutively (see FIGURE 3. The following is the flash sequence for "12": “long pause, flash, pause, flash-flash, long. pause,.flash, pause, flash. flash, long pause flash, pause, flash-flash.” DTC 12 (which means no crankshaft rpm. signal) indicates that the ECM’s diagnostic system is operating correctly at this time. If DTC 12 is not indi- cated, a problem is in the diagnostic system itself, Following the output of DTC 12, if additional codes are stored, the “Malfunction Indicator” lamp will flash the FLASH LONG PAUSE FLASH-FLASH DTC three times. If more than one DTC has been stored, in the ECM’s memory, the DTC's will be flashed start- ing with the newest DTC set and finishing with the old- est DTC set. Remember each DTC will be flashed three times, When all DTC’s have been flashed the sequence will start over again with DTC 12. Clearing Diagnostic Trouble Codes (DTC's) There are two ways to clear DTC's, manually or with a “SCAN” tool For the manual procedure do the following steps: 1. Jumper the DLC terminal “A” to “B”. 2, Tum the ignition key on (engine not running). 3. Push the throttle to above 80%. ‘The order of the above three steps is not important, as Jong as all three items are present at the same time, (The Malfunction Indicator lamp must not be flashing or “ON” at this time, If the TP Sensor voltage does not go high enough, then the DTC’s will not clear.) NOTE: Disconnecting the battery will not clear DTC's on this ECM. When using the second method, “SCAN” tool, install the tool according to the operators manual of the tool. Select clear DTC’s from the tools menu, This operation electronically clears all ECM DTC's. After using either procedure, always check for DTC’s again to see that the DTC's are cleared, LONG PAUSE FIGURE 3. DIAGNOSTIC TROUBLE CODE 12 EXAMPLE TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE ‘CODE DESCRIPTION TURN ON “MALFUNCTION INDICATOR” LAMP 14 [Engine Coolant Temperature Sensor Circuit — High Volts| Yes 15 [Engine Coolant Temperature Sensor Circuit - Low Volts Yes 21 _[ Throttle Position Sensor ~ High Volts Yes 22 | Throttle Position Sensor ~ Low Volts Yes 31 [Govemor Circuit Malfunction Yes 33. [MAP Sensor Circuit — High Volts Yes 34__ [MAP Sensor Cireuit - Low Volts, Yes 42 [EST Circuit Malfunction Yes 51 [ECM Intemal Problem Yes A CAUTION To prevent ECM damage, the key must be OFF when disconnecting or reconnecting ECM power. Diagnostic Mode When the DLC terminal "B” is connected to ground with the ignition ON and the engine “OFF”, the system will enter the Diagnostic Mode. In this mode the ECM will: 1. Display a DTC 12 by flashing the “Malfunction Indi- cator” lamp (indicating the system is operating correct- y), 2. Display any additional stored DTC's by flashing the “Malfunction Indicator” lamp. Each DTC will flash three times, then DTC 12 will flash again. 3. The IAC valve moves to its fully extended position, blocking the idle air passage. (This can be useful in checking the minimum idle air setting.) Field Service Mode If the diagnostic terminal is connected to ground with the engine running, the system will enter the Field Ser- vice mode. This will cause the engine to run at approxi- mately 1500 rpm and 8° before top dead center spark ad- vance, While the system is in Field Service Mode, new trouble codes can be kept in the ECM. ECM Learning Ability ‘The ECM has a “learning” ability that lets it make corrections for variations in the idle system to improve idle performance. If the battery is disconnected for any reason, the “learning” process resets and begins again. To “teach” the vehicle, make sure that the engine is at operating temperature. Drive the lift truck at part throttle, with moderate acceleration, and idle until nor- mal performance returns, TABLE 2. “SCAN” TOOL INFORMATION Test under following conditions: Idle speed, upper radiator hose hot, throttle closed, NEUTRAL, all accessories “OFF” *SCAN" Position Units Displayed Values Engine Speed 7m 100 rpm from Tale Speed om ECM idle command (Changes with temperature Coolant Temp. °C PF 35 10 100°C/I80" to 22°F Tenition Vols volts T2St 1S MAP VolisikPa Tio2 (depends on Vac. and BARO press), 30-40 KPa BARO VoiisikPa To 2 (depends on BARO pressure), 98-102 KPa Throttle Position vols Sw 120 Throitle Angle Tio 100% 0 Governor TPS O10 100% 0 Desired Govemor TPS Tio 100% 0 Governor Enable YesiNo Yes ‘Governor rpm Control ‘AativeNot Active | Not Active Govemor rpm Mode High rpmiNormal | Normal Tale Air Control CounisSieps Between 5 and 30 pm Overspecd YeiNo No Fuel Trim Steps NIK Injector Pulse Width MSec Bio 30mSEC Spark Advance No.of Degrees | Varies Base Timing NA NA Knock Signal YeuNo No