2000 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

6-2 Table of Contents
Balance Shaft Removal .............................. 6-183

Crankshaft Rear Oil Seal Removal ............. 6-184
Crankshaft Rear Oil Seal and Housing
Removal .................................................6-184
Oil Pan Removal ........................................6-185
Oil Pump Pipe and Screen Assembly
Removal .................................................6-185
Piston, Connecting Rod, and Bearing
Removal .................................................6-186
Crankshaft and Bearings Removal ............. 6-187
Engine Block Plug Removal ....................... 6-188
Engine Block Clean and Inspect ................ 6-189
Cylinder Boring and Honing ....................... 6-191
Crankshaft and Bearings Clean and
Inspect ...................................................6-192
Crankshaft Balancer Clean and Inspect ...... 6-194
Engine Flywheel Clean and Inspect
(Automatic Transmission) ........................ 6-195
(Manual Transmission) ............. , .............. 6-195
Piston and Connecting Rod Disass.emble ... 6-195
Piston, Connecting Rod, and Bearings
Clean and Inspect ................................... 6-196
Piston Selection ........... : ............................. 6-198
Piston and Connecting Rod Assemble ........ 6-200
Camshaft Bearing Removal ......................... 6-201
Camshaft and Bearings Clean and
Inspect .....................................................6-202
Camshaft Bearing Installation ..................... 6-203
Timing Chain and Sprockets Clean and
Inspect (VIN K) .... , .................................. 6-203
Valve Rocker Arm and Push Rods
Clean and Inspect .................................. 6-204
Valve Lifters and Guides Clean and
Inspect ........................ , .......................... 6-205
Cylinder Head Disassemble ....................... 6-205
Cylinder Head Clean and Inspect ............... 6-206
Valve Guide ReamingNalve and Seat
Grinding ................................................. :6-208
Cylinder Head Assemble ...................... , ..... 6-210
Oil Pump Clean and Inspect ...................... 6-211
Valve Rocker Arm Cover Clean
and Inspect ......................................... ; .. 6-213
Oil Pan Clean and Inspect ......................... 6-213
Intake Manifold Clean and Inspect
(Upper) ...................................................6-214
Intake Manifold Clean a.nd Inspect
(Lower) ...................................................6-214
Exhaust Manifold Clean and Inspect .......... 6-214
Water Pump Clean and Inspect ............. :, .. 6-215
Engine Front Cover Clean and Inspect ...... 6-215
Balance Shaft Clean and Inspect ............... 6-216
Balance Shaft Bearing and/or Bushing
Removal ..................................................6-216
Installation ..............................................6-216
Thread Repair ............................................6-218
Service Prior to Assembly .......................... 6-218
Engine Block Plug Installation ................... 6-219
Crankshaft and Bearings Installation ...........6-219
Engine
Installation ..............................................6-220
Installation .............................................. 6-222
Oil Pan Installation .....................................6-222
Camshaft Installation .............................. : ... 6-223
Balance Shaft Installation ........................... 6-223
Installation ..............................................6-225
Crankshaft Rear Oil Seal Installation .......... 6-226
Timing Chain and Sprockets
Installation (VIN K) ................................. 6-227
Oil Pump Cover and Gear Set
Installation ..............................................6-228
Oil Filter Adapter Installation ................. ; .... 6-228
Engine Front Cover Installation .................. 6-229
Crankshaft Front Oil Seal Installation ........ 6-230
Valve Lifter Installation ............................... 6-230
Cylinder Head Installation ........................... 6-231
Valve Rocker Arm and Push Rod
Installation ..............................................6-231
Valve Rocker Arm Cover Installation
(Left Side} .. , .......................................... '..6-232
(Right Side) .............................................6-232
Exhaust Manifold Installation (Left Side) , .... 6-232
Exhaust Manifold Installation
(Right Side) ............................................6-234
Intake Manifold Installation (Lower) ............6-234
Intake Manifold Installation (Upper) ............6-235
Water Pump Installation .............................6-237
Water Outlet Installation ............................. 6-238
Oil Level Indicator and Tube Installation ..... 6-238
Drive Belt Tensioner Installation ................. 6-238
Engine Flywheel Installation
(Automatic Transmission) ........................ 6:239
(Manual Transmission) ............................. 6~239
Crankshaft Balancer Installation .................. 6-239
Description and Operation .......................... 6-241
Engine Component Description ........... , ..... ,6-241
Drive Belt System Description .................... 6-241
Lubrication Description ............................... 6-242
Cleanliness and Care ................................. 6-243
Replacing Engine Gaskets ......................... 6-243
Use of RTV and Anaerobic Sealer .............6-243
Separating Parts ........................................6-244
Service Precautions ................................... 6-244
Installation Precautions ............................... 6-245
Tools and Equipment .................................6-245
Special Tools and Equipment .....................6-245
Engine Mechanical - 5.7L ....... ,...................6-249

Specifications ....................... :......................6-249
Fastener Tightening Specifications ............. 6-249
Engine Mechanical Specifications ............... 6-251
GM SPO Group Numbers .......................... 6-254
Engine
Sealers, Adhesives, and Lubricants ............ 6-256

Thread Repair Specifications ...................... 6-257
Diagnostic Information and Procedures ..... 6-270
Base Engine Misfire Diagnosis ................... 6-270
Engine Compression Test .......................... 6-272
Engine Noise Diagnosis ... ;.............. :, ......... 6-272
Valve Train Diagnosis ................................ 6-274
Oil Consumption Diagnosis .................... ,... 6-276
Oil Pressure Diagnosis and Testing ........... 6-276
. Oil Leak Diagnosis .....................................6-277
Symptoms. - Drive Belt ..... ;.........................6-278
Drive Belt Chirping Diagnosis ..................... 6-279
Drive Belt Squeal Diagnosis .......................6-281
Drive Belt Whine Diagnosis ........................ 6-283
Drive Belt Rumbling Diagnosis ............ ,...... 6-284
. Drive Belt Vibration Diagnosis .................... 6-285
Drive Belt Falls Off Diagnosis ..... ,.............. 6-287
Drive Belt Excessive Wear Diagnosis ......... 6-289
. Dri_ve Belt Tensioner Diagnosis .................. 6-289
Visual Identification ......................................6-290
Qisassembled Views .... ,.............................. 6-290
Repair Instructions ......................................6-296
Drive Belt Replacement - Accessory .......... 6-296
Drive Belt Replacement - A/C ..................... 6-298
Drive. Be.It Idler Pulley Replacement ,
Acce_ssory ........ : ......................................6-299
Drive Belt Idler Pulley
'
Replacement - A/C ................................. :6-299
Drive Belt Tensioner Replacement Accessory ... ,... : ............ ,.. : . ,..................... 6-300
Drive Belt Tensioner Replacement O A/C ..... 6-301
Engine Mount Inspection .................... :....... 6-302
Engine Support Fixture .................. ,........ :.. 6-302
Engine Mount Replacement (Left) ..............6-303
Engine Mount Replacement (Right) ............6-307
Intake Manifold Replace,ment ., ................... 6-311
Vapor Vent Pipe Replacement .................... 6-324
Engine Valley Cover Replacement ............. 6-325
Valve Rocker Arm Cover .
Replacement (Left) ................................. 6-326
Valve Rocker Arm Cover
Replacement (Right) ............................... 6-332

Replacement ... :, ......... ,............................ 6-334
Valve Stem Oil Seal a:nd Valve Spring
Replacement ............ , .......................,... ,.,.6-335
Oil Level Indicator and Tube
Replacement ...........................................6-339
Exhaust Manifold Replacement (Left) ......... 6-342
Exhaust Manifold Replacen:,ent (Right) ....... 6-345
Cylinder Head Replacement (Left) .............. 6-348
Cylinder Head Replacement (Right) ,......... :6-350
Valve Lifter Replacement :.......................... 6-352
Crankshaft Balancer Replacement .............. 6-353
Crankshaft Front Oil Seal Replacement ...... 6-356
Engine Front Cover Replacement ............... 6-357
Crankshaft Rear Oil Seal Replacement ...... 6-366
Engine Rear Cover Replacement ............... 6-367
Oil Pan Replacement .............. ,., ................ 6-370
Table of Contents
6-3
Oil Pump, Pump Screen and Deflector

Replacement ........................................... 6-379
Replacement ...........................................6-380
Camshaft Replacement ............................. ;6-382
Engine Flywheel Replacement ................ ;; .. 6-384
Engine Replacement .......................... , ....... 6-385
Engine Oil and Oil Filter Change ............... 6-416
Draining Fluids and Oil Filter Removal ....... 6-417
Crankshaft Balancer Removal .................... 6-419
Engine Flywheel Removal .......................... 6-420
Clutch Pilot Bearing Removal ..................... 6-421
Oil Level Indicator and Tube Removal ....... 6-422
Exhaust Manifold Removal (Left Side) ........ 6-422
Exhaust Manifold Removal (Right Side) ..... 6-424
Water Pump Removal ................................ 6-426
Throttle Body Removal.; ....... ,...................... 6-426
Fuel Rail and Injectors Removal ................ 6-427
Intake Manifold Removal ............................ 6-428
Vapor Vent Pipe Removal .......................... 6-431
Engine Valley Cover Removal .................... 6-432
Valve Rocker Arm Cover Removal
(Left Side) ................................. : ... , ........ 6-433
(Right Side) ........................................... :6-434
Removal .... :............................................6-436
Cylinder Head Removal (Left Side) ............ 6-437
Cylinder Head Removal (Right Side) .......... 6-438
Valve Lifter Removal ..................................6-438
Oil Filter, Adapter and Pan Cover
Removal .................................................6-439
Oil Pan Removal ................................ ,....... 6-440
Engine Front Cover Removal ..................... 6-442
Engine Rear Cover Removal ...................... 6-443
Removal .... ,.... ,.......................................6-444
Timing Chain and Sprockets Removal ........ 6-445
Camshaft Removal .....................................6-446
Removal .............................................. :.. 6-447
Crankshaft and Bearings Removal ............. 6-449
Engine Block Plug Removal ....................... 6-451
Engine Block Clean and Inspect ................ 6-455
Cylinder Boring and Honing ....................... 6-456
Inspect ............ '.......................................6-458
Crankshaft Balancer Clean .and Inspect ...... 6-467
Engine Flywheel Clean and Inspect ........... 6-468
Piston and Connecting Rod
Disassemble ..... : ...................................... 6-468
Clean and lnspect(Piston and Pin) ........ 6-470
Clean and Inspect
(Connecting Rod and Bearings) .............. 6-472
Clean and Inspect
(Measuring Piston Ring End Gap) .......... 6-475
. Piston Selection ......................................... 6-475
6-4
Table of Contents
Piston and Connecting Rod Assemble ........ 6-476

Camshaft Bearing Removal ........................ 6-479
Inspect ................................................... 6-481
Camshaft Bearing Installation ..................... 6-484
Inspect ...................................................6-485
Clean and Inspect .................................. 6-486
Inspect ..................................... , ...... , ...... 6-487
Cylinder Head Disassemble ....................... 6-489
Cylinder Head Clean and Inspect .............. ,6-491
Grinding ...... , ........................................... 6-493
Cylinder Head Assemble ............................ 6-497
Oil Pump Disassemble ............................... 6-501
Oil Pump Clean and Inspect ...................... 6-503
Oil Pump Assemble ................................... 6-505
Engine Front Cover Clean and Inspect ...... 6-508
Engine Rear Cover Clean and Inspect ....... 6-508
Engine Valley Cover Clean and Inspect ..... 6-508
Valve Rocker Arm Cover Clean and
Inspect ................................................... 6-509
Oil Pan Clean and Inspect ......................... 6-511
Intake Manifold Clean and Inspect ............. 6-514
Exhaust Manifold Clean and Inspect .......... 6-517
Vapor Vent Pipe Clean and Inspect ........... 6-519
Water Pump Clean and Inspect ................. 6-519
Thread Repair ............................................6-520
Service Prior to Assembly .......................... 6-528
Engine Block Plug Installation .................... 6-529
Crankshaft and Bearings Installation ........... 6-532
Installation .............................................. 6-535
Camshaft Installation .................................. 6-538
Timing Chain and Sprockets Installation ..... 6-539
Installation ..............................................6-541
Engine Rear Cover Installation ................... 6-542
Crankshaft Rear Oil Seal Installation .......... 6-545
Engine Front Cover Installation .................. 6-546
Crankshaft Front Oil Seal Installation ......... 6-548
Oil Pan Installation ..................................... 6-548
Oil Filter, Adapter, Pan Cover
Installation ..............................................6-551
Valve Lifter Installation ............................... 6-552
Cylinder Head Installation (Left Side) ......... 6-553
Cylinder Head Installation (Right Side) ....... 6-555
Installation ....................... , ...................... 6-557
(Left Side) .............................................. 6-559
(Right Side) ......................................... ,.. 6-560
Engine Valley Cover Installation ................. 6-562
Vapor Vent Pipe Installation ....................... 6-563
Intake Manifold Installation ......................... 6-564
Fuel Rail and Injectors Installation .............. 6-568
Engine
Throttle Body Installation ....................... ,, .... 6-568
Water Pump Installation ...................... ,...... 6-569
Exhaust Manifold Installation (Left Side) ..... 6-569
Exhaust Manifold Installation
(Right Side) .......................... ,.................6-571
Oil Level Indicator and Tube Installation ..... 6-574
Clutch Pilot Bearing Installation .................. 6-575
Engine Flywheel Installation ....................... 6-576
Crankshaft Balancer Installation .................. 6-577
Engine Set-Up and Testing ......................... 6-579
Description and Operation .......................... 6-580
Engine Component Description ................. ,6-580
Drive Belt System Description .................... 6-582
New Product Information ............................ 6-582
Engine Identification ............................. :..... 6-583
Lubrication .................................................6-584
Cleanliness and Care .................................6-585
Replacing Engine Gaskets ........ ,.......... : ..... 6-585
Use of RTV and Anaerobic Sealer .............6-586
Separating Parts ........................................ 6-587
Installation Precautions ............................... 6-587
Tools and Equipment .................................. 6-587
Special Tools and Equipment ........ , ............6-588
Engine Cooling .............................................6-594
Specifications ..............................................6-594
Fastener Tightening Specifications ...... , ...... 6-594
Engine Cooling System Specifications ........ 6-594
GM SPO Group Numbers ........................... 6-595
Schematic and Routing Diagrams ............ ,.6-595
Cooling System Schematic Icons ............... 6-595
Cooling Fan Schematics ............................ 6-596
Component Locator .....................................6-598
Cooling System Components ..................... 6-598
Cooling System Component Views ............. 6-599
Cooling System Connector End Views ....... 6-600
Engine Overheating .................................... 6-601
Loss of Coolant .........................................6-602
Thermostat Diagnosis ............. ,................... 6-604
Engine Fails To Reach Normal
Operating Temperature ........................ ,... 6-604
Coolant Concentration Testing ................ :'.,.6-604
Cooling System Leak Testing ..................... 6-606
Pressure Cap Testing ................. :............ :.6-608
Repair Instructions .......................................6-608
Draining and Filling Cooling
System (3.8 L) ........................................ 6-608
System (5.7 L) ........................................6-609
Flushing ..................................................... 6-609
Radiator Cleaning ...................................... 6-61 O
Coolant Recovery Reservoir
Replacement ...........................................661 O
Coolant Recovery Pipe Replacement ......... 6-613
Radiator Hose Replacement Inlet (3.8 L) ............................................ 6-614
Engine
Radiator Hos.e Replacement Inlet (5.7 L) ........ , ................................... 6-617

Radiator Hose Replacement Outlet (3.8 L) .................................. , ....... 6-620
Radi.ator Hose Replacement Outlet (5.7 L) ..........................................6-623
Throttle Body Heater Hose
Replacement - Inlet (5.7 L) ..................... 6-625
Throttle Body Heater Hose
Replacement " Outlet (5. 7 L) .................. 6-626
Cooling Fan Replacement - Electric ........... 6-627
Cooling Fan Motor Replacement Electric ......................... ,..........,............... 6-633
Cooling Fan Relay Replacement ................. 6-633
Thermostat Housing
Replacement (3.8 L) ................................ 6-634
. Thermostat Housing
Replacement (5.7 L) ............................... 6-637
Thermostat Replacement (3.8 L) ....... : ........ 6-638
thermostat Replacement (5.7 L) ................. 6-639
The.rmostat Bypass Pipes
Replacement (3;8 L) ............................... 6-639
Water Pump Replacement (3.8 L) .............. 6-640
Water Pump Replacement (5.7 L) .............. 6-642
Engine Coolant Temperature Sensor
Replacement(3.8 L) ., ............................. 6-650
Replacement (5.7 L) ............................... 6-651
Drain Cock Replacement ............................ 6-652
Fan Shroud Replacement ........................... 6-652
Radiator Replacement ................................6-654
Radiator Support Replacement ................... 6-658
Radiator Air Baffle Assemblies and
Deflectors (Lower) ..................................6-661
Radiator Air Baffle Assemblies and
Deflectors (Upper) ....................... , ..........6-662
Coolant Heater Replacement (3.8 L) .......... 6-663
Coolant Heater Replacement (5.7 L) ..........6-664
Coolant Heater Cord
Replacement (3:8 L) ...............................6-666
Coolant Heater Cord
Replacement (5.7 L) ............................... 6-667
Description and Operation ..........................6-669
Cooling System Description ........................ 6-669
Coolant Description ....................................6-669
Coolant Recovery System Description ........ 6-669
Throttle Body Coolant System
Description .............................................6-670
Coolant. Heater Description ......................... 6-670
. Radiator Assembly Description ............. ,..... 6-670
Pressure Cap Description ........................... 6-671
Engine Cooling Fan Description l::lectric ...................................................6-671
Cooling Fan Relay Description ................... 6-672
Water Pump Description ............................ 6-672
Thermostat Description .... ,.......... , ............... 6-672
Engine CoolantTemperature Sensor
Description .............................................6-672
Air Baffles and Seals Description ............... 6-673
Special Tools and Equipment ..................... 6-673
Table of Contents
6-5
Engine Electrical ..........................................6-674

Specifications ..............................................6-67 4
Fastener Tightening Specifications ............. 6-67 4
Battery Usage ............................................ 6-675
Battery Temperature vs Voltage Drop ........ 6-675
Starter Motor Usage ............................ .'...... 6-675
Generator Usage .......................................6~675
Spark Plug Usage ......................................6-675
Spark Plug Wire Resistance ....................... 6-676
Schematic and Routing Diagrams .............. 6-676
Engine Electrical Schematic Icons .............. 6-676
Starting and Charging Schematics .............. 6-677
Component Locator ..................................... 6-680
Engine Electrical Components .................... 6-680
Engine Electrical Component Views ........... 6-682
Engine Electrical Connector End Views ...... 6-686
A Diagnostic Starting Point - Engine
Electrical .................................................6-686
Symptoms - Engine Electrical ..................... 6-686
Starter Solenoid Does Not Click ................. 6-687
Starter Solenoid Clicks, Engine Does
Not Crank .............................. ,................ 6-689
Engine Cranks/Cranks Slowly, but Does
Not Start ................................................ :6-690
Starter Motor Noise Diagnosis .................... 6-691
Starter No Load Test ................................. 6-692
Battery Common Causes of Failure ............ 6-692
Battery Check ............................................ 6-693
Battery Terminal Check .............................. 6-694
Battery Hydrometer Displays Yellow Dot .... 6-695
Battery Not Operating Properly ... , ............... 6-696
Battery Hydrometer Displays Dark or
Yellow Dot ..............................................6-700
Battery Electrical Drain/Parasitic
Load Test ...............................................6-700
Generator Not Operating Properly .............. 6-704
Generator Assembly Check ........................ 6-706
. ..............
.
. 6-707
Spar k Pl ug V1suaID'1agnos1s
. ......
Spark Plug Wires Not Operating

Properly ..................................................6-709
Repair Instructions ......................................6- 71 o
Starter Motor Relay Replacement ............... 6-71 O
Starter Motor Replacement (3.8 L) ............. 6-711
Starter Motor Replacement (5. 7 L) .............. 6-713
Starter Pinion Clearance Check ................. 6-716
Starter Shield Replacement (3.8 L) ............ 6-717
Starter Shield Replacement (5. 7 L) ............ 6-717
Battery Charging ........................................6-718
Battery Charge Low or Completely
Discharged .............................................6-719
Jump Starting in Case of Emergency ......... 6-720
Battery Negative Cable Disconnect/
Connect Procedure .................................6-722
Battery Cable Replacement
(3.8 L Positive) .................................. ,: ... 6-723
(3.8 L Negative) .................................... :.6-727
6-6
Table of Contents

(5.7 L Positive) .......................................6-729
(5.7 L Negative) ..................................... 6-732
Battery Hold Down Retainer
Replacement ...........................................6-734
Battery Replacement ..................... , ........ :.. 6-735
Battery Tray Replacement .......................... 6-738
Underhood Fuse Block Replacement ...... ,... 6-741
Ground Strap Replacement .......... ::::.6-759
Generator Bracket Replacement (3.8 L) ... ,.6-761
Generator Bracket Replacement
(5.7 L Front) ........ , .................................. 6-762
.. .
(5.7 L Rear) ................................ , .... '. ..... 6~763
Generator Brace Replacement ................. : .. 6-763
Generator Replacement (3.8 L) ............ ,..... 6-764
Generator Replacement (5.7 L) ... ,,, ............ 6-766
Generator Splash Shield Replacement ........ 6-769
Spark Plug Wire Harness Replacement
(3.8 L Right Bank) ,................................. 6-770
(3.8 L Left Bank) ....................... , ............ 6-772
. Spark Plug Wire Harness
Replacement (5.7 L) ................................ 6-773

Spark Plug Replacement ........................ :: .. 6-774
Ignition Coil Replacement (3.8 L) ................ 6-775
Ignition Coil Replacement (5.7 L) ....... , ....... 6-776
Ignition Coil Module
,
Replacement (3.8 L) ... ,.............. :........ ,... 6~777
Description and Operation ................... ,...... 6-780
Starting System Description ...................... 6-780
Starting System Operation ......................... 6-780
Starting System Circuit Description ...... ,...... 6-780
Battery Description ..................................... 6-781
Battery Operation ................................ ;...... 6-781
Battery Tray and Hold-Down Retainer
Description .............. :..................... :., ... ,... 6-782
Charging System Description ................... ,.6-782
Charging System Operation .............. ,........ 6-783
Charging System Circuit Description ... :.:, .... 6-783
Ignition System Description (3.8 L) ............. 6-783
Ignition System Description (5.7 L) ...... ,..... 6-784
Ignition System Operation .......................... 6-784
Special Tools and Equipment ..................... 6-785
Engine Controls - 3.8L ................................6-786

Specifications ..............................................6-786
Temperature vs Resistance ....................... 6-786
Fastener Tightening Specifications ............. 6-786
Fuel System Specifications ...................... ,.. 6-787
Schematic and Routing Diagrams .............. 6, 788
Emission Hose Routing Diagram ................ 6-788
. Engine Controls Schematic Icons ............... 6-790
Engine Controls Schematics .. , .................... 6-791
Component Locator .................................,... 6-807
Engine Controls Components .................. :.. 60807
Engine Controls Component Views ............ 6-812
PCM Connector End Views ........... : ............ 6-814
Engine Controls Connector End Views ....... 6-818
Engine
Diagnostic Information and Procedures ..... 6826
A Diagnostic Starting Point ........................ 6826
A Powertrain On Board
Diagnostic (OBD) System Check ............. 6827

Scan Tool Data List .................. : ... : ... :........ 6828
Scan Tool Data Definitions ........ : ......... ,... : .. 6832
Diagnostic Trouble Code (OTC) Type '
Definitions ........................ : ...................... 6838
Diagnostic Trouble Code (OTC) List/Type ... 6839
Malfunction Indicator Lamp (MIL)
Inoperative .................. : .......................... :6-843

Data Link Connector Diagnosis ............... , .. 6845
Engine Cranks but Does Not Run ............... 6847
Fuel Pump Electrical Circuit Diagnosis ....... 13.854
Fuel System Diagnosis ........... : ........... ,, ..... 6856
DTC P0101 Mass Air Flow (MAF)
.
Sensor Performance :,,6857
Sensor Circuit Low Frequency ....... .'..........6861
.
' .
Sensor Circuit Higll Frequency ... ,......... ,.6864
DTC P0107 Manifold Absolute '
Pressure (MAP) Sensor Circuit Low
Voltage ................................................ ,.. 6-867
DTC P0108 Manifold Absolute
Pressure (MAP) Sensor Circuit High
Voltage ............... , .................. , ............. :.6870
DTC P0112 Intake Air Temperature (IAT)
Sensor Circuit Low Voltage ................. : ... 6872
DTC P0113 Intake Air
Temperature (IAT) Sensor Circuit
High Voltage ..........................................6-874
DTC P0117 Engine Coolant
Temperature (ECT) Sensor Circuit
Low Voltage ...........................................6877
High Voltage ......................... , .... :......... : .. 6-879
Temperature (ECT) Excessive . Time
to Closed Loop Fuel Control : .......... ._., .... 6882
OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 ............ , ......................... 6-885
DTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 ................ ,.................... 6887
DTC P0133 H02S Slow Response
Bank 1 Sensor 1 ......................................6890
DTC P0134 H02S Circuit Insufficient
Activity Bank 1 Sensor 1 ................. ,....... 6893
DTC P0135 H02S Heater Performance
Bank 1 Sensor 1 :: ... : ................'...... :6896
DTC P0137 H02S Circuit Low Voltage
Bank 1 Sensor 2 .............. ,., ...... :............. 6899
DTC P0138 H02S. Circuit High Voltage
Bank 1 Sensor 2 ................................... :.. 6902
Activity Bank 1 Sensor 2 ............ :.... :....... 6905
Bank 1 Sensor 2 .....................................6-908
DTC P0151 H02S Circuit Low Voltage
Bank 2 Sensor 1 .......................... ,.......... 6-911
Engine
DTC P0152 H02S Circuit High Voltage

Bank 2 Sensor 1 .....................................6-913
DTC P0153 H02S Slow Response
Bank 2 Sensor t .............................. ,...... 6-916
Activity Bank 2 Sensor 1 ......................... 6-919
Bank 2 Sensor 1 .............................. ;...... 6-922
DTC P0171 Fuel Trim System Lean
Bank 1 ............................................ ;....... 6-925
..DTC P0172 Fuel Trim System Rich
Bank 1 ...................................................6-928
DTC P0174 Fuel Trim System Lean
Bank 2 ........................... :........................6-931
DTC P0175 Fuel Trim System Rich
Bank 2 ...................................................6-934
DTC P0201 Injector 1 Control Circuit .......... 6-937
DTC P0202 Injector 2 Control Circuit ..........6-940
DTC P0230 Fuel Pump Relay Control
Circuit .....................................................6-955
DTC P0300 Engine Misfire Detected ..........6-958
DTC P0325 Knock Sensor (KS) Circuit ....... 6-963
DTC P0327 Knock Sensor (KS) Circuit
Bank 1 ....................................................6-965
Bank 2 ....................................................6-968
DTC P0336 Crankshaft Position (CKP)
Sensor Circuit .........................................6-971
DTC P0341 Camshaft Position (CMP)
Sensor Performance ............................... 6-974
DTC P0401 Exhaust Gas
.Recirculation (EGR) Flow Insufficient ....... 6-978
Recirculation (EGR) Solenoid Control
Circuit ....................................................6-980
Recirculation (EGR) Open Position
Performance ...........................................6-983
Recirculation (EGR) Position Sensor
Circuit Low Voltage ..................................6-986
DJ"C P0420 Cataly_st System Low _
Efficiency ................................................6-989
DTC P0440 Evaporative
Emission (EVAP) System ..... ,.................. 6-992
Emission (EVAP) System Small Leak
Detected .................................................6-997
Emission (EVAP) Purge Solenoid
Control Circuit .......................................6-1001
Emission (EVAP) Vent System
Performance .........................................6~ 1004
Emission (EVAP) Vent Solenoid
Control Circuit ...................................... :6-1007
Table of Contents
6-7
DTC P0452 Fuel Tank Pressure Sensor

Circuit Low Voltage ..................... ; ......... 6-1010
Circuit High Voltage .............................. 6-1013
DTC P0462 Fuel Level Sensor Circuit
Low Voltage ........................................ 6-1015
High Voltage ......................................... 6-1017
DTC P0480 Cooling Fan Relay 1
Control Circuit .......................................6-1020
DTC P0481 Cooling Fan Relay 2 and 3
Control Circuit .......................................6-1023
DTC P0500 Vehicle Speed
Sensor (VSS) Circuit ............................. 6-1026
DTC P0506 Idle Speed Low ..................... 6-1028
DTC P0507 Idle Speed High .................... 6-1030
DTC P0530 Air Conditioning (A/C)
Refrigerant Pressure Sensor Circuit ...... 6-1032
DTC P0560 System Voltage ..................... 6-1035
DTC P0567 Cruise Control Resume
Switch Circuit ................ : ....................... 6-1038
DTC P0568 Cruise Control Set Switch
Circuit ....................................................6-1040
DTC P0571 Cruise Control Brake
Switch Circuit ........................................ 6-1042
DTC P0601 Control Module Read Only
Memory (ROM) .....................................6-1046
DTC P0602 Control Module Not
Programmed ......................................... 6-1047
DTC P0604 Control Module Random
Access Memory (RAM) .......................... 6-1047
DTC P0606 Control Module Internal
Performance .........................................6-1048
DTC P0620 Generator Performance ......... 6-1049
DTC P0650 Malfunction Indicator
Lamp (MIL) Control Circuit .................... 6-1051
OTC P0704 Clutch Switch Circuit ............. 6-1054
Pressure (MAP) Sensor Circuit
Intermittent High Voltage ....................... 6-1057
Pressure (MAP) Sensor Circuit
Intermittent Low Voltage ...... : ................ 6-1059
OTC P1111 Intake Air
DTC P1112 Intake Air
Intermittent Low Voltage ....................... 6-1063
Intermittent. Low Voltage ....................... 6-1065
Intermittent High Voltage ........................ 6-1067
DTC P1120 Throttle Position (TP)
Sensor 1 Circuit .................................... 6-1069
DTC P1125 Accelerator Pedal
Position (APP) System .......................... 6-1073
DTC P1133 H02S Insufficient Switching
Bank 1 Sensor 1 ................................... 6-1074
6-8
Table of Contents
DTC P1134 H02S Transition Time
Ratio Bank 1 Sensor 1 ..... ; .................... 6-1077
OTC P1153 H02S Insufficient Switching
Bank 2 Sensor 1 ...................................6-1080
OTC P 1154 H02S Transition Time
Ratio Bank 2 Sensor 1 ......................... 6-1083
OTC P1220 Throttle .Position (TP)
Sensor 2 Circuit ....................................6-1086
OTC P1221 Throttle Position (TP)
Sensor 1- 2 Correlation ......................... 6-1090
OTC P1271 Accelerator Pedal
Position (APP) Sensor 1-2 Correlation ... 6-1093
Position (APP) Sensor 1 Circuit ............. 6-1096
Position (APP) SensorJ Performance ... 6-1098
OTC P 1280 Accelerator Pedal
Position (APP) Sensor 2 Performance ... 6-1102
Position (APP) Sensor 3 Performance .,.6-1106
OTC P1336 Crankshaft Position (CKP)
System Variation Not Learned ............... 6-1108
OTC P1351 Ignition Coil Control Circuit
High Voltage ......................... :............... 6-1109
OTC P1352 Ignition Bypass Circuit High
Voltage ......................................,........... 6-1111
OTC P1361 Ignition Control (IC) Circuit
Low Voltage .......................................... 6-1113
OTC P1362 Ignition Bypass Circuit Low
Voltage ................................................6-1116
DTC P1374 Crankshaft Position (CKP)
High to Low Resolution Frequency
Correlation ............................................6-1119
OTC P1380 Misfire Detected - Rough
Road Data Not Available ......... : ............ 6-1122
OTC P1381 Misfire Detected ~ No
Communication with Brake Control
Module ................................. ,............... 6-1123
OTC P1404 Exhaust Gas
Recirculation (EGR) Closed Position
Performance .................... , .................... 6-1125
Emission (EVAP) System Flow During
Non-Purge ............................................6~1128
OTC P1514 Throttle Body Performance .... 6-1132
OTC P1515 Control Module Throttle
Actuator Position Performance .:: ........... 6-1134
OTC P1516 Throttle Actuator
Control (TAC) Module Throttle
Actuator Position Performance .............. 6-1137
Control (TAC) Module Performance ....... 6-1140
Engine
Control (TAC) Module Serial Data
Circuit ............................ ;...................... 6-1141
DTC P1519 Throttle Actuator
Control (TAC) Module Internal Circuit .... 6-1144
DTC P1523 Throttle Closed Position
Performance ......................................... 6-1145
Clutch Relay Control Circuit ..... : ............ 6,1146
DTC P1571 Traction Control Torque
Request Circuit ................ ,.................... 6-1149
DTC P1574 Stoplamp Switch Circuit _
......... 6-1151
OTC P1586 Cruise Control Brake
Switch 2 Circuit .................................... 6-1154
OTC P1626 Theft Deterrent Fuel Enable
Signal Lost ...........................................6-1157
DTC P1629 Theft Deterrent Fuel Enable
Signal Not Received ............................ :6-1159
DTCP1635 5 Volt Reference 1 Circuit ,.... 6-1161
DTCP1639 5 Volt Reference 2 Circuit .... $1164
DTC P1689 Traction Control Delivered
Torque Output Circuit ................... ; ....... 6~1166
Symptoms ........ ;........................................6-1168
Hard Start ................................................6-1170
Surges/Chuggles ...................... , ............... 6~1172
Lack of Power, Sluggishness, or
Sponginess ........................ , ....... ,........... 6-1174
Detonation/Spark Knock ........................... 6-1176
Hesitation, Sag, stumble .... :... : .................. 6-1176
Cuts Out, Misses .................................... :.6-1178
Poor Fuel Economy ......... : ....................... 6-1180
Poor Fuel Fill Quality ..... , ... ;........... , ........ 6-1182
Rough, Unstable, or Incorrect Idle and
Stalling ..................... :................. ,......... 6-1183
Dieseling, Run-On .................................... 6-1185
Backfire ....................................................6-1185
Restricted Exhaust System Check ., .......... 6-1187
Powertrain Control Module Diagnosis ........ 6-1188
PCM Controlled A/C Circuit Diagnosis ...... 6-1189
MAP Sensor Circuit Diagnosis ..... , ............ 6-1194
Electric Cooling Fan Diagnosis
(Description) .............. ,.... , .................... 6-1197
(Functional Check) ... :....... ,...... ,............ 6-1198
(Table 1) ............................................... 6-1199

. (Table 2) ..............................................6-1200
.
(Table 3) ......................................... :.... 6-1202
Cruise Control Diagnosis ............................6-1205
Engine Oil Level Sensor/Switch
Diagnosis , .................................... ,,, ...... 6~1210
Fuel System Pressure Test ...................... 6-1212
Fuel Injector Balance Test ....................... 6-1217
Fuel Injector Balance Test with Tech 2 .... 6-1220
Fuel lnj Coil Test - ECT Between
10-35 Degrees C (5095 Degrees F) ..... 6-1222
Fuel lnj Coil Test - ECT Outside
10-35 Degrees C (50-95 Degrees F) ..... 6-1224
(_
.
Engine
Fuel Tank Leak Check ............................. 6-1226

Alcohol/Contaminants-in-Fuel Diagnosis .... 6-1226
Fuel Quality Diagnosis ................ ,............ 6-1226
EVAP Control System Diagnosis .............. 6-1228
Inspection/Maintenance Status Reset
Procedures ..... : .....................................6-1231
Service Bay Test ..................................... ,6-1231
Repair Instructions ....................................6-1232
PCM Replacement/Programming .............. 6-1232
CKP System Variation Learn Procedure ... 6-1234
ECT Sensor Replacement ........................6-1235
MAF Sensor Replacement ........................ 6-1236
MAP Sensor Replacement ....................... 6-1237
Heated Oxygen Sensor (H02S)
Replacement ........................ ,................ 6-1238
IAT Sensor Replacement ......................... 6-1240
Accelerator Controls Pedal
Replacement
(TAC Module and Bracket Assembly) .... 6-1241
Accelerator Controls Pedal Replacement
(Bracket and Rod Assembly) ................ 6-1244
Replacement (Pad, Spring and Pin) ...... 6-1245
Throttle Body Assembly Replacement ...... 6-1245
Throttle Body Air Inlet Screen
Replacement ......................................... 6-1246
Fuel Pressure Relief. Procedure ................ 6-1247
Quick Connect Fitting(s) Service
(Metal Collar) .................................. ,..... 6-1248
(Plastic Collar) ............................... : ...... 6-1250
In-Line Fuel Filter Replacement ................ 6-1253
Fuel Tank Draining Procedure ................. $1254
Fuel Tank Replacement ........................... 6-1255
Fuel Tank Pressure Sensor
Replacement .........................................6-1262
Fill Limiter Vent Valve Replacement ......... 6~1263
Filler Tube Replacement .......................... 6-1265
Fuel Sender Assembly Replacement ........ 6-1267
Fuel Tank Pump Module Replacement ..... 6-1268
Fuel Pump Strainer Replacement ............. 6-1270
Fuel Level Sensor Replacement ............... 6-1271
Fuel Hose/Pipes Replacement
(Chassis) ..............................................6-1272
(Engine Compartment) ...... :................... 6-1278
Fuel System Cleaning .............................. 6-1280
Fuel Rail Assembly Replacement ............. 6-1281
Fuel Pressure Regulator Replacement ...... 6-1283
Fuel Injector Replacement ........................ 6-1284
Fuel Pump Relay Replacement ................ 6-1285
EVAP Canister Purge Valve
Replacement ... : ..................................... 6-1285
EVAP Vent Valve Replacement ......... , ...... 6-1286
EV AP System Hoses/Pipes
Replacement ......................................... 6-1288
EV AP Canister Replacement .................... 6-1289
EVAP System Cleaning ............................ 6-1290
Ignition Control Module Replacement ....... 6-1292
Ignition Coil(s) Replacement ..................... 6-1293
Table of Contents
6-9
Crankshaft Position (CKP) Sensor

Replacement .........................................6-1293
Camshaft Position (CMP) Sensor
Replacement .........................................6-1294
Knock Sensor (KS) Replacement .............. 6-1295
EGR Valve Replacement .......................... 6-1296
Clutch Anticipate Switch Replacement ...... 6-1297
Crankcase Ventilation System
Inspection ............................................. 6-1298
Air Cleaner Element Replacement ............ 6-1298
Air Cleaner Intake Duct Replacement ....... 6-1299
Description and Operation ........................ 6-1300
Powertrain Control Module Description ..... 6-1300
Information Sensors/Switches
Description ...........................................6-1300
PCM Controlled Warning Lamps
Description ............................................6 1304
PCM Controlled Air Conditioning
Description ... ,... , ....... ,...... , ..... ,............... 6-1305
Engine Cooling Fan Description Electric ..................................................6-1305
PCM Controlled Generator Description ..... 6-1306
Fuel Supply Component Description ......... 6-1306
Fuel Metering Modes of Operation ........... 6-1309
Fuel Metering System Component
Description ............................................ 6-131 O
Short Term Fuel Trim Description ............. 6-1312
Long Term Fuel Trim Description ............. 6-1312
EVAP Control System Operation
Description ............................................ 6-1312
Electronic Ignition (El) System

Description ............................................6-1314
Knock Sensor (KS) System Description .... 6-1318
EGR System Descrip~ion ....... : .................. 6-1320
Throttle Actuator Control System
Description ............................................ 6-1321
Description ............................................6-1321
Air Intake System Description ................... 6-1322
Special Tools and Equipment ................... 6-1322
Engine Controls - 5.7L .............................. 6-1325
Specifications ............................................ 6-1325
Temperature vs Resistance .......... ,........... 6-1325
Fastener Tightening Specifications ............ 6-1325
Fuel System Specifications ....................... 6-1326
GM SPO Group Num.bers .... ,................... 6-1327
Schematic and Routing Diagrams ............ 6-1328
Emission Hose Routing Diagram ............... 6-1328
Engine Controls Schematic Icons ............. 6-1328
Engine Controls Schematics ...................... 6-1329
Component Locator .............. ;.................... 6-1348
Engine Controls. Components ................... 6-1348
Engine Controls Component Views ........... 6-1354
PCM Connector End Views ...................... 6-1368
Engine Controls Connector End Views ..... 6-1372
Diagnostic Information and Procedures ... 6-1380
A Diagnostic Starting Point ....................... 6-1380
A Powertrain On Board
Diagnostic (OBD) System Check ........... 6-1381
6-10
Table of Contents
Scan Tool Data List ................................. 6-1383

Scan Tool Data Definitions ................ ,...... 6-1386
Diagnostic Trouble Code (OTC) Type
Definitions .............................................6-1390
Diagnostic Trouble Code (OTC)
List/Type .... ,......... ,................................ 6-1391
Engine Cranks but Does Not Run ............ 6-1396
Ignition Relay Diagnosis ........... , ............... 601399
Fuel Pump Electrical Circuit Diagnosis ..... 6-1402
Fuel System Diagnosis ............................. 6-1406
OTC P0101 Mass Air Flow (MAF)
Sensor Performance ; ............................ 6-1411
Sensor Circuit Low Frequency .............. 6-1416
Sensor Circuit High Frequency .............. 6-1420
OTC P0107 Manifold Absolute
Pressure (MAP) Sensor Ci.rcuit Low
Voltage ................................................. 6-1423
OTC P0108 Manifold Absolute
Pressure (MAP) Sensor Circuit High
Voltage ....................... , ......................... 6-1427
Temperature (IAT) Sensor CircuiLLow
Voltage .................................................. 6-1431
OTC P0113 Intake Air.
High Voltage ......................................... 6-1434
OTC P0117 Engine Coolant
Low Voltage ......................................... 6-1438
High Voltage ......................................... 6-1441
OTC P0121 TP Sensor Circuit
Insufficient Activity .................................6-1445
Sensor Circuit Low Voltage ................... 6-1449
Sensor Circuit High Voltage .................. 6-1453
Temperature (ECT) Excessive Time
to Closed Loop Fuel Control ................. 6-1457
Bank 1 Sensor 1 ...................................6-1460
OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 ...................................6-.1463
OTC P0133 H02S Slow Response
Bank 1 Sensor 1 ...................................6-1467
OTC P0134 H02S Circuit Insufficient
Activity Bank 1 Sensor 1 ....................... 6-1471
OTC P0135 H02S Heater Performance
Bank 1 Sensor 1 ................................... 6-1475
Bank 1 Sensor 2 ................................... 6-1478
Bank 1 Sensor 2 ......... ;......................... 6-1482
Bank 1 Sensor 2 ...................................6- i 490
Engine
Bank 2 Sensor 1 ................................... 6~1493
Bank 2 Sensor 1 ................................... 6-1496
OTC P0153 H02S Slow Response
Bank 2 Sensor 1 ................................... 6-1500
Bank 2 Sensor 1 ................................... 6-1508
.Bank 2 Sensor 2 ................................... 6.~1511
Bank 2 Sensor 2 .................................... 6-1515
Bank 2 Sensor 2 ................................ ,.. 6-1523
OTC P0171 Fuel Trim System Lean
Bank 1 .................................................. 6-1526
OTC P0172 Fuel. Trim System Rich
Bank 1 .................................................:6-1529
OTC P0174 Fuel Trim System Lean
Bank 2 ....... ........................................... 6-1532
OTC P0175 Fuel Trim System Rich
Bank 2 .................................................. 6-1535
OTC P0200 Injector Control Circuit ........... 6-)538
OTC P0230 Fuel Pump Relay Control
Circuit ................................................... 6-1542
OTC P0300 Engine Misfire Detected ......... 6-1545
OTC P0325 Knock Sensor Module
Performance ......................................... 6-1550
OTC P0327 Knock Sensor (KS) 1
.Circuit ...................................................6-1552
OTC P0332 Knock Sensor (KS) 2
Circuit ...................................................6-1555
Sensor Circuit ...................................... 6-1558
Sensor Performance ....................... ,..... 6-1562
OTC P0341 Camshaft Position (CMP)
Sensor Performance ................. ;........... 6-1565
Sensor Circuit Low Voltage ............ ,.... :6-1568
. Sensor Circuit High Voltage ................ ,.6-1572
OTC P0351 Ignition Coil 1 Control
Circuit ...................................................61576
Circuit ...................................................6-1580
Circuit ....................................... ,........... 6-1584
Circuit ...................................................671588
Circuit ............................................ i ...... 6-1592
Circuit ................................................... 6-1596
Circuit ................................................... 6-1600
Engine

Circuit ............ ;......................................6-1604
Recirculation (EGR) Flow Insufficient ..... 6-1608
Recirculation (EGR) Open Position
Performance ......................................... 6-1610
Recirculation (EGR) Position Sensor
Circuit Low Voltage ............................... 6-1613
OTC P0410 Secondary Air
Injection (AIR) System ........................... 6-1617
DTC P0412 Secondary. Air
Injection (AIR) Solenoid. Control
Circuit ...................................................6-1623
DTC P0418 Secondary Air
Injection (AIR) Pump Relay Control
Circuit .................................................... 6-1626
DTC P0420 Catalyst System Low
Efficiency Bank 1 .............. ,................... 6-1629
DTC P0430 Catalyst System Low
Efficiency Bank 2.................................... 6-1631
Emission (EV AP) System ...................... 6-1633
Emission (EVAP) System Small. Leak
Detected ...............................................6-1639
Emission (EV AP) Purge Solenoid
Control Circuit ....................................... 6-1645
Emission (EVAP) Vent System
Performance .......................................... 6-1648
Emission (EVAP) Vent Solenoid
Control Circuit ....................................... 6-1652
Circuit Low Voltage ............................... 6-1655
Circuit High Voltage .............................. 6-1660
DTG P0461 Fuel Level Sensor
Performance .........................................6-1665
Low Voltage ......................................... 6-1668
High Voltage ......................................... 6-1671
DTC P0480 Cooling Fan Relay 1
Control Circuit ....................................... 6-1675
DTC P0481 Cooling Fan Relay 2 and 3
Control Circuit ....................................... 6-1678
DTC P0500 Vehicle Speed
Sensor (VSS) Circuit .............................. 6-1681
DTC P0506 Idle Speed Low ..................... 6-1683
DTC P0507 Idle Speed High .................... 6-1686
Refrigerant Pressure Sensor Circuit ...... 6-1689
DTC P0562 System Voltage Low ...... ;....... 6-1692
DTC P0563 System Voltage High ............. 6-1694
DTC P0601 Control Module Read Only
Memory (ROM) ..................................... 6-1696
Table of Contents
6-11
DTC P0602 Control Module Not

Programmed ......................................... 6-1697
OTC P0604 Control Module Random
Access Memory (RAM) .......................... 6-1698
DTC P0608 Vehicle Speed Output
Circuit ................................................... 6-1699
Clutch Relay Control Circuit .................. 6-1702
DTC P0650 Malfunction Indicator
Lamp (MIL) Control Circuit .................... 6-1705
DTC P0704 Clutch Switch Circuit ............. 6-1707
OTC P0801 Reverse Inhibit Solenoid
Control Circuit .........................................6-1710
OTC P0803 Skip Shift Solenoid Control
Circuit ................................................... 6-1713
Intermittent High Voltage ...... ,........ ,....... 6-1716
Temperature (IAT) Sensor. Circuit
Sensor Circuit Intermittent High
Voltage ......... ,................... , ................... 6-1728
Sensor Circuit Intermittent Low
Voltage .................................................6-1731
DTC P1133 H02S Insufficient Switching
Bank 1 Sensor 1 ................................... 6-1734
OTC P1134 H02S Transition Time
Ratio Bank 1 Sensor 1 .......................... 6-1737
OTC P1153 H02S Insufficient Switching
Bank 2 Sensor 1 ................................... 6-1740
OTC P1154 H02S Transition Time
Ratio Bank 2 Sensor 1 .......................... 6-17 43
Overtemperature - Protection Mode
Active .................................................... 6-17 46
System Variation Not Learned .............. 6-1747
OTC P1380 Misfire Detected - Rough
Road Data Not Available ...................... 6-1750
OTC P1381 Misfire Detected - No
Communication with Brake Control
Module ...................... : .......................... 6-1751
Recirculation (EGR) Closed Position
Performance .... :....................................6-1752
Injection (AIR) System Bank 1 ............... 6-1756
Injection (AIR) System Bank 2 ............... 6-1758
OTC P1441 Evaporative
Emission (EV AP) System Flow During
Non-Purge ............................................ 6-1760
6-12
Table of Contents
OTC P1539 Air Conditioning (A/C)

Clutch Feedback Circuit High Voltage ... 6-1762
Clutch Feedback Circuit Low Voltage .... 6-1764
OTC P1626 Theft Deterrent Fuel Enable
Signal Lost ........................................... 6-1767
OTC P1635 5 Volt Reference 1 Circuit ..... 6-1770
DTC P1637 Generator
L-Terminal Circuit ... ;................................ 6-1775
OTC P1639 5 Volt Reference 2 Circuit ..... 6-1778
Symptoms ................................................ 6-1781
Intermittent Conditions ........... , .................. 6-1782
Hard Start ................................................ 6-1783
Surges/Chuggles ...................................... 6-1784
Sponginess ........................... ; ............... 6 1786
Detonation/Spark Knock ........................... 6-1788
Hesitation, Sag, Stumble ......................... :6-1789
Cuts Out, Misses ..................................... 6-1790
Poor Fuel Economy ., ...... : ........................ 6-1791
Poor Fuel Fill Quality ... . .......................... 6-1794
Rough, Unstable, or Incorrect Idle and
Stalling .................. :.............................. 6-1795
Dieseling, Run-On ..... ,.............................. 6-1796
Backfire ....................................................6-1797
A/C Request Circuit Diagnosis .................. 6-1799
A/C Refrigerant Pressure Sensor Circuit
Diagnosis , ............................................. 6-1801
Electric Cooling Fan Diagnosis ................. 6-1803
PCM Controlled Generator Diagnosis .. ,.... 6-1810
PNP Switch Diagriosis ... ,................... , ...... 6-1812
Engine Oil Level Sensor/Switch
Diagnosis ..............................................6-1815
Fuel Injector Balance Test with .Tech 2 .... 6-1818
Fuel Injector Balance Test with Special
Tool .................................................; ..... 6-1821
Fuel lnj Coil Test - ECT Between
10-35 Degrees C (50-95 Degrees F) ..... 6-1824
Fuel lnj Coil Test - ECT Outside
10-35 Degrees C (50-95 Degrees F) .. , .. 6-1826
Fuel Tank Leak Check ., ................ , ......... :6-1828
Alcohol/Contaminantssin-Fuel Diagnosis .... 6-1828
Engine Speed Output Circuit Diagnosis .... 6-1829
Vehicle Speed Output Circuit Diagnosis ... 6-1831
Diagnosis .............................................. 6-1833
Procedures ........................................... 6-1836
Service Bay Test .......................................6-1836
Repair Instructions .......................... ,......... 6-1837
PCM Replacement/Programming .............. 6-1837
CKP System Variation Learn Procedure ... 6-1840
PCM Idle Learn Procedure ....................... 6-1840
ECT Sensor Replacement ........................ 6-1841
MAF Sensor Replacement ........................ 6-1842
MAP Sensor Replacement ....................... 6-1844
Heated Oxygen Sensor (H02S}
Replacement Bank 1 Sensor 1 .............. 6-1846
Engine
TP Sensor Replacement .......................... 6-1853
IAT Sensor Replacement ......................... 6-1853
IAC Valve Replacement ........................... 6-1854
Accelerator Controls Cable
Replacement .........................................6-1855
Replacement ......................................... 6-1857
Throttle Body Assembly Replacement ...... 6-1857
Throttle Body Cleaning Procedure ............ 6-1863
Fuel Pressure Relief Procedure ................ 6-1863
(Metal Collar) ..................... ,................. 6-1864
(Plastic Collar) ...................................... 6-1866
In-Line Fuel Filter Replacement ................ 6-1869
Fuel Tank Draining Procedure .................. 6-1870
Fuel Tank Replacement ........................... 6-1870
Replacement .........................................6-1878
Fuel Level Sensor Replacement ........ ,...... 6-1879
Fuel Strainer Replacement ............ , .......... 6-1880
Fuel Tank Pump Module Replacement ..... 6-1881
Fuel Sender Assembly Replacement ........ 6-1883
Fuel Pulse Dampener Replacement ......... 6-1886
(Chassis) ...............................................6-1886
(Engine Compartment) .......................... 6-1891
Fuel Hose/Pipes Assembly
Replacement (Rear) ............................... 6-1892
Fuel Filler Hose Replacement .................. 6-1893
Fuel System Cleaning .............................. 6-1895
Fuel Pressure Connection Valve
Replacement .... ,: ............................... 6-1896
Fuel Rail Assembly Replacement ............. 6-1897
Fuel Pressure Regulator Replacement ...... 6-1900
Fuel Injector Replacement ........................6-1901
EVAP Canister Purge Solenoid Valve
Replacement .........................................6-1903
EVAP Vent Valve Replacement ................ 6-1905
EVAP System Hoses/Pipes
Replacement .........................................6-1906
EVAP Canister Replacement .................... 6-1912
EVAP System Cleaning ............................ 6-1914
Replacement .........................................6-1915
Replacement .........................................6-1917
Knock Sensor (KS) Replacement .............. 6-1918
Secondary AIR Injection Pump
Replacement ......................................... 6-1919
AIR Check Valve/Pipe Replacement Bank 2 .................................................6-1921
AIR Check Valve/Pipe Replacement Bank 1 .................................................6-1922
Engine
Secondary Air Injection Pump Relay

Replacement ......................................... 6-1922
Secondary AIR Injection Shut Off Valve
Replacement ......................................... 6-1923
AIR Solenoid Valve Replacement ............. 6-1926
EGR Valve Replacement .......................... 6-1926
EGR Pipe Replacement ........................... 6-1927
EGR System Cleaning ............................. 6-1928
Air Cleaner Element Replacement ............ 6-1928
Air Cleaner Assembly Replacement .......... 6-1929
Engine Oil Life Monitor Reset
Procedure .............................................6-1931
Powertrain Control Module Description ..... 6-1932
Information Sensors/Switches
Description ............................................ 6-1938
Description ............................................6-1946
Engine Cooling Fan Description Electric .................................................6-1947
Fuel Supply Component Description ......... 6-1947
Fuel Metering Modes of Operation ........... 6-1951
Description ............................................6-1952
Short Term Fuel Trim Description ............. 6-1953
Long Term Fuel Trim Description ............. 6-1954
Speed Density System Description ........... 6-1954
EV AP Control System Operation
Description ............................................ 6-1954
Description ............................................6-1958
Knock Sensor (KS) System Description .... 6-1961
Secondary AIR Injection System
Description ............................................6-1962
EGR System Description .......................... 6-1963
Description ............................................ 6-1965
Air Intake System Description ................... 6-1967
Special Tools and Equipment ................... 6-1969
Table of Contents
6-13
Engine Exhaust ..........................................6-1972

Specifications ............................................ 6-1972
Fastener Tightening Specifications ............ 6-1972
GM SPO Group Numbers ........................ 6-1972
Exhaust System Clearances ..................... 6-1973
Diagnostic information and Procedures ... 6-1974
Vibration or Rattling ................................. 6-197 4
Restricted Exhaust ................................... 6-1974
Exhaust Noise ..........................................6-1975
Internal Muffler Rattles/Loss of Power ...... 6-1976
Exhaust Leakage ..................................... 6-1976
Repair Instructions .................................... 6-1976
Exhaust System Inspection ...................... 6-1976
Exhaust Crossover Pipe
Replacement (5.7 L) ............................. 6-1977
Catalytic Converter
Replacement (3.8 L) ............................. 6-1980
Oxidation Catalytic Converter
Replacement (5. 7 L Left) ...................... 6-1983
Replacement (5.7 L Right) .................... 6-1985
Muffler Replacement ................................. 6-1986
Converter Hanger Assembly
Replacement (3.8 L Automatic) ............. 6-1991
Replacement (3.8 L Manual) ................. 6-1992
Replacement (5.7 L) ............................. 6-1993
Exhaust Muffler Hangers
Replacement (3.8 L) ............................. 6-1995
Replacement (5.7 L) ............................. 6-1996
Engine Mount Heat Shield
Replacement (5.7 L) ............................. 6-1997
Converter Heat Shield Replacement ......... 6-1998
Exhaust Heat Shield Replacement ........... 6-1999
Exhaust Pipe and Muffler Heat Shields
Replacement .........................................6-2000
Exhaust System Description ..................... 6-2003
Catalytic Converter Description ................. 6-2003
Muffler Description ................................... 6-2003
Hangers Description ................................. 6-2003
Clamps Description .................................. 6-2003
6-14
Table of Contents
Engine
BLANK
Engine Mechanical - 3.8L
Engine
6-15

)
Specifications
Fastener Tightening Specifications
Specifications
Application
...
Metric
..
Accelerator Control Cable Bracket Bolt

Balance Shaft Gear Bolt
10N:m
891bin
22 + 70 N,m
16 +70 lb ft
Balance Shaft Retainer Bolt
30Nm
22 lb ft
Camshaft Position Sensor Bolt
10Nm
891bin
100-+ 90 N,m
74 + 90 lb ft
Camshaft Sprocket Bolt

Camshaft Thrust Plate Bolt
Connecting Rod Cap B.olt
...
Crankshaft Balancer Bolt
..
Crankshaft Main Bearing Cap Bolt

Crankshaft Main Bearing Cap Bolt (Side)
15 Nm
11. lb ft
27+ 50 Nm
20 + 50 lb ft
150 + 114 Nm
111+114lbft
40 .+ 110 Nm
30 + 11 0 lb ft
15 + 45 N,m
1t + 45 lb ft
30Nm
22 lb ft
15 + 50 Nm
11 + 50 lb ft
50 + 120 N,m
37 + 120 lb ft
50Nm
37 lb ft
50Nm
37 lb ft
29Nm
21 lb ft
29Nm
21 lb ft
EGR Valve Wiring Harness Heat Shield Bolt/Nut
10 Nm
891bin
Engine Block Coolant Drain Plug
.18 Nm
13 lb ft
Crankshaft Position Sensor Stud

Crankshaft Rear Oil Seal Housing Bolt
Cylinder Head Bolt
Drive Belt Tensioner Bracket Bolt
EGR Valve Adapter Nut
EGR Valve Nut
English
..
EGR Valve Outlet Pipe Bolt/Nut (Except Upper Intake Manifold)
25Nm
18 lb ft
Engine Flywheel Bolt (New)
15 + 50 N,m
11 + 50 lb ft
Engine Front Cover Bolt/Stud
20 + 40 N,m
15 + 40 lb ft
Engine Lift Bracket Bolt/Nut/Stud
30Nm
22 lb ft
Engine Mount Bracket Bolt
102 Nm
75 lb ft
Engine Mount Nut, Lower
43Nm
32 lb ft
Engine Mount Nut, Upper
47Nm
35 lb ft
Engine Mount Strut Bolt
48Nm
35 lb ft
Engine Mount Strut Bracket Bolt at Engine, Left
50Nm
37 lb ft
Engine Mount Strut Bracket Bolt at Engine, Right
50Nm
37 lb ft
Engine Mount Strut Bracket Bolt at Upper Radiator Support
28Nm
21 lb ft
Engine Mount Strut Nut
48Nm
35 lb ft
Engine Oil Gallery Plug
30Nm
22 lb ft
Exhaust Manifold Nut
23Nm
17 lb ft
Exhaust Manifold Bolt/Stud
23Nm
17 lb ft
9Nm
801bin
Fuel Injector Rail Stud
25Nm
18 lb ft
Fuel Injector Sight Shield Bracket Nut
30Nm
22 lb ft
Generator Brace Bracket Bolt
50Nm
37 lb ft
Fuel Injector Rail Assembly Nut
Heated Oxygen Sensor
42Nm
31 lb ft
ICM Bracket Stud
30Nm
22 lb ft
ICM Assembly Bolt/Nut
50Nm
37 lb ft
Lower Intake Manifold Bolt
15 Nm
11 lb ft
MAP Sensor Bracket Bolt
30Nm
22 lb ft
6-16
Engine Mechanical - 3.8l
Engine
Fastener Tightening Specifications (cont'd)

Specifications
Application
Metric
.English
MAP Sensor Bolt
3N-m
271bin
Oil Cooler Adapter Connector
50Nm
37 lb ft
15 N-m + 50
11 lb ft+ 50
19 N-m
14 lb ft
Oil Pan Bolt
14Nm
1251bin
Oil Pan Drain Plug
30N-m
22 lb ft
Oil Pump Cover Screw
11 Nm
981bin
Oil Pump Screen Bolt
15 N-m
11 lb ft
Power Brake Booster Heat Shield Nut
20Nm
15 lb ft
Oil Filter Adapter Bolt

Oil Level Indicator Tube Nut
Side Main Cap Bolt
15 + 45 Nm
11 + 45 lb ft
Starter Motor Heat Shield Bolt
30Nm
22 lb ft
Throttle Body Bolt/Nut
10Nm
891bin
Throttle Body Support Bolt
10Nm
891bin
Timing Chain Dampener Bolt
22Nm
.
Upper Intake Manifold Bolt

Valve Lifter Guide Retainer Bolt
Valve Rocker Arm Bolt
16 lb ft
Refer to Procedure
30Nm
22 lb ft
15 + 90 N-m
11 + 90 lb ft
10 Nm
891bin
Valve Rocker Arm Cover Bolt

Water Outlet Bolt
27Nm
20 lb ft
Water Pump Bolt
15 + 80 Nm
11 + .80 lb ft
13 Nm
1_16 lb in
Water Pump Pulley Bolt
Engine Mechanical Specifications

Specification
Application
Metric
English
General Data
Engine Type
90 V-6
Displacement
231 cu in
Liter (VIN)
3.8L (K)
RPO
L36
Bore
96.52 mm
Stroke
86.36 mm
Compression Ratio
3.8 in
3.4 in
9.4:1
Firing Order
1-6-5-4-3-2
Lubrication System
Oil Capacity with Oil Filter Change
4.25 L
4.5 qt
Oil Capacity without Oil Filter Change
3.75 L
4 qt
414 kPa
60 psi min
Oil Pressure @ Operating Temperature (1850 RPM) Using

10W-30 Oil.
Oil Filter Type
Throw Away Element and Can
Gear Pocket Depth
11.71-11.75 mm
Gear Pocket Diameter
89.10-89.20 mm
Inner Gear Tip Clearance
0.152 mm
0.461-0.4625 in
3.508~3.512 in
0.006 in
Outer Gear Diameter Clearance
0.203-0.381 mm
0.008-0.015 in
End Clearance
0.025-0.089 mm
0.001-0.0035 in
Valve-to~Bore Clearance
0.038-0.076 mm
0.0015-0.003 in
Engine
6-17
Engine Mechanical Specifications (cont'd)

Specification
Metric
Application
English
Type of Lubrication
Pressure
'
Main Bearings
Pressure
Connecting Rods
Splash
Piston Pins
Balance Shaft Bearing - Front
Splash
Balance Shaft Bushing - Rear
Pressure
Camshaft Bearings
Pressure
Splash
Timing Chain
Cvlinder Walls
Splash
.
'
-
Oil Pump Type
Ge rotor
Electrical
Oil Pressure Sending Unit

Oil Intake
"
Stationary
Full Flow
Oil Filter System

Cylinder Bore
96.5 mm
3.8 in
Out-Of-Round Maximum
0.0254 mm
0.001 in
Taper
0.0254 mm
0.001 in
Used Piston Clearance (41 mm from Top of Piston)
0.050-0.091 mm
0.0020-0.0036 in
New Piston Clearance (41 mm from Top of Piston)
0.010-0.051 mm
0.0004-0.0020 in
Diameter
Pis1on
Pis1on Ring Groove Depth

Top Compression
4.019-4.146 mm
0.158-0.163 in
2nd Compression
4.214-4.341 mm
0.01660.171 in
Oil Control
3.814-3.941 mm
0.150-0.155 in
0.25-0.46 mm
0.010-0.018 in
Piston Ring End Gap

Top Compression
2nd Compression
Oil Control
0.58-0.84 mm
0.023-0.033 in
0.254-0.762 mm
0.010-0.030 in
0.033-0.079 mm
0.0013-0.0031 in
0.033-0.079 mm
0.0013-0.0031 in
0.023-0.201 mm
0.0009-0.0079 in
Piston Ring Side Clearance

Top Compression
',
2nd Compression
Oil Control
Piston Ring Width
Top Compression
1.176-1.197 mm
0.0463-0.0471
2nd Compression
1.476-1.497 mm
0.0581-0.0589
Oil Control
1.854-2.007 mm
0.073-0.079
21.9950-22.0000 mm
0.8659-0.8661 in
Clearance in Piston
0.0020-0.0130 mm
o.,0000,8-0.00051, in
Fit-lnRod (Clearance)
0.0066-0.0217 _mm
0.0003-0.0009 in
Main Journal Diameter-All
63.470-63.495 mm
2.4988-2.4998 in ,,
Rod Journal Diameter-All
57.1170-57.1475 mm,
2.2487-2.2499 in
Main Journal Taper-Maximum
0.00889 mm
0.00035in
Rod Journal Taper-Maximum
0.00889 mm
0.00035 in
Main Journal Out-of-Round-Maximum
0.00635 mm
0.00025 in
Rod Journal Out-of-Round-Maximum
0.00508 mm
0.00020 in
Piston Pin
Diameter
Crankshaft
,,
6-18
Engine

Specification
Application
Metric
English
Main Bearing To Journal Clearance 1
0.0178-0.0406 mm
0.0007-0.0016 in
Main Bearing To Journal Clearance 2, 3, and 4
0.0229-0.0457 mm
0.0009-0.0018 in
Rod Bearing Clearance
0.0127-0.0660 mm
0.0005-0:0026 in
0.076-0.276 mm
0.003-0.011 in;
Crankshaft End Play

Connecting Rod
Rod Side Clearance
Connecting Rod Large End Bore ID
0.102-0.508 mm
0;004-0.0200 in
60.295-60.312 mm
2.37378-2.3745 in
..
Camshaft
Journal Diameter
47.655-46.858 mm
1.8462-1.. 8448 in
Bearing Inside Diameter 1 and 4
46.970-46.934 mm
1.8428-1.8492 in -. .
Bearing Inside Diameter 2 and 3
46.977-46.942 mm
1.8481-1.8495 in
0.041-0.119 mm
0.0016-0.0047 in
Bearing-to-Journal Clearance
Intake Maximum Lobe Lift
6.55 mm
Exhaust Maximum Lobe Lift
6.48 mm
. 0.258 in
0.255 in.
Balance Shaft
End Play
Rear Journal Diameter
Radial Play-Front, Bearing Clearance
Rear Bearing To Journal Clearance
Drive Gear Lash
0.0-0.171 mm
0.0-0.0067 in
1.4994-1 .5002 in, .
38.085-38.105 mm
0.0-0.026 mm
0.0-0.0010 in
0.0127-0.109 mm
0.0005-0.0043 in
0.050-0.125 mm
0.002-0.0049 in
51.973-51.999 mm
2.0462-2.0472 in
Bearing Bore Diameter-Rear, In Block
47.584-47.612 mm
1.8735-1.8745 in
Bearing Inside Diameter-Rear
38.118-38.194 mm
1.5007-1.5037ih
Bearing Bore Diameter-Front
Valve System
Lifter
Hydraulic
Rocker Arm Ratio
1.6:1
Face Angle
45
Seat Angle
45
Minimum Margin
Seat Runout-Maximum
Seat Width-Intake
Seat Width-Exhaust
0.635 mm
..
0.025 in
0.050 mm
0.002 in
1.53-2.03 mm
0.060~0.080 in
2.29-2.79 mm
0.090-0.110.in.
Stem Height-All
49.15-50.17 mm
1.935-1.975 in
Stem Clearance-All
0.038-0.089 mm
0.0015-0.0032 in
49.78 mm
1.960 in
Valve Spring
Free Length
Load-Closed
Load-Open
Installed Height
334N@
. -75 lb@ 1.72 in
43.69 mm
1014 N @ 32.4 mm
42.93-44.45 mm
228 lb @ 1.277 in
1.690-1 .720 in
Approximate Number of Active Coils
4.48
Approximate Number of Total Coils
6.60
Flywheel
Runout~Maximum
0.38 mm
0.015 in
Engine

GM SPO Group Numbers
Application
GM SPO Group Number
Automatic Transmission Engine Flywheel
0.666
Camshaft Bearing
0.539
Camshaft Timing Chain
0.724
Connecting Rod
0.603
Connecting Rod Bearing Kit
0.616
Crankshaft Balancer
0.659
Crankshaft Bearing Kit
0.096
Cylinder Head
0.269
Cylinder Head Gasket
N.S.
Engine Block.
N.S.
Engine Camshaft
0.519
Engine Cooling Manifold
1.097
Engine Cooling Manifold Gasket
1.097
Engine Cooling Thermostat
1.246
Engine Crankshaft
0.646
0.206
. Engine Front Cover

Engine Front Cover Gasket
..
3.680
EGR Valve Gasket
0.207
Exhaust Manifold
3.601
Exhaust Manifold Gasket
3.270
Intake Manifold
3.265
Intake Manifold Gasket
N.S.
Oil Filter
1.836
Oil Filter Adapter
1.840
Oil Filter Adapter Gasket
1.840
Oil Level Indicator
1.516
Oil Level Indicator Tube
1.516
Oil Pan Kit with Gasket
1.429
Oil Pan Reinforcement
1.426
Oil Pump Screen
1.656
Oil Pump Screen Gasket
1.657
Oil Pump Cover
1.723
Piston with Pin
0.629
Piston with Ring Kit
0.643
Spark Plug
2.270
Throttle Body
3.335
Throttle Body Gasket
3.336
Valve Lifter
0.459
Valve Lifter Guide
0.439
Valve Pushrod
0.426
0.386
Valve Rocker Arm Cover Gasket
0.423
Valve Spring
0.303
Water Pump Gasket
1.079
Water Pump Kit
1.069
Water Pump with Gasket
1.069
'
6-19
6-20
Engine,

Sealers, Adhesives, and lubricants
Application
Type of Material
GM Part Number
Accelerator Control Cable Bracket Bolt Threads
Thread lock
12345382
Coolant Temperature Sensor Threads
Sealant
Crankshaft Position Sensor Bolt/Stud Threads
Thread lock
12346004 .
12345382
Crankshaft Side Main Bolt Threads
Thread lock
Engine Block Coolant Drain Plug Threads
Sealant
12346004
Engine Block Oil Gallery Plug Threads
Sealant
12346004
Engine Front Cover Bolt Threads
Sealant
, 12346004
Engine Oil
Oil-10W-30
1234561.6
12345493
Engine Oil Supplement
Lubricant
.1052368
Exhaust Manifold Bolt and Stud Threads
Thread lock
12345493
Intake Manifold Bolt Threads (Lower)
Thread lock
12345382.
Intake Manifold Coolant Pipe
Sealant
12345493
Intake Manifold to Engine Block Mating Surface
Sealant
12346286
Knock Sensor Threads
Sealant
12346004
Oil Filter Bypass Hole Plug Threads
Sealant
12346004
Oil Pan Bolt Threads
Threadlock
12345382
Oil Pressure Switch Threads
Sealant
12346004
Piston and Piston Pin
Oil-10W-30
12345616
Rear Crankshaft Main Bearing Cap
Sealant
1052942
Valve Lifter and Camshaft Prelube
Lubricant
12345501
Valve Rocker Arm Cover Bolt Threads
Thread lock
12345382
Valve Rocker Arm Bolt Threads
Thread lock
12345493
'
Engine
6-21
Diagnostic Information and Procedures

Base Engine Misfire Diagnosis
Action
Checks
Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft,
worn or damaged bearings or bent valve pushrod.
This tap le ll'lill not isolate. a crossed fuel injector wire, faulty fuel injector or any other driveability component failure that may
cause a misfire.
The Powertrain On-Board Diagnostic ~ystem checks must be performed first.

. When using this. table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary
1. Perform OTC P0300 before proceeding with Base Engine Misfire Diagnosis
information .
2.
3.
4.
5.
6.
7.
Intake Manifold Leaks
. OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
Perform a visual inspection of the following:
A loose or improperly installed engine flywheel or crankshaft balancer
Worn, damaged or misaligned accessory drive system components
Listen to the engine for any abnormal internal engine noises.
Inspect the engine for acceptable oil pressure.
Verify if the engine has excessive oil consumption.
Verify if the engine has excessive coolant consumption.
Perform a compression test on the engine.
An intake manifold that has a vacuum leak may cause a misfire.

Inspect for t.he following:
Improperly installed or damaged vacuum hoses
Faulty .or improperly installed lower intake manifold and/or gaskets
c.racked or damaged lower intake manifold
Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be torn or damaged
Improperly installed throttle body or damaged gasket
Warped intake manifold
Warped or damaged cylinder head sealing surface
Coolant Consumption
Coolant consumption may or may not cause the engine to overheat.

Inspect for the following:
External coolant leaks
Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block
6-22
Engine Mechanical - 3~8L
Engine
Base Engine Misfire Diagnosis (cont'd)

Checks
Oil Consumption
Action
O.il consumption may or may not cause the engine to misfire.
1.. Remove the spark plugs and inspect for an oil fouled spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve guides, inspect the
following:
O Worn, brittle, or improperly installed valve stem oil seals
Worn valve guides
Worn valve stems
Worn or burnt valves or valve seats
4.' If the compr,ession test indicates worn or damaged piston rings, inspect the
following:
0
.Broken or improperly seated piston rings
Excessive piston ring end gap
Excessive cylinder bore wear or taper
Cylinder damage
Piston damage
Abnormal Internal Engine Noises
1. Start the engine and deter.mine i.f the noise is timed to the engine camshaft
speed or the crankshaft speed.
2. Using a timing light, two knocks per flash is the crankshaft speed and
one knock per flash is the engine camshaft speed.
3. If the noise is timed to the engine camshaft speed, inspect the following:
Missing or loose valve train components
Worn or loose valve. r9cker arms
Worn or bent valve pushrods
.Faulty valve springs
Bent or burnt valves
Worn engine camshaft lobes
Worn or damaged camshaft timing chain and/or sprockets
Important: A slight COLD kno'ck or piston slapping noise could be considered
normal if not present after the engine has reached normal operating temperatures .
.4. If the knock is timed to the crankshaft speed, inspect the following:
Worn crankshaft or connecting rod bearings
Piston or cylinder damage
Worn piston or piston pin
Faulty connecting rod
Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise
1. Inspect for a worn or improperly installed camshaft timing chain and/or

sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.
3. Inspect for the following:
Loose valve rocker arm studs
Bent valve push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Worn engine camshaft lobes
Engine
Engine Compression Test
1. Charge the battery if the battery is not fully
charged.
2. Disable the ignition system.
3 . .Disable the fuel injection system.
4. Remove all the spark plugs.
5. Turn the ignition to the ON position.
6 .. Depress the acceierator pedal to position the
throttle plate 'wide open.
7. Start with the compression gauge at zero and
crank the engine through four compression
strokes (four puffs).
8. Check the compression for each cylinder. Record

the readings.
9. if a cylinder has low compression, inject
approximately 15 ml (one tp.blespoon) of engine
oil into the combustion chamber through the spark
plug hole. Recheck the compression and record
the reading.
10. The minimum compression in any one cylinder
should not be less than 70 percent of the highest
cylinder. No cylinder should r.ead less than.
690 kPa (100 psi). For example, if the highest
pressure in any one cylinder is
1 035 kPa (150 psi), the lowest allowable pressure
any other cylinder would be 725 kPa (105 psi).
(1 035 x 70% = 725) (150x 70% = 105).
Normal :_ Compression builds up quickly and
evenly to the' specified compression for each
cylinder.
Piston Rings Leaking -,,-- Compression is low
on the first strpke. Then comP,ression build~
1,1p with the following strokes but dol3s not
reach. normal. Compression improves
considerably when you add oiL
Valves Leaking - Compression is low on the .

first stroke. Compression usually does not
build up on the following strokes. Compression
does not improve much when you add oil.
If two adjacent cylinders have lower than
normal compression, and injecting oil intothe
cylinders does not increase the compression,
the cause may be a head gasket leaking
between the cylinders.
for
Eng1ine Noise Diagnosis (Base Engine)

Notice: Some engine noise is.Characteristic to
the design. Compare the sounds in other engines in
order to make sure that you are not trying to correct a
normal condition.
There are four steps to diagnosing engine noise.
They include:
The type of noise

Under which operating conditions it exists
At what rate in the engine
At what location in the engine
6-23
Compare the sounds in other engines to ensure

the noise is not a normal condition.
Remember, engine noise is generally
synchronized to either engine speed (caused by
the crankshaft, connecting rods or pistons) or .
one-half engine speed (valve train noise). Try to
determine the rate at which the noise is occurring.
Main Bearing Noise

Damaged or worn main bearing noise is revealed
by dull thuds or knocks which happen on every
engine revolution. This noise is loudest when the
engine is under heavy load.
Excessive crankshaft end play is indicated by an
intermittent rap or knock sharper than a worn
main bearing.
The following are causes of main bearing noise:
- Low oil pump pressure
- Thin, diluted, or dirty oil and/or filter
- Excessive main bearing clearance
- Excessive crankshaft end play
- Out-of-round crankshaft journals
- Loose c.rankshaft pulley
- Loose flywheel or torque converter
Loose main bearing cap
- Belt pilling
Connecting Rod Bearing Noise

A damaged or worn connecting rod bearing will
produce a knock under all speeds. During the early
stages of wear, connecting rod noise may be confused
with piston slap or loose piston pins. Connecting rod
knock noise increases in volume with engine
speed and is at its lou.dest on deceleration.
The following are causes of connecting rod
bearing noise:
~ Excessive bearing clearance
Worn crankshaft connecting rod journal
Thin, diluted, or dirty oil and/or filter
Low oil pressure
Crankshaft connecting rod journals out-of-round
Misaligned connecting rod
Connecting rod bolts not properly torqued
The wrong bearing inserts or misaligned
bearing half
6-24
Engine
Timing Gear or Chain and Sprocket Noise
Rattle (Balance Shatt)
Engines designed with timing gears, or tho.se equipped

with a timing chain and sprockets, can produce
different noise. The most common noise is a high
frequency, light-knocking sound. This sound will
generally be the same in intensity whether the engine
is idling, operating at high speeds, or under load:
The following are causes of timing gear or chain and
sprocket noise:
Worn timing chain and/or gears
Misaligned gears
Excessive backlash
A damaged tooth
Gear or sprocket loose on the shaft
Too much end play in the camshaft or crankshaft
Loose or improperly seated camshaft timing gears are
usually loudest when warm. They are speed sensitive
only. They are not load sensitive.
Cam gear noise will usually be evident at a warm idle
in neutral and sounds much like a loose timing chain.
Balance shaft rattle sounds like a tinny, cha~ery rattle

or a knocking noise that seems to come from the
top rear of the engine. This noise is most pronounced
when the engine is hot, and is not affected by
engine load. An example would be dirt lodged in the
root between two gear teeth. Each time the root
between two balance shaft gear teeth meshes with a
cam gear.tooth, the balance shaft is momenJarily
forced upward. This pivots the shaft through the front
bearing, causing a downward force on the rear
bearing that eventually wears the rear bearirig; causing
a rattle. The following are other factors that contribute
to balance shaft bearing rattle:
A tight link on the timing chain

Damaged, broken, or dirty teeth on the balance
'
shaft gears
Aworn timing chain tensioner
Misaligned rear balance shaft bushing
Piston Noise
the torque converter clutch apply surface and

cause a shudder condition.
A loose or cracked flywheel will produce an irregular
thud or.click. To test for a loose.or cracked_flywheel,
operate the vehicle at approximately 32 km/h (20 mph)
and shut off the engine. If a thud is heard, the
flywheel may be loose or damaged. This type of thud
is loudest on deceleration. Loose torque
converter-to-flywheel or flywheel-to~crankshaft bolts
will resemble a bearing knock. This concjitiori produces
several raps during quick acceleration on a
free-running engine. Depending on the idle
smoothness, when the transaxle is in gear, the noise
may or may not appear. Check the torque
converter-to-flywheel and the flywheeHo-crankshaft
bolts before attempting to investigate any
bearing-related knock.
Piston pin, piston, and connecting rod noise are hard

to separate. A loose piston pin, for example, causes
a sharp double knock usually heard when the engine is
idling, or during sudden acceleration then deceleration
of the engine. A piston pin that has been improperly
fitted will emit a light ticking noise that is more
noticeable with no load on the engine. Excessive
piston-to-cylinder bore clearance.will caus~ a piston
slap noise. The noise is similar to a metallic knock, as
if the piston were slapping.the cyiinder waH during
its stroke. As with most engine noise, understanding
the cause of the noise will help you imagirie what
the noise sounds like. An indication of pistqn slap is a
decrease in noise as the engine warms up. When
the engine is cold, the piston-to-bore clearance
is greater and piston slap will be louder. The following
are causes of piston noise:
Worn or loose piston pin orbushing
Improper pin fit
Excessive piston~to-cylinder .bore clearance
Lack of lubrication
Carbon deposits on top of the piston striking the
cylinder head
Worn or broken piston ring land
Broken or cracked piston
Misaligned connecting rods
Worn or damaged rings
Excessive ring land clearance
Insufficient ring-end gap clearance
Piston 180 degrees out of position
Incorrect skirt profiles
Flywheel Noise
Notice: 9onverter bolts that are too. long may dimple
Knocks Cold and Continues for 2 to 3 Minutes

Cold engine knock usually disappears when the
specific cyHnder secondary ignition circuit. is grounded
out. Cold engine piston knock which disappears in
1.5 minutes sho.uld be considered acceptable.
Engine flywheel contacting the transmission
converter cover - reposition the transmission
converter cover.
Loose or broken crankshaft balancer or the drive
pulleys - tighten or replace the crankshaft
balancer or the drive pulleys as necessary.
Excessive piston-to-bore clearance - replace the
piston.
Bent connecting rod -
replace the connecting rod.
Engine
Knocks at Idle Hot
Inspect the drive belt for wear. Check the tension
and/or replace as necessary.
Inspect the A/C compressor or generator bearing.
Replace or repair as necessary.
Inspect the valve train. Replace the parts as
necessary.
Inspect for improper oil viscosity. Install the proper
viscosity oil for the expected temperature. Refer
to Maintenance and Lubrication for the engine
oi1I specifications,
Inspect for excessive piston pin clearance.
Replace the piston and the pin as necessary.
" Inspect the connecting rod alignment. Check and
replace the connecting rods as necessary.
Inspect for insufficient piston-to-bore clearance.
Hone the bore and fit the new piston.
Inspect the crankshaft balancer for. looseness.
Tighten and/or replace the worn parts.
Ensure that the piston pin is not offset to .the
wrong side. Properly install the pistdn.
Ensure that the camshaft drive gear backlash is
not excessive. The knock will also be heard on
a cold engine.
Knocks on Start-Up but Only Lasts a

Few Seconds
The following conditio.ns may produce engine knocks

on initial start-up, but only last a few seconds:
Improper oil viscosity
- Install the proper oil viscosity for the
expected temperatur~s.
- Refer to Maintenance and Lubrication.
Lifter bleed down - clean, test, and replace the
lifter as necessary.
- When the engine is off, some valves will be
open. Spring pressure against the lifters will
tend to bleed th~ liftElr dolJYn.Hepair the
lifter only if the problem is consistent.
- Engines operated for only short periods
between start-ups may have lifter noise that
lasts for a few seconds. This is a normal
condition.
Excessive crankshaft end play - replace the
crankshaft thrust bearing.
" Excessive front main bearing clearance - rep.lace
the worn parts.
Timing chain tensioner malfunction - clean,

inspect and, replace the timing chain tensioner, if
required.
Heavy Knock Hot in Heavy Load Condition

Broken crankshaft balancer or pulley hub replace the parts as necessary.
loose torque converter bolts - tighten the bolts.
The drive belt is too tight or nicked - replace
the drive belt as necessary.
The exhaust system is grounded - reposition the
exhaust system components as necessary.
6-25
The flywheel is cracked - replace the flywheel.