Knock Retard No. of Degrees | O Degrees [ Governor mph Control ‘ActiveiNot Active | Not Active Vehicle Speed mph ‘mph inph Overspeed YesiNo No Low Oi Pressure YesiNo No Power Steering Switch NonmalfAigh ‘Nonmnal Emergency Stop ‘Aative/Not Active _| Not Active Tift Mode ActivelNot Active _ | Not Active EEPROM ID number XXX (varies with calibration) — 220) Time From Star Tis, min,, sec, | 0:00:00 18:12:15 On-Board DIAGNOSTIC (OBD) System Check The On-Board Diagnostic (OBD) System Check is a troubleshooting chart to find a problem caused by a mal- function in the electronic engine control system. It must, be the starting point for any troubleshooting. ‘The "SCAN" data shown in TABLE 2 can be used for ‘comparison after doing the troubleshooting checks and finding the on-board diagnostics working correctly with no trouble codes shown, The data are an average of display values from normally operating vehicles and show a display of a normally operating system. ‘After the visual/physical inspection, the “On-Board Diagnostic (OBD) System Check” is the starting point for all troubleshooting procedures. ‘The correct procedure to find a problem is to follow three basie steps. 1. Are the On-Board Diagnostics working? This is de- termined by doing the “OBD System Check” Since this is the starting point for the troubleshooting procedures , always begin here. If the On-Board Diagnostics do not work, the “OBD ‘System Check” will not lead to a troubleshooting chart to fix the problem. If the On-Board Diagnostics are ‘working correctly, go to the next step. 2s there a Diagnostic Trouble Code? If there is a DTC, go directly to the DTC chart for that number. This will determine if the fault is still there. If there is no DTC, then; 3. “SCAN” Serial Data transmitted by the ECM. This involves reading the information available on the Serial Data Stream with one of the tools available for that pur- pose. Information on these tools and the meaning of the displays can be found in the operator’s manual of the tool. Readings for a certain operating condition can be found in TABLE 2, ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1, Diagnostic Trouble Code (DTC) 12 means no rpm. reference pulses from the ignition module. This i rect when engine is not running oor + IGNITION "ON," ENGINE “OFF." + LOOK AT THE "MALFUNCTION INDICATOR" LAMP STEADY LIGHT NOUGHT FLASHING DTC 12 USE CHART At 1 “JUMPER DATA LINK CONNECTOR (DLC) TERMINAL "8" TO "A" CHECK FOR GROUNDED FAULT DOES “MALFUNCTION INDICATOR” LAMP FLASH DTC 12/ OR ANALYSIS REQUEST CIRCUIT HS: ‘INSTALL "SCAN" TOOL USE WIRING DIAGRAMS ON DOES TOOL DISPLAY DATA? CHART Act NO (DOES "SCAN" TOOL DISPLAY ECM DATA? | ! USE CHART A- DOES ENGINE START? pthseeeseees {USE CHART A-2 yes No PoC. WERE ANY OTHERDTOS DISPLAYED?| | USE CHART AS! NO e ‘REFER TO APPLICABLE ‘COMPARE “SCAN” TOOL DATA WITH TYPICAL DIC CHART. VALUES SHOWN ON PAGES. ARE VALUES NORMAL START WITH LOWEST DTC, ‘OR WITHIN RANGE? -_——__ T T SEE TROUBLESHOOTING ‘SEE TROUBLESHOOTING - CHARTS. POOR OPERATION ON-BOARD DIAGNOSTIC SYSTEM CHECK TROUBLESHOOTING CHARTS GENERAL The following troubleshooting charts are designed to give an efficient method of fault analysis on the elec- tronic engine controls. A WARNING ‘This troubleshooting requires the operation of the engine for some of the tests. Make sure the tests are done carefully to prevent injury: Put the lift truck on a level surface. Lower the carriage and forks and apply the parking brake. Make sure the lift truck can not move and cause an injury during the tests. Use blocks as necessary to prevent movement of the lift truck. ‘© The fuel system and the engine must operate correctly. Any problems or leaks in the fuel system and the engine must be repaired before doing troubleshooting. ‘© The fan and the drive belts can remove fingers or cause other injuries. Be careful that your hands and tools do not touch the moving fan or the drive belts. ‘The engine exhaust and other parts of the en- gine are hot. Do not touch a hot surface and. cause a burn, A cauTION Electronic equipment can be damaged if trouble- shooting and repairs are not done corecty. Te fol lowing CAUTIONS must be followed when doing troubleshooting or repairs on an engine with an ECM: * Always disconnect the battery negative cable before disconnecting and removing any parts except as described in TROUBLESHOOT- ING. © Never start the engine unless the battery is, correctly connected. ‘Never disconnect the battery from any equip- ‘ment when the engine is running. * Never disconnect the battery from the charg- ing system when the engine is running. © Ifthe battery must be charged with a battery charger, ALWAYS