O Excessive crankshaft main bearing clearance
- replace the crankshaft main bearings as
necessary.
Excessive connecting rod bearing clearance replace the connecting rod bearings as
necessary.
light Knock Hot in light Load Condition

Light knock hot may be caused by one or. more of the
following conditions:
Loose torque converter bolts - tighten the torque
converter bolts.
Leak at the exhaust manifold - tighten the bolts
and replace the exhaust manifold gasket if
necessary.
Excessive connecting rod bearing clearance replace the connecting rod bearings as
necessary.
Detonation or spark knock, refer to Engine
Controls.
Engine Noise Diagnosis (Valve Train)

A light tapping at one-half engine speed, or any
varying frequency, can indicate a valve train problem.
These tapping noises increase with the engine
speed. Warm up the engine before attempting to judge
the valve train noise. This will bring all of the engine
components to a normal state of expansion. Run
the engine at various speeds and listen for engine
noise with the hood closed.
Caution: The following procedure is not

recommended. on engines with stainless steel
exhaust manifolds because manifold temperature
will exceed the flash point of the oil causing a
fire with possible personal injury.
If the valve mechanism is abnormally noisy, remove
the valve rocker arm covers and use a stethoscope to
determine which valve train components are causing
the noise. The causes of the valve noise include
the following conditions:
Broken or.weak valve springs
Sticking or warped valves
Bent push rods
Dirty, stuck, or worn valve lifters
Damaged or improperly machined camshaft lobes
Insufficient or poor oil supply to the valve train
(low oil pressure)
Excessive valve stem-to-guide clearance
Worn valve guides
Worn push rods
Worn valve rocker arms
Broken valve rocker arm bolt
Loose or worn valve rocker arm attachments
Missing or improperly positioned lifter guides (roller
lifter engines)
6-26
Engine Mechanical - 3.SL
Engine
Momentary Noise on Engine Startup

Value(s)
Action
Step
Yes
No
Repair as
required
No correction is
needed
Yes
No
DEFINITION: Momentary noise when the engine is started, usually cold

This condition is normal. Oil drains from the valve lifters
which hold the valves open when the engine is not
running. The valve lifter needs a few seconds to fill with oil
after you start the engine.
Does the noise.continue after a few seconds?
Intermittent Noise on Idle Only

Action
Step
Value(s)
DEFINITION: Intermittent noise on idle that disappears when engine speed increases
.
1. Disassemble the valve lifters.

2. Check the valve lifters for any dirt. Check the valve
lifters for a pitted or damaged check ball.
Are the valve lifters dirty or damaged?
ReplaCe the
valve lifter
System OK
Noise at Idle
Step
Action
Value(s)
Yes
No
Replace the
faulty.lifter
No correction is
needed
DEFINITION: Noise at idle or with hot oil that quiets at higher engine speeds or with .cold oil
1
Inspect the lifter for a high leakdown rate.

Does the lifter have a high leakdown rate?
Noise at High Vehicle Speeds

Step
Action
DEFINITION: Noise at.high RPM only
Value(s)
No
Yes
Check for a high engine oil level. An oil level above the
FULL mark allows the crankshaft counterweights to churn
the oil into a foam. When the foam is pumped into the
lifters, the lifters become noisy since a solid column of oil
ensures the proper operation.
Is th.e oil level too high?
Drain the oil to

the proper level
Go to Step 2
Add oil a.s

required
Go to Step 3
Check for a low engine oil level. An oi.1 level below the
ADD mark allows the oil pump to pump .air a.t high speeds.
This causes noisy valve lifters.
Is the oil level too low?
Check the oil pan.

Is the oil pan bent against the oil pump pickup?
Repair as
required
Go to Step 4
Check the oil pump screen.

Is the oil pump screen bent or loose?
Repair as
required
System OK
Engine Mechanical -. 3.8L
Engine
6-27
Noise at Idle, louder at High Engine Speed

Value(s)
Action
Step
Yes
No
Repair as
necessary
Go to Step 2
Replace the
valve spring
System OK
Yes
No
DEFINITION: Noise at idle that gets louder as the engine speed increases, up to 1500 RPM
This noise is not connected with lifter malfunction. The

noise becomes noticeable at 10 to 15 mph LOW range, or
30 to 35 mph DRIVE range. The noise is described as a
ticking sound. At idle, the sound may be entirely gone or
appear as a light ticking noise in one or more of the
valves. This noise is caused by one or more of the
following:
.A badly worn or sclJffed valve tip and rocker arm pad
Excessive valve stem-to-guide dearance
Excessive valve seat runout
An off-square valve spring
Excessive valve face runout
Are any components damaged or worn excessively?
The noise may be an off-square valve spring. Eliminate

this noise by rotating the valv.e spring .and the valve.
1. Crank the engine u.ntil the noisy valve is off its seat.
2. Rotate the spring. This Will a.lso rotate the valve.
3. Repeat until the valve is quiet.
4. If correction is obtained, check for an off-square valve
spring.
Is the valve spring off-square more than 1.6 mm (1/16 in)?
Noise at any Engine Speed

Action
Step
Value(s)
DEFINITION: Noise at all engine RPM
'
Check for excessive valve lash. To check for valve lash,

turn the engine so the piston in the cylinder is on TDC of
thefiring stroke. If valve lash is present, the push rod
moves freely up and down with the valve rocker arm held
against the valve.
Is the valve lash. excessive?
Check for aworn push rod upper end ball.

Is the push rod upper end ball worn?
Check for bent push rod.

Is the push rod bent?
Check the lubrication system feed to the push rod and for
a properly lubricated push rod.
Are the push .rod and feed system properly lubricated?
Check for a loose or damaged valve rocker arm.

Is the valve rocker arm loose or damaged?
If the push rod or the valve rocker arm does not need to
be replaced, this indicates trouble in the valve lifter or the
camshaft.
Is the camshaft worn or damaged?
a.
Repair as
required
Go to Step 2
Replace the push

rod and valve
rocker arm
Go to Step 3
Replace the
push rod
Go to Step 4
Go to Step 5
Replace the
push rod and
valve rocker arm
Replace the
valve rocker arm
Go to Step 6
Replace the
camshaft and
valve lifters
Replace the
valve lifters as
necessary
6-28
Oil Consumption Diagnosis

An engine that has excessive oil consumption uses
0.9L (1 qt) of oil, or more, within 2,000 mi (3 20.0 km).
The following list indicates the conditions and
corrections of excessive oil consumption:
An improperly read oil level indicator (dipstick)
- Inspect the oil level while the vehicle is
parked on a level surface.
- Allow adequate drain-down time.
- Use the recommended SAE viscosity for
prevailing temperatures.
- Refer to Maintenance and Lubrication for the
proper oil viscosity specifications.
Continuous high-speed driving
Severe hauling, such as a trailer. This causes
decreased oil mileage.
A malfunctioning crankcase ventilation system
External oil leaks
- Tighten the bolts, as needed.
- Replace the gaskets and seals, as needed.
Worn or.omitted valve guides and/or valve
stem seals
- Ream the guides.
- Install oversized service valves ancl/or new
valve stem seals.
Broken or worn piston rings
Improperly installed or unseated piston rings
Improperly installed or improperly fitted piston
Plugged cylinder head gasket oil drain holes
Damaged intake gaskets
Oil Pressure Diagnosis and Testing
Engine
Excessive bearing clearance bearings.
replace the
Cracked, porous, or plugged oil galleries -,- repair
or replace the engine block.

The gallery plugs are missing or improperly
installed - install or repair as necessary ..
The pressure. regulator valve is: stuck.'
- Check the pressure regulator valve for
sticking in the bore.
- Check the bore for scoring and burrs.
The camshaft is worn or poorly machined replace the camshaft.
Worn valve guides--'- repair as needed.
Oil Pressure Testing

Tools ,Required
J 25087-C Oil Pressure Test Kit

If the ve.hicle has low oil pressure perform the
following tests.
1. Check the oil level..
2. Raise the vehicle and remove the oil filter.
3. As$emble the plunger valve in tbe large hole of
J 25087-C base and the hose in the small hole
of J 25087-C base. Connect the gauge to the end
of the hose.
4. Insert the flat side of the rubber plug in the
bypass valve without depressing the bypass valve
itself.
5. Install J 25087-C on the filter mounting pad.
J 25087-C
Low or No Oil Pressure

The following can cause low or no oil pressure:
Low oil level - fill to the full mark on the oil level
indicator.
Slow idle speed
Incorrect or malfunctioning oil pressure switch -,replace the oil pressure switch.
Incorrect or malfunctioning oil pressure gauge-,replace the oil pressure gauge.
Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected
temperature.
- Install new oil if it is diluted.
The oil pump is worn or dirty - clean or replace
the oil pump.
The oil filter is plugged - replace the oil filter.
The oil pickup screen is loose or plugged replace the oil pickup screen.
A hole in the oil pickup tube - replace the oil
pickup tube.
566977
6. Start the engine and check the overall oil

pressure, the oil pressure switch, and for
noisy lifters. The engine should be at operating
temperature before checking the oil pressure. The
oil pressure should be approximately
414kPa (60 psi) at 1850 rpm using
1OW30 engine oil.
Engine
7. It adequate oil pressure is indicated, check the oil

pressure switch.
8. If a low reading is indicated, press the valve on
the tester base to isolate the oil pump and/or its
components from the lubricating system. An
6-29
adequate reading at this time indicates a good

pump and the previous low pressure was due to
worn bearings, etc. A low reading while pressing
the valve would indicate a faulty ,pump.
Oil Leak Diagnosis

Step
Action
Value(s)
No
Yes
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause ofJhe. leak as
well as the leak itself.
1. Operate the vehicle until it reaches normal operating

temperature.
2. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
3. Wait (15 minutes).
4. Check for drippings.
Are drippings present?
Can you identify the type of fluid and the approximate

location of the leak?
Go toStep2
System OK
Go to Step 10
Go to Step 3
1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas.
2. Check for leaks.at the following locations:

3
4.
Sealing surfaces
Fittings
Cracked or damaged components
1. Completely clean the entire engine and surrounding
components.
2. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
5. Identify the type of fluid, and the approximate location
of the leak.
Go to Step 10
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 7

2. Check for leaks at the following locations:

5
Sealing surfaces
Fittings
components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
of the leak, from the discolorations in the powder
surface.
6-30
Engine
Oil Leak Diagnosis (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
System OK


7
Sealing surfaces
Fittings
Can yOu identify the type of fluid and the approximate
Use J 28428-E in order to identify the type of fluid, and the
approximate location of the leak. Refer to the
manufacturer's instructions when using the tool.


9
Sealing surfaces
. Fittings
1. Inspect the engine for mechanical damage. Special

attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
10
11
Plugged or malfunctioning fluid filters or pressure

bypass valves
Plugged or malfunctioning engine ventilation
system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications to
the engine?
Repair or replace all damaged or modified components.
Does the engine still leak oil?.
(
-
Go to Step .11
System OK
Go to Step 1
System OK
Engine
Cylinder leakage Test

)
Tools Required
J 35667-A Cylinder Leakdown Tester
With the use of air pressure, a cylinder leakage test
will aid in the diagnosis. The cylinder leakage test may
be used in conjunction with the engine compression
test, to isolate the cause of leaking cylinders.
9.
Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
1. Remove the battery ground (negative) cable.
2. Remove the spark plugs. Refer to Ignition System.
3. Install the J 35667-A.
10.
11 .
12.
13.
6-31
Remove the suspect cylinder head and

inspect. Refer to Cylinder Head Clean
and Inspect.
If air is heard from the crankcase system at the
crankcase (oil filler tube), perform the following
procedure:
Remove the piston from the suspect cylinder.
Inspect the piston and connecting rod
assembly. Refer to Piston, Connecting Rod,
and Bearings Clean and Inspect.
Inspect the engine block. Refer to Engine
Block Clean and Inspect.
If bubbles are found in the radiator, perform the
following procedure:
Remove both cylinder heads and inspect.

Refer to Cylinder Head Clean and Inspect.
Inspect the engine block. Refer to Engine Block
Clean and Inspect.
Remove the J 35667-A.
Install the spark plugs. Refer to Ignition System.
Install the battery ground (negative) cable. Refer to
Battery.
Symptoms - Drive Belt

Important: Review the drive belt system operation in
order to familiarize yourself with the system
functions. Refer to Drive Belt System Description.
Visual/Physical Inspection
309966
4. Measure each cylinder on the compression

stroke, with both valves closed.
Important: It may be necessary to hold the crankshaft
balancer bolt, to prevent piston movement.
5. Apply air pressure, using the J 35667-A. Refer to
the manufacturer's instructions.
6. Record the cylinder leakage readings for each
cylinder.
Important:
Normal cylinder leakage is from 12 to 18 percent.
" Make a note of any cylinder with more leakage
than the other cylinders.
.. Any cylinder with 30 percent leakage or more
requires service.
7. Inspect the four primary areas, to properly
diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system,
perform the following procedure:
" Remove the valve rocker arm cover of the
suspect cylinder head.
- Ensure that both valves are closed.
- Inspect the cylinder head for a broken valve
spring.
Inspect for aftermarket devices which could affect

the operation of the drive belts.
Inspect the easily accessible or visible system

components for obvious damage or conditions
which could cause the symptom.
Inspect the drive belt for excessive wear,
shredding, or missing sections.
" Inspect the drive belt for contamination of
excessive dirt, oil, coolant or other substances
that may affect the drive belt operation.
Intermittent
Drive belt symptoms may be from intermittent
failure of an accessory drive component.
Drive belt symptoms may occur from changes in
load of the accessory drive components.
Ambient temperatures, moisture, or engine
operating temperature can affect the drive
belt operation .
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
Drive Belt Chirping Diagnosis
Drive Belt Squeal Diagnosis
Drive Belt Whine Diagnosis
Drive Belt Rumbling Diagnosis
Drive Belt Vibration Diagnosis
Drive Belt Faffs Off Diagnosis
Drive Belt Excessive Wear Diagnosis
6-32
Engine

Diagnostic Aids
The symptom may be intermittent due to moisture on
the drive belt or the pulleys. It may be necessary
to spray a small amount of water on the drive belt ih
order to duplicate the customers concern. If spraying
water on the drive belt duplicates the symptom,
cleaning the belt pulleys may be .the probable solution.
A loose or improper installation of a body component,
a suspension component, or other item(s) on the
vehicle may cause the chirping noise.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
2. The noise may not be engine related. This step is
to verify that the engine is making the noise. If
the engine is not making the noise do not proceed
further with this table.
3. Th.e noise may be an internal engine noise.
Remove the drive belt and operate the engine for
a brief period, this will verify if the chirping
noise is related to the drive belt. With the drive
belt(s) removed the water pump may not operate
and the engine may overheat. Also DTCs may
set when the engine is operated with the drive belt
removed.
4. Inspect all drive belt pulleys for pilling. Pilling .is
the small balls or pills or it may be strings in
the drive belt grooves from the accumulation of
rubber dust.
6. Misalignment of the pulleys may be caused from

improper mounting of the accessory drive
component, incorrect installation of the accessory
drive component pulley, or the pulley may be
bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge
in the pulley grooves across two or three pulleys.
If a misaligned pulley is found, refer to that
accessory drive component for the proper
installation procedure for that pulley.
10. Inspection of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer, or washer
was installed.
12. Inspecting the pulleys for being bent should
include inspecting for dents or other damage to
the pulleys that would prevent the drive belt

from not seating properly in all of the pulley
grooves or on the smooth surface of a pulley when
the back side of the belt is used to drive the
pulley.
14. Replacing the drive belt when it is not damaged or
there is not excessive pilling will only be a
temporary repair.
Engine
6-33

Action
Step
Yes
No .
Notice: Refer to Belt Dressing Notice in Cautions and Notices.
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp startup conditions.and will subside once the vehicle reaches normaloperating
temperature.
Did you review the Symptoms - Drive Belt diagnostic information and
perform th.e necessary inspections?
Does the engine make the chirping noise?

1. Remove the drive belt.
2. Operate the engine for no longer than 30 to 40 seconds.

Does the chirping noise. still exist?
5
6
..
Go to Step.3
Goto
Diagnostic Aids:
Does the belt grooves have pilling?
Go to Engine Noise
Diagnosis (Base
Engine)
Inspect for severe belt pilling exceeding 1/3 of the belt groove depth.
;
Go tp. Step 4
Go to Step 5
Go to. Step 6
Go toStep 15
Go toStep 6
Go to Step 7
Go to Step 8
Clean the drive belt pulleys with a suitable wire brush.

Were the drive belt pulleys cleaned?
Inspect for a misalignment of the pulleys.
Are any. of the pulleys misaligned?
Replace and/or repair any misaligned pulleys.
Were the misaligned pulleys repaired and/or replaced?
Go to Step 15
Inspect for bent and/or cracked brackets.

Were there any bent and/or cracked brackets?
Goto Step 8
(
.,
GotoStep9
Go to Step 10
Go to Step 15
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 15
Go to Step 12
Go to Step 13
Go to Step 14
Go to Step 15
Go to Step 14
Go to Step 15
Go to
Diagnostic Aids
Go to Step 3
System OK
Replace any bent and/or cracked brackets. Refer to Drive Belt

Tensioner Replacement.
Were the bent and/or cracked brackets replaced?
10
Go to Symptoms ~
Drive Belt ..
Verify that there is a chirping.noise.
Go to Step .2
Inspect for improper, missing and/or loose fasteners.

Were there any improper, missing and/or loose fasteners?
Replace any improper and/or missing fasteners.
11
12
13
14
15
Tighten any loose fasteners. Refer to Fastener Tightening

Specifications.
Did you complete the repair?
Inspect for a bent pulley.
Was a bent pulley found?
Replace the bent pulley.
Was the bent pulley replaced?
Replace the drive belt. Refer to Drive Belt Replacement.
Was the drive belt replaced?
Run the engine in order to verify the repair.
Does the drive belt still chirp?
6-34
Engine

Diagnostic Aids
a suspension component, or other items on the
vehicle may cause the squeal noise.
If the noise is intermittent, verify that the accessory
.drive components are not the cause, by varying their
loads makirig sure they are operating to their
maximum capacity. An overcharged A/C system, a
'power steering system restriction, or incorrect fluid, or
a failing generator are suggested items to inspect.
Test Description
further w.ith this table
3. The noise may be an internal engine noise.
Remove the drive belt and operate the engine for
a brief period, th.is will verify that the squeal
noise is the drive belt or an accessory drive
component. With the drive belt removed the water
pump may not operate and the engine may
overheat. Also DTCs may set when the engine is
operated with the drive belt removed.
4. This test is to verify that an accessory drive
component does not have a seized bearing. With
the drive belt removed test the bearings in the
accessory drive components for smooth operation.
Test the accessory drive components with the

engine operating by varying the load on the
components to verify that the components operate .
properly,
5. This test is to verify that the drive beltterisioner
operates properly. If the drive belt tensioner is
not operating properly, proper belt tension may not
be achieved to keep the drive belt from slipping
which could cause a belt squeal noise.
6. This test is to verify that the drive belt is not to
long, which would prevent the drive belt
tensioner from operating properly. Also if an
incorrect length drive belt were installed, it may
not be routed properly and may be turning
an accessory drive component in the wrong
direction.
drive component pulley, or the pulley is bent
inward or outward from a previous repair .. Tesl for
a misaligned pulley using a straight edge iri the
pulley grooves across two or three pulleys. If
a misaligned pulley is found refer to that accessory
.drive component for the proper installatio.n
procedure for that pulley.
8. This test is to. verify that the pulleys are the
co.rrect diameter or width. Using a known. good
vehicle compare the pulley sizes.
Engine
6-35

Step
Yes
Action
No

DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused. by .a slipping drive belt (this is unu.sual for a drive belt with multipie ribs)
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compress9r engagement
snapping the throttle, or slipping on a seized pulley or a faulty accessory drive.component.
1
perform the necessary inspections?
.
Verify that there is a squeal noise.
Does the engine make the squeal noise?
GotoStep2

Does the squeal noise still exist?
Inspect for an accessory drive component seized bearing or a faulty
accessory drive component.
Did you find and correct the condition?
Go to Symptoms Drive Belt.

..
Go to Step 3
Go to
Diagnostic Aids
Go to Engine Noise
Diagnosis (Base
Engine)
G.o to Step' 4
Go to Step 9
.Go to Step 5
..
Inspect the drive belt tensioner for proper operation. Refer to Drive
Belt Tensioner Diagnosis.
'
Did.you find.and correct thE:J condition?
Goto Step 9 ..
Check for the correct drive belt length. Refer.to Drivf?. BfJlt
Replacement.
Gcrto Step 9
Go to Step 7
Go tc:> Step 9
Go to Step 8
Go to Step 9.
Go to
Diagnostic Aids
Go. toStep3
System OK
'Inspect for misalignment of a pulley.

Inspect for the correct pulley size.


Does the drive belt still squeal?
'
Go to Step 6
6-36
Engine Mechanical - 3;8L
Engine

water pump may not operate and the engine may
overheat. Also DTCs may set when the engine
is operated with the drive belt removed.
Diagnostic Aids
The drive belt will not cause the whine noise.
'
If the whine noise is intermittent, verify the accessory
drive components are not the cause, by varying
their loads making sure they are operating to their
maximum capacity. An overcharged A/C system,
a power steering system restriction or incorrect fluid,
or a failing generator are suggested items to inspect.
Test Description
The number(s) below refer to the step nurriber(s) on
4. The inspection should include checking the drive

belt tensioner and the drive belt idler pulley
bearings. The drive belt may have to be installed
and the accessory drive components operated
separately by varying their loads. Refer to
the suspected accessory drive component for the
proper inspection and replacement procedure.
3. This test is to verify that the noise is being caused

by the drive belt or the accessory drive
components. With the drive belt removed the

Step
Action
Yes
No

DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
1
Go to Step2
Go to. Symptoms Drive Belt
Verify that there is a\rvhine noise.

Does the engine make the whine noise?
Go to Step 3
Goto
Diagnostic Aids
1 . Remove the drive belt.

Does tt,e whine noise still exist?
Go to Engine Noise
Diagnosis (Base
Engine)
Go to Step4
Inspect for a failed accessory drive component bearing.

Did you find and repair the condition?.
Go to Step 5
Go to
Diagnostic Aids

Does the drive belt still whine?
Go to Step 3
System OK
Engine
6-37

Diagnostic Aids
Vibration when the engine is operating may cause a
body component or another part of the vehicle to
produce rumbling noise.
The drive belt may have a condition that can not be
seen or felt. Sometimes replacing the drive belt may be
the only repair for the symptom.
If replacing the drive belt, and completing the
diagnostic table, the noise is only heard when the
drive belt is installed, there may be an accessory drive
component failure. Varying the load on the accessory
drive components may aid in identifying which
accessory drive component is causing the
rumbling noise.
Test Description
2. This test is to verify that the symptom is present
during diagnosing. Other vehicle components
may cause a similar symptom.
3. This test is to verify that the drive belt is causing

the rumbling noise. The rumbling noise may be
confused with an internal engine noise due to the
similarity in the description. Remoye only
one drive belt at a time if the vehicle has multiple
drive belts. With the drive belt removed the
water pump may not be operate and the engine
may overheat. Also DTCs may set when the
engine is operated with the drive belt removed.
4. Inspect the drive belt to ensure that the drive belt
is not the cause of the noise. Small cracks
across the ribs of the drive belt will not cause the
rumbling noise. Belt separation is identified by
the plys of the drive belt separating, this may be
seen at the edge of the belt or felt as lump
in the belt.
5. Small am9unts of pilling is normal condition and

acceptable. When the pllling is severe the drive
belt does not have a smooth surface for
proper operation.

Step
Action
Yes
No

DEFINITION:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
- Pilling, the accumulation of rubber dust that forms small balls (pills} or strings in the drive belt pulley groove
- The separation of the drive belt
- A damaged drive belt
1
Go to Step2
Go to Symptoms Drive Belt
Verify that there is a rumbling noise.

Does the engine make the rumbling noise?
Go to Step 3
Go to
Diagnostic Aids

Does the rumbling noise still exist?
Go to Engine Noise
Diagnosis (Base
Engine)
Go to Step 4
Inspect the drive belt for damage, separation, or sections of

missing ribs.
Did you find any of these conditions?
Go to Step 7
Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley
grooves.
Did you find severe pilling?
Go to Step 6
Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.

2. Reinstall the drive belt. Refer to Drive Belt Replacement
Go to Step 8
Go to Step 7
Install a new drive belt. Refer to Drive Belt Replacement

Did you complete the replacement?
Go to Step 8

Does the drive belt still rumble?
Go to
Diagnostic Aids
System OK
6-38
Engine

Diagnostic Aids
The accessory drive components may have ah affect
on engine vibration. An overcharged A/G system,
a power steering system restriction, or incorrect fluid,
or an extra load placed on the generator are some
systems that should be inspected. To help identify an
intermittentor an improper condition; vary the loads
on the accessory drive components.
Test Descr'iption
2. This testis to verify thal the symptom is present

during diagnosing. o.ther vehicle components
may cause a similar sympto!ll such as the exhaust
system, or the drivetrain.
3. This test is to verify that t.he drive belt or accessqry
drive components may be causing the vibration.
With the drive belt removed the water pump
may not operate and the engine may overheat.
Also DTCs may set when the engine is operated
with the drive belt removed.
4. The drive belt may cause a vibration. With the

drive belt removed inspect the condition of
the drive belt.
was installed.
8. This step should only be performed if the cooling
fan is driven. by the drive belt. Inspect the engine
cooling fan for bent, twisted,. loose, or cracked
blades. Inspect the fan clutch for smooth
operation. Inspect for a ben.t fan shaft or bent
mounting flange.
9. This step should only be performed if the water
pump is driven by the drive belt. Inspect the

water pump shaft for being bent. Also inspect the
water pump bearings for smooth operation and
excessive play. Compare the water pump
with a known good water pump.
1o. Accessory drive component brackets that are
bent, cracked, or loose may put extra strain
on that accessory component causing it to vibrate.
Engine
Engine Mechanical - 3.8L 6-39

Step
Action
No
Yes
DEFINITION: T~e following items are indications of drive belt vibration:

The vibration is engine-speed related.
The vibration may be sensitive to accessory load.
1
Does the engine make the vibration?
2 .. Operate the engine for no longer than 30 to 40 seconds.
Does the engine still make the vibration?
11
Go to
Diagnostic Aids
Go to Engine
Related Vibration in
Vibration and
Diagnosis
Go to Step4
Go to Step5
Go to Step 6
;
Go to Step 11
Inspect for improper, missing or loose fasteners.

Go to Step 7

Specifications.
Replace improper or missing fasteners.
Go to StepB
Go to Step 11
Inspect for damaged fan blades or bent fan clutch shaft, if the fan is
belt driven. Refer to Cooling Fan Motor Replacement - Electric in
Engine Cooling.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 11
Go to
Diagnostic Aids
Go to Step 3
System OK
Inspect for a bent water pump shaft, if the water pump is belt driven.
Refer to Water Pump Replacement (3.8 L) in Engine Cooling.
10
Go to Step 3
Install a new drive belt. Refer to Drive Belt Replacement.
Inspect the drive belt for wear, damage, debris build-up and missing
drive belt ribs.
Go to Step2
Verify that the vibration is engine related.

Inspect for bent or cracked brackets.

Does the drive belt still vibrate?
6-40
Engine
Drive Belt Falls Off Diagnosis

Diagnostic Aids
If the drive belt repeatedly falls off the drive belt
pulleys, this may be caused by pulley misalignment.
An extra load that is quickly applied on released by an
accessory drive component may cause the drive
belt to fall off the pulleys. Verify that.the accessory
drive components operate properly.
If the drive belt is the incor.rect length, the drive belt
tensioner may not maintain the proper tension on
the drive belt.
Test Description
2. This inspection is to verify the c.ondition of the
drive belt. Damage may have occurred to the drive
belt when the drive belt fell off the pulley. The
drive belt may of been damaged in which
case caused the drive belt to fall off the pulley.
Inspect the drive be.It tor cuts, tears, sections
of ribs missing, or damaged belt plys.
component, incorrect iristallatiori of the accessory
drive component pulley, or the pulley being bent .

inward or outward from a previous repair. Test
for a misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a
misaligned pulley is foundrefer to that accessory
drive component for the proper installation
procedure of that pulley.
5. Inspect the pulleys for dents, bends or other
damage. Damage to the pulleys that would
prevent the drive belt from seating properly in the
pulley grooves. Damage would also prevent
proper alignment of the drive belt pulley, when the
smooth surface of the drive belt is required to
drive the pulley.
6. Accessory drive component brackets that are .bent
or cracked will let the drive belt fall off.
was installed. Missing, loose, or the incorrect
fasteners may cause pulley misalignment from the
bracket moving under load. Over tightening of
the fasteners may cause misalignment of
the accessory component bracket.
Engine
Engine Mechanical - 3.8l 6-41

Step
Yes
Action
No

DEFINITION: The drive be.It falls off the pulleys or may not ride correctly .on the puUeys.
1
2
3
4
5
6
7
10
Did you find the condition?

Does the drive belt continue to fall off?
Go to Step 3
Goto Step 4
Go to Step 4
System OK
Go to Step 12
Go to Step 5.
Go to Step 12
Go to Step 6
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 9
System OK
Go to Step 11
Go to Step 10
Go to Step 11
System OK
Go to Step 12
Go to
Diagnostic Aids
Inspect for misalignment of the pulleys.

Did you find and repair the condition?
Inspect for a bent or dented pulley.
Inspect for a bent or a cracked bracket.
.

Did you find loose or missing fasteners?
Specifications.
Test the drive belt tensioner for operating correctly. Refer to Drive
Replace the drive belt tensioner. Refer to Drive Belt Tensioner
Replacement.
Inspect for failed drive belt idler and drive belt tensioner pulley
bearings.
12
Install a new drive belt. Refer to Drive Belt Replacement.
11
Go to Step2
Inspect for a damaged drive belt.
Does the drive belt tensioner operate correctly?
'

Does the drive belt still fall off?
System OK
6-42
Engine

Diagnostic Aids
Excessive wear on a drive belt is usually caused by
an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not
cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off the
pulley (s).
Excessive misalignment of the drive belt pulleys will
cause excessive wear and may also make the
drive belt fall off the pulley.
3. The installation of a drive belt that is to wide or to

narrow will cause wear on the drive belt. The
drive belt ribs should match all of the grooves on
all of the pulleys.
4. This inspection is to verify the drive belt is not
contacting any parts of the engine or body
while the engine is operating. There should be
sufficient clearance when the drive belt accessory
drive components load varies. The drive belt
should not come in contact with an engine or a
body component when snapping the throttle.
Test Description
2. The inspection is to verify the drive belt(s) is
correctly installed over all of the drive belt pulleys.
Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a
pulley.

Step
Yes
Action
No

DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
Go to Step2
Inspect the drive belt(s) for the proper installation. Refer to Drive Belt
Replacement.
Did you find this condition?
Go to Step 5
Go to Step 3
Inspect for the proper drive belt.

Go to Step 5
Go to Step 4
Inspect for the drive belt rubbing against a bracket, hose, or wiring
harness.
Go to Step 6
Go to
Diagnostic Aids
Replace the drive belt. Refer to Drive Belt Replacement.

Go to Step 6

Is there still excessive drive belt wear?
Drive Belt Tensioner Diagnosis

Important: When the engine is operating, the belt
tensioner arm will move. Do not replace the belt
tensioner because of movement in the belt
tensioner arm.
Notice: Allowing the drive belt tensioner to snap into

the free position may result in damage to the
tensioner.
1. Remove the drive belt. Refer to Drive Belt
Replacement.
2. Position a hex-head socket on the drive belt
tensioner arm and rotate the arm
counterclockwise.
System OK
3. Move the drive belt tensioner through it's full

travel.
" The movement should feel smooth
There should be no binding.
The tensioner should return freely.
4. If any binding is observed, replace the drive belt
tensioner. Refer to Drive Belt Tensioner
Replacement.
5. Install the drive belt. Refer to Drive Belt
Replacement.
Engine
5.;43
Disassembled Views
Cylinder Head and Components
54
52~~
53
55
2
3
45
11
13
43
19
41
22
35
34
32
31
29
28
589348
legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Engine Lift Rear Bracket

Generator Brace Bracket
Generator Brace Bolt
Valve Lifter Guide
Valve Rocker Arm Bolts
Valve Rocker Arm
Valve Rocker Arm Retainer
Pushrod
Valve Lifter
Valve Stem Keys
Valve Stem Cap
Valve Stem Spring
Valve Seal
Spark Plug
Cylinder Head
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26}
(27)
(28)
(29)
(30}
(31)
(32)
Intake Valve
Exhaust Manifold Gasket (Left)
Exhaust Manifold (Left)
Exhaust Manifold Stud
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Nut
EGR Valve Outlet Pipe
EGR Valve Outlet Pipe Bolt
EGR Va.Ive Outlet Pipe Nut
Heated Oxygen Sen~or
Engine Lift Front Bracket
EGR Valve Adapter Studs
EGR Valve Adapter Bolt
EGR Valve Adapter
6-44
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
Engine
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
EGR Valve Adapter Nuts

Drive Belt Tensioner
Drive Belt Tensioner Bolt
EGR Valve Gasket
EGR Valve
EGR Valve Nuts
Engine Block
Exhaust Manifold Heat Shield
Exhaust Manifold Stud
Exhaust Manifold (Right}
Exhaust Manifold Gasket (Right)

Intake Manifold Seal
Lower Intake Manifold Gasket
Cylinder Head
Oil Fill Cap
Oil Fill Cap Seal
Oil Fill Tube
Oil Fill Tube Seal
Crankshaft and Components

34
35
33
27
31
~~
~)~
29
~~
30
},.
22
26
23
24
25
21@)~
I~,,~
18
19
20
17
42447
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Crankshaft Balancer Key

Crankshaft Upper Bearing
Crankshaft Rear Oil Seal
Engine Flywheel
Flywheel Bolt
Engine Crankshaft
Crankshaft Main Bearing Cap
Side Main Bearing Bolt
Crankshaft Main Bearing Cap Bolt
Crankshaft Lower Bearing
Crankshaft Main Bearing Cap
Oil Pan Drain Plug
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20}
(21)
(22}
(23}
(24)
Oil Pan Drain Plug Gasket

Oil Pan Gasket
Engine Oil Pan
Oil Pan Bolt
Engine Oil Level Sensor
Crankshaft Position Sensor Shield
Crankshaft Balancer
Crankshaft Balancer Washer
Camshaft Position Sensor
Crankshaft Position Sensor
Engine
(25)
(26)
(27)
(28)
(29)
(30)

Oil Pump Gear Set
Oil Pump Cover
Oil Pump Cover Bolt
Crankshaft Front Oil Seal
Water Pump Bolt
Water Pump Pulley Bolt
(31)
(32)
(33)
(34)
(35)
6-45
Water Pump Pulley

Water Pump
Water Pump Gasket
Engine Front Cover
Intake Manifolds and Components

2
403765
Legend
(1) Fuel Injector Rail Nuts
(2) Fuel Injector Rail
(3) Water Outlet Bolts
(4) Water Outlet
(5) Water Outlet Gasket
(6) Thermostat
(7) Thermostat Gasket
(8) ICM Bracket Bolt
(9) ICM Bracket
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Upper Intake Manifold Gasket

Lower Intake Manifold
Coolant Temperature Sensor
Lower Intake Manifold Bolt
Throttle Body
Upper Intake Manifold
Upper Intake. Manifold Bolt
Vacuum Source Manifold
6-46
Engine
Piston and Components
43
44
_1
~
p~38
I
42
41~40
39~
/ -~
37
~8
36
35
-o~
i~
32
31
~ ~
28
~ , ;~...._
23
22
~J
. "a I,) o0
10
13
11
16
12
18-
17
42456
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
{13)
{14)
{15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Piston Pin Retainer Clip

Piston Rings
Piston
Connecting Rod
Connecting Rod Bearings
Connecting Rod Cap
Connecting Rod Cap Bolt
Crankshaft Rear Oil Seal Housing Bolt
Crankshaft Rear Oil Seal Housing
Crankshaft Rear Oil Seal Housing Gasket
Oil Level Indicator
Cylinder Head Location Hole Pin
ESC Knock Sensor
Engine Block
Oil Pump Screen Gasket
Oil Pump Screen
Engine Block Core Hole. Plug
Engine Front Cover Pin
Engine Block Oil Gallery Plug
Oil Pressure Relief Valve Spring
{23)
{24)
{25)
(26)
(27)
(28)
(29)
(30)
{31)
{32)
{33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
Oil Pressure Relief Valve

Oil Filter Adapter Gasket
Oil Filter Adapter
Oil Filter Adapter Bolt
Camshaft Thrust Plate
Camshaft Thrust Plate Bolt
Timing Chain Dampener
Crankshaft Sprocket
Timing Chain
Camshaft Position Sensor Magnet
Balance Shaft Drive Gear
Camshaft Key
Camshaft
Camshaft Bearings
Balance Shaft Bushing
Balance Shaft
Balance Shaft Gear
Balance Shaft Gear Bolt
Balance Shaft Gear Pin
Balance Shaft Retainer Bolt
Balance Shaft Retainer
Engine
5.;47
Repair Instructions
Drive Belt Replacement

Removal Procedure
. 1. Position a hex-head socket on the belt tensioner
pulley bolt.
2. Rotate the drive belt tensioner (2) clockwise to
relieve the tension on tfle drive belt (1 ).
3. Remove the drive belt (1) from the tensioner (2)
and pulleys.
4. Clean and inspect the belt surfaces of all the
pulleys.
41363
Installation Procedure
1. Route the drive belt (1) around the pulleys.

2. Position a hex-head socket on the belt tensioner
pulley bolt.
relieve the tension.
4. Install the drive belt (1) onto the drive belt
tensioner (2).
5. Inspect the drive belt (1) to ensure that the belt is
properly aligned into the grooves of the pulleys.
41363
6-48
Engine

Drive Belt Tensioner Replacement
Removal Procedure
1. Drain the engine coolant. Refer to Draining and

Filling Cooling System (3.8 L) in Engine Cooling.

Replacement.
3. Rem.ave the generator. Refer to Generator
Replacement (3.8 L) in Engine Electrical.
4. Remove the heater hoses from the drive belt
tensioner.
282933
5. Remove the drive belt tensioner bolts (3).
Important: The drive belt tensioner (2) must be

rotated if it is difficult to remove. Pulling the
tensioner (2) from the top may damage the engine
front cover. If necessary, break the plastic thermostat
bypass upper pipe (1) to allow rotation of the drive
belt tensioner (2), replace the pipe during installation.
6. Remove the drive belt tensioner (2).

7. Remove the thermostat bypass pipes (1, 4) from
the tensioner (2), if necessary.
441249
1. Install the thermostat bypass pipes (1, 4) to the
tensioner, if necessary.
2. Install the drive belt tensioner (2) to the engine.

Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the drive belt tensioner bolts (3).
Tighten
Tighten the drive belt tensioner bolts (3) to
50 Nm (37 lb ft).
441249
Engine
4. Install the heater hoses to the drive belt tensioner.

5. Install the generator. Refer to Generator
Replacement (3.8 L} in Engine Electrical.
6. Install the drive belt. Refer to Drive Belt
Repla<Jement.
7. Refill the engine coolant. Refer to Draining and
Filling Cooling System (3.8 L} in Engine Cooling.
282933
Drive Belt Idler Pulley Replacement

Removal Procedure
1. Remove the serpentine drive belt. Refer to Drive
Belt Replacement.
2. Remove the drive belt idler pulley bolt(1 ).
3. Remove the drive belt idler pulley (2).
2
500350
1. Install the drive belt idler pulley (2).

Notices.
2. Install the drive belt idler pulley bolt (1 ).
Tighten
Tighten the drive belt idler pulley bolt (1) to
50 Nm (37 lb ft).
3. Install the serpentine drive belt. Refer to Drive
Belt Replacement.
2
500350
6-50
Engine

Engine Mount Inspection
Notice: Broken or deteriorated mounts can cause

misalignment and destruction of certain drive
train components; When a single mount breaks, the
remaining mounts are subjected to abnormally ,
high stresses:
Notice: When raising or supporting the engine for any
reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
1. Measure the engine movement at the engine
mounts in order to check for damage to the
rubber portions of the mount.
1.1. Apply the park brake.
1.2. Start the engine.
1.3. Firmly apply the primary brakes.
1.4. Have an assistant stand to the side of the
vehicle to observe for engine movement.
1.5. Slightly load the engine in reverse and
drive. If the engine moves more than
24 mm (0.945 in) from the at rest position;
in either direction, check the engine
mount attachment.
2. If the engine mount attac.hment is within
specifications, replace the engine mount.
3. Replace the engine mount also if any of the
following conditions exist:
Heat check cracks cover the hard rubber
surface.
The rubber cushion is separated from the .
metal plate of the mount. .
There is a split through the rubber cushion.
4. If the mount is loose, lowerthe engine and tighten
the bolts or the nuts to the engine frame or the
bracket Refer to Fastener Tightening
Specifications.
Engine Support Fixtur~

J 28467-90A
578405
Tools Required
J 28467-90A Engine Support Adapters
J 41044 Engine Support Fixture Adapters
J 28467-8 Universal Engine Support Fixture
1. Remove two strut mounting nuts from the left and
right side strut towers.
2. Attach the engine support fixture adapters
J 28467-90A to the strut tower studs.
3. Install the engine support fixture adapters
J 41044-1 and J 41044-2 onto the fixture adapters
J 28467-90A on each strut tower.
4. Secure with the wings nuts provided.
Engine
5. Place the cross bar J 28467-3 into the engine

support adapters J 41044-1 and J 41044-2.
6. Install the quick release pins.
7. Thread the lift hooks J 28467-50 and J 28467-8
or (8A) into the support hook brackets J 28467-6A.
8. Place the support hook brackets J 28467-6A over
the cross bar J 28467-3 and connect the hooks to
the engine lift brackets.
9. Tighten the large wing nuts J 28467-34.
J 28467-50
6;.51
J28467-8 or-8A
J 28467-34 (2)
578415
Engine Mount Replacement

Removal Procedure
reason, do not use a jack under the oil pan,

crankshaft balancer, or any sheet metal. Due to small
clearances between the oil pan and the oil pump .
screen, jacking against the oil pan may cause it to be
bent against the pump screen, resulting in a
damaged oil pickup unit. Jacking against the
crankshaft balancer may also cause oil seal and/or
crankshaft bearing damage. Always use a J 28467-A
(Universal Support Fixture) along with J 41044
(Engine Support Adapters) when raising or supporting
the engine.
1. Remove the generator. Refer to Generator
2. Remove the ignition control module. Refer to
Ignition Coil Module Replacement (3.8 L) in
Engine Electrical.
3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
4. Remove the 3-way catalytic converter. Refer to
Catalytic Converter Replacement (3.8 L) in
Engine Exhaust.
5. Remove the right side engine mount through bolt
nut (2).
./
50513
6-52
Engine
6. Remove the .left side engine mount through bolt
nut (1 ).
7. Install the engine support fixture to the engine.
Refer to Engine Support Fixture.
8. Raise the engine slightly in order to relieve
tension on the through bolts.
50520
9. Remove the trar1smission oil cooler pipe bracket

bolt and bracket.
46662
10. Remove the air conditionjng compressor bolts.
282953
Engine
11. Remove the air conditioning compressor rear

bolts (2, 3).
12. Position the A/C compressor forward of the
bracket in order to remove the engine mount
through bolt without recovering the refrigerant.
6-53
365440
13. Remove the right engine mount through bolt (1).
50513
14. Remove the left engine mount through bolt (2).

15. Raise the engine enough to remove the engine
mounts and engine mount brackets.
50520
6-54
Engine
16. Remove the right engine mount bolts (1) and the
right engine mount (2).
49837
17. Remove the left engine mount bolts (1) and the
left engine mount (2).
50525
18. Remove the right engine mount bracket

bolts (1, 2) and the right engine mount bracket (3).
(
4
3
50517
Engine
6-55
19. Remove the positive cable from the engine

mount stud.
)
Remove the battery positive cable nut (2).
Remove the harness clamp from the stud.

Remove the RF (Radio Frequency)
ground strap.
211604
20. Remove the left engine mount bracket bolts (3).

21. Remove the left engine mount bracket stud (2)
and the engine mount bracket (1 ).
22. Visually Inspect the rubber portions of the engine
mount for damage.
50546
1. Install the left engine mount bracket (1) and
stud (2) to the engine block.

Notices.
2. Install the left engine mount bracket bolts (3).
Tighten
Tighten the engine mount bracket bolts (3) to
100 N-m (74 lb ft).
e
Tighten the engine mount bracket stud (2) to

87 N,m (64 lb ft).
50546
6-56
Engine
3. Install the positive cable to the engine mount
bracket stud.
Install the RF (Radio Frequency) ground strap.
Install the harness clamp to the stud.
Install the battery positive cable nut (2).
Tighten
Tighten the battery positive cable nut (2) to
25 Nm (18 lb ft).
211604
4. Install the right engine mount bracket (3) and

bolts (1, 2) to the engine block.
Tighten
Tighten the two engine mount bracket bolts
(10 to 100 N-m (74 lb ft).
Tighten the engine mount bracket bolt (2) to
50 N-m (37 lb ft).
4
50517
5. Install the left engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the left engine mount bolts (1) to
58 Nm (43 lb ft).
50525
Engine
6-57
6. Install the right engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the right engine mount bolts (2) to
58 N-m (43 lb ft).
7. Lower the engine until the mount bracket and
mount through holes line up together.
8. Remove the engine support fixture.
49837
9. Install the left engine mount through bolt (2).
50520
10. Install the right engine mount through bolt (1 ).
50513
6-58
Engine
11 . Position the A/C compressor rearward to the
bracket.
12. Install the air conditioning compressor rear
bolts (2, 3).
Tighten
Tighten the air conditioning compressor rear
bolts (2, 3) to 30 Nm (22 lb ft).
365440
13. Install the air conditioning compressor bolts.

Tighten
Tighten the air conditioning compressor bolts to
50 N-m (37 lb ft).
282953
14. Install the transmission oil cooler pipe bracket

and bolt.
Tighten
Tighten the oil cooler pipe bracket to
17 Nm (13 lb ft).
46662
Engine
6-59
15. Install the left side engine mount through bolt

nut (1).
Tighten
Tighten the engine mount through bolt nut (1) to
80 N-m (59 lb ft).
50520
16. Install the right side engine mount through bolt

nut (2).
Tighten
17.
18.
19.
20.

80 Nm (59 lb ft).
Install the 3-way catalytic converter. Refer to
Engine Exhaust.
Lower the vehicle.
Install the ignition control module. Refer to Ignition
Coil Module Replacement (3.8 L) in Engine
Electrical.
Install the generator. Refer to Generator
~
50513
Engine Mount Bracket Replacement

Removal Procedure

reason, do not use a jack under the oil pan, crankshaft
balancer, or any sheet metal. Due to small clearances
between the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent against the
pump screen, resulting in a damaged oil pickup unit.
Jacking against the crankshaft balancer may also cause
oil seal and/or crankshaft bearing damage. Always use
a J 28467-A (Universal Support Fixture) along with
J 41044 (Engine Support Adapters) when raising or
supporting the engine.
Engine Electrical.
~
50513
6-60
Engine
Information.
Engine Exhaust.
5. Remove the right side engine mount through bolt
nut (2).
6. Remove the left side engine mount through bolt
nut (1 ).
7. Install the engine support fixture. Refer to Engine
Support Fixture.
8. Raise the engine slightly in order to relieve
tension on the through bolts.
50520
9. Remove the transmission oil cooler pipe bracket

bolt and bracket.
46662
(
,
Engine
6-61
10. Remove the air conditioning compressor bolts.
282953
11. Remove the air conditioning compressor rear

bolts (2, 3).
12. Position the A/C compressor forward of the
bracket in order to remove the engine mount
through bolt without recovering the refrigerant.
13. Raise the engine slightly in order to relieve tension
on the through bolts.
365440
14. Remove the right engine mount through bolt (1 ).
50513
6-62
Engine
15. Remove the left engine mount through bolt (2).
16. Raise the engine enough to remove the engine
mounts and engine mount brackets.
50520
17. Remove the right engine mount bolts (1) and the
right engine mount (2).
49837
18. Remove the left engine mount bolts (1) and the
left engine mount (2).
50525
Engine
6-63

bolts (1, 2) and the right engine mount bracket (3).
3
50517
20. Remove the positive cable from the engine

mount stud.
Remove the battery positive cable nut (2).
Remove the RF (Radio Frequency)
ground strap.
211604

and the engine mount bracket (1 ).
23. Visually Inspect the rubber portions of the engine
mount for damage.
50546
6-64
Engine
stud (2) to the engine block.

Notices.
Tighten
Tighten the engine mount bracket bolts (3) to
100 N-m (74 lb ft).
Tighten the engine mount bracket stud (2) to
87 N-m (64 lb ft).
50546
3. Install the positive. cable to the engine mount

bracket stud.
1.nstall the RF (Radio Frequency) ground strap.
Install the battery positive cable nut (2).
Tighten
Tighten the battery positive cable nut (2) to
25 N-m (i 8 lb ft).
211604
4. Install the right engine mount bracket (3) and

bolts (1, 2) to the engine block.
Tighten
Tighten the two engine mount bracket bolts
(10 to 100 N-m (74 lb ft).
Tighten the engine mount bracket bolt (2) to
50 N-m (37 lb ft).
50517
Engine
6~65
5. Install the left engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the left engine mount bolts (1) to
58 N-m (43 lb ft).
50525
6. Install the right engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the right engine mount bolts (2) to
58 Nm (43 lb ft).
7. Lower the engine until the mount bracket and
mount through holes line up together.
49837
9. Install the left engine mount through bolt (2).
50520
6-66
Engine
1O. Install the right engine mount through bolt (1 ).
50513
11 . Position the A/C compressor rearward to the

bracket.
12. Install the air conditioning compressor rear

bolts (2, 3).
Tighten
Tighten the air conditioning compressor rear
bolts (2, 3) to 30 Nm (22 lb ft).
365440
13. Install the air conditioning compressor bolts.

Tighten
Tighten the air conditioning compressor bolts to
50 Nm (37 lb ft).
282953
Engine
6-67
14. Install the transmission oil cooler pipe bracket

and bolt.
Tighten
Tighten the oil cooler pipe bracket to
17 Nm (13 lb ft).
46662
15. Install the left side engine mount through bolt

nut (1).
Tighten
80 N-m (59 lb ft).
50520
16. Install the right side engine mount through bolt

nut (2).
Tighten
17.
18.
19.
20.
80 Nm (59 lb ft).
Install the 3-way catalytic converter. Refer to
Engine Exhaust.
Lower the vehicle.
Install the ignition control module. Refer to Ignition
Electrical.
Install the generator. Refer to Generator
50513
6-68
Engine
Oil Level Indicator and Tube Replacement

Removal Procedure
1. Remove the oil level indicator from the
indicator tube.
2. Remove the oil level indicator tube nut.

3. Remove the oil level indicator tube from the
engine block.
554751
1. Replace the 0-ring seal if necessary.
2. Install the oil level indicator tube to the
engine block.

Notices.
3. Install the oil level indicator tube nut.
Tighten
Tighten the oil level indicator tube nut to
19 Nm (14 lb ft).
4. Install the oil level indicator to the indicator tube.
554751
Intake Manifold Replacement (Upper)

Removal Procedure
Tools Required
J 37088-A Fuel Line Quick Connect Separator
2. Disconnect the intake air temperature (IAT) sensor
electrical connector.
208554
Engine
Engine Mechanical
3.8L
6-69
3. Remove the air intake duct.

4. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.
554755
5. Disconnect the fuel injector electrical

connectors (1) from the fuel injectors.
6. Disconnect the manifold absolute pressure (MAP)
sensor electrical connector (2).
439410
7. Disconnect the engine harness vacuum tube (1)

from the vacuum port.
439411
6-70
Engine
8. Remove the fuel pressure regulator tube (2) from
the following components: .
Manifold vacuum source (1)
Fuel pressure regulator valve (3)
439396
9. Remove the manifold vacuum source screws (2).

10. Remove the manifold vacuum source (1) from the
upper intake manifold.
441250
11. Disconnect the fuel. injector electrical

connectors (1) from the fuel injectors.
12. Disconnect the evaporative emission (EVAP)
canister purge valve switch electrical
connector (2).
13. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls - 3.8 L.
439467
Engine
6-71
14. Disconnect the fuel lines (1) from the fuel rail
using J 37088-A.
15. Disconnect the fuel vapor line (4) from the EVAP
canister purge valve (5).
439396
16. Remove the EVAP canister purge valve bolts (1).

17. Remove the EVAP canister purge valve (2) from
the upper intake manifold.
Engine Electrical.
439395
19. Reposition the brake booster hose clamp.

20. Remove the brake bo.oster hose (2) from the
upper intake manifold fitting (1 ),
439407
6-72
Engine
21. Remove the captured secondary lock from the
connector.
22. Disconnect the electronic throttle control (ETC)
electrical connector (1 ).
439418
5
4
3
1
23. Disconnect the following electrical connectors:

Mass airflow (MAF) sensor (1)
Engine coolant temperature (ECT) sensor (2)
24. Remove the engine harness rosebud clip (3) from
the throttle body.
25. Remove the engine harness clamp bolt (5) and
harness clamp (4).
26. Reposition the engine wiring harness.
27. Remove the thermostat housing. Refer to
Thermostat Housing Replacement (3.8 L) in
Engine Cooling.
28. Disconnect the wiring harness rosebud clips from
the fuel rail.
29. Reposition the wiring harness.
2
439428
30. Remove the fuel rail nuts (1 ).

Important: Clean ariy dirt ouf of.the injector bores
with compressed air.
31. Remove the fuel rail (2) from the upper intake
manifold.
441253
Engine
6-73
32. Remove the throttle body bolt (1) and nuts (2).
33. Remove the throttle body (3) and gasket (4).
2
439449
34. Remove the upper intake manifold bolts (1, 3, 4).

35. Remove the upper intake manifold (2).
441255
36. Remove the upperintake manifold gasket (1).

37. Clean the upper and lower intake manifold sealing
surfaces.
439503
6-74
38. Remove the lower .

Engine
seals (3.' 4) , 1"f necessary.
intake manifold O-nng$
.
439510
Installation Proc
ed ure
Install(3new
lowe r .intake manifold O .
1. seal
' 4) , i"f removed.
-nng
439510
2. Install the upper m

. take man 1"f0 Id gasket (1 ).
439503
Engine
6-75
3. Install the upper intake manifold (2) onto the lower

intake manifold.
Notices.
4. Install the upper intake manifold bolts (1, 3, 4).
Tighten
Tighten the upper intake manifold bolt (3) to
15 N-m (11 lb ft).
Tighten the nine upper intake manifold
bolts (4) to 10 N-m (89 lb in).
Tighten the two upper intake manifold bolts (1)
to 30 N-m (22 lb ft).
441255
5. Install the throttle body (3) and gasket (4).

6. Install the throttle body bolt (1) and nuts (2).
Tighten
Tighten the throttle body nuts (2) to
1O N-m (89 lb in).
Tighten the throttle body bolt (1) to
10 N,m (89 lb in).
439449
7. Install the fuel rail (2) to the upper intake manifold.

8. Install the fuel rail nuts (1 ).
9.
10.
11.
12.
Tighten
Tighten the fuel rail nuts (1) to 8.5 Nm (75 lb in).
Position the wiring harness.
Connect the wiring harness rosebud clips from the
fuel rail.
Install the thermostat housing. Refer to Thermostat
Housing Replacement (3.8 L) in Engine Cooling.
Position the engine wiring harness.
441253
6-76
Engine
13. Install the engine harness clamp (4) and harness
clamp bolt (5).
Tighten
Tighten the harness clamp bolt (5) to
6 N-m (53 lb in).
14. Install the engine harness rosebud clip .(3) to the
throttle body.
15. Connect the following electrical connectors:
MAF sensor (1)
ECT sensor (2)
439428
16. Connect the ETC electrical connector (1 ).

17. Install the captured secondary lock from the
connector.
439418
18. Install the brake booster hose (2) to the upper

intake manifold fitting (1 ).
19. Position the brake booster hose clamp.
20. Install the ignition control module. Referto Ignition
Electrical.
439407
Engine
Engine Mechanical
3.8l 6a77
21. Install the EVAP canister purge valve (2) to the

22. Install the EVAP canister purge valve bolts (t).
Tighten
Tighten the EVAP canister purge valve bolts (1)
to 10 N-m (89 lb in).
439395
23. Connect the fuel vapor line (4) to the EVAP

canister purge valve (5).
24. Connect the fuel lines (1) to the fuel rail.
439398
25. Connect the EVAP canister purge valve switch

electrical connector (2).
26. Connect the fuel injector electrical connectors (1)
to the fuel injectors.
439467
6-78
Engine
27. Install the manifold vacuum source (1) to the

28. Install the manifold vacuum source screws (2).
Tighten
Tighten the manifold vacuum source screws (2) to
10 N-m (89 lb in).
441250
29. Install the fuel pressure regulator tube (2) to the

following components:
" Manifoldvacuum source (1)
Fuel pressure regulator valve (3)
439396
30. Connect the engine harness vacuum tube (1) to

the vacuum port.
439411
Engine
6-79
31. Connect the MAP sensor electrical connector (2).

32. Connect the fuel injector electrical connectors (1)
to the fuel injectors.
33. Install the drive belt tensioner. Refer to Drive Belt
439410
34. Install the air intake duct.
554755
35. Connect the IAT sensor electrical connector.

208554
6-80
Engine
Intake Manifold Replacement (lower)
Removal Procedure
1. Remove the upper,intake manifold. Refer to
Intake Manifold Replacement (Upper).
2. Remove the coolant temperature sensor.
349800
3. Remove the 0-ring seals (3, 4), if necessary.

4. Remove the lower intake manifold bolts (1 ).
5. Remove the lower intake manifold (2).
439510
6. Remove the lower intake manifold seals (1).

7. Remove the lower intake manifold gaskets (2).
439530
Engine
6-81
1. Install the lower intake manifold gaskets (2).
2. Install the lower intake manifold seals (1 ).

Apply silicone sealer GM P/N 12345366 or
equivalent to the ends for the manifold seals (2).
439530
3. Install the lower intake manifold (2).

4. Apply thread lock compound GM P/N 12345493
or equivalent to the bolt threads before installing.
Notice: Refer to Fastener Notice in Cautions

and Notices.
5. Install the lower intake manifold bolts (1 ).
Tighten
Tighten the lower manifold bolts (1) to

15 Nm (11 lb ft).
439510
6. Remove the coolant temperature sensor.

Tighten
Tighten the coolant temperature sensor to
25 Nm (18 lb ft).
7. Remove the upper intake manifold. Refer to
Intake Manifold Replacement (Upper).
349800
6-82
Engine
Exhaust Manifold Replacement (Left)
Removal Procedure
Information.
Engine Exhaust.
3. Disconnect the connector position
assurance (CPA) retainer.
4. Disconnect the wiring harness connector (1) from
the oxygen sensor.
5. Remove the oxygen sensor connector from the
spark plug wire harness bracket.
439775
6. Remove the oxygen sensor from the exhaust

manifold.
577702
7. Disconnect the numbers 1, 3 and 5 spark plug

wires from the spark plugs.
211645
Engine
6-83
8. Remove the numbers 3 and 5 spark plugs from

the cylinder head.
14824
9. Remove the two rear exhaust manifold studs and

nut from the exhaust manifold.
10. Lower the vehicle.
613220
11. Remove the number 1 spark plug from the

cylinder head.
14824
6-84
Engine Mechanical
3.8L
Engine
12. Remove the exhaust manifold heat shield nuts.
13. Remove the exhaust manifold heat shields from
the exhaust manifold.
613198
14. Remove the exhaust manifold studs and nut from

15. Remove the exhaust manifold and gasket from
the cylinder head.
16. Remove the heat shield studs from the exhaust
manifold, if necessary.
613220
1. Install the heat shield studs to the exhaust
2. Install the exhaust manifold gasket and manifold

to the cylinder head studs.

Notices.
3. Install the front two exhaust manifold studs and
nut to the exhaust manifold.
Tighten
" Tighten the two front exhaust manifold studs to
15 N-m (11 lb ft).
O
Tighten the exhaust manifold nut to
18 N-m (13 lb ft).
613220
Engine
6-85
4. Install the exhaust manifold heat shields to the

exhaust manifold.
5. Install the exhaust manifold heat shield nuts.
Tighten
Tighten the exhaust manifold heat shield nuts to
10 N-m (89 lb in).
613198
6. Install the number 1 spark plug to the

cylinder head.
Tighten
Tighten the number 1 spark plug to
27 N-m (20 lb ft).

Information.
14824
8. Install the two rear exhaust manifold studs and

Tighten
Tighten the two rear exhaust manifold studs to
15 Nm (11 lb ft).
18 N-m (13 lb ft).
613220
6-86
Engine
9. Install the numbers 3 and 5 spark plugs to the

cylinder head.
Tighten
Tighten the numbers 3 and 5 spark plugs to
27 N-m (20 lb ft).
14824
10. Connect the numbers 1, 3 and 5 spark plug wires

to the spark plugs.
211645
11. Install the oxygen sensor to the exhaust manifold.
Tighten
Tighten the oxygen sensor to 42 N-m (31 lb ft).
577702
Engine
Engine Mechanical
3.8l 6;..87
i 2. Install the oxygen sensor connector to the spark

plug wire harness brackeL
13. Connect the wire harness connector (1) to the
oxygen sensor connector.
14. Connect the CPA retainer.
15. Install the 3-way catalytic converter. Refer to
Engine Exhaust.
439775
Exhaust Manifold Replacement (Right)

Removal Procedure
i . Raise and suitably support the vehicle. Refer to

Information.
Engine Exhaust.
3. Disconnect the connector position
assurance (CPA) retainer.
4. Disconnect the oxygen sensor electrical
connector (3) from the harness.
439410
5. Remove the oxygen sensor connector rosebud

from the engine lift bracket.
6. Remove the oxygen sensor from the exhaust
manifold.
577706
6-88
Engine
7. Disconnect the numbers 4 and 6 spark plug wires
from the spark plugs.
211642
8. Remove the number 6 spark plug from the

cylinder head.
14824
9. Remove the two rear exhaust manifold studs and

'
(
613225
Engine
6-89
11. Disconnect the number 2 spark pluQwire from the

spark plug.
211642
12. Remove the numbers 2 and 4 spark plugs from

the cylinder head.
14824
13. Remove the exhaust mrmifold heat' shjeld nuts.

14. Remove the exhaust ~anifold heat shields fr~m
,>
'
'
613223
6~90
Engine
15. Remove the two front exhaust manifold studs and
16. Remove the right exhaust manifold and gasket
from the cylinder head.
17. Remove the heat shield studs from the exhaust
613225
1. Install the heat shield stud to the exhaust manifold,
if necessary.
2. Install the right exhaust manifold gasket and

manifold to the cylinder head studs.

Notices.
3. Install the two front exhaust manifold studs and
nuts to the exhaust manifold.
I
\
Tighten
Tighten the two front exhaust manifold studs to
15 Nm (11 lb ft).
Tighten the exhaust manifold nuts to
18 Nm (13 lb ft).
613225
4. Install the exhaust manifold heat shields to the

exhaust manifold.
5. Install the exhaust manifold heat shield nut.

Tighten
Tighten the exhaust manifold heat shield nuts to
1O N-m (89 lb in).
'
'
613223
Engine
6-91
6. Install the numbers 2 and 4 spark plugs to the
cylinder head.
Tighten
Tighten the numbers 2 and 4 spark plugs to
27 N-m (20 lb ft).
14824
7. Connect the number 2 spark plug wire to the

spark plug.
Information.
211642
9. Install the two rear exhaust manifold studs and

Tighten
Tighten the two rear exhaust manifold studs to
15 N-m (11 lb ft).
18 N-m (13 lb ft).
613225
6-92
Engine Meclumical - 3.8L
Engine
10. Install the number 6 spark plug to the
cylinder head.
Tighten
Tighten the number 6 spark plug to
27 Nm (20 lb ft}.
14824
11. Connect the numbers 4 and. 6 spark plug wires to

the spark plugs.
211642
12. Install the oxygen :sensor to the exhaust manifold.
Tighten
Tighten the exhaust manifold to 42 N-m (31 lb ft}.
13. Connect the oxygen sensor electrical conneclor
rosebud to the engine lift bracket.
577706
Engine
6-93
14. Connect the oxygen sensor electrical

connector (3) to the wiring harness.
15. Connect the CPA retainer.
Engine Exhaust.
439410

Replacement (Left)
Removal Procedure

Engine Electrical.
2. Remove the exhaust gas recirculation (EGR)
valve outlet pipe bolt from the upper intake
manifold.
3. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
4. Remove the EGR valve outlet pipe.
577700
5. Disconnect the EGR valve electrical connector.
221704
6-94
Engine
6. Remove the EGR valve adapter nuts (2}.
7. Remove the EGR valve adapter bolt (1 ).
8. Remove the EGR valve adapter from the cylinder
head studs.
9. Remove the oil level indicator tube. Refer to Oil
Level Indicator and Tube Replacement.
2
577696
10. Remove the engine lift bracket from the cylinder

head studs.
11. Remove the top ignition control module
bracket bolt.
Information.
13. Remove the rear ignition control module
bracket bolts.
15. Remove the ignition control module bracket.
577690
16. Loosen the valve rocker arm cover bolts.

17. Remove the valve rocker arm cover (1).
18. Clean the following items:
Valve rocker arm cover
Cylinder head gasket surface
Valve rocker arm cover bolts
37442
Engine
Engine Mechan.ical - 3.8L
6-95
1. Apply thread lock adhesive GM P/N 12345493 or
equivalent, to the valve rocker arm cover bolt
threads.

Notices.
2. Install the valve rocker arm cover (1 ).
3. Tighten the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
10 Nm (89 lb in).
4. Install the ignition control module bracket.

Information.
6. Install the rear ignition control module
bracket bolts.
Tighten
Tighten the rear ignition control module bracket
bolts to 50 Nm (37 lb ft).
8. Install the top ignition control module bracket bolt.
37442
Tighten
Tighten the top ignition control module bracket
bolt to 50 Nm (37 lb ft).
9. Install the engine lift bracket to the cylinder
head studs.
10. Install the oil level indicator tube. Refer to Oil

Level Indicator and Tube Replacement.
577690
6-96
Engine
11. Install the EGR valve adapter to the cylinder
head studs.
12. Install the EGR valve adapter bolt (1).
13. Install the EGR valve adapter nuts (2).

Tighten
Tighten the EGR valve adapter nuts (2) to
50 N-m (37 lb ft).
" Tighten the EGR valve adapter bolt (1) to
25 N-m (18 lb ft).
2
577696
14. Connect the EGR valve electrical connector.
221704
15. Install the EGR valve outlet pipe.

16. Install the EGR valve outlet pipe nut to the
EGR valve adapter.
17. Install the EGR valve outlet pipe bolt to the upper
intake manifold.
Tighten
Tighten the EGP valve outlet pipe nut to
29 N-m (21 lb ft 1
O Tighten the EGR valve outlet pipe bolt to
29 Nm (21 lb ft).
18. Install the ignition control module. Refer to Ignition
Electrical.
577700
Engine
6-97

Replacement (Right)
Removal Procedure
2. Remove the spark plug wires from the 1,3 and
5 spark plugs.
3. Remove the spark plug wiring harness from the
clip and reposition the harness.
Information.
52978
5. Remove the rear engine left bracket bolt (1) and

stud (2).
6. Remove the rear engine lift bracket (3).
52977
8. Loosen the valve rocker arm cover bolts.

9. Remove the valve rocker arm cover.
35819
6-98
Engine
Engine Mechanical - .3.8L
10. Remove the oil fill tube cap, if necessary.

i 1. Remove the oil fill tube, if necessary.
To remove the fill tube press the tangs inside the
tube in and twist the tube.
12. Clean the following ite.ms:
0
Valve rocker arm cover
" Cylinder head gasket surface
~ Valve rocker arm cover bolts.
577684
installation Procedure
i. Install the oil fill tube to the valve rocker arm
cover, if .removed.
2. Install the oil fill tube cap, if removed.
577684

equivalent to the valve rocker arm cover b.olt
threads.
4. Install the valve rocker arm cover.

Notices.
5. Tighten the valve rocker arm cover bolts.
Tighten
1O Nm (89 lb in).
Information.
35819
Engine
6-99
7. Install the rear engine lift bracket (3).

8. Install the rear engine lift bracket stud (2) and
bolt (1 ).
Tighten
Tighten the rear engine lift bracket stud (2) and
bolt (1) to 50 N-m (37 lb in).
52977
10. Install the spark plug wiring harness to the clip.

11. Install the spark plug wires to the 1,3 and
5 spark plugs.
52978

Replacement
Removal Procedure
1. Remove the valve rocker arm covers. Refer to
Valve Rocker Arm Cover Replacement (Left) or
Valve Rocker Arm Cover Replacement (Right).
2. Remove the valve rocker arm bolts (1 ).
3. Remove the valve rocker arms (2).
554762
6-100
Engine
4. Remove the valve rocker arm retainer (1 ).
439870
5. Remove the pushrods (1 ).
439864
Tools Required
J 36660-A Torque Angle Meter
Important: Reinstall the rocker arms and pushrods in
the same locations from which they were removed.
Important: When installing valve rocker arms
and pushrods, coat the bearing surfaces with prelube
GM P/N 12345501 or equivalent. Install these
components in the locations from which they were
removed.
1. Install the pushrods (1 ).
439864
Engine
6-101
2. Install the valve rocker arm retainer (1 ).

I
439870
3. Install the valve rocker arms (2).

equivalent to the rocker arm bolt threads before
installing.
Notices.
5. Install the valve rocker arm bolts (1).
Tighten
Tighten the valve rocker arm bolts to
15 N-m (11 lb ft). Use the J 36660-A in order to
torque the bolts an additional 90 degrees.
6. Install the valve rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Right) or Valve
Rocker Arm Cover Replacement (Left).
554762
Valve Stem Oil Seal and Valve Spring

Replacement
Removal Procedure
Tools Required
J 23590 Spark Plug Port Adapter
J 38606 Valve Spring Compressor
1. Remove the valve rocker arm and push rod. Refer
to Valve Rocker Arm and Push Rod
Replacement.
2. Remove the spark plug. Refer to Spark Plug
Replacement in Engine Electrical.
Important: Rotate the engine so that the piston in the
cylinder being worked on is at top dead center (TDC)
before removing the valve keys. This will eliminate the
) possibility of the valve accidentally falling inside the
cylinder.
3. Install the J 23590 to the spark plug port and
apply compressed air in order to hold the
valves closed.
190565
6-102
Engine
4. Install the J 38606 on the valve spring.
J 38606
190566
5. Compress the valve spring using the J 38606.

6. Remove the valve keys.
7. Remove the valve spring ahd cap.
J 38606
190527
8. Remove the valve stem oil seal.

9. Inspect the valve spring for bent, cracked or
broken parts. Replace it if damaged. Refer to
Cylinder Head Clean and Inspect.
190567
Engine
6-103
Tools Required
e J 42863 Valve Seal Installer
" J 23590 Spark Plug Port Adapter
~428~
Important: The color of the replacement seal rnay not

be the same color as the original seal. Install the
seals in their correct location based on GM part and
package description. Ensure that the seal is fully
seated on the valve guide.
1. Place the valve stem oil seal over the valve stem
so the seal begins to contact the valve guide.
Important: Use hand pressure only when installing
the valve seal using J 42863. Using to much force may
cause damage to the oil seal and possibly lead to
excessive oil consumption.
2. Using J 41512 push the valve stem oil seal over
the vavle guide.
3. Install the J 38606 on the valve spring.
40071
J 38606
154517
4. Compress the valve spring using the J 38606.
J 38606
190527
6-104
Engine
5.
6.
7.
8.
9.
J 38606
Using install the valve spring and the valve cap.

Install the valve keys.
Release the valve spring.
Ensure that the valve keys are seated.
Remove the J 38606.
190566
10. Disconnect the air pressure, and remove

the J 23590.
11. Install the spark plug. Refer to Spark Plug
Replacement in Engine Electrical.
12. Install the push rod and valve rocker arm. Refer
Replacement.
190565
Valve Lifter Replacement

Removal Procedure
1. Remove the lower intake manifold. Refer to Intake
Manifold Replacement (Lower).
2. Remove the valve rocker arms and the pushrods.
Refer to Valve Rocker Arm and Push Rod
Replacement.
3. Loosen the valve lifter guide bolts.
4. Remove the valve lifter guide.
5. Remove the valve lifters.
41374
Engine
6-105
i. Coat the valve lifters with prelube, GM

P/N 12345501 or equivalent prior to installation.
2. Install the valve lifters.
3. Install the valve lifter guide.
Notices.
4. Tighten the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).
5. Install the valve rocker arms and pushrods. Refer
Replacement.
6. Install the lower intake manifold. Refer to Intake
41374
Crankshaft Balancer Replacement

Removal Procedure
Tools Required
J 38197 Crankshaft Balancer Puller
" J 37096 Flywheel Holding Tool
1 . Remove the drive belt. Refer to Drive Belt
Replacement.
Information.
3. Remove the starter motor. Refer to Starter Motor
4. If equipped with the M49 manual transmission
remove the following components:
5. Remove the transmission brace bolts (2, 3).
6. Remove the transmission brace (1 ).
349561
7. Remove the flywheel housing inspection cover

bolts (2).
8. Remove the flywheel housing inspection cover (3).
9. If equipped with the 4L60-E automatic
transmission remove the torque converter cover.
Refer to Torque Converter Cover Replacement
(3.8 L) in Automatic Transmission - 4L60-E.
349560
6-106
Engine
10. Use J 37096 in order to hold the flywheel.
309963
11. Remove the crankshaft balancer bolt (1) from the

balancer (2).
12. Remove the key (3) from the crankshaft.
440746
13. Remove the crankshaft balancer using

the J 38197.
13.1. Invert J 38197-2 so the leg of the tool is
facing away from the crankshaft balancer.
13.2. Install the silver bolts J 38197-4 to the
crankshaft balancer.
13.3. Remove J 38197-1, J 38197-2, and
J 38197-4 from the crankshaft balancer.
(
313955
Engine
6-107
Tools Required
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer (2).
3. Align the key slot in the balancer (2) to the key
slot in the crankshaft.
4. Install the key (3)
Notices.
5. Install the crankshaft balancer bolt (1 ).
6.
7.
8.
9.
10.
Tighten
Tighten the crankshaft balancer bolt (1) to
150 Nm (111 lb ft). Use the J 36660-A to torque
the crankshaft balancer bolt (1) an additional
114 degrees.
Remove the J 37096.
If equipped with the 4L60-E automatic
transmission install the torque converter cover.
Refer to Torque Converter Cover Replacement
(3.8 L) in Automatic Transmission - 4L60-E.
If equipped with the M49 manual transmission
install the following components:
Install the flywheel housing inspection cover (3).
Install the flywheel housing inspection cover
bolts (2).
Tighten
Tighten the flywheel housing inspection cover
bolts (2) to 48 N-m (35 lb ft).
440746
349560
6-108
Engine
11. Install the transmission brace (1 ),
12. Install the transmission brace bolts (2, 3).
Tighten
Tighten the brace bolts. (3) to the engine block

to 28 N-m (21 lb ft).
Tighten the brace bolts (2) to the transmission
to 50 N-m (37 lb ft).
Install the starter motor. Refer to Staner Motor
Lower the vehicle.
Install the drive belt. Refer to Drive Belt
Replacement.
Perform the crankshaft position (CKP)
system variation learn procedure. Refer to CKP
System Variation Learn Procedure in Engine
Controls - 3.8 L.
a
13.
14.
15.
16.
349561
Crankshaft Front Cover Oil Seal

Replacement .
Removal Procedure
1. Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement.
2. Use a screwdriver to pry outthe crankshaft front
oil seal. Use. care in order to avoid damage to the
seal bore or seal contact surfaces.
50499
Tools Required
J 35354 Seal Installer
1. Install the crankshaft front oil seal. Use the

J 35354 and a soft faced hammer.
2. Remove the J 35354.
3. Coat the outside seal surface of the crankshaft
balancer with lubricant GM P/N 12377985 or
equivalent.
4. Install the crankshaft balancer. Refer to Crankshaft
Balancer Replacement.
50499
Engine
6-109
Engine Front Cover Replacement

Removal Procedure
1. Drain the engine oil.
3. Disconnect the intake air temperature (IAT) sensor
208554

5. Loosen the coolant pump pulley bolts.
Belt Tensioner Replacement.
7. Remove the power steering pump. Refer to Power
Steering Pump Replacement (VB) in Power
Steering System.
Information.
554755
10. Disconnect the crankshaft position sensor

11. Remove the crankshaft position sensor shield.
440841
Engine
6-11 O Engine Mechanical - 3.8l

12.
i 3.
14.
15.
Remove the crankshaft position sensor studs,

Remove the crankshaft position sensor.
Remove the oil pan to front cover bolts.
Loosen the oil pan bolts, to drop the oil pan
slightly in order to add clearance for the front
cover installation.
554767
17. Remove the coolant pump pulley bolts.

18. Remove the coolant pump pulley.
221711
i 9. Remove the radiator outlet hose from the

front cover.
221689
Engine
Sm 111
20. Remove the engine front cover studs and bolts (1 ).

21. Remove the engine front cover (2).
50504
22. Remove the engine front cover gasket from the

engine block.
440843
23. Remove the coolant pump bolts (1 ).

24. Remove the coolant pump (2).
25. Remove the coolant pump gasket (3) from the
front cover (4).
11687
6-112
Engine
26. If replacing the front cover (1 ), disassemble the
.. Oil pump gear set (2)
Camshaft sensor (3)
" Oil filter adapter (5) and gasket

" Oil pressure relief valve (6) and spring
27. Remove the crankshaft front oil seal (4).
28. Clean the engine front cover and engine block
surfaces.
3
445496
Installation Procedure .
1
Tools Required
s

1. If replacing the front cover (1 ), assemble the
following parts:
e Oil pump gear set (2)
~ Camshaft sensor (3)
Oil filter adapter (5) and a new gasket
Oil pressure relief valve (6) and spring
2. Install a new crankshaft front oil seal (4)
O
3
445496
3. Install the coolant pump gaskElt (3) to the front

cover (4).
4. lnstallt~e,coolqnt pump (2).
Notices,
5. :Install .the coolant pump bolts (1 ).
Tighten
Tighten the coolant pump bolts (1) to
15 Nm (11 lb ft). Use the J 36660-A to torque the
coolant pump bolts (1) an additional 80 degrees.
11687
Engine
6-113
6. Install a new engine front cover gasket to the

engine block.
440843
7. Install the engine front cover (2).
50504
8. Apply sealant GM P/N 12346004 or equivalent to

the engine front cover bolts (1) and stud (2).
9. Install the engine front cover bolts (1) and stud (2).
Tighten
Tighten the front cover bolts (1) and stud (2) to
20 N-m (15 lb ft). Use the J 36660-A to torque the
front cover bolts (1) and stud (2) an additional
40 degrees.
445603
6-114
Engine
10. Install the radiator outlet hose. to the front cover.
221689
11. Install the coolant pump pulley.

12. Install the coolant pump pulley bolts.
Tighten
Tighten the coolant pump pulley bolts to
13 Nm (115 lb in).
Information.
14. Install the oil pan to front cover bolts.
Tighten
Tighten the oil pan bolts to 14 Nm (10 lb ft).
221711
15. Install the crankshaft position sensor. .

the crankshaft position sensor studs.
17. Install the crankshaft position sensor studs.
Tighten
Tighten the crankshaft position sensor studs to
20 N-m (15 lb ft). Use the J 36660-A to torque the
crankshaft position sensor studs an additional
40 degrees.
554767
Engine
Engine Mechanical~ 3.8l
6-115
18. Install the crankshaft position sensor shield.

19. Connect the crankshaft position sensor electrical
connector.
22. Install the power steering pump. Refer to Power
Steering Pump Replacement (VB) in Power
Steering System.
440841
554755
25. Connect the intake air temperature (IAT) sensor

26. Refill the engine oil.
208554
6-116
Engine
Oil Pump Cover and Gear Set
Replacement
Removal Procedure
1. Remove the engine front cover. Refer to Engine
Front Cover Replacement.
2. Remove the oil pump cover attaching screws.
3. Remove the oil pump cover.
4. Remove the oil pump gear set.
5. Inspect the oil pump gear set and housing. Refer
to Oil Pump Clean and Inspect.
153600
1. Lubricate the oil pump gear set with
petroleum jelly.
2. Install the oil pump gear set.

3. Pack the oil pump cavity with petroleum jelly.
4. Install the oil pump cover.
Notices.
5. Install the oil pump cover screws.
Tighten
Tighten the oil pump cover screws to
11 N-m (98 lb in).
6. Install the engine front cover. Refer to Engine
153600
Oil Filter Adapter and Valve Assembly

Replacement
Removal Procedure
Replacement.
2. Remove the engine ground strap bolt (1) and
ground strap (2).
3. Disconnect the air conditioning compressor
electrical connector (3).
Information.
6. Remove the air conditioning compressor mounting
bracket. Refer to Compressor Mounting Bracket
Replacement (3.8 L) in Heating, Ventilation and Air
Conditioning.
445688
Engine Mee hanical - 3.8L
Engine
7 Disconnect the
oil pressure
6-117
sensor electrical
connector (2).
a.
Remove the oil pressure sensor.
9. Remove the engine oil filter.
---------4444(0847
6-118
Engine
10. Remove the oil filter adapter bolts (3).
11. Remove the oil filter adapter (2) and gasket (1).
12. Remove the pressure relief valve (4) and
spring (5).
13. Clean the parts in a suitable solvent. Dry the parts.
14. Clean all of the gasket sealing surfaces.
15. Inspect the following areas:
The oil pressure relief valve (4) and the valve
bore for burrs
O The spring (5) for loss of tension, replace the
spring if you are in doubt.
440844
Tools Required
1. Install the pressure relief valve (4) and spring (5).
2. Install the oil filter adapter (2) and gasket (1 ).

and Notices.
3. Install the oil filter adapter bolts (3).
Tighten
Tighten the oil filter adapter bolts (3) to
15 Nm (11 lb ft). Use the J 36660-A to torque the
oil filter adapter bolts (3) an additional 50 degrees.
440844
4. Install a new oil filter.

Tighten
Tighten the oil filter to 30 Nm (22 lb ft).
(
440847
Engine
Eng .me Mechanical - 3.8 L
6-119
5. Install the oil press ure sensor.

Tighten the oil. pressure sensor to
Tighten
16 N-m (12 lb ft).
440848
oil pressure .se nsor electrical .

. Connect the
mounting
connector (2).condilloning compre~~~~g Bracket .
7. Install the a;:r to CompiessC?r M~entilation and Air
bracket. Re .
L) in Heating,
.
. . Replace"!ent .1138 .
.
Conditioning.
8. Lowe r the vehicle.
6
440853
. co mpressor electrical
h air conditioning
9 Connect t e
It (1)
. connector (3).
d strap (2) and bo
.
10. Install the en gine groun
Tighten the engine
. ground strap bolt to
Tighten
11
25 N,m (18 lb ft).
lnsta II the drive belt.
R fer to Drive Belt

e
Replacement.
.
e 011
12. Ref I11 the engin
6-120
Engine Mechanical - .3.8l
Engine
Timing Chain and .Sprockets Replacement
Removal Procedure
2. Align the timing marks (2) on the sprockets (1, 3)
so that they are as close together as possible.
3. Remove the timing chain dampener.
4. Remove the camshaft sprocket bolt.
550171
5. Remove .the timing chain (1) and camshaft

sprocket (2).
Important: If the crankshaft sprocket does not come
off easily, a light .blow on the edge of .the sprocket
(with a pla$tiC mallet) should dislodge the sprocket.
6. Remove the crankshaft sprocket (3).
7. Clean the timing chain.
8. Clean the sprockets.
9. Inspect all the components for wear or damage.
10. If the balance shaft timing has been disturbed.
Refer to Balance Shaft Removal and Balance
Shaft Installation.
11. Use the following steps if the pistons have been
moved in the engine:
11.1. Turn the crankshaft in order to set the
number one piston is at top dead center.
11.2. With the sprocket installed, turn the
camshaft in order to have the timing
mark straight down.
550172
Tools Required
J 36660-ATorque Angle Meter
1. Install the timing chain (1) onto the
sprockets (2, 3) with the timing marks in their
closest together position.
2. Install the timing chain (1) and sprockets (2, 3).
Notices.
3. Install the camshaft sprocket bolt.
Tighten
Tighten the camshaft sprocket bolt to
100 N-m (74 lb ft). Use the J 36660-A to torque
the camshaft sprocket bolt an additional
90 degrees.
4. Install the timing chain dampener.
550172
Engine
6-121
5. Install the timing chain dampener bolt.