disconnect the battery from the electrical system. ‘© Make sure that all electrical connections are clean and have good electrical contact. ‘© Never connect or disconnect the wiring har- ness at the ECM when the key switch is “ON”. ‘© Always disconnect the battery and the ECM. connectors if electric are welding must be done on the vehicle. * If the engine compartment is cleaned with steam, make sure that any water or steam is not sent toward the ECM or its sensors. The heat and steam can damage the electror components and cause corrosion in the elect cal connections. © Use only the tools and test equipment de- scribed in “TOOLS AND TEST EQUIP- MENT” to prevent damage to good compo- nents and to obtain correct test results. * All voltage measurements must be made with a digital voltmeter with a rating of 10 megonm. input impedance. © When a test light is used in troubleshooting, the test light must have less than 0.3 amps (300 milliamps) of maximum current flow. A test for a correct test light is shown in FIGURE 4. TOOLS AND TEST EQUIPMENT The following tools are necessary for troubleshooting the system: © Ohmmeter © Digital voltmeter. The voltmeter must have a minimum input impedance of 10-megohms. (A digital voltmeter and ohmmeter are normally in- cluded in a multi~meter test instrument. © Tachometer with inductive trigger signal sensor, © Test light that has a low current draw as described in FIGURE 4. ‘© Vacuum pump with a gauge. This vacuum pump is held and operated with the hand. The gauge ‘must be able to indicate a gauge pressure (vacu- um) of 34 kPa [20 inches of mercury (20” Hg)]. (See the PRESSURE CONVERSION CHART at the end of this section.) ‘© Spark tester. The spark tester is used to check the secondary ignition, The spark tester is also called an ST125 and creates a 25 kilovolt load on sec- ‘ondary ignition components, + BATTERY if the ammeter indicates less than 0.3 amps (300 miliamps), the test light can be used. Ifthe ammeter indicates more than 0.3 amps (300 miliamps), the test light can not be used because it can cause damage to the electronic ‘components. FIGURE 4. CURRENT FLOW TEST FOR A TEST LIGHT FUELPUNP FUSE BATTERY. ECM ia He 1§$ oe oT |__ BATTERY VOLTAGE + 0 108 HC. KEEP ALIVE MEMORY ac ECMIGN a 1 2 nS IanO = ELECTRONC DAVVER comcurr —_wruruncrioocaTon HALFUNTION NDICATCR LAME IGNITION. ae AZ SwToH orl SAN ie 1 axock noun es 6 Hoe ss “Se 08 svste 2 7 GROUNDS WTAE MANIFOLD OUND G SERIAL DATA 7 DATAUNK CONNECTOR FAULT ANALYSIS REQUEST ale (DLC) 18: ELECTRONIC CONTROL MODULE 10-12. CHART A-1 NO “MALFUNCTION INDICATOR” LAMP. CIRCUIT DESCRIPTION ‘The "Malfunction Indicator” lamp will be “ON” when the ignition is ON and engine is not running, Voltage from the ignition switch is supplied to the light bulb. The Electronic Control Module (ECM) will control the lamp and turn it ‘ON” by connecting it to ground through circuit AZ. ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. This test gives a ground circuit for the Malfunction In- dicator Lamp circuit. If lamp works now, then the exter- nal circuits are correct. 2. This tests circuits HD, HC, and JM for voltage. 3. Using a test light connected to Battery +, check each fof the system ground circuits to be sure there is a good ground. 4. 1a fuse is open, remember to locate any short circuits to ground or other high ampere causes on that circuit 10 Other Troubleshooting Checks: If engine runs correctly, check for the following: Fault in the light bulb, Circuit AZ is open. ‘© 5 ampere circuit breaker is no good. This will cause no dash indicator lights, gauges, oF seat belt reminder. If Engine Cranks But Will Not Run: ‘+ ECM Battery + fuse/cireuit JY or HD or HC. open, ‘+ ECM ignition fuse/cireuit IM/JN is open. * Poor connections to ECM. DOES ENGINE START? @J-aneor OJ. exoroz OT ccrene SAO OF cy conmecTOns eae rare Bhecrtics Seaman Set er uns 70 cao. CONNECT TEST LIGHT TO GROUND ‘AND CIRCUIT HD, HC AND JM ANDGIRCUT AZATMOOUEPLUGS. Sa TO ore ror a cnCuTE? NO cmaceo —] [ Geox @fosas | Of spncrunce ehanecrows | | “atc ry sawene eaones ERS acrN ry coer aca cone MODULE. “OPEN CIRCUIT AZ, MODULE: “Sado ag geo ec When repairs are complete, clear the codes from the ECM and check that the “Malfunction Indicator” lamp does not indicate another problem. CHART A~1 — NO “MALFUNCTION INDICATOR” LAMP FUEL PUMP FUSE a Be HF or 9— vv 108, HE 'gnmon J ‘SWITCH 10 STHRTER ECMIGN tr 7s 10 MALFUNCTION I e ” L Tn BREAKER SAMP a ocK GROUND) INTAKE MANIFOLD GROUND 2 é Hz DATA LINK i) CHART 3 fe 5 -—0—e— Jw 4-H HOB 2 ELECTRONIC CONTROL NODULE BATTERY VOLTAGE, > KEEP ALIVE MEMORY 'GNMTION ELECTRONIC DRIVER, INDICATOR MALFUNCTION INDICATOR LAMP 6 1, SERIAL DATA, ‘CONNECTOR FAULT ANALYSIS REQUEST Hs A-2 NO “SCAN” DATA, NO DTC 12, “MALFUNCTION INDICATOR” LAMP ON CIRCUIT DESCRIPTION ‘The "Malfunction Indicator” lamp (MIL) will be “ON” when t he ignition is ON and the engine is "not running. Voltage from the ignition switch is supplied to the light bulb. The ECM will control the light and tum it “ON” by connecting it to ground through circuit AZ.to the ECM, With the diagnostic terminal is connected to ground, the light will flash a DIC 12, followed by any trouble code(s) kept in memory. A steady light means a short to ground in the light control circuit AZ, or an open in circuit HS. ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. If there is a problem with the ECM that causes a “SCAN” tool to not read data from the ECM, then the. ECM will not flash a DTC 12. If DTC 12 does flash, be sure that the "SCAN" tool is working correctly on another vehicle. 2 If the "SCAN" is working correctly and circuit HZ is good, the ECM can be the cause for the "NO SCAN DATA" symptom. 2. This step will check for an open diagnostic circuit HS, 3. Ifthe light turns “OFF” after the ECM connector J2 is disconnected, then circuit AZ has a short circuit 10 ground 4, At this point, the "Malfunction Indicator” lamp wir- ing is good. If DTC 12 does not flash, replace the ECM. IGNITION "ON" ‘NO “TEST THE VOLTAGE BETWEEN: DLC TERMINALS ‘B" AND “A” IS MALFUNCTION INDICATOR LAMP (MIL) "ON"? + CONNECT TERMINAL "A" TO TERMINAL *B" AT THE DLC. DOES MALFUNCTION INDICATOR LAMP FLASH DTC 12? IS VOLTAGE BETWEEN 10- 12 VOLTS? USE CHART A-t YES i [> aerar open on storm ocurt HZ. IF CIRCUTT HZ 1S CORRECT, ‘THEN REPLACE ECM “IGNITION KEY ‘OFF* + DISCONNECT ECM CONNECTORS. + IGNITION KEY "ON" REPAIR SHORT TO GROUND (ON CIRCUIT Az. WATCH MALFUNCTION INDICATOR LAMP + REPAIR: OPEN OR GROUND CIRCUIT HS, OPEN CIRCUIT Ha, OR IF THESE CIRCUITS ARE CORRECT: REPLACE DAMAGED ECM . LAMP ‘OFF When repairs are complete, clear the codes from the ECM and check that the “Malfunction Indicator” lamp does not indicate another problem. CHART A-2 - NO “SCAN” DATA, NO DTC 12, “MALFUNCTION INDICATOR” LAMP ON FUEL INJECTOR HARNESS CONNECTOR INJ FUSE, ‘WINDING primany | cvectronicianmion [2] NDING | CONFAOK fon MODULE | TO TACHOMETER. ELECTRONIC CRANKSHAFT POSITIONSENSOR CONTROL MODULE HARNESS CONNECTOR ECMIGN FUSE, NS IM 38 IonTion ELECTRONIC DRIVER, INJECTOR eer BO 8A INJECTOR GROUND REFERENCE BYPASS CONTROL IGNITION ‘CONTROL () sa21.82 Gxtooos CHART A-3 THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (1 of 3) CIRCUIT DESCRIPTION Before using this chart, battery condition, engine cranking speed, and fuel quantity must be checked to make sure they are correct. ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. A "Malfunction Indicator” Lamp "ON" is a test to de~ termine if there is battery and ignition voltage at the ECM. ‘¢ No “SCAN” data can be caused by an ECM prob- Jem, CHART A-2 will diagnose the ECM. ‘+ If throttle or coolant sensors are not within these ranges, the ECM can be using the wrong mode for starting. © The “SCAN” tool will display RPM during cranking if pulses are received at the ECM. 2. Because the Electronic Ignition (EI) System uses two plugs and cables to complete the circuit of each coil, 4 leave the opposite spark plug cable connected. If RPM was indicated during crank, the ignition module is re- ceiving a crank signal, but "No Spark” at this test indi- cates the ignition module is not triggering the coil. 3. While cranking the engine, there must be no fuel spray with the injector electrical connector discon- nected. Replace the injector or seals if fuel sprays or drips. 4. The test light will flash, indicating the ECM is con- trolling the injector. 5. Fuel spray from the injector indicates that fuel is available, However, the engine can be getting too much fuel, No fuel spray from injector indicates a fault in the fuel system or no ECM control of injector. Other Troubleshooting Checks: ‘© Water or foreign material can cause a no start condition during freezing weather. The engine can start after approximately $ minutes in a heated shop. © A MAP sensor voltage reading between .5 and 3.0 volts can cause a no start condition. Discon- neet the MAP sensor. If the engine starts, replace the MAP sensor. See MAP sensor test in RE~ PAIRS. If fuel pump fuse is damaged, test current draw of pump motor in tank. If more than 5 to 6 amps, cor rect the circuit or replace the pump motor in the tank. 1s QJ tanition on. tf MALFUNCTION INDICATOR LAMP 1S “OFF, USE When repairs are complete, CHART At clear the codes from the ECM +, INSTALL SCAN” TOOL, IF NOT DATA, USE CHART A-2 ‘and