Tighten
Tighten the dampener bolt to 22 N-m (i 6 lb ft).
Important: Rotate the engine two revolutions and
check the timing marks. Ensure the marks are aligned.
Camshaft Replacement
Removal Procedure
1 . Recover the refrigerant. Refer to Refrigerant
2.
3.
4.
5.
Recovery and Recharging in Heating, Ventilation

and Air Conditioning.
Remove the radiator with the A/C condenser.
Refer to Radiator Replacement in Engine
Cooling.
Remove the valve lifters. Refer to Valve Lifter
Replacement.
Remove the timing chain and sprockets. Refer to
Timing Chain and Sprockets Replacement.
Remove t11e balance shaft gear (2) from the
camshaft (1).
441129
6. Remove the camshaft thrust plate baits.

7. Remove the camshaft thrust plate.
8. Remove the camshaft key.
Notice: All camshaft journals are the same diameter,
so care must be used in removing or installing the
camshaft to avoid damage to the camshaft bearings.
9. Use the following procedure to remove the
camshaft:
9.1. Install three 5/16-18 x 4 in bolts in the
camshaft bolt holes.
9.2. Carefully rotate and pull the camshaft out.
10. Inspect the camshaft and bearings. Refer to
Camshaft and Bearings Clean and Inspect.
35815
6-122
Engine

1. Coat the camshaft with prelube GM P/N 12345501

or equivalent before installation.
2. Install the camshaft.
3. Install the camshaft key.
4. Install the camshaft thrust plate.
Notices.
5. Install the camshaft thrust plate bolts.
Tighten
Tighten the camshaft thrust plate bolts to
15 Nm (11 lb ft).
35815
6. Install the balance shaft drive gear (2) to the

camshaft (1) .
441129
7. Align the timing marks (2) on the balance shaft.

gear (1) and the balance shaft drive gear (3).
8. Install the timing chain and sprockets. Refer to
9. Install the valve lifters. Refer to Valve Lifter
Replacement.
10. Install the radiator with the A/C condenser. Refer
to Radiator Replacement in Engine Cooling.
11. Charge the A/C system. Refer to Refrigerant
441151
Engine
6-123
Cylinder Head Replacement (Left)

Removal Procedure
3. Remove the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Left) in Engine
Exhaust.
4. Remove the valve rocker arms and pushrods.
Replacement.
5. Remove the cylinder head bolts (1 ).
6. Remove the left cylinder head (2).
441261
7. Remove the left cylinder head gasket (1).

8. Disassemble the cylinder head. Refer to Cylinder
Head Disassemble.
441262
Tools Required
Important: The arrow on the gasket must point to the

front of the engine. Failure to install the gasket
properly will cause gasket failure and possible engine
failure.
1. Assemble the cylinder head. Refer to Cylinder
Head Assemble.
2. Install a new left cylinder head gasket (1) to the
aHgnment pins (2).
441262
6-124
Engine

3. Install the left cylinder head (2).
441261

Notices.
4. Torque the cylinder head bolts following the given

sequence.
5. Install the cylinder head bolts.
6.
7.
8.
38826
9.
10.
Tighten
Tighten the cylinder head bolts to 50 N-m (37 lb ft)
in sequence shown. Use the J 36660-A to
torque the cylinder head bolts an additional
120 degrees.
Install the valve rocker arms and pushrods. Refer
Replacement.
Install the left exhaust manifold. Refer to Exhaust
Manifold Replacement (Left) in Engine Exhaust.
Install the lower intake manifold. Refer to Intake
Refill the engine coolant. Refer to Draining and
Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Replacement.
Engine
6-125
Cylinder Head Replacement (Right)

Removal Procedure
3. Remove the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Right).
4. Remove the valve rocker arms and the pushrods.
Replacement.
5. Remove the cylinder head bolts (1 ).
6. Remove the right cylinder head (3).
441261
7. Remove the right cylinder head gasket (3).

8. Disassemble the cylinder head. Refer to Cylinder
Head Disassemble.
441262
Tools Required
Important: The arrow on the gasket must point to the

front of the engine. Failure to install the gasket
properly will cause gasket failure and possible engine
damage.
1. Install the new right cylinder head gasket (3) to
the alignment pins (2).
441262
s~12s
Engine
2. Install the right cylinder head (3).
441261

Notices.
3. Tighten the cylinder head bolts following the given
sequence.
4.
5.
6.
38826
7.
8.
Tighten
in sequence shown. Use the J 36660-A to
torque the cylinder head bolts an additional
120 degrees.
Install the pushrods and the valve rocker arms.
Replacement
Install the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Right) in Engine
Exhaust.
Install the lower intake manifold. Refer to Intake
Refill the engine coolant. Refer to Draining and
Change the engine oil and Jilter. Refer to.Engine
Engine
6-127
Oil Pan Replacement

Removal Procedure
Information.
4. Remove the right side engine mount (2) to cradle
bolts (1 ).
49837
5. Remove the left side engine mount (2) to cradle

bolts (1 ).
50525
6. Remove the right and left side shock absorber

lower mounting bolts.
220629
6-128
Engine
7. Remove the intermediate steering shaft bolt from

the rack and pinion.
8. Support the engine cradle with appropriate
equipment.
220630
9. Disconnect the oil level sensor electrical

connector ( 1) .
440880
Notice: Remove the oil level sensor, located in the oil

pan, before the oil pan is removed. The sensor may
be damaged if the oil pan is removed first.
10. Remove the oil level sensor from the oil pan.
441263
Engine
12. Remove the front crossmember bolts.
i
220632
13. Remove the oil pan bolts (1 ).

14. Remove the oil pan (2).
Lower the rear of the oil pan while rotating the
pan outward.
441269
15. Remove the oil pan gasket.

16. Clean the oil pan gasket mating surface.
441265
6-130
Engine

1. Install the oil pan gasket.
441265
2. Install the oil pan (2).

Notices.
3. Install the oil pan bolts (1 ).
Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).
441269
4. Install the front crossmember bolts.

Tighten
.. Tighten the upper four crossmember bolts to
125 Nm (92 lb ft).
..
" Tighten the lower two crossmember bolts to
145 N-m (107 lb ft).
5. Install the starter motor. Refer to Starter Motor
~
220632
Engine
6-131
6. Install the oil level sensor to the oil pan.

Tighten
Tighten the oil level sensor to 20 N-m (15 lb ft).
441263
7. Connect the oil level sensor electrical

connector (1 ).
8. Remove the equipment used to support the

engine cradle.
440880
9. Install the intemediate steering shaft from the rack

and pinion.
Tighten
Tighten the intermediate shaft bolt to
47 Nm (35 lb ft).
220630
6-132
Engine
10. Install the right and left side shock absorber lower
mounting bolts.
Tighten
Tighten the shock bolts to 65 Nm (48 lb ft).
220629
11. Install the left side engine mount (2) to cradle

bolts (1 ).
Tighten
Tighten the left side engine mount to cradle
50525
12. Install the right side engine mount (2) to cradle

bolts (1 ).
Tighten
Tighten the right side engine mount to cradle
15. Change the engine oil and filter. Refer to Engine
49837
Engine
6-133

Replacement
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan
Replacement.
2. Remove the oil pump screen attaching bolts (2).
3. Remove the oil pump screen (1 ).
4. Remove the oil pump screen gasket (3).
5. Clean the screen and housing with solvent and
blow dry with compressed air.
6. Clean the gasket mating surfaces on the pipe
flange and cylinder block.
441270
1. Install the oil pump screen gasket (3).
2. Install the oil pump screen (1 ).

Notices.
3. Install the oil pump screen bolts (2).
Tighten
Tighten the oil pump screen bolts (2) to
15 Nm (11 lb ft).
4. Install the oil pan. Refer to Refer to Oil Pan
Replacement.
441270
Engine Flywheel Replacement

Removal Procedure
Tools Required
J 37096 Flywheel Holding Tool
1. If equipped with a manual transmission remove
the clutch pressure plate and driven disc. Refer
to Clutch Pressure Plate arid Clutch Driven
Plate (3.8 L) in Clutch.
2. Remove the automatic transmission, if equipped.
Refer to Transmission Replacement (3.8 L) in
automatic Transmission - 4L60-E.
3. Use the J 37096 to hold the flywheel to loosen the
flywheel bolts.
309963
6134
Engine
4. If equipped with the manual transmission, remove

the following components:
4.1. Remove the flywheel bolts (1 ).
4.2. Remove the flywheel (2).
441112
5. If equipped with the automatic transmission,

remove the following components:
5.1. Remove the flywheel bolts (1 ).
5.2. Remove the flywheel (2).
441271
Tools Required
1. If equipped with the automatic transmission, install
1.1. Install the flywheel (2).
1.2. Install the flywheel bolts (1) finger tight.
441271
Engine
6-135
2. If Elquipped with the manual transmission, install

2.1. Install the flywheel (2).
2.2. Install the flywheel bolts (1) finger tight.
. 441112
3. Use the. J 37096 to hold the flywheel when

ti,ghtening the flywheel bolts.
Notices.
4. Tighten the flywheel bolts.
Tighten
Tighten the flywheel bolts to 15 N-m (11 lb ft). Use
the J 36660-A to torque the flywheel bolts an
additional 50 degrees.
5. Install the .automatic transmission, if equipped.
Refer to Transmission Replacement (3.8 L) in
automatic Transmission - 4L60-E.
6. If equipped with a manual transmission install the
clutch pressure plate and driven disc. Refer to
Clutch Pressure Plate and Clutch Driven Plate
(3.8 L) in Clutch.
309963

Replacement
Removal Procedure
1. Drain the engine coolant .from the cooling system.
Refer to Draining and Filling Cooling System
(3.8 L) in Engine Cooling.
2. Remove the engine flywheel. Refer to Engine

Flywheel Replacement.
3. Loosen all of the oil pan bolts.
4. Remove the crankshaft rear oil seal housing bolts.
5. Remove the crankshaft rear oil seal housing.
6. Remove the rear oil seal housing gasket.
)
Important: Make sure not to damage the crankshaft

OD surface with any tool.
7. Remove the oil seal from the housing.
153604
6-136
Engine
8. Clean the gasket surfaces of the oil seal housing
and the engine block.
9. Inspect the ID of the. oil seal housing bore.
Replace the crankshaft rear oil seal housing
as required.
10. Inspect the crankshaft for nicks or burrs on the
surface that contacts the seal.
11. Repair or replace the crankshaft as required.
Tools Required
J 41349 Crankshaft Rear Oil Seal Housing
Aligning Tool
Notice: Do not use sealers or adhesives on rear main
oil seal housing gasket. Use of sealers or adhesives
on this gasket may cause oil leaks.
1. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
Important: The plastic inserts in the crankshaft rear

oil seal housing are used .to aid assembly only.
The inserts are not required for ser:vice.
2. Finger tighten the crankshaft rear oil seal
housing bolts.
153604
3. Apply engine oil to both sides of the J 41349.
Notice: Sealability of the rear mai.n oil seal depends

on the correct alignment of the rear main oil seal
housing and the oil pan. Incorrect alignment
may cause oil leaks.
J 41349
4. Install the J 41349 over the crankshaft. Twist the

tool to aid in sliding the tool over the crankshaft.
5. Raise the oil pan and finger tighten the oil
pan bolts.
Notices.
6. Tighten the crankshaft rear oil seal housing bolts.
153603
Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 Nm (11 lb ft). Use the J 36660-A to
torque the crankshaft rear oil sea.I housing bolt an
8. Tighten the oil pan bolts.
Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).
9. Remove th.e engine flywheel. Refer to Engine
Flywheel Replacement.
Filling Cooling System {3.8 L) in Engine Cooling.
Engine
Engine Mechanical~ 3.8L
6-137
Engine Replacement
Removal Procedure
Tools Required
J 37088-A Fuel Line Disconnect Tool Set
J 39549 Ball Joint/Tie Rod Separator
O J 39580 Universal Engine Support Table
J 21366 Converter Holding Strap
2. Disconnect the positive battery cable.
211587
3. Disconnect the intake air temperature (IAT)

sensor electrical connector.
208554

5. Recover the refrigerant. Refer to Refrigerant
6.
7.
8.
9.
10.
11 .

Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls - 3.8 L.
Raise and suitably support the vehicle. Refer to
Information.
Drain the engine oil.
Remove the front wheels. Refer to Tire and
Wheel Removal and Installation in Tires and
Wheels.
Drain the engine coolant. Refer to Draining and
Remove the 3-way catalytic converter. Refer to
Engine Exhaust.
554755
6-138
Engine
12. Drain the transmission fluid, if equipped with a
manual transmission.
13. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
14. Remove the torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
15. On vehicles equipped with a automatic
transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transmission.
208264
16. Remove the retainer from the range selector

lever cable.
.ml
I
341079
Engine
17. Remove the range selector lever cable from the

cable bracket.
208276
18. On vehicles equipped with a manual transmission,

disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221.
19. Remove the left side front air deflector. Refer to
Air Deflector Replacement - Front Bumper Fascia
in Bumpers.
20. Remove the stabilizer bar bracket bolts.
21. Remove the stabilizer bar brackets.
43255
22. Remove the steering gear coupling shield.

23. Remove the intermediate steering shaft bolt and
shaft from the rack.
220630
6-140
Engine Mechanical- .3.8L
Engine
24. Remove the wiring harness ground bolt and RF
(Radio Frequency) ground strap and cruise
control ground lead from the front rail.
25. Disconnect the knock sensor electrical connectors.
346034
26. Disconnect the wheel speed sensors electrical

connectors.
346036
27. Remove the air conditioning (A/C) compressor

and condenser hose nut at the condenser.
28. Discard the 0-ring.
569444
Engine
6-141
29. Remove the front fuel pipe heat shield nuts {1 ).

30. Remove the front fuel pipe heat shield (2).
31. Disconnect the brake lines from the brake
pipe clip.
7cP
173551
33; Remove the engine wiring harness ground

bolt (1 ).
34. Remove the engine ground.
445688
35. Remove the A/C compressor and condenser hose

bolt at the accumulator.
282936
6-142
Engine
37. Remove the heater hoses from the drive belt
tensioner.
282933
38. Using J 37088-A disconnect the following pipes:

The fuel feed (1) from the fuel rail
.. The fuel return (2) from the fuel rail
39. Disconnect the EVAP pipe (6) at the engine.
215517
40. Remove the capture secondary lock from the

41. Disconnect the electronic throttle control (ETC)
42. Remove the forward lamp harness branch from
the wire harness clip.
439418
Engine
6-143
43. Remove the inlet hose from the water outlet.
221680
44. Remove the outlet hose from the water pump.
221689
45. Remove the brake booster vacuum hose (2) from

the intake manifold fitting (1 ).
46. Remove the front two brake pipes from the brake
modulator.
439407
6-144
Engine
47. Disconnect the captured secondary locks.
48. Disconnect the forward lamp harness from the
engine harness.
49. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.
(
\
346047
50. Disconnect the powertrain control module (PCM)

connectors.
51. Remove the PCM from the vehicle.
52. Remove the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right in
Instrument Panel, Gauges and Console.
53. Remove the hinge pillar trim panel. Refer to Trim
Replacement - Hinge Pillar in Interior Trim.
346043
54. Disconnect the engine wiring harness from the

instrument panel wiring harness.
346039
Engine
6-145
55. Remove the engine wire harness through the front

of dash. Place the harness on top of the engine.
56. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
Transmission - 4L60-E.
57. Remove the transmission control, if equipped.
Refer to Shift Control Assembly Replacement in
Manual Transmission - M49.
Information.
346041

60. Remove the cotter pins and nuts from the left and
right upper ball joints.
61. Using J 39549 separate the upper control arms
from the steering knuckles.
62. Support both steering knuckles.
63. Position J 39580 below the engine.
65. Lay the engine wire harness on top of the engine.
220629
~
220632
6-146
Engine
67. Remove the transmission support bolts.

68. Raise the vehicle and remove the engine and
transmission fromthe vehicle.
69. Secure the crossmember to the J 39580.
208587
70. Position a hex-head socket on the belt tensioner,

pulley bolt.
relieve the tension on the drive belt (1 ).
72. Remove the drive belt (1) from the tensioner (2)
and pulleys.
41363
73. Remove the A/C compressor.rear bolts (2, 3).

74. Remove the A/C compressor rear bracket
stud (1 ).
75. Remove the A/C compressor rear bracket.
(
365440
Engine
6-147
76. Remove the A/C compressor bolts.

77. Remove the A/C compressor.
282953
78. Remove the drive belt tensioner bolts.

79. Remove the drive belt tensioner.
35804
80. Remove the power steering pump nuts (3).

81. Reposition the power steering pump to
crossmember.
290569
5.;14s
Engine
---- \ --
82. Disconnect the generator electrical connector.
211637
83. Remove the positive cable nut from the generator

terminal.
84. Remove the generator from the engine.
85. Install a lifting devise to the engine.
43670

bolts (1, 2) and the right engine mount bra,c~et (3).
3
50517
Engine
6-149

and the left engine mount bracket (1 ).
89. With the aide of an assistant, raise the engine
and transmission from the crossmember.
50546
90. If equipped with the automatic transmis$ion

remove the following:
91. Right side transmission support brace
bolts (1, 2, 3).
92. Right side transmission support but (6).
93. Right side transmission support (4).
208574
94.
95.
96.
97.
Left side transmission support brace bolts (3, 5).

Left side transmission support nut (1 ).
Left side transmission support (4).
Remove the torque converter cover (2).
208577
6-150
Engine Mechanical - 3.8L.
Engine
98. Remove the flywheel to torque converter bolts.
208580
99. If equipped with the manual transmission remove

the following:
100. Right side transmission support bolts (3, 4).
448855
102. Left side transmission support bolts (2, 3).

103. Left side transmission support (1 ).
104. Disconnect the electrical connectors from.the
transmission.
349561
Engine
6-151
105. For the automatic transmission, remove the

transmission to engine bolts and nut.
106. Separate the transmission from the engine.
107. Attach the J 21366 to the transmission.
208594
108. For the manual transmission, remove,t~e

flywheel housing to engine bolts (l, 2) and
nuts (3).
109. Separate the flywheel housing from the engine.
441492
11 O. For the manual transmission, remove the

pressure plate bolts (1 ).
111. Remove the pressure plate (2) an.d the clutch
disc (6) from the flywheel (5).
6
441865
6-152
Engine
112. For the automatic transmission, remove the
flywheel bolts (1) and flywheel (2).
441271
113. For the manual transmission, remove the

flywheel bolts (1) and flywheel (2).
114. Install the engine to a engine stand.
441112
Tool.s Required
J 39580 Universal Engine Support Table
1. Install engine lifting devise and remove engine
from the stand.
Notices.
2. For the manual transmission, install the
flywheel (2) and flywheel bolts (1 ).
Tighten
Tighten the flywheel bolts (1) to 15 Nm (11 lb ft).
Use the J 36660-A to torque the flywheel bolts
an additional 50 degrees.
441112
Engine
6-153
3. For the automatic transmission, install the

flywheel (2) and flywheel bolts (1 ).
Tighten
Tighten the flywheel bolts (1) to 15 N-m (i 1 lb ft).
Use J 36660-A to torque the flywheel bolts an
441271
4. For the manual transmission; install the clutch

disc (6) and pressure plate (2) to the flywheel (5).
5. Install the pressure plate bolts (1).
Tighten
Tighten the pressure plate bolts (1) to
20 N-m (15 lb ft). Use J 36660-A to torque the
pressure plate bolts (1) an additional 45 degrees.
6. Align the flywheel housing to the engine.
6
441865
7. For the manual transmission, install the flywheel,

housing to engine bolts (1, 2) and nuts. (3). . J
Tighten
Tighten the flywheel housing to engine bolts (1, 2)
and nuts (3) to 95 Nm. (70 lb ft).
8. If equipped with a automatic transmission remove
the J 21366 from the transmiss'ion.
441492
6-154
Engine
9. For the automatic transmission, install the
transmission to engine bolts and nut.
Tighten
Tighten the transmission to engine bolts and nut
to 95 N-m (70 lb ft).
10. Connect the electrical connectors to the
transmission.
208594
11. If equipped with the manual transmission install

the following:
12. Left side transmission support (1 ).
13. Left side transmission support brace bolts (2, 3).
Tighten
Tighten the left side transmission support
brace bolts (2) to 50 N-m (37 lb ft).
brace bolts (3) to 28 N-m (21 lb ft).
(-
349561
14. Right side transmission support (1 ).

15. Right side transmission support brace bolts (3, 4).
Tighten
Tighten the right side transmission support brace
bolts (3, 4) to 50 N-m (37 lb ft).
448855
Engine
6-155
16. If equipped with the automatic transmission install

the following:
17. Install the torque converter to flywheel bolts.
Tighten
Tighten the torque converter to flywheel bolts to
63 Nm (47 lb ft).
208580
18.
19.
20.
21.
Install the torque converter cover (2).

Left side transmission support (4).
Left side transmission support bolts (3, 5).
Left side transmission support nut (1 ).
Tighten
bolts (3) to 8.5 N-m (75 lb in).
O Tighten the left side transmission support
nut (1) to 80 N-m (59 lb ft).
208577

23. Right side transmission support brace
bolts (1, 2, 3).
24. Right side transmission support nut (6).
Tighten
Tighten the right side transmission support
brace bolts (1) to 8.5 N-m (75 lb in).
bolts (2, 3) to 50 N-m (37 lb ft).
nut (6) to 80 N-m (59 lb ft).
25. With the aide of an assistant, lower the engine
and transmission to the crossmember.
208574
6-156
Engine Mechanical - 3~8l
Engine
mount bracket stud (2).
Tighten
Tighten the left engine mount bracket bolt (3)
to 100 Nm (74 lb ft).
Tighten the left engine mount bracket stud (2)
to 87 N-m (64 lb ft).
50546
28. Install the right engine mount bracket (3) and the
engine mount bracket bolts (1, 2).
Tighten
Tighten the two right engine mount bracket
bolts (1) to 100 N,m (74 lb ft).
Tighten the right engine mount bracket bolt (2)
to 50 N-m (37 lb ft).
29. Remove the lifting devise from the engine.
50517
30. Install the generator to the engine.

31. Install the positive cable nutto the generator
terminal.
Tighten
Tighten the positive cable nut to generator
terminal to 22 Nm (16 lb ft).
43670
Engine
6-157
32. Connect the generator electrical connector.
211637
33. Install the power steering pump.

34. Install the power steering pump nuts (3).
Tighten
Tighten the power steering nuts (3) to
30 N-m (22 lb ft).
290569
35. Install the drive belt tensioner.

36. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 Nm (37 lb ft).
35804
6-158
Engine
37. Install the A/C compressor.
38. Install the A/C compressor bolts.
Tighten
Tighten the A/C compressor bolts to

50 Nm (37 lb ft).
282953
39. Install the A/C compressor rear bracket.

40. Install the A/C compressor rear bracket stud (1 ).
41. Install the A/C compressor rear bolts (2, 3).
Tighten
Tighten the A/C compressor rear bra.cket .
stud (1) to 50 N,m (37 lb ft).
O
Tighten the A/C compressor rear bolts (2, 3) to

30 Nm (22 lb ft).
365440
42. Route the drive belt (1) around the pulleys.

pulley bolts.
relieve the tension on the drive belt (1 ).
45. Install the drive belt (1) onto the tensioner (2).
46. Remove the crossmember to J 39580 security
straps.
47. Lower the vehicle and install the engine and
transmission to the vehicle.
48. Align the crossmember to the vehicle body.
41363
Engine
6-159
49. Install the.front crossmember bolts
Tighten
Tighten the upper four cradle bolts to
125 N-m (92 lb ft).
Tighten the lower two cradle bolts to
145 N-m (107 lb ft).
i
220632
50. Install the transmission support bolts.
51.
52.
53.
54.
Tighten
Tighten the transmission support bolts to
57 N-m (42 lb ft).
Raise and suitably support the vehicle. Refer to
Information.
Remove the J 39580 from below the vehicle.
Remove the supports from both steering knuckles.
Connect the ball stud to the steering knuckle.
208587
55. Install the nuts and cotter pins to the left pnd right
upper ball joints.
Tighten
Tighten the upper ball joint nuts. to
53 N-m (39 lb ft).
56. lnstal the right and left side shock absorber lower
mounting bolts.
Tighten
Tighten the shock bolts to 65 Nm (48 lb ft).
58. Install the transmission control, if equipped. Refer
to Shift Control Assembly Replacement in Manual
Transmission - M49.
59. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
220629
6-160
Engine
60. Install the engine wire harness through the front
of dash.
346041
61. Connect the engine wiring harness to the

62. Install the hinge pillar trim panel. Refer to Trim
63. Install the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right
in Instrument Panel, Gauges and Console.
346039
64. Install the PCM to the vehicle.

65. Connect the PCM connectors.
346043
Engine
6-161
66. Connect the engine harness vacuum tube to the

bottom of the vacuum check valve.
67. Connect the forward lamp harness to the engine
harness.
68. Connect the captured secondary locks.
69. Install the front two brake pipes to the brake
modulator.
346047
70. Install the brake booster vacuum hose (2) to the

intake manifold fitting (1 ).
439407
71. Install the outlet hose to the water pump.
221689
6-,162
Eng in~
72. Install the inlet hose to the water outlet.
221680
73. Install the forward lamp harness branch to the

wire harness clip.
74. Connect the electronic throttle control (ETC)
75. Install the capture secondary lock to the electrical
connector.
439418
76. Connect the EVAP pipe (6) at the engine.

77. Connect the fuel return pipe (2) to the fuel rail.
78. Connect the fuel feed pipe (1) to the fuel rail.
215517
Engine
6-163
79. Install the heater hoses to the drive belt tensioner.
282933
80. Install a new 0-ring.

81. Install the A/C compressor and condenser hose
bolt at the accumulator
Tighten
Tighten A/C compressor and condenser hose bolt
at the accumulator to 48 N-m (36 lb ft).
569444
82. Install the engine ground.

83. Install the engine wiring harness ground bolt (1) to
25 N-m (18 lb ft).

Information.
85. Connect the brake lines to the brake pipe clip.
445688
6-164
Engine
86. Install the front fuel pipe heat shield (2).
87. Install the front fuel pipe heat shield nuts (1).
Tighten
Tighten the front fuel pipe heat shield nuts (1) to
5 N-m (44 lb in).
7~
173551

nut at the condenser.
Tighten
Tighten the A/C compressor and condenser hose
nut at the condenser to 16 N-m (12 lb ft).
365450

91. Install the A/C compressor and condenser
hose bolt.
Tighten
bolt to 33 N-m (24 lb ft).
365423
Engine
6-165
92. Connect the wheel speed sensors electrical
connectors.
93. Connect the knock sensors electrical connectors.
\
346036
94. Install the RF ground strap, cruise control lead

and wiring harness ground bolt to the front rail.
Ti,ghten
Tighten the wiring harness ground bolt to
12 N-m (106 lb in).
346034
95. Install the intermediate steering shaft and bolt to

the rack.
Tighten
47 N-m (35 lb ft).
96. Install the steering gear coupling shield.
97. Install the stabilizer bar brackets.
98. Install the stabilizer bar bracket bolts.
Tighten
Tighten the stabilizer bar bracket bolts to

55 Nm (41 lb ft).
99. Install the left side front air deflector. Refer to Air
Deflector Replacement - Front Bumper Fascia in
Bumpers.
220630
6-166
Engine
100. On vehicles equipped with a manual

transmission, connect the clutch actuator
cylinder line to the actuator cylinder.
43255

transmission, install the range selector lever
cable to the cable bracket.
208276
102. Install the retainer to the range selector

lever cable.
~
I
341079
Engine
6.;.167
103. Snap the transmission range selector lever cable

to the range selector lever at the transmission.
104. Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
105. Install the propeller shaft. Refer to Propeller

Shaft Replacement - One.Piece or Propeller
Shaft Replacement - Two Piece in
Propeller Shaft.
Engine Exhaust.
107. Install the front wheels. Refer to Tire and Wheel
Removal and Installation in Tires and Wheels.
208264
554755
110. Connect the intake air temperature (IAT) sensor

208554
6-168
Engine Mechanical. - 3.8L
Engine
211587
111. Connect the positive battery cable.

Replacement (3.8 L) in Engine ElectricaL
113. Refill the engine a.ii.
114. Refill the transmission .fluid.
115. Refill the engine co9lant. Refer to Draining and
116. Recharge the refrigerant. Refer to Refrigerant
Recovery and.RechargingJn Heating, Ventilation
117. Bleed the brakes. Refer to Hydraulic Brake

System Bleeding (Manual Bleeding) or
Hydraulic Brake System Bleeding (Pressure
Bleeding) in Hydraulic Brakes.
118. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.
119. Perform the crankshaft postion (CKP)
Controls - 3.8 L.
Engine Oil and Oil Filter Replacement

Removal Procedure
1. Raise and suitably support the vehicle .. Refer to
Information.
2. Position the oil drain pan under the engine oil
drain plug.
3. Remove the engine oil drain plug.
4. Clean and'inspect the engine oil drain plug,
replace if necessary.
5. Clean and inspect the engine oil drain plug
sealing surface on the. oil pan, replace the oil pan
if necessary.
190564
6. Remove the .oil filter.

7. Clean and inspect the oil filter sealing area on the
oil filter adapter, replace .if necessary. Refer to Oil
Filter Adapter Removal.
(
440847
Engine
6-169
1. Ughtly oil the replacement oil filter gasket with
clean engine oil.

Notices.
2. Install a new engine oil filter.
Tighten
Tighten the engine oil filter to 30 N-m (22 lb ft).
440847
3. Install the engine oil drain plug.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Tighten
Tighten the engine oil drain plug to
30 Nm (22 lb ft).
Remove the oil drain pan.
Lower the vehicle.
Fill the engine with new engine oil.
Start the engine.
Inspect for oil leaks after engine start up.
Turn off the engine and allow the oil a few minutes
to drain back into the oil pan.
Remove the oil level indicator from the oil
indicator tube.
Clean off the indicator end of the oil level indicator
with a clean paper towel or cloth.
Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle
contacts the top of the oil level indicator tube.
Again, remove the oil level indicator from the oil
level indicator tube keeping the tip of the oil level
indicator down.
14. Check the level of the engine oil on the oil level
indicator.
15. If needed add or drain the engine oil to the

correct level.
190564
6-170
Engine
Draining Fluids and Oil Filter Removal
Draining the Engine
1. Remove the oil drain plug.

3. Remove the oil filter.
192725
4. Remove the coolant drain plugs.

5. Drain the coolant.
'
I
211914
Crankshaft Balancer Removal

Tools Required
J 38197 Crankshaft Balancer Puller
1. Use J 37096 to hold the flywheel.
309963
Engine
6-171
2. Remove the crankshaft balancer bolt.
192730
3. Use J 38197to remove the crankshaft balancer.

Important: Do not separate the crankshaft pulley from
the crankshaft balancer. Service the crankshaft .
pulley and the crankshaft balancer as an assembly.
3.1. Invert J 38197-2 so the leg of the tool is
facing away from the crankshaft balancer.
3.2. Install the silver screws J 38197-4 to the
crankshaft balancer.
3.3. Turn J 38197-1 to remove the crankshaft
balancer from the crankshaft.
3.4. Remove J 38197-1, J 38197-2, and
J 38197-4 from the crankshaft balancer.
J 38197
313955
Engine Flywheel Removal (Manual

Transmission)
1. Remove the flywheel bolts. Discard the bolts.
2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.
192727
6-172
Engine

Engine Flywheel Removal
(Automatic Transmission)
1. Remove the flywheel bolts. Discard the bolts.

2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.
36665
Drive Belt Tensioner Removal

313973
Oil level Indicator and Tube Removal

1. Remove the oil level indicator bolt.
2. Remove the oil level indicator.
36615
Engine
6-173
Water Outlet Removal

1.
2.
3.
4.
Remove
Remove
Remove
Remove
the
the
the
the
water outlet bolts.

water outlet.
water outlet gasket.
thermostat.
36621
Water Pump Removal

1. Remove tHe water pump pulley bolts.
2. Remove the water pump pulley.
313967
3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gasket.
36600
6-174
Engine

Intake Manifold Removal (Upper)
1.
2.
3.
4.
Remove the
Remove the
Remove the
Remove the
manifold.
right spark plug wires.

manifold vacuum source.
EGR outlet pipe bolt and nut.
EGR outlet pipe from the intake
36609
Notice: The two bo.lts which .fasten the lower intake

manifold to the. cylinder head are .accessible only after
the upper intake is removed. The bolts are located
in the right front and left rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.
5. Remove the throttle body nuts and bolt.
6. Remove the throttle body.
7. Remove the throttle body gasket.
36624
8. Remove the fuel injectior rail nuts.

9. Remove the fuel injector .rail.
36631
Engine
6-175
10. Remove the upper intake manifold bolts.

11 . Remove the upper intake manifold.
12. Remove the upper intake manifold gasket.
36634
Intake Manifold Removal (lower)

1. Remove the ignition control module and bracket.
2. Remove the generator bracket.
566980
3. Remove the lower intake manifold bolts.
Notice: The two bolts which fasten the lower intake

manifold to the cylinder head are accessible only after
the upper intake is removed. The bolts are located
in the right front and left rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.
4. Remove the lower intake manifold.
5. Remove the lower intake manifold gasket.
50046
6-176
E11gine
Exhaust Manifold Removal (left Side)

i. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
589352
Important: When removing th.e EGR inlet tube from

the le_ft exhaust manifold, inspect the pipe for leaks
during installation. Replace the EGR adapter if
the pipe leaks.
3. Remove the EGR inlet pipe bolt and nuts.
4. Remove the EGR inlet pipe from the exhaust
manifold.
589355
5. Remove the engine lift hook.
(
.566982
Engine
6-177
6. Remove the exhaust manifold nuts.

7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.
589361
Exhaust Manifold Removal (Right Side)

1. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
589365
3. Remove the exhaust manifold nuts.

4. Remove the exhaust manifold.
5. Remove the exhaust manifold gasket.
589366
6-178
Eng in~

(Left Side)
1. Remove the valve rocker arm cover bolts.
35819

(Right Side)

63414
Valve Rocker: Arm and Push Rod Removal

1. Remove the valve rocker a'rm bolts.
2. Remove the valve rocker arm.
3. Remove the push rods.
35840
Engine
Engine Mechanical .. 3.8L
6-179
Cylinder Head Removal

1.
2.
3.
4.
Remove the cylinder head bolts.

Discard the cylinder head bolts.
Remove the cylinder head.
Remove the cylinder head gasket.
35842
Valve Lifter Removal

1. Remove the valve guide retainer bolts.
2. Remove the valve guide retainers.
3. Remove the valve lifters.
41374
Crankshaft Front Oil Seal Removal

lmponant: Do not damage the seal bore odhe
contact surfaces.
Use a screwdriver to pry out the crankshaft front
oil seal.
26135
6-180
Engine
Engine Front Cover Removal
1. Remove the crankshaft position sensor shield;
35844
2. Remove the crankshaft position sensor studs.

3. Remove the crankshaft position sensor.
4. Remove the. bolts connecting the oil pan to the
engine front cover.
36589
5. Remove the engine front cover bolts and stud.

6. Remove the engine front cover.
7. Remove the engine front cover gasket.
(
345236
Engine
6-181
Oil Filter Adapter Removal

1. Remove the
front cover.
2. Remove the
3. Remove the
4. Remove the
5. Remove the
oil filter adapter bolts from the engine

oil
oil
oil
oil
filter adapter.
filter adapter gasket.
pressure relief valve.
pressure relief valve spring.
36655
Oil Pump Cover and Gear Set Removal

1. Remove the oil pump cover screws.
3. Remove the oil pump gears.
26160

Removal (VIN K)
1. Align the timing marks on the sprockets.
192708
6-182
Engine
2. Remove the timing chain dampener.
154523
3.
4.
5.
6.
7.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
camshaft sprocket bolt.

camshaft sprocket.
timing chain.
crankshaft sprocket.
crankshaft balancer key.
192716
8. Remove the balance shaft drive gear.
(
154519
Engine
6-183
Camshaft Removal
)
1. Remove the camshaft thrust plate screws.

2. Remove the camshaft thrust plate.
3. Remove the camshaft. Carefully rotate and pull
the camshaft out of the camshaft bearings.
35815
Balance Shaft Removal

Tools Required
J 6125-18 Slide Hammer
1. Remove the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear.
154521
3. Remove the balance shaft retainer bolts.

4. Remove the balance shaft retainer.
42237
6184
Engine Mechanical .. 3.8L
Engine
5. Use J 6125-18 to remove the balance shaft
J 6125-18
36705
Crankshaft Rear Oil Seal Removal

Important: Do not damage the crankshaft or the
crankshaft rear oil seal housing.
Pry the crankshaf(rear oil seal out with a screwdriver.
26129

Removal
1. Remove the crankshaft rear oil seal housing bolts.
The bolts may remain in the crankshaft rear oil
seal housing.
2. Remove the crankshaft rear oil seal housing.
26125
Engine
6-185
Oil Pan Removal

Notice: Remove the oil level sensor, located in the oil
pan, before the oil pan is removed. The sensor
may be damaged if the oil pan is removed first.
1. Remove the oil level sensor.
35861
2. Remove the oil pan bolts.

3. Remove the oil pan.
4. Remove the oil pan gasket.
44775

Removal
1. Remove the oil pump pipe and screen
assembly bolts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly
gasket.
4. Use solvent to clean the oil pump pipe and
screen.
26202
6-186
Engine
Removal
J 24270
11497
Tools Required
J 41507 Connecting Rod Assembly Guide
J 24270 Cylinder Ridge Reamer
1. Mark the connecting rod cap and the connecting
rod for proper installation.
Notice: If there is a pronounced ridge at the top of the
piston travel, the ridge must be removed with a
ridge reamer before the piston and connecting rod
assembly are removed. Applying force may break the
piston rings or damage the piston.
2. Use the J 24270 to remove the cylinder bore
ring ridge.
2.1. Turn the crankshaft until the piston is at the
bottom of the stroke.
2.2. Cover the piston with a cloth.
2.3. Remove the cylinder ring ridge.
top of the stroke.
2.5. Remove the cloth.
2.6. Remove the metal shavings from the
cylinder and piston.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap.
38153
Engine
6-187
5. Install J 41507to the connecting rod. Hand

tighten the tool to the connecting rod.
6. Use hand pressure on J 41507 to push the
connecting rod towards the top of the cylinder.
Important: Mark the piston with the number of the
cylinder from which it was removed. Mark the piston as
to what is the front for proper reassembly.
7. Remove the piston, the connecting rod, and the
connecting rod bearings.
38180
Crankshaft and Bearings Removal

Tools Required
J 41348 Main Bearing Cap Puller
Important: This engine has side bolts on all of the
main caps except the rear cap. These bolts must be
removed to service the caps.
1. Remove the crankshaft main bearing cap
side bolts.
2. Remove the crankshaft main bearing cap bolts.
35863
Notice: Main bearing caps are press fit. Remove the

caps carefully for service. J 41348 has been designed
to work with J 6125-B in order to prevent damage
to the bearing and cap. J 41348 MUST be installed
properly into the bolt holes of the caps and J 6125-B
attached to J 41348 in order to properly remove
the main cap without damaging the bearing or the
cap. Any deviation from this procedure may cause
damage to the cap and the bearing and may result in
future engine damage.
J 6125-18

Notices.
3. Install J 41348 into the crankshaft main bearing
cap bolt holes.
Tighten
Tighten the bolts on J 41348 to 12 N-m (100 lb in).
4. Install J 6125-18 to J 41348.
5. Use J 6125-18 to remove the crankshaft main
bearing caps.
36704
6-188
Engine
6. Remove the crankshaft.

7. Remove the upper main bearings from the
engine block.
35863
Engine Block Plug Removal
1. Remove the threaded coolant jacket plugs.
589370
2. Remove the remaining plugs using the following

procedure.
2.1. Obtain a suitable self-threading screw.
2.2. Drill a hole into the plug.
2.3. Install the self-threading screw.
2A. Use the screw to pry out the plug.
26198
Engine
6-189
Engine Block Clean and Inspect
Tools Required
e J 8087 Cylinder Bore Checking Gauge
" J 8001 Dial Indicator Set
1. Clean the sealing material from the gasket mating
surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined
surfaces with engine oil.
7. Inspect the threaded holes. Clean the holes with a
tap. If necessary, drill out the holes and install
thread inserts. Refer to Thread Repair.
8. Use a straight edge and a feeler gage to check
the deck surface for flatness. Carefully machine
minor irregularities. Replace the block if more than
0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front
cover attaching area for nicks. Use a flat mill file
to remove any nicks.
10. Inspect the mating surfaces of the
transmission case.
Notice: A broken flywheel may result if the
transmission case mating surface is not flat.
11. Use the following procedure to measure the
engine block flange runout at the six mounting bolt
hole bosses:
11.1. Temporarily install the crankshaft. Measure
the crankshaft flange runout.
11 .2. Hold the gauge plate flat against the
crankshaft flange.
11.3. Place J 8001 on the transmission mounting
bolt hole boss. Set the indicator to 0.
11 .4. Record the readings obtained from all of
the bolt hole bosses. The measurements
should not vary more than 0.254 mm
(0.010 in).
1 i .5. Recheck the crankshaft flange runout if
the readings vary more than 0.254 mm
(0.010 in).
5272
38648
6~190
Engine
12. Inspect the crankshaft main bearing bores. Use
J 8087 to measure the bearing bore concentricity
and alignment at the following locations:
" The camshaft
" The crankshaft
Important: Recondition the engine block with the

crankshaft main bearing caps and the crankshaft main
bearing cap side bolts installed and tightened to
specification ..
13. Ensure that the crankshaft main bearing caps are
installed correctly. The arrows should point toward
the front of the engine.
14. Replace the engine block if the bores are ou1 of
specification.
38663
15. Use J 8087 to inspect the cylinder bores. Inspect

for the following items:
"Wear
" Taper
" Run-out
.. Ridging
J 8087
Important: If the bore is worn beyond the limits, refit

the bore with oversized pistons. Select the smallest
available oversize piston. Refer to Piston Selection.
16. Leave sufficient material to allow honing when
fitting the piston.
38662
Engine
Cylinder Boring and Honing
Boring Procedure
1. Before honing or boring, measure all of the new
pistons. Select the smallest piston for the piston
fitting. Slightly varied pistons in a set may provide
correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file th.e top of
the engine block to remove any dirt or burrs. If the
cylinder block is not straight, the boring bar may
be tilted, causing the bored cylinder wall to
have incorrect right angles to the crankshaft.
3. Carefully follow the instructions fumished by the
manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to
specification when boring cylinders. Cover or tape
the crankshaft bearings and other internal parts
to protect these parts during the boring or honing
operation.
5. Leave 0.03 mm (0.001 in) on the diameter for
finish honing when performing the final cut with
a boring bar. Carefully perform the honing
and boring operation to maintain the specified
clearances between pistons, rings, and
cylinder bores.
Honing Procedure
1. Follow the manufacturer's recommendations for

use, cleaning, and lubrication when honing the
cylinders. Use only clean, sharp stones of
the proper grade for the amount of material to be
removed. Dull, dirty stones cut unevenly and
generate excessive heat. When using coarse or
medium-grade stones, leave sufficient metal so all
stone marks may be removed with the fine
stones used for finishing to provide the proper
clearance.
2. During the honing operation, thoroughly clean the
cylinder bore. Check for the correct piston fit.
Engine Mechanical.., 3.SL
6-191
3. Make full strokes in the cylinder to eliminate taper.

Repeatedly check the measurement at the top,
the middle, and the bottom of the cylinder bore.
Notice: Handle the pistons with care. Do not force the

pistons through the cylinder until you hone the
cylinder to the correct size. The piston can be distorted
through careless handling.
Important: The finish marks should be clean but not
sharp. The finish marks should be free from
imbedded particles and torn or folded metal.
4. When finish honing a cylinder bore to fit a piston,
move the hone up and down at a sufficient speed
to obtain a fine and uniform surface finish in a
cross hatch pattern.
5. Determine the finish hone cylinder measurement
by measuring the piston to be installed, and by
adding the average of the clearance specification.
Measure the block and the piston at normal
room temperature.
6. True up the refinished cylinder bores. Final hone
each cylinder bore to remove all stone or
cutter marks.
7. After final honing and before the piston is checked
for fit, clean the bores with hot water and
detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to
remain in the cylinder bores. This abrasive
material will wear the new rings, the cylinder
bores, and the bearings lubricated by the
contaminated oil. After washing dry the bore.
8. Permanently mark the piston for the cylinder to
which the piston has been fitted.
9. Apply clean engine oil to each bore to prevent
rusting.
6-192
Engine Mechanical. - 3.SL
Engine
Crankshaft and Bearings .Clean and
Inspect
Tools Required
J 8087 Cylinder Bore Checking Gauge
1. Cle.an the crankshaft of the following elements:
Oil
Sludge
Carbon
2. Inspect the rankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for nicks or wear.
4. Inspect the crankshaft threads.
26122
Important: If cracks, severe gouges or burned spots

are found, the crankshaft must be replaced. Slight
roughness may be removed with a fine polishing cloth
soaked in clean engine oil. Burrs may be removed
with a fine oil stone.
5. Inspect the crankshaft bearing journals and the
crankshaft thrust surfaces for the following
conditions:
Cracks
Chips
Gouges
Roughness
Grooves
Overheating (discoloration)
6. Inspect the corresponding crankshaft bearings for
embedded foreign material and determine the
source.
Important: Note the location of the crankshaft main

bearing high spots. If they are not in. line, the
crankshaft is bent and must be replaced.
7. Inspect the crankshaft bearings for uneven
side-to-side wear. This may indicate a bent
crankshaft or a tapered bearing journal.
0
0
50027
Important: The crankshaft bearings are of the

precision insert type. The crankshaft bearings are
available in standard and various undersizes.
Notice: Do not scrape, shim, or file bearing inserts. If
the bearing surface of the insert is touched with
bare fingers, the skin oil and acids will etch the bearing
surface.
8. Inspect the outer surfaces of the crankshaft
bearings for the following conditions:
. Wear - surface wear indicates either movement
of the insert or high spots in the surrounding
material (spot wear).
Overheating or discoloration
Looseness or rotation indicated by flattened
tangs and wear grooves
9. Inspect the thrust surfaces of the main thrust
bearing for the following conditions:
Wear
Grooving (Grooves are caused by irregularities
of the crankshaft thrust surface.)
Engine
Engine Mechanical;. 3.8L
6-193
Important: If crankshaft bearing failure is due to other

than normal wear, investigate the cause. Inspect the
crankshaft or connecting rod bearing bores.
10. Using the J 8087 inspect the connectJng rod
bearing bores or crankshaft main bearing
bores using the following procedure:
10.1. Tighten the bearing cap to specification.
10.2. Measure the bearing bore using J 8087 for
taper and out-of~round.
10.3. No taper or out-of-round should exist.
()
38663
Bearing Selection
Measure the bearing clearance to determine the
correct replacement bearing insert size. There are
two methods to measure bearing clearance. Method A
gives more reliable results and is preferred.
f\ilethod A yields measurement from which the
bearing clearance can be computed.
" Method B yields the bearing clearance directly.
l\ilethod B does not give any indication of
bearing run-out.
Method A
Important: Do not mix inserts of different nominal.size
in the same bearing bore.
1. Measure the crankshaft bearing journal diameter
2.
3.
4.
5.
with a micrometer in several places, 90 degrees

apart. Average the measurements.
Measure the crankshaft bearing journal taper and
run out.
Install the crankshaft bearing inserts. Tighten the
bearing cap bolts to specification.
Measure the connecting rod inside diameter in the
same direction as the length of the rod with an
inside micrometer.
Measure the crankshaft main bearing inside
diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce

the desired clearance.
7. If the specified clearances cannot be met, the
crankshaft journals must be reconditioned and
undersized bearing inserts installed.
5265
6494
Engine
Method B
Important: Do not mix inserts of different nominal size
in the same bearing bore.
1. Clean the. used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire
t>E:laring width.
4. Install the bearing caps .
Notice: In order to prevent the possibility of cylinder
block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification.
.o
4981
Important: Do not rotate the crankshaft.

6. Remove the bearing cap, leaving the gagirig .
plastic in place. It does not matter whether the
gaging plastic adheres to the journal or to
the bearing cap.
7. Measure the gaging plastic at .its widest point with
the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Selectaset of bearing inserts that will produce
the desired clearance.
Crankshaft Balancer Clean and Inspect

Inspect the crankshaft balancer for damage.
Inspect the outside of the crankshaft balancer
mounting shaft for grooves.
ReplacE:l the cra11kshaft balancer if grooves are
. present and appear to be causing an oil leak.
313962
Engine
6-195

Clean the flywheel.
Inspect the engine flywheel for damage and
cracks.
Inspect the engine flywheel ring gear for
damaged teeth.
Replace the flywheel if any damage is found.
187014

(Manual Transmission)
Clean the flywheel.
Inspect the engine flywheel for damage and
cracks.
Inspect the engine flywheel ring gear for
damaged teeth.
Replace the flywheel if any damage is found.
427582
Piston and Connecting Rod Disassemble

Caution: Handle the piston carefully. Worn piston
rings are sharp and may cause bodily injury.
1. Remove the piston rings. Use a suitable tool to
. expand the rings. Piston rings must not be
reused.
4977
6-196
Engine
Important: Two retainers hold the. piston pins in
place. Reuse the retainers if they are n9t damaged.
Ensure the piston pin is not damaged.
2. Remove the piston pin retaining clips.

3. Remove the piston pin.
~
~-q/
/
35866

Clean and Inspect
Caution: Bodily injury may occur if the carburetor
cleaning fluidis exposed to the skin orif the
fumes are inhaled.
1. Clean the piston and connecting rod in solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the components with compressed air.
3. Clean the piston ring grooves with a suitable ring
groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
~-q/
/
35866
5. Inspect the piston for the following conditions:

Eroded areas (1) on top of the piston
Scuffed or damaged skirt (2)
Damage to the pin bore (3)
Cracks in the piston ring 1ands, the piston skirt,
or the pin bosses

Piston ring grooves for nicks, burrs, or other
warpage which may cause the piston ring
to bind.
6. Inspect the piston for scoring, wear or other
damage.
156168
Engine
6-197
7. To determine the piston-to bore clearance, use a

micrometer and measure the piston pin.
4976
8. To determine the piston pin-to bore clearance,

use an inside micrometer and measure the piston
pin bore.
9. To determine the piston pin-to-bore clearance,
subtract the piston pin diameter from the piston
pin bore diameter.
4975
10. Inspect the connecting rod for an out-of-round

bearing bore.
156167
6-198
Engine

11. Inspect the connecting rod for twisting.
156169
12. Inspect the connecting rod cap bolts for stretch

(compare to known good bolt). (1) is a stretched
bolt, (2) is a new or good bolt.
~~b\--~~~{({~((~({(-l{(_~~(~(((~l
(
~~)~l~____.....((~(((~[((~((~[~~(~((~WD
187037
Piston Selection
1. Measure the pston diameter. Remove the piston
pin to measure the piston for size and taper.
2. Replace the piston with a standard or an oversized
piston if the piston is damaged.
Important: Cosider both the piston condition and the
cylinder bore condition when fitting the pistons.
Production and service pistons have the same nominal
weight. Production and service pistons can be
intermixed without affecting the engine balance. If
necessary, fit used pistons to any cylinder of the
engine. Ensure that the pistons are in good condition.
3. Measure the cylinder bore. If the cylinder bore
is worn beyond specifications, rebore the
cylinder bore. Use the following procedure to
hone the cylinder bore to the correct size:
3.1. Select a piston.
3.2. Hone the cylinder bore to obtain the
recommended clearance.
4988
Engine
)
4.
5.
6.
7.
8.
9.
')
10.
11.
3.3. Scrub the cylinder bore and the piston with

soap and water. Remove all foreign
material. Dry the cylinder bore. Rub clean
engine oil into the cylinder bore.
Use the following procedure to measure
piston-to-cylinder bore clearance:
4.1. Measure the cylinder bore with a
telescoping gauge. If the cylinder bore is
damaged, rebore or hone the cylinder bore
to size.
4.2. Subtract the piston diameter from the
cylinder bore diameter to determine the
piston-to-bore clearance.
4.3. Compare the piston-to-bore clearance with
the specifications to determine if the
clearance is within the acceptable range.
If the used piston is not within the acceptable
clearance range, check the service piston sizes
to determine if a new piston can be selected.
Service pistons are available in standard
and 0.508 mm (0.020 in) oversize.
11 the cylinder bore needs reconditioning, measure
the new piston diameter and hone the cylinder
bore to the correct clearance.
Select a new piston. Mark the piston to identify
the corresponding cylinder.
Select a set of new piston rings.
Place each ring, one at a time, into the
corresponding cylinder.
Place the piston for that cylinder, upside down
(top of the piston pushing on the ring). Push the
ring down to the bottom of the ring travel.
Remove the piston.
6-199
4987
<O
c:::,
~
(Q)
~
(_j
4967
6.;.200
Engine
Engine Mechanical- 3.SL
12. Measure the ring gap.

13. If the ring gap is not within an acceptable
specification range, increase the ring gap. Do this
by filing any excess material from the ends of
the ring:
4968
14. Measure the piston ring side clearance

(compression rings).
Notice: Do norcut the ring groove with a. file or a
rough edged tool. Good performance and durability
depends on the straightness and smoothness of
the ring groove.
15. Use the following procedure to measure piston
compression ring side clearance:
15.1. Roll the piston ring around the groove.
15.2. Measure the side clearance.
15.3. If the ring is too tight, check for nicks
or burrs.
Use emery cloth to remove burrs.
15.4. Determine if the ring is within
specifications. If necessary, replace
the ring.
22934
Piston and Connecting Rod Assemble

1. Coat the piston pin with oil.
2. Install one piston pin retainer into the retaining
groove.
3. Install the connecting rod and piston pin. The
connecting rod can be installed in either
direction. Push the piston pin in until it bottoms
against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Ensure the piston pin moves freely.
-~
Important: To provide an effective compression seal,

the ring gaps must be staggered.
35866
Engine
6-201
Notice: Use a piston ring expander to install the

piston rings. The rings may be damaged if expanded
more than necessary.
6. Install the following components of the bottom ring
assembly (oil control ring):
6.1 . The expander
6.2. The lower oil control ring
6.3. The upper oil control ring
4977
7. Install the middle ring (compression ring) with the

manufacturer's mark facing up.
8. Install the top ring (compression ring).
4967
Camshaft Bearing Removal

Tools Required
J 33049 Camshaft Bearing Remover/Installer
1. Select the expander assembly and driving washer.
2. Assemble J 33049.
tJ
E;I
Q
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00
DJJ (IDO)
(ID 0)
@(@
@(
(ID@
622704
6~202
Engine

3. Drive out the camshaft bearings.
35815
Camshaft and Bearings Clean and Inspect

Tools Required
J 7872 Magnetic Base Indicator Set
1. Measure the camshaft journals with a micrometer.
If the camshaft journals are not within
specifications, replace the camshaft. Refer to
Engine Mechanical Specifications.
35212
2. Measure the camshaft runout using J 7872.

2.1. Mount the camshaft in V-blocks between
centers.
2.2. Use J 7872fo check the intermediate
camshaft journal.
3. If the runout exceeds specifications, the camshaft
is bent and should be replaced. Refer to Engine
Mechanical Specifications.
35211
Engine
6-203
Camshaft Bearing Installation

Tools Required
J 33049 Camshaft Bearing Installer
1. Select the camshaft bearings.
35815
2. Use the following procedure to install the camshaft

bearings:
2. i. Assemble J 33049 according to the
manufacturer's instructions.
2.2. Place the bearing on the tool.
Notice: Severe engine damage may result if the oil
holes are not correctly aligned.
2.3. Index the bearing oil holes with the engine
block oil passages.
~-l
~
@)
@)
JJD @O)
00
@O)
((ID(
~)COD
@
622704

Inspect (VIN K)
1. Inspect the timing chain and sprockets for
damage.
2. Inspect the timing chain for overall in and out
movement. Movement should not exceed
25 mm (1 in).
3. Inspect the sprockets for wear.
192708
6-204
Engine
Valve Rocker Arm and Push Rods Clean

and Inspect
2
635934
Important: Parts that are too be reused must be

marked, sorted, and organized for assembly.
Mark, sort, and organize the components for
assembly.
Caution: Bodily injury may occur if the carburetor
cleaning fluid is exposed to the skin or if the
fumes are inhaled.
damage.
Clean the components with cleaning solvent.
Dry the components with compressed air.
Inspect the valve rocker components for the
following:
Valve rocker arm valve pushrod socket contact
surface (1)
The contact surface must be smooth with no
scoring or excessive wear.
Valve rocker arm roller pivot for binding. or
damage (2)
Valve rocker arm valve stem contact
surface (3)
The contact surface should be smooth with no
Inspect the valve pushrods for the following:
Restriction of the oil passage (1)
Wear or scoring of the end contact surfaces (2)
The end contact surfaces must be smooth with
no scoring or excessive wear.
Shaft for bends (3)
Roll the valve pushrod on a flat surface to
determine if the valve pushrod is bent.
488857
Engine
6-205

Inspect
1. Keep the valve lifters in order so they can be
installed in their original position.
Important: When new valve lifters are installed, coat
the valve lifters with camshaft and lifter prelube
GM P/N 1052365 (or equivalent).
2. Inspect the following areas of the valve lifters:
The retaining clip (1)
The push rod socket for wear (2)
The valve lifter body for wear and scuffing (3)
The valve lifter bore for wear
The valve lifter roller assembly for wear (4)
The valve lifter roller pin for damage (5)
The oil hole for plugging (6)
3. Inspect the valve lifter guides for cracks or
damage.
178485
Cylinder Head Disassemble

Tools Required
J 38606 Valye Spring Compressor
Important: During disassembly, ensure the valve train

components are kept together and identified so they
can be reinstalled in their original locations and
with the same mating surfaces as when removed.
1. Use J 38606 to compress the valve spring.
187057
2. Remove the valve keys.

3. Remove the valve cap and spring.
4. Remove the valve stem oil seal by prying up on
the bottom.
42226
6206
Engine Mechanical 3.8L
Engine
Cylinder Head Clean and Inspect
Tools Required
J 9666 Valve Spring Tester
1. Inspect the cylinder head gasket and the mating
surfaces for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. Gasket
failure is caused by the following conditions:
Improper installation
A loose or warped cylinder head
Missing dowel pins
3. Clean the cylinder head of all foreign material. Do
not use a motorized wire brush on any gasket
sealing surface.
4. Clean the threaded holes.
5. Inspect the cylinder head for cracks typically
between the valve seats and inside of the
exhaust ports.
26157
Important: Do not attempt to weld the cylinder head.

If the cylinder head is damaged, replace the
cylinder head.
6. Inspect the cylinder head deck for corrosion.
7. Inspect the following locations for flatness:
The cylinder head deck
The intake manifold mating surface
The exhaust manifold mating surface
8. Recondition the surfaces by parallel grinding.
Replace the cylinder head if more than 0.254 mm
(0.010 in) is removed.
36712
Engine
9. Measure the height from the deck surface to the

cast pads. Do this to determine if the cylinder
head has sufficient deck surface thickness
to resurface.
New cylinder heads measure from
1.372-1.676 mm (0.054-0.066 in). If the cylinder
head does not meet the minimum thickness
after resurfacing, replace the cylinder head.
10. Inspect all of the threaded holes for damage.
Repair the threaded holes, if necessary.
11. Inspect the valve seating surfaces.
12. Inspect the cooling jacket plugs.
13. Inspect the valve guides for wear. Clean the valve
guides.
14. Inspect the valve seats for excessive wear and
hot spots.
36714
15. Inspect the valve springs expanded height.

16. Inspect the valve spring ends. If the valve spring
ends are not parallel, the valve spring is bent.
Replace the bent valve spring.
63468
17. Using the J 9666 test the valve spring load. If the
valve spring load js below specification, replace
the valve spring.
18. Inspect the valve spring seating surface of the
valve spring retainers for wear or gouging. If the
seating surface is damaged, replace the valve
spring retainers.
19. Use the following procedure to measure the valve
seat concentricity:
19.1. Lift the valve off its seat.
19.2. Apply a dab of blue dye to the valve face.
19.3. Seat and rotate the valve.
The blue dye traces transferred to the valve
seat are an indication of concentricity of
the valve seat.
4960
6-208
Engine
run out:
20:L Clean off the blue dye.
20.2. Apply blue dye to the valve seat.
20.3. Seat and rotate the valve.
The traces of blue dye transferred to the
valve indicates valve runout.
20.4. Recondition the valve seat or valve face, if
needed.

Grinding
4955
5
6
Tools Required
J 8001 Dial Indicator Set
1. Recondition the valve seats by grinding. Use an
oscillating type valve seat grinder. Follow the
grinder manufacturer's instructions. If the valve
seat is too wide after grinding, use a 20 degree
stone or a 70 degree stone in order to narrow the
valve seat. The 20 degree stone will lower the
seat. The 70 degree stone will raise the seat.
Replace or recondition the valves if the seats are
reconditioned.
2. After grinding the valves, measure the valve
margin. Replace the valve if less than the
minimum recommended specification.
Notice: Clean the valve guides before reaming.
Packing of chips or carbon may result in the reamer
jamming into the valve guide or broken reamer flutes.
3. Clean any foreign material from the valves.
Use a wire brush to remove carbon. Do not
scratch the valve stem. Soak the valves in
carburetor cleaning fluid to remove varnish.
4. Use a suitable tool to clean the valve guides.
5. Follow the grinder manufacturer's instructions.
Ensure that the new surface is perpendicular to
the valve stem.
6. Inspect the valve key grooves for chipped or worn
lands (5). Replace the valve if the valve key
groove is damaged.
7. Inspect the valve stem tip for wear (6).
Recondition the valve stem tip by grinding.
8. lnspectthe valve stem for burrs and
scratches (4). Use an oil stone to remove burrs
and minor scratches.
9. Inspect the valve stem for straightness (3). Use
V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
10. Inspect the valve face for grooving (1, 2). If the
groove is so deep that refacing the valve face
would result in a knife edge, replace the valve.
(
156174
Engine
6-209
11. Inspect the valve face for burning, pitting, or

cracking (1, 2, 3, 4). If pieces of the valve face
are broken off, inspect the corresponding
piston and cylinder head area for damage.
156173
12. Measure the valve movement:

12.1. Insert the valve into the guide.
12.2. Lift the valve 2 mm (1/8 in) off of the seat.
12.3. Move the valve from side to side.
12.4. Use J 8001 to measure the amount of
movement.
40076
Important: Clean the valve guide before reaming to

avoid breaking the reamer flutes. Do not push down
on the reamer.
13. Ream the valve guides for oversize valves if the
clearance exceeds the specifications.
14. Ream the valve guide bores for the oversize
valves.
15. Recondition the valve seats after reaming the
valve guide bores or installing the new valve
guides.
40073
6-210. Engine Mechanical - 3.SL
Engine
156172
16. Inspect the valve stem for straightness. Use

V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
It is essential that the valve guide bores
are free of carbon or dirt to ensure the proper
centering of the pilot in the guide.
The valve seats should be concentric to within
0.05 mm (0.031 in) total indicator reading.
Reface pitted valves on a valve refacing
machine to ensure the correct relationship
between the valve head and the valve stem.
Replace the valve if the valve stem is
warped (2), or if the valve stem shows signs of
excessive wear.
Inspect the valve key area (1) for damage and
carbon build up.
Replace the valve if the edge of the head is
less than 0.79 mm (0.031 in) thick after
grinding.
Use the manufacturer's recommendations of
equipment for the proper results.
Cylinder Head Assemble

Tools Required
J 42863 Valve Seal Installer
1. Install the valves. The valves are available in
standard size and 0.015 in oversize.
Be sure to use oversize valve seals if oversize
valves are used.
~428~
Important: Use hand pressure only when installing

the valve seal using J 42863. Using to much force may
cause damage to the oil seal and possibly lead to
excessive oil consumption.
2. Place the valve stem oil seal over the valve stem
so the seal begins to contact the valve guide.
3. Use J 42863 to push the valve stem oil seal over
the valve guide.
40071
Engine
4. Use J38606 to install the valve spring and the
valve cap.
5. Install the valve keys.
stem height:
6.1. Place the valve in the guide. Hold the valve
in the closed position.
6.2. Use a valve stem height gauge to measure
the valve stem height.
6.3. The measurement should be
49-50 mm (1.93-1.97 in).
6-211
J 38606
154517
Important: Grinding the valves increases the valve

stem height and the valve spring installed height. Add
shims to correct the valve spring installed height.

spring installed height:
7.1. Place the valve in the valve guide.
7.2. Install the valve spring cap and the valve
cap keys.
7.3. Seat the valve spring retainer by pulling up.
7.4. Use a steel machinists' rule to measure
the distance from the spring seat to the
bottom of the valve spring cap.
7.5. The measurement should be
42-44 mm (1.69-1.75 in).
If the measurement is not within
specifications add shims under the valve
spring.
40072
Oil Pump Clean and Inspect

1. Use a suitable solvent to clean the oil pump.
2. Remove all old gasket material from the engine
front cover and from the engine block.
3. Inspect the oil pump cover and the engine front
cover for the following damage:
Cracks
Scoring
Porous or damaged casting
" Damaged threads
Excessive wear
4. Inspect the pressure regulator valve for the
1ollowing damage:
Scoring
Sticking in the bore
Burrs
Foreign material
26160
6-212
Engine
5. Inspect the pressure regulator spring for loss of
tension or bending. Replace the pressure
regulator spring if damaged.
6. Inspect the oil pump gears for the following
conditions:
Chipping
Galling
Scoring
Excessive wear
7. Measure the inner oil pump gear tip clearance.
38819
8. Measure the outer oil pump gear diameter

clearance.
38820
Engine
6-213
9. Measure the oil pump gear end clearance.

10. Measure the pressure regulator valve-to-bore
clearance.
36663
Valve Rocker Arm Cover Clean

and Inspect
Clean the valve rocker arm cover mating surface.
Clean the valve rocker arm cover. Remove all
the sludge and th~ oil deposits.
Inspect the valve rocker arm cover for damage.
Replace the valve rocker arm cover if any
damage is found.
187054
Oil Pan Clean and Inspect

Clean the oil pan mating surface.
Clean the oil pan. Remove all the sludge and the
oil deposits.
Inspect the threads for the oil level sensor and the
engine oil drain plug.
Inspect the oil pan for dents or distortion.
Repair or replace the oil pan as necessary.
35861
6-214
Engine
Intake Manifold Clean and Inspect (Upper)
Clean the upper intake manifold mating surfaces.

Clean the upper intake manifold.
Inspect the upper intake manifold for damage.
Replace the upper intake manifold as necessary.
403785
Intake Manifold Clean and Inspect (lower)
Clean the lower intake manifold mating surfaces.

Clean the lower intake manifold.
Inspect the threaded holes for damage.
Inspect the lower intake manifold for damage or
nicks in the mating surfaces.
Replace or repair the lower intake .manifold as
necessary.
187073
Exhaust Manifold Clean and Inspect

1. Clean the exhaust manifold mating surfaces.
2. Clean the exhaust manifold.
3. Inspect the exhaust manifold mating surfaces for
damage.
589373
Engine
6-215
4. Inspect the exhaust manifold flange for

straightness, using a straight edge and a
feeler guage.
5. If the exhaust manifold flange is warped more
than 0.05 mm (0.002 in) replace the exhaust
manifold.
589375
Water Pump Clean and Inspect
Oean the water pump mating surface.

Clean the water pump.
Inspect the water pump shaft for looseness.
Inspect the water pump vanes for damage.
Inspect the water pump mating surfaces for nicks.
Repair or replace the water pump as necessary.
187022
Engine Front Cover Clean and Inspect
"
Clean the engine front cover mating surface.

Clean the engine front cover.
Inspect the engine front cover threaded holes.
Inspect the engine front cover for damage.
O Inspect the engine front cover mating surfaces
for nicks.
Repair or replace the engine front cover as
necessary.
345236
6.;216
Engine
Balance Shaft Clean and Inspect

1. Clean the balance shaft.
2. Inspect the balance shaft bearing/bushing journals
for excessive wear.
3. Inspect the balance shaft driven gear and the
balance shaft drive gear for nicks and burrs.
4. Inspect the balance shaft retainer for damage.
5. Inspect the balance shaft threads for damage.
6. Repair or replace the balance shaft components
as necessary.
388909

Removal
Tools Required
J 36995Balance Shaft Bearing Remover/Installer
1. Use J 36995 to remove the balance shaft bearing.
2. Use J 36995 to remove the balance shaft
bushing. It may take a considerable amount
of force to loosen the bushing from the block bore.
J 36995
36706

Installation
Tools Required
J 21465-13 Drive Handle Extension
J 36995 Balance Shaft Bearing Remover/Installer
1. Dip the balance shaft bushing in clean engine oil.
Important: The J 36995 installs the balance shaft

bushing to the correct depth. The balance sl1aft
bushing is properly installed when J 36995 fully
contacts the balance shaft bore or the engine
block/transaxle mounting flange.
2. Use the balance shaft bushing installers to install
the balance shaft bushing.
3. Remove J 36995.
J 36995
36707
Engine
4. Dip the balance shaft bearing into clean engine oil.

5. Use J 21465-13 and J 36995 to install the balance
shaft bearing into the engine block.
6-217
J 36995
J 21465-13
622251
6-218
Engine
Thread Repair
General purpose thread repair kits are available
commercially.
4963
4962
Caution: Refer to Safety Glasses Caution in

Important: Refer to the thread repair kit
manufacturer's instructions regarding the size of the
drill and which tap to use.
Always avoid any buildup of chips. Back out the tap
every few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the
damaged thread.
2. Adjust the stop collars on the cutting tool as
needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the

thread insert installer. Engage the tang of the
thread insert onto the end of the mandrel.
Important: The thread insert should be flush to 1 turn
below the surface.
9. Lubricate the thread insert with clean engine oil
(except when installing in aluminum) and install
the thread insert.
10. If the tang of the thread insert does not break off
when backing out the thread insert installer, break
off the tang using a drift punch.
Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine.
Clean all of the components. Use the proper tools
in order to measure components when inspecting for
excessive wear. Repair or replace the components
that are not within the manufacturers specification.
When components are reinstalled into an engine,
return the components to their original location,
position, and direction. During assembly, lubricate all
of the moving parts with clean engine oil or engine
assembly lubricant (unless otherwise specified). This
will provide initial lubrication when the engine is.
first started.
Engine
Engine Block Plug Installation
Notices.
1. Install the threaded oil jacket plugs.
6-219
1
I
Tighten
Tighten the oil jacket plugs to 30 N-m (22 lb ft).
589370
2. Install the remaining oil gallery plugs using GM

P/N 12346004 sealant or equivalent.
26198
Crankshaft and Bearings Installation

Tools Required
1. Install the upper crankshaft main bearings.
2. Install the crankshaft. Lubricate the crankshaft to
crankshaft main bearing contact areas with engine
oil or engine assembly lubricant.
Notice: In order to prevent the possibility of cylinder

block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.
3. Install the lower crankshaft main bearings into the
main bearing caps.
35863
6-220
Engine Mechani.cal - 3.8l
Engine
4. Install the crankshaft main bearing caps. Us13
GM P/N 1052942 sealer at the number
4 crankshaft main bearing cap to the engine block

surtace.
Notice: Refer to Permanently Stretching Bolt Notice in

Notices.
5. Install the crankshaft main bearing cap bolts. Start
the crankshaft main bearing cap bolts by hand.
Ensure the bottom of the crankshaft main bearing
cap is parallel to the bottom of the channel.
26153
Tighten
Tighten the crankshaft main bearing cap bolts
in equal increments. Do not completely
tighten one bolt at a time to prevent the cap
from being cocked.
Tighten the bolts to 70 N-m (52 lb ft) to fully
seat the crankshaft main bearing caps.
Loosen the bolts 360 degrees
counterclockwise,
O Tighten the bolts to 20 N-m (15 lb ft), then
40 degrees (30 lb ft).
" Use J 36660-A to tighten the bolts in steps:
35 degrees + 35 degrees + 40 degrees for
a total of 110 degrees.
6. Install the side main bolts. Apply
GM P/N 12345493 or equivalent to the side
main bolts.
Tighten
Tighten the side crankshaft main bearing cap
bolts to 15 Nm (11 lb ft). Use J 36660-A to tighten
the bolts an additional 45 degrees.

Installation
38180
Tools Required
" J 8037 Piston Ring Compressor
J 41507 Connecting Rod Guide
1. Position the crankshaft so the connecting rod
journal is opposite th.e piston and connecting
rod assembly being install.ed. This .will aid in 1he
installation of the connEicting rod assembly.
2. Lubri.cate the cylinder wall with engine oiL
3. Install the connecting rod bearing inserts.
4. Lubricate the connecting rod .bearingjnsert surtace
with engine oi.1.
5. Install J 4.15.07 to the connecting md; Hand
tighten the tool,to the connecting rod.
6. Install JB037to the piston.
Engine
Engine Mechanical - 3;8l
6-,221
Notice: Guide the lower connecting rod end carefully

to avoid damaging the crankshaft journal.
7. Use J 8037 to compress the piston rings for
installation of the piston and connecting rod
assembly.
8. Install the piston and connecting rod assembly
into the engine.
Important: Ensure the arrow on top of the piston or
the markings made during removal face towards
the front of the engine or are in the same location as
when removed.
9. Use J41507to pull the connecting rod into place.
10. Remove J 41507.
J 8037
5159
11. Install the connecting rod bearing cap.

Notices.
12. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
27 N-m (20 lb ft) + 50 degrees using J 36660-A.
13. Pry the connecting rod back and forth and check
for binding. If necessary loosen and retighten the
connecting rod bearing cap.
38153
14. Measure the connecting rod side clearance.
5163
6-222
Engine

Installation
1. Install the oil pump pipe and screen assembly
gasket.
Important: The oil pan gasket must be installed

before the oil pump pipe and screen assembly.
2. Install the oil pan gasket.
3. Install the oil pump pipe and screen assembly.

Notices.
4. Install the oil pump pipe and screen
assembly bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft).
26202
Oil Pan Installation

1.
2.
3.
4.
Install the oil pan gasket to the oil pan flange.

Install the oil pan.
Clean the oil pan bolts.
Apply one drop of GM P/N 12345382 to each bolt.

Notices.
5. Install the oil pan bolts.
Tighten
Tighten the bolts to 14 Nm (125 lb in).
44775
Notice: Install the oil level sensor, located in the oil

pan, after the oil pan is installed. The sensor may be
damaged if the oil level sensor is installed first.
6. Install the oil level sensor.
Tighten
Tighten the oil level sensor to 20 Nm (15 lb ft).
35861
Engine
6-223
Camshaft Installation
1. Coat the camshaft with prelube GM P/N 12345507
or equivalent.
2. Install the camshaft.
3. Install the camshaft thrust plate.
Notices.
4. Install the camshaft thrust plate bolts.
Tighten
35815
Balance Shaft Installation
J 36996
Tools Required
" J 8001 Dial Indicator
J 21465-13 Drive Handle Extension
J 36996 Balance Shaft Installer
1. Use J 21465-13 and J 36996 to install the balance
shaft into the engine block.
J 21465-13
566836
2. Install the balance shaft bearing retainer.

Notices.
3. Install the balance shaft bearing retainer bolts.
Tighten
Tighten the balance shaft retainer bolts to
30 Nm (22 lb ft).
.
42237
6-224
Engine
4. Install the balance shaft driven gear.
5. Install the balance shaft driven gear bolt.
Tighten
Tighten the balance shaft driven gear bolt to
22 N-m (16 lb ft). Use J 36660-A to tighten the bolt
an additional 70 degrees.
154521,
6. Using J 8001 measure the balance shaft end play.

End play must not exceed 0.028 mm (0.008 in).
38470
7. Using J 8001 measure the balance shaft radial

play at the rear. Radial play must be between
0.0127-0.119 mm (0.0005-0.0047 in).
J 8001
8. Install the balance shaft drive gear.

9. Install the camshaft sprocket.
10. Turn the camshaft so the timing mark on the
camshaft sprocket is straight down.
11 . Remove the camshaft sprocket and balance shaft
drive gear.
12. Turn the balance shaft so the timing mark on the
balance shaft driven gear points straight down.
13. Install the balance shaft drive gear.
14. Align the marks on the balance shaft driven gear
and the balance shaft drive gear. Do this by
turning the balance shaft.
38472
Engine
6"'.225
15. Turn the crankshaft so the number one piston is

at top dead center,
16. Install the timing chain.
17. Install the camshaft sprocket.
18. Using J 8001 measure the gear lash at
four places. Measure every quarter turn. Gear
lash must be between 0.050-0.127 mm
(0.002-0.005 in).
'
38477

Installation
Tools Required
J41349 Crankshaft Rear Oil Seal Aligning Tool
1. Clean the gasket from the crankshaft rear oil seal
housing.
2. Clean the crankshaft rear oil seal housing.
3. Inspect the crankshaft rear oil seal housing for
damage.
Notice: Do not use sealers or adhesives on rear main

oil seal housing gasket. Use of sealers or adhesives
on this gasket may cause oil leaks.
4. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
Important: The plastic inserts in the crankshaft rear
oil seal housing are used to aid assembly only.
The inserts are not required for service.
5. Install the crankshaft rear oil seal housing. Hand
tighten the crankshaft rear oil seal housing bolts.
Notice: Sealability of the rear main oil seal depends

on the correct alignment of the rear main oil seal
housing and the oil pan. Incorrect alignment
may cause oil leaks.
6. Apply engine oil to both sides of J 41349.
26125
6-226
Engine
7. Install J 41349 over the crankshaft. Twist the tool
to aid in sliding the tool over the crankshaft.
8. Place a straight edge on the engine block oil pan
flange and the crankshaft rear oil seal housing
flange. Use a feeler gage to ensure there is
no more than 0.10 mm (0.004 in) step on each
side. Rotate the crankshaft rear oil seal housing to
make the step equal on each side. Replace 1he
crankshaft rear oil seal housing if the rotation does
not make the step equal.

Notices.
9. Tighten the crankshaft rear oil seal housing bolts.
44779
Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 N-m (11 lb ft). Use J 36660-A to tighten
the bolts an additional 50 degrees.
10. Remove J 41349.
11. Recheck the step height on each side to ensure
the crankshaft rear oil seal housing did not move.
If the step height is beyond specification,
reinstall the crankshaft rear oil seal housing and
measure the step again. Replace the crankshaft
rear oil seal housing if the clearance is still beyond
specification.
Crankshaft Rear Oil Seal Installation

Tools Required
J 38196 Crankshaft Rear Oil Seal Installer
1. Apply engine oil to the inside diameter and tile
outside diameter of the crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel
until the back bottoms squarely against the collar
of the tool.
26129
Engine
6-227
3. Use the following procedure to install the seal:
\
I

Notices.
J 38196
3.1 . Attach J 38196 to the crankshaft by hand or

tighten attaching screws to 5 N-m (54 lb in).
3.2. Turn the T handle of J 38196 so the collar
pushes the crankshaft rear oil seal into the
bore. Turn the handle until the tool is
bottomed out. Ensure the crankshaft rear oil
seal is seated properly.
3.3. Loosen the T handle of J 38196 until it
comes to a stop.
3.4. Remove the attaching screws.
37747
Timing Chain and Sprockets Installation
(VINK)
Tools Required
1. Install the crankshaft balancer key into the
crankshaft keyway.
The crankshaft balancer key should be parallel to
the crankshaft or with a slight incline.
2. Install the timing chain on the sprockets. Align the
timing marks.
192708
3. Install the timing chain, the crankshaft sprocket,

and the camshaft sprocket.

Notices.
4. Install the camshaft sprocket bolt.
Tighten
Tighten the camshaft sprocket bolt to
100 Nm (74 lb ft). Use J 36660-A to tighten the
camshaft sprocket bolt an additional 90 degrees.
192716
6-228
Engine
5. Install the timing chain dampener.
Tighten
Tighten the timing chain dampener bolt to
22 Nm (16 lb ft).
154523
Oil Pump Cover and Gear Set Installation

1. Lubricate the oil pump gears with petroleum jelly.
2. Install the oil pump gears.
3. Pack the oil pump cavity with petroleum jelly.
Notices.
5. Install the oil pump cover screws.

Tighten
Tighten the screws to 11 N-m (98 lb in).
Oil Filter Adapter Installation

1. Install the oil pressure relief valve spring into the
engine front cover.
2. Install the oil pressure relief valve into the engine
front cover.
3. Install a new oil filter adapter gasket.
4. Install the oil filter adapter.

Notices.
5. Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to
15 Nm + 50 (11 lb ft+ 50).
36655
Engine
6-229
Engine Front Cover Installation
Tools Required
1. Install the engine front cover gasket.
2. Install the engine front cover.
Align the cogs on the crankshaft sprocket with the
cogs on the oil pump in the engine front cover.
the engine front cover bolt threads.
Notices.
4. Install the engine front cover bolts.
Tighten
Tighten the engine front cover bolts to
20 N-m (15 lb ft). Use J 36660-A to tighten the
engine front cover bolts an additional 40 degrees.
5. Install the oil pan to engine front cover bolts.
Tighten
Tighten the oil pan bolts to 14 N-m (125 lb in).
6. Install the oil filter.
Tighten
the crankshaft position sensor stud threads.
8. Install the crankshaft position sensor.
Tighten
Tighten the crankshaft position sensor studs to
30 N-m (22 lb ft).
345236
36589
6-230
Engine
9. Install the crankshaft position sensor shield ..
35844
Crankshaft Front Oil Seal Installation

Tools Required
1. Coat the inside diameter of the crankshaft front oil
seal with lubricant GM P/N 10522497 or
equivalent.
2. Use J 35354 and a soft faced hammer to install
the crankshaft front oil seal.
3. Remove J 35354.
J 35354
36662
Valve lifter Installation

1. Dip the valve lifters in prelube GM P/N 12345501
or equivalent.
2. Install the valve lifters.
3. Install the valve lifter guides.

Notices.
4. Install the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).
41374
Engine
6-231
Cylinder Head Installation
Tools Required
1. Install the cylinder head gasket. Ensure the
arrows point towards the front of the
engine. The left cylinder head gasket has .the
letter L stamped next to the arrow.

2. Install the cylinder head.
35842

Notices.
3. Install new cylinder head bolts.

Tighten
in sequence. Using J 36660-A rotate each
cylinder head bolt an additional 120 degrees.
@
~
38826

Installation
Tools Required
J 36660-ATorque Angle Meter
1. Install the push rods.
2. Install the push rod guide plates.
3. Install the valve rocker arms.
4. Apply GM P/N 12345493 threadlocker or
equivalent to the valve rocker arm bolt threads.
Notices.
5. Install the valve rocker arm bolts.

Tighten
Tighten the valve rocker arm bolts to
15 Nm (11 lb ft) + 90 degrees using J 36660-A.
35840
s. 232
Engine
(Left Side)
equivalent to threads..

Notices.
3. Install the valve rocker arm cover bolts.
Tighten
10 N-m (89 lb in).
35819

(Right Side)
equivalent to.the threads.

Notices.
3. Install the valve rocker arm cover bolts.
Tighten
10 N-m (89 lb in).
63414
Exhaust Manifold ln.stallation (Left Side)

1. Install the exhaust manifold gasket to the
cylinder head,
2. Install the exhaust manifold to the cylinder head.

Notices.
3. Install the exhaust manifold nuts.
Tighten
Tighten the nuts 23 N,m (17 lb ft).
589361
Engine
6-233
4. Install the exhaust manifold heat shield.

Tighten
Tighten the two end nuts to 23 N-m (17 lb ft).
Tighten the bottom nut to 10 Nm (89 lb in).
589352
6. Install the engine lift hook.
566982
Important: Inspect the .EGR inlet pipe for leaks.

Replace the EGR adapter if the pipe leaks.
7. Install the EGR inlet pipe to the exhaust manifold.

8. Install the EGR inlet pipe bolt and nuts.
Tighten
Tighten the nuts to 50 Nm (36 lb ft) and the bolt
to 25 N-m (18 lb ft).
589355
6;..234
Engine
Exhaust Manifold Installation (Right Side)

1. Install the exhaust m~nlfold ga.sket tb the
cylinder head.
2. Install the exhaust manifold to the cylinder head.

Notices.
3. Install the exhaust manifold nuts.
Tighten
Tighten the nuts to 23 Nm (17 lb ft).
589366
4. Install the exhaust manifold heat shield.