check that the “Malfune- : WING: icaiors “TPS IF OVER 25 V AT CLOSED THROTTLE, USE DTC 21 tion Indicator” lamp does not ~ IF LESS THAN 2V, USE DTC 22 indicate another problem. ~ COOLANT TEMP. — IF BELOW ~30°C, USE DTC 15 = RPM IF NO RPM WHILE CRANKING, USE CHART A-3, PAGE 2 OF 3 = MAP = IF BELOW 3V, SEE "OTHER TROUBLESHOOTING CHECKS * CHECK FUEL PUMP FUSE, IF DAMAGED, USE CHART A-7 "IGNITION OFF” FOR 10 SECONDS. LISTEN FOR FUEL PUMP RUNNING IN FUEL TANK DURING NEXT STEP! ‘IGNITION “ON" - PUMP SHOULD RUN FOR ABOUT TWO SECONDS AFTER SWITCH IS TURNED ‘ON DOES IT? YES NO a (@) | cRANKENGINE AND CHECK FOR SPARK WITH ST-125 ‘ON SPARK PLUG CABLES; 1&4, THEN 283. “+ CHECK ONE CABLE AT A TIME. GROUND COMPANION ‘SPARK PLUG CABLE. LEAVE THE OTHER PAIR CONNECTED | ‘TO THE SPARK PLUGS DURING CRANKING. IS THERE SPARK FROM BOTH COILS? ves - REPLACE I _ Tisecaaarad | lawton @J- gscamect nveaToR conmecron, crac eNane fPaged0t9) foDute IS THERE FUEL SPRAY FROM INJECTOR? hs 10 3 @ J concer mecron esrusm at mace ERAGE ONINGED WECTOROR Zs 13 ames ConecISE A MECTOR accion - ECan DOES LIGHT FLASH? YES NO Eas: © -ecaESTmRETOR comETTOR Popeciaarast + CRANK ENGINE, 8 THERE FUEL SPRAY 1 Pagesof + rouncecroR” NO —— + IGNITION“OFF- INSTALL FUEL PRESSURE GAUGE “+ CHECK FOR WET SPARK PLUGS, SIGNITION-ON” LOW FUEL PRESSURE - USE CHART CORRECT FUEL PRESSURE IS 62-90 KPA (9-13 PS}. AT isir? + SEE “OTHER TROUBLESHOOTING CHECKS", PAGE 14 REPLACE INJECTOR, Useaaatar CHART A-3 - THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (1 of 3) 16 FUEL INJECTOR HARNESS CONNECTOR 7 * aL ignmion ‘Swirce & INJFUSE SECONDS: WINDING PRIMARY WINDING JD. 9— cA 0 SE ELECTRONIC (CRANKSHAFT POSITION SENSOR 'HAPNESS CONNECTOR . IiwecroR (GROUND AT INTAKE MANIFOLD, ‘GROUND REFERENCE BYPASS CONTROL IGNTON ‘CONTROL ¢c) TO TACHOMETER, CHART A-3 THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (2 of 3) CIRCUIT DESCRIPTION ‘A magnetic crank sensor is used to determine the position of the engine crankshaft. The sensor is mounted in the block, near a wheel with slots on the crankshaft, The rotation of the wheel creates a flux change in the sensor, producing @ voltage signal. The Ignition Control Module (ICM) processes this signal and creates the reference pulses needed by the ECM to energize the correct coil at the correct time. If the "SCAN" too! did not indicate cranking RPM, and there is no spark at the plugs, the problem is in the Ignition System or the power and ground supplies to the ICM. Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. The Electronic Ignition (El) system uses two spark plugs and cables to complete the circuit of each coil. The ‘other spark plug cable in the circuit must be left con- nected to create a spark. 2. This test will determine if the 12 volt supply and a g00d ground is available at the DIS ignition module. 3. This test will determine if the ignition module is not ‘making the reference pulse, or if the wiring or ECM have a fault. Touching and removing a test light from Battery + to circuit GY will make a reference pulse. If rpm is indicated, the ECM and wiring are good, 4, This test will determine if the ICM is not energizing the problem coil, or if the tested coil has a fault This test can also be performed by changing a known good coil ‘The secondary coil winding can be checked with a Digi- tal Volt Ohmmeter (DVOM). There will be 5,000 to 10,000 ohms across the coil towers. There will be no continuity from either coil tower to ground. 5, This tests contimunity of the sensor, connections, and, wires. 6. Normal voltage from the crank sensor is 8 to 1.4 volts (800 mV to 1400 mY) with a charged battery and engine at room temperature. Minimum output voltage (slow cranking/low battery) can be as low as .5 volts (300m), ” 18 (DJ crank ecm ano CHECK FOR Spark WT ST-125 ON SPARK PLUG CABLES; 184, then 283. “CHECK ONE CABLE AT A TIME. GROUND THE COMPANION. ‘SPARK PLUG CABLE. LEAVE THE OTHER PAIR CONNECTED “TO THE SPARK PLUGS DURING CRANKING, IS THERE SPARK FROM BOTH COLS? When repairs are complete, clear the codes from the ECM and check that the “Malfunction Indicator” lamp does not indicate another problem. NO SPARK. ‘SPARK ON BOTH 14 AND 288 COUS ‘SPARK ON 1&6 OR 2&3 COLS @franoor Op anor “TEV COU OW TTAR “Dacontecr zen comecron | ©) “pct pnssem “townon t= ronan on Comectonmranmonuooue || ‘esrfeetace or suspect TON Ok “emmor'on: GALE SHOUD EE LESS TN “Tesrowmovocuros “repeaeneyroucnoncuroy || Sosmscueaoncr someo iimavesracrrrocetun | | wreatesrusrroscima || teenomo mend esas 600, Sesto Oesenm uon ne Sm Toot || reve toon cous (SPH NOITED neneepce oF cara PAGS AON Groningen comecen SENeaVCDL NO MOOD eS ic 1S ND T_T Testanouno | [ OPW FEPAGE ] [oPEvonswoM) (@)]-swToX cot PosmONS] [REPLACE Graces’ use | Lomcures.