Tighten
Tighten the two end heat shield nuts to
23 Nm (17 lb ft).
Tighten the bottom nut to 10 N-m (89 lb in).
589365
Intake Manifold Installation (Lower)

1. Install the lower intake manifold gasket.
2. Install the lower intake manifold.
equivalent on the threads.
50046
Engine
6-235

Notices.
4. Install the lower intake manifold bolts.
Tighten
Tighten the bolts in sequence to 15 Nm (11 lb ft).
50288
5. Install the generator bracket.

6. Install the ignition control module bracket.
Tighten
Tighten the ignition control module bracket bolts
to 50 Nm (37 lb ft).
7. Install the ignition control module and nuts.
Tighten
Tighten the ignition control module nuts to

30 Nm (22 lb ft).
566980
Intake Manifold Installation (Upper)

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the water outlet.
403782
6-236
Engine
Notice: Refer to. Fastener Notice in Cautions and

Notices.
4. Install the upper intake manifold bolts.
Tighten
Tighten the vertical bolts in sequence to
15 Nm (11 lb ft).
Tighten the two water outlet bolts in sequence
to 27 N-m (20 lb ft) ..
Tighten the side bolts in sequence to
30 N-m (22 lb ft).
403789
5. Install the fuel injector rail.

6. Install the fuel injector rail nuts.
Tighten
Tighten the fuel injector rail nuts
9 Nm (80 lb in).
to
403779
7. Install the throttle body gasket.

8. Install the throttle body.
9. Install the throttle body nuts and bolt.
Tighten
Tighten the throttle body nuts and bolt to
10 N-m (89 lb in).
403776
Engine
6-237
10. Install the EGR outlet pipe to the intake manifold,
Tighten
Tighten the EGR outlet pipe bolt. and nut to
29 Nm (21 lb ft).
11. Install the m1:1nifold vacuum source.
12. Install the rear generator mounting bracket
and bolts.
Tighten
. Tighten the bolts to 50 N-m (37 lb ft).
403772
Water Pump installation

Tools Required
J 36660-ATo'rque Angle Meter
1. Install. the water pump gasket.
2. Install the water pump.

Notices.
3. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 15 Nm (11 Jb ft).
Use J 36660-A to tighten the bolt an additional
80 degrees.
187022
4. Install the water pump pulley.

5. Install the water purnp pulley bolts.
Tighten
Tighten the water pump pulley bolts to
13 Nm (116 lb in),.
313967
6-238
Engine
Water Outlet Installation
1. Install the thermostat.
2. Install the water outlet gasket.

Notices.
4. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 27 N-m (20 lb ft).
36621
Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.
Lubricate the 0-ring with engine oil and make
sure it is in place.
Make sure the assembly is fully seated in the
engine block.

Notices.
2. Install the oil level indicator tube bolt.
Tighten
Tighten the bolt to 1O Nm (89 lb in).
36615
Drive Belt Tensioner Installation

2. Install the heater water bypass inlet pipe to the
lower intake manifold and to the tensioner.

Notices.
3. Install the tensioner bolts.
Tighten
313973
Engine
a..239

Tools Required
1. Install the flywheel.
Notices.
2. Install the new flywheel bolts.
. Tighten
Tighten the bolts to 15 Nm (11 lb ft). Use the
J 36660-A to tighten the bolts an additional
50 degrees.
36665
Engine Flywheel ~nstallation

Tools Required
1. Install the flywheel.
Notices.
.
2. Install the new flywheel bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft). Use
J 36660-A to tighten the bolts an aaditional
50 degrees.
192727
Crankshaft Balancer Installation

Tools Required
.. J 37096 Flywheel Holding Tool
.. J 36660-A Torque Angle Meter
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer.
3. Use J 37096 to hold the flywheel.
309963
6~240
Engine

Notices.
4. Install the crankshaft balancer bolt.

Tighten
Tighten the crankshaft balancer bolt to
150 Nm (111 lb ft). Use J 36660-A to tighten the
crankshaft balancer bolt an additional
114 degrees.
192730
Engine
6-241
Description and Operation

) Engine Component Description
Engine Construction
Starting at the front of the engine, the cylinders of the
left bank are numbered 1-3-5 and the cylinders of
the right bank are numbered 2-4-6. The crankshaft is
supported in the engine block by four bearings. The
crankshaft is counterbalanced by the flywheel,
the crankshaft balancer, and the weights cast into the
crankshaft. Additional counterbalancing is obtained
from the balance shaft which rides in the engine block
above the camshaft and is driven by the camshaft.
All 3800 engines are even-firing, the cylinders
fire at equal 120 degree intervals of crankshaft rotation.
The location of the crankshaft journals has been
offset by 30 degrees to fire the cylinders at 120 degree
intervals of crankshaft rotation. The camshaft lobes
and timing also reflect the 120 degree intervals.
The even firing crankshaft provides an equal interval
of 120 degrees between ignition of each of the
cylinders throughout the firing order. The firing order is
1-6-5-4-3-2. The aluminum alloy pistons have
slipper skirts and are cam turned. Four drilled holes or
casted slots in the oil ring grooves permit drain
back of the oil collected by the oil ring. The camshaft
is supported by four bearings in the engine block
and is driven by the crankshaft through sprockets and
a timing chain. The cylinder heads are cast iron

)
and incorporate integral valve stem guides. Right and
1
left cylinder heads are identical and are
interchangeable, but it is good practice to reinstall the
cylinder heads on the side from which they are
removed. The intake manifold is bolted to the inner
faces of both cylinder heads so it connects with
all inle1 ports.
Each exhaust and intake valve has a valve spring to
insure positive seating throughout the operating speed
range. The valve rocker arms for each bank of the
cylinders pivot on pedestals bolted to the cylinder
head. Hydraulic roller valve lifters and tubular push
rods are used to operate overhead rocker arms
and valves of both banks of the cylinders from a single
camshaft. This system requires no lash adjustment
at the 1ime of assembly or service.
In addition to its normal function of a cam follower,
each valve lifter also serves as an automatic adjuster
which maintains zero lash in the valve train under
all operating conditions. By eliminating all lash in the
valve train and also providing a cushion of oil to absorb
operating shocks, the valve lifter promotes quiet
valve operation. It also eliminates the need for periodic
valve adjustment to compensate for wear of parts:
Oil is supplied to the valve lifter through a hole in the
side of the valve lifter body which indexes with a
groove and a hole. in the valve lifter plunger. Oil is then
metered past the oil metering valve in the valve
\ lifter, through the push rods to the valve rocker arms.
) When the valve lifter begins to move up the
e;amshaft lobe, the check ball is held against its seat
in the plunger by the check ball spring which traps the
oil in the base of the valve lifter body belowthe
plunger.
The plunger and the valve lifter body then raise as a

unit, pushing up the push rod to open the valve.
The force of the valve spring which is exerted on the
plunger through the valve rocker arm and push
rod, causes a slight amount of leakage between the
plunger and the valve lifter body. This leakage allows a
slow escape of trapped oil in the base of the valve
lifter body. As the valve lifter .rolls down the other side
of the camshaft lobe and reaches the base circle or
valve closed position, the plunger sprir::ig quickly moves
the plunger back (up) to its original position. This
movement causes the check ball to open against the
ball spring, and any oil inside the plunger is drawn
into the base of the valve lifter. This restores the valve
lifter to the zero lash.
Drive Belt System Description

The drive belt system consists of the following
Components:
The drive belt
The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory driv.e component mounting
brackets
The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use one belt or two belts.
The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the
pulleys. There also may be a V-belt style belt used to
drive certain accessory drive components. The
drive belts are made of different types of rubbers
(chloroprene or EPDM) and have different layers or
plys containing either fiber cloth or cords for
reinforcement.
Both sides of the drive belt may be used to drive the
different accessory drive components. When the
back side of the drive belt is used to drive a pulley,
the pulley is smooth.
The drive. belt is pulled by the crankshaft balancer
pulley across the accessory drive component pulleys.
The spring loaded drive belt tensioner keeps
constant tension on the drive belt to prevent the drive
belt from slipping. The drive belt tensioner arm will
move when loads are applied to the drive belt by the
accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which
is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory
drive component when the vehicle is not equipped with
the accessory.
6-242
Engine
lubrication Description
44529
The engine lubrication system is of the force-feed

type. The oil is supplied under full pressure to
the crankshaft, connecting rods, valve lifters, camshaft,
and rear balance shaft bearing. A controlled volume
of oil is supplied to the valve rocker arms and
push rods. All other moving parts are lubricated by
gravity flow or splash. The engine oil is stored in the
lower crankcase (oil pan) which is filled through a
filler opening in the valve rocker arm cover. A
removable oil level indicator, on the left side of the
engine block, is provided to check the oil level. The oil
pump is located in the engine front cover and is
driven by the crankshaft. It is a gerotor-style pump
which is a combination of a gear and a rotor pump. It
is connected by a passage in the cylinder block to
an oil screen and pipe assembly. The screen is
submerged in the oil supply and has ample vol.ume for
all operating conditions. If the screen becomes
clogged, oil may be drawn into the system through the
oil pressure relief valve in the oil filter adapter. Oil is.
drawn into the pump through the screen and pipe
assembly, and a passage in the crankcase, connecting
to the passages in the engine front cover. Oil is
discharged from the oil pump to the oil filter adapter.

The oil filter adapter consists of an oil filter bypass
valve and a nipple for installation of an oil filter. The
spring-loaded oil pressure relief valve, located in.
the engine front cover, limits the oil pressure. The oil
filter bypass valve opens when the oil filter is
.
restricted to approximately 68.95 kPa (10 psi) of
pressure difference between the oil filter inlet and
discharge. The oil will then bypass the oil filter
and channel unfiltered oil directly to the main oil
galleries of the engine. A full-flow oil filter is externally (
mounted to the oil filter adapter on the lower right
front side of the engine. If the filter element becomes
restricted, not allowing engine oil to pass through,
a spring-loaded bypass valve opens.
Engine
The main oil galleries run the full length of the engine
block and cut into the valve lifter guide holes to
supply oil at full pressure to the valve lifters. Holes,
drilled from the crankshaft bearings to the main
oil gallery, intersect the camshaft bearing bores to
supply oil to the cam bearings.
Oil is transfered from the crankshaft bearings to the
connecting rod bearings through holes drilled in
the crankshaft. Pistons, piston pins, and cylinder walls
are lubricated by oil splash from the crankshaft and
connecting rods.
Each valve rocker arm and valve is supplied with oil
through the tubular push rod. The oil comes from
the inside of the valve lifter passing around the
metering valve and through a hole in the push rod
seat. Oil from the push rod passes through a hole in
the push rod seat, and emerges on top of the push rod
seat boss.
Cleanliness and Care
An automobile engine is a combination of many of the

following surfaces:
Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the
ten-thous.andths of an inch. When you service any
internal engine part, clean.liness and care are .
important. Apply a liberal coating of engine oi.1 to the
friction areas during assembly in order to protect
and lubricate the surfaces on initial operation.
Throughout this section, practice proper cleaning and
protection procedures to the machined surfaces
and to the friction areas.
Notice: Engine damage may result if an abrasive
paper, pad, or motorized wire brush is used to clean
any engine gasket surfaces.
Whenever you remove the valve train components,
keep the components in order. Follow this procedure in
order to install the components in the same locations
and with the same mating surfaces as when
removed.
Disconnect the negative battery cables before you'
perform any major work on the engine. For more
information on the disconnection of the battery, refer
to Engine Electrical.
Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise
specified. Reusable gaskets will be identified in the

service procedure. Do not apply sealant to any
gasket or sealing surface unless called out in the
service procedure.
2. Use a rubber mallet in order to separate
components. Bump the part sideways in order to
loosen the components. Perform the bumping
at the bends or at the reinforced areas in order to
prevent the distortion of components.
6~243
Important: Do not use any other method or technique

in order to remove the gasket material from a
components.
Do not use the following items in order to clean the
gasket surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the
component.
Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. Tflis grit is abrasive
and may cause internal engine damage.
3. Remove all of the gasket and the sealing material
from the qomponent using a plastic or a wood
scraper. Do not gouge or scrape the sealing
surfaces.
Important: Do not allow the sealant to enter any blind

threaded holes. The sealant may cause the following
conditions:
Prevent you from properly seating the bolt

Ca.use damage when you tighten the bolt
4. When assembling components, use only the
sealant 'specified inthe service procedure.
Ensure that the sealing surfaces are clean and
free of debris or oil. Wheri applying sealant
to a component, apply a bead size as specified in
the service procedure.
5. Tighten the bolts to the specifications.
Use of RTV and .Anaerobic Sealer

The following 2 types of sealer are commonly used i.n
engines:
The RTV sealer
The anaerobic gasket eliminator sealer
Follow the service procedure instructions. Use the
correct sealer in the proper place in order to prevent
oil leaks. Do not interchange the 2 types of sealers.
Use th.e sealer recommended in the service procedure.
Applying RTV Sealer

Do not. use the room temperature
vulcanizing (RTV) sealant in areas where extreme
temperatures are expected. These areas include
the following locations:
- The exhaust manifold
- The head gasket
- The other surfaceswhere gasket eliminator
is specified
Use a rubber mallet in order to separate the
components sealed with RTV sealant. Bump the
part sideways in order to shear the RTV sealer.
Perform the bumping at the bends or the
reinforced areas in order to prevent distortion of
the components. The RTV sealant is weaker
in shear (lateral) strength than in tensile (vertical)
strength.
6-244
Engine

component.
Do not use the following items in order to clean
the gasket surfaces:
- Abrasive pads
- Sand Paper
- Power tools
These methods of cleaning may damage the part
cannot remove from the oil. This grit is abrasive
and may cause internal engine damag~.
Remove all of the gasket material from the
component using a plastic or a wood scraper. Use
Loctite brand gasket remover P/N 4MA or the
equivalent. Follow all of the safety
recommendations and the directions that are on
the container.
Important: Do not allow the sealer to enter the blind
threaded holes. The sealer may cause the following
conditions:
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt
Apply the RTV sealant to a clean surface. Use a
bead size as specified in the procedure. Apply
the bead to the inside of any bolt holes.
Assemble the components while the RTV sealant
is still wet (within 3 minutes). Do not wait for the
RTV sealant to skin over.
Important: Do not overtigliten the bolts.
Tighten the bolts to specifications.
Applying Anaerobic Sealer

The anaerobic gasket eliminator hardens in the
absence of air. This type of sealer is used where
2 rigid parts (such as castings) are assembled
together. When 2 rigid parts are disassembled and no
sealer or gasket is readily noticeable, the parts
were probably assembled using a gasket eliminator.
component.
Do not use the following items in order to clean the
gasket surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the part.
cannot remove from the oil. This grit is abrasive
and may cause internal engine damage.
Remove all of the gasket material from the
component using a plastic or a wood scraper. Use
Loctite brand gasket remover P/N 4MA or the
equivalent. Follow all of the safety
recommendations and the directions that are on
the container.
Apply a continuous bead of the gasket elimina.tor

to 1 flange. Clean and dry any surfaces that you
will reseal.
Important: Anaerobic sealed joints that are partially

torqued and allowed to cure more than 5 minutes may
result in incorrect shimming and sealing of the joint.
Do not allow the sealer to enter the blind
threaded holes. The sealer may cause the
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt
Spread the sealer evenly in order to get a uniform
coating on the sealing surface.
Tighten the bolts to the specifications.
Remove the excess sealer from the outside of
the joint.
Separating Parts
The components of an internal combustion engine
develop wear patterns with their mating components.
During disassembly of the engine, parts should be
separated and kept in order so they may be reinstalled
in the same location from which they were removed.
Service. Precautions
Important: Follow the engine service information
below. This information is important in order to prevent
damage and in contributing to reliable engine
performance.
In order to avoid damage to the engine oil pan, use a

block of wood between the jack and the oil pan.
Ensure that the block of wood extends past the
complete width of the oil pan. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the oil
pan to bend against the pump screen. This condition
results in a damaged oil pick-up unit.
Caution: Refer to Fastener Notice in Cautions and

Notices.
When working on the engine, remember that the
12-volt electrical system is capable of causing short
circuits. When performing any work where electrical
terminals may possibly be grounded, disconnec1
the ground cable of the battery at the battery.
Any time you remove the air cleaner, cover the intake
opening. This procedure protects against the
accidental entrance of foreign material. Foreign
material may follow the intake passage into the
cylinder. This condition causes extensive damage
when you start the engine.
In the mechanical procedures described in this
section, generally no references will be made to the
removal of optional equipment such as the power
steering pump, the air conditioning compressor, etc.
If you need to remove any optional equipment in order
to perform other service, refer to the appropriate
section of this service manual for the specific
information.
Engine
Installation Precautions
Caution: Before removing or installing any

electrical unit, or when a tool or equipment could
easily come in contact with "live" or "hot all
the times" exposed electrical terminals, disconnect
the negative battery cable to help prevent
personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the
ignition switch must be in the OFF or LOCK
position.
Notice: The following information on engine service
should be noted carefully, as it is important in
preventing damage and contributing to reliable engine
performance.
When raising or supporting the engine tor any reason,
do not use a jack under the oil pan. Due to the
small clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the
oil pan to be bent against the oil pump screen resulting
in a damaged oil pump screen or oil pump pipe.
Any time the throttle body or air induction tube is
removed, the intake opening should be covered. This
will protect against the accidental entrance of
foreign material which could follow the intake passage
into the cylinder and cause extensive damage when
the engine is started.
Special Tools and Equipment

Illustration
Tool Number/Description
J 6125-18
Slide Hammer
4865
J 7872
Magnetic Base Indicator Set
2014
Tools and Equipment
Work in a clean and well-lit area. Have the following

components available before you begin to work:
A suitable parts cleaning tank
A compressed air supply
Trays, in order to keep the parts and the fasteners
organized
An adequate set of hand tools
An approved engine repair stand will prevent personal
injury or damage to the engine components. The
special tools are designed in order to quickly
and safely accomplish the operations tor which the
tools are intended. Using the tools will minimize
possible damage to the engine components. Precision
measuring tools are required for the inspection of
certain critical components. Torque wrenches
are needed for the correct assembly of various parts.
J 8001
Dial Indicator Set
2014
J 8037
Universal Piston Ring
Compressor
J 8087
Cylinder Bore
Checking Gauge
5110
6-246

Illustration
Engine
Illustration
(
J 25087-C
Oil Pressure Test Kit
J 8520
Dial Indicator Adapter
3408
60304
J 9666
Valve Spring Tester
J 28428~E
High Intensity Black Light
5112
62292
J 21465-13
Drive Handle Extension
J 28467-B
Engine Support Fixture
3400
190562
~
J 23590
Spark Plug Port Adapter
~ ~
~ ~
~
3400
J 28467-90A
Engine Support Adapters
367798
J 24270
Cylinder Ridge Reamer
3412
J 33049
Camshaft Bearing
Remover/Installer Set
5118
Engine
Engine Mechanical- 3.8L
Illustration
Illustration
. Tool Number/Description
J37088-A
Fuel Line Quick Connect
Seperator
J -35354
Seal Installer
13542
37773
J 37096.
Flywheel Holding Tool
J 36660
Torque Angle Meter
37623
3413
J 38196
Installer
J 35667-A
Cylinder Leakdown Tester
38068
62295
J 36995
Balance Shaft Bearing
Remover/Installer
J 38197
Crankshaft Balancer Puller
13547
38285
J 36996
Balance Shaft Installer
3411
6-247
J 38606
Valve Spring Compressor
49850
6~248

Illustration
Engine
Illustration
(
J 41044
220634
J 41507
Connecting Rod Guide
38090
J 41348
Main Bearing Cap Puller
38515
J42863
Valve Seal Installer
223541
J 41349
Housing Alignment Tool
49848
Engine

Specifications
Specification
Metric
English
Accelerator Control Cable Bracket Bolts
Application
10 N,m
891bin
Air Conditioning Compressor Bolts
50Nm
37 lb ft
. Air Conditioning Compressor Bracket Bolts
50Nm
37 lb ft
Air Conditioning Idler Pulley Bolt
50 N,m
37 lb ft
Air Conditioning Tensioner Bolt
25Nm
18 lb ft
Air Injection Reaction (AIR) Pipe-to-Exhaust Manifold Bolts
20Nm
15 lb ft
Camshaft Retainer Bolts
25Nm
.18 lb ft
Camshaft Sensor Bolt
25Nm.
18 lb ft
35 N,m
26 lb ft
Camshaft Sprocket Bolts
Catalytic Converter Nut
25Nm
Connecting Rod Bolts - First Design (First Pass)
20Nm
Connecting Rod Bolts - First Design (Final Pass) .

Connecting Rod Bolts - Second Design (First Pass)
'"'
20Nm
Connecting Rod Bolts - Second Design (Final Pass)
18 lb ft
15 lb ft
60degrees
15 lb ft
75 degrees
Coolant Temperature Gauge Sensor
20Nm
Crankshaft Balancer Bolt (Installation Pass-to Ensure the Balancer is

Completely Installed)
330 N:m.
Crankshaft Balancer Bolt (First Pass-Install a NEW Bolt After the

Installation Pass and Tighten as Described in the First and Final
Passes)
50Nm
Crankshaft Balancer Bolt (Final Pass)

Crankshaft Bearing Cap Bolts (Inner Bolts-First Pass in Sequence)
15 lb ft
'
240 lb ft
.. 37 lb ft
140 degrees
15 lb ft
20Nm
Crankshaft Bearing Cap Bolts (Inner Bolts-Final Pass in Sequence)
80 degrees
Crankshaft Bearing Cap Side Bolts
25Nm
18 lb ft
Crankshaft Bearing Cap Studs (Outer Studs-First Pass in Sequence)
20Nm
15 lb ft
Crankshaft Bearing Cap Studs (Outer Studs-Final Pass in Sequence)
53 degrees
Crankshaft Oil Deflector Nuts
25Nm
18 lb ft
. Crankshaft Position Sensor Bolt
25Nm
18 lb ft
Cylinder Head Bolts (First Pass all M11 Bolts in Sequence)
30Nm
22 lb ft
Cylinder Head Bolts (Second Pass all M11 Bolts in Sequence)
90 degrees
Cylinder Head Bolts (Final Pass all M11 Bolts in Sequence-Excluding

the Medium Length Bolts at the Front and Rear of Each Cylinder Head)
90 degrees
Cylinder Head Bolts (Final Pass M11 Medium Length Bolts at the Front
and Rear of Each Cylinder Head in Sequence)
50 degrees
Cylinder Head Bolts (MB Inner Bolts in Sequence)
30Nm
22 lb ft
Cylinder Head Coolant Plug
20 N-m
15 lb ft
Cylinder Head Core Hole Plug
20Nm
15 lb ft
Drive Belt Idler Pulley Bolt
50Nm
37 lb ft
Drive Belt Tensioner Bolts
50Nm
37 lbft
Engine Block Coolant Drain Plugs
60Nm
44 lb ft
Engine Block Heater
40Nm
30 lb ft
Engine Block Oil Gallery Plugs
60Nm
44 lb ft
Engine Coolant Air Bleed Pipe Bolts and Studs
12 Nm
1061bin
Engine Crossmember Bolts (Large)
145 Nm
107 lb ft
6-249
6-250
Engine

Specification
Metric
Application
Engine Crossmember Bolts (Small)
125 N-m
Engine Flywheel Bolts (First Pass)
English
.
92 lb ft
20N-m
50 N-m
37 lb ft
Engine Flywheel Bolts (Final Pass)
100N-m
74 lb ft
Engine Flywheel-to-Torque Converter Bolts
60N-m
44 lb ft
Engine Front Cover Bolts
25N-m
18 lb ft.
Engine Mont Heat Shield Nuts
10 N-m
891bin
50N-m
37 lb ft
Engine Mount Through Bolts
95N-m
70 lb ft
..
15 lb ft
Engine Flywheel Bolts (Second Pass)
Engine Mount Stud-to-Engine Block.
..
Engine Mount Through Bolt Nuts
80 N-m
59 lb ft
Engine Mourit-to-Engine Block Bolts
50N-m
37 lb ft
Engine Rear Cover Bolts
25N-m
18 lb ft
Engine Service Lift Bracket M10 Bolts
50N-m
37 lb ft
Engine Service Lift Bracket M8 Bolt
25 N-m
18 lb ft
Engine Valley Cover Bolts
25N-m
18 lb ft
Engine Wire Harness Clip Bolt
50N-m
37 lb ft
Engine Wire Harness Ground Strap Bolt
50 N-m
37 lb ft
Exhaust Gas Recirculation (EGR) Valve Bolts (First Pass)
10 N-m
891bin
EGR Valve Bolts (Final Pass)
30 N-m
22 lb ft
EGR Valve Pipe-to-Cylinder Head Bolts
50N-m
EGR Valve Pipe-to-Exhaust Manifold Bolts
30 N-m
EGR Valve Pipe-to-Intake Manifold Bolt
10 N;m
891bin
Exhaust Manifold Bolts (First Pass)
15 N-m
11 lb ft
Exhaust Manifold Bolts (Final Pass)
25 N-m
:J8 lb ft
Exhaust Manifold Heat ShieldBolts
9Nm
801bin
Exhaust Manifold Pipe Nuts
35N-m
26 lb ft
37 lb ft
22 lb ft
Front Shock-to-Engine Crossmember Bolts
65N-m
48 lb ft
Fuel Injection Fuel Rail Bolts
10 N-m
891bin
Generator Bracket Bolts
50N-m
37 lb ft
Generator Rear Bracket-to-Engine Block Bolt
25N-m
18 lb ft
Generator Rear Bracket-to-Generator Bolt
25N-m
18 lb ft
Ground Strap Bolt (at Rear of Cylinder Head)
50N-m
Ignition Coil-to-Bracket Bolts
12 N-m
106 lb in
Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts
12 N-m
106 lb in
Intake Manifold Bolts (First Pass in Sequence)
5N-m
441bin
Intake Manifold Bolts (Final Pass in Sequence)
10 N-m
89lbin
Knock Sensors
20N-m
15 lb ft
Oil Filter
30N-m
22 lb ft
Oil Filter Fitting
55N-m
40 lb ft
Oil Level Indicator Tube Bolt
25N-m
18 lb ft
Oil Level Sensor
37 lb ft
13 N-m
115 lb in
Oil Pan Baffle Bolts
12 N-m
i061bin
Oil Pan Closeout Cover Bolt (Left Side)
12 N-m
106 lb in
Oil Pan Closeout Cover Bolt (Right Side)
12 N-m
106 lb in
Oil Pan Cover Bolts
12 N-m
106 lbin
Oil Pan Drain Plug
25N-m
18 lb ft
Oil Pan M8 Bolts (Oil Pan-to-Engine Block and Oil Pan-to-Front Cover)
25N-m
18 lb ft
..
Engine
6-251

Specification
Application
Metric
English
Oil Pan M6 Bolts (Oil Pan-to-Rear Cover)
12 Nm
1061bin
Oil Pressure Sensor
20Nm
15 lb ft
Oil Pump-to-Engine Block Bolts
25Nm
1.8 lb ft
Oil Pump Cover Bolts
12 Nm
1061bin
Oil Pump Relief Valve Plug
12.Nm
1061bin
Oil Pump Screen Nuts
25N-m
18 lb ft
Oil Pump Screen-to-Oil Pump Bolt
12 N-m
1061bin
Oxygen Sensor
42Nm
31 lb ft
Positive Crankcase Ventilation (PCV) System Strap Nut (at Right Front
Vapor Vent Pipe Stud)
12 Nm
1061!:? in
Power Steering Pump Bolts
25Nm
18 lb ft
Power Steering Pump Bracket Bolts
25Nm
18 lb ft
Spark Plugs (Cylinder Heads-New)
20Nm
15 lb ft
Spark Plugs (all Subsequent Installations)
15 N-m
1 {lb ft
Throttle Body Bolts
12 N-m
1061bin
Transmission Housing Bolt
50Nm
37 lb ft
Valve Lifter Guide Bolts
12 Nm
1061bin
Valve Rocker Arm Bolts
30 N-m
22 lb ft
Valve Rocker Arm Cover Bolts
12 N-m
1061bin
Water Inlet Housing Bolts
15 N:m
11 lb ft
Water Pump Bolts (First Pass)
15 N-m
11 lb ft
Water Pump Bolts (Final Pass)
30Nm
22 lb ft
Water Pump Cover Bolts
15 N-m
11 lb ft
Engine Mechanical Specifications

Specification
Application
Metric
English
General Data
VB
Engine Type
Displacement
5.7L-5665 cc
346 C.ID
Bore
99.0 mm
3.898 in
Stroke
92.0 mm
3.622 in
Compression Ratio
10.1:1
1-8-7-2-6-5-4-3
Firing Order
Spark Plug Gap
1.524 mm
0.06 in
Lubrication System
Oil Capacity (without Oil Filter Change)
Oil Capacity (with Oil Filter Change)
Oil Pressure (Minimum-Hot)
4.7 Liters
5.0 Quarts
5.2 Liters
5.5 Quarts
41 kPa at 1,000
el'.lgine RPM
124 kPa at 2,000
engine RPM
165 kPa at 4,ooo
engine RPM
6 psig at 1,000
engine RPM
18 psig at 2,000
engine RPM
24 psig at 4,000
engine RPM
5W~30
Oil Type
Camshaft
Camshaft End Play
0.025-0.305 mm
0.001-0.012 in
Camshaft Journal Diameter
54.99-55.04 mm
2.164-2.166 in
6-252
Engine

Specification
Metric
English
0.025 mm
0.001 in
Camshaft Lobe Lift (Intake)
7.43 mm
0.292 in
Camshaft Lobe Lift (Exhaust)
7.43 mm
0.292 in
Camshaft Runout (Measured at the Intermediate Journals)
0.05 mm
0.002 in
56.505-56.525 mm
2.224-2.225 in
Connecting Rod Bearing Bore Out~of-Round (Production)
0.004 mm
0.00015 in
Connecting Rod Bearing Bore Out~of-Round (Service Limit)
0.008 mm
0.0003 in
Connecting Rod Bearing Clearance (Production)
0.015-0.063 mm
0.0006-0.00248 in
Connecting Rod Bearing Clearance (Service Limit)
0.015-0.076 mm
0.0006-0.003 in
0.11-0.51 mm
0.00433-0.02 in
0.018-0.054 mm
0.0007-0.00212 in
53.318-53.338 mm
2.0991-2.0999 in
53.308 mm
2.0987 in
0.005 mm (Maximum
for 1/2 of the Journal
0.0002 in (Maximum for

1/2 of the Journal
Application
Camshaft Journal Diameter Out-of-Round
Connecting Rod
Connecting .Rod Bearing Bore Diameter
Connecting Rod Side Clearance

Crankshaft
Crankshaft Bearing Clearance (Production)
Crankshaft Connecting Rod Journal Diameter (Production)
Crankshaft Connecting Rod Journal Diameter (Service Limit)
Crankshaft Connecting Rod Journal Taper (Production)
.,
Crankshaft Connecting Rod JournalTaper (Service Limit)

Crankshaft Connecting Rod Journal Out-of-Round (Production)
Crankshaft Connecting Rod Journal Out-of-Round (Service Limit)
Crankshaft End Play
Crankshaft Main Journal Diameter (Production)
Length)
0.00078 in (Maximum)
0.005 mm
0.002 in
0.01 mm
0.00039 in
0.04-0.2 mm
0.0015-0.0078 in
64.993-:65.007 mm
2.558-2.559 in
..
64.993 mm (Minimum)
2.558 in (Minimum)
Crankshaft Main Journal Out-of-Round (Production)
0.003 mm
0.000118 in
Crankshaft Main Journal .Out-of-Round (Service. Limit)
0.008 mm
0.00031 in
Crankshaft Main Journal Taper (Production)
O.D1 mm
0.00039 in
Crankshaft Main Journal Taper (Service Limit)
0.02 mm
0.00078 in
Crankshaft Reluctor Ring Runout (Measured 1.0 mm (0.04 in) Below

the Tooth Diameter)
0.25 mm
0.01 in
0.05 mm (Maximum)
0.002 in (Maximum)
0.025 mm
0.001 in
Crankshaft Main Journal Diameter (Service Limit)
Length)
0.02 mm (Maximum)
Crankshaft Runout (at Rear Flange)

CrankshaftThrust Wall Runout
26.14-26.22 mm
1.029-1.032 in
26.2 mm (Maximum)
1.0315 in (Maximum)
99.0-99.018 mm
3.897-3.898 in
0.018 mm (Maximum)
0.0007 in (Maximum)
0.08 mm
0.003 in
Cylinder Head Engine Block.Deck Flatness. (Measuring the Overall

Length of the Cylinder Head)
0.1 mm
0.004 in
Cylinder Head Exhaust Manifold Deck Flatness
0.22 mm
0.008 in
Cylinder Head Intake Manifold Deck Flatness
0.22 mm
0.008 in
120.2 mm (Minimum)
4.732 in (Minimum)
55.063-55.088 mm
2.168-2.169 in
Crankshaft Thrust Wall Width (Production)

Crankshaft Thrust Wall Width (Service)
Cylinder Bore
Cylinder Bore Diameter
Cylinder Bore Taper Thrust Side
Cylinder Head
Cylinder Head Engine Block Deck Flatness (Measured within a
152.4 mm (6.0 in) area)
Cylinder Head Height (Measured from the Cylinder Head Deck to the
Valve Rocker Arm Cover Seal Surface)
Engine Block
Camshaft Bearing Bore Diameter
Engine
6-253

Specification
Application
Metric
English
Engine Block Cylinder Head Deck Surface Flatness (Measured within a

152.4 mm (6.0 in) area)
0.08 mm
0.003 in
Engine Block Cylinder Head Deck Surface Flatness (Measuring the

Overall Length of the Block Deck)
0.22 mm
0.008 in
234.57-234.82 mm
9.23ff-9.245 in
69.871-69.889 mm
2.75....:2.751 in
0.5mm
0.02 in
21.417-21.443 mm
0.843-0.844 in
0.5mm
0.02 in
Engine Block .Cylinder Head Deck Height (Measuring from the

Centerline of Crankshaft to the Deck Face)
Main Bearing Bore Diameter (Production)
Main Bearing Bore Out-of-Round
Valve Lifter Bore Diameter (Production)
Intake Manifold
ln1ake Manifold Cylinder Head Deck Flatness (Measured at Gasket
Sealing Surfaces)
Oil Pan and Front/Rear Cover Alignment
Oil Pan to Rear of Engine Block Alignment (at Transmission
Bellhousing Mounting Surface)
0.0-0.25 mm
(Maximum)
0.0-0.01 in (Maximum)
Front Cover Alignment (at Oil Pan Surface)
0.0-0.5 mm
0.0-0.02 in
Rear Cover Alignment (at Oil Pan Surface)
0.0-0.5 mm
0.0-0.02 in
98.964-98.982 mm
3.8962-3.8969 mm
Piston
Piston Outside Diameter (at Size Point)
Piston Out-of-Round (Service Limit)
0.018 mm
..
0.0007 in
Piston to Bo.re Clearance (Production)
0.018-0.054 mm
o.0007....:0.00212 in
Piston to Bore Clearance (Service Limit)
0.018-'-0.054 mm
(Maximum)
0.0007-0.00212 i.n
(Maximum)
Piston Pin Clearance to Piston Bore (Production)
0.01-0.02 mm
0.0004-0.00078 in
Piston Pin Clearance to Piston Bore (Service Limit)
0.01-0.02 mm
(Maximum)
0.0004-0.00078 in
(Maximum)
23.997-24.0 mm
0.9447-0.9448 in
0.02-0.043 mm
(Interference)
0.00078-0.00169 in
(Interference)
Piston Compression Ring End Gap (Production-Top) (Measured in

Cylinder Bore)
0.23-0.38 mm
0.009-0.0149 in
Piston Compression Ring End Gap (Production-2nd ) (Measured in

Cylinder Bore)
0.44-0.64 mm
0.0173-0.0251 in
Piston Pin
Piston Pin Diameter

Piston Pin Fit in Connecting Rod
Piston Rings
'
Piston Oil Ring .End Gap (Production) (Measured in Cylinder Bore)
0.18-0.69 mm
0.007-0.0271 in
Piston Compression Ring End Gap (Service-Top) (Measured in

Cylinder Bore)
0.23-0.38 mm
(Maximum)
0.009-0.0149 in
(Maximum)
Piston Compression Ring End Gap (Service-2nd ) (Measured in

Cylinder Bore)
0.44-0.64 mm
(Maximum)
0.0173-0.0251 in
(Maximum)
Piston Oil Ring End Gap (Service Limit) (Measured in

Cylinder Bore)
0.18-0.69 mm
(Maximum)
0.007-0.0271 in
(Maximum)
Piston Compression Ring Groove Clearance (Production-Top)
0.04-0.085 mm
0.00157-0.003346 in
Piston Compression Ring Groove Clearance (Production-2nd )
0.04-0.08 mm
0.00157-0.003149 in
Piston Oil Ring Groove Clearance (Production)
0.01-0.22 mm
0.0004-0.00866 in
Piston Compression Ring Groove Clearance (Service-Top)
0.04-0.085 mm
(Maximum)
0.00157-0.003346 in
(Maximum)
Piston Compression Ring Groove Clearance (Service-2nd )
0;04-0.08 mm
(Maximum)
0.00157-0.003149 in
(Maximum)
Piston Oil Ring Groove Clearance (Service Limit)
0.01-0.22 mm
(Maximum)
0.0004-0.00866 in
(Maximum)
6-254
Engine
Engine .Mechanical -5.7L

Specification
Metric
Application
English
Valve System
45 degrees
Valve Face Angle

Valve Guide Installed Height (Measured from the Cylinder Head
Spring Seat Surface to the Top of the Valve Guide)
17.32 mm
0.682 in
Net Lash-No Adjustment
Valve Lash
Valve Lift (Exhaust)
12.15 mm
0.479 in
Valve Lift (Intake)
11.99 mm
0.472 in
Hydraulic Roller
Valve Lifter
1.25 mm (Minimum)
Valve Margin
0.05 in (Minimum)
1.70:1
Valve Rocker Arm Ratio

Valve Seat Angle
46 degrees
0.002 in (Maximum)
Valve Seat Runout
0.05 mm (Maximum)
1.78 mm
0.07 in
Valve Seat Width (Intake)
1.02 mm
0.04 in
Valve Spring Free Length
52.9 mm
2.08 in
Valve Spring Installed Height (Exhaust)
45.75 mm
45.75 mm
1.8 in
1.8 in
Valve Spring Pressure (Closed)
340 N at 45.75 mm
Valve Spring Pressure (Open)
980 N at 33.55 mm
76 lb at 1.8 in
220 lb at 1.32 in
Valve Seat Width (Exhaust)
Valve Spring Installed Height (Intake)
0.025-0.066 mm
0.025-0.066 mm
0.001-0.0026 in
Valve Stem Clearance (Production-Intake)

Valve Stem Clearance (Service-Exhaust)
0.093 mm (Maximum)
0.0037 in (Maximum)
Valve Stem Clearance (Service_;lntake)
0.093 mm (Maximum)
0.0037 in (Maximum)
7.955-7.976 mm
0.313-0.314 in
7.95 mm (Minimum)
0.313 in (Minimum)
18.1-19.1 mm
0.712-0.752 in
Valve Stem Clearance (Production-Exhaust)
Valve Stem Diameter (Production)

Valve Stem Diameter (Service)
Valve .Stem Oil Seal Installed Height (Measured from the Valve Spring
Shim to Top Edge of Seal Body)
0.001-0.0026 in

Application
Camshaft
-.
,,
..
Camshaft Bearing
GM SPO Group Number
0.519
0.539
.Camshaft Timing Chain
0.724
Connecting Rod
0.603
Connecting Rod Bearing Kit
0.616
Coolant Radiator
1.219
Crankshaft
0.646
Crankshaft Balancer
0.659
.. Crankshaft Bearing Kit
0.096
Crankshaft Transmission Pilot Bearing
0.649
Crankshaft Oil Defl~ctor
1.430
Crankshaft .Front Oil Seal

0.213
0.137
Cylinder Head
0.269
0.289
N.S.
Engine Block
Engine Coolant Air Bleed Pipe
0.1097
Engine Coolant Air Bleed Pipe Gasket
0.1097
Engine
GM SPO Group Numbers (cont'd)

Application
Engine Cooling Thermostat
Engine Front Cover
Engine Flywheel (Automatic Transmission)
Engine Flywheel (Manual Transmission)
Engine Rear Cover
Engine Rear Cover Gasket
Exhaust Manifold
Ignition Coil
Intake Manifold
Oil Filter
Oil Level Indicator
Oil Pan
Oil Pan Gasket
Oil Pump
Oil Pump Screen
Oil Pan Cover
Oil Pan Cover Gasket
Piston with Pin
Piston with Ring Kit
Radiator Fan Shroud
Spark Plug
Sta1ier Motor
Throttle Body
Valley Cover
Valley Cover Gasket
Valve Lifter
Valve Lifter Guide
Valve Pushrod
Valve Rocker Arm
Valve Rocker Arm Support
Valve Spring
Valve Spring Shim
Valve Stem Oil Seal
Water Pump Gasket
Water Pump with Gasket
GM SPO Group Number
1.246
0.206
0.207
0.666
0.666
0.137
0.137
3.601
3.27
2.17
3.265
3.270
1.836
1.. 516
1.516
1.426
1.429
1.652
1.656
1.426
1.429
0.629
0.643
1.277
2.270
2.041
3.335
3.336
3.265
3.270
0.459
0.439
0.426
0.333
0.386
0.423
0.429
0.303
0.303
0.308
1.079
1.069
6-256
Engine
Sealers, Adhesives, and lubricants
Application
Type of Material
GM Part Number
Coolant Sensor Threads
Sealant
12346004
Cylinder Head Core Hole Plugs
Thread lock
12345382
Cylinder Head Expansion Plugs
Thread lock
12345382
Cylinder Head M8 Bolt Threads
Thread lock
12345382
Engine Block Front Oil Gallery Plug
Thread lock
12345382
Engine Block Plug Sealing Washers
Sealant
12346004
Engine Flywheel Bolt Threads
Thread lock
12345382
Engine Oil (FN Car)
5W-30 Oil
12345610
Engine Oil (Y Car)
5W-30 Synthetic Oil
12345885
Engine Oil Supplement
Lubricant
12345795
Exhaust Manifold Bolt Threads
Thread lock
12345493
Fuel Rail Bolt Threads
Thread lock
12345382
Ignition Coil and Bracket Assembly Bolts
Threadlock
12345382
Intake Manifold Bolt Threads
Thread lock
12345382
Oil Pan Surface at Front .and Rear Covers
Sealant
12378190
Oil Pressure Sensor Threads
Sealant
12346004
Engine
6-257
Thread Repair Specifications

Engine Block-Front View
64583
Engine Block-Front View
..
Thread
Hole, Size
1-6
.7
.......
8
:.
M8
xJ.25
M10
.x 1.5 .
M10
x. 1..5 .
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
Insert
Drill
Counterbore
Tool
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
..
Tap
.
J 42385:215
J 42385-211
J 42385-212
J 42385:213
J 42385-214
25.0 (0.984)
19.5 (0.767)
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
32.5 (1.28)
25.0 (0.984)
,.
MB
x 1.25
J42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
10
M10
x 1.5
J42385-215
J42385-211
J 42385-212
J 42385-213
J 42385-214
Thru
Thru
1H3
Ml}
x i.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
14
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
Thru
18.0 (0.708)
15
MB
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
16
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
Thru
18.0 (0.708)
17-27
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
.
.
6-258
Engine
Engine Block-Rear View
15
12
11
10
6
64590
Engine Block-Rear View

Hole
1
Thread
Size
M10
x 1.5
MB
2-4
x 1.25
5-6
x 1.5
7-13
x 1.25
14-16
x 1.5
.. 17-18
M10
MB
M10
MB
x 1.25
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
Insert
Drill
Counterbore
Tool
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
27.0 (1.06)
21.5 (0.846)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
27.0 (1.06)
21.5 (0.846)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
27.0 (1.06)
21.5 (0.846)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
Tap
17.5 (0.688) .
Engine
Engine Mechanical -5.7L
6-259
Engine Block-Left Side View
20
19 i8 17
16
15
13
14
12
64602
Engine Block-Left Side View

'
... Thread
Hole
Size
1
'
. 2-3
..
4
..
MS
x 1.25
M11
x 2.0
MB
x 1.25
M6 x 1.0
M11
6-7
x2.0
x 1.25
9
10
11
MS
.. rv,11.
x 2.0
M11
x 2.0
M16
x 1.5
M10
12-17
x 1.5
18
x 1.25
M28
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
Insert
Drill
Counterbore
Tool
J 42385-210
J 42385-206
J 42385-207
J42385-108
J 42385-105
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-205
J 42385-201
J 42385-202
J 42385-203
J 42385-204
22.5 (0.885)
16.0 (0.629)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
J 42385-210
J 42385-206
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
69.0 (2.72)
60.0 (2.36)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
J 42385-215
-
J 42385-211
-
J 42385-207
J 42385-212
-
Tap
J 42385-213
-
J 42385-214
-
29.0 (1.14)
23.0 (0.905)
6-260
Engine
Engine Block-left Side View (cont'd)

Hole
Thread
Size
Insert
Drill
Counterbore
Tool
J 42385-206
J 42385-207
19'.""20
MS
x 1.25
J 42385-210
21
M16
x 1.5
22
M10
x 1.5
J 42385-215
J 42385-211
23
M11
x 2.0
J 42385-108
J 42385-105
24
M11
x 2.0
J 42385-108
25
MS
x 1.25
26-27
J 42385-212
Tap
J 42385-208
-
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
J 42385-209
21.0 (0.826)
16.0 (0.629)
J 42385-213
J 42385-214
27.0 (1.06)
21.5 (0.846)
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
J 42385-105
J 42385-106
J 42385-107
69.0 (2.72)
60.0 (2.36)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
M11
x 2.0
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
28
M6 x 1.0
J 42385-205
J 42385-201
J 42385-202
J 42385-203
J 42385-204
22.5 (0.885)
16.0 (0.629)
29
MS
x 1.25
J42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)
drill depth.
Bolt holes 9 and 24 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2. 72 in) drill depth. Use sleeve
J 42385-315 with the drill and tap.
Engine
6-261
Engine Block-Right Side View
22
~~
21
14
18
64579
Engine Block-Right Side View

Hole
Thread
Size
MB
x 1.25
M11
2-3
x 2.0
x 1.25
M6 x 1.0
5
6-7
MB
Mi1
x 2.0
MB
x 1.25
x 2.0
10
x 2.0
11-14
x 1.5
15-19
x 1.5
20
x 1.5
M11
M11
M10
M10
M16
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
Insert
Drill
Counterbore
Tool
J 42385-210
J 42385-206
J 42385-207
J 42385-108
J 42385-105
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-205
J 42385-201
J 42385-202
J 42385-203
J 42385-204
22.5 (0.885)
15.0 (0.590)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
J 42385-210
J 42385-206
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
69.0 (2.72)
60.0 (2.36)
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
J 42385-215
J 42385-21-1
J 42385-212
J 42385-213
J 42385-214
27.0 (1.06)
21.5 (0.846)
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
29.0 (1.14)
23.0 (0.905)
---
J 42385-207
Tap
--
6-262
Engine

Engine Block-Right Side View (cont'd)
Hole
Thread
Size
Insert
Drill
Counterbore
Tool
Tap
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
21
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17 .5 (0.688)
22
M11
x 2.0
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88)
115.0 (4.52)
23
M11
x 2.0
J 42385-108
J 42385-105
J 42385-106
J 42385-107
69.0 (2.72)
60.0 (2.36)
24
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
25-26
M11
x 2.0
J 42385-108
J 42385-105
J 42385-106
J 42385-107
124.0 (4.88}
115.0 (4.52)
27
M6 x 1.0
J 42385-205
J 42385-201
J 42385-202
J 42385-203
J 42385-204
22.5 (0,885)
15.0 (0.590)
28
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0(0.784)
Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) '
drill depth.
Bolt holes 9 and 23 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve
Engine
6-263
Engi,ne Block-Bottom View
25
24 23 22 21 20
19
18
16 15
17
64655
Engine Block-Bottom View

Hole
Thread
Size
Insert
Drill
Counterbore
Tool
Tap
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44.0 (1.73)
M8
x 1.25
J 42385-210
J 42385-206
J42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
M10
x 2:0
J 42385-104
J 42385-101
J 42385-102
J 42385~ 103
31.0 (1.22)
25.5 (1.0)
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44.0 (1.73)
M16
x 1.5
N/A
M8
x 1.25
J 42385-210
J 42385-206
M10
x 2.0
J 42385-104
J 42385-101
10-11
M10
x 2.0
J 42385-104
12
M10
x 2.0
J 42385-104
..
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44.0 (1.73)
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
6~264
Engine
Engine Block-Bottom View (cont'd)

Hole
Thread
Size
Insert
Drill
13-14
M10
x 1.5
J 42385-215
J 42385-101
15
M8
x 1.25
J 42385-210
J 42385-206
Counterbore
Tool
J 42385-207
Tap
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
J 42385-213
J 42385-214
42.5 (1.67)
37.0 (1.45)
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.588)
..
16
M16
x 1.5
..
17
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44.0 (1.73)
18
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
.J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.588)
19
MB
x 1.25
20
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44:o (1.73)
21
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209 22.5 (0.885)
22
MB
x.1.25
17.5 (0.688)
23
M10
x 2.0
J 42385-104
J 42385-101
J.42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
24
M10
x 2.0
J 42385-104
J 42385-101
J 42385-.1 02
J 42385-103
53.5 (2.10)
44.0 (1.73)
J 42385-210
J 42385-206
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
27
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (1.0)
28-29
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
53.5 (2.10)
44.0 (1.73)
30
x2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
25.5 (lO)
J 42385-210
J 42385-206
J 42385-208
J 42385-209
22.5 (0.885)
25-26
31
32
33
MB
x 1.25
M10
MB
x 1.25
M28
x 1.25
MB
x 1.25
J 42385-207
J 42385-207
17.5 (0.688) .
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
44.0 (1.73)
34
M10
x 2;0
J.42385-104
J 42385-101
J.42385-102
J 42385-103
53.5 (2.10)
35
M10
x 2.0
J 42385-104
J 42385-101
J 42385-102
J 42385-103
31.0 (1.22)
M8
x 1.25
J 42385-210
36
25 . 5(1.0)
I>
J 42385-206
J 42385-207
J 42385-208
J 42385-209
22.5 (0.885)
17.5 (0.688)
Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the. 53.5 mm
(2.1 O in) drill depth.
O Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore included in the 31.0 mm (1.22 in)
drill depth. Use sleeve J 42385-316 with the drill and tap.
O Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm (1.67 in) drill depth. Use sleeve
Engine
6-265
Engine Block-Top View
14
10
7
64573
Engine Block-Top View

Hole
Insert
Drill
Counterbore
Tool
J 42385-210
J 42385-206
J 42385-207
Thread
Size
Tap
J 42385-208
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
J 42385-209
26.5 (1.04)
19.0 (0.784)
1-4
M8
x 1.25
M16
x 1.5
6-7
M8
x 1.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
M10
xi .5
J 42385-216
J 42385-211
J 42385-212
J 42385-213
J 42385-214
22.5 (0.885)
17.0 (0.669)
9-10
M8
x i.25
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
11
M10
x 1.5
J 42385-216
J 42385-211
J 42385-212
J 42385-213
J 42385-214
22.5 (0.885)
17.0 (0.669)
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
- 12-14
M8
x 1.25
-- -,J 42385-210
~----- ,~--.......----
6~266
Engine
Cylinder Head-Top View
11
12
6
260168
Cylinder Head-Top View

Hole
1-5
6-9
10-12
Thread
Size
MB
x 1.25
M6
x 1.0
MB
x 1.25
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
Insert
Drill
Counterbore
Tool
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (1.04)
19.0 (0.784)
J 42385-205
J 42385-201
J 42385-202
J 42385-203
J 42385-204
20.05 (0.789}
16.05 (0.632}
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
26.5 (i .04}
19.0 (0.784)
Tap
Engine
Cylinder Head-End View
v1
oe2
. :J .
6)D
0
?-
6-267
~
3
64503
Cylinder Head-End View

Hole
Thread
Size
M10
x 1.5
-
Insert
Drill
Counterbore
Tool
J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
NIA
M10
x 1.5
J 42385-215
J 42385-211
NIA
5-6
M10
x 1.5
J 42385-215
2
3
J 42385-211
J 42385-212
J 42385-212
Tap
Driver
J 42385-213
J 42385-213
J 42385-214
J 42385-214
Drill Depth
(Maximum)
... mm (in)
Tap Depth
(Maximum)
mm (in)
w.o (1.10)
20.0 (0.787)
'28.0 (1.10)
28.0 (1.10)
20.0 (0.787)
20.0 (0.787)
6-268
Engine Mechanical - 5.. 7l
Engine
Cylinder Head-Exhaust Manifold Deck View
64555
Cylinder Head-Exhaust Manifold Deck View

Hole
1-2
3
Thread
Size
M10
x 1.5
MB
x 1.25
M14
x 1.25
x 1.25
x 1.25
7-8
MB
M14
MB
x 1.25
M14
x 1.25
10
x 1.25
MB
M14
11
x 1.25
12
x 1.25
MB
13
M12
x 1.5
14-15
M10
x 1.5
Driver
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
Insert
Drill
Counterbore
Tool
J42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
28.0 (1.10)
20.0 (0.787)
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
21.0 (0.826)
16.0 (0.629)
J 42385-210
-
J 42385-210
-
J 42385-210
J 42385-206
J 42385-206
J 42385-206
J 42385-207
J 42385-207
-
J 42385-207
Tap
J 42385-208
J 42385-208
J 42385-208
J 42385-209
J 42385-209
-
J 42385-209
J 42385-210
J 42385-206
J 42385-207
J 42385-208
J 42385-209
21.0 (0.826)
16.0 (0.629)
21.0 (0.826)
16.0 (0.629)
21.0 (0.826)
---
16.0 (0.629)
21.0 (0.826)
16.0 (0.629)
--
- f---,-~---J 42385-215
J 42385-211
J 42385-212
J 42385-213
J 42385-214
28.0 (1.10)
20.0 (0.787)
Engine
Engine Mechanical.- 5.7l
6-269
Cylinder Head-Intake Manifold Deck View

1
3
64557
-Cylinder Head-.lntake Manifold Deck View

Hole
1-2
3-4
5-7
Thread
Size
x 1.0
x 1.0
M6 x 1.0
Insert
Drill
Counterbore
Tool
Tap
Driver
J 42385-204
J 42385-204
J 42385-204
M6
J 42385-205
J 42385-201
J 42385-202
J 42385-203
M6
J 42385-205
J 42385-201
J 42385-202
J 42385.-203
J 42385-205
J 42385-201
J.42385-202
J 42385-203
Drill Depth
(Maximum)
mm (in)
Tap Depth
(Maximum)
mm (in)
Thru
Thru
22.5 (0.885)
15.0 (0.688)
Thru
Thru
6-270
Engine Mechanical - S.7L
Engine

Base Engine Misfire Diagnosis
Checks
Action
Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty camshaft, worn or
damaged bearings or bent pushrod.
This table will not isolate a crossed injector wire, faulty injector or any other driveability component failure that may cause a
misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary
Intake Manifold Leaks
1. Perform OTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection for the following:
A loose or improperly installed engine flywheel or crankshaft balancer
Worn, damaged, or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
Refer to Oil Pressure Diagnosis and Testing.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has coolant consumption.
7. Perform a compression test on the engine.
Refer to Engine Compression Test.
An intake manifold that has a vacuum leak may cause a misfire.

Improperly installed or damaged vacuum hoses
Faulty or improperly installed intake manifold and/or gaskets
Loose Exhaust Gas Recirculaton (EGR) valve pipe or damaged or missing
0-ring seal
Cracked or damaged intake manifold
Inspect the areas between the intake runners.
Improperly installed or damaged Manifold Absolute Pressure (MAP) sensor
housing (located at the rear of the intake manifold)
Improperly installed or damaged MAP sensor housing 0-ring seal
Improperly installed MAP sensor or vacuum hoses
The sealing grommet of the MAP sensor should not be torn or damaged.
O Improperly installed throttle body or damaged gasket
A loose EGR valve pipe assembly or damaged or missing 0-ring seal
Warped intake manifold
Warped or damaged cylinder head sealing surface
Coolant Consumption
Coolant consumption may or may not cause the engine to overheat.

External coolant leaks
Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block
Engine
s~211
Base Engine Misfire Diagnosis (cont'd)

Checks
Oil Consumption
Abnormal Internal Engine Noises
No Abnormal Internal Engine Noise
Action
1. Oil consumption may or may not cause the engine to misfire.

2. Remove the spark plugs and inspect for an oil fouled spark plug.
3. Perform a cylinder compression test.
Refer to Engine Compression Test.
If
the compression test indicates worn valves or valve guides, inspect for the
4.
following:
Worn valve guides
Worn valve stems
Worn or burnt valves or valve. seats
Worn, brittle, or improperly installed valve stem oil seals
5. 1.f the compression test indicates worn or damaged piston rings, inspect the
following:
Broken or improperly seated piston rings

Excessive piston ring end gap
Excessive cylinder bore wear or taper
Cylinder damage
Piston damage
1. With the engine running try and determine if the noise is timed to camshaft
speed or crankshaft speed.
2 .. Using a timing light, two knocks per flash is crankshaft speed and one knock
per flash is camshaft speed.
3. If the noise is timed to camshaft speed, inspect the following:
Missing or loose valve train components
Worn or loose valve rocker arms
Worn or bent pushrods
Faulty. valve springs
O Bent or burnt valves
Worn camshaft lobes
O Worn or damaged timing chain and/or sprockets
Important: A slight .COLD knock or piston slapping noise could be considered
normal if not present after the engine has reached normal operating temperatures.
4. If the knock.is timed to crankshaft speed, inspect the following:
Worn crankshaft main or connecting rod bearings
Piston or cylinder damage
O Worn piston or piston pin
Damaged or faulty connecting rod
.Excessive carbon build-up on the top of the piston
1. Inspect for a worn or improperly installed timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.
Loose valve rocker arm bolts
Bent push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Worn camshaft lobes
6-272
Engine
Engine Compression Test

1. Charge the battery if the battery is not fully
charged.

3. Disable the fuel injection system.
4. Remove all the spark plugs.
5. Block the throttle plate wide open.
6. Start with the compression gauge at zero, and
crank the engine through four compression
strokes (four puffs).
. 7. Make the compression check for each cylinder.
Record the reading.
8. If a cylinder has low compression, inject
approximately 15 ml (one tablespoon) of engine
oil into the combustion chamber through the spark
plug hole.
Recheck the compression and record the reading.
9. The minimum compression in any one cylinder

should not be less than 70 percent of the highest
cylinder. No cylinder should read less than
690 kPa (100 psi). For example, if the highest
pressure in any one cylinder is 1035 kPa (150 psi),
the lowest allowable pressure for any other
cylinderwould be 725 kPa (105 psi).
(1035 x 70% =725) (150 x 70% = 105).
. No.rmal - Compression builds up quickly and
evenly to the specified compression for each
cylinder.
Piston Rings Leaking - Compression is low
on the first.stroke. Compression then builds
up with the following strokes but does not
reach normal. Compression improves
considerably when you add oil.
Valves Leaking - Compression is low on the
firststroke: Compression usually does not
build up on the following strokes. Compression
does not improve much when you add oil.
' " lftvito adjacent cylinders have lower than
normal compression and injecting oil into
the cylinders does not increase the
cornpression, the cause may be a head gasket
leaking between the cylinders.
Engine Noise Diagnosis

Symptom
Cause
There are four steps to diagnosing engine noise. You must determine the following:
The type of noise
For example, is the noise a light rattle/tapping or a low rumble/knocking?
The exact operating condition under which the noise exists.
Note factors such as the ambient temperature, the amount of engine warm-up time, the engine temperature, engine
RPMs, and other specifics.
At what rate the noise. occurs, and at what location in the engine .
Remember, engine noi~es are generally synchronized to either engine speed (crankshaft, flywheel, connecting rods,
balancer, or pistons and related components) or one-half engine speed (valve train noise such as rocker arms, valve
lifters, and timing chain). Try to determine the rate at which the noise is occurring,
Compare the engine .sounds to other engines and make sure you are not trying to correct a normal condition.
Noise on Start-Up but Only Lasts a
Few Seconds
Improper oil viscosity. Install the recommended oil viscosity. for the expected
temperatures.
Incorrect oil filter without the anti-drainback feature
Worn or dirty valve lifters
Excessive piston to bore clearance
Excessive piston pin to piston clearance
Excessive crankshaft bearing clearance
Knocks Cold and Continues for

1 to 2 Minutes
Loose or broken crankshaft balancer or accessory drive components

Excessive piston to bore clearance
A cold piston knock which disappears in 1.5 minutes should be considered
acceptable.
A cold engine knock usually disappears when the specific cylinders secondary
ignition circuit is grounded out.
Intermittent Noise on Idle,

Disappearing When Engine Speed is
Increased
Improper oil viscosity. Install the recommended oil viscosity for the expected
temperatures.
Lower than specified oil pressure
Install an oil pressure gauge and measure the engine oil pressure.
Dirty or worn valve lifter
Engine
5.;273
Engine Noise Diagnosis (cont'd)

Symptom
Valve Train Noise (Rattle/Tapping)
Cause
The following conditions may cause valve train noise:

Lower than specified oil pressure
Worn or faulty oil pump
Loose oil pump-to-engine block bolts
Loose valve rocker arm attachments
Worn valve rocker arm bearings
Worn valve rocker arm and/or pushrod
Broken valve spring

Sticking valves
Worn, dirty, or faulty valve lifters
Worn camshaft lifter lobes
Worn valve guides or valve stems
Bent, broken, or damaged timing chain sprocket teeth
Knocks at Idle Hot

(Rumble/Knocking)
The following conditions may cause a knocking noise:

Malfunctioning accessory drive system components
Loose or broken crankshaft balancer
Loose prop shaft hub or clamp (Corvette only)
Detonation or spark knock
Check for proper operation of the cooling, knock, and ignition control
components.
Refer to diagnostic information. in Engine Controls.
Excessive connecting rod bearing clearance
Excessive piston pin to bore clearance
Bent connecting rod
Excessive crankshaft main or thrust bearing clearance
Loose torque converter bolts
Cracked or damaged flywheel
Exhaust leak at the manifold
Exhaust System Noise and/or

Leakage
Exhaust system noise and/or leakage may be caused by the following conditions:
Improperly installed or misaligned exhaust system components
A cracked or broken exhaust manifold
Damaged or worn gaskets and/or seals
Burned or rusted out exhaust system components
A broken or loose exhaust clamp and/or bracket
6274
Engine

Valve Train Diagnosis
Symptom
Cause
A light tapping noise at one-half engine speed, or any varying frequency, may indicate a valve train problem.
These tapping noises will typically increase with engine speed.
Before attempting to diagnose valve train noise, check for the proper oil level and thoroughly warm up the engine.
By doing this you will bring all engine components to a normal state of expansion.
While sitting in the drivers seat, run the engine at various speeds and listen for any abnormal engine noise.
Whenever Valve Lifter Diagnosis is necessary, always. use a listening device such as and engine stethoscope, or
listening ears J 39565. These tools will help to isolate any lifter noise and identify noises that could be mis-diagnosed as
lifter noise.
A light tapping noise similar to valve
train noise may be caused by the
Fuel injectors
Evaporative emission (EVAP) purge solenoid
O
Detonation
O
Loose heat shields
. Poor oil quality caused by water contamination, aeration, or fuel dilution

The Causes of Valve Train Noise
May Include the Following Conditions:
Low engine oil pressure
Worn or faulty oil pump
A loose or plugged oil pump screen
0
Loose valve rocker arm attac.hments (causing excessive valve lash)
Worn or damaged valve rocker .arm bearings
Worn valve rocker ar.m and/or pushrod
O Broken valve spring
Sticking valves
Valve lifters worn, dirty, or faulty
Broken valve lifter guide
Camshaft valve lifter lobes worn
Worn valve guides or valve stems
Worn, damaged, or missing valve keys
Bent pushrods
Excessive play in the camsha~ timing chain
Bent, broken, or damaged timing chc:1in sprocket teeth
Engine
Diagnostic Table
Action
Step
Value(s)
Yes
No
Go to Step 2
System OK
Drain the oil to

the proper level.
System OK
Go to Step 3
Add oil as
required.
System OK
Go to Step 4
Go to Step 7
Go to Step 5
Repair as
required.
System OK
Go to Step 6
Repair as
required.
System OK
Go to Step 10
Replace the
components as
required.
System OK
Go to Step B
DEFINITION: A light tapping noise at one half engine speed, or any varying frequency.
Is there valve train noise?

Check for a high engine oil level. A engine with the oil
level above the FULL mark allows the crankshaft
counterweights to churn the oil into foam. When foamy oil
is pumped into the lifters, the lifters become noisy. A solid
column of oil ensures proper lifter operation.
Is the oil level too high?
Check for a low engine oil level. A engine with the oil level
below the ADD mark may allow the oil pump to pump air
at high engine RPMs.
Is the oil level too low?
Check for proper engine oil pressure. Refer to Engine

Mechanical Specifications and Oil Pressure Diagnosis and
Testing.
Is the engine oil pressure within specifications?
1. Check the oil pump screen for damage or a loose fit

to the oil pump.
2. Inspect for a missing or damaged oil pump screen

0-ring seal.
Is the oil pump screen loose or is the screen or 0-ring

seal damaged?
Check for a damaged oil pump or loose mounting bolts
6
Refer to Oil Pump Clean and Inspect

Is the oil pump damaged or are the fasteners loose?
Remove and inspect the valve lifters, guides, rocker arms,
and pushrods. Refer to Valve Rocker Arm and Push Rods
Clean and Inspect and Valve Lifters and Guides Clean and
Inspect.
Are components worn or damaged?
Perform a camshaft lobe lift test. Refer to Camshaft and

Bearings Clean and Inspect
Is the test within Engine Mechanical Specifications ?
Go to Step 9
Replace the
camshaft and
valve lifters.
System OK
Replace the
components as
required.
System OK
Go to Step 10
Camshaft is OK
Remove the engine front cover and inspect the timing

chain and sprockets for excessive wear or damage.
10
Refer to Timing Chain and Sprockets Clean and Inspect

Important: Pushrod engines are designed so that a timing
chain more than one tooth improperly positioned will cause
valve interference with the piston.
Are the components worn or damaged, or improperly
positioned?
Perform a complete disassembly of the engine and inspect
all components.
Are the components worn or damaged?
Replace the
components as
required.
System OK
6-276
Engine
EngineMechanical - 5.7l
Oil Consumption Diagnosis
Checks
Causes
Excessive oil consumption (not due to leaks) is the use of 0.95 liters (1.0 qt) or more of engine oil within 2414 kilometers
(1,500 miles),
The causes of excessive oil consumption may include the following conditions:
Preliminary
External oil leaks
Refer to oil leak diagnosis.
Incorrect oil level or improper reading of the oil level indicator
With the vehicle on a level surface, run the engine for a few minutes, allow
adequate drain down time (2-3 minutes) and check for the correct engine
oil level.
Refer to the vehicle owners manual and use the recommended SAE grade and
viscosity for the prevailing temperatures.
Continuous high speed driving and/or severe usage
Crankcase ventilation system restrictions or malfunctioning components
Worn valve guides and/or valve stems
Refer to Cylinder Head Clean and Inspect.
Worn or improperly installed valve stem oil seals
Piston rings broken, worn, not seated properly
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
Piston and rings improperly installed or miss-fitted to the cylinder bore
Oil Pressure Diagnosis and Testing

Tools Required
J 21867 Pressure Gauge and Hose Assembly
J 42907 Oil Pressure Testing Tool
416607
1. With the vehicle on a level surface, run the

vehicle for a few minutes, allow adequate
drain down time (2-3 minutes) and measure for a
low oil level.
2. If required, add the recommended grade engine
oil and fill the crankcase until the oil level
measures full on the oil level indicator.
3. Run the engine briefly (10-15) seconds and verify
low or no oil pressure on the vehicle gauge
or light.
4. Listen for a noisy valve train or a knocking noise.

5. lnspct for the following:
" Oil diluted by water or glycol (anti freeze)
Foamy oil
6. Remove the oil filter and install the J 42907.
7. Install J 21867 or equivalent to the J 42907.
8. Run the engine and measure the engine oil
pressure.
9. Compare the readings. to Engine Mechanical
Specifications.
10. If the engine oil pressure is below specifications,
inspect the engine for one or more of the following:
.. Oil pump worn or dirty
Refer to Oil Pump Clean and. Inspect.
0 Oil pump-to-engine block bolts .loose
Refer to Oil Pump, Pump Screen and Deflector
Installation.
" Oil pump screen loose, plugged, or damaged
O Oil pump screen 0-ring seal missing or
damaged
" Malfunctioning oil pump pressure
regulator valve
" Excessive bearing clearance
.. Cracked, porous, or restricted oil galleries
Oil gallery plugs missing or incorrectly installed
Refer to Engine Block Plug Installation.
.. Broken valve lifters
Repair as necessary
i 1. If the oil pressure reading on the J 21867 or
equivalent is within specifications, inspect for
the following:
Plugged or incorrect oil filter and/or
malfunctioning oil bypass valve
.. Malfunctioning oil pressure gauge or sensor
Repair as necessary
0
Engine
6-277
Oil Leak Diagnosis

Step
Action
Value(s)
Yes
No
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as
well as the leak itself.
1. Operate the vehicle until it reaches normal operating
temperature.
4. Check for drippings.
Are drippings present?


Sealing surfaces
Fittings

components.
of the leak.

Sealing surfaces
Fittings
location of the .leak?

components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
of the leak, from the discolorations in the powder
surface.

Sealing surfaces
Fittings
Go to Step2
System OK
Go to Step 10
Go to Step 3
Go to Step 10
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 10
Go to Step 8
6-278
Engine
Engine Mechanical - 5~7l

Oil Leak Diagnosis (cont'd)
Step
10
11
Action :
Use. J 28428-E in order to identify the type of fluid, and the
approximate l9cation .of the leak. Refer to the
manufacturer's instructio.ns when using the tool.
Can you identify the type offluid and the approximate
Sealing surfaces
Fittings
1. Inspect the engine for mechanical damage. Special
attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning .fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
Improperly tightened or damagi:3d fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications to
the engine?
Repair or replace all damaged or modified components.
Does the engine still leak oil?
Symptoms - Drive Belt

Important: Review the drive belt system operation in
order to familiarize yourself with the system
functions. Refer to Drive Belt System Description.
the operation of the drive belts.
Inspect the easily accessible or visible system
Inspect the drive belt for excessive wear,
shredding, or missing sections.
Inspect the drive belt for contamination of
excessive dirt, oil, coolant or ot_her substances
that may affect the drive belt operation.
Value(s)
Yes
No
(
,,,
Go to Step 10
Go to Step9
Go to Step 10
..
System. OK
..
-
..
,,
(
-
Go to Step 11
System OK
G.o to Step 1
System OK
Intermittent
Drive belt symptoms may be from intermittent
failure of an accessory drive component.
.. Drive belt symptoms may occur from changes in
load of the accessory drive components.
" Ambient temperatures, moisture, or engine
operating temperature can affect the drive
belt operation.
Symptom list
O
O Drive Belt Whine Diagnosis
O Drive Belt Rumbling Diagnosis
.. Drive Belt Vibration Diagnosis
Engine

Diagnostic Aids
The symptom may be intermittent due to moisture on
the drive belt(s) or the pulleys. It may be necessary
to spray a small amount of water on the drive belt(s) in
order to duplicate the customers concern. If spraying
water on the drive belt(s) duplicates the symptom,
cleaning the belt pulleys may be the probable solution.
a suspension component, or other item(s) on the
vehicle may cause the chirping noise.
Test Description
Remove the drive belt(s) and operate the engine
for a brief period, this will verify if the chirping
noise is related to the drive belt(s). With the drive
belt(s) remove the water pump may not be
operate and the engine may overheat. Also DTCs
may set when the engine is operated with the
drive belt(s) removed.
4. Inspect all drive belt pulleys for pilling. Pilling is

the small balls or pills or it may be strings in
the drive belt grooves from the accumulation of
rubber dust.

drive component pulley, or the pulley may be
bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge
in the puUey grooves across two or three pulleys.
If a misaligned pulley is found refer to that
accessory drive component for the proper
installation procedure for that pulley.
was installed.
12. Inspecting the pulleys for being bent should
include inspecting for a dents or other damage to
the pulleys that would prevent the drive belt(s)
from not seating properly in all of the pulley
grooves or on the smooth surface of a pulley when
the back side of the belt is used to drive the
pulley.
14. Replacing the drive belt(s) when it is not damaged
or there is not excessive pilling will only be a
temporary repair.
6-280
Engine

Action
Step
No
Yes

DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp startup conditio.ns and will subside once the vehicle reaches normal operating
temperature.
1
Go to Step 2
Verify t.hat there is a chirping noise.

Does the engine make the ch\rping noise?
Goto Step 3


.
Go to
Diagnostic Aids
Go to Engine Noise
Diagnosis
Go to Step4
Inspect for sel,'.ere pilling exceeding 1/3 of the belt groove depth.
Does the belt grooves have pilling?
Go to Step 5
Go to 8tep6
Clean the drive belt pulleys with a suitable wire brush.

Were the drive belt pulleys cleaned?
Go toStep 15
Go toStep6
Inspect for a misalignment of the pulleys.

Are any of the pulleys misi:\ligned?
Go to Step7
Go to Steps
Replace and/or repair any misaligned pulleys.

Were the misaligned pulleys repaired and/or replaced?
Does the chirping noise still. exist?
'
Go to Step 1.5
Go to.Steps
Inspect for bent and/or cracked brackets.

Did you find any bent and/or cracked brackets?
Go to Step 9
Go to Step 10
Replace any bent and/or cracked brackets.

Were the bent and/or cracked brackets replaced?
Go to Step 15
Go to Step 10
10
Inspect for improper, missing and/or loose fasteners.

Were there any improper, missing and/or loose fasteners?
Go to Step 11
Go to Step 12
11
Replace any improper and/or missing fasteners.

Specifications.
Go to Step 15
Go to Step 12
12
Inspect for a bent pulley.

Go to Step 13
Go to Step 14
13
Replace the bent pulley.

Was the bent pulley replaced?
Go to Step 15
Go to Step 14
Replace the drive belt(s). Refer to Drive Belt Replacement Accesso,y or Drive Belt Replacement - A/C.
Was the drive belt(s) replaced?
Go to Step 15
Go to
Diagnostic Aids

Does the drive belt still chirp?
Go to Step 3
System OK
15
Engine
6-281

Diagnostic Aids
a suspension component, or other items on the
vehicle may cause the squeal noise.
If the noise is intermittent, verify that the accessory
drive components are not the cause, by varying their
loads making sure they are operating to their
maximum capacity. An overcharged A/C system, a
power steering system restriction, or incorrect fluid, or
a failing generator are suggested items to inspect
Test Description
the accessory drive components for smooth . .

operation. Test the accessory drive components
with the engine operating by varying the load
bn the components to verify that the components
operate properly.
5, This test is to verify that the drive belt(s) tensioner
operates properJy. If the drive belt tensioner is not
operating properly; proper belt tension may not
be achieved to keep the drive belt from slipping
which could cause a belt squeal noise.
6. This test is to verify that the drive belt(s) is not to
long, which would prevent the drive belt tensioner
from operating properly. Also if an incorrect
length drive belt(s) were installed, it may not be
routed properly and may be turning an accessory
drive component in the wrong direction.

Remove the drive belt(s) and operate the engine
for a brief period, this will verify that the squeal
noise is the drive belt(s) or an accessory
drive component. With the drive belt(s) removed
the water pump may not operate and the
engine may overheat. Also DTCs may set when
the engine is operated with the drive belt(s)
removed.
7. Misalignmentof the pulle!ys may be.caused from

component, incorrect .installation of the accessory
inward or outward from a previous repair. Test for
a misaligned pulley using a straight edge in the
a misaligned pulley is found refer to that accessory
drive c;omponent for the proper installation
procedure for that pulley ..
4. This test is to verify that a:n accessory drive

component does not have a seized bearing. With
the drive belt(s) removed test the bearings in
8.. This test is to verify _that the pulleys are the

correct diameter or width. Using a known good
vehicle to compare the pulley sizes.
6-282
Engine

Step
Action
Yes
No
Notice:. Refer to Belt Dressing Notice in Cautions and Notices.

DEFINITION: The.following items.are indications of.drive belt squeal:
.A loud screec~ing nois.e that is caused bya slipping drive belt {this is unusual for a .drive belt with multiple ribs)
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement
snapping the throttle, or slipping on a seized pulley or a faulty accessory drive component.
Did you. review the. Symptoms - Drive Belt diagnostic information and
perform the necessary inspections? .
Go to Step2
Verify that there )s a squeal rioise.

Doesthe engine make the squeal noise?
Go to Step 3
Go to
Diagnostic Aids
1.. Remove the.drive belt(s).

2.. Operate the engine for no longer than 30 to 40 seconds.
Does the squeal noise still exist?
Go to Engine Noise
Diagnosis
Go to Step4
Inspect for an accessory drive component seized bearing or a faulty

acGessory drive component.
Did you firid and correct the condition?
Go to Step 9
Go to Steps
lnspectthe drive belt tensioner for proper operation. Refer to Drive

Did. you find and correct the condition?
Go to Step 9
Go to Step6
Check for the correct drive belt length. Refer to Drive Belt
Replacement - Accessory or Drive Belt Replacement - A!C.
Go to Step 9
Go to Step 7
Did you find and correct the condition?.
Go to Step 9
Go to StepB
Inspect for the correct pulley size.

Did you find. and .correct the condition?
Go to Step 9
Go to
Diagnostic Aids

Does the drive belt still squeal?
Go to Step 3
System OK
Inspect for misalignment of a pulley.
Engine
6-283

Diagnostic Aids
The drive belt(s) will not cause the whine noise.
If the whine noise is intermittent, verify that the
accessory drive components are not the cause, by
varying their loads making sure they are operating to
their maximum capacity. An overcharged A/C
system, a power steering system restriction, or
incorrect fluid, or a failing generator are suggested
items to inspect.
Test Description

is operated with the drive belt(s) removed.
4. The inspection should include checking the drive
belt tensioner and the drive belt idler pulley
bearings. The drive belt(s) may have to be
installed and the accessory drive components
operated separately by varying their loads. Refer
to the suspected accessory drive component
for the proper inspection and replacement
procedure.
3. This test is to verify that the noise is being caused

by the drive belt(s) or the accessory drive
components. With the drive belt(s) removed the

Step
Action
Yes
No

DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
Did you review the Symptoms Drive Belt diagnostic information and
Go to Step2
Verify that there is a whine noise.

Does the engine make the whine noise?
Go to Step 3
Go to
Diagnostic Aids
1. Remove the drive belt(s).

Does the whine noise still exist?
Go to Engine Noise
Diagnosis
Go to Step4
Go to Step5
Goto
Diagnostic Aids
Inspect for a failed accessory drive component bearing.


Does the drive belt still whine?
System OK
Engine
Diagnostic Aids
Vibrationwhen the' engine is operating may cause a
body component or another part of the vehicle to
produce a rumbling no.ise.

The drive belt(s) may have a condJtion that can not be
seen or felt. So.metimes replacing the drive qelt(s)
may be.the only repair forth.e symptom.
If after replacing the drive belt(s) and completing the
diagnostic table, the noise is only heard with the
drive belt(s) installed; there may be an accessory drive
component failure. Varying the load on the accessory
drive components may aid in identifying which
accessory drive component is causing the
rumbling noise.
Test Description
2. Thi.s test is to verify that the symptom is present
may cause a similar symptom.
3. This test is to verify that the drive belt(s) is

causing the rumbling noise. The rumbling noise
may be confused with an internal engine
noise due to the similarity in the description.
Remove only one drive belt at a time if the vehicle
has multiple drive belts. With the drive belt(s)
removed the water pump may not operate and the
engine may overheat. Also DTCs may set when
the engine is operating with the drive belt(s)
removed.
4. Inspect the drive belt(s) to ensure that the drive

belt is not the cause of the noise. Small cracks
across the ribs of the drive belt will not cause the
rumbling noise. Belt separation is identifi'3d by
the plys of the drive belt separating, this may be
seen at the edge of the belt or felt as a lump
in the belt.
5. Small amounts of pilling is a normal condition and
acceptable. When the pilling is severe the drive
belt does not have a smooth surface for
proper operation.

Step
Action
No
Yes
Notice: R~fer. tq Belt Ores.sing Notice in Cautions and Notices.

DEFINITION:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused. from:
- Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
..:.. The sepa.ration of the drive belt
- A damaged drive belt
[)id yOu review the Symptoms - Drive Belt diagnostic information and
Go to Step 2
Verify that there is a rumbling noise.

Does the engine make the rumbling noise?
Go to Step 3
Go to
Diagnostic Aids
1. Remove the drive belt(s).

Does the rumbling noise still exist?
Go to Engine Noise
Diagnosis
Go to Step4
Inspect the drive belt(s) for damage, separation, or sections of

missing ribs.
Go to Step 7
Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley
grooves.
Did you find severe pilling?
Go to Step 6
Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.

2. Reinstall the drive belt. Refer to Drive Belt Replacement Accessory or Drive Belt Replacement - AIC.
Go to Step 8
Go to Step 7
Install a new drive belt. Refer to Drive Belt Replacement - Accessory

or Drive Belt Replacement - A/C.
Go to Step 8
.;

does the drive belt still rumble?
Go to
Diagnostic Aids
System OK
Engine
Diagnostic Aids
The accessory drive components may have an affect
on engine vibration. An overcharged A/C system,
a power steering system restriction, or incorrect fluid,
or an extra load placed on the generator are some
systems that should be inspected. To help identify an
intermittent or an improper condition, vary the loads
on the accessory drive components.
Test Description
2. This test is to verify that the symptom is present
may cause a similar symptom such as the exhaust
system, or the drivetrain.
3. This test is to verify that the drive belt(s) or
accessory drive components may be causing the
vibration. With the drive belt{s) removed the
is operated with the drive belt(s) removed.
6-285
4. The drive belt(s) may cause a vibration. With the

drive belt(s) removed inspect the condition of
the drive belt.
was installed.
8. This step should only be performed if the cooling
fan is driven by the drive belt. Inspect the engine
cooling .fan for bent, twisted, loose, or .cracked
blades. Inspect the fan clutch for smo.oth
operation. Inspect for a bent fan shaft or a bent
mounting flange.
9. This step should only be performed if the water
pump is driven by the drive belt Inspect the
water pump shaft for being bent Also inspect the
water pump bearings for smooth operation and
excessive play .. Compare the water pump
with a known, good water pump.
10. Accessory drive component brackets that are
bent, cracked, or loose may put an extra strain on
that accessory component causing it to vibrate.
6-286
Engine

Step
Action
Yes
No

DEFINITION: The following items are indications of drive belt vibration:
The vibration is engine-speed related.
The vibration may be sensitive to accessory load.
Did you review the Symptoms -Drive Belt diagnostic information and
Go to Step2
Verify that the vibration is engine related.

Does the engine make the vibration?
Go to Step 3
Go to
Diagnostic Aids
1. Remove the drive belt (s).

2. Operate the engine for no longer t.han 30 to 40 seconds.
Does the engine still make the. vibration?
Go to Engine
Related Vibration in
Vibration and
Diagnosis
Go to Step4
Inspect the drive belt for wear, damage, debris build-up and missing
drive belt ribs.
Go to Step 5
Go to Step6
Install a new drive belt. Refer to Drive Belt Replacement - Access01y

Go to Step 11


Specifications.
Go to Step 11
Inspect for damaged fan blades or a bent fan clutch shaft, if the fan
is belt driven.
Go to Step 11
Go to Step 9
Inspect for a bent water pump shaft, if the water pump is belt driven.
Refer to Water Pump Replacement (5. 7 L) in Engine Cooling.
Go to Step 11
Go to Step 10
10
Inspect for bent or cracked brackets.