| }icxmow | | roaRovNo on ONWODULE ANDRE TEST LIGHT TO MODULE. CIRCUIT GB OR INSTALL. BY en owuaceD ecu | | -recvecxron sear WT25 FROM 000 cot. on suSFec| fa Posmion ue IS SPARK PRESENT Ofrarorar PETROS + DISCONNECT 3-PIN CONNECTOR AT 'GNITION MODULE + MEASURE RESISTANCE BETWEEN TERMINALS "A" & \WITH OHMETER, DOES T READ BETWEEN 800 OHMS. 1200 OHMS? REPLACE COIL ORIGINALLY ‘CONNECTED TO THIS COIL POSTION, * SET VOLTWETER ON AG VOLTS POSTION + CRANK ENGINE AND OBSERVE READING. IS READING GREATER THAN 3 VOLTS (300m)? LESS THAN 800 OHMS GREATER THAN 1200 OHMS ‘CRANK SENSOR LEADS SHORTED TOGETHER OR DAMAGED SENSOR. ‘OPEN CRANK SENSOR ‘CIRCUTT, DAMAGED CONNECTION, OR DAMAGED SENSOR. “INSPECT CONNECTIONS IF THEY ARE GOOD, REPLACE IGNITION MODULE, ‘DAMAGED CONNECTION OR DANAGED CRANK SENSOR CHART A-3 ~ THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (2 of 3) FUEL INJECTOR HAFINESS CONNECTOR, ee IGNITION, ‘SWITCH ow igumon WNOIG CONTROL (6) primary | cLectaoncionmon | 8] WINDIS | ContOL icin MoOULET A] a. 221-92 ‘TO TACHOMETER. ioooe ELECTRONIC ‘CRANKSHAFT POSITIONSENSOR CONTROL MODULE HARNESS CONNECTOR tenon ELECTRONIC ‘RIVER INJECTOR GROUND AT INTAKE MANIFOLD. HK cy oz ‘GROUND REFERENCE BYPASS CONTROL, CHART A-3 THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (3 of 3) CIRCUIT DESCRIPTION Ignition voltage is supplied to the fuel injector on circuit JEA/JE. The injector will pulse (tum "ON" and "OFF"), when the ECM closes ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. This test determines if injector connector has ignition voltage, and on only one terminal. 2. This tests for a short circuit in the electronic driver for the injector in the ECM. 3. A test light connected from ECM hamess terminal "32-21" to ground will iluminate due to continuity through the injector. and connects the injector driver to ground through circuit JBA/B. 4, A short to voltage in circuit JBA/JB can damage the ECM. Repair the short circuit and start the engine. If it does not start, test from the beginning of this chart ICHART A-3 (3 of 3)] 5. A bad ECM can cause damage to the injector. 6. An injector that has lower than 1.6 ohms resistance ‘can damage the ECM. 19 When repairs are complete, clear the FROM codes from the ECM and check that the re “Malfunction Indicator” lamp does not (Page 1043) indicate another problem. To ‘OBSERVE TEST LIGHT DURING PREVIOUS TEST. FIT DID NOT FLASH, WAS IT? QJ] -atororsan or @f-snoror “Scone nteevon Connecron “Seenescon cowecrone ‘Sresruant‘enr ght OFF” UGHT-OFF." BOTH TERMINALS UGHT-“ON- [ONE TERMINAL UGHT “ON BOTH TERMINALS| ‘REPAIR SHORT ‘TOGROUND. REPAIR SHORT TO IN CIRCUIT JBiJBA, VOLTAGE ON JB.uBA| fama EPA GPE AREA “RECONNECT INJECTOR. | | CHECK INJECTOR FUSE. © TGnaTION STATCHECEE! SosconNecTeCM | | Ir FUSE Was DAMAGED, MEASURE RUECTOR RESISTANCE Connectors WAKE SURE THAT (SRESSTANGE OVERS OFS? STGNITION ON ESISTANGE ACROSS “rest rerwnacazar_| | nueoton remmanats wiuarest ucHTT0 | [IS WORE THAN 6 Ons. GROUND. NES ISTHE UGHT-On REPLACE INJECTOR. YES 1 DAMAGED ECM CONNECTOR TERMINAL J2-21 NO REPLACE EOM AND INJECTOR. DAMAGED CONNECTION oR. OPEN IN CIRCUIT JBA/JB. CHART A-3 ~ THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN (3 of 3) ‘STARTER 5 0 coma. ee = gy 108 FUEL PUN ne BELAY PSE tt Lene 10a oe uetruur reas abe Cowen race EW, ELECTRONIC CONTROL MODULE ELECTRON DAVER FUEL PUMP RELAY co [sista GROUNDS CHART A-5. FUEL PUMP RELAY CIRCUIT CIRCUIT DESCRIPTION ‘When the ignition switch is tumed ON, the ECM will activate the fuel pump relay with a 12 volt signal and run the fuel pump. The fuel pump relay will operate as long as the engine is cranking or running if the ECM is receiving ignition reference pulses. The ECM will top the fuel pump relay signal two seconds after the ignition reference pulses stop. This will also occur two seconds after the key is ON and the engine not started. If the fuel pump relay or the 12 volt relay drive from the ECM fail, the fuel pump will receive electrical current through the circuit for the oil pressure switch, ‘The fuel pump test terminal is near the relay in the engine compartment. When the engine is stopped, the pump can be tumed "ON" by applying Battery + to the test terminal ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. The test light will connect to ground through the relay to the fuel pump. 2. If pump does not run, it can be damaged or worn, 3. After the fuel pump relay is replaced, continue with the “Oil Pressure Switch Test.” 4. At this point, the fuel pump relay is operating correct- ly, Test the parallel circuit