Go to Step 11
Go to
Diagnostic Aids
11

Does the drive belt still vibrate?
Go to Step 7
Go to StepB
System OK
Engine
6-287
Diagnostic Aids
If the drive belt(s) repeatedly falls off the drive belt
pulleys, this may be caused by pulley misalignment.
An extra load that is quickly applied or released by an
accessory drive component may cause. the drive
belt(s) to fall off the pulleys. Verify that the accessory
drive components operate properly:
If the drive belt(s) is the incorrect length, the drive belt
tensioner may not maintain the proper tension on
the drive belt.
Test Description
2. This inspection is to verify the condition of the

drive belt(s). Damage may have occurred to
the drive belt when the drive belt(s) fell off the
pulley. The drive belt(s) may have been damaged
in which case caused the drive belt to fall off
the pulley. Inspect the drive belt(s) for cuts, tears,
sections of ribs missing, or damaged belt plys.

inward or outward from a previous repair. Test for
a misaligned pulley using a straight edge in the
a misaligned pulley is.found refer to that accessory
drive component for the proper installation
procedure of that pulley.
5. Inspect the pulleys for dents, bends or other

damage. Damage to the pulleys would prevent the
drive belt(s) from seating properly in the pulley
grooves. Damage would also prevent proper
alignment of the drive belt to pulley, when
the smooth surface of the drive belt is required to
drivethe pulley.
6. Accessory drive component brackets that .are bent
or cracked will allow the drive belt(s) to fall off the
pulley.
was installed. Missing, loose, or incorrect
fasteners may cause pulley misalignment from the
bracket moving under load. Over tightening of
the fasteners may also cause misalignment of the
accessory component bracket.
6-288
Engine

Step
Yes
Action
No
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
Go to Step2
Inspect for a damaged drive belt.

Go to Step 3
Go to Step4
Install a new drive belt. Refer to Drive Belt Replacement - Accessory

or Drive Belt. Replacement - A/C.
Go to Step 4
System OK
Inspect for misalignment of the pulleys.

Go to Step 12
Go to Step5
Inspect for a bent or dented pulley.

Go to Step 12
Go to Step6
Inspect for a bent or a cracked bracket.

Go to Step 12
Go to Step7

Did you find loose or missing fasteners?
Go to Step 8
Go to Step9
Go to Step9
System OK
Go to Step 11
Go to Step 10
Specifications.

Test the drive belt tensioner for operating correctly. Refer to Drive
Does the drive belt tensioner operate correctly?
10
11
12
Replace the drive belt tensioner. Refer to Drive Belt Replacement Accessory or Drive Belt Replacement - A/C.
Go to Step 11
System OK
Inspect for failed drive belt idler and drive belt tensioner pulley
bearings.
Go to Step 12
Go to
Diagnostic Aids

Does the drive blet still fall off?
System OK
Engine
6-289

)
Diagnostic Aids
Excessive wear on a drive belt(s) is usually caused by
incorrect installation or the wrong drive belt(s) for
the application.
Minor misalignment of the drive belt pulleys will not
cause excessive wear, but will probably cause
the drive belt(s) to make a noise or to fall off the
pulley(s).
Excessive misalignment of the drive belt pulleys will
cause excessive wear and may also make the
drive belt(s) fall off the pulley(s).
3. The installation of a drive belt that is to wide or to

narrow will cause wear on the drive belt(s). The
drive belt ribs should match all of the grooves
on the pulleys.
4. This inspection is to verify the drive belt(s) is not

contacting any parts of the engine or body while
the engine is operating. There should be sufficient
clearance when the drive belt accessory drive
components load varies. The drive belt(s) should
not come in contact with an engine or a body
component when snapping the throttle.
Test Description
The number(s) below refer to the step .number(s) on
the diagnostic .table.
2. The inspection is to verify that the drive belt(s) is

correctly installed over all of the drive belt
pulleys. Wear on the drive belt(s) may be caused
by mis-positioning the drive belt(s) by one groove
on a pulley.

Step
Yes
Action
No
Notir:e: Refer to BeltDressing Notice in Cautions and Notices.

DEFINITION: Wear at the outside ribs of the drive belt(s) due to an incorrectly installed drive belt(s).
1
Inspect the drive belt(s) for the proper installation. Refer to Drive Belt
Replacement - Accesso,y or Drive. Belt Replacement - AIC.
)
3.
Did you. find this condition?
Go to Step 5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 6
Go to
Diagnostic Aids
Inspect for the drive belt rubbing against a bracket, hose, or wiring
harness.
Replace the drive belt. Refer to Drive Belt Replacement - Accesso,y
Go tci Symptoms Drive Belt
Inspect for the proper drive belt.
Did you find and repair the .condition?
Go to Step2

Is there still excessive drive belt wear?
Drive Belt Tensioner Diagnosis

Important: When the engine is operating, the belt
tensioner arm will move. Do not replace the. belt
tensioner because of movement in the belt
tensioner arm.
Notice: Allowing the drive belt tensioner to snap into

the free positio.n may result in damage to the
tensioner.
Replacement - Accessory or Drive Belt
Replacement - AIC.
pulley bolt.
Go to Step 6
System OK
3. Move the belt tensioner through it's full travel.

The movement should feel smooth.
There should be no binding.
The belt tensioner should return freely.
4. If any binding is observed, replace the drive belt
tensioner. Refer to Drive Belt Tensioner
Replacement - Accessory or Drive Belt Tensioner
Replacement - AIC.
5. Install the drive belt. Refer .to Drive Belt

Replacement - Accessory or Drive Belt
Replacement - AIC.
6-290
Engine Mechanical - s~7L
Engine
Visual Identification
Disassembled Views
Intake Manifold/Upper Engine
21~
17
(
12
363236
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(1 O)
Fuel Rail (with Injectors)

Fuel Rail Bolt
Fuel Rail Stop Bracket
Manifold Absolute Pressure (MAP) Sensor
Intake Manifold Bolt
Intake Manifold
Throttle Body
Throttle Body Bolt
(11) Valley Cover Gasket
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Valley Cover
Valley Cover Bolt
Knock Sensor Oil Seal
Knock Sensor
Knock Sensor Wire Harness
Engine Coolant Air Bleed Hose
Engine Coolant Air Bleed Pipe Stud
Engine Coolant Air Bleed Pipe
Engine Coolant Air Bleed Pipe Gasket
Engine Coolant Air Bleed Pipe Bolt
Engine
6-291
Cylinder Head/Upper Engine
26
eJ
10
24
---11
14
23
~19
21
'--20
16
490779
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Valve Rocker Arm Cover Bolt

Valve Rocker Arm Cover Bolt Grommet
Cylinder Head Bolt (Short)
Cylinder Head Bolt (Medium)
Cylinder Head
Cylinder Head Bolt (Long)
Valve Stem Keys
Valve Spring Cap
Valve Spring
Valve Stem Oil Seal
Valve Spring Shim
Valve
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Exhaust Manifold (with Heat Shield)

Exhaust Manifold Bolts
Push rod
Coolant Temperature Gauge Sensor
Valve Rocker Arm Bolt
Valve Rocker Arm
Valve Rocker Arm Pivot Support
Oil Fill Tube
Oil Fill Tube Cap
Ignition Coil and Bracket Assembly
Ignition Coil and Bracket Assembly Bolt
6-292
Engine

lower Front of Engine
;>--4
r
30
7
29
22
15
~
18
17
(
14
16
11
19
309874
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Oil Level Indicator Tube Bolt

Oil Level Indicator Tube 0-ring Seal
Valve Lifter Guide Bolt
Valve Lifter Guide
Valve Lifter
Engine Block
Engine Rear Cover Bolt
Engine Rear Cover
Engine Rear Cover Gasket
Crankshaft Sprocket
Timing Chain
Oil Pump Assembly
Oil Pump Assembly Bolt
(17)
(18)
(19)
(20)
(21)
(22}
(23}
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Engine Front Cover

Crankshaft Balancer
Engine Front Cover Bolt
Camshaft Sprocket Locating Pin
Camshaft Sprocket
Camshaft Retainer Bolt
Camshaft Retainer
Camshaft
Camshaft Bearings
Water Pump
Water Pump Bolt
Water Pump Gask~ts
Oil Level Indicator
Engine
6-293
lower Engine Assembly
26
24
t---21
t:J--22 20
27
19
178454
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)

Oil Pressure Sensor
Engine Block
Piston Rings
Piston and Connecting Rod Assembly
Connecting Rod Bearings
Connecting Rod Cap
Connecting Rod Bolt
Crankshaft Oil Deflector
Engine Flywheel (Manual Transmission)
Engine Flywheel (Automatic Transmission)
Engine Flywheel Bolt
Oil Pan Gasket
Oil Pan
Oil Pan Cover Gasket
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Oil Pan Cover

Oil Pan Cover Bolt
Oil Pan Closeout Cover Bolt (Left Side)
Oil Pan Closeout Cover (Left Side)
Oil Filter Adapter
Oil Filter
Oil Level Sensor
Oil Pan Closeout Cover (Right Side)
Oil Pan Closeout Cover Bolt (Right Side)
Crankshaft Bearing Cap Side Bolt
Crankshaft Bearing Caps
Crankshaft Bearing Cap Studs
Crankshaft Bearing Cap Bolts
Crankshaft Bearing
Crankshaft Thrust Bearing
Crankshaft
6-294
(33)
(34)
(35)
(36)
Engine
Crankshaft Sprocket Key

Engine Block Front Oil Gallery Plug
Clutch Pilot Bearing
(37) Oil Pump Screen

(38) Oil Pump Screen Nut
(39) Oil Pump Screen 0-Ring
Cylinder Head Assembly (Aluminum)
64108
legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cylinder Head
Valve Stem Keys
Valve Spring Cap
Valve Spring
Valve Stem Oil Seal
Valve Spring Shim
Valve Guide
Cylinder Head Expansion Plugs
Exhaust Valve Seat
Exhaust Valve
Intake Valve Seat
Intake Valve
Engine
6-295
Oil Pump Assembly
64190
Legend
(1)
(2)
(3)
(4)
Driven Gear
Oil Pump Housing
Pressure Relief Valve
Pressure Relief Valve Spring
(5)
(6)
(7)
(8)
Plug
Drive Gear
Cover Bolt
Cover
6-296
Engine
Repair Instructions
Drive Belt Replacement - Accessory
Removal Procedure
2. Disconnect the mass airflow (MAF) sensor
208553
3. Remove the air intake duct from the throttle body

and the air cleaner box.
208569
Engine
6-297
4. Position a hex-head socket on the belt

tensioner bolt.
5. Rotate the drive belt tensioner clockwise to relieve
the tension on the drive belt.
6. Remove the drive belt from the tensioner and
pulleys.
7. Clean and inspect the belt surfaces of all the
pulleys.
551461
1. Route the drive belt around the pulleys.

2. Position a hex-head socket on the belt
tensioner bolt.
the tension.
4. Install the drive belt onto the drive belt tensioner.
5. Inspect the drive belt to ensure that the belt is
properly aligned into the grooves of the pulleys.
551461
6. Install the air intake duct to the throttle body and

the air cleaner box.
208569
6-298
Engine
7. Connect the MAFsehsOr electrical connector.
208553
Drive Belt Replacement;. A/C

Removal Procedure
1. Remov~ the a:~~essory clrive belLRefer to Drive
Belt Replacement - j\ccessory.
2. Pdsition a hex-head socket on the belt
tensioner bolt.
3. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt.
4. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.
5. Clean and inspect the A/C belt surfaces of the
balancer and compressor pulley.
551463
Installation Procedme
1. Route the A/C belt over the crankshaft balancer.
2. Rotate the A/C belt tensioner clockwise to
3. Install the drive belt between the idler and the
tensioner and over the compressor pulley.
4. Inspect the drive belt to ensure that the belt is
properly aligned on all the pulleys.
5. Install the accessory drive belt. Refer to Drive Belt
Replacement - Accessory.
(
551463
Engine
6-299
Drive Belt Idler Pulley Replacement Accessory
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive
Belt Replacement - Accessoty'.
2. Remove the drive belt idler pulley bolt.
3. Remove the drive belt idler pulley.
220582
1. Install the drive belt idler pulley.
Notices.
Important: Be sure the idler pulley is fully seated
against the shoulder on the generator bracket before
tightening the bolt.
2. Install the drive belt idler pulley bolt.
Tighten
Tighten the drive belt idler pulley bolt to
50 N-m (37 lb ft).
Replacement - Accessow
220582
Drive Belt Idler Pulley Replacement - A/C

Removal Procedure
1. Remove
Refer to
2. Remove
3. Remove
the air conditioning (A/C) drive belt.

Drive Belt Replacement - AIC.
the A/C drive belt idler pulley bolt (2).
the A/C drive belt idler pulley (1 ).
3
220584
6-300
Engine
Engine Mechanical -<5.7L

1. Install the A/C drive belt idler pulley (1).

Notices.
Important: Be sure the idler pulley is fully seated

against the shoulder on the A/C compressor bracket
before tightening the bolt.
2. Install the A/C drive belt idler pulley bolt (2).
Tighten
Tighten the A/C drive belt idler pulley bolt to
50 N-m (37 lb ft).
3. Install the A/C drive belt. Refer to Drive Belt
Replacement - A/C.
3
220584
Drive Belt Tensioner Replacement Accessory

Removal Procedure
Belt Replacement - Accessol)I.
220581
Notices.
2. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 N-m (37 lb ft).
Replacement - Accesso,y.
(
220581
Engine
Engine Mechanical-5.7l
6-301
Drive Belt Tensioner Replacement - A/C

Removal Procedure
1. Remove the air conditioning (A/C) drive belt.
Refer to Drive Belt Replacement - AIC.
2. Remove the A/C drive belt tensioner bolt (3).
3. Remove the A/C drive belt tensioner (4).
3
220584
1. Install the A/C drive belt tensioner (4).
Notices.
Important: Be sure the tensioner is fully seated

against the compressor bracket before tightening
the bolt.
2. Install the A/C drive belt tensioner bolt (3).
Tighten
Tighten the A/C drive belt tensioner bolt (3) to
25 N-m (18 lb ft).
Replacement - AIC.
3
220584
6-302
Engine
Engine Mount Inspection
Notice: Broken or deteriorated mounts can cause
misalignment and destruction of certain drive
train components. When a single mount breaks, the
remaining mounts are subjected to abnormally
high stresses.
reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
1. Measure the engine movement at the engine
mounts in order to check for damage to the
rubber portions of the mount.
~ .1. Apply the park brake.
1.2. Start the engine.
1.3. Firmly apply the primary brakes.
1.4. Have an assistant stand to the side of the
vehicle to observe for engine movement.
1.5. Slightly load the engine in reverse and
drive. If the engine moves more than
24 mm (0.945 in) from the at rest position,
in either direction, check the engine
mount attachment.
2. If the engine mount attachment is within
specifications, replace th.e engine mount.
3. Replace the engine mount also if any of the
following .conditions exist:
.. Heat check cracks cover the hard rubber
surface.
The rubber cushion is separated from the
metal plate of the mount.
There is a split through the rubber cushion.
4. If the mount is loose, lower the engine and tighten
the bolts or the nuts to the engine frame or the
bracket. Refer to Fastener Tightening
Specifications.
Engine Support Fixture

Tools Required
J 28467-90A Engine Support Adapters
J 41044 Engine Support Adapters
J 42451 Engine Support Adapter Kit
J 28467-B Universal Engine Support Fixture
J 36462-A Engine Support Adapter Leg
1. Remove the exhaust gas recirculation (EGR)
valve pipe bolts (2, 3, and 4).
2. Remove the EGR valve pipe (1) and solenoid.
(
551485
Engine
3. Remove two strut mounting nuts from the left and

right strut towers.
4. Screw the engine support fixture adapters
J 28467-90A onto the strut tower studs.
5. Set the engine support adapters J 41044-1 and
J 41044-2 over the fixture adapters J 28467-90A
on each strut tower.
6. Secure with the wings nuts provided.
7. Place the cross bar J 28467-3 into the engine .
support adapters J 41044-1 and J 41044-2.
8. Secure with the quick release pins.
9. Install the fixture support leg J 28467-2A through
the cross bracket J 28467-1A on the top of the
cross bar J 28467-3.
10. Place the rubber padded foot of the front support
J 28467-4A on the radiator support.
11. Install the tube of the front support J 28467-4A
through the large hole in the support leg
J 28467-2A until level.
12. Install the quick release pin.
13. Install the support leg J 36462-A through the
cross bracket J 28467-1 A on the top of the
cross bar J 28467-3.
14. Bolt the lifting brackets to the cylinder heads.
15. Thread lift hooks J 28467-50 and J 28467-8
or (8A) into the support hook brackets J 28467-6A.
16. Place the support hook brackets J 28467-6A over
the cross bar J 28467-3 and connect the hooks to
the lifting brackets.
17. Tighten the large wing nuts J 28467-34.
J 28467-90A
578405
Engine Mount Replacement (left)

Removal Procedure
208553
6304
Engine
Support Fixture.
Information.
6. Remove the left oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (5.7L Left) in Engine Exhaust.
208569
7. Remove the engine mount heat shield nuts.

8. Remove the engine mount heat shield.
220590
9. Remove the engine mount bracket to

crossmember bolts.
11. Raise the left side of the engine using the support
fixture in order to remove tension on the
engine mount.
Information.
(
220588
Engine
6-305
13. Remove the erigine mount bracket to block studs.
14. Remove the engine mount assembly.

15. Separate the upper and lower mount on
the b~nch.
220591
Installation ,Procedure.
1. Loosely install the upper and lower mount
together on the bench.
2. Install the engine mount assembly.
3. Loosely install the engine mount bracket to
block studs.
5. Lower the left side of the engine using the support
fixture.
Information.
220591

Notices.
7. Install the engine mount bracket to

crossmember bolts.
Tighten
0
Tighten the engine mount bracket to
crossmember bolts to 58 Nm (43 lb ft).
e Tighten the engine mount bracket to block
studs to 50 N-m (37 lb ft).
8. Tighten the engine mount through bolt and
mount nut.
Tighten
Tighten the engine mount through bolt to
95 Nm (70 lb ft).
" Tighten the engine mount through bolt nut to
80 Nm (59 lb ft).
220588
6-306
Engine
9. Install the engine mount heat shield.
10. Install the engine mount heat shield nuts.
Tighten
Tighten the engine mount heat shield nuts to
1O Nm (89 lb in).
11. Install the left oxidation catalytic converter. Refer
to Oxidation Catalytic Converter Replacement
(5. 7 L Left) in Engine Exhaust.
'
220590
208569

16. Connect the MAF sensor electrical connector.
(
208553
Engine
6-307
Engine Mount Replacement (Right)

Removal Procedure
1. Disconnect the intake air temperature (IAT}
208553

Support Fixture.
Information.
208569
6. Disconnect the oil level sensor electrical

connector (1 ).
)
487459
6-308
Engine
7. Remove the negative battery cable lead to engine
block bolt (1 ).
Replacement (5. 7 L) in Engine Electrical.
4
211595
9. Remove the engine mount bracket to

crossmember bolts.
11. Raise the right side of the engine using the
support fixture in order to remove tension on
the engine mount.
Information.
220585
13. Remove the engine mount bracket to block bolts.

14. Remove the engine mount assembly.
15. Separate the upper and lower mount on
the bench.
(
220586
Engine
6-309
1. Loosely install the upper and lower mount
together on the bench.
2. Loosely install the engine mount bracket to
block bolts.
4. Lower the right side of the engine using the
support fixture.
Information.
220586

Notices.
6. Install the engine mount bracket to

crossmember bolts.
Tighten
Tighten the engine mount bracket to

crossmember bolts to 58 Nm (43 lb ft}.
Tighten the engine mount bracket to block
bolts to 50 Nm (37 lb ft}.
7. Tighten the engine mount through bolt and
mount nut.
Tighten
Tighten the engine mount through bolt to
95 Nm (70 lb ft}.
Tighten the engine mount through bolt nut to
80 Nm (59 lb ft).
220585

Replacement (5.7L) in Engine Electrical.
9. Install the negative battery cable lead to engine
block bolt ( 1) .
Tighten
Tighten the negative battery cable lead to engine
block bolt (1) to 32 Nm (24 lb ft)
)
4
211595
6-310
Eng int:!
10. Connect the oil level sensor electrical
connector (1 ).
12. Remove.the engine SLJpport fixture.
487459
208569
14. Connect the IATsensor electrical connector~

208553
Engine
6-311
Intake Manifold Replacement

)
Removal Procedure
1. Drain the cooling system. Refer to Draining and
Filling Cooling System (5. 7 L) in Engine Cooling.
Information
3. Remove the transmission fluid level indicator
tube bolt.
5. Relieve the fuel system pressure. Refer to
Fuel Pressure Relief Procedure in Engine
Controls - 5.7 L.
Important: Cap the fittings and plug the holes w.hen

separating fuel system components in order to prevent
dripping of fuel and/or dirt and other contaminants
from entering the fuel system.
6. Disconnect the fuel line from the fuel raiL
7. Disconnect the vapor line from the fuel vapor
purge valve.
220597
8. Disconnect the intake air.temperature (IAT)

208553
6-312
Engine
10. Remove the air intake duct from;the throttle body
208569
11 .. Disconnect the idle air control (IAO) valve , .

electrical connector from the throttle body.
12. Disconnect the throttle .position sensor (TPS)
electrical connector from the throttle body:
13. Remove the accessory drive .. belt,Refer.to Drive
Belt Replacement - Accessory.
220606
14. Disconnect the exhaust gas'recirctJlation (EGR).

solenoid electrical connector.
220595
Engine Mechanical - 5.7L 6-.313
Engine
15. Remove the EGR valve pipe bolts (2, 3, and 4).
16. Using mild force, pull the EGR valve pipe (1) up
out of the intake manifold.
17. Remove the 0-ring seal from the EGR valve
pipe (1 ).
18. Discard the exhaust manif.old gasket (5) and
0-ring seal.
551485
19. Unsnap the cruise control cable .from the throttle

lever, if equipped.
Push the cruise cable connectorforward to
unsnap.
Unsnap the cable from the engine bracket.
220601
20. Remove the accelerator cable from the

throttle lever.
220602
6-314
Engine
21. Remove the accelerator controlcable and cruise

control servo bracket.
220603
22. Disconnect the right side .fuel injector electrical

connectors.
220605
23. Disconnect the left side fuel injector electrical

connectors.
24. Disconnect the secondary air injection (AIR)
25. Remove the fuel rail. Refer to Fuel Rail and
Injectors Removal.
220608
Engine
26. Remove the fresh air tube from the throttle body
and rocker cover.
551464
27. Remove the vapor vent tube from the

throttle body.
220621
28. Remove the throttle. body. heater otlet hose from

the throttle body.
220620
6-316
Engine Mechanical "' 5.7L
Engine
29. Removethe evapora.tive emission (EVAP)
canister purge tube.
220615
30. Remove the canister purge valve

from the intake manifold.
ana .bracket
220617
31: Disconnect the knock sensor harness electrical

connector (4).
379365
Engine
6-317
32. Disconnect the manifold absolute pressure (MAP)

33. Disconnect the vacuum hose from the vacuum
port on the MAP sensor housing.
34. Disconnect all the remaining electrical connections
from the intake manifold.
35. Remove the intake manifold. Refer to Intake
Manifold Removal.
220609
1. Install the intake manifold. Refer to Intake
Manifold Installation.
2. Connect the MAP sensor electrical connector.
3. Connect the vacuum hose to the vacuum port on
the MAP sensor housing.
220609
4. Connect the knock sensor harness electrical

connector (4).
379365
6-318
Engine
5. Install the canister purge valve and bracket to the
intake manifold.
220617
6. Install the EVAP canister purge tube.
220615
7. Install the throttle body heater outlet hose to the

throttle body.
220620
Engine
6-319
8. Install the vapor vent tube hose to the

throttle body.
220621
9. Install the fresh air tube to the throttle body and

rocker cover.
10. Install the fuel rail. Refer to Fuel Rail and Injectors
Installation.
551464
11. Connect the left side fuel injector electrical

connectors.
12. Connect the AIR solenoid electrical connector.
220608
6-320
Engine
13. Connectthe right side fuel injector electrical
connectors.
14. Connect all remaining electrical connectors to the
intake manifold.
220605

Notices.
15. Install the accelerator control cable and cruise
control servo bracket.
Tighten
Tighten the accelerator control cable and cruise
control servo bracket nut to 10 N-m (89 lb in).
220603
16. Install the accelerator cable to the throttle lever.
220602
Engine
Engine Mechanical - 5.7L 6-3.21
17. Install the cruise control cable to the throttle lever,

if equipped.
220601
Important: Do .not reuse EGR pipe gaskets or seals

during assembly, install NEW gaskets and seals.
18. Apply a light coatirig of clean engine oil to a NEW

0-ring seal and install the seal onto the EGR
valve pipe (1 ).
19. Install the EGR valve pipe (1) into the intake
manifold.
20. Finger start the EGR valve pipe (1) to intake
manifold bolt (2).
21. Finger start the EGR valve pipe (1) to cylinder
head bolts (3).
22. Finger start a NEW EGR valve pipe exhaust
manifold gasket (5) and bolts (4).
Tighten
22.1. Tighten the EGR valve pipe to intake
manifold bolt (2) to 10 Nm (89 lb in).
22.2. Tighten the EGR valve pipe to cylinder
head bolts (3) to 50 Nm (37 lb ft).
22.3. Tighten the EGR valve pipe to the exhaust
manifold bolts (4) to 30 Nm (22 lb ft).
551485
6-322
Engine
Replacement - Accessory.
25. Connect the TPS sensor electrical connector to

the throttle body.
26. Connect the IAC sensor electrical connector to
the throttle body.
220606
208569
Engine
6-323
28. Connect the MAF sensor electrical connector to

the intake duct.
29. Connect the IAT sensor electrical connector to the
intake duct.
208553
30. Connect the fuel line to the fuel rail.

31. Connect the vapor line to the fuel vapor
purge valve.

Information
220597
33. Install the transmission fluid indicator tube bolt.

Tighten
Tighten the transmission fluid indicator tube bolt
to 50 N-m (37 lb ft).
35. Fill the cooling system. Refer to Draining and
208459
6-324
Engine
Vapor Vent Pipe Replacement
Removal Procedure

Manifold Replacement.
551466
2. Remove the engine coolant air bleed pipe. Refer'

to Vapor Vent Pipe Removal.
550330
1. Install the engine coolant air bleed pipe. Refer to
Vapor Vent Pipe Installation.
550330
Engine
6-325
2. Install the intake manifold. Refe.r to Intake

Manifold Replacement.
551466
Engine Valley Cover Replacement

Removal Procedure
1. Remove the engine coolant air bleed pipe. Refer
to Vapor Vent Pipe Removal.
550330
2. Remove the engine valley cover. Refer to Engine

Valley Cover Removal.
65048
6-326
Engine

1. Install the engine valley cover. Refer to Engine

Valley Cover Installation.
65048

Vapor Vent Pipe Installation.
.
'
,,,--,
(""
. o~
550330

Replacement (Left)
Removal Procedure
1. Relieve the fuel system pressure. Refer to
Fuel Pressure Relief Procedure in Engine
Controls - 5.7 L.
2. Disconnect the fuel line from the fuel rail.
purge valve.
220597
Engine
6-327
4. Remove the positive crankcase ventilation (PCV)

valve pipe from the rocker cover.
379366
5. Disconnect the ignition coil harness main electrical

connector.
6. Remove the spark plug wires from the
ignition coils.
spark plugs.
490925
8. Disconnect the secondary air injection (AIR) pump

hose from the AIR shutoff valve.
9. Separate the AIR pump hose, if necessary.
551472
6-328
Engine
10. Remove the AIR shutoff valve bracket nut.

11. Disconnect the AIR solenoid tube from the
shutoff valve.
628105
12. Loosen the AIR shutoff valve bolt on the rear of

the cylinder head.
13. Slide the AIR shutoff valve off from the bolt.
567573
14. Remove the AIR shutoff valve hose clamps

and hose.
567570
Engine
Engine Mechanical - 5.7L . 6-329
15. Remove the AIR pipe (with check valve), bolts

and gasket from the left exhaust manifold.
16. Remove the valve rocker arm cover. Refer to
Valve Rocker Arm Cover Removal (Left Side).
551470
1. Install the valve rocker arm cover. Refer to Valve
Rocker Arm Cover Installation (Left Side).

Notices.
2. Install the AIR pipe (with check valve), NEW
gasket and bolts to the left exhaust manifold.
Tighten
Tighten the AIR pipe bolts to 20 Nm (15 lb ft).
551470
3. Install the AIR shutoff valve hose and clamps.
567570
6-330
Engine
4. Slide the AIR shutoff.valve onto the bolt.

5. Tighten the AIR shutoff valve bolt on the rear Of
the cylinder head.
Tighten
Tighten the AIR shutoff valve bolt to
20 Nm (15 lb ft).
567573
6. Install the AIR shutoff valve bracket nut.

Tighten
Tighten the AIR shutoff valve bracket nut to
12 Nm (106 lb in).
7. Connect the AIR solenoid tube to the shutoff valve.
8. Connect the AIR pump hose together, if
necessary.
628105
9. Connect the AIR pump hose to the AIR

shutoff valve .
. ~
551472
Engine
)
6-331
10. Install the spark plug wires to the spark plugs.

11. Install the spark plug wires to the ignitions coils.
12. Connect the ignition coil harness main electrical
connector.
490925
13. Install the PCV valve pipe to the rocker cover.
379366
14. Install the fuel line to the fuel rail.

15. Install the vapor line to the fuel vapor purge valve.
220597
6-332
Engine
Replacement (Right)
Removal Procedure
1. Remove the evaporator tube. Refer to Evaporator
2.
3.
4.
5.
Tube Replacement in Heating, Ventilation and Air

Conditioning.
Remove the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (5. 7 L) in Heating,
Ventilation and Air Conditioning.
Remove the secondary air injection (AIR) pump
hose from the hose clamps.
Disconnect the AIR pump hose from the
shutoff valve.
Remove the AIR pipe (with check valve), bolts
and gasket from the right exhaust manifold.
551467
6. Di$connect the ignition coi.1 harness main electrical

connector.
ignition coils.
spark plugs.
490925
Engine
Engine Mechanical- 5.7L 6-333
9. Remove the. positive crankcase. ventilation (PCV)

v,3.lve pipe from the rocker cover.
.
.
10. Remove the PCV valve pipe strap nut, if needed.
11 . Remove the PCV valve pipe frorh the intake
manifold, if needed.

Valve Rocker Arm Cover Removal (Right Side).
379367
1. lnstallthe valve rocker arm cover. Refer to 1/alve
Rockflr Arm Cover Installation (Right Sidel
2. Install the PCV valve pipe to the intake manifold,
if removed.

Notices.
3. Install the PCV valve pipe strap nut, if removed.
Tighten
Tighten the. PCV valve pipe strap nut to
12 Nm (106 lb in).
4. Install the PCV valve pipe to the rocker cover.
379367
6-334
Engine
6. Install the spark plug wires to the ignition coils.
7. Connect the ignition coil harness main electrical
connector.
490925
8. Install the AIR pipe (with check valve), NEW

gasket and bolts to the right exhaust manifold.
9.
10.
11.
12.
Tighten
Tighten the AIR pipe bolts to 20 N-m (15 lb ft).
Connect the AIR pump hose to the shutoff valve.
Connect the AIR pump hose to the hose
clamps.
Install the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (5. 7 L) in Heating,
Ventilation and Air Conditioning.
Install the evaporator tube. Refer to Evaporator
Tube Replacement in Heating, Ventilation. and
Air Conditioning.
551467.

Replacement
Removal Procedure
1. Remove the valve rocker arm covers. Refer to
Valve Rocker Arm Cover Replacement (Right)
or Valve Rocker Arm Cover Replacement (Left).
2. Remove the valve rocker arms, push rods, and
pedestals. Refer to Valve Rocker Arm and Push
Rod Removal.
260140
Engine
Engine Mechanical -5.7l
5.;335
Installation Procedure .
1. Install the valve rocker arms, push rods, and
pedestals. Refer to Valve Rocker Arm and
Push Rod Installation.
2. Install the valve rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Left) or Valve
Rocker Arm Cover Replacement (Right).
260140
Valve Stem Oil,Sealand ValveSpring

Replacement
Removal Procedure
Tools Required
J 22794 Spark Plug Port Adapter
J 38606 Valve Spring Compressor (Head 0 on)
J 42078 Valve Stem Oil Seal Installer
1. Remove the valve. rocker arms and pushmds.
Replacement.
2. Remove the spark plug from the cylinder to be
serviced.
14824
3. Install the J22794 to the spark plug hole.

4. Attach and apply compressed air to the J 22794
in order to retain the valves in their closed
position.
11517
5.;335
Engine
5. Compress the valve spring (4) using J 38606.
(
J 38606
31730
6.
7.
8.
9.
10.
Remove the valve

Release the valve
Remove the valve
Remove the valve
Remove the valve
stem keys (1 ).
spring compressor.
spring cap (2).
spring (3).
stem oil seal (4 or 8).
551480
Engine
Engine Mechanical .. 5. 7L 6-337
)
Important: The valve stem oil seal alignment and

position on the valve guide is critical.
An improperly installed valve stem oil seal may lead to
excessive oil consumption, increased vehicle
emissions, or component damage.
1. Install the valve stem oil seal onto the guide.
1.1. Lubricate the valve guide and valve
stem oil seal with clean engine oil.
1.2. Install the valve stem oil seal onto the
valve stem.
1.3. Using the J 42078 Push the seal down until
the seal contacts the valve guide.
63193
2. Measure the valve stem oil seal for the properly

installed height.
There should be c;1. 18.1-19:1 mm (0.712~0.752 in)
gap between the top edge of the oil seal body
and the shim spring seat surface.
18.1-19.1 mm
(0.712-0.752")
63158
3. Install the valve spring to J 38606.

4. Compress the valve spring using J 38606.
J 38606
31730
6~338
Engine
5. Install the valve spring cap (2).
6. Install the valve stem keys (1 ).
6.1. use grease to.hold the keys (1) in place
.and remove the J 38606.
6.2. Ma~e sure the keys (1) seat.properly in the
groove of the valve (10 and 12) stern.
6.3 .. Tap the end to thevalve (6 and 7) stern
with a plastic faced hammer to seat the
keys (if necessary) ..
551480
7. Disconnect and remove the air supply

from J 22794.
8. Remove J 22794 from the spark plug hole.
11517
Engine
5..;339

Notices.
9. Install the spark plug.

Tighten
Tighten the spark plug to 15 N-m (11 lb ft).
10. Install the valve rocker arms, pedestal, and valve
pushrods. Refer to Refer to Valve Rocker Arm
and Push Rod Replacement.
14824
Oil Level Indicator and Tube Replacement

Removal Procedure
1. Disconnect the exhaust gas recirculation (EGR)
220595

pipe (1 ).
5. Discard the exhaust manifold gasket (5) and
0-ring seal.
6. Remove the number 4 and 6 spark plug wires.
569980
6-340
Engine Mechanical
5.7L
Engi11e
7. Remove the number 4 and 6 ignition coils from
the coil bracket.
309850
8. Remove the oil level indicator from the

indicator tube.
565268
9. Remove the oil level indicator tube bolt.

10. Remove the indicator tube from the engine block.
11. Remove the 0-ring from the tube.
(
'
565269
Engine
6-341
1. Clean the indicator tube.
2. Install a new 0-ring to the tube.

3. Install the oil level indicator tube.
4. Rotate the tube into the proper position.
Notices.
5. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to
25 Nm (18 lb ft).
'
565269
6. Install the indicator 1o the indicator tube.
565268
7. Install the number 4 and 6 ignition coils to the coil

bracket.
Tighten
Tighten the ignition coil bolts to 12 Nm (106 lb in).
8. Install the number 4 and 6 spark plug wires.
309850
6-342
Engine Mechanical';. 5.71...
Engine
Important: Do not reuse EGR pipe gaskets or seals
during assembly, install NEW gaskets and seals.
551485
9. Apply a light coating of clean engine oil to. a NEW

0-ring seal and install the. seal onto the E.GR
valve pipe (1 ).
10. Install the EGR valve plpe (1) into the intake
manifold.
manifold bolt (2).
head be.Its (3).

13. Finger start a NEW EGR valve pipe exhausl
Tighten
manifold bolt (2) to 10 N-m (89 lb in).
head bolts (3) to 50 N-m (37 lb ft).
13.3. Tighten the EGR valve pipe to the exhaust
manifold bolts (4) to 30 Nm (22 lb ft).
14. Conneqtthe EGR solenoid electrical connector.
220595
Exhaust Manifold Replacement (left)

Removal Procedure
t. Remove the left .valve rocker arm cover. Refer to
Valve Rocket Arm Cover Replacement (Left).
2. Remove the spark plugs.
Information.
4. Remove the left side catalytic converter. Refer to
Oxidation Catalytic Converter Replacement
(5.7 L Left) in Engine Exhaust.
~..
(
14824
Engine
6-343
5. Remove the left exhaust manifold bolts.
6. Remove the left exhaust manifold and gasket

7. Discard the gasket.
569981
8. Remove the heat shield bolts (3) and heat shield

(2) from the manifold (1 ), if required.
492586'
Important: Tighten the exhaust manifold bolts as
specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may effect
vehicle emissions and/or on-board diagnostic (080) II
system performance.
The cylinder head exhaust manifold bolt hole threads
must be clean and free of debris and/or threadlocking
material.

Notices.
1. Install the heat shield (2) and heat shield bolts (3)
to the manifold (1 ), if required.
Tighten
Tighten the heat shield bolts (3) to
9 N-m (80 lb in).
492586
6344
Engine
Important: Do not apply threadlock to the first three .
threads of the exhaust manifold bolts.
2. Apply a 5 mm (0.2 in) wide band of threadlo.ck

GM P/N 12345493 or equivalent to the threads
of the exhaust manifold bolts.
3. Install a NEW exhaust manifold gasket and the
exhaust manifold.
4. Install the exhaust manifold bolts.
s6se81
5.
6.
7.
8.
Tighten
4.1. Tighten the exhaust manifold bolts a
first pass to 15 N-m (11 lb ft). Tightening
the exhaust manifold bolts beginning
with the center 2 bolts. Alternate from
side-to-side, and work toward the
outside bolts.
4.2. Tighten the exhaust manifold bolts a final
pass to 25 N-m (18 lb ft). Tighten the
exhaust manifold bolts beginning with the
center 2 bolts. Alternate from side-to-side,
and work toward the outside bolts.
Using a flat punch, bend over the expos.ed edge
of the exhaust manifold gasket at the rear of the
cylinder head.
Install the left side catalytic converter. Refer to
Lower the vehicle.
Install the spark plugs.
Tighten
Tighten the spark plugs to 15 N-m (11 lb ft).
9. Install the left valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement (Left).
14824
Engine
Exhaust Manifold Replacement (Right)

Removal Procedure
Valve Rocker Arm Cover Replacement (Right).
2. Remove the right side catalytic converter. Refer to
(5. 7 L Right).
3. Remove the spark plugs.
14824
4. Disconnect the exhaust gas recirculation (EGA)

valve electrical connector.
220595

'pipe (1).
8. Discard the exhaust manifold gasket (5) and
0-ring seal.
569980
6-346
Engine Mechanical - .5.7L
Engine
9. Remove the left exhaust manifold bolts.
10. Remove the left exhaust manifold and gasket.

11 . Discard the gasket.
569980
12. RE:3move the heat shielci: bolts. (3) and heat..

shield (2) from the manifold (1).;if required.
492583
Installation .Procedure
and/or leaking exhaust manifold gasketsmay effect
vehicle emissions and/or on-board diagnostics (OBD) II
system performance.
must be clean and free of debris and/or threadlocking
material.

Notices.
1. Install the heat shield (2) and heat shield bolts (3)
to the manifold (1), if required.
Tighten
Tighten the heat shield bolts (3) to
9 N-m (80 lb in).
492583
Engine
)
Important: Do not apply threadlock to the first three

threads of the exhaust manifold bolts.
2. Apply a 5 mm (0.2 in) wide band of threadlock
3. Install a NEW exhaust manifold gasket and the
exhaust manifold.
Tighten
first pass to 15 N-m (11 lb ft). Tightening
the exhaust manifold bolts beginning
with the center 2 bolts. Alternate from
outside bolts.
center 2 bolts. Alternate from side-to-side,
and work toward the . outside
bolts.
.
..
5. Using a flat punch, bend over the exposed edge
cylinder head.
569980
Important: Do not reuse EGR pipe gaskets or seals

during assembly. Install NEW gaskets and seals.
6. Apply a light coating of clean engine oil to a NEW
O~ring seal and install the seal onto the EGR
valve pipe (1 ).
7. Install the EGR valve pipe (1) into the intake
manifold.
manifold bolt (2).
head bolts (3).
10. Finger start a NEW EGR valve pipe exhaust
Tighten
manifold bolt (2) to 1O N-m (89 lb in).
head bolts (3) to 50 N,m (37 lb ft).
10.3; Tighten the EGR valve pipe to the exhaust
manifold bolts (4) to 30 N-m (22 lb ft).
551485
6-348
Engine
Engine Mecharaical - 5.7l
11 ..Connect the EGR valve electrical connector.
12. Install the spark plugs.
Tighten
Tighten the spark plugs to 15 N,m (11 lb ft).
13. Install the right side catalytic converter. Refer to
(5. 7 L Right).
14. Install the valve rocker arm cover. Refer to Valve
Rocker Arm Cover Replacement (Right).
14824
Cylinder Head Replacement (Left)

1
Removal Procedure
to. Vapor Vent Pipe Replacement.
2. Remove the power steering pump rear bracket.
Refer to Power Steering Pump Rear Bracket
Replacement in Power Steering System.
3. Remove the left side exhaust manifold. Refer to
Exhaust Manifold Replacement (Left).
Replacement.
5. Remove the harne.ss ground bolts (2 and 3) from
the ~ear of the cylinder head.
2
4
379365
Engine
6-349
6. Remove the left side cylinder head. Refer to

Cylinder Head Removal (Left Side).
260146
1. Install the left side cylinder head. Refer to
Cylinder Head Installation (Left Side).
260146

Notices.
2. Install the harness ground bolts to the

cylinder head.
3.
4.
5.
6.
Tighten
Tighten the harness ground bolts (2 and 3) to
50 N-m (37 lb ft).
Install the valve rocker arms and pushrods. Refer
Replacement.
Install the left side exhaust manifold. Refer to
Exhaust Manifold Replacement (Left).
Install the power steering pump rear bracket.
Refer to Power Steering Pump Rear Bracket
Replacement in Power Steering.
Install the engine coolant air bleed pipe. Refer to
Vapor Vent Pipe Replacement.
4
379365
6-350
Engine

Cylinder Head Replacement (Right)
Removal Procedure

to Vapor Vent Pipe Replacement.
2. Remove the right side exhaust manifold. Refer to
Replacement.
4. Remove the engine wiring harness clip bolt from
the cylinder head.
346049
5. Remove the transmission fill. tube bolt from the

cylinder head.
208459
6. Remove the right side cylinder head. Refer to

Cylinder Head Removal (Right Side).
260149
Engine
6-351
1. Install the right side cylinder head. Refer to

Cylinder Head Installation (Right Side).
260149
Notict1: Refer to Fa.stener Notice in Cautions and

Notices.
2. Install the transmission fill tube boltto the

cylinder head.
Tighten
Tighten the transmission fill tube bolt to

47 Nm (35 lb ft).
208459
3. Install the engine wiring harness clip bolt to the

rear of the cylinder head.
Tighten
Tighten the engine wiringtiarness clip bolt to
50 N-m (37 lb ft).
4. Install the valve rocker arms and pushrods. Refer
Replacement.
5. Install the right side exhaust manifold. Refer to
Vapor Vent Pipe Replacement.
346049
6-352
Engine Mechanical 5. 7L
Engine
Valve Lifter Replacement
Removal Procedure
Tools Required
J 3049-A Valve Lifter Remover
1. Remove the cylinder head. Refer to Cylinder
Head Replacement (Right) or Cylinder Head
Replacement (Left).
2. Remove the valve lifter guide bolt.
3. Remove the valve lifter guide.
551476
Important: Some valve lifters may be stuck in their

bores because of gum or varnish deposits.
4. Use the J 3049-A or equivalent to remove the

valve lifters, if required.
31350
5. Remove the valve lifters from the lifter guide, if

necessary.
6. Organize or mark the lifters so that they can be
installed in the same location from which they
were removed.
63233
Engine
6-353
Important: When reusing lifters, install the lifters in

their original locations.
1. Lubricate the valve lifters and engine block lifter
bores with clean engine oil.
2. Insert the lifter into the lifter guides.
Align the flat area on top of the lifter with the flat
area in the lifter guide bore. Push the lifter
completely into the guide bore.
63233
3. Install the lifters and guide to the engine block.

Notices:
4. Install the lifter guide bolt.
Tighten
Tighten the lifter guide bolt to 12 Nm (106 lb in).
5. Install the cylinder head. Refer to Cylinder Head
Replacement (Right) or Cylinder Head
Replacement (Left).
551476
Crankshaft Balancer Replacement

Removal Procedure
Refer to Drive Belt Replacement - AIC.

Information.
4. Remove the right closeout cover and bolt.
208464
6-354
Engine
5. Unsnap the oil cooler lines from the clip at the
generator.
341084
6. Remove the transmission oil cooler lines from the

radiator.
7. Remove the power steering cooler, if equipped ...
Refer to Power Steering Cooler Pipe/Hose
Replacement in Steering.
208321

Crankshaft Balancer Removal.
. r;;:,
(
64275
Engine
6-355
Balancer Installation.
2. Install the power steering cooler, if removed.
Refer to Power Steering Cooler Pipe/Hose
Replacement in Steering.
64275

Notices.
3. Install the transmission oil cooler lines to the

radiator.
Tighten
Tighten the oil cooler line connections to
27 N-m (20 lb ft).
208321
4. Snap the oil cooler lines into the clip at the

generator.
341084
6-356
Engine
5; Install the right closeout cover and bolt.
6.
7.
8.
9.
Tighten
Tighten the closeout cover bolt to
12 Nm (106 lb in).
Install the starter motor. Refer to Starter Motor
Replacement (5. 7 L) in Engine Electrical:
Lower the vehicle.
Install the A/C drive belt. Refer to Drive Belt
Replacement - AIC.
Perform the crankshaft postion (CKP) system
variation learn procedure. Refer to CKP
Controls - 5. 7 L.
208464
Crankshaft Front Oil Seal Replacement '

Removal Procedure
2. Pry the crankshaft oil seal out from the front cover.
64275
1. Install a NEW crankshaft front oil seal (1). Refer
to Crankshaft Front Oil Seal Installation.
490689
Engine
6-357

64275
Engine Front Cover Replacement

Removal Procedure
Information.
2. Remove the cooling fan electrical connectors.
3. Remove the harness rosebud clips from the fan
shroud.
221692

208553
6-358
Engine
Refer to Drive Belt Replacement - A/C.
208569
1O. Remove the upper radiator hose from the

water pump.
221676
11 . Remove the radiator hose from the water inlet

housing.
221671
Engine
6-359
12. Remove the two heater hoses from the

water pump.
282934
13. Remove the upper radiator support.
221697
14. Remove the fan shroud.

Belt Tensioner Replacement - Accessoty.
41692
6360
Engine
16. Remove the overflow hose from the radiator.
221645
17. Remove the throttle body heat.er hose from the .

radiator.
18. Remove the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement - Accesso,y.
19. Remove the water pump. Refer to Water Pump
Replacement (5.7 L) in Engine Cooling.
Information.
220620
22. Remove the oil pan-to~tront cover bolts.
451709
Engine
Important: Do not slide the front cover/gasket across

the oil pan gasket or damage could result.
23.
24.
25.
26.
27.
Remove the front cover-to-engine block bolts.

Remove the front cover and gasket.
Discard the front cover gasket.
Remove the crankshaft oil seal from the cover.
Discard the oil seal.
64278
Tools Required
J 41476 Front/Rear Cover Alignment-Crankshaft Oil
Seal Area
Important:
., Do not reuse the crankshaft oil seal or front cover
gasket.
Do not slide the front cover/gasket across the oil
pan gasket
The special tool in this procedure is used to
properly align the crankshaft front oil seal.
The crankshaft front oil seal MUST be centered in
relation to the crankshaft.
An improperly aligned front cover may cause
premature front oil seal wear and/or engine
oil leaks.
1. Install a NEW crankshaft oil seal to the front cover.
2. Apply a 5 mm (0.20 in) bead.of sealant GM
PJN 12378190 to the corner where the oil pan
meets the engine block.
3. Install the front cover, gasket and bolts on to the
engine.
4. Install the front cover bolts finger tight. Do not
overtighten.
64278
6-362
Engine Mechanical ..; 5. 7L
Engine
5. Install the oil pan-to-front.cover bolts until snug in
order to position the:cover at the pan rail.
451709
6. Install the J 41476 to the.front cover.

7. Align the tapered legs of the J 41476 with th~
machin~d alignn;ient surfaces on the front cover.
8. Install the crankshaftbalancer bolt until snug. Do
not overtighten.
Notices.
9. Tighten the oil pan bolts in the following order:
Tighten
9.1.. Tighten the oil pan-to-front cover bolts to
25 N-m (18 lb ft).
9.2. Tighten the. engine front cover bolts to
25 N-rn (18 lb ft).
10. Remove the J 41.476.
451712

13. Install the water pump. Refer to Water Pump
Replacement (5. 7 L) in Engine Cooling.
14. Install the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement - Accessol)I.
Engine
15. Install the throttle body heater hose to the

radiator.
220620
16. Install the overflow.hose to the radiator.

Tensioner Replacement - Accessory.
221645
18. Install the fan shroud.
41692
5...354
Engine
19. Install the upper radiator support.
Tighten
Tighten the radiator supporVair cleaner bolts to
12 N-m (106 lb in).
221697
20. Install the lower radiator hose to the water inlet

housing.
221671
21. Install the upper radiator hose to the water pump,.
221676
Engine
\
!
Engine Mechanical
5.7.L
5.;3fi~
22. Install the two heater hoses from the water pump.
Replacement - A/C.
282934
24. Install the air ihtake duct.
208569
25. Cor1nect the MAF sensor electrical connector.

27. Refill the cooling system. Refer to Draining and
208553
6-366
Engine
28. Install the electrical connectors to the fan shroud.

29. Install the rosebud clips to the fan shroud.
221692
Crankshaft Rear Oil Seal Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.
178458
2. Pry the crankshaft rear oil seal (1) out of the

rear cover.
490692
Engine
6-367
1. Install the crankshaft rear oil seal (1). Refer to
Crankshaft Rear. Oil .Seal Installation.
490692
2. Install the flywheel. Refer to Engine Flywheel

Replacement.
178458
Engine Rear Cover Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.
2. Remove the oil pan-to-rear cover bolts.
178458
6-368
Engine
3. Remove the rear cover bolts.

4. Remove the re~r cover and gasket.
5. Remove the crankshaft oil seal from the cover.
Gasket sealing surfaces for excessive
scratches or gouging.
Cover -to-oil pan threaded bolt holes for
damaged threads or debris.
Crankshaft oil seal mounting bore for damage.
Oil pan gasket for damage.
64282
Tools Required
J41476 Front/Rear Cover Alignment-Crankshaft Oil
Seal Area
Important:
Do not reuse the crankshaft oil seal or rear cover
gasket.
Do not slide the rear cover gasket across the oil
pan gasket.
The special tool in this procedure is used to
properly align the crankshaft rear oil seal.
The crankshaft rear oil seal MUST be centered in
relation to the crankshaft.
An improperly aligned rear cover may cause
premature rear oil seal wear and/or engine
oil leaks.
1. Apply a 5 mm (0.20 in) bead of sealant GM
P/N 12378190 to the corner where the oil pan
meets the engine block.
451897
2. Install the rear .cover, gasket and bolts to the

engine.
3. Tighten the rear cover bolts finger tight. Do not
overtighten.
4. Install the oil pan-to-rear cover bolts finger tight.
Do not overtighten.
64282
Engine
5. To properly align the rear cover, rotate the

crankshaft until two opposing flywheel bolt holes
~re para,llel. to the oil pan surface.
6. Align the tapered legs of J 41476 so the legs
enter the rear cover oil seal bore.
7. Install the J41476 and bolts onto the rear of the
crankshaft.
8. Tighten the tool mounting bolts by hand until
snug. Do not overtighten.
9: Install the oil pan-to-cover bolts until snug in order
to position the cover to the pan rail.

J 41476

Notices.
10. Tighten the oil pan-to-rear cover bolts in the

following order:
Tighten
10.1. Tighten the oil pan-to-rear cover bolts to
12 N-m (106 lb in).
10.2. Tighten the rear cover bolts to
25 N-m (18 lb ft).
12. Install the rear oil seal. Refer to Crankshaft Rear
Oil Seal Installation.
13. Install the flywheel. Refer to Camshaft
Replacement.
451716
178458
5;.370
Engine

Oil Pan Replacement
Removal Procedure

Information.
3. Remove the oil drain plug.
309862
178469
6. Remove the right side engine mount to

pradle bolts.
(
220585
Engine
6-371
7. Remove the left side engine mount to crad.le bolts.
220588

220629
9. Remove the intermediate steering shaft bolt:

10. Support the engine cradle using adjustable jack
stands.
220630
6-372
Engine Mechanical;. 5.7L
Engine
11. Disconnect the oil level sensor connector, if
required.
220633
12. Remove the oil level sensor from the oil pan, if
required.
178467
14. Remove the right side closeout and bolt.
208464
Engine
Engine Mechanical -, 5.7L
6-373
15. Remove the left side closeout and bolt.
208478
16. Loosen the six cradle bolts three or four turns.

17. Lower the cradle slightly using the cradle support,
using the adjustable jack stands.
It may be necessary to also raise the engine
using the supportfjxture.
18. Remove the bottom two transmission
bellhousing bolts.
~
220632
19. Remove the oil pan bolts (1).

20. Lower the oil pan, position the pan until it can be
removed from around the oil pump screen.
21. Use care not to gouge, score, or damage the oil
pan sealing surface.
451962
6-374
Engine
Important: DO NOT allow foreign material to. enter
the oil passages of .the oil pan, cap or cover the
openings as required.
22. Drill out the oil pan gasket rivets (2) and remove
the gasket (1) from the oil pan.
23. Discard the old gasket and rivets.
384699
Important: The alignment of the struc,ural oil pan is
critical. The rear bolt hole locations ofthe oil pan
provide mounting points for the transmission
bellhousing. To ensure the rigidity of the powertrain
and correct transmission alignment, it is. important th.at
the rear of the block and the rear of th.e oil pan
must NEVER protrude beyond the engine 'block and
transmission bellhousing plane.
P/N 12378190 or equivalent 20 mm (0.8 in) long to
the engine block.
2. Apply the sealant directly onto the tabs of the
front cover gasket that protrudes into the oil
pan surface.
451897

P/N 12378190 or equivalent 20 mm (0.8 in) long
to the engine block.

4. Apply the sealant directly onto the tp.bs of the rear
cover gasket that protrudes into the oil pan
surface.
'
451898
Engine
6-375
5. Pre-assemble the oil pan gasket to the pan (2).
5.1. Install the gasket onto the pan (2).

5.2. Install the oil pan bolts (1) to the pan
through the gasket.
6. Install the oil pan (2), gasket and bolts (1) to the
engine block.
7. Snug the oil pan bolts (1) finger tight. Do not
overtighten.
8. Install the two lower bellhousing bolts to position
the oil pan correctly.

Notices.
9. Snug the lower bellhousing bolt finger tight. Do

not overtighten.
Tighten
9.1. Tighten the oil pan-to-block and oil
pan-to-oil pan front cover bolts to
25 N-m (18 lb ft).
451962

12 N-m (106 lbin).
,
9.3. Tighten the bellhousing bolts to
50 N-m (37 lb ft).
10. Raise the engine cradle and/or if necessary, lower
the engine.
11. Tighten the cradle bolts.

Tighten
Tighten the upper four cradle bolts to
125 Nm (92 lb ft).
Tighten the lower two cradle bolts to
145 N-m (107 lb ft).
~
220632
6-376
Engine
12. Install the left side closeout and bolt.
Tighten
Tighten the left side closeout bolt to
12 N-m (106 lb in).
208478
13. Install the rlght side closeout and bolt.

Tighten
Tighten the right closeout bolt to
12 Nm (106 lb in).
208464
15. Install the oil level sensor to the oil pan, if

removed.
Tighten
Tighten the oil level sensor to 35 N-m (26 lb ft).
178467
Engine
6-377
16. Connect the oil level sensor electrical connector.
17. Remove the cradle support.
220633
18. Connect the intermediate steering shaft bolt ,

Tighten
47 N-m (35 lb ft).
220630
mounting bolts.
Tighten
Tighten the shock absorbers bolts to
65 N-m (48 lb ft).
220629
6-378
Engine Mechanical .; 5.7L
Engine
20. Install the left side engine mount cradle bolts.
Tighten
Tighten the engine mount to cradle bolts to
58 N-m (43 lb ft).
220588
21. Install the right side engine mount cradle bolts.

Tighten
Tighten the right side engine mount cradle bolts
to 58 N-m (43 lb ft).
220585
22. Install the oil drain plug.

Tighten
Tighten the oil drain plug to 25 N-m (18 lb ft).
309862
Engine
6-379

Tighten
Tighten the.oil filter to 30 N,m (22 lb ft) ..
26. Change the engine oil. Refer to Engine Oil and
Oil Filter Change.
178469

Replacement
Removal Procedure
.A
64278
2. Remove. the engine oil pan (2). Refer to Oil Pan

Replacement.
3. Remove the oil pump, pump screen and deflector.
Removal.
451962
6.;.380
Engine
1. Install the deflector, pump screen and oil pump.
Installation.
2. Install the engine oil pan (2). Refer to Oil Pan
.Replacement.
451962

64278
Timing Chain and Sprockets Replacement
Removal .Procedure
1. Remove the oil pump. Refer to Oil Pump, Pump
Screen and Deflector Replacement.
64281
6-381
Eogin. e
.
chain
d sprocket. Refer to
.
an Remova I.
R move the t1m1ng
kets
2. T:ning Chain and Sproc
.
63263
Installation Pro~e
dure
inand sprocket. _Refer to

ti~rnng
1. Install
Timingthe
Cham
an J~~rockets lnstallatt0n.
63263
.
Refer to 01/. Pump' Pump
2. ,.Install the o1Lp~;~tor Replacement.
,
Screen and De
64281
6-382
Engine

Camshaft Replacement
Removal Procedure
1. Remove the valve lifters. Refer to Valve Lifter

Replacement.
2. Remove the radiator. Refer to Radiator
Replacement in Engine Cooling.
221724
3. Remove the timing chain and sprocket. Refer to

63263
4. Remove the camshaft. Refer to Cam.shaft

Removal.
(
63212
Engine
6-383
1. Install the camshaft. Refer to Camshaft
Installation.
63212
2. Install the timing chain and sprocket. Refer to

63263
3. Install the radiator. Refer to Radiator Replacement

in Engine Cooling.
4. Install the valve lifters. Refer to Valve Lifter
Replacement.
221724
6~384
Engine
Engine Flywheel Replacement
Removal Procedure
1. Remove the automatic transmission, if applicable.
Refer to Transmission Replacement (5. 7 L) in
Automatic Transmission - 4L60-E.
2. Remove the automatic transmission flywheel, if
applicable. Refer to Engine Flywheel Removal.
178458
3. Remove the manual transmission, if applicable.

Refer to Transmission Replacement in Manual
Transmission - MM6.
4. Remove the manual transmission flywheel, if
applicable. Refer to Engine Flywheel Removal.
156166
1. Install the manual transmission flywheel, if
applicable. Refer to Engine Flywheel Installation.
2. Install the manual transmission, if applicable.
Refer to Transmission Replacement in Manual
Transmission - MM6.
156166
Engine
Engine Mechanical - 5.7l.
6-385
3. Install the automatic transmission flywheel, if

applicable. Refer to Engine Flywheel Installation.
4. Install the automatic transmission, if applicable.
Refer to Transmission Replacement (5. 7 L) in
Automatic Transmission - 4L60-E.
178458
Engine Replacement
Removal Procedure
Tools Required
J 39580 Engine Support Table
.. J 36221 Hydraulic Clutch Line Separator
J 39549 Ball Joint/Tie Rod Separator

1. Disconnect the positive battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.
211587

208553
6-386
Engine Mechanical ~. 5.7L
Engine
4. Remove the air intake duct resonator.
5. Recover the refrigerant. Refer to Refrigerant
6. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure in Engine Controls.
Information
208569
8. Remove the oil pan drain plug.

10. Remove the front wheels. Refer to Tire and
11.
12.
13.
14.
15.
16.
309862
17.
Wheel Removal and Installation in Tires and

Wheels.
Drain the engine coolant. Refer to Draining and
Remove the left catalytic converter. Refer
to Oxidation Catalytic Converter Replacement
Remove the right catalytic converter. Refer to
(5.7 L Right) in Engine Exhaust
Drain the transmission fluid, if equipped with a
manual transmission.
Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece in Propeller Shaft.
Remove the torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
Remove the starter motor. Refer to Starter .Motor
Engine
6-387

transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transm.ission.
208264
19. ,Remove the retainer from the range selector

lever cable.
~
I
341079
20. Remove the range selector lever cable from the

cable bracket.
208276
6-388
Engine
disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221.
22. Remove the left side front air deflector. Refer to
Air Deflector Replacement - Front Bumper Fascia
in Bumpers.
23. Remove the stabilizer bar bracket bolts.
24. Remove the stabilizer bar brackets.
43255
25. Remove the. intermediate steering shaft bolt and

shaft from the rack.
220630

(Radio Frequency) ground strap and cruise
control ground lead from the front rail.
(
346034
Engine
6-389
27. Disconnect the wheel speed sensor electrical

connectors.
\
346036
28. Remove the air conciitioning (A/C) compressor

and condenser hose bolt.
365448
30. Remove the front fuel pipe heat shield nuts (1 ).

31. Remove the front fuel pipe heat shield (2).
32. Disconnect the brake lines from the brake
pipe clip.
7c'
173551
6-390
Engine
34. Remove the A/C compressor and condenser hose
282941
36. Remove the inlet and outlet heater hoses,from the

water pump.
36.1. Squeeze the hose clamp together with
pliers.
36.2. Slide the hose clamp away from the water
pump fitting.
36.3. Gently twist and pull the heater hose from
the water pump fitting.
282934
37. Disconnect the fuel line from the fuel rail.

purge valve.
220597
Engine
6-391
39. Remove the cruise control cable from the

throttle lever.
220601
Caution: In order to avoid possible irrjury or

vehicle damage, always replace the accelerator
control cable with a NEW cable whenever you
remove the engine from the vehicle.
In order to avoid cruise control cable damage,
position the cable out of the way while you remove
or install the engine. Do not pry or lean against
the cruise control cable and do not kink the cable.
You must replace a damaged cable.
40. Remove the accelerator control cable from the
throttle lever.
41. Unsnap and remove the accelerator and cruise
control cable from the throttle body bracket.
220602
42. Remove the cruise control and accelerator control

cables from the servo adjuster, if equipped.
6-392
Engine Mechanical- 5.7l
Engine
221676
44. Remove the inlet hose from the water inlet.

45. Remove the brake booster vacuum hose.
46. Remove the front two brake lines from the brake
pressure modulator valve.
221671
47. Disconnect the secondary captured locks.

engine harness.
49. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.
(
346047
Engine
6-393
50. Disconnect the powertrain control module (PCM)

connectors.
51. Remove the PCM from the vehicle.
52. Remove the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right in
53. Remove the hinge pillar trim panel. Refer to Trim
346043
54. Disconnect the engine wiring harness from the

346039
55. Remove the engine wire harness through the front

of dash. Place the harness on top of the engine.
56. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
57. Remove the transmission control, if equipped.
Refer to Shift Control Assembly Replacement in
Manual Transmission - MM6.
Information.
346041
6-394
Engine

60. Remove the cotter pins and nuts from the left and
right upper ball joints.
61. Using J39549 separate the upper control arms
from the steering knuckles.
62. Support both steering knuckles.
63. Position the J 39580 below the vehicle.
64. Lower the vehicle until the crossmember is resting
on the J 39580.
65. Lay the engine wire harness on top of the engine.
220629
~
220632
67. Remove the transmission support bolts.

68. Raise the vehicle and remove the engine and
transmission from the vehicle.
69. Secure the crossmember to the J 39580.
208587
Engine
Engine Mechanical .. 5..7l
6395
70. Position a hex-head socketon the belt tensioner

pulley bolt.
the tension on the drive belt.
72. Remove the drive belt from the tensioner and
pulleys.
551461

pulley bolt.
74. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt.
75. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.
551463
76. Disconnect the A/C compressor electrical

connector.
365446
6-396
Engh1e

77. Remove the A/C compressorbolts.
78. Remove the A/C compressor.
282955
79. Remove the power steering pump bolts, (4) and

pump brace (3).
80. Remove the power steering pump (1) from the

bracket (2).
81. Reposition the power steering pump to the
crossmember.
290570
82. Disconnect the generator electrical connector (3).
211624
Engine
6~397
83. Remove the positive cable nut from the generator.

84. Remove the positive cable from the generator.
85. Install a engine hoist the block.
211599
86. Remove the right side engine mount bracket to

blo.ck bolts and bracket.
220586
87. Remove the engine mount heat .shield nuts.

220590
6-398
Engine
89. Remove the left side engine mount bracket to

block studs and bracket.
90. With the aide of an assistant, raise the engine
and transmission from the crossmember.
220591
91. Remove the harness clamp bolt (1).

92. Disconnect the following electrical connectors
from the transmission:
20-way connector (2)
Vehicle speed sensor (3)
93. If equipped with an automatic transmission
perform the following:
481327
94. Remove the left side transmission closeout

and bolt.
(
208478
Engine
6-399
95. Remove the right sidetransmission closeout

and bolt.
208464
96. Remove the flywheel to torque converter bolts.
208580
97. Remove the transmission to engine bolts.

98. Separate the transmission from the engine.
9~.. Attach the. J 21366 to the transmission.
100. If equipped with.a manual transmission, perform
the following:
208590
6-400
Engine
101. Remove the flywheel housing to engine bolts (2).

102. Separate the flywheel housing from the engine.
210528
103. Remove the pressure plate bolts (4).

104. Remove the pressure plate (3) and clutch
dJsc (2) from theflywheel (1 ).
105. Install the engine to a engine stand.
106. Remove the engine hoist.
441863
Tools Required
J 38836 Pilot Bushing Installer/Clutch Alignment Arbor

1. Install a Elrigirie hoist to the block
2. Remove the engine from the engine stand.
3. If equipped with a manual transmission, perform
the following:
4. Install the clutch disc and pressure plate to the
flywheel.
5. Install the pressure plate bolts finger tight.
6. Use the J 38836 to align the clutch disc splines
with the pilot bearing.
(
J 38836
71488
Engine
6-401
Notices.
7. Tighten the clutch pressure plate bolts.
Tighten
Tighten the clutch pressure plate bolts in
sequence (as shown) and evenly over
3 increments with the fourth increment to
70 Nm (52 lb ft).
5
71490
9. Install the flywheel housing to engine bolts (2).
lighten
Tighten the flywheel housing to engine bolts (2) to
50 Nm (37 lb ft).
..
. '
1O. 11 equipped with an automatic transmission

210528
11. Remove the J 21366 from the transmission.

12. Install the transmission to engine bolts.
Tighten
Tighten the transmission to engine bolts to
50 Nm (37 lb ft).
.
208590
6-402
Engine
13. Install the flywheel to torque converter bolts.
Tighten
Tighten the flywheel to torque converter cover
bolts to 60 Nni (44 lb ft).
208580
14. Install the right side transmission closeout

and bolt.
Tighten
Tighten the right side closeout bolt to
12 Nm (106 lb in).
208464
15. lnstal.1 the left side transmission closeout .and bolt.

Tighten
Tighten the left side closeout bolt to
12 Nm (106 lb in).
(
208478
Engine
16. Connect the following electrical connectors to the

transmission:
20-way connector (2)
Vehicle speed sensor (3)
17. Install the harness clamp bolt (1):
6-403
Tighten
Tighten the harness clamp bolt (1) to
2.5 Nm (22 lb in).
18. With the aide of an assistant, lower the engine
and transmission to the crossmember.
481327
19. Install the left side engine mount bracket,

and studs.
Tighten
Tighten the engine mount bracket studs to
50 N-m (37 lb ft).
220591

lighten
10 N-m (89 lb ft).
220590
6-404
Engine
22. Install the right side engine mount bracket

and bolts.
Tighten
Tighten the engine mount bracket boltsto

50 N:m (37 lb ft). .
23. Remove the hoist from the engine.
220586
24. Install the positive. cable to the generator;
25. Install the positive cable nut to the generator,

Tighten
Tighten the positive cable nutto the generator to
22 Nm (16 lb ft).
211599
26. Connect the generator electrical connector (3).
(
211624
,engine
27. Install the power steering pump (1) to the

bracket (2).
28. Install the power steering brace (3) and bolts (4).
Tighten
Tighten the power steering pump bolts (4) to
25 Nm (18 lb ft).
2
290570
29. Install the A/C compressor.

30. Install the A/C compressor bolts.
Tighten
, Tighten the AfC compressor bolts to
50 Nm (37 lb ft).
282955
31. Connect the A/C compressor electrical connector.
365446
6-406
Engine
32. Route the A/C belt over the crankshaft balancer.

33. Rotate the A/C drive belt tensioner clockwise to
34. Install the drive belt between the idler and over
the tensioner (1) and onto. the compressor
pulley.
.
.
551463
35. Route the drive belt around the pulleys.

36. Position the hex-head socket on the belt tensioner
pulley bolt.
37. Rotate the drive belt te.nsio.n~r clockwise to relieve
tension.
38. Install the drive belt around the tensioners.
39. Remove the strap from the crossmember to
the J 39580.
40. Lower the vehicle and install the engine and
transmission to the vehicle.
551461
41. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to
90 N-m (66 lb ft}.
'
(
208587
Engine
42. Install the front crossmember bolts. ,

Tighten
Tighten the four upper crossmember bolts to
125 N-m (92lb ft).
Tighten t.he two lower crossmember bolts to
145 N-m (107 lb ft).
43. Raise and suitably support the ve.hicle. Refer to
Information.
44. Remove the J 39580 from below the vehicle.
45. Remove the support from both steering knuckles.
46. Install the upper control arm ball studs to the
steering knuckles.
47. Install the nuts to the left and right upper ball
joints.
Tighten
Tighten the upper control arm nuts to
53 N,m (39 lb ft).
48. Install cotter pins to the upper control arm nuts.
6-407
i
220632
mounting bolts.
Tighten
Tighten the shock absorber bolts to
65 N,m (48 lb ft).
51. Install the transmission control, if equipped. Refer
to Shift Control Assembly Replacement in Manual
Transmission - MM6.
52. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
220629
53. Install the engine wire harness through the front

ofdash.
346041
6-408
Engine
54. Connect the engine wiring harness to the 1/P

wiring harness.
55. Install the hinge pillar trim panel. Refer to Trim
56. Install the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right
in lnstrumentPanel, Gauges and Console.
57. Install the PCM to the vehicle.
346039
58. Connect the PCM connectors to the PCM.

Tighten
Tighten the PCM connector bolts to
8 N-m (71 lb in).
346043
59. Connect the engine harness vacuum tube to the

bottom of the vacuum check valve.
harness.
61. Connect the secondary captured locks.
62. Install the front two brake pipes to the brake
pressure modulator valve.
63. Install the brake booster vacuum hose.
(
346047
Engine
Engine Mechanical~ s~7l
5..409
64. Install the inlet hose to the water inlet.
221671
221676
66. Install the cruise control and accelerator control

cables to the servo adjuster, if equipped.
296567
6-410
Engine
Caution: In order to avoirJ possible injury or

vehicle damage, always replace the accelerator
control cable with a NEW cable whenever you
remove the engine from the vehicle.
In order to avoid cruise control cable damage,
position the cable out of the way while you remove
or install the engine. Do not pry or lean against
the cruise control cable and do not kink the cable.
You must replace a damaged cable.
67. Install the accelerator control cable to the throttle

body bracket.
68. Install a NEW accelerator control cable to the
throttle lever.
220602
69. Install the cruise control cable to the throttle lever;
220601
70. Connect the fuel line.Jo the fuel rail.

71. Connect the vapor line to the fuel vapor
purge valve.
220597
Engine
5..;411
72. Install the inlet and outlet heater hoses to the

water pump.
282934

Tighten
Information.
282941
76. Connect the brake lines to the brake pipe clip.

77. Install the front fuel pipe heat shield (2).
78. Install the front fuel pipe heat shield nuts (1 ).
Tighten
Tighten the front fuel pipe heat shield nuts (1) to
5 N-m (44 lb in).
7c!)
173551
6-412
Engine Mechanical-. 5.7L
Engine
79. Install a new o~ring ..
nut at the condenser.
Tighten
nut at the condenser to 16 Nm (12 lb ft).
365450

82. Install the A/C compressor and.condenser
hose bolt.
Tighten
365448
83. Connect the wheel speed sensor electric.al

connectors.
\
(
346036
Engine
6-413
84. Install the RF ground strap and cruise control

)
ground lead from the front rail.

85. Install the wiring harness ground bolt.
Tighten
12 Nm (106 lb in).
346034
86. Install the intermediate steering shaft and shaft

bolt to the rack.
Tighten
Tighten the intermediate steering shaft bolt to
47 Nm (35 lb ft).
87. Install the stabilizer bar brackets.
88. Install the stabilizer bar bracket bolts.
Tighten
Tighten the stabilizer bar bracket bolts to
55 Nm (41 lb ft).
89. Install the left side front air deflector. Refer to Air
Deflector Replacement - Front Bumper Fascia in
Bumpers.
220630

connect the clutch actuator cylinder line to the
actuator cylinder.
43255
6-414
Engine
transmission, install the range selector lever cable
to the cable bracket.
208276
92. Install the retainer to the range selector

lever cable .
~
I
341079
93. Snap the transmission range selector lever cable

to the range selector lever at the transmission.
95. Install the torque arm. Refer to Torque Arm
96. Install the propeller shaft. Refer to. Propeller Shaft
Replacement - One Piece in Propeller Shaft.
97. Install the right side catalytic converter. Refer to
(5. 7 L Right) in Engine Exhaust.
98. Install the left side catalytic converter. Refer to
99. Install the front wheels. Refer to Tire and Wheel
Removal and Installation in Tires and Wheels.
208264
Engine
6-415
101. Install the air intake duct resonator.
208569

103. Connect the MAF sensor. electrical connector.
208553
104.
105.
106.
107.
Connect the positive battery cable.

Refill the engine oil.
Refill the transmission fluid.
Recharge the refrigerant. Refer to Refrigerant
108. Bleed the brakes. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding) or
Hydraulic Brake System Bleeding (Pressure
Bleeding) in Hydraulic Brakes.
109. Bleed the clutch hydraulic system. Refer to
Clutch Pedal Replacement in Clutch.
110. Perform the crankshaft position (CKP)
Controls - 5.7 L.
211587
6-416
Engine
Engine Oil and Oil Filter Change

Removal Procedure
1. Open the hood.
2. Remove the oil fill cap.
information.
4. Remove the oil pan drain plug.
6. Wipe the excess oil from the drain plug hole
and plug.
309862
7. Remove the oil filter from the engine block.;
Important: Check the old oil filter to ensure that the

filter seal is not left on the engine block.
8. Wipe the excess oil from the oil filter mounting.
178469
Notices.
1. Install the oil filter to the engine block.
and
Tighten
Tighten the oil filter to 30 N-m (22 lb ft).
178469
Engine
6-417
2. Install the drain plug to the oil pan.
3.
4.
5.
6.
7.
Tighten
Tighten the drain plug to 25 N-m (18 lb ft).
Lower the vehicle.
Fill the engine with oil.
Remove the oil level indicator in order to check
the oil level.
Reinstall the oil level indicator.
Close the hood.
309862

Tools Required
J 41712 Oil Pressure Sensor Socket
Important: In order to completely drain the oil from
the oil pan internal baffling, the bottom of the oil
pan must be level during the oil drain procedure.
1. Remove the oil pan drain plug and allow the oil
to drain.
309862
2. Remove the engine oil filter.
178469
6-:418
En gme
Mechanical - 5.7L
3. Remove the right
Engine
plug and allow th:~~~~~1itnedblo_ck coolant drain
o rain.
63164
4. Remo~e the left front e .

plug (1f applicable) and :11ine
coolant
ow block
the coolant
to drain
drain.
63165
5. Re~ove the engine blo

applicable) and allo thck coolant heater (if
w e coolant to drain.
(
65332
Engine
6-419
6. Use the J 41712 or equivalent in order to remove

the oil pressure sensor (if required).
J 41712
178483
Crankshaft Balancer Removal
\
)
Tools Required
J 41816 Cranksl')aft Balancer Remover
J 41816-2 Crankshaft End Protector
J 42386:A Flywheel Holding Tool
Notice: Refer to. Fastener Notice in Cautions. and
Notices:
Important:
Do not reuse the crankshaft balancer bolt. Install
a NEW, crankshaft balancer bolt during final
assembly.
Make sure that the teeth of the flywheel holding
tool mesh with the teeth of the engine flywheel.
1. Install the J 42386-A and bolts.
Use one M10-1.5 x 120 mm and one M10-1.5 x
45 mm bolt for proper tool operation.
Tighten
Tighten the J 42386-A bolts to 50 N-m (37 lb ft).
J42386-A
260126
2. Remove the crankshaft balancer bolt.

Do not discard the crankshaft balancer bolt The
balancer bolt will be used during the balancer
installation procedure.
)
260154
6-420
Engine
3, Use the J 41816 and the J 41816-2 in order to
remove the crankshaft balancer.
4. Remove the J 42386-A and bolts.
J 41816
J41816-2
156164
Engine Flywheel Removal

Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the. engine flywheel
bolts. This procedure requires a three stage tightening
process.
1. Remove the engine flywheel bolts.
2. Remove the automatic transmission engine
flywheel (if applicable).
178458
3. Remove the manual transmission engine flywheel

(if applicable).
156166
Engine
Clutch Pilot Bearing Removal
Tools Required
J 43276 Clutch Pilot Bearing Remover
Notice: When using the J 43276 Clutch Pilot Bearing
Remover always secure the J 43276-1. Clutch Pilot
Bearing Remover tool body using a wrench. Do
not allow the J 43276-1 Clutch Pilot Bearing Remover
tool body to rotate. Failing to do so will cause
damage to the J 43276-1 Clutch Pilot Bearing
Remover tool body.
1. Remove the clutch pilot bearing using
the J 43276.
1.1. Install the J43276-1 into the clutch
pilot bearing.
1.2. Using a wrench, secure the J43276-1.
1.3. Insert the J43276-2 into the J43276-1.
1.4. Rotate the J43276-2 clockwise into
the J43276-1 until the clutch pilot bearing is
completely removed from the crankshaft.
1.5. Rotate the J43276-2 counterclockwise to
remove the J4.3276-2 from the J43276~ 1.
1.6. Remove the J43276-1 from the tool body.
2. Discard the pilot bearing.
J 43276
353275
63195
6-422
Engine
Oil Level Indicator and Tube Removal

1. Remove the oil level indicator from the tube.
2. Remove the oil. level indicator tube bolt from the
cylinder head.
3. Remove the oil level indicator tube from the .
engine b.lock.
Important: Inspect the 0-ring seal for cuts or damage.

The 0-ring seal may be reused if not cut or damaged.
4. Remove the 0-ring seal from the tube (if
required).
178459
Exhaust Manifold Removal (Left Side)

1. Loosen the Air Injection Reaction (AIR) hose
clamps and remove the hose assembly.
346024
Important: Do not remove the check valve from the

AIR pipe unless service is required.
2. Remove the AIR pipe (with check valve), bolts
and gasket from the left exhaust manifold.
spark plugs.
Do not remove the spark plug wires from the
ignition coils unless required.
(
346026
Engine
6-423
Important: Do not remove the oxygen sensor from

the manifold unless service is required.
4. Remove the oxygen sensor from the manifold (if
required).
346021
5. Remove the exhaust manifold, bolts and gasket.

492589
7. Remove the heat shield (2) and bolts (3)from the

manifold (1) (if required).
492586
6-424
Engine
Exhaust Manifold Removal (Right Side)
Important: Do not remove the Exhaust Gas
Recirculation (EGR) valve from the pipe assembly
unless service is required.
1. Remove the EGR valve, gasket, and bolts.
178487
2. Remove the EGR valve pipe bolt. (1) from the

intake manifold.
492575
3. Remove the EGR valv13 pipe bolts (1) .and gasket

from the exhaust manifold.
492580
Engine
6-425
4: Remove the EGR valve pipe bolts from the

cylinder head.
5. Remove the EGR valve pipe assembly.
With mild force, pull the EGR valve pipe from the
intake manifold.
6. Remove the 0-ring seal from the EGR valve pipe
assembly.
7. Discard the exhaust manifold gasket and
0-ring seal.
178489
Important: Do not remove the check valve from the

Air Injection Reaction (AIR) pipe unless service is
required.
8. Remove the AIR pipe (with check valve), bolts,

and gasket from the right exhaust manifold.
spark plugs.
Do not remove the spark plug wires from the
ignition coils unless required.
346029
Important: Do not remove the oxygen sensor from

the manifold unless service is required.
10. Remove the oxygen sensor from the manifold.

11. Remo.ve .the exhaust manifold, bolts, and gasket.
)
492592
6-426
Engine Mechanical - 5. 7l
Engine
13. Remove the heat shield (2) and bolts (3) from the
manifold (1) (if required).
492583
Water
Pump Removal
1. Remove the water pump bolts.

2. Remove the water pump and gaskets.
3. Discard t~e water purnp gaskets.
309751
Throttle Body Removal

Important: The intake manifold, throttle body, fuel
injection rail, and fuel injectors may be removed as an
assembly. If not servicing the individual components,
remove the manifold as a complete assembly.
1. Remove the electrical wire harness connectors
from the throttle body.
2. Remove the engine coolant air bleed hose
and clamp.
3. Remove the throttle body bolts.
4. Remove the throttle body.
222051
Engine
6-427
5. Remove the throttle body gasket (1 ).

Important: DO NOT reuse the throttle body gasket.
Install a NEW gasket during assembly.
490580
Fuel Rail and Injectors Removal

injection rail and fuel injectors may be removed as an
remove the intake manifold as a complete assembly.
Caution: The fuel rail stop bracket must be

installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel could be
sprayed possibly causing a fire and personal
injury from burns.
1. Remove the fuel rail bolts.
Important: Do not separate the fuel injectors from the
fuel rail unless component service is required.
Use cleanliness and care when handling the fuel
system components.
222050
Do not allow dirt or debris to enter the fuel injectors or

fuel rail components, cap ends as necessary ....
2. Remove the fuel rail (with injectors), lifting evenly
from both sides of the fuel rail until all the injectors
have left their bores.
6-428
Engine
Intake Manifold Removal
injection rail, and fuel injectors may be removed as an
remove the manifold as a complete assembly.
1. Remove the Manifold Absolute Pressure (MAP)
sensor (if required).
58838
2. Disconnect the knock sensor wire harness

connector (1) from the fuel rail stop bracket [2).
490736
3. Remove the Positive Crankcase Ventilation [PCV)

valve pipe from the left rocker cover (if required).
(
379366
Engine
4. Remove the PCV valve pipe strap nut.

5. Remove the PCV valve pipe from the right rocker
cover and intake manifold.
379367

injury from burns.
6. Remove the intake manifold bolts (1) and fuel rail
stop bracket (2).
490927
6-430
Engine
7. Remove the engine coolant air bleed clamp and
hose from the throttle body.
8. Remove the intake manifold.
178557
9. Remove the intake manifold-to-cylinder head

gaskets (1 ).
10. Discard the gaskets.
490579
11. Remove the throttle cable bracket (2) and bolt (1)
from the manifold (if required).
(
490573
Engine
6-431
Vapor Vent Pipe Remc:>Val

1. Disconnect the knock sensor wire harness
retaining clips from the pipe.
2. Remove the engine coolant air bleed pipe bolts
and studs.
3. Remove the pipe and gaskets.
'
363239
4. Remove the gaskets from the pipe.

5. Discard the gaskets.
64262
6. Remove the hose (2) from the pipe (1):
490724
6-432.
Engine
Engine Valley Cover Removal
1. Remove the knock sensor wire harness.
309859
2. Remove the knock sensors.
309864
3. Remove the. valley cover bolts.

4. Remove the valley cover and gasket.
5. Discard the valley cover gasket.
(
65048
Engine
6~433
6. Remove the knock sensor oil seals (1) from the

cover (2).
1~
I
490851
Valve Rocker Arm. Cover Removal

(Left Side)
Important: Do not remove the Positive Crankcase
Ventilation (PCV) valve grommet from the cover unless
service is required.
If the grommet has been removed from the cover, a

NEW grommet must be installed.
1. Remove the ignition coil and bracket assembly
and bolts.
309727

3. Remove the valve rocker arm cover..
6-434
Engine
4. Remove the gasket (1) from the cover.
The bolt grommets may be reused if not damaged.
6. Remove the ignition coils, wire harriess, and bolts

from the bracket (if required).
309850
'
Valve Rocker Arm Cover Removal .

(Right Side)
'
Important: Do not remove the oil fill tube from the

cover unless service is required.
If the oil fill tube has been removed from the cover,
install a NEW tube during assembly.
and bolts.
(
309721
Engine
6-435

3. Remove the valve rocker arm cover:
260084
4. Remove the oil fill .cc;1p from the oiLfiU tube.

5. Remove the.oil fill tube (if required).
6. Discard the oil fill tube.
260110
7. Re.move the gasket (1) from the cover. .

The bolt grommets may be reused if not damaged.
490696
6-436
Engine
9. Remove the ignition coils, wire harness, and bolts
from the bracket (if required).
309850
Valve Rocker Arm and Push Rod Removal

lmportanJ: P,ace valve rocker arms, valve pushrods,
and pivot support, in a rack so that they can be
installed in the same location from which they were
removed.
1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arms.
260140
3. Remove the valve rocker arm pivot support.
260141
Engine
6-437
4. Remove the pushrods.
260142
Cylinder Head Removal (Left Side)

1. Remove the spark plugs from the cylinder head.
Important: The M11 cylinder head bolts are NOT

reuseable. Install NEW M11 cylinder head bolts during
assembly.
2. Remove the cylinder head bolts.
Notice: After remdval, place the cylinder head on

two wood blocks to prevent damage.
3. Remove the cylinder head.
260146
4. Remove the gasket.

6. Discard the M11 cylinder head bolts.
63169
6438
Engine
Cylinder Head Removal (Right Side)
1. Remove the spark plugs from the cylinder head.
Important: The M11 cylinder head bolts are NOT
reuseable. Install NEW M11 cylinder head bolts during
assembly.
2. Remove the cylinder head bolts.
Notice: After removal, place the cylinder head on

two wood blocks to prevent damage.
3. Remove the cylinder head.
260149
4. Remove the gasket.

6. Discard the M11 cylinder head bolts.
63170
Valve lifter Removal

Tools Required
J 3049-A Valve Lifter Remover
1. Remove the valve lifter guide bolts (1 ).
2. Remove the valve lifters and guide.
(
63230
Engine
5;.439
Important: Some valve lifters may be stuck in their

bores because of gum or varnish deposits.
3. Use the J 3049-A or equivalent in order to remove

the valve lifters (if required).
31350
4. Remove the valve lifters from the guide.

5. Organize or mark the components so that they
can be installed in the same location from which
they were removed.
Refer to Separating Parts.
63233
Oil Filter, Adapter and Pan Cover Removal

178469
6~440
Engine
2. Rernove the oil pan cover, bolts, and gasket
178471
4. Remove thE> oil filter fitting {1') and bypass

y~lve (2) (ifrequired).
490699
Oil Pan Removal

Important: The original oil pan gasket is retained and
aligned to the oil pan by rivets. When installing a
new gasket, it is not necessary to install new oil pan
gasket rivets.
DO NOT reuse the oil pan gasket. When installing the
oil pan, install a NEW oil pan gasket.
It is not necessary to remove the oil level sensor prior
to oil pan removal. Remove the oil level sensor if
1. Remove the left closeout cover and bolt.
178477
Engine
6-441
2. Remove the right closeout cover and bolt.
178480
3. Remove the oil level sensor from the oil pan (if
required).
178467
4. Remove the oil pan bolts.

5. Remove the oil pan.
178558
6-442
Engine
Important: DO NOT allow foreign material to enter

the oil passages of the oil pan, cap or cover the
openings as required.
6. Drill (3) out the oil pan retaining rivets (2)

(if required).
7. Discard the gasket and rivets.
384699
8. Remove the oil pan baffle bolts and baffle

(if required).
178491
Engine Front CoverRemoval

1. Remove the front cover bolts.
2. Remove the front cover and gasket.
3. Discard the front cover gasket.
. c;;:,
64278
Engine
Engine Mec.hanical 5.7L
6-443
4. Remove the crankshaft front oil seal (1) from

the cover.
490689
Engine Rear Cover Removal

1. Remove the rear cover bolts.
2. Remove the rear cover and gasket.
3. Discard the rear cover gasket.
64282
4. Remove the crankshaft rear oil ~eal (1) from

the cover.
490692
6-444
Engine Mechanical :- 5.7L
Engine

Removal
1.
2.
3.
4.
Remove the oil pump screen bolt and nuts.

Remove the oil pump screen with 0-ring seal.
Remove the 0-ring seal from the pump screen.
Discard the 0-ring seal.
64268
5. Remove the remaining crankshaft oil

deflector nuts.
6. Remove the crankshaft oil deflector.
64270
7. Remove the oil pump bolts.

Important: Do not allow dirt or debris to enter the oil
pump assembly, cap ends as necessary.
8. Remove the oil pump.
64281
Engine
Engine Mechanical - 5.7L 6445
Timing Chain and Sprockets Removal
Tools Required
" J 8433 Two Jaw Puller
" J 41816-2 Crankshaft Pilot
J 41558 Crankshaft Sprocket Remover
Notice: Do not turn the crankshaft assembly after the
timing chain has been removed in order to prevent
damage to the piston assemblies or the valves.
1. Remove the camshaft sprocket bolts.
2. Remove the camshaft sprocket and timing chain.
63263
3. Use the J 8433, the J 41816,2, and.the J 41558 in

order.to remove the crankshaft sprocket.
J 8433-1
63189
4. Remove the crankshaft sprocket.
156150
6-446
Engine
5. Remove the crankshaft sprocket key (if required).
156149
Camshaft Removal
1. Remove the camshaft sensor bolt and the sensor.
260128
2. Remove the camshaft retainer bolts and ttie

retainer.
(
63211
l:11gine .
6-447

3. Remove the camshaft.

3.1. Install the three M8-1.25 x 100 mm bolts.in
the camshaft front bolt . holes.
3.2. Using the bolts as a handle, carefully rotate
and pull the camshaft out of the
engine block.
3.3. Remove the bolts from the front of the

camshaft.
63212
Piston, Connecting Rod,;,~md Bearing

Removal
Tools Required
J41556 Connecting Rod Guide
.. J 24270 Cylinder Ring Ridge Remover
Important: The connecting rods and the bearing caps

are NOT interchangeable.
1. Use the J 24270 in order to remove the cylinder
bore ring ridge (if required).
bottom of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 or equivalent in order to
remove cylinder ring ridge.
1.4. Turn the crankshaft so the piston is at the
top of the stroke.
1.5. Remove the cloth.
1.6. Remove the cuUing debris from the cylinder
and piston.
J 24270
11497
6,-448
Engine
Important: Using a paint stick or etching tool, place
matchmarks or numbers on the connecting rods and
the connecting rod caps. The connecting rods and
caps MUST be assembled to their original position and
direction.
I
\
A stamping mark on the side of the connecting rod at

the crank journal may effect component geometry.
Mark the top of the piston to the specific cylinder bore.
2. Remove the connecting rod bolts.
Important: Mark, sort, or organize the connecting rod
bearings so they may be installed to their original
position and location.
3. Remove the connecting rod cap.
53223
4. Install the .J 41556 to the connecting rod.
J 41556
63186
5. Use a hammer and tap lightly on the end of the

J 41556 in order to remove the piston and
connecting rod assembly from the cylinder bore.
(
64285
Engine
6-449
6. Upon removal of the piston and connecting rod

assembly, assemble the connecting rod cap and
bolts onto the matching connecting rod.
53223

Tools Required
O J 41818 Crankshaft Bearing Cap Remover
O J6125-18 Slide Hammer
Important: The crankshaft bearing caps are machined
with the engine block for the proper clearances.
Mark or identify each crankshaft bearing cap location
and direction before removal. The crankshaft
bearing caps MUST be installed to their original
position and direction.
Do not reuse the bearing cap MS side bolts.
Remove the bearing cap MS side bolts prior to cap
removal.
1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
55322
3. Remove the crankshaft bearing cap MS side bolts.

4. Remove the bearing cap M10 bolts and studs.
Note the M10 stud locations.
156155
6-450
Engine
Notices,
5. Install the J 41818.
Tighten
Tighten the J 41818 bolts to 11 N-m (100 lb in).
6. Install the J 6125-18 to the J 41818 in order to
remove the crankshaft bearing caps.
63188
7. Remove the bearing caps.
156152
8. Remove the crankshaft.
(
156151
Engine
6-451
Important: Use. care. when handling the crankshaft.

Avoid damage to the crankshaft position sensor
reluctor ring teeth. Nicks, burrs or other damage to the
teeth may effect On-Board Diagnostics (OBD) II
system performance.
9. Lay the crankshaft onto two wooden V-blocks or
other protective surface.
156153
10. Remove the crankshaft bearings from .the bearing

caps and the engine block.
11. Mark, sort, or organize the crankshaft bearings so
they may be installed to their original position and
location. Refer to Separating Parts.
64293
Engine Block P,lug Removal

Tools Required
J 41712
Important: Do not remove the engine block front oil

gallery plug unless service is required.
If the front oil gallery plug is removed for service, a
NEW oil gallery plug must be installed.
1. Remove the oil pressure sensor (if not previously
removed) using the J 41712 or equivalent.
178483
6-452
Engine
2. Remove the engine block right rear coolant plug.
63164
3. Remove the engine block coolant heater (if

applicable).
65332
4. Remove the engine block left front coolant plug (if

applicable).
53165
Engine
5;.453
5. Remove the engine block left front oil gallery plug.
63167:
6. Remove the engine block left rear oil gallery plug.

7. Inspect the block plug sealing washers.
If the block plug and heater sealing washers are
not damaged, they may be used during assembly.
64923
6-454
Engine
Engine Mechanical - 5. 7L
8. Remove the engine block rear.oil gallery plug.

9. Inspect the 0-ring seal of the rear oil gallery plug.
If the 0-ring seal is not cut or damaged, the plug
and 0-ring seal may be use during assembly.
63228
.--------------------,
Important: Remove the front oil gallery plug only if

If the front oil gallery plug is removed, a NEW oil

gallery plug must be installed.
10. Remove the engine block front oil gallery plug.
64295
Engine

Tools Required
J 8087 Cylinder Bore Checking Gauge
1. Clean the following areas:
Notice: Do not use a caustic solution to clean the
aluminum engine block.
J 8087
Important: When cleaning an engine block in a

thermal type oven, do not exceed 232C (450F).
The engine block in the solvent, remove all
sludge, dirt, or debris.

Refer to Cleanliness and Care.

damage.
Dry the block with compressed air.
The gasket surfaces
Refer to Replacing Engine Gaskets.
The coolant passages
The oil galleries
The main bearing caps
The engine block cylinder head bolt holes for
threadlocking material
Thread repair driver tool J 42385-107 may be
used to clean the threads of old threadlocking
material.
2. Inspect the following areas:
The cylinder walls for excessive scratches,
gouging, or ring ridge
The coolant jacket for cracks
The valve lifter bores for excessive scoring
or wear
The crankshaft bearing webs for cracks
The gasket sealing surfaces for excessive
scratches or gouging
The oil galleries for restrictions
All threaded bolt holes for damage
3. Measure the following areas:
The cylinder bores for taper
The cylinder bores for excessive ring ridge at
the top of the cylinder
Measuring Cylinder Taper

1. Adjust the micrometer to 96.0 mm (3.78 in).
4974
6-456
Engine
2. Insert the bore gauge into the micrometer and
zero the bore gauge dial.
3. Use a bore gauge and measure the cylinder bore
for taper.
Slide the bore gauge up and down throughout the
length of the cylinc::ler bore. Check the bore
both parallel and perpendicular to th.e centerline of
the crankshaft.
Recoridition cylinders with less than _0.018 mm
(0.0007 in) wear or taper with a hone.
Cylinders with more than 0.018 mm (0.0007 in)
wear or taper must be fitted with an oversize
piston.
4972
Cylinder Boring and Honi_ng

Boring Procedure
1. A 0.25 mm (0.01 in) oversize s~rvice piston and
piston ring set are av_ailable for the LS1 engine.
Important: Do not bore the cylinder liners on the

LS1 engine.
2. It is recommended to hone the cylinder to achieve
proper fit for the oversize piston.
Refer to the Cylinder Honing information for the
proper honing procedure.
Honing Procedure
186747
1. When honing the cylinders, follow the

manufacturer's recommendations for equipment
use, cleaning, and lubrication. Use only clean,
sharp stones of the proper grade for the amount
of material you remove. Dull, dirty stones cut
unevenly and generate excessive heat. Do
not hone to final clearance with a coarse or
medium-grade stone. Leave sufficient metal so
that all stone marks. may be removed with
fine-grade stones. Perform final honing with a
fine-grade stone, honing the cylinder to the proper
clearance.
2. During the honing operation, thoroughly clean the
cylinder bore. Repeatedly check the cylinder bore
tor fit with. the selected piston.
All measurements of the piston or the cylinder
bore should be made with the components
at normal room temperature.
3. When honing a cylinder for fit to an oversize
piston, first perform the preliminary honing
with a 100 grit stone.
4. Perform final cylinder honing with a 240 grit stone
and obtain a 45 degree cross hatch pattern.
A 240 grit stone is preferred for final honing. If a
240 grit stone is not available, a 220 grit stone
may be used as a substitute.
Engine
6-457
5. When honing to eliminate taper in the cylinder,

make full strokes the complete length of the bore.
Repeatedly check the measurement at the.
top, the middle, and the bottom of the bore.
6. The finish marks should be clean but not sharp.
The finish marks should also be free from
imbedded particles and torn or folded metal.
7. By measuring the selected piston at the sizing
point and by adding the average of the clearance
specification, you can determine the final
cylinder honing dimension required.
8. When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
9. After final honing and before the piston is checked
for fit, clean the cylinder bores with hot water and
detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to
remain in the cylinder bores. This abrasive
material may cause premature wear of the new
piston rings and the cylinder bores. Abrasive
material will also contaminate the engine oil and
may cause premature wear of the bearings.
After washing the cylinder bore, dry the bore with
a clean rag.
1o. Perform final measurements of the piston and the
cylinder bore.
11 . Permanently mark the top of the piston for the
specific cylinder to which it has been fitted.
12. Apply clean engine oil to each cylinder bore in
order to prevent rusting.
Deglazing Procedure
Using a ball type or self centering honing tool, deglaze
the cylinder bore lightly. Deglazing should be done
only to remove any deposits that may have formed.
Use a 240 grit stone of silicone carbide or equivalent
material when preforming the deglazing procedure.
A 240 grit stone is preferred for final honing. If a
240 grit stone is not available, a 220 grit stone may be
used as a substitute.
490757
6-458
Engine
Inspect
Cleaning Procedure
lmportant:.Use care when handling the crankshaft.

Avoid damage to the bearing surfaces or the lobes of
the crankshaft position reluctor ring. Damage to the
teeth of the crankshaft position reluctor ring may effect
On-Board Diagnostics (OBD) II system performance.
1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for
restrictions or burrs.

damage.
3. Dry the crankshaft with compressed air.
156153
Inspection Procedure:
Tools Required
J 7872 Magnetic Base Dial Indicator Set
Important: The .reluctor ring teeth should not have
imperfections on the rising or falling edges.
Imperfections of the reluctor ring teeth may effect
OBD II system performance.
1. Perform a visual inspection of the crankshaft for
damage.
2. Inspect the crankshaft position reluctor ring lobes
for damage.
156153
3. Inspect the crankshaft journals for wear(1).

Journals should b.e smooth with no signs of
scoring, wear, or damage. ;
4. Inspect the crankshaft journals for grooves or
scoring (2).
5. Inspect the crankshaft journals for scratches or
wear (3).
6. Inspect the crankshaft journals for pitting or
imbedded bearing material (4).
(
156170
Engine
6-459
7. Inspect the crankshaft key (1), keyway (2), and

threaded hole (3) for damage.
188090
8. Measure the crankpins for the out-of-round.

9. Measure the crankpins for taper.
35207
10. Measure the crankshaft thrust wall width.

A crankshaft with a thrust wall width in excess of
26.2 mm (1.0315 in) must be replaced.
26.14 - 26.2mm
(1.029 - 1.0315)
490749
6-460
Engine
11. Measure the crankshaft runout..

Use wooden V blocks or a fixture to support the
crankshaft on the front and rear journals.
12. Use the J 7872 in order to measure the crankshaft
runout at the front and rear intermediate journals.
13. Use the J 7872 in order to measure the runout of
the crankshaft rear flange.
14. Use the J 7872 in order to measure the runout of
the crankshaft position reluctor ring. Reluctor ring
runout should be measured 1.0 mm (0.04 in)
below the ring teeth.
If the reluctor ring has runout in excess of
0.25 mm (0.01 in), replace the crankshaft.
J7872
35210
Important: A loose or damaged,crankshaftoiJgallery,

plug must be replaced.

15. Inspect the rear crankshaft oil gallery plug for a

loose fit or leaking.
63238
Engine
6-461
16. Inspect crankshaft bearings for craters or pockets.

Flattened sections on the bearing halves also
indicate fatigue.
52051
17. Inspect the crankshaft bearings for excessive

scoring or discoloration.
18. Inspect the crankshaft bearings fordirt or de.bris

imbedded into the bearing material.
52053
19. Inspect the crankshaft bearings for improper

seating indicated by bright, polished sections of
the bearing.
If the lower half of the bearing is worn or
damaged, both upper and lower halves should be
replaced.
Generally, if the lower half is suitable for use, the
upper half should also be suitable for use.
52056
6.;462
Engine
Measuring Main Bearing Clearance
Tools Required
J 41818 Crankshaft Bearing Cap Remover
Important: The crankshaft main bearings are a

precision insert type. Main bearing caps are machined
with the engine block for proper clearance and
cannot be shimmed or filed for bearing fit. If the
clearances are found to be excessive, new bearings
and/or engine block and cap repair or replacement
may be required.
Do not rotate the crankshaft while gauging plastic is

between the crankshaft journal and the bearing
surface.
156155
The crankshaft bearing clearances are critical.

Excessive bearing clearance may effect crankshaft
position sensor signals and may effect On-Board
Diagnostics (OBD) II system operation.
Important: Remove the bearing cap .side bolts prior to
cap removal.
1. Remove the bearing cap M8 side bolts.
2. Remove the bearing cap M10 bolts and studs.
156152
Engine
Notice: Refer to Fastener Notice in Cautions and.
Notices.
3. Install the J 41818 to the bearing cap.

Tighten
Tighten the J 41818 bolts to 11 N-m (tOO lb in).
4. Install the J 6125-18 to the J4181S in order to
remove the bearing cap.
J 41818
63188
5. Remove,the bearing cap and lower bearing.
64293
6. Install gauging plastic onto the crankshaft journal.

Install the gauging plastic the full width of
crankshaft bearing journal.
4980
6-464
Engine
7. Install the bearing, bearing cap, bolts and studs.
Tighten
7.1. Tighten the inner bolts (1-10) a first pass in
sequence to 20 N-m (15 lb ft).
7.2. Tighten the inner bolts (1-10) a final
pass.in sequence to 80 degrees using
the J 36660-A.
7.3. Tighten the outer studs (11-20) a first pass
in sequence to 20 Nm (15 lb ft).
7.4. Tighten the outer studs (11-20) a final
19
pass in sequence to 53 degrees using

the J 36660-A.
7.5. Tighten the side cap bolts to
25 N-m (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.
10
20
63214
Important: Remove the bearing cap side bolts prior to

cap removal.
8. Remove the bearing cap M8 side bolts.
156155
9. Remove the bearing cap bolts and studs.
(
156152
Engine
6-465
10. Use the J 41818 and the J 6125-18 in order to

remove the bearing cap.
63188
11. Measure the,gcJ.uging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
If the gaugirig plastic shows irregularity in the
journal exceeding 0.025 mm (0.001 in),
remove the crankshaft and measure the journal
with a micrometer.
If the bearing clearance is greater than
0.054 mm (0.00212 in), select and install an
undersized bearing set, and measure the
clearance with gauging plastic.
If clearance cannot be brought to
specifications, replace the crankshaft or grind
the crankshaft for use with tt1e next
undersized bearing.
4981
12. Measure the crankshaftend play.

12. i. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft and
measure t.he bearing clearance.
The proper crankshaft end play clearance is
0.04-0.2 mm (0.0015-0.0078 in):
12.3. If the bearing clearance is not within
specifications:
0
Inspect the thrust surfaces for nicks,
gouges or raised metal. Minor
imperfections may be removed with a
fine stone.
" Replace the thrust bearings and
measure the end play.
O
It the correct measurements cannot be
obtained, repair the crankshaft thrust
surfaces or replace the crankshaft.
64316
6"'.466
Engine
Measuring Connecting Rod Bearing Clearance

Tools Required
Important: Connecting rod bearings are a precision

insert type. Connecting rods are of a powdered
metal design and cannot be shimmed or filed for
bearing fit. If clearances are found to be excessive, a
new bearing and/or connecting rod are required.
Do not rotate the crankshaft while gauging plastic is
between the crankshaft journal and the bearing
surface.
1. Remove the bearing cap, bearing half and bolts.
53223
2. Install the gauging plastic onto .the connecting rod.

bearing journal. Install the gauging plastic the full
width of the journal.
(
4980

Notices.
3. Install the bearing cap, bearing, and bolts.

Tighten
3.1. Tighten the connecting rod bolts first pass
3.2. Tighten the connecting rod bolts final pass
to 60 degrees using the J 36660-A.
4. Remove the bearing cap, bearing, and bolts.
(
53223
Engine
5. Measure the gauging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
.
.
The connecting rod bearing clearance should be
0.015-0.076 mm (0.0006~0.003 in).
4981
C,rankshaft Balancer Clean and Inspect
1. Cleari the crankshaft balancer in solvent.

2. Clean the belt grooves. of all dirt or debris with a
wire brush.
3. Dry the crankshaft balanc~r with compressed air.
4. Inspect.the crankshaft balancer for the following:
Worn, grooved, or damaged hub seal surface
A crankshaft balancer hub seal surface with
excessive scoring, grooves, rust or other
damage must be replaced.
Minor imperfections on the hub seal surface
may be removed with polishing compound
or fine grade emery cloth.
Important: In order for the belt to track properly, the

belt grooves should be free of all dirt or debris.
Dirty or damaged belt grooves
The balancer belt grooves should be free of
any nicks, gouges, or other damage that
may not allow the ,belt. to track properly.
Minor imperfections may be removed with a
fine file.
Worn, chunking or deteriorated'rubber between
the hub and pulley
260155
6.;.468
Engine

1. Clean the flywheel in solvent.
2. Dry the flywheel with compressed air,
3. Inspect the manual transmission flywheel for the
following:
.. Pitted surfaces (1)
"
"
Grooves or scoring (2)

Rusted surface (3)
Damaged ring gear teeth (4)
Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
flywheel and should be positioned completely
against the flange of the flywheel.
Missing, bent, or damaged pressure plate
locating pins
The two locating pins are installed into the
flywheel and spaced 170 degrees apart.
188086
4. Inspect the automatic transmission flywheel .for

the following:
Damaged ring gear teeth
Stress cra:cks around the flywheel-to-crankshaft
bolt hole locations
Important: Do not attempt to repair the welded areas

that retain the ring gear to the flywheel plate. Install
a new flywheel.
Welded areas that retain the ring gear on1o the
flywheel for cracking
178458
Piston and Connecting Rod Disassemble

Tools Required
J 24086-C Piston Pin Remover/Installer
1. Using piston ring pliers, remove the piston rings
from the piston.
(
490763
Engine
6-469
2. Install fork insert J 24086-920 into fixture

J 24086-10 Piston Pin Remover/Installer Base ..
533475
3. 1.nstall the piston and connecting rod assembly

onto J 24086-10.
4. Install the J 24086-107 into the piston pin
and J 24086-88A through the fixture and
into J 24086-107.
J 24086-BSA
533478
Notice: After the installer hub bottoms on the support

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the tool.
5. Press the piston pin from the piston and
connecting rod assembly.
6. The piston and pin are a matched set and are not
to be serviced separately. Mark, sort or organize
the piston and the matching piston pin.
J 24086-88A
533480
5..;470
Engine Mechanical-5. 7(
Engine
Clean and Inspect (Piston and Pin)
lmporta.nt: Replace the pistons and the pins that are
damaged or show signs of excessive wear.
The piston ar;id the pin are a matched set. If service is

required, replace the piston and the pin as an
asse.mbly.
Do notwire brush any part of the piston.
1. Clean the varnish from the piston and the pin with
cleaning solvent.
2. Dry the piston and the pin with compressed air.
64180
3. Clean the piston ring grooves with a suitable ring

groove cleaning tool.
4. Clean the oil lubrication holes and slots.
4977
5: Inspect the piston and the pin for the following:

Cracks in the piston ring lands, the piston skirt,
or the pin bosses
Piston ring grooves for nicks, burrs, or warpage

which may cause the piston ring to bind
MINOR imperfections may be removed from
the piston with a fine. file.
Scuffed or damaged skirts (2)
Eroded areas at the top of the piston (1)
Scoring to the piston pin bore (3) or the
piston pin
(
156168
Engine Mechanical -
Engine
s.7L
6-471
Important: Measurements of components should be

taken with the components at normal room
temperature.
6. Measure the piston ring-to-piston ring groove side
clearance.
6.1. Insert the edge of the piston ring into the
piston ring groove.
6.2. Roll the piston ring completely around the
piston.
If binding is caused by a distorted piston
ring groove, MINOR ring groove
imperfections may be removed with a
fine file.
If binding is caused by a distorted piston
ring, replace the piston ring.
4969
7. Measure the piston ring side clearance with
feeler. gauge.
8. If side clearance is not within specifications, try
another piston ring set.
9. The proper piston ring-to-piston ring groove side
clearance is:
The top. compression ring side clearance is
0.04-0.085 mm (0.00157-0.003346 in).
The second compression ring side clearance is
0.04-0.08 mm (0.00157-0.003149).
The oil control ring side clearance is
0.01-0.22 mm (0.0004-0.00866).
10. If proper piston ring-to-piston ring groove side
clearance cannot be achieved, replace the
piston and pin assembly.
22934
11. To determine piston pin-to-bore clearance, use a

micrometer and measure the piston pin.
4976
6-472 .. Engine Mechanical - 5?L
E11gine
12. To determine piston pin-to-bore clearance, use an
inside micrometer and measure the piston
pin bore.
Important: The piston and pin are a matched.set. If

the clearance is not within specifications, replace
the piston and pin as an assembly.
13. To determine the proper piston pin-to-bore
clearance, subtract the piston pin diameter
from the piston pin bore diameter.
The proper piston pin-to-bore clearance is
0.01-,-0.02 mm (0.0004-0.00078).
4975
14. Measure the piston for out-of-round.

14.1. With the micrometer at a right angle to the
piston, measure the piston at 11 nim
(0.433 in) from the bottom of the skirt.
14.2. Measure the piston at two different points
and compare the readings.
14.3. If the piston is more than 0.018 mm

(0.0007 in) out-of-round, replace the
piston and pin as an assembly.
188016

Clean and Inspect (Connecting Rod and
Bearings)
Important: The powdered metal connecting rod and
cap are machined for the proper clearances. The
connecting rod and the cap must be used as
an assembly with no repair or modifications to either
mating surface.
Do not attempt to repair the connecting rod or the cap
mating surfaces. If service is required, the connecting
rod and the cap must be replaced as an assembly.
1 . Clean the connecting rod and the cap in solvent.
Important: Replace the connecting rod if the bolt

hole threads are damaged. Do not attempt to repair
the bolt hole threads of the connecting rod.
2. Clean the connecting rod threaded bolts holes.
64180
Engine
6-473
Caution: Wear safety glasses ih order to avoid eye

damage.
3. Dry the connecting rod with compressed air.
4. Inspect the connecting rod for the following:
Twisting
Nicks or gouging in the bearing bore
Damage to the bearing locating slots in the
bearing bore
Proper fit of the connecting rod and the cap
mating surfaces
156169
5. Measure the connecting rod bearing bore for

out-of-round.
If the measurement exceeds 0.008 mm
(D.0003 in), replace the connecting rod assembly.
156167
6-474
Engine Mechanical-5.7L
Engine
6. Inspect the connecting rod bearings for craters or
pockets. Flattened sections on the bearing halves
also indipate fatigue.
52051
7. Inspect the connecting rod bearings for excessive

scoring or discoloration.
8. Inspect the connecting rod bearings for dirt or
debris imbedded into the bearing material..
52053
9. Inspect the connecting rod bearings for improper

seating indicated by bright, polished sections of
the bearing.
(
52056
Engine
Engine Mechanical - 5. 7L . 6-475

Clean and Inspect (Measuring Piston Ring
End Gap)
Important: Do not attempt to file the end of the piston
ring for fit in the cylinder bore.
Important: Measure the piston ring in the cylinder in
which the piston ring will be used.
1. Place the piston ring into the cylinder bore.
2. Push the piston ring into the bore 6.5 mm (0.25 in)
below the piston ring travel area.
3. Insert a feeler gauge and measure the piston ring
end gap.
The proper top compression ring end gap is
0.23-0.38 mm (0.009-0.0149 in).
The proper second compression ring end gap
is 0.44-0.64 mm (0.0173-0.0251 in).
The proper oil control ring end gap is
0.18-0.69 mm (0.007-0.0271 in).
4968
Piston Selection
Important: Measurements of all components shou.ld
be taken with the components at normal room
temperature.
For proper piston fit, the engine block cylinder bores
must not have excessive wear or taper.
A used piston and pin set may be reinstalled if, after

cleaning and inspection, they are within specifications.
1. Inspect the engine block cylinder bore for
scoring or other damage.
2. Inspect the piston and the piston pin.
Refer to Piston, Connecting Rod, and Bearings
Clean and Inspect (Piston and Pin).
3. With a micrometer or caliper at a right angle to
the piston, measure the piston 11 mm (0.433 in)
from the bottom of the skirt.
4. Record the piston diameter.
188016
5. Adjust the micrometer to the recorded piston

diameter.
6. Insert the bore gauge into the micrometer and
zero the bore gauge dial.
J 8087
4974
5.;475
Engine
7. Use a bore gauge and measure the cylinder bore
diameter. Measure at a poiht 64 mm (2.5 in) from
the top of the cylinder bore.
8. Record the cylinder bore diameter.
9. Subtract the piston diameter from the cylinder

bore diameter in order to determine piston-to-bore
clearance.
J 8087
The proper piston-to-bore clearance should be

between 0.018-0.054 mm (0.0007-0.00212 in).
10. If the proper clearance cannot be. obtained, select

another piston and measure for the clearances.
If the proper fit cannot be obtained, the cylinder
bore may require honing for an oversize piston or
block replacement.
i 1 . When the piston-to-cylinder bore clearance is

within specifications, permanently mark the top
of the piston for installation to the proper cylinder.
4972
Piston and Connecting Rod Assemble

Tools Required
J 24086-C Piston Pin Remover/Installer Set
Important: Assemble the piston for the specific
cylinder with the connecting rod for the corresponding
crankshaft journal.
The piston and connecting rod MUST be assembled
properly.
1. Install fork insert J 24086-920 into

fixture J 24086-10.
J 24086-10
533475
Caution: A void contact with HOT components.

Wear safety glasses and protective gloves to
avoid personal injury.
Notice: Applying excessive l1eat. to the connecting rod

may damage or distort the rod. Rod temperature
SHOULD NOT exceed 315C (600F). At this
temperature the end of the connecting rod will turn a
straw color upon visual inspection.
2. Use a torch and apply MILD heat to the pin end
of the connecting rod.
Mild heating of the connecting rod will ease in
piston and pin assembly.
3. With the piston and connecting rod properly
assembled, both the flat flange area of the
connecting rod and the alignment mark on the top
of the piston will be facing the front of the
engine.
63227
Engine
6-477
4. Assemble the piston, connecting rod and adapter

J 24086-16A and install onto fixture J 24086-10.
J 24086-16A
533488
5. Adjust installation pin J 24086-9 to 1-8.
J 24086-9
533486
Notice: After the installer hub bottoms on the support

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the tool.
6. Insert pin J 24086-9 through fixture J 24086~10

and to the piston pin.
7. Press pin J 24086~9 until the installer bottoms on
fixture J 24086-10.
533483
6-478
Engine
8. Measure the piston (1), pin (3), and connecting

rod (2) for proper assembly.
8.1. Place the piston and connecting rod
assembly onto a table or other flat
surface.
Lay the flat top of the piston (1) onto the
table surface.
8.2. Slide the connecting rod (2) and pin (3) to
one side and hold firmly against the inside
of the piston (1 ).
8.3. Measure the pin (3) for proper installation.
A properly installed piston pin should
protrude 1.27 mm (0.05 in) from the side of
the piston.
63156
Important: When installing the piston rings onto the

piston, use a ring expanding plier type tool. Do not roll
the piston rings into the grooves of the piston.
Use caution and care to expand the piston rings only
slightly larger than the Outside Diameter (OD) of
the piston.
490763
9. Using piston ring pliers, install the piston rings

onto the piston.
9.1. Install the oil control ring spacer in the
groove.
9.2. Install the lower oil. control ring.
The oil control rings do not have a dimple
or orientation mark and may be installedin either direction.
9.3: Install the upper oil control ring ...
9.4. Stagger the three oil control ring endgaps
a minimum of 90 degrees.
9.5. Using piston ring pliers, install the lower
compression ring.
The lower compression ring has a dimple or
orientation mark and must face the top of
the piston.
9.6. Using piston ring pliers, install the upper
compression ring.
The upper compression ring does not have
a dimple or orientation mark and may be
installed in either direction.
9.7. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).
Engine
6-479
Camshaft Bearing Removal

. Tools Required
) J 33049 Camshaft Bearing Remover/Installer
Important: A loose camshaft bearing may be caused
by an enlarged, out .of round or. damaged engine
block bearing bore.

.1. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine. block
bearing bores.
Refer to Camshaft and Bearings Clean and
Inspect.
2. Repair or replaGe the components as required.
63163
3. Select the expanding driver (4-8) and

washer (2 or 3) from the tool usage information.
4. Assemble the tool.
15~
~1
10
66100
5. Insert the tool through the front of the engine

block and into the bearing.
6. Tighten the expander assembly (15) nut .until snug.
7. Push the guide cone (1) into the frontcamshaft
bearing to align the tool.
8. Drive the bearing from the block bore.
Important: To remove the front camshaft bearing,

operate the tool from the rear of the block using the
guide cone (1) in the rear camshaft bearing bore.
9. Repeat the above procedures to remove
the remaining bearings.
)
63219
6-480
Engine
Tool Usage Information
15~
t14
; \ _,.,.--1
tJ--13
~12
f!!: 2
@)-'"
00-11 4~3
rm~
@;OJ
~
10
@ID
8
@00
66100
Bearing, Expander, and Expander Driver

Information
Th.e tool consists of a guide cone (1), driving
washers (2 or 3), expander bearing drivers (4-8),
driverbars (9 or 10), expander jaws (11),
expander sleeve (12), expander cone (13),.
expander shaft (14), and expander assembly (15).
Expander bearing driver number one .inside
diameter is 28.575-37.465 mm (1.12S:-1.475 in)
and is used with the expander assembly and
the small washer.
Expander bearing driver number two inside
diameter is 37.465-43.18 mm (1.475-1.7 in) and
is used with number one expanding driver and
the small washer.
Expander bearing driver number three inside
is used with number two expanding driver and
the large washer.
Expander bearing driver number four inside
diameter is 48.895-54.61 mm (1.925-2.15 1n) and
is used with number three expanding driverand
the large washer.
Expander bearing driver number five inside
is used with number four expanding driver and
the large washer.
Expander bearing driver number six inside
diameter is 60.325-68.326 mm (2.375-2.69 in)
and is used with number five expanding driver and
the large washer.
Tool Assembly and Operation
1. Select the proper expanding driver and washer
from the expanding driver and washer information.
Important: To install or remove the expanding driver,
always push on or pull from the ends.
64183
Pressure on the outside diameter may cause a bind

against the rubber expanding sleeve.
2. Place the expanding driver onto the expander
assembly.
3. Check to insure that the separation lines between
the segments of the expanding driver align with
the separation lines of the expander assembly.
4. Place the guide cone over the driving bar (with
the small end of the cone facing the driver
assembly).
5. Place the driving washer over the .threaded
portion of the expander assembly.
6. Screw the expander assembly (with driving
washer) onto the driving bar.
It may be necessary to install the driver bar
extension for removal of the inner bearings.
Engine
6-481
7. Insert the tool into a inner camshaft bearing and

tighten until snug.
Operate the tool from the front or rear of the
engine block.
On some engine blocks the nut on the expander
assembly is inaccessible except from either
end. In this case you must use a socket and
extension to enlarge and reduce the expander
assembly.
8. Slide the nylon cone into the front or rear camshaft
bearing (this will properly align the tool}.
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner
bearings.
11. For the two end bearings (front and rear), remove
the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.
63219
Camshaft and Bearings Clean and Inspect

Tools Required
J 7872 Magnetic Base Dial Indicator Set
O J 8520 Camshaft Lobe Lift Indicator
1. Clean the components in solvent.
damage.
3. Inspect the camshaft bearing journals (1) for
4. Inspect the camshaft valve lifter lobes (2) for
5. Inspect the threaded bolt holes (3) in the front of
the camshaft for damaged threads or debris.
6. Inspect the camshaft sprocket pin (4) for damage.
7. Inspect the camshaft position reluctor ring for
nicks or damage.
3
188095
6-482
Engine
8. Inspect the camshaft retainer plate for wear or a

damaged sealing gasket.
If the camshaft retainer plate sealing gasket is not
cut or damaged, it may be reused.
(
\
63211
9. Inspect the camshaft bearings for proper fit in the

engine block. The camshaft bearings have an
interference fit to the engine block and should not
be loose in their engine block bearing bores.
10. Inspect the camshaft bearings for excessive wear
or scoring.
Bearings with excessive scoring or wear must be
replaced.
63163
11. Measure the camshaft journals for wear and

out-of-round with a micrometer.
A camshaft with bearing journals that measure
more than 0.025 mm (0.001 in) out-of-round,
must be replaced.
A camshaft with bearing journal diameters that
measure less that 54.99 mm (2.164 in), must
be replaced.
(
35212
Engine
6-483
12. Measure the camshaft lobes for wear with a

micrometer.
A camshaft with an intake lobe that measures
46.67 mm (1.8376 in) or less, must be
replaced.
A camshaft with an exhaust lobe that measures
46.67 mm (1.8376 in) or less, must be
replaced.
260130
13. Measure the camshaft runout.

13;1: Mount the camshaft in wooden V-blocks or
between centers on a fixture.
13.2. Check the runout of the intermediate
camshaft bearing journals using
the J 7872.
13.3. If camshaft runout exceeds 0.05 mm
(0.002 in), the camshaft is bent and
should be replaced.
J7872
64297
6-484
Engine
Measuring Camshaft lobe lift
Important: Measuring camshaft lobe lift is a procedure
used to determine if the camshaft lobes have worn.
This test is to be performed prior to engine
disassembly and with the camshaft and valve train
components installed in the engine.
1. Measure camshaft lobe lift using J 8520.
1.1. Remove the valve rocker arms and bolts
1.2. Install the dial indicator mounting stud
into the valve rocker arm bolt hole.
1.3. Assemble the components of the J 8520
and position onto the stud.
1.4. Position the shaft of the dial indicator onto
the end of the pushrod.
i .5. Rotate the face of the dial indicator to zero.
1.6. Slowly rotate the crankshaft clockwise
64967
until the dial indicator obtains its highest

and lowest readings.
1.7. Compare the total lift shown to
specifications.
The proper lobe lift for the intake lobes
is 7.43 mm (0.292 in).
The proper lobe lift for the exhaust lobes
is 7.43 mm (0.292 in).
1.8. Remove the tool.
2. Compare measurements to specifications.
If the readings are not within specifications,
remove the camshaft. Inspect and/or replace
components as required.
Camshaft Bearing Installation

Tools Required
J 33049 Camshaft Bearing Remover/Installer
Important: A loose camshaft bearing may be caused
by an enlarged, out of round or damaged engine
block bearing bore.
1. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine block
bearing bores.
2. Repair or replace the components as required.
63163
Engine
'3. Select the expanding driver (4-8) and
washer (2 or 3) from the tool usage information.
4. Assemble the tool.
15~
t14
5.;4a5
/;g-1
u-13
~12
00-11 4@y-3
rm 50)
@:o)
@;(.
10
rum
9(00)
66100
')
5. Insert the tool through the front of the engine

block and to. the bearing bore.
6. Install the new bearing onto the tool.
7. Tighten the expander assembly nut until snug.
8. Push the guide cone into the front camshaft
bearing to align the tool.
9. Properly align the oil hole in the bearing with the
oil gallery in the engine block.
10. Drive the bearing into the block bore.
Important: To install the front camshaft bearing,
operate the tool from the rear of the block using the
guide cone in the rear camshaft bearing bore.
11. Repeat the above procedures to install the
remaining bearings.
12. Check the installed bearing for proper alignment
of the oil gallery holes.
J 33049
63219

Inspect
1. Clean the components with cleaning solvent.

damage:
3. Inspect the timing chain for binding or wear.
156158
6-486
Engine
4. Inspect the camshaft and crankshaft sprockets for:
Worn teeth (1)
Damaged teeth (2)
Chipped teeth (3)
Worn valleys between the sprocket teeth
188097
5. Inspect the crankshaft sprocket keyway for wear.

6. Inspect the crankshaft sprocket oil pump drive
splines for wear.
156150
Valve Rocker Arm and Push Rods Clean

and Inspect
Important: Parts. that are to be reused must be
marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
2. Clean the components with cleaning solvent.

damage.
4. Inspect the valve rocker arms bearings (2) for
binding or roughness.
5. Inspect the valve rocker arm pushrod sockets (3)
and valve stem mating surfaces (1 ). These
surfaces should be smooth with no scoring or
exceptional wear.
490772
Engine
6-487
6. Inspect the pushrods for worn or scored ends.

These surfaces should be smooth with no scoring
or exceptional wear.
7. Inspect the pushrods for bends. RoU the pushrod
on a flat surface to determine if the pushrod
is bent.
8. Inspect the pushrod oil passages for restrictions.
260142
9. Inspect the pivot supports for cracks, wear, or

other damage.
260141

Inspect
Important: Components that are to be reused must
be marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
2. Clean the components in cleaning solvent.

damage.
178485
6-488
Engine
4. Inspect the valve lifters for the following:
Bent or broken clip (1)
Worn pushrod socket (2)
" Scllffed or worn sides (3)
If the valve lifter shows wear, inspect the
engine block lifter bores for wear or damage.
Flat spots on the roller (4)
Loose or damaged pin (5)
Plugged oil hole (6)
Worn or damaged roller bearing
The roller should rotate freely with no binding
or roughness.
5. Inspect the valve lifter guides for the following:

For cracks or damage
Excessive wear in the lifter mounting bores
63233
Engine
6-489
Cylinder Head Disassemble

Tools Required
Important: Remove the spark plugs from the cylinder
head with the components at room temperature.
Mark, organize, or sort the cylinder head components
for assembly. Return the components to their
original location during assembly.
Do not remove the cylinder head expansion plugs (8)
or valve seats (9 and 11) unless service is required.
1. Remove the spark plugs from the cylinder heads.
64108
2. Use the J 8062 in order to compress the valve

spring.
260151
6-490
Engine
3.
4.
5.
6.
7.
8.
Remove the valve stem keys (2).

Remove the valve spring cap (3).
Remove the valve spring (4).
Remove the valves (10 and 12).
Remove th.e valve stem oil seal (5).
Remove the valve spring shim (6).
12
64108
9. Remove the cylinder head expansion plugs (1) (if

required).
490662
Engine
6-491
1O. Remove the coolant sensor from the left

cylinder head.
260086
11. Remove the coolant plug from the right

cylinder head.
260157
Cylinder Head Clean and Inspect

Tools Required
J 8089 Carbon Removing Brush
J 9666 Valve Spring Tester
damage.
Important: When cleaning an cylinder head in a
thermal type oven, do not exceed 204C (400F).
1. Clean the following components:
J 8089
Important: Be careful not to scuff the chamber.

Use the J 8089 in order to remove the
carbon from the combustion chambers.
Gasket surfaces
Valve stems and heads on a buffing wheel
Bolt hole threads. Remove all dirt, debris, or
threadlocking material from the bolt holes.
4957
6-492
Engine
2. Inspect the following:

2.1. The cylinder head (1) for cracks in the
exhaust ports and combustion chambers
2.2. The cylinder head for external cracks in the
water chambers
2.3. The gasket surfaces for excessive scratches
or gouging.
2.4. The bolt hole threads for debris or damaged
threads.
Refer to Thread Repair or Thread Repair
Specifications.
3. Inspect the cylinder head for warpage.
64318
Engine
6-493
4. Inspect the valve springs for squareness.
40075
5. Use the J 9666 in order to measure the valve

spring tension.
Replace the spring if the spring tension is less
than 310 N (70 lb) at 45.75 mm (1.80 in).
4960
Valve Guide Reaming/Valve and Seat

Grinding
Valve Guide Reming
Tools Required
J 37378-1 Valve Guide Reamer
Important: Excessive valve stem-to-guide clearance
may cause a noisy valve train, premature valve
stem oil seal wear, component damage, and/or
excessive engine oil consumption.
Insufficient valve stem-to-guide clearance will result in
noisy or sticking valves. Valves that are too tight
may disturb engine smoothness or lead to component
damage.
1. Measure the valve stem-to-guide clearance using
a dial indicator.
Valve stem-to-guide clearance may also be
obtained by using a micrometer to measure the
valve stem diameter and a ball type measuring
gauge to measure the guide bore.
65822
6-494
Engine
2. A valve stem (1) and guide (2) with clearance in

excess of 0.093 mm (0.0037 in) must be repaired
or the components replaced.
156172
3. Inspect the valve stems for excessive scoring,

wear, or warpage.
.. A valve stem that has excessive
scoring (3 or 4) or wear (4 or 6) must be
replaced.
" A valve guide that is worn and has excessive
stem-to-guide clearance should be reamed
and valves with oversize stems installed.
4. Measure the valve stem diameter. A valve stem
with a diameter less than 7.95 mm (0.313 in)
must be replaced. Position the tip of the
dial indicator at the top of the valve guide.
If the va.lve stem diameter is within specifications,
a.nd the stem-to-guide clearance is excessive,
the valve guide must be reamed oversize and a
valve with oversize stem .installed.
5
6
156174
5. Ream the valve guide using the J 37378-1.
6. Clean the guide bore of all metal shavings and

debris.
572270
Engine
7. Install the valve (2) (with oversize stem) into the

cylinder head (1 ).
8. Inspect the valve for proper fit,
Move the valve back and forth in the guide. The
valve should move freely with no resistance
or drag.
572278
Valve and Seat Grinding

Important:
Reconditioning the valve seats is very important.
The seating of the valves must be perfect for
the engine to deliver optimum power and
performance. Several different types of equipment
are available for grinding valve seats.
Another important factor is the cooling of the valve
head. Good contact between the valve and the
,seat will ensure that heat will be properly
dissipated.
" The recommendations of the manufacturer of the
equipment should be followed carefully to obtain
the proper results. Regardless of what type of
equipment is used, it is essential that valve guide
bores be free from carbon or dirt to ensure
proper centering of the tool pilot in the guide.
Valves that are pitted must be refaced to the
proper angle. Valve stems that show excessive
wear, or valves that are warped excessively must
be replaced. When a valve head that is warped
excessively is refaced, a knife edge may be
ground on part or all of the valve head due to the
amount of metal that must be removed. Knife
edges lead to breakage, burning or pre-ignition
due to heat localizing on this knife edge. If
the edge of the valve head is less than 1.25 mm
(0.05 in) after grinding, replace the valve.
Several different types of equipment are available
for refacing valves. The recommendation of the
manufacturer of the equipment should be carefully
followed to obtain the proper results.
DO NOT reface intake valves. Intake valves with
excessive wear or damage MUST be replaced.
5
6
156174
6r496
Engine Mechanical- 5.7l
Engim!
1. Inspect the valve for the following:
Burnt or eroded areas (1)
A worn margin (2)
A bent stem (3)
A worn or scored stem (4)
A worn key groove (5)
A worn stem tip (6)
2. Inspect the valve face for the following:
Worn or no margin (1 or 4)
Pitted surfaces (2)
Burnt or eroded areas (3)
156173
3. Inspect the valve margin.

The exhaust valve may be refaced if the margin is
greater than 1.25 mm (0.05 in) thick before
grinding.
4. Reface pitted exhaust valves on a suitable valve
refacing. machine.
5. Replace the valve if the margin is less than
1.25 mm (0.05 in) thick after grinding.
6. If the valve face has been ground, it may be
necessary to shim the valve spring to obtain
the proper spring insta.lled height. Refer to .
Cylinder Head Assemble.
4955
Engine
Engine Mechani.cal "'. 5.7l
6~497
7. Inspect for a loose valve seat (9 or 11) in the

cylinder head (1 ). The valve seat has an
interference fit to the cylinder head.
8. Clean the valve guide (7) bores with a sui\able
tool. Remove all carbon or dirtfrom th.e bores.
The valve guide must be clean forthe seat
grinding tool to obtain proper results:
9. Grind the valve seat.
The recommendations of the manufacturer of the
equipment should be followed carefully to
obtain the proper results. Regardless of what type
of equipment is used, it is essential that valve
guide bores be free from carbon or dirt to ensure
proper centering of the toolpilot in the guide.
10. Inspect the valve seats.
The valve seats should be concentric to within
0.05 mm (0.0021in) total indicator reading.
If the valve seat has been ground, it may be
necessary to shim the valve spring to attain
the proper spring installed height.
Refer to Cylinder Head Assemble.
64108
Cylinder Head Assemble

Tools. Required
J 42078 Valve Stem Oil Seal Installer
1. Clean the cylinder head valve spring shim area.
Important: When reusing the valves and related

components, install the parts to their original location.
2. Install the valves (1 O and 12) into the proper port.
3. Install the valve spring shim (6).
64108
6-498
Engine
Important: The valve stem oil seal alignment and
position on the valve guide is critical.
An improperly i.nstalled valve stem oil seal may lead to
excessive oil consumption, increased vehicle
emissions, or component damage.
4. Install the .valve stem oil seal (5).onto the

guide (7).

'
4.1. Lubricate the valve guide (7) and valve

stem (5) oil seal with clean engine oil.
4.2. Install the valve stem off seal onto the valve
stem. Push the seal down until the seal
contacts the valve.guide.
4.3. Use. the J 42078 in order to install the valve
stem oil seal.
Push or lightly tap the tool until the tool
bottoms against the valve spring shim (6).
63193
5. Measure the valve stem oil seal for the properly

installed height.
18.1-19.1 mm
(0.712-0.752")
Specification
There should be a 18.1-19.1 mm (0.712-0.752 in)
gap between the top edge of the oil seal body
and the valve spring shim surface.
63158
Eogioe
6.-499
6. Install the valve spring (4).

7. Install the valve spring cap (3).
64108
8. Compress the valve spring (4) using the J 8062.

9. Install the valve stem keys (2).
9.1. Use grease to hold the keys (2) in place
and remove the J 8062.
9.2. Make sure the keys (2) seat properly in the
groove of the valve stem (10 and 12).
9.3. Tap the end to the valve stem (10 and 12)
with a plastic faced hammer to seat the
keys (if necessary).
260151
6-500
Engine
10. Measure the valve spring installed height using

a ruler.
Measure from the base of the valve spring to the
top of the valve spring.
Specification
If the installed height exceeds 46.25 mm
(1.82 in), install a valve spring shim of
approximately 0.5 mm (0.02 in) thick.
Do not shim the valve spring to obtain less
than the specified height.
Do not assemble the components without a
spring shim on the cylinder head.
11. Install the remaining valves (10 and 12),
springs (4) and other components.
64315
12. Install sealant GM P/N 12346004 or equivalent to

the threads of the coolant sensor.

Notices.
13. Install the coolant sensor into the left
cylinder head.
Tighten
Tighten the coolant sensor to 20 Nm (15 lb ft).
260086
14. Install the coolant plug to the right cylinder head.

Tighten
Tighten the coolant plug to 20 N-m (15 lb ft).
260157
Engine
15. Apply threadlock GM P/N 12345382 or equivalent

to the sides of the cylinder head expansion
plugs (1 ).
16. Install the expansion plugs into the cylinder head.
A properly installed plug should be slightly below
flush with the face of the head.
490662
Oil Pump Disassemble

Important: The internal parts of the oil pump assembly
are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.
1. Remove the oil pump cover bolts.
65055
65057
6-502
Engine
lmportant:Mark or identify the gears for assembly.
3. Remove the drive gear.
65058
4. Remove the driven gear.
-65060
5. Remove the pressure relief valve plug.
(
65064
Engine
5..,503
6. Remove the pressure reliefvatve spring.
65068
7. Remove the pressure relief valve.

8. Inspect the oil pump components.
Refer to Oil Pump Clean and Inspect.
65076
Oil Pump Clean and Inspect
important: The internal parts of the oil pump assembly

are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.
The oil pump pipe and screen are to be serviced as
an assembly. Do not attempt to repair the wire
mesh portion of the pump and screen assembly.
1. Clean the parts in solvent.
damage.
2. Dry the parts with compressed air.
3. Inspect the oil pump housing and the cover for
cracks, excessive wear, scoring, or casting
imperfections.
4. Inspect the oil pump housing-to-engine block oil
gallery surface for scratches or gouging.
5. Inspect the oil pump housing for damaged bolt
hole threads.
65060
5.;504
Engine
6. Inspect the relief valve plug and plug bore for

damaged threads.
7. Inspect the oil pump internal oil passages for
restrictions.
65064
8. Inspect the drive gear and driven gear for

chipping, galling or wear.
Minor burrs or imperfections on the gears may be
removed with a fine oil stone.
65060
9. Inspect the drive gear splines for excessive wear.
65058
Engine
Engine Mechanical -5.7l 6-505
10. Inspect the pressure relief valve and bore for

scoring or wear.
The valve must move freely in the bore with no
restrictions.
65076
11. Inspect the oil pump screen for debris or

restrictions.
12; Inspect the oil pump screen for broken or loose
wire mesh.
64268
Oil Pump Assemble<

Important: Prior to assembling the oil pump, coat all
wear or internal surfaces with clean engine oil.
1. Install the driven gear into the pump housing.
Install the driven gear with the orientation mark
facing the pump cover.
65060
6-506
Engine
2. Install the drive gear into the pump housing.
65058
65057

Notices.
4. Install the pump cover bolts.

Tighten
Tighten the oil pump cover bolts to
12 N-m (106 lb in).
65055
Engine
6-507
5. Install the regulator valve.
65076
6. Install a NEW regulator valve spring.
65068
7. Install the pressure relief valve plug.

Tighten
Tighten the pressure relief valve plug to
12 N-m (106 lb in).
8. Inspect the oil pump for smoothness of operation
by rotating the drive gear.
65064
6-508
Engine
Engine Front Cover Clean and Inspect
490689
Important: Do not reuse the crankshaft oil seal. Install

a NEW crankshaft oil seal during assembly.
Do not reuse the front cover-to-engine block gasket.
1. Remove the crankshaft oil seal (1) from the
front cover.
2. Clean the cover in solvent. Remove the sealant
from the cover oil pan surface.
damage.
3. Dry the cover with compressed air.
4. Inspect the gasket sealing surfaces for excessive
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for
damage.
Engine Rear Cover Clean and Inspect
490692
Important: Do not reuse the crankshaft oil seal. Install

a NEW crankshaft oil seal during assembly.
Do not reuse the rear cover-to-engine block gasket.
1. Remove the crankshaft oil seal (1) from the
rear cover.
2. Clean the cover in solvent. Remove the sealant
from the cover oil pan surface.
damage.
3. Dry the cover with compressed air.
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for
damage.
Engine Valley Cover Clean and Inspect

Important: Do not reuse the valley cover knock .
sensor oil seals .. In.stall NEW oil seals during assembly.
Do not reuse the valley cover gasket. Install a NEW
gasket during assembly.
1. Remove the knock sensor oil seals (1) from the
valley cover (2).
2. Clean the valley cover in solvent.
1~
I

damage.
3. Dry the valley cover with compressed air.
5. Inspect the valley cover oil seal bores for
excessive scratches or gouging.
490851
Engine
6-509
Va.Ive Rocker Arm Cover Clean and

Inspect
Important:
" Do not reuse the valve rocker arm cover gasket.
" Remove the ignition coils from the bracket before
cleaning the bracl<et in solvent. Do not submerge
the ignition coils in solvent.
a Do not remove the oil fill tube from the cover
unless service is required.
" If the oil fill tube has been removed from the
rocker arm cover, install a NEW tube during
assembly.
and bolts from the rocker cover (if required).
309727
2. Remove the ignition coils and bolts from the

bracket (if required).
309850
3. lnsp~ct the tube for a loose fit or damage.

4. Remove the oil fill cap and .tube from. the right
cover (if required).
260110
6-5.10
Engine
5. Remove the gaskets (1) from the covers.
6. Remove the cover mounting bolts (with
grommets).
Cover mounting bolts and grommets that are not
damaged may be reused during assembly.
7. Clean the covers and coil brackets in solvent.
490696

damage.
9. Inspect the ventilation system passages for
restrictions.
10. Inspect the gasket grooves for damage.
11. Inspect the coil bracket threaded bolt holes for
damaged threads or debris.
260085
12. Inspect the coil mounting brackets for cracking,

stripped bolt hole threads, or other damage.
13. Inspect the ignition coils for exterior damage and
bent or broken connector pins.
(
309850
Engine
6-511
Oil Pan Clean and Inspect

Important:
Do not reuse the oil pan cover gasket. Install a
NEW cover gasket during assembly.
Do not reuse the oil pan to engine block gasket.
When installing a NEW oil pan gasket, it is not
necessary to install the rivets that retain the
NEW gasket to the pan.
1. Remove the oil level sensor from the pan.
178467
2. Remove the oil pan cover, gasket, and bolts.
178471
3. Remove the oil pan drain plug and 0-ring seal.
178475
6-512
Engine
4. Remove the oil pan baffle bolts and baffle.
178491
5. Drill, out (3) the oil pan gasket retaining rivets (2)
(if required).
6. Remove the gasket (1) from the oil pan.
7. Clean the oil pan in solvent. Be sure to thoroughly
clean all of the oil passages and recesses of
the pan.
8. Clean the oil pan gasket surfaces. Refer to
Replacing Engine Gaskets.

damage.
9. Dry the oil pan with compressed air.
scratches or gouging. Refer to Replacing Engine
Gaskets.
384699
11. Inspect the oil pan oil level sensor seal surface for
damage.
If the 0-ring seal of the sensor is not cut or
damaged, it may be reused.
178467
Engine
6-513
12. Inspect the oil pan drain plug and threaded drain
hole for damaged threads.
The drain plug 0-ring seal may be reused if not
cut or damaged.
178475
13. Inspect the oil filter sealing surface for scratches

or gouging.
14. Inspect the oil passages for restrictions.
178469
15. Inspect the oil filter fitting (1) for a loose fit or
damaged threads.
16. Inspect the oil filter bypass valve (2) for proper
operation.
Lightly push the bypass valve into the bore. The
valve spring should reseat the valve to the
proper position.
490699
6-514
Engine
Intake Manifold Clean and Inspect
Cleaning Procedure
Important: Do not reuse the intake

manifold-to-cylinder head sealing gaskets.
1. Remove the Manifold Absolute Pressure (MAP)
sensor from the rear of the intake (the MAP
sensor is to be reinstalled upon completion of the
cleaning and inspection procedures).
2. Inspect the sealing grommet on the MAP sensor.
The grommet should not be torn or damaged.
58838
3. Remove the throttle body and bolts.
222051
4. Remove the throttle body gasket (1 ).

490580
Engine
. Engine Mechanical - 5.7L
6-515
6. Remove the accelerator control cable bracket (2)

and bolts (1) (if required),
490573
7. Remove the fuel rail with injectors.

Refer to Fuel Rail and Injectors Removal.
222050
8. Remove and discard the intake

manifold-to-cylinder head gaskets (1).
490579
6-516
Engine
9. Clean the intake manifold in solvent.
" Clean the intake manifold gasket grooves:
Clean the intake manifold vacuum passages at
the rear of the intake.

damage.
10. Dry the intake manifold with compressed air.
11. Upon installation of the intake manifold, install
NEW manifold-to-cylinder head gaskets.
178557
Inspection Procedure
1. Inspect the throttle body bolt inserts for looseness
or damaged threads.
222051
2. Inspect the fuel rail bolt inserts for loosen!3ss or
'
damaged .threads.
3. Inspect the intake manifold vacuum passages for
debris or restrictions.
(
222050
Engine
6.;517
Important: The rear Manifold Absolute

Pressure (MAP) sensor housing is retained to the
intake manifold by push-in-place snaplock design.
The rear MAP sensor housing is sealed at the intake
manifold by an 0-ring seal.
4. Inspect the rear MAP sensor housing.

Inspect for damaged or broken vacuum fittings,
damaged MAP sensor mounting bore, or
broken MAP sensor retaining tab.
Inspect the rear MAP sensor housing for
looseness or poor sealing to the intake
manifold. Repair or replace the components as
necessary.
5. Inspect the composite intake manifold assembly
for cracks or damage.
Inspect the areas between the intake runners.
6. Inspect all the gasket sealing surfaces and
grooves for cracking or damage.
58838
7. Inspect the fuel injector bores for excessive

scoring or damage.
8. Inspect the intake manifold cylinder head deck for
warpage.
8.1. Locate a straight edge across the intake
manifold cylinder head deck surface.
8.2. Insert a feeler gauge between the intake
manifold and the straight edge.
A intake manifold with warpage in excess of
0.5 mm (0.02 in), must be replaced.
9. Upon completion of inspection, install the MAP
sensor to the manifold.
222050
Exhaust Manifold Clean and Inspect

Important:
Do not reuse the exhaust manifold-to-cylinder
head gaskets. Upon installation of the exhaust
manifold; install a NEW gasket. A improperly
installed gasket or leaking exhaust system may
effect On-Board Diagnostics (OBD) II system
performance.
Remove the oxygen sensor prior to cleaning the
manifold, do not submerge the oxygen sensor
in cleaning solvent.
1. Remove the oxygen sensor from the manifold.
2. Clean the exhaust manifold (1) and heat shield (2)
in solvent.

damage.
3. Dry the exhaust manifold with compressed air.
492586
5.;51 s
Engine Mechanical - 5.~7L
Engine
4. Inspect the exhaust manifold air injection
reaction (AIR) passages for restrictions.
5. Inspect the AIR flange threaded bolt holes threads
. for damage.
6. Inspect the AIR flange gasket surface for
excessive scratches or gouging.
7. Inspect the exhaust manifold-to-cylinder head
gasket surface for excessive scratches or
gouging.
8. lnsp~ct the. right side manifold exhaust gas .
recirculation (EGA) flange sealing surface for
excessive scratches or gouging:
. .
9. Inspect the right side manifold EGRflange bolt
.
hole threads tor damage.
10. Inspect for a loose or damaged. heat shield (2) or
missing bolts (3),
(.
.
346026
11. Inspect the take down studs tor damaged threads.
220594
12. Use a straight edge and a feeler gauge and

measure the exhaust manifold cylinder head deck
tor warpage.
A exhaust manifold deck with warpage in excess
of 0.25 mm (0.01 in), may cause an exhaust
leak and may effect OBD II system performance.
Exhaust manifolds not within specifications
must be replaced.
(
66607
6-519
Vapor, Vent Pipe Clean and Inspect

lmporta~o not reuse the engine coolant air bleed
pipe gaskets."'Ue_on installation of the pipe, install
NEW gaskets.
1. Remove the engine coolant air bleed hose,
clamps, and sealing gaskets from the pipe.
64262
2. Clean the pipe (1) and hose (2) in solvent.

damage.
3. Dry the pipe with compressed air.

4. Inspect the pipe for damage or restrictions.
5. Inspect the gasket and hose sealing surfaces for
damagE3.
6. Inspect the hose (2) for restrictions, cracking
or wear.
The hose may be reused if not damaged.
490724
Water Pump Clean and Inspect

1 . Remove the old gasket f.rom the water pump
sealing surfaces. Refer to Replacing Engine
Gaskets.
2. Clean all dirt and debris from the water pump
housing.
3. Inspect the water pump for the following:
Gasket sealing surfaces for excessive
scratches or gouging
Hose sealing surfaces for scratches or gouging
Restrictions within the internal coolant
passages
309751
6-520
Engine
Excessive side-to-side play in the pulley shaft
" A loose belt pulley or a pulley with excessive

wear or scoring on the belt tracking area
Leakage at the water outlet housing or rear

cover gasket
Leakage at the water pump vent hole
A stain around the vent hole is acceptable. If
leakage occurs (dripping) with the engine
running and the c6oling system pressurized,
replace the water pump.
Thread Repair
General Thread Repair
Tools Required
J 42385-200 General Threads Kit

320670
1. Drill outthe. threads of the damaged hole (1 ):

M6 inserts require a minimum drill depth of
15 mm (0.59 in).
MS inserts require a minimum drill depth of
20 mm (0.79 in). .
..
~ M1 o ins~rts requir~ a mi~imum drill. depth of
23.5 m.m (0.93 in).
2. Using compressed air, cle~n out any chips.
t ~
.
.. J
.
',
(
'.
320675
The thread repair process involves a solid, thin walled,

self-locking, carbon steel, bushing type insert (1):
During the bushing installation process, the. driver tool
expands the bottom external threads of the insert
into the base material (2). This action mechanically
locks the insert in place. Also, when installed to
the proper depth, the flange of the insert will be seated
against the counterbore of the repaired hole.

damage.
Important: The use of a cutting type fluid
GM P/N 1052864, WD 40, or equivalent is
recommended when performing the drilling,
counterboring, .and tapping procedures.
:;:__
~
~
320672
3. Counterbore the hole to the full depth permitted

by the tool (1 ).
4. Using compressed air, clean out any chips.
Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a suitable
tap wrench or drill motor.
Engine
1
6-521
'
2
313567
320670
5. Using a tap wrench (2), tap the threads of the
10. Install the insert (2) onto the driver tool (1).
drilled hole.
M6 inserts require a minimum tap depth of

15 mm (0.59 in).

20 mm (0.79 in).
23.5 mm (0.93 in).
\)

7. Spray cleaner GM P/N 12346139, P/N 12377981,
or equivalent into the hole.
8. Using compressed air, clean any cutting oil and
chips out of the hole.
313572
11 . Apply thread lock Loctite 277, J 42385-109 ( 1), or

equivalent to the insert OD threads (2).
2
313562
Important: Do not allow oil or other foreign material to

contact the outside diameter (OD) of the insert.
9. Lubricate the threads of the installer tool (2) with

the driver oil (1 ).
6-522
Engine
Engine Mechanical - 5c"7l

Cylinder Head Bolt Hole Thread Repair
Tools Required
J 42385-100 Cylinder Head/Main Bearing Boit Kit
J 42385-300 Fixtures and Hardware Kit
320673
12. Install the insert (2) into the hole.

Install the insert until the flange of the insert
contacts the counterbored surface. Continue to
rotate the installer tool (1) through the. insert.
The installer tool will tighten up before screwing
completely through the insert. This is acceptable.
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.
1
2
313560
1. The cylinder head bolt hole thread repair kit

consists of the following items:
Drill (1)
Tap (2)
Installer (3)
Sleeve (4)
Alignment Pin (5)
Bushing (6)
" Bolts (7)
Fixture Plate (8)
320675
13. Inspect the insert for proper installation into

the hole.
A properly installed insert (1) will be either flush or
slightly below flush with the surface of the base
material (2).
Engine
15
[7
13
11
12
'-"""'
.........
.........
5
14
:]
260150
Caution: Wear safety glasses in order to avoid

eye damage.
6.. Cylinder head bolt holes l-c-8 are the deep holes
andwill be drilledwithoutthe drill sleeve.
Important: The use of a cutting type fluid GM ,

P/N 1052864,. WD 40, or equivalent is recommended
when performing the drilling and tapping procedures.
Cylinder head bolt holes 9 and 10 are the

shallower holes, driUing MUST be done with the
drill sleeve in place.
Driver oil MUST be used on the insfallerdrivertool.

The tool kits are designed for use with ej_ther 'a s.uitable
tap wrench or drill m.otor.
2. Install the fixture plate (3), bolts (1 ), and

bushing (2) onto the engine block deck, ..
Position the fixture plate and bushing over the
hole that is to be repaired (4).
2
313570
7. Install the sleeve (2) onto the drill (1) (if required).
313577
3. Position the alignment pin (1) through the

bushing and into the hole.
4. With the alignment pin in the desired hole, tighten
the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6-524
Engine
309861
Important: During the reaming process, it is necessary

to repeatedly remove the drill and clean the chips
from the hole.
8. Drill out the threads of the damaged hole.
Drill the hole until the stop collar of the drill bit or
the sleeve contacts the bushing.
377637
11. In order to tap the new threads to the proper

depth, rotate the tap into the hole until the
marks (1 or 4) on the tap align with the top of the
drill bushing (3).
For the deeper cylinder head bolt holes (1-8),
rotate the tap until the upper mark on the tap (4)
aligns with th~ top of the drill bushing.
For the shallower cylinder head bolt
holes (9 and 10), rotate the tap until the lower
mark on the tap (1) aligns with the top of the drill
bushing.
12. Remove the fixture plate (2), bushing (3),
and bolts.
14. Spray cleaner GM P/N 12346139, P/N 12377981,
15. Using compressed air, clean any cutting oil and
320667
1O. Using a tap wrench, tap the threads of the

drilled hole.
Engine
313572
terial to
.
other foreign ma
not allow oil or
f the insert.
Important: Dotside diameter (OD_) o I totil (2) w.ilh
contact the ou
ds of the instal er . .
Lubricate t~e threa
16.
driver oil (1 ).
.
fue
.
~~
J 42385-109
(1), or
2 77 ___e_a_ds
(2)
18. Appy
1 nt to the mse
I threadlock
~octite\ID
rtI_ ,o~~D_:t::.:.hr
__
equ1vae
~1
.
'
'
313567
17. Install the .mse rt (2) onto the driver tool (1 ).
.
(1) into the hole.
I the insert an d driver
.
mark on t h e
19. lnstal
.
tool until the
f the
Rotate. ns
the wit
d~1vhetrhe deck surface o
I
tool a 19
k
fore screwing
engine bloc . I will tighten up be s acceptable.
The installer too h the insert. This I of the
completely th~o~~he bottom !hre~~s insert to the
You
formmhanically
locking
.
rtare
and
mec
mse
terial
threads.
base ma
6-526
Engine Mechanical -5:7l
Engine
Main Cap Bolt Hole Thread Repair

J 42385-306
Tools Required
J 42385-100 Cylinder Head/Main Bearing Bolt Kit

J 42385-300 Fixtures and Hardware Kit
,'
377630
2. Install the fixture plate, bolt, and bushing, onto the

engine block.
,
Position the fixture plate and bushing over the
hole that is to be repaired.
3. Position the alignment pin in the desired hole and

tighten the fixture retaining bolts.
tr ~
8
7
313556
1. The main cap bolt hole thread repair kit consists

of the following items:
19
9
Drill (1)
Tap (2)
Installer (3)
10
20
Fixture Plate (4)

Long Bolts (5)
Short Bolts (6)
63214
Alignment Pin (7)

Bushing (8)
4. Drill out the damaged hole.

The outer bolt hole locations (11-20) have the
shallower counterbores. Use sleeve J 42385-316
with the drill.
Drill until the stop collar of the drill bit or the
sleeve contacts the bushing.
Engine
6-527
3
'
'
377637
6. Using a tap wrench, tap the threads of the

drilled hole.
In order to tap the new threads to the proper
depth, rotate the tap into the hole until the mark
on the tap aligns with the top of the bushing.
For the deeper main cap holes (1-i 0), rotate the
tap until the upper mark (4) on the tap aligns
with the top of the bushing (3).
For the shallower main cap holes (11-20), rotate
the tap until the lower mark (1) on the tap
aligns with top of the bushing (3).
8. Spray cleaner GM P/N 12346139, or equivalent
into the hole.
9. Using compressed air>clean any cutting oil and
313567
11. Install .the insert (2) onto the driver tool (1 ).
313572
12. Apply threadlock Loctite 277, J 42385-109 (1), or

equivalent to the insert OD threads (2).
313562
Important: Do not allow oil or ot11er foreign material to

contact the outside diameter (OD) of the insert.
10. Lubricate the threads of the installer tool (2) with
the driver oil (1 ).
6-528
Engine

Service Prior to Assembly
Dirt or debris will cause premature wear of the

rebuilt engine. Clean all the components.
Refer to Cleanliness and Care.
Use the proper tools to measure components
when checking for excessive wear. Components
that are not within the manufacturers specifications
must be repaired or replaced.
When the components are reinstalled into an
engine, return the components to their original
location, position and direction.
During assembly, lubricate all the moving parts
with clean engine oil. This 'Nill provide initial
lubrication when the engine is first started.
377635
Important: The fixture plate and bushing remains

installed onto the engine block during the insert
13. lnstaUthe insert and driver (1) through the fixture
plate and bushing and into the hole.
Rotate the driver tool until the mark on the tool (3)
aligns with the top of the bushing (2).
The installer tool will tighten up before screwing
completely through the insert. This is acceptable.
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.
Engine
Engine Block Plug Installation
Tools Required
6.;.529
Important:
Engine block plug (oil gallery and coolant) sealing
washers may be reused if not bent, scored or.
otherwise damaged.
Apply the proper amount and type of sealant to
the sealing washer as recommended in the
service procedure.
1. Apply a 3.175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to. the engine
block coolant heater sealing washer (if applicable).
Refer to SeaJers, Adhesives, and Lbricants.

Notices.
2. Install the engine block coolant heater to the
engine block (if applicable).
65332
Tighten
Tighten the block coolant heater to
40 Nm (30 lb ft) ..
3. Apply a 3:175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to the engine
block left front coolant drain plug sealing washer
(if applicable).
4. Install the engine block left front coolant drain
plug (if applicable).
Tighten
Tighten the block left front coolant drain plug to
60 N-m (44 lb ft).
63165
6".'.530
Engine
5. Apply a 3.175 mm (0.125 in} bead of sealant

block right rear coolant drain plug sealing washer.
6. Install the engine block right rear coolant
drain plug.
Tighten
Tighten the block right rear coolant drain plug to
60 N-m (44 lb ft).
63164

block left front oil gallery plug sealing washer.
8. Install the engine block left front oil gallery plug.
Tighten
Tighten the block left front oil gallery plug to
60 .Nm (44 lb ft).
.
.
'
',,.)
63167

block left rear oil gallery plug sealing washer.
10. Install the engine block left rear oil gallery plug.
Tighten
Tighten the block left rear oil gallery plug to
60 Nm (44 lb ft).
(
64923
Engine
6-531
11. Inspect the engine block rear oil gallery plug and
0-ring seal. If the 0-ring seal on the plug is not
cut or damaged, the rear oil gallery plug may
be reused.
12. Lubricate the 0-ring seal with clean engine oil.
13. Install the block rear oil gallery plug into the
oil gallery bore.
A properly installed oil gallery plug will protrude
0.8-1.4 mm (0.0315-0.055 in) beyone the
rear face of the block.
63228
Important: The engine block front oil gallery plug

should not be removed unless service is required.

the sides of the NEW front oil gallery plug.
15. Install a NEW engine block front oil gallery plug {if
required). Install the front oil gallery plug into the
oil gallery.bore 2.2-2.8 mm (0.0086-0.0.j 1 in)
below flush.
64295
6-532
Engine
the threads of the oil pressure sensor.
17. Use the J 41712 or equivalent in order to install
the oil pressure sensor.
J 41712
Tighten
Tighten the oil pressure sensor to
20 Nm (15 lb ft).
178483

Tools Required
Important:
64293
Crankshaft bearing clearances are critical.

Excessive crankshaft bearing clearance may effect
crankshaft position sensor signals and/or
On-Board Diagnostics (OBD) II system
performance.
Crankshaft bearing caps must be installed to the
proper location and direction.
When installing the crankshaft bearings, align the
locating tabs on the bearings with the locating
notches in the engine block journal bore and the
bearing cap.
Always install crankshaft bearings with their
machined partner. Do not file bearings or
mix bearing halves.
" To prevent engine block oil leakage, install NEW

M8 crankshaft bearing cap side bolts.
The crankshaft bearing cap M8 side bolts have a
sealant patch applied to the bolt flange.
1. Install the crankshaft thrust bearings to the engine
block and center bearing cap.
2. Install the remaining crankshaft bearings to the
engine block and bearing caps.
3. Lubricate the bearing surfaces and crankshaft
journals with clean engine oil.
Engine
Engine Mechanical - 5.7.l
6-533
Notic~: To maintain proper crankshaft end play, use

extreme care during crankshaft installation. Avoid
scoring or damaging the thrust bearing.
4. Install the crankshaft.
156151
Important: The bea.ring caps must be installed in the

proper location and direction.
5. Install the crankshaft bearing caps (with bearings)
into the engine block.
6. Start the M10 bolts and studs.
7. Tap th.e bearing caps into place with .a
plastic-faced hammer.
156152
8. Install the NEW M8 bearing cap side bolts.
156155
6-534
Engine
Notices.
9. Tighten the bearing cap bolts and studs.
Tighten
Tighten the inner M1 O bearing cap bolts first pass
in sequence to 20 N-m (15 lb ft).
Important: To properly align the crankshaft thrust
bearings, the final thrust of the crankshaft MUST be in
the forward direction.
10. Using a plastic faced hammer, tap the crankshaft
rearward then forward to align the thrust bearings.
i9
9
10
20
63214
Tighten
10.1. Tighten the inner M10 bolts final
pass in sequence 80 degrees using
the J 36660-A.
10.2. Tighten the outer M10 bolts first pass in
sequence to 20 N-m (15 lb ft).
10.3. Tighten the outer M10 bolts final
pass in sequence 53 degrees using
the J 36660-A.
10.4. Tighten the bearing cap side M8 bolts to
25 N-m (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.
11. Install the crankshaft position sensor.
. 11.1. Inspect the crankshaft position sensor
0-ring seal. If the 0-ring seal is not cut or
damaged, it may be used.
11.2. Coat the 0-ring seal with clean engine oil.
11.3. Install the sensor. Align the notch in the
sensor retaining bracket with the bolt hole
in the block.
11.4. Install the sensor bolt.
(.
Tighten
Tighten the crankshaft position sensor bolt
to 25 N-m (18 lb ft).
55322
Engine
5;.535
12. Measure the crankshaft end play.

12.1. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft arid
measure the bearing clearance.
The proper crankshaft end play Clearance is
0.04-0.2 mm (0.0015-0.0078 in).
12.3. If the bearing clearance is not within
specifications, inspect the thrust surfaces
for nicks, gouges or raised metal.
Minor imperfections may be removed with
a fine stone.
64316

Installation
Tools Required
" J 41556 Connecting Rod Guide
" J 8037 Piston Ring Compressor
Important: The piston and cylinder bore have been
measured and the bore has been sized for the proper
clearance. Install the piston and connecting rod
assembly into the proper cylinder bore.
The piston alignment mark MUST face the front of the
engine block.
1. Lightly lubricate the following components with
clean engine oil:
The piston
The piston rings
The cylinder bore
The bearing surfaces
2. Stagger the oil control ring end gaps a minimum
of 90 degrees.
3. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).
4. Install the J 41556 to the connecting rod.
5. Install the J 8037 onto the piston and compress
the piston rings.
64180
6-536
Engine Mechanical a; 5.7L
Engine
Important: The piston alignment mark MUST facing
the front of the engine block.
6. Install the piston and connecting rod assembly
into the proper cylinder bore.
6.1. Hold the piston ring compressor firmly
against the engine block. Using a wooden
hammer handle, lightly tap the top of
the piston until all of the piston rings enter
the cylinder bore.
6.2. Use the J 41556 to guide the connecting
rod end onto the crankshaft journal.
63217
J 41556
63186
Engine
8. Identify the type of connecting rod bolt.
O The first design connecting rod bolt (1) can be
identified by a single dimple/mark on the
head of the bolt and no retaining sleeve on the
bolt shank.
The second design connecting rod bolt (2) can
be identified by two dimples/marks on the
head of the bolt and a retaining sleeve (3) on
the bolt shank.
6~537
568498

Notices.
Important:
O When replacing connecting rod bolts, both bolts
MUST be of the same design for each connecting
rod assembly.
The use of different design connecting rod bolts
on the same connecting rod assembly may lead to
uneven clamploads and/or connecting rod
bearing bore distortion.
Position the connecting rod cap onto the
connecting rod properly.
Align the flat side of the connecting rod cap with
the flat side of the connecting rod.
9. Install the bearing, cap, and bolts.
Tighten
9.1. Tighten the first design bolts a first pass
evenly to 20 Nm (15 lb ft).
9.2. Tighten the first design bolts a final pass to
60 degrees using the J 36660-A.
9.3. Tighten the second design bolts a firstpass
evenly to 20 Nm (15 lb ft).
9.4. Tighten the second design bolts a final pass
to 75 degrees using the J 36660-A.
53223
s.:.53a
Engine.
10. Inspect the connecting rods for proper orientation

onto the crankshaft journal.
11. With the pistons-and connecting rods installed,
use a soft faced mallet and lightly tap each
connecting rod assembly parallel to the crankpin
to make sure that the rods have s.ide clearance.
12. Measure the connecting rod side clearance using
a feeler gauge or a dial indicator. Connecting rod
side clearance should be within 0.11-0.51 mm
(0.0043-0.02 in).
63227
Camshaft h1stallaticm
Important: If camshaft replacement is required, the
valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings
with clean engine oil.
2. Install three MB-1.25 x 100 mm (MB-1.25 x 4.0 in)
bolts into the camshaft front bolt holes.
3. Using the bolts as a handle, carefully install
the camshaft into the engine block.
4. Remove the th.ree bolts from the. front of the
camshaft.
63212

Notices.
Important: Install the retainer plate with the sealing
gasket facing the engine block.
The gasket surface on the engine block should be

clean and free of dirt or debris.
5. Install the camshaft retainer and the bolts.

Tighten
Tighten the. camshaft retainer bolts to
25 N-m (18 lb ft};
6. Inspect the camshaft sensor 0-ring seal. If the
0-ring seal is not cut or damaged, it may be
reused.
7. Lubricate the 0-ring seal with clean engine oil.
63211
Engine
6-539
8. Install the camshaft sensor and bolt.
Tighten
Tighten the camshaft sensor bolt to
25 Nm (18 lb ft).
260128

Tools Required
J 41665 Crankshaft Balancer and Sprocket Installer
1. Install the key into the crankshaft keyway (if

previously removed).
156149
2. Tap the key (1) into the keyway until both ends. of
the key bottom onto the crankshaft.
490871
6-540
Engine
3. Install the crankshaft sprocket onto the front of the

crankshaft. Align the crankshaft key with the
crankshaft sprocket keyway.
156150
4. Use the J 41665 in order to install the crankshaft

sprocket.
Install the sprocket onto the crankshaft until fully
seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment
mark is in the 12 o'clock position.
63199
Important:
Properly locate the camshaft sprocket locating pin
with the camshaft sprocket alignment hole.
The sprocket teeth and timing chain must mesh.
The camshaft and the crankshaft sprocket
alignment marks MUST be aligned properly.
Locate the camshaft sprocket alignment mark in
the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.
63263
Engine
6-541
7. If necessary, rotate the camshaft or crankshaft

sprockets in order to align the timing marks.
Notices.
8. Install the camshaft sprocket bolts.
Tighten
Tighten the. camshaft sprocket bolts to
35 N-m (26 lb ft).
156158

Installation
Important: Inspect the oil pump and engine block oil

gallery passages. These surfaces must be clear
and free of debris or restrictions.
1. Align the splined surfaces of the crankshaft
sprocket and the oil pump drive gear and
install the oil pump.
2. Install the oil pump onto the crankshaft sprocket
until the pump housing contacts the face of the
engine block.
Notices.
3. Install tht3 oil pump bolts.
Tighten
Tighten the oil pump bolts to 25 Nm (18 lb ft).
64281
4. Install the crankshaft oil deflector.