through the oil pressure switeh, 5. If fuse was damaged, check the circuit for too much current useage (including fuel pump). Other Troubleshooting Checks: ‘+ A fuel pump relay that does not work can cause Jong cranking times. The extended crank period is caused by the time necessary for oil pressure to reach the pressure required to close the oil pres- sure switch and turn ON” the fuel pump. “IGNITION “OFF When repairs are complete, clear the codes from the “TOUGH FUEL PUMP TEST TERMINAL WITH] ECM and check that the “Malfunction Indicator” ae lamp does not indicate another problem. UGHTON® UGHT “OFF Lemon] “IGNITION MUST BE “OFF” FOR TEN SECONDS, * DISCONNECT FUEL PUMP RELAY HARNESS ‘TURN IGNITION “ON.” (CONNECTOR. ‘TEST LIGHT SHOULD GO “OFF* FOR ABOUT + TOUCH CONNECTOR TERMINAL °E* WITH A ‘TWO SECONDS. DOES IT? ‘TEST LIGHT TO BATTERY +. UGHT-ON = -pmcomecr rue] | gPewaincut Pour Reusy HARNESS pares eat TERMINAL AND “TOUCH Harwiess Tuna. CONNECTOR TERMINAL Fe "D" WITHA TEST LIGHT LAY. TOBATTERY «. LIGHT “OFF OPEN CIRCUIT GiGH OPEN GIRCUIT GMLIWA, DAMAGED CONNECTIONS, (OR DAMAGED FUEL PUMP. * DISCONNECT FUEL PUMP FELAY HARNESS CONNECTOR. ‘+ TOUCH CONNECTOR TERMINAL "A" WITH TEST LIGHT TO GROUND, UGHT-ON UGHT-OFFY REPAIR OPEN UGHTOFF UGHT-ON circu uae. aa (CHECK FUEL Pune Fuse. REPAIR OPEN “TOUCH FUEL PUMP RELAY HARNESS WIRING. ANDIOR| — [_GIRCUTT HP. CONNECTOR TERMINAL “F° WITH A CONNECTIONS) ‘TEST LIGHT TO GROUND. “IGNITION MUST BE"OFF” FOR TEN ‘SECONDS, “TURN IGNITION “ON. ‘APPLY BATTERY + TO RELAY. ‘TEST LIGHT SHOULD UGHT FOR, TTERWINAL "E.” DOES PUMP RUN? [ABOUT TWO SECONDS. DOES IT? NO REPLAGE FUEL PUMP, ae L__ REPLACE RELAY, OPEN OR Of meee] | shale ey: CIRCUIT JAOR ‘lL PRESSURE DAMAGED ECM ‘SWITCH TEST. ‘+ LET ENGINE RUN AT NORMAL TEMPERATURE AND OIL PRESSURE. ‘+ DISCONNECT FUEL PUMP RELAY HARNESS CONNECTOR, ‘ENGINE CONTINUES TO RUN? NO TROUBLE FOUND, (CHECK CIRCUITS JL AND GGIGH TO OIL PRESSURE [SWITCH IF GOOD, REPLACE SWITCH CHART A-5 — FUEL PUMP RELAY CIRCUIT ELECTRONIC CONTROL MODULE pe & 10 ECMB+ HD BATTERY VOLTAGE oe Ry ae Ss 5 eee mera eet ot fae pana aret RE ‘FUEL PUMP RELAY Oe EES CMESTOR FACE EW, TOC.USTER HARNESS, ‘CONNECTOR co system GROUNDS t= PUNPINTANK. CHART A-7 FUEL SYSTEM TROUBLESHOOTING (1 of 3) CIRCUIT DESCRIPTION ‘When the ignition switch is turned ON, the ECM will activate the fuel pump relay with a 12 volt signal and run the fuel pump. The fuel pump relay will operate as long as the engine is cranking or running if the ECM is receiving ignition reference pulses. The ECM will stop the fuel pump relay signal two seconds after the ignition references stop. This will also occur two seconds after the key was ON and the engine not started. Ifthe fuel pump relay or the 12 volt relay drive from the ECM fail, the fuel pump will receive electrical current through the oil pressure switch circuit, When the engine is stopped, the fuel pump can be tured “ON” by applying Battery + to the fuel pump “test” terminal This terminal is located near the pump relay. ‘The fuel pump delivers fuel to the TBI unit where the system pressure is controlled to 62 to 90 kPa (9 to 13 psi). Excess fuel is returned to the fuel tank. ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. Check the fuel pressure while the pump is running. Pressure will stat to drop as soon as the pump stops be- cause of an intemal relief in the pressure regulator. 2. If engine does not run use CHART A-3 3. This test checks the operation of the fuel pump check valve. A check valve that leaks will cause fuel in the pressure line to drain back to the tank and cause long start times. The amount of pressure is not important as long as some pressure is maintained, Other Troubleshooting Checks: Fuel system pressure that is not correct can casue one of the following symptoms: © Cranks, but will not start. ‘© Starts, but will not continue to run. Q “IGNITION “OFF {FUEL TANK QUANTITY GOOD. “INSTALL PRESSURE GAUGE. (SEE A-7 page 3 of 3) “APPLY BATTERY + TO THE FUEL PUMP TEST CONNECTOR USING A 10 AMP FUSED JUMPER WIRE + OBSERVE FUEL PRESSURE, IT SHOULD BE 62-90 kPa (2-18 pi), Long cranking times before engine stars, Rough idle or low idle speed. Engine miss, feels like ignition problem. High fuel useage, loss of power, pocr perfor- When repairs are complete, clear the codes from the ECM and check that the “Malfunction indicator” lamp does not indicate another problem. NO TROUBLE FOUND. PUMP FUNNING. J PUMP NOT RUNNING. NO FUEL FUEL PRESSURE BETWEEN FUEL PRESSURE, BUT PRESSURE. 