5. Lubricate a NEW oil pump screen Osring seal with
clean engine oil.
6. Install the NEW 0-ring seal onto the oil pump
screen.
64270
6-542
Engine
Important: Push the oil pump screen tube completely
into the oil pump prior to tightening the bolt. Do not
allow the bolt to pull the tube into the pump.
Align the oil pump screen mounting brackets with the

correct crankshaft bearing cap studs.
7. Install the oil pump screen.
8. Install the oil pump screen bolt and the
deflector nuts.
Tighten
8.1. Tighten the oil pump screen bolt to
12 N-m (106 lb in).
8.2. Tighten the crankshaft oil deflector nuts to
25 Nm (18 lb ft).
64268
Engine Rear Cover Installation

Tools Required
J41480 Front/Rear Cover Alignment (Oil Pan
Surface)
J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)
Important:
Do not reuse the crankshaft rear oil seal or the
engine rear cover gasket.
Do not apply any type sealant to the rear cover
gasket (unless specified).
The special tools in this procedure are used to
properly align the engine rear cover at the oil
pan surface and to center the crankshaft
rear oil seal.
The crankshaft rear oil seal will be installed after

the rear cover has been installed and aligned.
Install the rear cover without the crankshaft
oil seal.
- The crankshaft rear oil 'seal MUST
centered in relation to the crankshaft.
- The oil pan sealing surface at the rear cover
and engine block MUST be aligned within
specifications.
- An improperly aligned rear cover may cause
premature rear oil seal wear and/or engine
assembly oil leaks.
1. Inspect the rear oil gallery plug for proper
installation.
be
63228
Engine
)
6-543
2. Install the rear cover gasket, rear cover and bolts,

3. Tighten the bolts finger tight Do not overtighteh.
64282
Notice: Refer to Fastener Notice in Cautions and,

Notices.
Important: Start .the J 41480.tool-to-rear cover bolts.

Do not tighten the bolts at this time.
4. Install the J 414$0 and bolts.

Tighten
Tighten the tool-to~engine block bolts to

.25Nm (181b ft).
64204
Important: To properly align the rear cover, the

J 41476 must be installed onto the rear of the
J 41480
crankshaft with the tool mounting bolts parallel to the

oil pan surface.
5. Rotate the crankshaft until two opposing flywheel
bolt holes are parallel to the oil pan surface.
J 41476
63243
6".'544
Engine
Important: The tapered legs of the alignment tool

must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the
crankshaft.
Tighten
6.1. Tighten the tool mounting bolts until snug:
Do not overtighten.
6.2. Tighten the J 41480 tool-to-rear cover bolts

evenly to 12 Nm (106 lb in).
6.3. Tighten the rear cover bolts to
25 N-m (18 lb ft).
7. Remove the tools.
65286
8. Measure the oil pan surface for flatness (rear

cover-to-engine block).
8.1. Place a straightedge onto the engine.block
and rear cov~r oil pan sealing 9urfaces.
Avoid contact with the portion of the gasket
that protrudes into the oil pan surface.
8.2. Insert a feeler gauge between the rear.
cover and the straight edge. The cover
must be flush with the oilpanor no more
than 0.5 mm (0.02 in) below flush'.
9. If the rear cover-to-engine block oil pan surface
alignment is not within specifications, repeat the
cover alignment procedure.
10. If the correct rear cover-to-engine block alignment
at the oil pan surface cannot be obtained, replace
the rear cover.
63240
Engine
6-545
Crankshaft Rear Oil Seal Installation

)
Tools Required
J 41479 Crankshaft Rear Oil Seal Installer
Important:
Do not lubricate the oil seal inside diameter (ID) or
the crankshaft surface.
Do not reuse the crankshaft rear oil seal.
1. Lubricate the outside diameter (OD) of the oil
seal (1) with clean engine oil.
DO NOT allow oil or other lubricants to contact
the seal surface.
2. Lubricate the rear cover oil seal bore with clean
engine oil.
DO NOT allow oil or other lubricants to contact
the crankshaft surface.
490692
3. Install the J 41479 cone (2) and bolts onto the

rear of the crankshaft.
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered
cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered
cone until the tool (1) contacts the oil seal.
7. Align the oil seal'onto the tool (1).
8. Rotate the handle of the tool (1) dockwise until
the seal enters the rear cover and bottoms into
the cover bore.
9. Remove the tool.
J 41479
63200
6"-546
Engine

Tools Required
J 41480 Front/Rear.Cover Alignment (Oil Pan
Surface)
J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)
Important:
Do not reuse the 9ranksha,ft oil seal or the engine
front cover gasket.
Do not apply any type sealant to the front cover
64278
The special tools in.this procedure are used to

properly align the engine front cover at the .oil
pan surface and to center the crankshaft
front oil seal.
- All gasket surfaces should be free of oil or
other foreign material during assembly.
The crankshaft front oil seal MUST be centered
in relation to the crankshaft.
- The oil pan sealing surface at the front cover
and engine block MUST be aligned within
specifications.
- An improperly aligned front cover may cause
premature front oil seal wear and/or engine
assembly oil leaks.

1. Install the front cover gasket, cover, and bolts
onto the engine.
2. Tighten the cover bolts finger tight. Do not
overtighten.

Notices.
Important: Start the tool-to-front cover bolts. Do not

tighten the bolts at this time.
3. Install the J 41480. .
lighten
Tighten the tool-to-engine block bolts to
25 N,m (18 lb ft).
63182
Engine
Important: Align the tapered legs of the tool with the

machined alignment surfaces on the front cover.
4. Install the J 41476.
5. Install the crankshaft balancer bolt.

Tighten
5.1. Tighten the crankshaft balancer bolt by
hand until snug. Do not overtighten.
5.2. Tighten the J 41480.
5.3. Tighten the engine front cover bolts to

25 Nm (18 lb ft).
6. Remove the tools.
63185
7. Measure the oil pan surface flatness (front

cover-to-engine block).
7.1. Place a straight edge across the engine
block and front cover oil pan sealing
surfaces.
Avoid contact with the portion of the gasket

that protrudes into the oil pan surface.
7.2. Insert a feeler gauge between the front
cover and the straight edge tool. The
cover must be flush with the oil pan surface
or no more than 0.5 mm (0.02 in)
below flush.
8. If the front cover-to-engine block oil pan surface
alignment is not within specifications, repeat the
cover alignment procedure.
9. If the correct front cover-to-engine block alignment
cannot be obtained, replace the front cover.
0.0-0.5mm
(0.0 - 0.02")
63242
6-548
Engine
Crankshaft Front Oil Seal Installation
Tools Required
J 41478 Crankshaft Front Oil Seal Installer
Important: Do not lubricate the oil seal sealing

surface.
Do not reuse the crankshaft front oil seal.

1. Lubricate the outer edge of the oil seal (1) with
clean engine oil.
2. Lubricate the front cover oil seal bore with clean
engine oil.
490689
3. Install the crankshaft front oil seal onto the

J 41478 guide.
4. Install the J 41478 threaded rod (with nut, washer,
guide, and oil seal) into the end of the crankshaft.
5. Use the J 41478 in order to install the oil seal into
the cover bore.
5.1. Use a wrench and hold the hex on the
installer bolt.
5.2. Use a second wrench and rotate the
installer nut clockwise until the seal
bottoms in the cover bore.
5.3. Remove the tool.
5.4. Inspect the oil seal for proper installation;
The oil seal should be installed evenly and
completely into the front cover bore.
J 41478
63177
Oil Pan Installation

Important: The alignment of the structural oil pan is
critical. The rear bolt hole locations of the oil pan
provide mounting points for the transmission housing.
To ensure the rigidity of the powertrain and correct
transmission alignment, it is important that the rear of
the block and the rear of the oil pan are flush or
even. The rear of the oil pan must NEVER protrude
beyond the engine block and transmission
housing plane.
Do NOT reuse the oil pan gasket.

It is not necessary to rivet the NEW gasket to the
oil pan.
It is not necessary to remove the oil level sensor prior
to oil pan installation.
178491
Engine
6-549

Notices.
1. Install the oil pan baffle and bolts (if previously
removed).
Tighten
Tighten the oil pan baffle bolts to
12 Nm (106 lb in).
2. Apply a 5 mm (0.2 in) bead of sealant
GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the front cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.
63176
3. Apply a 5 mm (0.2 in) bead of sealant

GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the rear cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.
63175
6-550
Engine
Important: Be .sure to align the oil gallery passages in
the oil pan and engine block properly with the oil pan
gasket.
4. Preassemble the oil pan gasket to the pan.

4.1. Install the gasket onto the oil pan.
4.2. Install the oil pan bolts to the pan and
through the gasket.
5. Install the oil pan, gasket and b.olts to the

engine block, '
'
6. Tigbten .bolts finger tight. Dq not overtighten.
7. Place a straight edge across the rear of the engine
block and the rear of the oil pan at the
transmission housing mounting surfaces.
178558
8. Align the. oil pan until the. rear of engine block and
rearof oil pan are flush or even.
Tighten
8.1. Tighten the oil pan-to-block and oil
pan-to-front cover bolts to 25 Nm (18 lb ft).
12 Nm (106 lb in).
9. Measure the oil pan~to-engine block alignment.
9.1. Place a straight edge across the rear of
the engine block and rear of oil pan a1 the
transmissiohhousing mounting surfaces.
'SJm:j]
<.::=J
0.0 -- 0;25 mm
0.010")
(o.o -
_..,jl.,._..
II .
178474
Important: The rear of the oil pan must .NEVER

protrude beyond the engine block and transmission
housing mounting surfaces.
9.2. Insert a feeler gauge between the straight
edge and the oil pan transmission housing
mounting surface and check to make
sure that there is no more than a 0.25 mm
(0.01 in) gap between the pan and
straight edge.
9.3. If the oil pan alignment is not within
specifications, remove the oil pan and
repeat the above procedure.
Engine
6-551
10. Install the oil level sensor.

)
Tighten
Ti,ghten the oil level sensor to 13 Nm (115 lb in).
178467
Oil Filter, Adapter, Pan Cover Installation

Notices.
1. Install a NEW oil pan cover gasket, the cover and
the bolts.
Tighten
Tighten the oil pan cover bolts to
12 Nm (106 lb in).
178471
2. Install a new oil filter bypass valye (2) into the oil
pan (if required).
3. Install the oil filter fitting (1 ).
Tighten
Tighten the oil filter fitting to 55 N-m (40 lb ft).
490699
6-552
Engine

Tighten
178469
5. lnstallthe oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 25 Nm (18 lb ft).
309862
Valve Lifter Installation

Important: When reusing valve lifters, install the lifters
to their original locations.
If camshaft replacement is required, the valve lifters
must also be replaced.
.
1. Lubricate the valve lifters and engine block valve
lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides.
Align the flat area on the top of the lifter with the
flat area in the lifter guide bore. Push the lifter
completely into the guide bore.
63233
Engine
6-553
3. Install the valve lifters and guide assembly to the

engine block.

Notices.
4. Install the valve lifter guide bolt (1).
Tighten
Tighten the valve lifter guide bolt to
12 N,m (106 lb in).
63230
Cylinder Head Installation (left Side)

Tools Required
Important: Do not reuse the M11 cylinder head bolts.
Install NEW M11 cylinder head bolts during assembly.
Do not use any type sealant on the cylinder head
The cylinder head gaskets must be installed in the
proper direction and position.

damage.
Notice: Clean all dirt, debris, and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Clean the engine block cylinder head bolt holes (if
required).
Th re.ad repair tool J 42385-107 may be. used to
clean the threads of old threadlocking material.
2. Spray cleaner GM P/N.12346139, PIN 12377981,
or equivalent into the h.ole.
3. Clean the cylinder head bolt holes with
compressed air.
4. Check the cylinder head locating pins for proper
installation.
63235
6-554
Engine
5. Install the NEW left cylinder head gasket onto the
locating pins.
63169
Important: When properly installed, the tab on.the left

cylinder head gasket will be located left of center, or
closer to the front of the engine, and the words
"This Side Up", and the engine displacement, will be.
visible.
6. Inspect the gasket for proper installation.
490861
7. Install the cylinder head onto the locating pins and

the gasket.
8. Install the NEW M11 cylinder head bolts.
9. Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalentto the threads of
the MB cylinder head bolts.
Refer to Sealers, Adhesives, and Lubricants.
10. Install the M8 cylinder head bolts.
260146
Engine
6-555

Notices.
11. Tighten the cylinder head bolts.

Tighten
11.1. Tighten the M11 cylinder head
bolts (1-10) a first pass in sequence
to 30 N-m (22 lb ft).
bolts (1-10) a second pass in sequence to
bolts (1,2,3,4,5,6,7,8) to 90 degrees and
the M11 cylinder head bolts (9 and
10) to 50 degrees a final pass in sequence
to using the J 36660-A.
11 .4. Tighten the MS cylinder head
bolts (11, 12, 13, 14, 15) to 30 N-m (22 lb ft).
Begin with the center bolt (11) and
alternating side-to-side, work outward
tightening all of the 9olts.
15
13
11
12
14
:J
260150
Cylinder Head lnstallaUon (Right Side)

Tools Required
Important: Do not reuse the M11 cylinder head bolts.

Install NEW M11 cylinder head bolts during assembly.
Do not use any type sealant on the cylinder head
The cylinder head gaskets must be installed in the
proper direction and position.
damage.
Notice: Clean all dirt, debris, and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Clean the engine block cylinder head bolt holes
(if required).
Thread repair tool J 42385~107 maybe used to
clean the threads of old threadlocking material
2. Spray cleaner GM P/N 12346139, P/N ~2377981,
3. Clean the. cylinder head bolt holes with

compressed air.
4. Check the cylinder head locating pins for proper
installation.
63235
6-5.56
Engine
5. Install the NEW right cylinder head gasket onto

the locating pins.
63170
Important: When properly installed, the tab on.the

right cylinder head gasket will be located right of
center, or closer to the front of the engine, and the
words "This Side Up", and the engine displacement will
be visible.
6. _Inspect the gasket for proper installation.
490854
7. Install the cylinder head onto the locating pins and

~~~~
8. Install the NEW M11 cylinder head bolts.

9, Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the M8 cylinder he~d bolts.
1o. Install the M8 cylinder head bolts.
260149
Engine
Notices.
11. Tighten the cylinder head bolts.
Tighten
bolts {1-10) a first pass in sequence
bolts (1-10) a second pass in sequence to
bolts (1,2,3,4,5,6,7,8) to 90 degrees and
the M11 cylinder head bolts (9 and
10) to 50 degrees a final pass in sequence
to using the J 36660-A.
11.4. Tighten the MS cylinder head
bolts {11,12,13,14, 15) to 30 N-m {22 lb ft).
Begin with the center bolt {11) and
alternating side-to-side, work outward
tightening all of the bolts.
15
11
..._,,,
1
12
..._,,,
5
13
..._,,,
14
:J
260150

Installation
Important: When reusing the valve train components,
always install the components to the original location
and position.
Valve lash is net build, no valve adjustment is required.

1. Lubricate the valve rocker arms and pushrods
2. Lubricate the flange of the valve rocker arm bolts
Lubricate the flange or washer surface of the bolt
that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support.
260141
Important: Make sure that the pushrods seat properly

to the valve lifter sockets.
4. Install the pushrods.
260142
6-558
Engine
Important: Make sure that the pushrods seat properly
to the ends of the rocker arms.
DO NOT tighten the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
260140
6. Rotate the crankshaft until number one piston is

at top dead center of compression stroke.
In this position, the crankshaft and camshaft
sprocket marks will be aligned, cylinder number
one rocker arms will be off lobe lift, and the
crankshaft sprocket key will be at the 1:30
position. While viewing from the rear of the engine,
the additional crankshaft pilot hole (non-threaded)
will be in the 10:30 position.
.
The engine firing order is i ,8,7,2,6,5,4,3.
Cylinders 1,3,5 and 7 are left ban.k.
Cylinders 2,4,6, and 8 are right bank.
(.

Notices.
7. With the engine in the number one firing position,
tighten the following valve rocker arm bolts:
156158
Tighten
Tighten exhaust valve rocker arm bolts 1, 2, 7,
and 8 to 30 N-m (22 lb ft).
Tighten intake valve rocker arm bolts 1, 3, 4,
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts:
Tighten
Tighten exhaust valve rocker arm bolts 3, 4, 5,
Tighten intake valve rocker arm bolts 2, 6, 7,
Engine
6-559

(left Side)
Important: All gasket surfaces should be free of oil or
DO NOT reuse the .valve. rocker arm cover gasket.
The valve rocker arm cover bolt grommets may
be reused.
1. Install a NEW cover gasket (1) into the valve
rocker arm cover.
490696
2. Install the valve rocker arm cover onto the

cylinder head.
Notices.
3. Install the cover bolts with grommets.
Tighten
12 N-m (106 lb in).
260085
4. Install the. ignition coils, wire harness, and bolts

onto the mounting bracket.
Tighten
Tighten the ignition coil bolts to 12 N-m (106 lb in).
309850
6-560
Engine Mechanical
i-.
5.7L
Engine
to the threads of the bracket bolts.
6. Install the ignition coils and bracket assembly and
bolts onto the rocker cover.
Tighten
Tighten the ignition coil bracket bolts to
12 N-m (106 lb in).
7. Install the crankcase ventilation hose.
309727

(Right Side)
DO NOT reuse the valve rocker arm cover gasket.
The valve .rocker arm cover.bolt grommets may
be reused.
If the oil fill tube has been removed from the valve
rocker arm cover, install a NEW oil fill tube during
assembly.
1. Lubricate the 0-ring seal of the NEW oil fill tube
2. Insert the NEW oil fill tube into the rocker arm
cover and rotate the tube clockwise until locked
in the proper position.
3. Install the oil fill cap into the tube and rotate
clockwise until locked in the proper position.
260110
4. Install a NEW gasket (1) into the valve rocker

arm cover.
490696
Engine
6-561

Notices.
5. Install the valve rocker arm cover onto the
cylinder head.
6. Install the cover bolts with grommets.
Tighten
12 N-m (106 lb in).
260084
7. Install the ignition coils, wire harness, and bolts

onto the mounting bracket.
Tighten
Tighten the ignition coil b.olts to 12 Nm (106 lb in).
309850

to the threads of the bracket bolts.
9. Install the ignition coils and bracket assembly and
bolts to the rocker cover.
'
'
Tighten
Tighten the ignition coil bracket bolts to
12 Nm (106 lb in).
10. Install the crankcase ventilation hoses to
the cover.
309721
6-562
Engine
Engine Valley Cover Installation
1. Install NEW knock sensor oil seals (1) into the
valley cover (2).
Lubricate the seal surfaces with clean engine oil.
1~
490851
2. Install the valley cover and NEW gasket.

Notices.
3. Install the valley cover bolts.
Tighten
Tighten the valley cover bolts to 25 N-m (18 lb ft).
65048
4. Install the knock sensors.

Tighten
Tighten the knock sensors to 20 N-m (15 lb ft).
309864
Engine
6-563
5. Install the knock sensor wire harness.
309859
Vapor Vent Pipe Installation

Important: Install the pipe gaskets properly onto
the pipe:
Position the gasket 0-ring seal onto the nipple portion
of the pipe.
1. Install the gaskets onto the engine coolant air
bleed pipe.
64262
Important: Route the knock sensor wire harness over

the top of the engine coolant air bleed pipe. The pipe
and knock sensor wire harness should be installed
in a manner as to allow the removal of the wire
harness without requiring the removal of the pipe.
2. Install the pipe and gaskets onto the

cylinder heads.
Notices.
3. Install the pipe bolts and studs.
Install the two pipe studs to the front of the
engine.
Tighten
Tighten the pipe bolts and studs to
i2 Nm (106 lb in).
363239
6-564
Engine
4. Install the hose and clamp (2) onto the pipe.
.490724
Intake Manifold Installation

injection rail and fuel injectors may be removed as an
assElmbly. If. not servicing the individual con;iponents,
install the intake manifold as a complete assembly.
1. Install. NEW intake manifold-to-cylinder head
gaskets (1 ).
490579
2. Install the manifold to the engine.
178557
Engine
6-565

to the threads of the intake manifold bolts (1).

instaJled onto the engine assembly. The stop
injury from burns.
4. Install the fuel rail stop bracket (2).
490927

Notices.
5. Install the intake manifold bolts.
lighten
5.1. Tighten the intake manifold bolts a first pass

in sequence to 5 N,m (44 lb in).
5.2. Tighten the intake manifold bolts a final
pass in sequence to 10 N-m (89 lb in).
0..___1---o,....._5_....,,o a
(@
@)
@)
(@
@)
@)
@)
Q . - - -......,0,......--~Q
63222
6. Install the knock sensor wire harness

connector (1) onto the fuel rail stop bracket (2).
490736
5.;.555
Engine
7. Install the Ma.nifold Absolute Pressure (MAP)
sensor (if previously removed).
58838
8. Install the accelerator control cable bracket (2)

and bolts (1 ).
Tighten
Tighten the bracket bolts to 10 N-m (89 .lb in).
490573
Engine
5;.557
9. Install the Positive Crankcase Ventilation (PCV)

valve pipe to the right rocker cover and intake
manifold.
10. Install the PCV strap and nut onto the right front
vapor vent pipe stud.
Tighten
Tighten the PCV strap nut to 12 N-m (106 lb in).
379367
11. Install the PCV valve pipe to the left rocker cover.
379366
6-568
Engine

Fuel Rail and Injectors Installation
Important: DO NOT reuse fuel injector 0-ring seals.

Install NEW fuel injector 0-ring seals during assembly.
1. Lubricate the NEW fuel injector 0-ring seals
2. Install the o~ring seals onto the fuel injectors.
3. Install the fuel rail (with fuel injectors) into
the intake manifold.
Press evenly on both sides of the fuel rail until all
of the injectors are seated in their bores.
4. Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the fuel rail bolts.
222050

bracket serves as a protective shield for the tuel
injury from burns.
Notices.
'
5, Install the fuel rail bolts.
Tighten
Tighten the fuel rail bolts to 10 Nm (89 lb in).
Throttle Body Installation

Important: DO NOT reuse the throttle body gasket.
1. Install the throttle body gasket (1) to the intake
manifold.
490580
Engine
6-569
Notice: Refer to Fastener Nqtice in Cautions and

Notices.
2. Install the throttle body and bolts.

Tighten
Tighten the throttle body bolts to
12 N-m (106 lb in).
3. Install the engine coolant airbleed hose
and clar:np.
222051
Water Pump Installation
Notice: DO NOT use cooling system seal tabs (or

similar compounds) unless otherwise instructed. The
use of cooling system seal tabs (or similar compounds)
may restrict coolant flow through the passages of
the cooling system or the engine components.
Restricted coolant flow may cause engine overheating
and/or damage to the cooling system or the engine
components/assembly.
1. Install the water pump and NEW gaskets.
2. Install the water pump bolts.
Tighten
2.1. Tighten the water pump bolts a first pass to
15 Nm (11 lb ft).
2.2. Tighten the water pump bolts a final pass to
30 Nm (22 lb ft).
309751
Exhaust Manifold Installation (Left ?ide)

vehicle emissions and/or On-Board Diagnostic (OBD) II
system performance.
must be clean and free of debris or threadlocking
material.
Important: Do not apply sealant to the first three

threads of the bolt.
2. Install the exhaust manifold and NEW exhaust
manifold gasket.
492589
6-570
Engine
Notices.
Tighten
first pass to 15 Nm (11 lb ft}. Tighten
the exhaust manifold bolts beginning with
the center two bolts. Alternate from
outside bolts.
pass to 25 Nm (18 lb ft). Tighten the
exhaust manifold bolts beginning with 1he
center two bolts. Alternate from side-to-side,
left cylinder head.
5. Install the heat shield (2) and bolts (3).
Tighten
Tighten the heat shield bolts to 9 Nm (80 lb in).
492586
6. Install the Air Injection Reaction (AIR} pipe (with

check valve), NEW gasket and bolts.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20 .Nm (15 lb ft}.
(
346026
Engine
6-571
7. Install the oxygen sensor into the intake manifold.
Tighten
Tighten the oxygen sensor to 42 N-m (31 lb ft).
346021
Exhaust Manifold Installation (RightSide)

vehicle emissions and/or on-board diagnostic (OBD) II
system performance.

must be clean and free of debris or threadlocking
material.
Do not reuse exhaust gas recirculation (EGR) valve
and pipe gaskets or seals during assembly. Install
NEW gaskets and 0-ring seal.
Important: Do not apply sealant to the first three
threads of the bolt.
2. Install the exhaust manifold gasket and exhaust
manifold.

Notices.
lighten
3.1 . Tighten the exhaust manifold bolts first pass
to 15 N-m (11 lb ft). Tighten the exhaust
manifold bolts beginning with the center
two bolts. Alternate from side-to-side, and
work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts final
center two bolts. Alternate from side-to-side,
of the exhaust manifold gasket at the front of the
right cylinder head.
492592
6-572
Engine
5 . .Install the heat shield (2) and bolts (3).
Tighten
Tighten the heat shield bolts to 9 Nm (80 lb in).
492583
6. Install the air injection .reaction (AIR) pipe (with

check valve), NEW gasket and bolts.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20. Nm (15 lb ft).
346029
7. Install the AIR tubing and clamps.
346024
Engine
6-573
8. Install the oxygen sensor into the intake manifold.
Tighten
Tighten the oxygen sensor to 42 Nm (31 lb ft).
346021
9. Apply a light coating of clean engine oil to a NEW

0-ring seal and install the seal onto the EGA
valve pipe.
10. Insert the EGA pipe into the .intake manifold.
178489
11. Start the EGA valve pipe to inta.ke manifold

bolt (1 ).
Do not tighten the bolt at this time.
12. Install the EGR valve pipe to cylinder head bolts.
Do not tighten the bolts at this time.
492575
6-574
Engine Mechanical.; 5.7L
Engine
13. Install a NEW EGR valve pipe exhaust mani1old
gasket and bolts (1 ).
Tighten

manifold bolt to 10 N-m (89 lb in).
head b.olts to 50 Nm '(37 lb ft).
13.3. Tighten the EGR valve pipe to exhaust
manifold bolts to 30 Nm (22 lb ft).
492580
14. Install the EGRvalve, a NEW gasket and bolts.

Tighten
14.1. Tighten the EGR valve bolts a first pass to

1O Nm (89 lb in).
14.2. Tighten the EGR valve bolts a final pass
178487
Oil level Indicator and Tube Installation

1. Inspect the 0-ring seal for cuts or damage. If the
oil level indicator tube 0-ring seal is not cut or
damaged, it may be reused.
2. Lubricate the 0-ring seal with clean engine oil:
3. Install the 0-ring seal onto the oil level

indicator tube.
4. Install the oil level indicator tube into the engine

block and rotate into proper position.

Notices.
5. Install the tube bolt to the right cylinder head.

Tighten
Tighten the oil level indicator tube bolt to
25 N-m (18 lb ft).
6. Install the oil level indicator into the tube.
178459
Engine
6-575
Clutch Pilot Bearing Installation

)
Tools Required
J 38836 Pilot Bushing Installer/Clutch
1. Install a 5/8 inch washer ( 1) onto the J 38836 or
equivalent.
The washer serves as a stop. against the
crankshaft face and will assist in installing the
bearing to the proper depth.
2. Install the new pilot bearing (2) onto the tool.
J 38836
-2
260131
3. Install the new pilot bearing into the crankshaft

using the J 38836.
490867
6-576
Engine
4. Inspect the clutch pilot bearing for proper

installation.
A properly installed clutch pilot bearing will be
installed until flush to the rear face of the
crankshaft.
63195

Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the engine flywheel
bolts. This procedure requires a three stage tightening
process.
1. Install the manual transmission engine flywheel to
the crankshaft (if applicable).
156166
Engine
6-577
2. Install the automatic transmission engi'ne flywheel

to the crankshaft (if applicable).
178458

to the threads of the flywheel bolts.

Notices.
4. Install the engine flywheel bolts.
Tighten
4.1. Tighten the engine flywheel bolts first pass
in sequence to 20 N-m (15 lb ft).
4.2. Tighten the engine flywheel bolts
second pass in sequence to
50 Nm (37 lb ft) .
.4.3. Tighten the engine flywheel bolt.s final pass
in sequence to 109 Nm (7 4 lb ft).
,
63174
Crankshaft Balancer Installation

Tools Required
J 41665 Crankshaft Balancer and Sprocket
Installer
J 42386-A Flywheel Holding Tool
Important: The crankshaft balancer installation and
bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed
completely onto the crankshaft. The second, third and
fourth passes tighten the new bolt to the proper
torque.
The used crankshaft balancer bolt will be used only

during the first pass of the balancer installation
procedure. Install a NEW crankshaft balancer bolt and
tighten as described in the second, third and
fourth passes of the balancer bolt tightening procedure.
J 42386-A
260126
6.;578
Engine
Important, Make sure. the teeth. of the tool engage the
engine flywheel teeth.
Notices.
1. Install the J 42386-A and bolts.
Use one M 10-1.5 x 120 mm and one
M 10-1.5 x 45 mm bolt for proper tool operation.
Tighten
Tighten the J 42386-A bolts to 50 Nm (37 lbft).
Important: The balancer should be positioned onto
the end of the crankshaft as straight as possible prior
to tool installation.
2. Install the balancer onto the end of the crankshaft.
260154
c::,
J 41665-1
63187
3. Use the J 41665 in order to. install the balancer.

3.1. Assemble. the threaded rod, nut, washer
and installer.
Insert the smaller end of the installer into
the front of the balancer.
3.2. Use a wrench and hold the hex end of the
threaded rod.
3.3. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is started onto crankshaft.
3.4. Remove arid reverse the installation tool.
Position the larger end of theinstaller
agairist the front of the1 balancer.
3.5. Use a wrench and hold the hex end of the
threaded rod.
3.6. Use a second wrench and .rotate the
installation tool n'ut clockwise until the
balancer is installed onto the crankshaij.
3.7. Remove the balancer installation tool.
Engine
6-579
4. Install the used crankshaft balancer bolt.
Tighten
Tighten the crankshaft balancer bolt to
3.30 Nm (240 lb ft).
5. Remove the used crankshaft balancer bolt.
Important: The nose of the crankshaft should be
recessed 2.40-4.48 mm (0.094-0.176 in) into
the balancer bore.
6. Measure for a correctly installed balancer.
If the balancer is not installed to the proper
dimensions, install the J 41665 and repeat the
63245
7. Install the NEW crankshaft balancer bolt.
Tighten
7.1 . Tighten the crankshaft balancer bolt a
first pass to 50 Nm (37 lb ft).
7.2. Tighten the crankshaft balancer bolt a
second pass to 140 degrees using
the J 36660-A.
8. Remove the J42386-A.
260154
Engine Set-Up and Testing

Important: After overhaul, the engine should be tested
before installation into the vehicle. If a suitable test
stand is not available, the following procedure can be
used after the engine is installed into the vehicle.
1. Fill the crankcase with the proper quantity and
grade of engine oil.
2. Add engine oil supplement GM P/N 12345795 or
equivalent.
3. Fill the cooling system with the proper quantity
and grade of coolant.
5. Crank the engine several times. Listen for any
unusual noises or evidence that parts are
binding.
6. Start the engine and listen for unusual noises.
6-580
7. Check the vehicle oil pressure gauge or light and

confirm that the engine has acceptable oil
pressure.
If necessary, istall an oil pressure gauge and
measure the engine oil pressure.
8. Run the engine speed at about 1000 RPM until
the engine has reached normal operating
temperature.
. Engine
9. Listen for sticking lifters and other unusual noises.
10. Inspect for fuel, oil and/or coolant leaks while
the engine is running.
11. Perform a final inspection for the proper engine oil

and coolant levels.

Engine Component Description
5.7 liter lS1 V-8
309875
The 5.7 Liter V-8 engine is identified as RPO-LS1

and VIN-G.
Camshaft and Drive System

A billet steel one piece camshaft is supported by
five bearings pressed into the engine block. The
camshaft has a machined camshaft sensor reluctor
ring incorporated between the fourth and fifth bearing

journals. The camshaft timing sprocket is mounted
to the front of. the camshaft and is ddven by the
crankshaft sprocket through the camshaft timing chain.
Engine Me.chanical- 5.7L
Engine
The crankshaft sprocket is splined and drives the oil
pump driven gear. A. retaining plate mounted to
the front of the engine block maintains camshaft
location.
Crankshaft
The crankshaft is cast nodular iron. The crankshaft is
supported by five crankshaft bearings. The bearings
are retained by crankshaft bearing caps which
are machined with the engine block for the proper
alignment and clearance. The crankshaft journals are
undercut and rolled. The center main journal is the
thrust journal. A crankshaft position reluctor ring
is mounted at the rear of the crankshaft. The reluctor
ring is not serviceable separately.
Cylinder Heads
The cylinder head assemblies are cast aluminum and
have pressed in place powdered metal valve guides
and valve seats. Passages for the Engine Coolant Air
Bleed system are at the front and rear of each
cylinder head. There are no exhaust gas passages
within the cylinder head. The cylinder head design has
changed. Valve rocker arm covers are now retained
to the cylinder head by four center mounted rocker arm
cover bolts.
Engine Block
The engine block is a cam~in-block deep skirt
90 degree V configuration with five crankshaft bearing
caps. The engine block is aluminum with cast in
place iron cylinder bore liners. The five crankshaft
bearing caps each have four vertical M1 O and
two horizontal M8 mounting bolts. The camshaft is
supported by five camshaft bearings pressed into
the block.
Exhaust Manifolds
The exhaust manifolds are one piece cast iron design.
The exhaust manifolds direct exhaust gasses from
the combustion chambers to the exhaust system. Each
manifold has a single inlet for the Air Injection
Reaction (AIR) system and the left exhaust manifold
has a threaded opening for installation of an
oxygen sensor. Exhaust system gasses are directed
from the right exhaust manifold through the Exhaust
Gas Recirculation (EGA) pipe assembly and valve
to the intake manifold. The EGA pipe assembly
is retained to the exhaust manifold by two bolts and
sealed at the exhaust manifold flange with a gasket.
Each manifold also has an externally mounted
heat shield that is retained by bolts.
Intake Manifold
The IAFM or integraged air fuel module is a one piece
composite design that incorporates brass threaded
inserts for mounting the fuel rail, throttle cable bracket,
throttle body, and EGR inlet pipe. The intake
manifold is sealed to the cylinder heads by
eight separate non-reuseable silicone sealing gaskets
which press into the grooves of the intake housing.
6-581
The cable actuated throttle body assembly bolts to the

front of the intake manifold. The throttle body is
sealed to the intake manifold by a One piece push in
place silicone gasket. The fuel rail assembly with
eight separate fuel injectors is retained to the intake
by four bolts. The injectors are seated in their
individual manifold bores with. 0-ring seals. to. provide
sealing. A fuel rail stop bracket is retained at the
rear of the left fuel rail by the intake manifold mounting
bolts. A snap fit Manifold Absolute Pressure (MAP)
sensor housing is mounted at the rear of the manifold
and sealed by an 0-ring seal. The MAP sensor is.
installed and retained to the MAP sensor housing. An
externally mounted Exhaust Gas Recirculation (EGA)
pipe assembly installs into the top front of the
intake manifold. The EGA pipe assembly is sealed to
the intake manifold by an 0-ring seal and is,retained
to the manifold by one bolt. There are no coolant
passages within the intake manifold.
Oil Pan
The structural oil pan is cast aluminum. Incorporated
into the design are the oil filter mounting boss,
drain plug opening, oil level sensor mounting bore,

and oil pan baffle. The oil pan cover and oil level
sensor mount to the side of the oil pan. The alignment
of the structural oil pan to the rear of the engine
block and transmission bell housing is critical.
Piston and Connecting Rod Assemblies

The pistons are cast aluminum. The pistons use
two compression rings and one oil control ring
assembly. The piston is a low friction, lightweight
design with a flat top and barrel shaped skirt.
The piston pins are chromium steel. They have a
floating fit in the piston and are retained by a press fit
in the connecting rod. The connecting rods are
..
powdered metal. The connecting rods are fractured at
the connecting rod journal and then machined for
the proper clearance.
Valve Rocker Arm Cover Assemblies

The valve rocker arm covers are cast aluminum and
use a pre-molded silicone gasket for sealing. Mounted
to each rocker cover is an ignition coil and bracket
assembly. Incorporated intO the covers are the oil fill
tube, the Positive CrankcaseVentilation (PCV)
system passages, and the engine fresh air passages.
Rocker arm cover design has changed. The covers
are now retained to the cylinder head by four center
mounted rocker cover bolts.
Valve Train
Motion is transmitted from the camshaft through the
hydraulic roller valve lifters and tubular pushrods to the
roller type rocker arms. The valve lifter guides
position and retain the valve lifters. The valve rocker
arms for each bank of cylinders are mounted on
pedestals (pivot supports). Each rocker arm is retained
on the pivot support and cylinder head by a bolt.
Valve lash is net build.
6-582
Engine
Drive Belt System Description
New Product Information
The drive belt system consists of the following

compor:ients: .
The drive belt
The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory drive component mounting
brackets
The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
'- The engine cooling fan, i.f belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use one belt or two belts.
The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the
pulleys. There also may be a V-belt style belt used to
drive certain accessory drive components. The
drive belts are made of different types of rubbers
(chloroprene or EPDM) and have different layers or
plys containing either fiber cloth or cords for
reinforcement.
Both sides of the drive belt may be used to drive the
different accessory drive components. When the
back side of the drive belt is used to drive a pulley,
the pulley is smooth.
The drive belt is pulled by the crankshaft balancer
pulley across the accessory drive component pulleys.
The spring loaded drive belt tensioner keeps
constant tension on the drive belt to prevent the drive
belt from slipping. The drive belt tensioner arm will
move when loads are applied to the drive belt by the
accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which
is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory
drive component when the vehicle is not equipped with
the accessory.
The purpose of New Product Information is to highlight

or indicate important product changes from the
previous model year.
Changes may include one or more of the
following items:
Torque values and/or fastener tightening strategies
Changed engine specifications
New sealants and/or adhesives
Disassembly and assembly procedure revisions
Engine .mechanical diagnostic procedure revisions
New special tools required
A component comparison from the previous year
Torque Values and/or Fastener Tightening

Strategies
The new service thread repair tools .and service
procedures are identified.
Refer to Thread Repair, Thread Repair
Specifications, and Fastener Tightening
Specifications for additional information.
A second design connecting rod bolt may be
used. The proper fastener tightening value MUST
be used with the correct bolt.
Refer to Piston, Connecting Rod, and Bearing
Installation.
New Sealants and/or Adhesives
No sealant or adhes.ive changes from the previous

year. Refer to Sealers, Adhesives, and Lubricants.
Engine Mechanical Diagnostic

Procedure Revisions
'
Base Engine
Misfire, Valve Train, and other diagnostic
information is now provided in table form. Potential
or probable causes are supplied for each specific
concern.
Engine
New Special Tools Required
6-583
Engine Identification
The proper thread repair procedures for aluminum

cylinder blocks and cylinder heads have been added.
Refer to Thread Repair.
A Component Comparison from the Previous

Year
" Exhaust manifolds are a cast iron design with bolt.
on heat shields.
Refer to Engine Component Description.
" The vapor vent pipe, located above the engine
valley cover will now be referred to as the
engine coolant air bleed pipe.
Refer to Disassembled Views.
363593
The 5.7 Liter LS1 engine has two locations where

information is stamped on the blockto identify
the component. Location one (1) is the primary
stamping location. Location two (2) is the secondary
stamping location. Both stamping locations contain the
engine identification .numbers.
6-584
Engine
Lubrication
Lubrication Flow Schematic
t
9
u
63257
Engine lubrication is supplied by a gerotor type oil

pump assembly. The pump is mounted on the front of
the engine block and driven directly by the crankshaft
sprocket. The pump gears rotate and draw oil from
the oil pan sump through a pick-up screen and pipe.
The oil is pressurized as it passes through the
pump and is sent through the engine block oil galleries.
Contained within the oil pump assembly is a pressure
relief valve that maintains oil pressure within a
specified range. Pressurized oil is directed through the
lower gallery to the full flow oil filter where harmful
contaminants are removed. A bypass valve is
incorporated into the oil pan which will permit oil flow
in the event the filter becomes restricted. At the rear

of the block, oil is then directed to the upper main
oil galleries which are drilled just above the camshaft
assembly. From there oil is then directed to the
crankshaft and camshaft bearings. Oil that has entered
the upper main oil galleries also pressurizes the
valve lifter assemblies and is then pumped through
the pushrods to lubricate the valve rocker arms
and valve stems. Oil returning to the pan is directed
by the crankshaft oil deflector. Oil temperature,
pressure and crankcase level are each monitored by
individual sensors.
Engine
6-585
Oil Pump Assembly
64190
Legend
(1)
(2)
(3)
(4)
Driven Gear
Oil Pump Housing
Pressure Relief Valve
Pressure Relief Valve Spring
) Cleanliness and Care

Throughout this section, it should be understood
that proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop
practice even if not specifically stated.
O When any internal engine parts are serviced, care
and cleanliness is important.
When components are removed for service, they
should be marked, organized or retained in a
specific order for reassembly.
., At the time of installation, components should be
installed in the same location and with the same
mating surface as when removed.
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces
with tolerances that are measured in millimeters or
thousandths of an inch. These surfaces should
be covered or protected to avoid component
damage.
O A liberal coating of clean engine oil should be
applied to friction areas during assembly.
Proper lubrication will protect and lubricate friction
surfaces during initial operation.
(5)
(6)
(7)
(8)
Plug
Drive Gear
Cover Bolt
Cover
Replacing Engine Gaskets

Gasket. Reuse and Applying Sealants
Tools Required
J 28410 Gasket Remover
Do not reuse any gasket unless specified.
Gaskets that can be reused will be identified in
the service procedure.
Do not apply sealant to any gasket or sealing
surface unless called out in the service
information.
Separating Components
Use a rubber .mallet to separate components.
Bump the part sideways to loosen the
components.
Bumping should be done at bends or reinforced
areas to prevent distortion of parts.
6-586
Cleaning Gasket Surfaces

Remove all gasket and sealing material from the
part using the J 28410 or equivalent.
Care must be used to avoi.d gouging or scraping
the sealing surfaces ..
Do not use any other method or technique to
remove sealant or gasket material from a part.
Do not use abrasive pads, sand paper, or power
tools to clean the gasket surfaces ..
- These methods of cleaning can cause
damage to the component sealing surfaces.
- Abrasive pads also produce a fine grit
that the oil filter cannot remove from the oil.
- This grit is abrasive 9nd has been known to
cause internal engine damage.
Assembling Components.
When assembling components, use only the
sealant specified or equivalent in the service
procedure.
Sealing surfaces should be clean and free of
debris or oil.
Specific components such as crankshaft oil seals
or valve stem oil seals may require lubrication
during assembly.
Components requiring lubrication will be identified
in the service procedure.
When applying seala.nt to a component, apply the
amount specified in the service procedure.
Do notallow the sealant to enter into any blind
threaded holes, as it may prevent the bolt
from clamping properly or cause component
damage when tightened.
Tighten bolts to specifications. Do not overtighten.
Use of RTV and Anaerobic Sealer

Pipe.Joint Compound
Important: Three types of sealer are commonly used
in engines. These are RTV sealer, anaerobic gasket
eliminator sealer, and pipe joint compound. The correct
sealer and amount must be used in the proper
location to prevent oil leaks. DO NOT interchange the
three types of sealers. Use only the specific sealer
or the equivalent as recommended in the service
procedure.
Pipe joint compound is a pliable sealer that does
not completely harden. This type sealer is used
where two non-rigid parts (such as the oil pan and
the engine block) are assembled together.
Do not use pipe joint compound in areas where
extreme temperatures are expected. These
areas include: exhaust manifold, head gasket, or
other surfaces where gasket eliminator is
specified.
Follow all safety recommendations and directions
that are on the container.
To remove the sealant or the gasket material,
refer to Replacing Engine Gaskets
Engine
Apply the pipe joint compound to a clean surface.
Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt
holes. Do not allow the sealer to enter any
blind threaded holes, as it may prevent the bolt
from clamping properly or cause component
damage when the bolt is tightened.
Apply a continuous bead of pipe joint compound
to one sealing surface. Sealing surfaces to be
resealed must be cl.ean and dry.
Tighten the bolts to specifications. Do not
overtighten.
RTV Sealer
Room Temperature Vulcanizing (RTV) sealant
hardens when exposed to air. This type sealer
is used where two non-rigid parts (such as
the intake manifold and the engine block) are
assembled together.
Do not use Room Temperature Vulcanizing (RTV)
sealant in areas where extreme temperatures are
expected. These areas include: exhaust
manifold, head gasket, or other surfaces where a
gasket eliminator is specified.
Apply RTV to a clean surface. Use a bead size as
specified in the procedure. Run the bead to the
inside of any bolt holes. Do not allow the sealer to
enter any blind threaded holes, as it may
prevent the bolt from clamping properly or cause
damage when the bolt is tightened.
Assemble components while RTV is still wet
(within 3 minutes). Do not wait for RTV to
skin over.
~ Tighten bolts to specifications. Do not overtighten.
Anaerobic Sealer
Anaerobic gasket eliminator hardens in the
absence of air. This type sealer. is used where
two rigid parts (such as castings) are assembled
together. When two rigid parts are disassembled
and no sealer or gasket is readily noticeable;
the parts were probably assembled using a gasket
eliminator.
Apply a continuous bead of gasket eliminator to
one flange. Surfaces to be resealed must be
clean and dry.
Spread the sealer evenly with your finger to get a
uniform coating on the sealing surface.
Do not allow the sealer to enter any blind threaded (
holes, as it may prevent the bolt from clamping
properly or cause damage when tightened.
Engine
)
Important: Anaerobic sealed joints that are partially

torqued and allowed to cure more than five minutes
may result in incorrect shimming and sealing of
the joint.
Do not allow the sealer to enter any blind threaded
holes, as it may prevent the bolt from seating properly
or cause damage when the bolt is tightened.
" Tighten bolts to specifications. Do not overtighten.
" Af1er properly tightening the fasteners, remove
the excess sealer from the outside of the joint.
Separating Parts
Important: Many internal engine components will
develop specific wear patterns on their friction
surfaces.
VVhen disassembling the engine, internal components
MUST be separated, marked, or organized in a
way to ensure reinstallation to their original .location
and position.
Separate, mark, or organize the following components:
" Piston and the piston pin
Piston to the specific cylinder bore
" Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap
A paint stick qr etching/engraving type tool are
recommended. Stamping the connecting rod
or cap near the bearing bore may affect
component geometry.
" Crankshaft main and connecting rod bearings
.. Camshaft and valve lifters
" Valve lifters, guides, pushrods, pivot supports and
rocker arms
Valve to the valve guide
O
Valve spring and shim to the cylinder head

location
Engine block main bearing cap location and

direction
Oil pump drive and driven gears
Installation Precautions
Important: Follow the engine service information
below. This information is important in order to prevent
damage and in contributing to reliable engine
performance.
In order to avoid damage to the engine oil pan, use a

block of wood between the jack and the oil pan.
Ensure that the block of wood extends past the
complete width of the oil pan. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the oil
pan to bend against the pump screen. This condition
results in a damaged oil pick-up unit.
6-587
Caution: Refer to Fastener Notice in Cautions and

Notices.
When working on the engine, remember that the
12-volt electrical system is capable of causing short
circuits. When performing any work where electrical
terminals may possibly be grounded, disconnect
the ground cable of the battery at the battery.
Any time you remove the air cleaner, cover the intake
opening. This procedure protects against the
accidental entrance of foreign material. Foreign
material may follow the intake passage into the
cylinder. This condition causes extensive damage
when you start the engine.
In the mechanical procedures described in this
section, generally no references will be made to the
removal of optional equipment such as the power
steering pump, the air conditioning compressor, etc.
If you need to remove any optional equipment in order
to perform .other service, refer to the appropriate
section of this service manual for the specific
information.
Tools and Equipment

Special tools are listed and illustrated throughout this
section with a complete listing at the end of the
section. These tools (or their equivalents) are specially
designed to quickly and safely accomplish the
operations for which they are intended. The use of
these special tools will also minimize possible damage
to engine components. Some precision measuring
tools are required for inspection of certain critical
components. Torque wrenches and a torque angle
meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the following
items should be readily available:
Approved eye protection and safety gloves
A clean, well-lit, work area
.. A suitable parts cleaning tank
" A compressed air supply
Trays or storage containers to keep parts and
fasteners organized
" An adequate set of hand tools
Approved engine repair stand
" An approved engine lifting device that will
adequately support the weight of the components
6-588
Engine

Tool Number/ Description
Illustration
Illustration
J 3049-A
J 8037
Valve Lifter Remover
Piston Ring Compressor
14487
J 8062
(head off-vehicle)
J 6125-18
Slide Hammer
3414
4865
J 7872
J 8087
Magnetic Base Dial

Indicator Set
Cylinder Bore
Checking Gauge
5110
35463
J 8089
Carbon Removal Brush
J 8001
Dial Indicator Set
3415
35464
Engine
Illustration
Illustration
J 8433
J 24086-C
Two Jaw Puller
Piston Pin Remover/Installer
216164
14495
J 8520
J 24270
Camshaft Lobe Lift Dial

Indicator Set
3408
Cylinder Ridge Remover
3412
. J 9666
6-589
J 28410
Gasket Remover
Valve Spring Tester
5112
54479
J 21366
J 28428-E
Converter Holding Strap
Leak Detector Kit
47935
62292
J 22794
Spark Plug Port Adapter
J 28467-90A
26998
6-590
Engine

Illustration
Illustration
(
J 28467-B
Universal Support Fixture
J 37378-1
Valve Guide Reamer
J 33049
Camshaft Bearing
Remover/Installer
J 38836
Pilot Bushing Installer/Clutch
220640
5118
18093
J 36221
Hydraulic Clutch Line
Separator
J 38606
40271
105916
J 36462-A
Engine Support Adapter Leg
J 39411
54471
220642
J 36660-A
Torque Angle Meter
3413
J 39549
Ball Joint/Tie Rod Separator
181116
Engine
Illustration
5;.591
Illustration
J 41479
J.39580

. Installer
Engine Support Table
82341
64249
J 41480
J 39580,500
Front and Rear .Cover

Alignment (at oil pan
surface)
Engine SupportTable Top
74284
64211
J 41044
Ill
(i,);))j
220634
64260
J 41476
Front and Rear Cover
Alignment(at crankshaft
sea.I a.rea)
64207
64248
J 41556
Connecting Rod Guide
J 41558
Crankshaft Sprocket
Remover
98060
J 41478
J 41665

lnstalle'r
Crankshaft Balancer and

Sprocket Installer
64240
6-592

Illustration
Engine
Illustration
(
J 42078
Valve Stem Oil Seal Installer
J 41712.
Oil Pressure Sensor Socket
9192
98042
J 41798
Engine Lifting Brackets
74283
J 42386
54471
J 41816
Crankshaft Balancer
Remover
54474
J 42385-100
Thread Repair Kit (Cylinder
Head/Main Bearing Bolt)
54577
J 42385-200
Thread Repair Kit (General
Threads)
J 41816-2
Crankshaft End Protector
98058
54577
J 41818
Crankshaft Bearing Cap
Remover
38515
J 42385-300
Thread Repair Kit (Fixtures
and Hardware)
54577
Engine
Illustration
Tool Num.ber/ Description
/fl 1
~ JJ
Illustration
J 43276
Clutch Pilot Bearing
Remover
J 42451
Engine Support Adapter Kit
220638
(=@
13545
355040
J 42907
Oil Pressure Testing Tool
6-593
6-594
Engine Cooling
Engine
Engine Cooling
Specifications
Specification
Application
English
Accelerator and Cruise Control Servo Cable Adjuster Bolt
Metric
8N,m
Air Cleaner Bolt
12 N,m
1061bin
Air Conditioning Condenser Tube Nut

Coolant Heater Bolt (3.8 L)
16 Nm
2N,m
181bin
Coolant Heater (5.7 L)
40N-m
30 lb ft
Coolant Recovery Reservoir Bolt
12 Nm
1061bin
Cooling Fan Blade Nut
6Nm
531bin
Cooling Fan Motor Bolt
6Nm
531bin
Drive Belt Tensioner Bolt
50 N-m
37 lb ft
EGR Valve Outlet Pipe Bolt
29N,m
21 lb ft
EGR Valve Outlet Pipe Nut
29Nm
21 lb ft
Engine Block Coolant Drain Hole Plug (5.7 L)
60 Nm
44 lb ft
Engine Coolant Temperature Sensor (3.8 L)
25 Nin
20N,m
18 lb ft
71 lb in
12 lb ft
15 lb ft
Evaporator Tube Bolt
16N,m
12 lb ft
Knock Sensor (3.8 L)
19Nm
14 lb ft
Radiator Air Lower Deflector Screw
10 Nm
891bin
Radiator Drain Cock
2Nm
181bin
Transmission Oil Cooler Line Fitting (radiator end)
27Nm
20 lb ft
Vapor Vent Pipe Stud/Bolts (5.7 L)
12 Nm
27N,m
1061bin
Water Outlet Bolt (3.8 L)
20 lb ft
Water Outlet Bolt (5.7 L)
10Nm
891bin
Water Pump Bolt (3.8 L)
15 Nm + 80 degrees
11 lb ft + 80 degrees
Water Pump Bolt (5.7 L)
30N-m
22 lb ft
Water Pump Pulley Bolt (3.8 L) .
13 N-m
115 lb in
Engine Cooling System Specifications
I
Application
Specification
Metric
English
I
I
11.8 liters
I
I
12.5 quarts
11.6 liters
14.5 liters
15.3 quarts
14.3 liters
15.1 quarts
3.8 L (VINK)
Manual Transmission
Automatic Transmission
12.3 quarts
5.7 L (VIN G)
Manual Transmission
Engine Cooling
Engine
6"'.595
Application
GM SPO Group Number
Coolant Radiator
Coolant Recovery Reservoir
1.000
Coolant Recovery Reservoir Hose
1.000
Electric Engine Cooling Fan Motor
1.000
Engine Coolant Thermostat
1.000
1.000
3.000
Engine Electric Coolant Fan
1.000
Engine Electric Cooling Fan Shroud Kit
1.000
Radiator Air Lower Baffle
1.000
Radiator Air Upper Baffle.
1.000
Radiator Fill Cap
1.000
Radiator Inlet Hose
1.000
Radiator Outlet Hose
1.000
Vapor Vent Pipe (5.7 L)
1.000
Water Pump
1.000
.
.
...
Schematic and Routing Diagrams

Cooling System Schematic Icons
Icon Definition
.I.con
Refer to ESD Notice in Caution and Notices.
19384
Refer to 080 II Symbol Description Notice in Caution and Notices.
1.000
c:
Cooling Fan Schematics (V6 VIN K)

_ _ _ _ _ _ _ _
Power
COOL FAN
Distribution
MaxiFuse
Schematics In
40 A
Wiring Systems
..I --I
I
I
L
Power
Distribution
Schematics In
Wiring Systems
-1- -
3 RED I 402
rm
rm
-J- - -
0.35 ORN I 1640
IDEsc!
3 RED 1402
0.35 ORN I 1640
0.35 ORN I 1640

3WHTI 504
-r-----r---------:.1- - - - - -..T- - - -- -- - - - 83
Hrun~,
Junction I
I)1 Q1~
~~
Engine
Mini Relay
Block 1 1
C8
---c1! - - - - - - - - -
IL81-
- - -
~ Left
Engine
Cooling
Fans
_ _ _ _ _ B4
_
C10
- - - - - - - - - - - - - - - -
- - - - -
-----------
- - - - - - - - - - - - - - - - - :.-.:.-.:.
Cooling
I
Fan Relay 1
I " ...f Control
JI!
I
PCM
C1 =BLU
C2=CLR
2.
c.c
:::i
I
:
.i
~ Engine
B
Right
Cooling
Fan
C100
0.35 DK BLU 473
Cooling
Fan
2
_ _ _ _B6 _ ____
3 WHT 504
3 BLK
150
.
8167
3 WHT 504
O35
DK BLU 473
H
,,
(1)
-.;;r=-:
____ .
0.35 DK BLU 473
0.35 DK GAN 335
c.c
- -- __,
8166
J J, C100
A
3 GAY 532
M1m Relay
...
--------
- - - - - - - - - -;;;r- --
0.35
DK BLU 473
3 LT BLU 409
0.35 DK GRN I 335
Engine
Cooling
810
..
5179
Engine ..
W . . I C3
1nng I
en
:::i
.I
8169
3 RED I 402
CD
:::i
...------~~~~~~~~~~~~~~~~-r'--~~~~~~~~~~~~~~~~~~~~~~~~~~--,
0.35 ORN I 1640
!Loe
(RofAtAII Timesi
}
- - - ., Engine
COOL
I W'
J?
FAN
I mlig
.
MiniFuse 1Harness Junction
Js
10A
Block
1
I
c.n
. .
--=:.: :.-.:.-.:. --= :.-:.-.:. --= ..J} ~1Cool_~~ -
- - , Powertrain
Fan Relay
._ -f 2 and 3
- JI! Control
-
I Control
I Module (PCM)
I A
,,-
~
---------~-----..1~
'"-----------------
3 BLK 150
8113
/
/
Ground
Distribution
11>- - - - - .., .
Schematics In
Wiring!ystems
3 BLK I 150
1 BLK
150
=
c.c
~G106
:::J
502404
~
(1)
-~
Cooling Fan Schematics (V8 VIN G)
:::I
rsJ 111
[HotAtAII Timesi
--------- ;;w: - - - - - - - - - - {
1
~
Power
Distribution
Schematics
In Wiring
Systems
COOL FAN
MaxiFuse
40 A
Distribution
Schematics
In Wiring
J7
c~o~ --
FAN
MiniFuse
10 A
K1
J6
__________
~~m:, __________
. . : ____
0.35 ORN I 1640
3 RED 3 REDl402
402
~ E~Qine
I Wmng
Harness
1Junction
~ Block 1
[B
8169
3 REDl402
8179
0.35 ORN I 1640

3WHTl504
3 REDl402
~T"-----~-,
0.35 ORN I 1640
0.35 ORN I 1640
--------------- ,-
..
------
.
\,
I
"'
'
"
'
= , "'"'"
- :....:.... - - + - "- - - , Engine
Engine
CoolIng
Fan
Relay #1
Cooling
Fan
I Harness
onng
I
Junction
:Block 1
I
I
. ---------.1
'--
0.35
DKBLUr73
8166.
L__ _
0.35 DKBLU
3WHT 504
8167
.____ _
1
473
3 WHT 504
0.35
DKBLUl473
J J, C100
H.I. C100
I I
3 GRYl532
42
C1
r - - Cociling- -
I }
Fan Relay 1
I ---f Control
.i_
PCM
C1=BLU
C2=RED
33 C2
_____ - - - - - , - - :- - - - , Powertrain
1~21ay
I Control
"--f 2 and 3
I Module (PCM)
.i. Control
I ,._
L-------------------
-=-
. DK BLU1473
..
0.35
0.35 DK GRN 335
3BLK
150
~~i
-:-
-----------J~
:~g~~e
Cooling
Fan
A
3 BLKl150
. / /+s113
.
Ground
Distribution
Schematics I!>- In Wiring
-'
3 BLKl150
:::I
(C
:::I
Cl)
0
0
2.
1 BLK
150
:::I
(C
c.n
G106
488034
"'-I
6-598
Engine Cooling
Engine
Component locator
(
Cooling System Components

Name
Engine Cooling Fans
Location
Behind the radiator
Locator View
Connector End View
Cooling System
Component Views
Cooling System
Connector End Views
In the left front corner of the engine

compartment
Power and Grounding

Component Views in
Wiring Systems
Powertrain Control
Module (PCM)
(V6 VINK)
On the right side of the engine

compartment, rear of the .wheelhouse
Power and Grounding

Component Views in
Wiring Systems
PCM Connector End

Views in Engine Controls
Powertrain Control
Module (PCM)
(V8 VIN G)

compartment, rear of the wheelhouse
Engine Controls
Component Views in
Engine Controls
PCM Connector End

C100 (10 cavities)
Engine to forward lamp IJarness, in lhe

engine compartment, above the right
wheelhouse
Harness Routing Views in

Wiring Systems
lnline Harness Connector

End Views in Wiring
Systems
G106
Attached to the top left side of the radiator

support

Wiring Systems
G109
Attached to the left front frame rail, forward

of the brake pressure mod~lator ~alve
bracket

Wiring Systems
8113
In the forward lamp harness approximately

7 cm (2.8 in) from the electronic throttle
control (ETC) module/cruise control
module breakout
8166
.In the forward lamp harness,

approximately 14 cm (5.5 in) from G105
breakout
8169
In the forward lamp harness,

approximately 6 cm (2.4 in) from the main
branch into the engine wiring harness
junction block .1 breakout
8179
In the forward lam harness, approximately

25 cm (9.8 in) from the engine wiring.
harness junction block 1 breakout
Engine Wiring Harness

Junction Block 1
Engine Coo I.mg
6-599
Engine System _
Component
Cooling
_ _ _ _Views
_ _ __Cooling~Fa~n~s'..__ _ _ _ _
legend
(1) Cooling Fan 2
(2) Cooling Fa~n~1'.__ _ _ _ _ __
6-600
Engine Cooling
Engine
Right Engine Cooling Fan Motor
Cooling System Connector End Views
Left Engine Cooling Fan Motor
~0 0~
~0 0~
62489
.
62489
Connector Part
Information
Pin
Wire Color
. . GRY
LT BLU
1203-3769
2 Way FMetri-Pack
630 Series (BLK)
Circuit
No.
532
409
Function
Connector Part
Information
..
Pin
Wire Color
BLK
WHT
1203-3769
2 Way F Metri-Pack
630 Series (BLK)
Circuit
No.
150
504
Function
Ground
Cooling Fan Motor Feed
Cooling Fan Motor Feed

Cooling. !=an Motor Feed
Engine Cooling
Engine
6-601

Engine Overheating
Step
Action
Value
Yes
No
DEFINITION: Engine temperature lamp comes ON and stays ON, or the temperature gauge shows hot, or coolant overflows
from the reservoir .onto the ground while the engine is running.
1
2
,
Check for a.loss of coolant. Refer to Loss of Coolant.

Is there a loss of coolant?
1. Check for weak engine coolant solution.

2. Perform a concentration test. Refer to Coolant
Concentration Testing.
Does the engine still overheat?
Go to Step 2
1. Check for obstructed radiator air flow or bent

radiator firis.
2. If necessary, r$move or relocate added-on parts that
block air to the radiator.. Clean away any bugs,
leaves, or other debris.
Poes .the engine still overheat?
Go to Step 3
System OK
Go to Step 4
System OK
Go to Step 5
System OK
Go to Step 6
System OK
Go to Step 7
System OK
Go to Step 8
System OK
Go to Step 9
System OK
1. Check for a loss of system pressure.

2. Perform a radiator fill cap pressure test. Refer to
Pressure Cap Testing.
1. Check for a faulty Engine Coolant Temperature (ECT)

sensor. Refer to one of the following procedures:
OTC P0117 Engine Coolant Temperature (ECT)
Sensor Circuit Low Voltage in Engine
Controls-3.8L.
Sensor Circuit High Voltage in Engine
Controls-3.8L.
Sensor Circuit Low Voltage in Engine
Controls-5.?L.
Sensor Circuit High Voltage in Engine
Controls-5. 7L.
2. If necessary, replace the sensor.
1. Check for a damaged coolant recovery reservoir.

2. Check for a leaking or kinked reservoir hose.
6
3. If necessary, reroute the reservoir hose or replace the

recovery reservoir. Refer to Coolant Recovery
Reservoir Replacement.
1. Check for a loose accessory drive belt.
2. Check the tension of the drive belt. Refer to the
following procedures:
e Drive Belt Replacement in Engine
Mechanical - 3.8L.
Drive Belt Replacement - Accessory in Engine
Mechanical - 5.7L.
)
8
1. Check for advanced or retarded ignition timing.

2. If necessary, adjust the timing.
6-602
Engine Cooling
Engine
Engine Overheating (cont'd)
Step
Action
Value
1. Check for blocked cooling system passages.

2. Flush the cooling system. Refer to Flushing.
3. If necessary, remove and inspect the cylinder head.
10
1. Check for an incorrect or damaged cooling fan

blade(s).
2. Check for the correct fan blade(s) part number.
3. If necessary, replace the fan blade(s). Refer to
Cooling Fan Replacement - Electric.
11
1. Check for inoperative cooling fans. Refer to Electric

Cooling Fan Diagnosis (Description) in Engine
Controls - 3.8 L or Electric Cooling Fan Diagnosis in
Engine Controls - 5.7 L.
2. If necessary, replace the cooling fan and motor. Refer
to Cooling Fan Replacement - Electric.
12
1. Check for a stuck closed thermostat. Refer to

Thermostat Diagnosis.
2. If necessary, replace the thermostat.
~ For the 3.8 L engine, refer to Thermostat
Replacement (3.8 L).
For the 5.7 L engine, refer to Thermostat
Replacement (5. 7 L).
13
14
Yes
No
Go to Step 10
System OK
Go to Step 11
System OK
Go to Step 12
System OK
Go to Step 13
System OK
1. Check for a faulty coolant pump.

2. If necessary, replace the coolant pump.
e For the 3.8 L engine, refer to Water Pump
For the 5.7 L engine, refer to Water Pump
1. Check the radiator cooling capacity.

2. Check if the radiator is the proper size for the vehicle.
3. If necessary, determine the proper radiator size and
replace the radiator. Refer to Radiator Replacement.
Is the repair complete?
Go to Step 14
System OK
System OK
Loss of Coolant
Step
Action
1. Check for a wrong or defective radiator fill cap.
2. Perform a cap pressure test. Refer to Pressure Cap
Testing: If necessary, replace the fill cap.
Is there still a coolant loss?
Value
Yes
No
124 kPa (18 psi)
1. Check for a distorted radiator fill neck.

2. If the upper sealing area of the fill neck is distorted,
use a wood block and a mallet to reshape the neck in
order to fit the cap.
1. Check for a leaking coolant recovery reservoir.

2. Check for a loose or damaged reservoir hose.
3. If the reservoir or hose is damaged, replace the
reservoir or the hose. Refer to Coolant Recovery
Go to Step 2
System OK
Go to Step.3
System OK
Go to Step 4
System OK
Engine Cooling
Engine
6603
Loss of Coolant (cont'd)

Step
Action
Value
Yes
No
1. Check for any lo.ose or damaged radiator hoses or

4
..
heater hoses.
2. Re-seat the hoses and clamps. If necessary, replace
the hoses and the clamps.
Go to Step 5

1. Check for a seal leak at the water pump.

2. If the seal is leaking, replace the water pump.
6
System OK
I
1. Check for a water pump gasket leak.

2. If necessary, replace the water pump gasket.
Go to Step6
System OK
Goto Step 7
System OK

1. Check if the cylinder head bolts are tightened to
)
7
specification. Refer to the following procedures:

Fastener Tightening Specifications in Engine
Mechanical - 3.8L
Fastener Tightening Specifications in Engine
Mechanical - 5.7L
2. Tighten the cylinder head bolts to the specification. If
necessary, replace the cylinder head gasket. Refer to
one of the following procedures:
Cylinder Head Replacement (Left) in Engine
Mechanical 3.8L
Cylinder Head Replacement (Right) in Engine
Mechanical 3.8L
Cylinder Head Replacement (Left) in Engine
Mechanical-5.7L.
Cylinder Head Replacement (Right) in Engine

Mechanical-5. 7L.
1,
,I
System OK
Go to Step 9
System OK
Goto Step
1. Check for any coolant leaks at the radiator.

2. Inspect the radiator.
8
3. If necessary, replace the radiator. Refor to .Radiator

Replacement.
Is there still a loss of coolant?
1. Check the following for leaks:

O The intake manifold
The cylinder head gasket
. The engine block coolant drain hole plug or the
1,
knock.sensor
The heater core
2. Make the necessary repairs or replace the
components as necessary in order to repair the leak.
System OK
..
6-604
Engine
Engine Cooling
Thermostat Diagnosis
Thermostat Test
The coolant thermostat can be tested using a
temperature (tempi!) stick. The temperature stick is a
pencil like device. It has a wax material containing
certain chemicals which melt at a given temperature.
Temperature sticks can be used to determine a
thermostat's operating range, by rubbing 87C (188F)
and 97C (206F) sticks on the thermostat housing.
Tools Required
J 24731-188 188F Tempilstick
J 24731-206 206F Tempilstick
1. Use a tempilstick in order to find the opening and
the closing temperatures of the coolant thermostat.
J 24731-188 tempilstick melts at 87C (188F).
The thermostat should begin to open.
J 24731-206 tempilstick melts at 97C (206F).
The thermostat should be fully open.
2. Replace the coolant thermostat if it does not
operate properly between this temperature range.
Engine Fails To Reach Normal Operating Temperature

Step
Action
Notice.: When adding coolant, use DEX-COOL coolant. If

silicated coolant is added to the system, premature engine,
heater core or radiator corrosion may result. In addition,
the engine coolant will require change sooner-at
50,000 km (30,000 mi) or 24 months.
1. Check the level of the coolant in the coolant recovery
reservoir. The coolant level should be at the FULL
COLD mark.
2. Add engine coolant as necessary.
Does the engine reach normal operating
temperature now?
1. Check for a blockage in the coolant passages.

2. Flush the cooling system or flow check the radiator.
Refer to Flushing.
Does the engine reach normal operating
temperature now?
1. Check to see if the correct type of thermostat was

installed.
2. Check if the thermostat is stuck in the open position.
Refer to Engine Overheating.
3. If necessary, replace the thermostat.
Replacement (5. 7 L)
Does the engine reach normal operating temperature?
Coolant Concentration Testing

Cleaning The Instruments
Tools Required
J 23688 Coolant and Battery Fluid Tester
(Fahrenheit Scale)
O
J 26568 Coolant and Battery Fluid Tester

(Centigrade Scale)
Some coolant manufacturers mix other types of glycol

into their coolant formulations. Propylene glycol is
the most common new ingredient.
A hydrometer does not always provide a correct
measurement of freeze protection when anything other
than ethylene glycol and water is being tested. The
degree of inaccuracy varies depending on the
proportion of other glycols present in the coolant.
Value(s)
Yes
No
System OK
Go to Step 2
System OK
Go to Step 3
System OK
All new GM vehicles are produced with coolant that

can be accurately measured with a hydrometer;
however, when the type and quality of coolant being
measured is unknown, such as a customer vehicle that
has accumulated mileage, the use of the refractometer
is recommended.
Coolant testers J 23688 (Fahrenheit Scale) or J 26568
(Centigrade Scale) can be used to check the
antifreeze protection of the coolant. Make sure the
refractometer markings are correct. Unless J 23688 or
J 26568 has a provision for temperature correction,
test the temperature at which J 23688 or J 26568
is calibrated. If the coolant is warmer or cooler, 1he
reading may be incorrect. Follow the manufacturer's
direction on using J 23688 or J 26568.
Engine
Engine Cooling
6-605
2. Ensure that the dropper is free of any previous

sample before starting the testing procedure.
3. Dip the end of the plastic dropper i.nto the coolant
without removing it from the tester. Be sure to
insert the tube slightly below the fluid level.
4. Press and release the bulb to draw a sample of
coolant.
J 23688 or
J 26568
13712
1. To clean, swing back the plastic sample cover

located at the slanted end of the J 23688 or
J26568.
2. Wipe clean both the prism and the bottom of the
sample cover.
3. Dry them with a tissue or a clean soft cloth.
4. Close the sample cover.
402834
5. Bend the plastic tube around the J 23688 or

J 26568 so that the tip can be inserted in the
sample cover opening.
6. Eject a few drops of the coolant onto the
measuring prism by pressing the bulb. Take
a reading.
7. The J 23688 and the J 26568 are equipped with
an eyeguard that can be used in two positions.
when wearing eyeglasses, the eyeguard should be
folded back; when no eyewear is worn the
eyeguard should be extended. Proper positioning
of the eyeguard will help eliminate stray light
and improve image quality.
Testing Procedure
13709
1. Release the clear plastic dropper, located on the

side of the J 23688 or J 26568 should be used to
draw the test sample.
6-606
Engine
Engine Cooling
Important: The temperature scale is reversed from a

standard thermometer scale. Readings below
O degrees are on the upper half of the scale. The
scale is not visible until a sample is placed on
the prism. If the concentration of the solution tested is
greater than the limits of the scale, the shadow will
not be visible.
Calibrating Testers
The J 23688 and the J 26568 are factory calibrated
and sealed. The testers should not require adjustment.
If adjustment is required, perform the following
adjustment procedure:
1. Make sure the temperature of the J 23688 and

the J 26568 is between 21 and 29 degrees
Centigrade (70 and 85 degrees Fahrenheit).
2. Using distilled water, take a reading.

3. If the reading departs from a O degrees Centigrade
(32 degrees Fahrenheit) reading on the scale
3.1. Remove the sealant covering the scre,v.
3.2. Turn the screw in the direction necessary to
adjust the reading to the O degrees
Centigrade (32 degrees Fahrenheit) line.
l!Tlportant: Never remove the screw from the J 23688

or the J 26568.
3.3. Reseal the screw using silicone sealant.
Cooling System leak Testing

Leak Testing Procedure (On Vehicle)
402832
8. To take a reading, point the J 23688 or the

J 26568 toward any light source and look into the .
eyepiece.
1...0 0 - - - 0
BOl6S%)
40(47")
OOIS3%).
1.250
1.200
==
~10(44%)
a:
~
5(41%)
0('!8%)
== :e
-==
-
Tools Required
J 24460-01 Cooling System and Cap Pressure Tester

Caution: Under pressure, the temperature of
the solution in the radiator can be considerably
higher, without boiling. Removing the radiator cap
while the engine is hot (pressure is high), will
cause the solution to boil instantaneously, with
explosive force. The solution will spew out
over the engine, fenders, and the person removing
the cap. Serious bodily injury may result.
Flammable antifreeze, such as alcohol, is not
recommended for use at any time. Flammable
antifreeze could cause a serious fire.
&(34%)
1.,..
Caution: In order to help avoid being burned, do

not remove the radiator cap while the engine
and the radiator are hot. Scalding fluid and steam
can be blown out under pressure if the cap is
removed too soon.
+t0(3fl%}
-=o
-=- a:
-=
==-BATTISRY
UJ
1.100
CHARGE
+25(12%/
SPECtFfC
GRAVITY
PFIOPOYLEN&
GLYCOL
+U'
1. After the system has cooled, remove the

radiator/surge tank pressure cap.
(10%)
"F
FREE2E POINT
('loGLYCOLaY\IOl.UME)
13713
9. The coolant freeze point reading is taken where

the dark and light portions of the scale meet.
Take the coolant reading on the right-hand scale.
10. To obtain the best contrast between the light and
dark portions of the scale, tilt the J 23688 or the
J 26568 toward a light source. if the edge between
the light and dark shadow is not sharp, the
measuring prism was not sufficiently clean and
dry or there was not enough fluid on the
measuring prism.
Engine Cooling
Engine
6-607
J24460-01
11658
2. Connect the cooling system tester J 24460-01 to

the radiator/surge tank.
3. Apply normal system operating pressure. Do not
exceed 138 kPa (20 psi).
1375
6. Check the radiator/surge tank cap with J 24460-01

in order to ensure the cap maintains the correct
pressure.
7. If the radiator leaks during the pressure test, mark
the leak area so the leak can be located once the
radiator has been removed from the vehicle.
Testing Procedure (Off Vehicle)

Tools Required
J 24460-01 Cooling System and Cap Pressure Tester
1374
4. Watch the gauge needle for an indication of a

leak. Examine all cooling system connections
and components, including the radiator and the
heater core, for leaking coolant.
5. Tighten the hose connections or repair as
required.
Notice: Do not use boil-out tanks or any other tank

that has been used for copper or brass radiators. The
remaining solutions or chemicals in these tanks
could cause radiator failure.
1. Plug the inlet and outlet tubes. Make sure the
drain cock is closed.
2. Attach the J 24460-01 to the radiator.
3. Apply pressure to the radiator. Do not exceed
138 kPa (20 psi) of pressure.
'
4. Observe the gauge for any pressure loss.
5. Run water over the repair area and look for any
bubbles. If a large tank is available, the radiator
can be submerged in order to check for air
bubbles.
6-608
Engine Cooling
Engine
Pressure Cap Testing
Notice: When adding coolant, it is important that you

use GM Goodwrench DEX-COOL or HAVOLINE
DEX-COOL coolant. If Coolant other than
DEX-COOL or HAVOLINE DEX-COOL is added to
the system the engine coolant will require change
sooner-at 50 000 km (30,000 mi) or 24 months.
1. Park the vehicle on a level surface.
2. Remove the coolant recovery reservoir fill cap.
3. Remove the radiator pressure cap.
Radiator Fill Cap Inspection Procedure

Check the cap for a weak spring washer or
damage to the gasket. If the spring washer
is weak, or damaged replace the cap.
Check the inner sealing surface of the radiator
neck for damage or debris.
Pressure Testing Procedure

Tools Required
3.1. Slowly rotate the cap counter clockwise

until the cap reaches the stop. Do not
press down while turning the radiator
pressure cap.
J 24460-01 Cooling System Pressure Tester

1. Clean the radiator fill cap.
3.2. Wait until any remaining pressure, indicated

by a hissing sound, is relieved.
3.3. After all the pressure is relieved, press
down on the pressure cap and continue to
rotate the pressure cap counter clockwise.
01
4. Open the radiator drain cock.

5. Open the air bleed vent located on top of the
water outlet. Open the air bleed vent two or
three turns ..
6. Place a shop towel under the bleed valve in order
to prevent coolant from splashing onto the EGR
valve outlet pipe.
7. Remove the engine knock sensors, located on
either side of the engine block.
1375
2. Install the cap on the J 24460-01.

3. In order to obtain the minimum holding pressure,
slowly pump the J 24460-01.
" If the cap fails to hold 83 kPa (12 psi) of
pressure, replace the cap.
" If a new cap is installed, coat the gasket with
engine coolant.
Repair Instructions
System (3.8 l)
Draining Procedure
Caution: As long as there is pressure in the
cooling system, the temperature can be
considerably higher than the boiling temperature
of the solution in the radiator without causing
the solution to boil. Removal of the pressure cap
while the engine is hot and pressure is high
will cause the solution to boil instantaneously possibly with explosive force - spewing the
solution over the engine, fenders and the person
removing the cap.
Important: Store used engine coolant in the proper

manner, such as in a used engine coolant holding
tank. Do not pour used engine coolant down a drain.
Ethylene glycol antifreeze is a very toxic chemical.
Do not dispose of coolan.t into the sewer system
or ground water. This is illegal and ecologically
unsound.
8. Allow the system to drain completely.
Filling Procedure
Notices.
1. Close the radiator drain cock.
Tighten
Tighten the radiator drain cock to 2 N-m (18 lb in).
2. Install the engine knock sensors.
Tighten
Tighten the knock sensor to 19 Nm (14 lb ft)
3. Add enough water to fill the coolant system.
4. Run the engine until the thermostat opens.
5. Stop the engine. Repeat the draining procedure
until the drained fluid is colorless.
6. Remove, clean, and then reinstall the coolant
recovery reservoir. Refer to Coolant Recovery
Engine
7. Complete the following steps in order to .fill the

cooling system:
7.1. Close the air bleed vent when the bubbles
disappear and only the coolant is visible.
7.2. Fill the radiator to below the fill neck.
7.3. Fill the coolant recovery reservoir to the
FULL HOT mark.
7.4. Install the coolant recovery reservoir cap.
8. With the radiator pressure cap removed, run the
engine until the engine reaches normal operating
temperature. The radiator inlet hose will
become hot.
9. With the engine idling, add coolant to the radiator
until the coolant level reaches the bottom of the
filler neck.
10. Install the pressure cap. The arrows on the cap
must line up with the vent tube.
11. After the engine reaches normal operating
temperature, check for coolant leaks.
Engine Cooling
Filling Procedure

Notices.
2.
3.
4.
5.
6.
7.

System (5.7 l)
Drail1ing Procedure
Caution: As long as there is pressure in the

cooling system, the temperature can be
considerably higher than the boiling temperature
of the solution in the radiator without causing
the solution to boil. Removal of the pressure cap
while the engine is hot and pressure is high
will cause the solution to boil instantaneously possibly with explosive. force - spewing the
solution over the engine, fenders and the person
removing the cap.
Notice: When adding coolant, it is important that you
use GM Goodwrench DEX-COOL or HAVOLINE
DEX-COOL coolant. If Coolant other than
DEX-COOL or HAVOLINE DEX-COOL is added to
the system the engine coolant will require change
sooner-at 50 000 km (30,000 mi) or 24 months.
1. Park the vehicle on a level surface.
2. Follow the steps below to remove the radiator
pressure cap:
Slowly rotate the cap counterclockwise until
the cap reaches the stop. Do not press
down while turning the radiator pressure cap.
Wait until any remaining pressure, indicated by
a hissing sound, is relieved.
After all the pressure is relieved, press down
on the cap and continue to rotate the
pressure cap counterclockwise.
3. Open the radiator drain cock.
4. Remove the engine block coolant drain hole plugs.
5. Inspect the engine coolant:
Discolored - follow the flush procedure below.
Normal in appearance - Continue with the
next step.
6. Allow the system to drain completely.
6-609
8.
9.
10.
11.
Tighten
Install the coolant drain hole plugs.
Tighten
Tighten the drain hole plugs to 60 Nm (44 lb ft).
Add enough water to fill the coolant system.
Run the engine until the thermostat opens.
Stop the engine. Repeat the draining procedure
until the drained fluid is colorless.
Remove, clean, and reinstall the coolant recovery
reservoir. Refer to Coolant Recovery Reservoir
Replacement.
Complete the following steps in order to fill the
coolant system:
7 .1. Fill the radiator to below the fill neck.
7.2. Fill the coolant recovery reservoir to the
FULL HOT mark.
7.3. Install the coolanfrecovery reservoir cap.
With the radiator pressure cap removed, run the
engine until normal operating temperature is
reached. The radiator inlet hose will become hot.
With the engine idling, add coolant to the radiator
until the coolant level reaches the bottom of the
fill neck.
Install the pressure cap.
After the engine reaches normal operating
temperature, check for coolant leaks.
Flushing
Important: Store used engine coolant in the proper
manner, such as in a used engine coolant holding
tank. Do not pour used engine coolant down a drain.
Ethylene glycol antifreeze is a very toxic chemical.
Do not dispose of coolant into the sewer system
or ground water. This is illegal and ecologically
unsound.
You can use various methods and equipment to flush
the cooling system. If special equipment is used
(such as a back flusher) follow the manufacturer's
instructions. However, always remove the thermostat
before flushing the system.
Engine Coolant Recycling

Whenever the cooling system needs maintenance or
repairs, remove and. replace the coolant with new
coolant.
Important: Do not. recycle coolant on vehicles

manufactured with GM Goodwrench DEX-COOL.
Recover the used coolant.
" Store the coolant in a used coolant holding tank.
Submit the used coolant for recycling on a
regular basis.
6-610
Engine Cooling
Engine
Radiator Cleaning
Caution: NEVER spray water on a hot radiator. The
resulting steam could cause personal injury.
Notice: The radiator fins are necessary for good heat

transfer. Do not brush the fins. This may cause
damage to the fins, reducing heat transfer.
Important: Do not brush the radiator fins. The radiator

fins are necessary for good heat transfer. Brushing
damages the fins and reduces heat transfer.
Clean the front face of the radiator annually.
Clean the front face of the condenser.
Remove bugs, leaves, etc. by blowing compressed
air through the radiator.
Blow the air from the rear toward the front. If
compressed air is not available a water hose can
be used to force water through the radiator.
Use water only with the engine not running
and cool.
Coolant Recovery Reservoir Replacement

Removal Procedure
1. Remove the battery. Refer to Battery Replacement
in Engine Electrical.
2. Remove the coolant recovery reservoir hose from
the radiator.
221645
3. Remove the accelerator and cruise control servo

cable bolts, if equipped with a 5.7 L engine:
4. Reposition the accelerator and cruise control
servo cable adjuster, if equipped with a
5.7 L engine.
221646
Engine
Engine Cooling
6-611
5. Remove the coolant recovery reservoir bolt.
221653
6. Remove the wiring harness rosebud clip from the

reservoir neck.
7. Remove the coolant recovery reservoir.
221650

the reservoir.
9. Clean the coolant recovery reservoir with soap
and water. Thoroughly rinse the reservoir.
)
221663
6-612
Engine Cooling
Engine
1. Install the coolant recovery reservoir hose to the
reservoir.
2. Install the coolant recovery reservoir.
221663
3. Install the wiring harness rosebud clip to the

reservoir neck.
221650

Notices.
4. Install the coolant recovery reservoir bolt.

Tighten
Tighten the coolant recovery reservoir bolt to
12 Nm (106 lb in).
(
221653
Engine
Engine Cooling
6-613
5. Position the accelerator and cruise control servo

cable adjuster, if equipped with a 5. 7 L engine.
6. Install the accelerator and cruise control servo
cable bolts, if equipped with a 5. 7 L engine.
Tighten
Tighten the accelerator and cruise control servo
cable adjuster bolts to 8 Nm (71 lb in).
221646

radiator.
8. Install the battery. Refer to Battery Replacement
9. Add engine coolant to the FULL COLD mark on
the reservoir.
221645
Coolant Recovery Pipe Replacement

Removal Procedure
1. Remove the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.
2. Remove the coolant recovery hose and grommet
from the reservoir.
221663
6-614
Engine Cooling
Engine
1. Install the coolant recovery hose and grommet to
the reservoir.
2. Install the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.
221663
Radiator Hose Replacement - Inlet (3.8 l)

Removal Procedure
Fil/ing Cooling System (3.8 L).
208554
3. Remove the air intake duct resonator .
(
554755
Engine
Engine Cooling
6-615
221680
5. Remove the inlet hose (1) from the radiator.
349794
1. Install the inlet hose (1) to the radiator.
349794
6-616
Engine Cooling
Engine
221680
3. Install the air, intake duct resonator.
554755
4. Connect the IAT sensor electrical connector:

5. Fill the cooling system. Refer to Draining and
Filling Cooling System (3.8 L).
208554
Engine
Engine Cooling
6-617
Radiator Hose Replacement - Inlet (5.7 L)

Removal Procedure
Filling Cooling System (5. 7 L}.
2. Disconnect the intake air temperature sensor (IAT)
208553
208569
349797
6-618
Engine
Engine Cooling
6; Remove the inlet hose from the power steering

cooler, if equipped.
221666
7. Remove the inlet hose from the water pump.
221676
1. Install the inlet hose to the water pump.
(
221676
Engine
Engine Cooling
6-619
2. Install the inlet hose to the power steering cooler,

if equipped.
221666
349797
208569
6-620
Engine
Engine Cooling

7. Refill the cooling system. Refer to Draining
and Filling Cooling System (5. 7 L).
208553
Radiator Hose Replacement Outlet (3.8 L)

Removal Procedure
208554
(
554755
Engine
Engine Cooling
6-621

Information.
221689
6. Remove the outl.et hose (2) from th.e radiator.

7. Remove the hose support from the fan shroud.
349794
1. Install the outlet hose support to the fan shroud.
2. Install the outlet hose (2) to the radiator.
349794
6-622
Engine Cooling
Engine
221689
554755

(
208554
Engine
Engine Cooling
6-623
Radiator Hose Replacement Outlet (5.7 l)

Removal Procedure
1 . Drain the cooling system. Refer to Draining and
Filling Cooling System (5. 7 L).
208553
208569
5. Remove the ou'tlethose from the water outlet.

Information.
221671
6~624
Engine
Engine Cooling
7. Remove the outlet hose (2) from the radiator.

2
349797
2
1. Install the outlet hose (2) to the radiator.

349797
3. Install the outlet hose to the water outlet.
(
221671
Engine
Engine Cooling
6-625
208569
5. Connect the IAT sensor electricalconnector.

7. Refill the cooling system. Refer to Draining
208553
Throttle Body Heater Hose Replacement Inlet (5. 7 L)

Removal Procedure
2. Disconnect the throttle position sensor (TPS)
electrical connector, if necessary.
3. Reposition the hose clamps at the throttle body
and engine coolant air bleed pipe.
4. Remove the throttle body heater inlet hose from
the throttle body.
5. Remove the throttle body inlet hose from the
engine coolant air bleed pipe.
220621
6-626
Engine
Engine Cooling
1. Install the throttle body inlet hose to the engine

coolant air bleed pipe.
2. Install the throttle body heater inlet hose to the
throttle body.
and engine coolant air bleed pipe.
4. Connect the TPS electrical connector, if
necessary.
220621
Throttle Body Heater Hose Replacement Outlet (5. 7 l)

Removal Procedure
and radiator.
3. Remove the throttle body heater outlet hose from
the throttle body.
4. Remove the throttle body outlet hose from the
radiator.
220620
1. Install the throttle body outlet.hose to the radiator.
2. Install the throttle body heater outlet hose to
the throttle body.
and radiator.
220620
Engine
Engine Cooling
6-627
Cooling Fan Replacement - Electric

Removal Procedure
Caution: Keep hands, tools, and clothing away
from the electric engine coolant fans in order
to help prevent personal injury. These fans are
electric and can turn on whether or not the engine
is running. The fans can start automatically with
the ignition in the ON position.
1. Disconnect the intake air temperature (IAT) and
mass airflow (MAF) sensors electrical connectors,
if equipped with the 5.7 L engine.
208553
2. Remove the air intake duct resonator, if equipped

with the 5.7 L engine.
208569
3. Disconnect the electrical connector from the

intake air temperature (IAT) sensor, if equipped
vvith the 3.8 L engine.
208554
6-628
Engine Cooling
Engine
554755
5. Disconnect the rosebud clips from the fans.
211602
6. Disconnect the coolant fan electrical connectors

from the fans.
221692
Engine
Engin~ Cooling
6~629
7. Remove the air cleaner bolts.

8. Remove the air cleaner.
221697
9. Remove the electric engin~ coolant fan. The fan

will slide off of the radiator.
41692
10. Remove the fan blade nut.

Caution: If a fan blade is bent or damaged in any
way, do not repair or reuse the damaged part.
Always replace a bent or damaged fan blade. Fan
blades that have been damaged can not be
assured of proper balance and could fail and fly
apart during subsequent use. This creates an
extremely dangerous situation.
The fan blades must remain in proper balance. You
cannot assure fan blade balance once a fan blade
has been bent or damaged. A fan blade that is not in
proper balance could fail and fly apart during use,
creating an extremely dangerous situation.
11. Remove the fan blade.
12. Inspect for the following conditions:
Bent or cracked fan blades
Smoothness of the fan blade mating surfaces
Remove burrs or other imperfections as
necessary
342281
6-630
Engine Cooling
Engine
1. Install the fan blade.
Notices.
2. Install the fan blade nut.
Tighten
Tighten the fan blade nut to 6 Nm (53 lb in).
342281
3. Install the electric engine coolant fan. The fan will

slide into place on the radiator.
41692
4. Install the air cleaner.

5. Install the air cleaner bolts.
Tighten
Tighten the air cleaner bolts to 12 Nm (106 lb in).
221697
Engine
Engine Cooling
6-631
6. Connect the coolant fan electrical connectors to

the fans.
221692
7. Connect the rosebud clips to the fans.
211602
8. Install the air intake duct resonator, if equipped

554755
6-632
Engine Cooling
Engine
9. Connect the electrical connector to the IAT
sensor, if equipped with the 3.8 L engine.
208554

208569
11 . Connect the IAT and the MAF sensors electrical

connectors, if equipped with the 5. 7 L engine.
208553
Engine
Engine Cooling
6-633
Cooling Fan Motor Replacement - Electric

Removal Procedure
1. Remove the cooling fan. Refer to Cooling Fan
Replacement - Electric.
2. Remove the cooling fan motor.
342295
Notices.
1. Install the cooling fan motor.
Tighten
Tighten the cooling fan motor bolts to
6 N-m (53 lb in).
2. Install the cooling fan. Refer to Cooling Fan
Replacement - Electric.
342295
Cooling Fan Relay Replacement

Removal Procedure
1. Remove the cover from the number 1 underhood
electrical center.
2. Remove the cooling fan relay from the underhood
electrical center. Refer to Electrical Center
Identification Views in Wiring Systems.
401242
6-634
Engine Cooling
Engine
1. Install the cooling fan relay to the underhood
electrical center. Refer to Electrical Center
2. Install the cover to the number 1 underhood

electrical center.
401242
Thermostat Housing Replacement (3.8 l)

Removal Procedure
1 . Open the radiator drain cock.
2. Drain the engine coolant to a level below the
thermostat.

Notices.
Tighten
Tighten the radiator drain cock to 2 Nm (18 lb in).
4. Disconnect the exhaust gas recirculation (EGR)
valve electrical connector.
221704
5. Remove the EGR valve outlet pipe bolt from the

6. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
7. Remove the EGR valve pipe.
221706
Engine
Engine Cooling
6-635
221680
9. Remove the water outlet bolts (1 ). ,

10. Remove the water outlet (2).
~)
349798
1. Install the water outlet (2).
Notices.
2. Install the water outlet bolts (1 ).
Tighten
Tighten the water outlet bolts (1) to
27 N-m (20 lb ft).
349798
s.:.636
Engine Cooling
Engine
221680
4. Install the EGR valve pipe.

5. Install the EGR valve outletpipe nut from the
EGR valve adapter.
Tighten
Tighten the EGR valve outlet pipe nut to
29 Nm (21 lb ft}.
6. Install the EGR valve outlet pipe bolt from the
Tighten
Tighten the EGR valve outlet pipe bolt to
29 N-m (21 lb ft).
221706

8. Add engine coolant.
221704
Engine
Engine Cooling
6-637
Thermostat Housing Replacement (5.7 L)

Removal Procedure
1. Open the radiator drain cock. Drain the engine
coolant to a level below the thermostat.

Notices.
Tighten
3. Remove the radiator outlet hose from the water
outlet.
221671
4. Remove the water outlet housing bolts.

5. Remove the water outlet.
221708
1. Thoroughly clean the water outlet and water pump
surfaces.

Notices.
3. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 10 N-m (89 lb in).
221708
6-638
Engine Cooling
Engine
4. Install the radiator outlet hose to the water outlet.
5. Add engine coolant.
22167f
Thermostat Replacement (3.8 L)

1
Removal Procedure
1. Remove the water outlet (2). Refer to Thermostat
Housing Replacement (3.8 L).
2. Remove the engine coolant thermostat (3).
349798
1
1. Install the engine coolant thermostat (3).

2. Install the water outlet (2). Refer to Thermostat
Housing Replacement (3.B L).
349798
Engine
Engine Cooling
6-639
Thermostat Replacement (5. 7 l)

Removal Procedure
1. Remove the water outlet. Refer to Thermostat
Housing Replacement (5. 7 L).
2. Remove the thermostat.
221709
1. Install the thermostat.
2. Install .the water.outlet. Refer to Thermostat
Housing Replacement (5. 7 L).
221709
Thermostat Bypass Pipes

Replacement (3.8L)
Removal Procedure
Belt Tensioner Replacement in Engine
Mechanical - 3.8 L.
2. Remove the thermostat bypass upper (1) and/or
lower (2) pipe.
2
500325
6-640
Engine
Engine Cooling
1. Install the thermostat bypass upper (1) and/or

lower (2) pipe.
2. Install the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement in Engine
Mechanical - 3.8 L.
'
2
500325
Water Pump Replacement (3.8 L)

Removal Procedure
1. Open the radiator drain cock. Drain the engi1ne
coolant to a level below the thermostat.
Notices.
Tighten
3. Loosen the water pump pulley bolts.
Belt Replacement in Engine Mechanical - 3.8 L.
5. Remove the radiator inlet hose from the
water pump.
221689
6. Remove the water pump pulley bolts.

7. Remove the water pump pulley.
221711
Engine
Engine Cooling
6-641
8. Remove the water pump bolts (1 ).
9. Remove the water pump (2).

10. Remove the water pump gasket (3).
11. Clean all of the gasket mating surfaces, including
the water pump bolts.
11687
Tools Required
1. Install a new water pump gasket (3).
2. Install the water pump (2).
3. Install the water pump bolts (1 ).
Tighten
Tighten the water pump bolts (1) to
15 N-m (11 lb ft). Use J 36660-A to torque the
water pump bolts (1) an additional 80 degrees.
11687
4. Connect the radiator inlet hose to the water pump.

5. Install the water pump pulley and the bolts.
Tighten
Tighten the water pump pulley bolts to
13 N-m (115 lb in).
Replacement in Engine Mechanical - 3.8 L.
7. Add the engine coolant.
8. Start the engine. After the engine reaches normal
operating temperature, check for coolant leaks.
221689
6-642
Engine Cooling
Engine
Water Pump Replacement (5.7 L)
Removal Procedure
Lifting ahd Jacking the Vehicle in General
Information.
2. Disconnect the coolant fan electrical connectors.
3. Drain the cooling system. Refer to Draining
550332

208553
7. Remove the air intake,ductresonatoL
208569
Engine
Engine Cooling
6-643
8. Remove the outlet hose from the water outlet.
221671
9. Remove the inlet hose from the coolant pump.
221676
10. Remove the air cleaner bolts ..

11. Remove the air cleaner I upper radiator support.
221697
6-644
Engine Cooling
Engine
349797
13. Remove the electric engine coolant fans.

Belt Replacement - Accessory in Engine
Mechanical - 5.7 L.
41692
15. Remove the drive belt tensioner pulley from the

co9lant pump.
220581
Engine
Engine Cooling
6-645
16. Remove the throttle body heater outlet hose from

the radiator.
220620
17. Remove the coolant pump bolts.
550333
18. Remove the coolant pump.

19. Remove the coolant pump gaskets.
20. Clean all gasket mating surfaces, also clean the
water pump bolts.
550334
6-646
Engine Cooling
Engine
1. Install the coolant pump and gaskets to the
engine block.
550334

Notices.
2. Install the coolant pump bolts.
Tighten
Tighten the coolant pump bolts to
30 N-m (22 lb ft).
550333
3. Install the throttle body heater outlet hose to the

radiator.
220620
Engine
Engine Cooling . 6-647
4. Install the drive belt tensioner to the coolant pump.

Tighten
Tighten the drive belt tensioner bolt to
50 Nm (37 lb ft).
5. Install the accessory drive belt. Refer to Drive
Belt Replacement - Accesso,y in Engine
Mechanical - 5. 7 L.
220581
6. Install the electric engine cooling fans.
41692
349797
6-648
Engine Cooling
Engine
8. Install the air cleaner I upper radiator support.
9. Install the air cleaner bolts.
Tighten
Tighten the air cleaner bolts to 12 N,m (106 lb in).
221697
10. Install the inlet hose to the coolant pump.
221676
11. Install the outlet hose to the water outlet.
221671
Engine
Engine Cooling
5,.549
208569

208553
15. Connect the coolant fan electrical connectors.

16. Refill the.cooling system. Refer to Draining and
Filling Cooling System (5. 7 L);
550332
6-650
Engine Cooling
Engine
Replacement (3.8 L)
Removal Procedure

2. Disconnect the engine coolant temperature (ECT)
sensor electrical connector (2).
2
439428
Important: Care must be taken when handling the

ECT sensor. damage to the sensor wilLaffect proper
operation of the fuel injection system.
3. Remove the ECT sensor.
349800
1. Coat the ECT sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the ECT sensor into the engine.
Notices.
3. Tighten the ECT sensor.
Tighten
Tighten the ECT sensor to 25 N-m (18 lb ft).
349800
Engine
Engine Cooling
6-651
4. Connect the ECT sensor electrical connector (2).

439428

Replacement (5.7 l)
Removal Procedure

2. Disconnect the engine coolant temperature (ECT)
3. Remove the number 1 spark plug wire.
ECT sensor. Damage to the sensor will affect proper
operation of the fuel injection system.
550336
1. Coat the ECT sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the ECT sensor.
Notices.
Tighten
Tighten the ECT sensor to 20 Nm (15 lb ft).
4. Install the number 1 spark plug wire.
5. Connect the ECT sensor electrical connector.
550336
6-652
Engine Cooling
Engine
Drain Cock Replacement

Removal Procedure
1 . Drain the cooling system. Refer to Draining and
Filling Cooling System (3.8 L) or Draining and
2. Remove the radiator drain cock.
457901
1. Install the radiator drain cock.
Filling Cooling System (3.8 L) or Draining and
457901
Fan Shroud Replacement .

Removal Procedure .
1. Remove the radiator upper support. Refer to
Radiator Support Replacement.
2. Remove the fan shroud:
O Move the fan shroud up in order to clear the
four mounts.
" Move the fan shroud down in order to remove
it from the vehicle.
185073
Engine
Engine Cooling
6-653
3. Remove the cooling fan brackets from the fan.

shroud.
349792
1. Install the cooling fan brackets to the fan shroud.
349792
2. Install the fan shroud into the four retaining tabs

on the radiator.
3. Install the radiator upper support. Refer to
Radiator Support Replacement.
185073
6.;654
Engine .Cooling
Engine
Radiator Replacement
Removal Procedure
1. Recover air conditioning system. Refer to
Refrigerant Recovery and Recharging in HVAC
Systems with A/C - Manual.
Filling Cooling System (3.8 L) or to Draining and
3. Remove the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (3.8 L) or to Radiator
Hose Replacement - Inlet (5. 7 L).
4. Remove the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (3.8 L) or to Radiator
Hose Replacement - Outlet (5. 7 L).
5. Remove the evaporator tube bolt.
6. Remove the evaporator tube from the condenser.
221720
7. Remove the upper oil cooler line from the. radiator.

Information.
9. Remove the lower oil cooler line from the radiator.
208321
1O. Remove the air conditioning condenser. tube nut.

11. Remove the condenser tube from the condenser.
221721
Engine
Engine Cooling
6-655

the radiator.
14. Remove the electric engine coolant fans. Refer to
221645
15. Remove the radiator from the vehicle.
221724
16. Remove the condenser from the radiator.
221726
6-656
Engine Cooling
Engine
1. Install the condenser to the radiator.
221726
2. Install the radiator to the vehicle.

3. Install the electric engine coolant fans. Refer to
221724
4. Install ,the coolant recovery reservoir hose to the

radiator.
Information.
(
221645
Engine
Engine Cooling
6-657
6. Install the condenser tube to the condenser.

Notices.
7. Install the condenser tube nut.
Tighten
Tighten the A/C condenser tube nut to
16 N-m (12 lb ft).
221721
8. Install the lower oil cooler line to the radiator.

Tighten
Tighten the lower oil cooler line to
27 Nm (20 lb ft).
10. Install the upper oil cooler line to the radiator.
Tighten
Tighten the upper oil cooler line to
27 N-m (20 lb ft).
208321
11. Install the evaporator tube to the condenser;

12. Install the evaporator tube bolt.
Tighten
Tighten the evaporator tube bolt to
i6 Nm (12 lb ft).
13. Install the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (3.8 L) or to Radiator
Hose Replacement - Outlet (5. 7 L).
14. Install the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (3.8 L) or to Radiator
Hose Replacement - Inlet (5. 7 L).
~
-~
Filling Cooling System (3.8 L) or to Draining and

16. Recharge the air conditioning system. Refer to
Refrigerant Recovery and Recharging in HVAC
Systems with A/C - Manual.
221720
6.;ij58
Engine Cooling
Engine
Radiator Support Replacement
Removal Procedure
1. Disconnect the intake air temperature (IAT) and
mass airflow (MAF) sensors electrical connectors,
if equipped with the 5.7 L engine.
208553

208569

sensor electrical connector, if equipped with the
3.8 L engine.
208554
Engine
Engine Cooling
6-659

554755
5. Release the retaining strap latches.

6. Lift the top of the air cleaner housing off.
7. Remove the air filter element.
245337
8. Remove the air cleaner I radiator support bolts.

9. Remove the radiator support.
221697
6-660
Engine Cooling
Engine
1. Install the radiator support.

Notices.
2. Install the air cleaner I radiator support bolts
Tighten
Tighten the air cleaner bolts to 12 Nm (106 lb in).
221697

554755
4. Connect the IAT sensor electrical .connector, .if

equipped with the 3.8 L engine.
208554
Engine Coo I.m g
Engine
5. Install th~ ;
with the
.1 intake duct
~ engine.
5.;551
resonator, if equipped
208569
F sensors el~ctrical
and thewith
MAthe 57 L engine.
Connect th\' IAT
equipped
_ connectors,
. Baffle Assemblies and

d . tor Air
Ra
ia
Deflectors (Lower)
I Procedure
screws (3).
Remova
the
air
lower
cleflectorb
1 Remove
.
air lower affle retainers (4).
2
. Remove the radiator . lower baffle (1 ).
diator air
3 Remove the ra
;nent damage.
4: Inspect for any comp
11689
6-662
Engine
Engine Cooling
1. Install the radiator air lower b~ffle (1 ).

2. Install the radiator air lower baffle retainers (4).

Notices.
3. Install the radiator air lower deflector screws (3).
Tighten
Tighten the radiator air lower deflector screws to
10 N-m (89 lb in).
11689
Radiator Air. Baffle Assemblies and

Deflectors (Upper)
Removal Procedure
1. Remove the radiator air upper baffle from the
retainers (3).
2. Remove the radiator air upper baffle (1) from the
radiator (2).
11690
1. Install the radiator air upper baffle (1) to the
radiator (2).
2. Install the radiator air upper baffle to the
retainers (3).
11690
Engine
Engine Cooling
6~66~
Coolant Heater Replacement (3.8 L)

Removal Procedure
Information.
3. Disconnect the electrical cord from the coolant
heater.
298431
4. Loosen the coolant heater bolt.

Important: When removing the engine coolant heater
from the engine block, be careful not to score the
machined surface of the plug hole.
5. Remove the coolant heater from the engine block.
6. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.
298427
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a coat of engine coolant heater lubricant,
GM P/N 12345996 or equivalent, to the 0-ring
and walls of the coolant heater hole.
298427
6-664
Engine
Engine Cooling

Notices.
2. Install the coolant heater into the coolant hole
using the following steps:
.
.
..
'
Insert the heating element end of the heater
into the engine block.
Une up the heater with the plug hole and push
it straight into place.
Rotate the heater so that the center electrical
contact and bolt are in line horizontally.
Tighten the bolt so that the yoke presses
against the engine block inner wall.
Tighten
Tighten the coolant heater bolt to
2 N-m (18 lb in).
3. Connect the coolant heater electrical cord to the
heater.
5. Refill the engine cooling system. Refer to Draining
and Filling Cooling System (3.8 L).
298431
Coolant Heater Replacement (5.7 l)

Removal Procedure
1 . Raise and suitably support the vehicle. Refer to
Information.
3. Disconnect the electrical cord from the coolant
heater.
298433
Engine
Engine Cooling
6-665
Important: When removing the engine coolant heater

from the engine block, be careful not to score the
machined surface of the plug hole.
4. Remove the coolant heater from the engine block.
5. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.
550337
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a coat of engine coolant heater lubricant,

GM P/N 12345996 or equivalent, to the 0-ring
and walls of the coolant heater hole.
2. Finger start the coolant heater to the engine block.

Notices.
3. Tighten the coolant heater.
Tighten
Tighten the coolant heater to 40 Nm (30 lb ft).
550337
4. Install the coolant heater electrical cord to the

heater.
298433
6-666
Engine Cooling
Engine
Coolant Heater.Cord Replacement (3.8 L)
Removal Procedure
1. Disconnect the heater cord from the block heater.
2. Route the block heater end of the cord under
the power steering rack lines.
3. Cut the heater cord strap at the power steering
reservoir.
298431
4. Cut the heater cord strap at the fuse block center.

5. Remove the.heater cord from the vehicle.
298430
1. Install the heater cord and a new strap to the fuse
block center.
298430
Engine
Engine Cooling
6-667
2. Route the cord up under the power steering

rack lines.
3. Install a new heater cord strap to the power
steering reservoir.
4. Connect the heater cord to the coolant heater.
298431
Coolant Heater Cord Replacement (5.7 l)

Removal Procedure
1. Disconnect the heater cord from the block heater.
2. Cut the heater cord strap at the power
steering line.
298433
3. Cut the heater cord strap at the fuse block center.

4. Remove the heater cord from the vehicle.
298430
6-668
Engine
Engine Cooling
1. Install the heater cord to the vehicle.

2. Install the heater cord and a new strap to the fuse
block center.
298430
3. Install the heater cord and a new strap to the

power steering line.
4. Connect the heater cord to the coolant heater.
298433
Engine Cooling
Engine
6-669

Cooling System Description
The cooling system consists of the following major
components:
Radiator
Coolant recovery reservoir
Cooling fans
Thermostat
Water pump
" Engine coolant air bleed pipe
Engine coolant temperature (ECT) sensor
Transmission oil cooler
All related hoses
Fan shroud
Fan motor/blade
The cooling systems functions is to maintain an
efficient engine operating temperature during all
speeds and under all operating conditions. Cooling
systems are designed to remove about
one-third (30 to 35 percent) of the heat produced in
the combustion chambers by the burning of the air-fuel
mixture. The engine is very inefficient while cold.
Therefore the cooling system includes a devise
(thermostat) that prevents normal cooling action during
engine warm-up. The thermostat allows the engine
parts to reach their .normal operating temperature more
quickly. This shortens the inefficient cold-operating
time. When the engine reaches its normal operating
temperature, the cooling system begins to function.
The cooling system removes excess heat when
the engine is hot, and slowly or not at all when th.e
engine is cold or warming up.
The coolant absorbs heat as it passes through the
engine. Then the hot coolant flows through a radiator
in. which the heat in the coolant is passed on to
the air that is flowing through the radiator. The cooled
coolant then flows back through the engine. This
circulatior:i of the coolant continually removes heat from
the engine. The coolant is kept in circulation by the
water pump.
Water jackets are designed to keep the cylinder block
and cylinder heads cool. The water jackets are
open spaces. between the outside wall of the cylinder
and the inside of the cylinder block and head. The
coolant can circulate freely around the engine
hot spots. These hot spots include the following:
Valve guides
Valve seats
Upper parts of the cylinder walls
When the engine is running at the normal operating
temperature, coolant flows into the block and through
the water jackets surrounding the cylinders. Vapor
is vented off through the engine coolant air bleed pipe.
Then coolant is forced through the head gasket
openings and into the cylinder head water jackets. In
the heads, the coolant flows around the combustion
chambers and valve seat, picking up additional
heat. From the heads, the coolant flows through the
upper hose into the radiator. There, the coolant

temperature is lowered, and the coolant is drawn again
into the engine by the water pump to provide
passenger compartment heat and defrost. The coolant
recovery reservoir provides a coolant fill point. The
reservoir is translucent for coolant level viewing.
Coolant Description
This vehicle has a newly developed engine coolant.
GM Goodwrench DEX-COOL was developed to last
for 240 000 km (150,000 mi) or 5 years, whichever
occurs first. Follow the instructions in Draining
and Filling Cooling System. Make sure only GM
Goodwrench DEX-COOL (silicate-free) or Havoline
DEX-COOL is used when coolant is added or
changed.
A 50/50 mixture of DEX-COOL and clean drinkable
water will provide the following protection:
Notice: Pure coolant can be added to raise the boiling

point of the coolant, but too much will affect the
freezing point. Do not use a solution stronger than
70 percent, as the freeze level rises rapidly after this
point. Pure coolant will freeze at -22C (-8F).
Give freezing protection down to -37C (-34F).
Give boiling protection up to 129C (260F).
Protect against rust and corrosion.
O
Help keep the proper engine temperature.
Let the warning lights and gauges work correctly.
Coolant Recovery System Description

The cooling system has a separate plastic, translucent
coolant recover reservoir. The reservoir, also caner
a recovery tank or expansion tank, is partly filled with
coolant and is connected to the overflow tube on
the radiator fill neck to the reservoir by the O\/erflow
tube. The coolant in the engine expands as the engine
heats up. Instead. of dripping out the overflow tube
onto the ground and being lost from the cooling system
completely, the CQOlant flows into the reservoir.
When the engine cools, a vacuum is created in the
cooling system. The vacuum siphons some of
the coolant back into the radiator from the reservoir. In
effect, a cooling system with a recovery reservoir is
a closed system. Coolant can flow back and forth
between the radiator and the reservoir. This occurs as
the coolant expands and contracts from heating
and cooling. Under normal conditions, no coolant
is lost.
An advantage to the use of a coolant recovery
reservoir is that it eliminates almost all air bubbles
from the cooling system. Coolant without bubbles
absorbs heat much better than coolant with bubbles in
it. Although the coolant level in the recovery reservoir
goes up and down, the radiator and cooling system
are kept full. This results in maximum cooling
efficiency.
6-670
Engine
Engine Cooling
Throttle Body Coolant System Description
Coolant Heater Description
The fuel injection system has coolant passages in

the throttle body, The heated coolant flow through
these passages improves the cold weather driveability
of the vehicle.
The engine coolant heater is used to heat the engine

coolant prior to vehicle start up, making it easier to
start the engine in very cold climates. It is installed into
the engine block at a water jacket plug location. An
engine coolant heater cord is routed inside the engine
compartment. The heater is rated at 600 watts and
uses a 110 volt ac power supply.
Radiator Assembly Description
47015
The radiator is a heat exchanger that removes heat

from the coolant passing through it. The radiator holds
a large volume of coolant in close contact with a
large volume of air so that heat will transfer from the
coolant to the air. The radiator core is divided into
two separate compartment~ cool.an.t passes throygh
one, and air passes through the other. The aluminum
radiator core (1) is a crossflow tube and fin design.
A tube and fin radiator consists of a series of
tubes extending from side to side on the radiator core.
The tubes run from the inlet tank (4) to the outlet
tank (9). Fins are placed around the outside of
the tubes to improve heat transfer. Air passes between
the fins. As the air passes by, it absorbs heat from
the fins which have, in turn, absorbed heat from
the coolant.
In a typical radiator, there are five fins per inch.

Radiators used in vehicles that have factory installed
air conditioning have seven fins per inch. This
provides the additional cooling surface required to
handle the additional heat load imposed by air .
conditioning.
The inlet (4) and outlet (9) tanks are molded with high.
temperature nylon-reinforced plastic. A high
temperature rubber gasket (2, 12) seals the tank
flange edge. The tanks are clamped to the core with
clinch tabs. The tabs are part of the aluminum
header at each end of the core (1 ). A plastic
serviceable drain cock (7) and rubber seal is used.
The integral transmission oil cooler (3) is housed inside
the outlet (4) tank. The cooler provides the automatic
transmission fluid cooling capacity. This maintains
a fairly constant temperature under all operating
conditions.
Engine
Engine Cooling
6-671
Pressure Cap Description

Radiator Fill Cap
Caution: Under pressure, the temperature of the
solution in the radiator can be considerably higher,
without boiling. Removing the radia.tor cap while
the engine is hot (pressure is high), will cause the
solution to boil instantaneously, with explosive
force. The solution will spew out over the engine,
fenders, and the person removing the cap.
Serious bodily injury may result. Flammable
antifreeze,.such as alcohol, is not recommended
for use at any time. Flammable antifreeze could
cause a serious fire.
48305
The cooling system is sealed and pressurized by a

radiator pressure cap. There are two advantages
to sealing and pressurizing the cooling system.
Increased pressure raises the boiling point of the
coolant. This increases the efficiency of the
cooling system.
Sealing the cooling system reduces coolant losses
from evaporation and permits the use of the
recovery reservoir.
As .the pressure goes up~ the boiling point goes up.
Therefore, the coolant can be safely run at a
temperature higher than 212 degrees F
(100 degrees C) without boiling. The higher the
coolant temperature, the greater the difference
between it and the outside air temperature. This
difference in temperature is what causes the cooling
system to work. The hotter the coolant, the faster
the heat moves from the radiator to the cooler passing
air. This means that the pressurized, sealed cooling
system can take heat away from the engine faster.
Therefore, the cooling system works more efficiently
when the coolant is under higher pressure.
However, the cooling system can be pressurized too
much. If the pressure in the system gets too high,
it can damage the radiator and blow off the hoses. To
prevent this the radiator cap has a pressure relief
valve. When the pressure gets too high, it raises the

valve so that the excess pressure can escape into the
recovery reservoir.
The radiator pressure cap also has a vacuum vent
valve. This valve protects the system from developing
a vacuum that could collapse the radiator. When
the engine is shut off and cools, the coolant volume is
reduced. Cold coolant takes up less space than hot
coolant. As the temperature of the coolant drops,
a vacuum develops in the cooling system. To prevent
excessive vacuum from developing, the vacuum
valve opens to allow outside air or coolant from the
recovery reservoir to flow into the cooling system. This
relieves the vacuum that could otherwise cause
outside air pressure to collapse the radiator.
Engine Cooling Fan Description - Electric

The cooling fans are located behind the radiator.
The cooling fans are driven by an electric motor. The
cooling fan motors both have five blades that are
each 312 mm (12.3 in) in diameter. One cooling fan
will start and run and then both cooling fans will
run depending on the. amount of cooling the
radiator needs.
6-672
Engine
Engine Cooling
The advantage of the electric fan is less power drain

on the engine and less fan noise. Also, there is
no fan belt to inspect, adjust, or replace. This means
less cooling system maintenance.
The engine cooling fan relays provide the current

required for the motors based on a low current signal
received from the powertrain control module (PCM).
Cooling Fan Relay Description

The cooling tan relays are used to control the high
current flow to power the cooling fan motors. Both fans
operate together. When minimum cooling is required,
the PCM energizes cooling fan relay #1 and both
fans operate at low speed, since the fans are
connected in series through cooling fan relay #2
and #3. When maximum cooling is required, the PCM
energizes all three cooling fan relays. The left fan
is still powered through cooling fan relay #1, but is now
grounded through cooling fan relay #3. The right fan
is now powered directly through cooling fan
relay #2 and both fans operate at high speed.
Water Pump Description

The die-cast water pump is a centrifugal vane impeller
type. The pump consists of a housing, with coolant
inlet and outlet, and an impeller. The impeller is a flat
plate mounted on the pump shaft with a series of
flat or curved blades, or vanes. When the impeller
rotates, the coolant between the blades is thrown
outward by centrifugal force. Then the coolant is forced
through the pump outlet and into the cylinder block.
The pump inlet is connected by a hose to the bottom of
the radiator. Coolant from the radiator is drawn into
the pump to replace the coolant forced thmugh
the outlet.
The impeller shaft is supported on one or more
bearings. A seal prevents<c:;oolant from leaking out
around the bearings. The water pump uses sealed
bearings, \J\fhich never need lubrication. With a sealed
bearing, grease cannot leak out, and dirt and water
cannot get in.
Thermostat Description
The thermostat is a coolant flow control components
that utilizes a temperature sensitive wax-pellet
element (4). Its purpose is to close off the coolant
passage when the engine is cold. Now coolant
circulation is restricted, causing the engine to reach
normal operating temperature more quickly. Also, after
warm-up, the thermostat keeps t.he engine running
at a higher temperature than it would without a
thermostat. The higher operating temperature
improves engine efficiency and reduces exhaust
emissions.
The thermostat performs the following functions:
" Controls the flow of coolant through the radiator
" Enables controlled engine warm up
.. Assists in coolant temperature control
3
13706
The wax pellet element (40 in the thermostat expands

with increasing temperatures, and contracts with
decreasing temperatures. The element connects
through a piston (1) to a thermostat valve (2). When
the element is heated, pressure is exerted against
a rubber diaphragm (3) which forces the thermostat
valve to open. As the element is cooled, the
contraction allows a spring (5) to close the thermostat
valve. While the coolant is cold, the thermostat
valve remains closed. This prevents circulation of
coolant through the radiator. At this point, coolant is
only allowed to circulate throughout the engine
block and heater core in order to allow the engine to
warm quickly. As the engine warms, the element
expands and the thermostat valve opens. This permits
coolant to flow through the radiator, where the heat
dissipates to the atmosphere.

Description
The engine coolant temperature (ECT) sensor is a
variable resistance device. The ECT sensor resistance
determines the position of the temperature gauge.
As the temperature increases, the ECT sensor
resistance decreases. This allows for more current to
flow through the gauge, causing a higher temperature
reading.
Engine Cooling
Engine
Air Baffles and Seals Description
A deflector redirects air flow. Deflectors are installed
under the vehicle and redirects the air flow beneath the
vehicle to flow through the cooling system. The
defleciors perform the following functions:
Reduce drag
o Prevent front end lift
Increase radiator cooling
Air baffles are used to direct air into the radiator and
A/C condenser. Air seals ensure that air passes
through, and does not bypass, the radiator and the
A/C con.denser. A missing, damaged, or incorrectly
installed baffle or seal may cause the engine to
overheat.
6-673

Illustration
J 23688
Coolant Tester
(Fahrenheit Scale)
1409
J 24460-01
Cooling System and Cap
Pressure Tester
1405
J 24731
Tempi! Stick
23570
J 26568
Coolant Tester
(Celsius Scale)
12869
J 36660
Torque Angle Meter
3413
6-674
Engine Electrical
Engine
Engine Electrical
(
Specifications
Specification
Application
Metric
English
ABS/SIR Electrical Ground Stud
14 N-m
10 lb ft
Accelerator and Cruise Control Servo Cable Adjuster Bolt (5.7 L)
7.5N-m
66lbin
Battery Hold Down Retainer Bolt
13 lb ft
Battery Side Terminal Adapters

Coolant Recovery Reservoir Bolt
18 Nm
15 N-m
12 N-m
11 lb ft
106 lb in
Engine Wiring Harness Ground Bolt to Engine Block (5.7 L)
25N-m
18 lb ft
Forward Lamp Wiring Harness Grommet Bolt
2N-m
71 lb in
Forward Lamp Harness Ground Stud
16 N-m
12 lb ft
Generator Brace Bracket Bolt (3.8 L)
50Nm
37 lb ft
Generator Bracket Bolt (5.7 L)
50Nm
37 lb ft
Generator Mounting Bolt (5.7 L)
50 Nm
37 lb ft
Generator Bolt (to drive belt tensioner lower) (3.8 L)
37 lb ft
Generator Bolt (to drive belt tensioner upper) (3.8 L)
50 Nm
30 N-m
Generator Rear Brace Bolt (3.8 L)
25 N-m
20 lb ft
Generator Bolt (to rear brace) (3.8 L)
30N-m
22 lb ft
Generator Mounting Bolt (5.7 L)
50 N-m
37 lb ft
Generator Mounting Bolt (rear to generator) (5.7 L)

Ignition Coil Bolt (5.7 L)
25 N-m
18 lb ft
1061bin
22 lb ft
Ignition Coil Bolt (3.8 L)
12 Nm
4N-m
Ignition Control Module Bolt {3.8 L)
3N-m
Ignition Control Module Nut
30 N-m
22 lb ft
Left Front Forward Lamp Wiring Ground Bolt
10 Nm
891bin
Lift Bracket to Ignition Control Module Bolt (3.8 L)
25 Nm
18 lb ft
Negative Battery Cable Bolt
15 N-m
22 N-m
16 lb ft
32Nm
6N,m
24 lb ft
531bin
15 Nm
25 N-m
18 lb ft
Positive Cable Nut to Generator Output Stud

Positive Cable to Fuseblock Stud Nut
22N-m
16 lb ft
14 Nm
10 lb ft
Positive Cable to Starter Nut
10 N-m
891bin
.Negative Cable to Engine Block Stud Nut (3.8 L)

. Negative Cable to Engine Block Bolt (5.7 L)
. Negative Cable at Ground Terminal Nut
Positive Battery Cable Bolt
Positive Cable RF Ground Nut {3.8 L)
351bin
271bin
11 lb ft
11 lb ft
Right Front Ground Bolt
10 N-m
891bin
Spark Plug (New Installation) (5.7 L)
20N-m
15 lb ft
Spark Plug (Subsequent Installation) (5.7 L)

Spark Plug (3.8 L)
15 N-m
27N-m
11 lb ft
20 lb ft
Starter Motor Bolt {3.8 L)
47N-m
35 lb ft
Starter Motor Bolt (5.7 L)
37 lb ft
Starter Motor Stud (3.8 L)
50Nm
45N-m
Starter Motor Shield Nut (3.8 L)
10 N-m
891bin
Starter Motor Shield Bolt (to transmission brace) (3.8 L)
10 N-m
891bin
Starter Motor Shield Bolt (to engine block) (3.8 L)
30 N-m
12 N-m
Wiring Harness Ground Bolt

Wiring Harness Starter Lead Nut
2N-m
33 lb ft
22 lb ft
1061bin
18 lb in
Engine Electrical
Engine
6-675
Battery Usage
Description
Application
'
3.8 L (VINK)
Catalog Number
674
Cold Cranking Amperage (CCA)
690
'
Load.Test (AMPS)
345
Replacement Model Number
75B-84
Reserve Capacity Minutes
90
5.7 L (VIN G)
Catalog Number
670
525
Cold Cranking Amperage (AMPS)

Load Test (AMPS)
260
Replacement Model Number
75-60
Reserve Capacity Minutes
90
Battery Temperature vs Voltage Drop

Degrees Fahrenheit (F)
Degrees Celsius (C)
Voltage
Temperature vs Minimum Voltage

21
70
9.6
10
50
9.4
32
9.1
-10
14
8.8
-18
8.5
Below -18
Below O
8.0
Starter Motor Usage

Description
Application
No Load Test at 11.5 Volts
PG-260
Starter Motor
Current Draw (AMPS)
60-125
Pinion Speed (RPM)
2900-3400
Pinion Clearance
0.25 mm (0.01 in)-4.06 mm (0.16 in)

Starter Solenoid Switch
Hold-in Windings
5-15 Amps
Both Windings
30-50 Amps
Generator Usage
.
Application
Description
Engine
3.8 L (VIN K) and 5.7 L (VIN G)
Rated Amperes
105
Model Type
CS-1300
Spark Plug Usage

Engine Application
Sparl Plug Type
Spark Plug Gap - Metric
Spark Plug Gap - English
3.8 L (VINK)
41-921
1.524 mm
0.060 in
41-931
1.524 mm
0.060 in
5.7 L (VIN G)
6-676
Engine Electrical
Engine
Spark Plug Wire Resistance

Tools Required
J 39200 Digital Multimeter
l. Remove the spark plug wire to be tested.
Ensure that the plug wire terminals are clean
before proceeding:
2. Use the J .39200 on the high scale.
3. Connect an ohmmeter lead to each end of the

plug wire.
4. Gently twist the wire while watching the ohmmeter
reading.
5. If the ohmmeter reads above 10,000 ohms,
replace the wire.
6. If the resistance of the wire being tested is not
within 3,000 - 10,000 ohms replace the wire.

Application
1.
GM SPO Group Number
Electronic Ignition Control Module
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
2.000
Generator
Generator Brace Bracket (3.8 L)
Generator Bracket (5.7 L)
Generator Rear Brace (3.8 L)
Generator Rear Bracket (5.7 L)
Ignition Coil
Negative Battery Cable
Positive Battery Cable
Starter Motor
Starter Motor Shield
Spark Plug
Spark Plug Wire
Schemat.ic and Routing Diagrams
Engine Electrical Schematic Icons

Icon
Icon Definition
Refer to ESD Notice in Caution and Notices.
19384
Refer to 080 II Symbol Description Notice in Caution and Notices.
19385
Starting and Charging Schematics (Battery and Ignition Switch)

Power
Distribution
Schematics In
Wiring Systems
!L c I
0
19 RED 1
r
.,
Battery
+ - - - ~- ~ Junction
19 RED 1 Block
r-----I Power
Distribution
I Schematics in
I Wiring Systems
I
:::,
K2
L------
- - - ., Engine Wiring
I
IGN
Harness
MaxiFuse 1 Junction Block 2
50A
32BLK 1 (VINK}
5YEL 5
-
H11
. __
---J
5 RED 2
Power
__
5_.R_E_D
___S_1_83
_ _5_R_E_D_---t A Starter
Distribution
Schematics in
2
Relay
2
Wiring Systems
--------------------
I" -
H10
- - - - ., Engine Wiring
S:f'.lTR 1 Harness
~~~use : Junction Block 2
19 RED 1 (VIN G)
----..i
c
Starter
Solenoid
0.8 PPWWHT 1035
- - - - - - - - - - - - - - - - "'.Ignition
Power
I Switch
Distribution
I
Schematics in Ace
Start
I
Wiring Systems
~.,
/
I
Lock.,. ___ _... - Bulb - I
Olf
R1.1n Test
I
;i
:::J
Cl)
~c
~
,,
..
~
~
- P100
1 (VINK)
8170
..
I
I
I
I
I
I
ce.
0.8 PPL/WHT 1035
1 (VING)
0.8 PPL/WHT 1035
Generator
J
C101
1..----------------J
A
C2
0.5PPWWHT 1035
5YEL 5
13 BLK 50
Starter
Relay
0.5 PPL/WHT 1035
0.5 PPL/WHT 1035
~
23 C2
r - - - cr;;;;k., Powertrain
I PCM Signal I Control
I Module ~
I C1_=BLU
~ ~=~L~ __ ~ (PCM) ~
::,
32 BLK 50 (VINK)
(Q
Ground
Distribution
Schematics in
Wiring Systems
19BLK 50 (VIN G)
85
'"c;;'nk, Instrument
I Signal I Cluster
I
:::,
Cl)
cir
(")
l'
::!.
I~
(")
r - - - .J
e!..
G101
a,
1..-..11~
G100
en
.......
502408
.......
Starting and Charging Schematics (Starter Relay and Starter Solenoid)
0,
I
0,
!Loe I
C2000
f.
0..5 PPLNVHT
35
!Automatic!
......
ClO
:::::s
loEsc!
cc
C'D
[B
:::::s
ci>"'
(')
' "'I
5
e?.
Starting and Charging Schematics {Battery, Generator and Powertrain Control Module)
Battery I"'
Junction I
Block I
!Loe I
-
I. -
.,
_I _ _..
i
-
.I
Power
Distribution
Schematics In
Wiring Systems
::s
(Q
::Ii
(1)
(SJc
'" - -v;;:;; - -v;;:;; - - - - - - - - - - ., Powertrain
I
I
PCM
I Control
I Module
I (PCM)
PCM
C1=BLU
C2=CLEAR
c1--BLU
Generator
Terminal L
Output
C2=RED
'-------------------.!
61
19 RED 1
15
C2(VIN K)
C2 (VIN G)
~
'
0.35 RED 225
13 RED 1 (VIN Kl
13 BLK 1 (VIN G)
32BLK
19RED
Starter
Generator
Solid State Regulator