62.90 Pa (9-13 ps). OUTSIDE OF SPECIFICATIONS, STEN FOR @)| ENSINE RUNS. BUT HAD ‘USE CHART A? PUMP RUNNING LONG CRANK TIMES @0r3) AT FUEL TANK BEFORE STARTING + CHECK FOR: "PLUGGED IN-LINE FILTER. PLUGGED FUEL PUMP “DISCONNECT FUEL PUMP FELAY. “USING A 10 AMP FUSED. “ RECONNECT FUSED JUMPER WIRE AND WAIT FOR PUMP TO BUILD PRESSURE. + DISCONNECT JUMPER WIRE AND IMMEDIATELY CLOSE THE FUEL RETURN ‘SHUT OFF VALVE AT THE TANK DOES SOME PRESSURE HOLD? STRAINER. JUMPER WIRE, CONNECT RESTRICTED FUEL FEED CIRCUIT GJTO BATTERY +.] | PROBLEM IS INTERMITTENT. UNE: DOES PUMP RUN? DISCONNECTED PUMP oteoineed NO TROUBLE FOUND COUPLING HOSE, pale \FALL THESE ARE AEPLACE FUEL PUMP. “INSPECT FOR PARTIALLY DISCONNECTED DAMAGED OPENIN CIRCUIT Qu/GH, PUMP COUPLING ‘CONNECTION DAMAGED FUEL PUMP.OR, nose AT RELAY OR INADEQUATE GROUND. “IF HOSE GOOD, DAMAGED FUEL REPLACE PUMP. PUMP RELAY, + REOPEN SHUT-OFF VALVE. 4 CHART A-7 — FUEL SYSTEM TROUBLESHOOTING (1 of 3) FUELPRESSURE ‘GUGE ‘TEST PORT FOR FUEL PRESSURE I< FUEL FEED Fue. SHUT OF VALVE —, FUBLALTER FUEL PRESSURE LINE IN-TAN PUMP FUEL STRANER CHART A-7 FUEL SYSTEM TROUBLESHOOTING (2 of 3) ‘Test Description: The number(s) below are a reference to number(s) in circles in the troubleshooting chart on the next page. 1. Fuel pressure less than 62 kPa (9 psi) can cause sever- al problems, It can cause hard starting in cold conditions and poor performance. Low fuel pressure can also allow the engine to run at idle or low speeds, but cause the en- gine to run poorly or stall when more fuel is required (such as accelerating or at high speed). 2, Causing a restriction in the fuel flow at the tank (as shown) causes the fuel pump to develop its maximum pressure. With the fuel pump running, pressure will in- crease to more than 90 kPa (13 psi). NOTE: Do not block the fuel retum line completely (outlet side of TBI assembly) as too much pressure can damage the TBI pressure regulator. 3. This test determines if the high fuel pressure is caused by a restriction in the fuel retum line, or a problem with the pressure regulator. 4. IF pressure is correct at idle, yet becomes lower as the engine is accelerated, then repair the restriction in fuel feed line. If there is no restriction, replace the fuel pump. ‘5, Wrong fuel pump (too much capacity) can also cause high pressure. 6. Check that the shut-off valves are open when fin- ished. When repairs are complete, clear the ecu codes from the ECM and check that the crart “Malfunction Indicator” lamp does not page indicate another problem. 1 (Page 1 OF 3 PRESSURE LESS THAN 62 kPa (9p) ‘PRESSURE ABOVE 90 KPa (19 pa. QJ creokronnestricreD @ J dscomect 10 awe Fuse JUMPER wine FUEL FILTER OR RESTRICTED “DISCONNECT FUEL RETURN LINE AT LINE BETWEEN FUEL PUMP THROTTLE BODY. AND TEST GAUGE. + ATTACH PROPER SIZED FLEXIBLE HOSE TO ‘THROTTLE BODY OUTLET FITTING. INSERT OTHER END OF HOSE IN AN APPROVED GASOLINE CONTAINER “APPLY BATTERY TO FUEL PUMP TEST RESTRICTIONS ‘CONNECTOR USING A 10 AMP FUSED JUMPER WIRE AND OBSERVE PRESSURE. NO RESTRICTIONS REPLACE FILTER, OR REPAIR RESTRICTION AND RETEST PRESSURE ABOVE PRESSURE BETWEEN © IGNITION “OFF 90 kPa (13 pei. 62 90KPa (9-19 pai. {APPLY BATTERY « TO FUEL PUMP TEST TERMINAL USING 10 AMP JUMPER WIRE, QJ -seecron restricreo LOCATE AND “GRADUALLY CLOSE VALVE FUEL RETURN INSIDE connect (ON RETURN FITTING AT FUEL TANK| ‘THROTTLE BODY. RESTRICTED FUEL| OBSERVE PRESSURE “IE NO RESTRICTION RETURN LINE TO REPLACE PRESSURE FUEL TANK, REGULATOR PRESSURE ABOVE PRESSURE LESS: THAN 62 KPa (Oped, REPLACE PRESSURE, REGULATOR, “REPLACE AS NECESSARY: DAMAGED FUEL PUMP. * PARTIALLY REMOVED PUMP COUPLING HOSE. RESTRICTED FUEL PUMP STRAINER, CHART A-7 — FUEL SYSTEM TROUBLESHOOTING (2 of 3) 6 ‘TEST PORTFOA FUEL PRESSURE ETURNLINE rere Fue. RETURN saree lol Gy swrar inte FUELTANK C| ’ FUELPRESSURE LINE FUBLFILTER INTANK PUMP CHART A-7 - FUEL SYSTEM TROUBLESHOOTING (3 of 3) FUEL PRESSURE CHECK; Tools Required: Fuel Pressure Gauge A WARNING A small amount of fuel may be released when con- necting the fuel pressure gauge. To prevent a fire or personal injury, puta shop towel near the fuel pres- sure port fitting before connecting the gauge. Clean any fuel that leaks out. Put the towel in approved container when connection is completed. 1. Clean any dirt or grease from the cap forthe pressure gauge por, then remove it. 2. Connect fuel pressure gauge. 3, Energize fuel pump. 4, Compare fuel pressure to specifications. 5, Disconnect power supply for the fuel pump. 6, Disconnect fuel pressure gage. 7. Replace the cap for the pressure gauge port. 8, Tum the ignition switch ON and OFF twice, waiting ten seconds between cycles, and check for fuel leaks. 7 ENGINE COOLANT ‘TEMPERATURE. ‘SENSOR ELECTRONIC CONTROL MODULE TO MAP SENSOR,

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