Ground
Dislribulion
Schematics In
Wiring Systems
32 BLK 50 (VIN Kl
19 BLK 50 (VIN G)
TL _13- ,BLK 50
'
G101
Rectifier
Bridge'--+-----'
G100
O')
I
en
-..J
502413
(0
6-680
Engine
Engine Electrical
Component Locator
Engine Electrical Components

Name
Body Control
Module (BCM)
Location
Under the right side of the IP near the
blower motor
Locator View
Connector End View
Body Control Module

Component Views in
Body Control Systems
Body Control Module

Connector End Views in
Clutch Pedal
Position (CPP) Switch
Mounted to the clutch pedal bracket
Cruise Control
Component Views in
Cruise Control
Engine Electrical
Connector End Views

Junction Block 2

compartment
Power and Grounding

Component Views in
Wiring Systems
Generator (V6 VIN K)
On the front right side of the engine
Engine Electrical
Component Views
Engine Electrical
Connector End Views
On the front left side of the engine
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Electrical
Connector End Views
Engine Electrical
Component Views
Engine Electrical
Connector End Views
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Instrument Panel,
Gauges, and Console
Instrument Panel,
Gauges and Console
Shift Lock Control
Component Views in
Engine Controls
Engine Controls
Generator (VB VIN G)
Ignition Switch
Instrument Cluster
Park/Neutral Position
.Switch
Mounted near the base of the steering

column
On the left side of the IP
Under the center console, on the base of

the shift control lever
Powertrain Control
Module (PCM).
(V6 VINK)

Power and Grounding

Component Views in
Wiring Systems
PCM Connector End

Powertrain Control
Module (PCM)
(VB VIN G)

Engine Controls
Component Views in
Engine Controls
PCM Connector End

Starter Motor
(V6 VINK)
On the bottom left side of the engine
Engine Electrical
Component Views
Starter Motor
(VB VIN G)
On the bottom right side of the engine
Engine Electrical
Component Views
Starter Solenoid
(V6 VIN K)
On the bottom .left side of the engine,

above the starter motor
Engine Electrical
Component Views
Starter Solenoid
(VB VIN G)
On the bottom right side of the engine,

above the starter motor
Engine Electrical
Component Views
C101 (10 cavities)
Engine to forward lamp harness, in the

wheelhouse

Wiring Systems
C102 (1 cavity)

wheelhouse

Wiring Systems
C200A (17 cavities)
Forward lamp to IP harness, between the

left kick panel and the steering column

Wiring Systems

End Views in Wiring
Systems
C200B (18 cavities)


Wiring Systems

End Views in Wiring
Systems
C200D (48 cavities)
Part of the IP harness, between the left

kick panel and the steering column

Wiring Systems

End Views in Wiring
Systems

End Views in Wiring
Systems
Engine Electrical
Engine
6;..681
Engine Electrical Components (cont'd)

Name
Location
Locator View
Connector End View
C220 (10 cavities)
IP to engine harness, under the right side

of the IP, behind the knee bolster

End Views in Wiring
Wiring Systems
Systems
G100 (V6 VIN K)
On the lower right side of the engine,

above the A/C compressor

Wiring Systems
G100 (V8 VIN G)
On the lower right side of the engine,

above the starter solenoid

Wiring Systems
G101
In the engine compartment, attached to

the front of the left wheelhouse

Wiring Systems
P100
Left side in the dash panel, engine to the

passenger compartment

Wiring Systems
P110
Right side in the dash panel, engine to the


Wiring Systems
8170

approximately 13 cm (5.1 in) from
G 106 breakout
8183

approximately 10 cm (4 in) from the engine
wiring harness junction block 1 breakout
6-682
Engine Electrical
Engine
Engine Electrical Component Views

Base of Steering Column
(
2
374168
Legend
(1) Steering Column
(2) Ignition Switch
(3) Headlamp Dimmer Switch
(4) Isolation Diode (Wipers)

(5) Forward Lamp Harness
Engine
Engine Electrical
6-683
Front Left Side of Engine (V6 VIN K)
)
374175
Legend
(1) Generator
6-684
Engine Electrical
Engine
lower Right Sid.e of Engine (VS VIN G)
374313
Legend
(1) Engine Mount Bracket

(2) A/C Compressor
(3) Battery Cable
(4) Starter Motor

(5) Starter Solenoid
Engine
Engine Electrical
6-685
l.ower left Side of Engine (V6 VIN K)

1
6
374318
Legend
(1) Starter Solenoid

(2) Starter Motor
(3) Oil Level Switch
(4) Lower Control Arm

(5) Steering Gear
(6) Left Engine Mount
6-686
Engine
Engine Electrical
Ignition Switch (C2)
Engine Electrical Connector End Views
Clutch Pedal Position (CPP) Switch
0G
i:--
392027
295466
Connector Part
Information
1203-3711
2 Way F Metri-Pack
480 Series (BLK)
Pin
Wire Color
Circuit
No.
PPUWHT
1035
Starter Relay Coil Feed
DKGRN
1433
Clutch Pedal Position

Switch (CPP) Output
Function
289326
A
B
C-D
Wire Color
RED
1218-6568
4 Way F Metri-Pack
150 Series Sealed (BLK)
e
Circuit
No.
225
-
YEL
RED
PNK
Circuit
No.
5
2
3
Function
Ignition Crank Output
Fused Battery Feed
Ignition 1 Output
Not Used
D
BRN
Ignition Accessory Output
A Diagnostic Starting Point - Engine

Electrical
(~o~o[J~c@l
Pin
Wire Color
1201-0966
5 Way F 56 Series (BLU)
Diagnostic Information and

Procedures
E::::::::::l
Connector Part
Information
Pin
Generator
Connector Part
Information
Function
Not Used
Generator Regulator
Reference Voltage
Not Used
Begin the system diagnosis by reviewing the system

Description and Operation. Reviewing the Description
and Operation information will help you determine
the correct symptom diagnostic procedure when
a malfunction exists. Reviewing the Description and
Operation information will also help you determine
if the condition described by the customer is normal
operation. Refer to Symptoms - Engine Electrical
in order to identify the correct procedure for diagnosing
the system and where the procedure is located.
Symptoms - Engine Electrical

Important: Review the system operation in order to
familiarize yourself with the system functions. Refer to
one of the following operations:
" Starting System Operation
" Battery Operation
.. Charging System Operation
Ignition System Operation
the operation of the Engine Electrical System.
Refer to Checking Aftermarket Accessories
in Wiring Systems .
.. Inspect the easily accessible or visible system
Engine
Engine Electrical
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittent conditions. Refer to Testing for
Intermittent and Poor Connections in Wiring Systems.
Symptom list
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks/Cranks Slowly, but Does Not Start
Starter Motor Noise Diagnosis
"
"
..
"
6-687
Starter No Load Test

Battery Common Causes of Failure
Battery Check
Battery Terminal Check
Battery Hydrometer Displays Yellow Dot
Battery Not Operating Properly
Battery Electrical Drain/Parasitic Load Test
Generator Not Operating Properly
Generator Assembly Check
Spark Plug Visual Diagnosis
Spark Plug Wires Not Operating Properly
Starter Solenoid Does Not Click

Step
1
Action
Did you review the system operation and perform the
necessary inspections?
Attempt to start the vehicle.
Does the starter solenoid click audibly?
Value(s}
Connect a test lamp between the engine wiring harness

junction block 2 terminal C4 and ground. Refer to Circuit
Testing in Wiring Systems.
Does the test lamp illuminate?
No
Go to Step 2
Go to Symptoms
- Engine
Electrical
Go to Testing for
Intermittent and
Poor Connections
in Wiring
Systems
Go to Step 3
Go to Step 4
Go to A
Diagnostic
System Check Theft Deterrent
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
..
1. Remove the starter relay from engine wiring harness

junction block 2.
2. Connect a test lamp between the starter relay
terminal C6 and battery voltage. Refer to Circuit
3. While obseNing the test lamp, turn the ignition switch
to the START position.
1. Connect a test lamp between the engine wiring

harness. junction block 2 terminal B4 and ground.
Refer to Circuit Testing in Wiring Systems.
2. Place the transmission in PARK or NEUTRAL
(automatic) or press the clutch pedal (manual).
3. While observing the test lamp, turn the ignition switch
to the ST ART position.
Yes
Repair the open in circuit 2 between the engine wiring

harness junction block and S183. Refer to Wiring Repairs
in Wiring Systems.
1. Install the starter relay into the engine wiring harness

junction block 2.
2. Disconnect circuit 6 (the PPL wire) from the starter
solenoid.
3. Connect a test lamp between circuit 6 and ground.
4. Place the transmission in PARK or NEUTRAL
(automatic) or press the clutch pedal (manual).
5. While obseNing the test lamp, turn the ignition switch
to the START position.
Does the test lamp illuminate.?
Go to Step
18,
Go to Step 15
Go to Step 12
6-688
Engine Electrical
Engine
Starter Solenoid Does Not Click (cont'd)
Step
Action
Test for and repair an open or a poor connection in

circuit 1433 from the engine wiring harness junction
block 2 terminal 84 to the transmission range switch
terminal F (automatic) or the clutch pedal position switch
terminal B (manual). Refer to Circuit Testing or Testing for
Intermittent and Poor Connections and Wiring Repairs or
Connector Repairs in Wiring Systems.
Did you find and repair an open or a poor connection?
Test for and repair a poor connection at the transmission

range switch (automatic) or the clutch pedal position
switch (manual): Refer to Testing for Intermittent and Poor
Connections and Connector Repairs in Wiring Systems.
Did you find and repair a poor connection?
10
Test for and repair an open in circuit 1035 from the

transmission range switch terminal E (automatic) or the
clutch pedal position switch terminal A (manual) to C200D.
Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Value(s)
Yes
No
Go to Step 18
Go to Step 9
Go to Step 18
Go to Step 10
Go to Step 18
Go to Step 11
Did you find and repair an open?

Adjust or replace the transmission range switch
(automatic) or the clutch pedal position switch. Refer to
one of the following procedures:
11
12
13
Park/Neutral Position Switch Adjustment in Automatic

Transmission - 4L60-E
Park/Neutral Position Switch Replacement in
Automatic Transmission - 4L60-E
Clutch Pedal Position Switch Replacement in Clutch
Did you complete the replacement or adjustment?
Test for and repair a poor connection at the starter relay.
Refer to Testing for Intermittent and Poor Connections and
Test for and repair an open or a poor connection in
circuit 6. Refer to Circuit Testing or Testing for Intermittent
and Poor Connections and Wiring Repairs or Connector
Repairs in Wiring Systems.
Go to Step 18
Go to Step 18
Go to Step 13
Go to Step 18
Go to Step 14
Did you find and repair an open or a poor connection?

-
15
Test for and repair a poor connection in circuit 1 at the

positive battery terminal and the starter solenoid. Refer to
Testing for Intermittent and Poor Connections and
16
Test for and repair an open in circuit 1. Refer to Circuit

Testing and Wiring Repairs in Wiring Systems.
Did you find and repair an open?
17
Replace the starter. Refer to Starter Motor Replacement

(3.8 L) or Starter Motor Replacement (5.7 L).
Operate the system in order to verify the repair.

Did you correct the condition?
18
Replace the starter relay. Refer to Starter Motor Relay

Replacement.
14
Go to Step 18
Go to Step 18
Go to Step 16
Go to Step 18
Go to Step 17
Go to Step 18
System OK
Go to Step 3
Engine
Engine Electrical
6-689
Starter Solenoid Clicks, Engine Does Not Crank

Action
Step
Value(s)
Yes
No
Important: To avoid misdiagnosis, perform the following procedures:
Battery Terminal .Check

Battery Check
Did you review th.e system operation and perform the

Does engine crank?
..
1. (Automatic transmission) Set the gear selector to the

PARK position.
(Manual transmission) Set the park brake and place
the transmission in neutral.
2. Turn the ignition switch to the START position.
3. Use a DMM to measure the voltage from the battery
positive terminal to the starter solenoid terminal B.
Is the voltage equal to the specified value?
Go to Step 2
Go to Symptoms
- Engine
Electrical
Go to Testing for
Intermittent and
Poor Connections
in Wiring
Systems
Go to Step 3
Go to Step 4
Go to Step 5
QsQ.5V
'
2. Use a DMM to measure the voltage from the battery

negative terminal to G100. B. Refer to Circuit Testing
0-0.5V
in Wiring Systems.
Go to Stepl
Is the voltage equal to the specified value?
Replace the battery positive cable. Refer to Battery Cable

Replacement (3.8 L Positive) or Battery Cable
Replacement (5. 7 L Positive).
Replace the negative battery cable. Refer to Battery Cable

Replacement (3.8 L Negative) or Battery Cable
Replacement (5. 7 L Negative).
Replace the starter. Refer to Starter Motor Replacement

(3.8 L) or Starter Motor Replacement (5. 7 L).
Go to Step 8

Go to Step 8
Did you complet\3 the repair?
Go to Step 6
Go to Step 8
System OK
Goto Step 3
6-690
Engine Electrical
Engine
Engine Cranks/Cranks Slowly, but.Does Not Start

Step
Action
Did you review the system operation and perform the

Does the engine start?
Value(s)
Yes
No
Go to Step2
Go to Symptoms
- Engine
Electrical
Go to Testing for
Intermittent and
Poor Connections
in Wiring
Systems
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 7
Go to Step 11
1. The battery is fully charged.

3. Wait 15 seconds and measure the voltage at the
battery while cranking the engine. Refer to Circuit
Is the reading greater than the specified value?
> 9.5 V
Measure the voltage between the negative battery terminal

and the engine block while cranking the engine. Refer to
Circuit Testing in Wiring Systems.
Load test the battery. Refer to Battery Electrical

Drain/Parasitic Load Test.
Is the battery OK?
Replace the negative battery cable. Refer to Battery Cable

Replacement (3.8 L Negative) or Battery Cable
Replacement (5. 7 L Negative).
Does.the starter solenoi.d continue to click and the engine
to crank slowly or not at all?
> 0.5 V
Measure the voltage between the B+ terminal and the

starter solenoid terminal B while cranking the engine.
Repair or replace the starter motor. Refer to Starter Motor

Replacement (3.8 L) or Starter Motor Replacement (5.7 L).
Does the starter solenoid continue to click and the engine
Replace the battery. Refer to Battery Replacement.

Does the starter solenoid continue to click and the engine
10
Replace the positive battery cable. Refer to Battery Cable

Replacement (3.8 L Positive) or Battery Cable
Replacement (5.7 L Positive).

11
> 0.5 V
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 11
Go to Step 11
System OK
Go to Step 3
6-691
Engine Electrical
Engine
Starter Motor Noise Diagnosis
Step
Action
Value
Yes
No
Do you hear a high pitched whine during cranking (before

the engine fires) but the engine cranks and. fires normally?
Go to Step 2
Go to Step 3
Reduce the distance between the starter pinion and the

flywheel.
Has the noise stopped?
As the key is being turned, do you hear a high-pitched

whine after the engine fires?
(The engine cranks and fires normally. This is often
diagnosed as starter hang-in or a weak solenoid.)
Increase the distance between the starter pinion and the

flywheel.
(Flywheel runout makes this appear to be intermittent.)
Is there a loud "whoop" (It may sound like a siren if the

engine is rewed while the starter is engaged) after the
engine fires, but while the starter is still held engaged?

Replacement (3.8 L) or Starter Motor
2. Check the starter motor clutch.
3. Replace the worn parts.
Go to Step 4
Go to Step 5
System OK
Go to Step 6
Go to Step 7
System OK
Do you hear a rumble, a growl, or in severe cases a knock

as the starter is coasting down to a stop after starting the
engine?
1. Remove the starter motor. Refer to Starter

Motor Replacement (3.8 L) or Starter Motor
2. Check for a bent or unbalanced starter armature.
3. Replace worn parts.
System OK
Go to Step 8
System OK
System OK
6-692
Engine
Engine Electrical
Starter No load Test
8. If the starter motor energizes and the pinion

rotates, then, while maintaining 10 Volts on
the voltmeter, check the current draw on the
ammeter and the pinion speed on' the RPM
indicator.
Turn OFF the switch.
Compare the values to the starter
specifications table. Rerer to Starter
Motor Usage.
- If the current draw and the pinion
speed (RPM) are within the specifications,
then the starter motor is good.
- If the current draw or the pinion
speed (RPM) is not within the specifications,
then replace the starter motor. Refer to
Starter Motor Replacement (3.8 L) or Starter
Motor Replacement (5. 7 L).
1. Remove the starter motor. Refer to Starter

Motor Replacement (3.8 L) or Starter Motor
2. Turn OFF the carbon pile.
Battery Common Causes of Failure
1052
Caution: Keep fingers, tools, and any other

objects away from the opening in the drive end
housing while making electrical connections. The
strong shifting action of the starter solenoid
can cause severe personal injury or damage to
components as the drive pinion moves into
the cranking position.
3. Make connections as shown with the switch open.
4. Close the switch.
5. Adjust the carbon pile in order to obtain 10 Volts.
6. Compare the readings of the current, the
RPM's, and the voltage. Refer to Starter
Motor Usage.
7. If the pinion does not shift into the cranking
position or the pinion does not rotate, then
turn OFF the switch immediately. Ensure that the
test electrical connections were properly made.
If so, then replace the starter motor.
If the vehicle's battery tests good but st.ill fails to

perform well, the following are some of the more
common causes:
A vehicle accessory was left on overnight.
O The driving speeds have been slow with frequent
stops (stop-and-go driving).
The electrical load has exceeded the generator
output (particularly with the addition of aftermarket
equipment).
Existing conditions in the charging system,
including the following possibilities:
- An electrical short
- A slipping belt
- A bad generator
The battery has not been properly maintained,
including the following situations:
- A failure to keep the terminals tight
- A failure to keep the terminals clean
- A loose battery hold-down
" Power failure caused by an existing mechanical
condition in the electrical system, such as a
short or pinched wire.
The car is in storage for extended periods of time.
Extended cranking periods caused by spark
plug fouling.
The hydrometer has been read incorrectly.
There has been an insufficient ampere-hour
charge rate for a discharged battery.
There is a burned out charge indicator bulb
causing a NO CHARGE condition.
There is a continuous current draw on the battery
through excessive parasitic drain.
The battery is old.
(
\
Engine Electrical
Engine
Battery Check
Caution: Batteries produce explosive gasses.
Batteries contain corrosive acid. Batteries supply
levels of electrical current high enough to
cause burns. Therefore, to reduce the risk of
personal injury while working near a battery:
Always shield your eyes.
" A void leaning over the battery whenever
possible.
6-693
Do not expose the battery to open flames or

sparks.
.. Do not allow battery acid to contact the eyes
or the skin.
- Flush any contacted areas with water
immediately and thoroughly.
- Get medical help.
Battery Check
Step
Action
1. Inspect the following areas for

battery acid:
The battery case
The battery tray
The area around and
underneath the battery tray
2. Inspect the battery for a
cracked, broken, or
damaged case.
Compare the Cold Cranking
Amperage (CCA) and the Reserve
Capacity (RC) of the battery or the
Original Equipment (OE)
specification. Refer to
Battery Usage.
Normal Result(s)
Refer to Battery Replacement.
The ratings of the vehicle battery

meet or exceed the CCA and the RC
of the original equipment
specification.
Refer to Battery Replacement.
Inspect the battery hydrometer for a

green dot.
The battery hydrometer displays a

green dot.
If the battery hydrometer has a

dark dot (no green dot visible),
test the condition of the battery.
Refer to Battery Not Operating
Properly.
If the battery hydrometer has a
yellow dot, check the battery for
low electrolyte. Refer to Battery
Hydrometer Displays Dark or
Yellow Dot.
Turn the ignition key to START and

check to see if the engine cranks
normally and starts.
The engine cranks normally and

starts.
Engine does not crank or cranks

slowly, refer to Battery Not
Operating Properly.
Engine cranks normally but does
not start, refer to Engine Cranks
but Does Not Run in Engine
Controls - 3.8 L or Engine
Cranks but Does Not Run in
Engine starts but does not start
overnight or after a couple of
days, refer to A Diagnostic
Starting Point - Engine Electrical
and Battery Electrical
Drain/Parasitic Load Test.
Abnormal Result(s)*
The battery case, the battery

tray, and the surrounding area
are dry.
The battery is not cracked,
broken, or damaged.
1. Inspect the battery for proper

installation and retention in the
battery tray.
2. Inspect the battery terminals for
clean and tight connections.
The battery is firmly held in place

in the tray and the hold-down bolt
is properly tightened.
The battery terminals are clean
and tight.
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.
Install the battery in the battery

tray correctly. Refer to Battery
Replacement.
Refer to Battery Terminal Check.
6-694
Engine Electrical
Engine
Battery Terminal Check
Step
Action
Vatue(s)
Yes
No
1. Turn the ignition key to the OFF position.

1
2. Attempt to rotate the negative battery cable connector

clockwise with light finger pressure.
Does the. negative connector rotate?
Use a torque wrench in order to verify .the torque to loosen

the negative battery terminal bolt.
Disconnect the negative battery cable. Refer to Battery
Negative Cable Disconnect/Connect Procedure.
Go to Step 3
Go to Step 4
Go to Step 3
10 Nm (7 lb ft)
Is the torque above the specified value?
Go to Step 2
Go to Step 5
Is the cable disconnected?

Ensure the negative battery cable is disconnected.
Inspect for the following conditions and repair as needed:

The cable bolt is too long or misformed at the end.
There is foreign material present inside the nut in the
battery terminal.
Damage to the battery terminal face or cable
connector ring.
Rotate the positive battery cable connector clockwise with
light finger pressure.
Go to Step 5
Go to Step 6
Does the positive connector rotate?
Go to Step 7
..
Use a torque wrench in order to verify the torque to loosen

the positive battery terminal bolt.
10 Nm (7 lb ft)
Go to step 8
Is the torque above the specified value?

7
Disconnect the positive battery cable.

Is the cable disconnected?
Go to Step 9
Go to Step 7
Ensure the positive battery cable is disconnected.
Inspect for the following conditions and repair as needed:

The cable bolt is too long or misformed at the end.
There is foreign material present inside the nut in the
battery terminal.
Damage to the battery terminal face or cable
connector ring.
Go to Step 9
1. Clean and wire brush the lead face of both battery

terminals and the metal contact rings in both cable
connectors.
2. Remove the bolts from the cable connectors in order
to provide access to the connector rings as needed.
3. If eithe.r the battery terminals or the cable rings are
excessively damaged or corroded, replace as

needed.
Are the metal connecting parts clean and in good
condition?
Go to Step 10
1. Connect the positive battery cable to the battery

positive terminal.
10
2. Tighten the cable bolt to the specified value.
Go to Step 11
Is the cable bolt properly tightened?

1. Connect the negative battery cable to the battery
negative terminal.
11
2. Tighten the cable bolt to the specified value.

Is the cable bolt properly tightened?
15 Nm (11 lb ft)
15 Nm (11 lb ft)
Battery
Terminals OK
Engine
Engine Electrical
6-695
Battery Hydrometer Displays Yellow Dot

Step
Action
Was the Battery Check performed?
Tap the hydrometer lightly on top with the handle of a

small screwdriver to dislodge any air bubbles inside the
battery.
Does the hydrometer display a green or dark dot?
Value(s)
-
Replace the battery. Refer to Battery Replacement

Visually inspect the hydrometer in the new battery.
Does the hydrometer display a green dot?
Does the hydrometer display a yellow dot?
Tap the hydrometer lightly on top with the handle of a

small screwdriver to dislodge any air bubbles inside the
battery.
Does the hydrometer display a green dot?
Is the hydrometer dot still yellow?
9
10
Does the hydrometer display a dark dot?

Charge the battery. Refer to Battery Charging.
Was the battery recharged?
No
Go to Step 2
Battery Check
Go to
Is the hydrometer dot still yellow?
Yes
Go to Step 4
Go to Step 3
Hydrometer OK
. Go to Step 4
Go to Step 5
Go to Step 11
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 4
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 10
Go to Step 11
Check the charging system for proper operation. Refer to
11
A Diagnostic Starting Point - Engine Electrical.

Is the charging system OK?
Hydrometer OK
6-696
Engine Electrical
Engine

Tools Required
J 4.2000 Digital Battery Tester
GM PIN 12303040 Battery Side Terminal Adap\ers
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
3. Follow the instructions for testing the battery

outside of the vehicle.
4. Replace the battery only if the. second test
shows a REPLACE BATTERY .result.
For warranty purposes, use the test code
from the,second test.
.. , Use the approved terminal adapters.
Important: The battery test using the J 42000 Battery

Tester requires correct connections to the battery
terminals. A failure to obtain the correct connections
during the testmay result in replacing the battery
unnecessarily. Adhere to the following instructions in
order to avoid an incorrect diagnosis due to poor
connections:
When testing the vehicle with the battery cables
still connected, rock the J 42000 clips back and
forth on the terminal .bolt in order o cut through any
coating or oxidation that may be present on
the bolt.
Even new bolts contain a protective coating that
may insulate or cause a resistance in the test
circuit.
If it is uncertain that correct connections can be
made to the battery terminal bolts in the vehicle,
perform the following steps:
1. Disconnect the battery cables.
2. Install the test adapters on the terminals.
3. Follow the instructions for testing the battery
outside of the vehicle.
If a REPLACE BATTERY result is obtained for a
battery tested in the vehicle with the battery
cables connected, perform the following steps:
1. Disconnect the battery cables.
2. Install the approved adapters.
Do hot use any common bolts or a combination of

bolts, nut, and washers as adapters when
testing the battery.
Use the test adapters that are provided with the
J 42000 tester or GM part number. 12303040
terminal. adapters. If the adapters that are provided
' with.the J.42000 tester requirereplacement,
only use adapters with the GM part
number 12303040. Any other adapters may not
contact the correct areas of the battery terminal,
causing resistance that may resultin an invalid
battery test result.
In order to test the top terminal, threaded stud
batteries outside of the vehicle, use GM part
number i 2303040 adapters.
Do not connect the .tester
terminals.
to the
plain threaded
Important: For warranty purposes, always place the

test code displayed by the tester on the repair
order. The number is a unique identifier that describes
the test data for a particular battery at a particular time.
While the test code may occasionally repeat when
retesting the same battery, it is more likely that
a different code will result each time the battery is
tested.

Step
1
Action
Has the Battery Check been performed?
Value(s)
Is the battery in the vehicle, with the battery cables

connected?
i . Lightly wire brush the lead faces of both battery

terminals.
2. Install the terminal adapters to both of the terminals.
Are the adapters installed?
1. Turn the ignition switch to the OFF position.

2. Turn the electrical loads and all accessory lights to
the OFF position.
Are all of the electrical loads and accessory lights OFF?
Yes
No
Go to Step 2
Go to
Battery Check
Go to Step 4
Go to Step 3
Go to Step 5
Go to Step 5
Engine Electrical
Engine
6-697
Battery Not Operating Properly (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 16
Go to Step 11
Go to Step 24
Go to Step 28
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 36
Go to Step 12
Go to Step 36
Important: When testing the battery in the vehicle,

connect the tester directly to the cable bolts. Do not
connect either of the tester clamps to a remote terminal,
such as a junction block or a jump start terminal. The use
of a remote terminal will cause invalid test results.
1. Connect the red clamp on the J 42000 to the adapter
or the cable bolt on the battery positive terminal.
5
2. Connect the black clamp on the tester to the adapter
or cable bolt on the battery negative terminal.
3. Rock both of the tester clamps back and forth in

order to cut through to the bare metal.
The message GM MICRO 410 should appear for a short
time on the tester display, and then change to
SELECT TEST.
Does the display read SELECT TEST?
Does a CHECK CONNECTION message appear on the

J 42000 display?
Inspect the tester connections to the battery terminal

adapters or cable bolts for the following conditions:
Both sides of each tester clamp must make the correct
contact.
Ensure that the red clamp is connected to the positive

post and the black clamp is connected to the
negative post.
If the adapters or the bolts appear corroded, rock the

clamps back and forth in order to ensure a correct
connection.
Use a wire brush in order to clean the adapters or
cable bolts, if needed.
Does the tester display now read SELECT TEST?
Use J 39200 in order to test the battery voltage with the

J 42000 tester connected.
5.5 V
Is the voltage at or below the specified value?:

Use the scroll keys on the J 42000 tester in order to select
either IN-VEHICLE or OUT-OF-VEHICLE testing,
depending on the following conditions:
Use IN-VEHICLE testing if the battery cables are

connected to the battery.
Use OUT-OF-VEHICLE testing if the battery cables

are disconnected and the terminal adapters are
installed.
Was IN-VEHICLE testing selected?
10
The display on the tester will show ALWAYS TEST AT

BATTERY TERMINAL, and then change to SELECT
RATING.
Does the display read SELECT RATING?
11
For OUT-OF-VEHICLE testing, the display on the tester

will show USE TERMINAL ADAPTERS, and then change
to SELECT RATING.
Does the tester display read SELECT RATING?
6-698
Engine Electrical
Engine
Step
Action
i2
Important: Refer to Battery Usage for the correct rating

for the vehicle's OE battery. If a battery with a lower CCA
rating has been installed in the vehicle, the battery may
not perform properly during the use of the vehicle even if
the battery passes the test using the J 42000 tester.
1. Use the scroll keys on the J 42000 tester in order to
select the CCA rating on the battery label.
2. Press the ENTER key on the tester.
TESTING will appear briefly on the display, followed by the
resu Its of the test.
Are the results of the test displayed?
13
14
15
16
17
Value(s)
Does GOOD BATTERY appear on the J 42000 display?

Does GOOD-RECHARGE appear on the display?
Does CHARGE & RETEST appear on the display?
Does REPLACE BATTERY appear on the display?
Does BAD CELL-REPLACE appear on the display?
19
Does SELECT TEMP appear on the display?
20
Does SYSTEM NOISE-CHECK LOADS, alternating with

RETESTING, appear on the display?
1. Press the CODE button on the J 42000.

2. For warranty purposes, write the displayed code on
the repair order.
Bo to Step 13
Go to Step 14
Go to Step 24
Go to Step 15
Go to Step 28
Go to Step 16
Go to Step 25
Go to Step 17
Go to Step 27
Go to Step 18
Go to Step 29
Go to Step 19
Go to Step 32
Go to Step 20
Go to Step 33
Go to Step 36
Go to Step 23
Go to Step 22
Go to Step23
Go to Step 38
Is the green dot visible in the battery's hydrometer?
23
Charge the battery. Refer to Battery Charging.
. ls the green dot visible in the hydrometer?

The battery is OK. Install the battery. Refer to Battery
Replacement.
Is the action complete?
System OK
i. Press the CODE button on the J 42000.

2. For warranty purposes, write the displayed code on
24
the repair order.
3. Charge the battery. Refer to Battery Charging.

Go to Step 23
Is the green dot visible in the hydrometer?
25
Was the battery tested in the vehicle with the battery

cables still attached?
Go to Step 26
Go to Step 27
1. Turn the ignition key to the OFF position.

2. Disconnect the negative battery cable. Refer to
26

Procedure.
3. Disconnect the positive battery cable.
Are the actions complete?
Go to Step 3
2. For warranty purpose, write the displayed code on

27
the repair order.
3. Replace the battery. Refer to Battery Replacement.

Go to Step 2

2. For warranty purpose, write the displayed code on
28
the repair order.
3. Charge the battery. Refer to Battery Charging.

Is the green dot visible in the battery hydrometer?
Go to Step 13
18
22
No
'
Does SURFACE CHARGE DETECTED appear on the

display?
21
Yes
Go to Step 2
Engine
Engine Electrical
6-699

Step
Action
29
Important: Surface charge removal is only necessary

when the tester detects that a surface charge may affect
the results of the test. The tester will not compl,ete the
testing sequence until the surface charge is removed.
Follow the tester prompts in order to remove the surface
charge by turning the vehicle's headlights ON and OFF. If
the sequence is followed properly, the tester will
automatically complete the test. If the sequence is not
followed properly, the tester will display the message
DISCONNECT AND RETEST.
Does the DISCONNECT AND RETEST message appear?
30
Disconnect the tester from the battery terminals.

31
The tester will display the word RETESTING and show the
CCA rating that was selected for the test. If the test is
successfully completed, the test results will be displayed.
Do the test results appear on the display?
32
Important: Temperature compensation is only necessary

when the tester detects that the battery temperature may
affect the results of the test.
1. Use the scroll keys in order to indicate whether the
internal temperature of the battery is above or below
0c (32F). Use the temperature of the battery to
which the battery has been exposed for the past
several hours in order to estimate the temperature.
2. Push the ENTER key.
The tester will briefly display the RETESTING message
and the CCA rating selected for the test. The test results
will then show on the display.
Do the test results show on the display?
33
The tester detects that a vehicle electrical load is not

present (such as a light is on or the ignition key is not in
the OFF position).
Turn OFF all of the system electrical loads .
.Are all of the system electrical loads OFF?
34
The J 42000 automatically retests the battery. A

RETESTING message and SYSTEM NOISE message on
the display alternates up to 5 minutes while all circuits
power down. The test results will then display on the
tester.
Value(s)
No
Go to Step 30
Go to Step 31
Go to Step 2
Go to Step 13
Go to Step 35
Go to Step 13
Go to Step 36
Go to Step 34
Are the test results displayed on the tester?
Go to Step 13
An undetected load or parasitic drain can cause the

alternating RETESTING and SYSTEM NOISE messages
to continue for more than 5 minutes.
1. Disconnect the J 42000 tester.
2. Eliminate all electrical drains. Refer to Battery
Electrical Drain/Parasitic Load Test.
Are all electrical loads and parasitic drains eliminated?
36
A J 42000 problem is indicated. Inspect the tester for

correct operation.
Is the tester operating properly?
37
Repair or replace the tester.

38
A problem exists with the battery's built-in hydrometer.

Replace the battery. Refer to Battery Replacement.
35
Yes
Go to Step 35
Go to Step 2
Go to Step 2
Go to Step 1
Go to Step 37
-
System OK
s.:.100
Engine
Engine Electrical
4. A low electrolyte (5) level can be caused by any

of the following conditions:

Yellow Dot
Prolonged charging
An excessive charge
A broken case
Excessive battery tipping
5. When finding a battery in this condition it may
indicate high charging voltages caused by a
faulty charging system. The charging and electrical
systems should be checked.
6. If there is a cranking complaint, inspect for trouble
in the charging or electrical systems.
7. If a cranking complaint exists and is caused by
the battery, the battery should be replaced.
Battery Electrical Drain/Parasitic

Load Test
Tools Required
J 38758 Parasitic Draw Test Switch
A Fused Jumper Wire
(
405478
1. The battery has a built-in hydrometer (1 ). The

hydrometer lens provides a visual indication of
the condition of the electrolyte.
2. Tap lightly on the lens and observe the built-in
hydrometer (1 ).
3. Under normal operation, one of three color
conditions on the hydrometer (1) is possible:
Green ball. visible (2).
This condition indicates a sufficient state of
electrolyte (5) charge (65 percent or above) for
normal charging system operation.
Dark lens (3) (Green ball not visible)
This condition indicates an insufficient state of
electrolyte (5) charge below 65 percent).
Recharge the battery before further testing.
" Clear lens (4) (or Yellow lens).
208241

Procedure.
This condition indicates that the electrolyte (5)

is low. The battery electrolyte (5) cannot be
refilled. Replace the battery.
Engine Electrical
Engine
6-701
1
405480
2. Install the male end of the J 38758 (1) to the

negative battery terminal.
405483
5. Turn the test switch (1) ON.

Notice: Do not turn the parasitic draw test switch to
the OFF position with the engine running. Damage will
occur to the vehicle's electrical system.
6. Road test the vehicle. Activate all accessories,

including the air conditioning system and radio.
7. Turn OFF the ignition switch. Remove. the key.
Important: This allows the electronically timed
components to power down, preventing false parasitic
drain readings.
8. Wait 15 minutes before continuing the test.
405481
3.. Turn the test switch (1) OFF.

4. Connect the negative battery cable (2) to the
female end of the test switch.
405486
9. Connect the fused jumper wire (1) to the

terminals of the test switch.
10. If the fuse does not fail, the J 39200 can be
installed. A current of less than 10 amps is
present.
6-702
Engine Electrical
Engine
405490
405487
15. Turn the test switch (1) OFF. Current is now .

flowing through the ammeter option of J 39200.
11. Turn the test switch (1) ON.

12. Remove the fused jumper wire.
16. Wait one minute.

17. Wait until the current reading is 2 amps or less.
405488
13. Set the J 39200 to the 10A scale (1 ).

405495
Important: If an ammeter other than the J 39200 is

used, ensure that the vehicle does rot have a
high current drain that would damage the ammeter
when connected to the circuit.
18. Turn the test switch to (1) ON.

19. Switch the J 39200 from the 1OA setting to the
2A setting.
14. Connect the J 39200 to the terminals (2) of the

test switch.
Engine
Engine Electrical
6-703
ei5[ggABR~!
. BA"TT
WINDOWS
(NOT
USED)
RADIO
@1sc: 5:1 e 17[:15 :1

{NOT USED)
IP DIMMER
.
ACCY
405490
310933
26.1. To find the source of the excessive
20. Turn the test switch (1) to OFF.
21. Read the current in milliamps. This is the parasitic

drain value.
22. Note the battery reserve capacity. Refer to
Battery Usage.
loa.d perform the following:
26.2. Remove the courtesy lamp fuse

(number 8). Note the J 39200 reading.
26.3. lf,the parasitic load is still excessive start
23. Divide the battery reserve capacity by 4, this will

be the parasitic drain number.
24. The parasitic drain number should not exceed 114

of the battery's reserve capacity.
25. If the parasitic drain number exceeds 114 of the

battery's reserve capacity go to step 27.
removing the remaining fuses.
26.4. Keep the. courtesy lamp fuse out during

diagnosis,
so the. door can
remain open.
27. Continue removing the fuses one at a time,

starting with the fuses .that are hot all the
time. When the voltage drops across the J 39200,
note the last fuse removed. The current drain
comes from the circuit or circuits protected
by that fuse.
28. Repair the circuit and perform the parasitic load

test again to verify the repair.
405483
26. Turn the test switch (1) to ON.

Notice: The test switch must be in the ON position
) .when removing the fuses in order to maintain
continuity in the electrical system. This avoids
damaging the digital multimeter due to accidental
overloading, such as a door being opened to change
a fuse.
208241
29. Connect the negative battery cable. Refer

to Battery Negative Cable Disconnect/Connect
Procedure.
6-704
engine Electrical
Engine

Test Description
9. If the test has shown the generator to be OK,

however the condition remains, test the PCM or its
control circuit(s) to the generator.

Step
Action
Value{s)
Did. you review the system operation and perform the

Yes
No
Go to Step2
Go to Symptoms
- Engine
Electrical
Go to Step 5
Go to Step 3
Go to Step 13
Go to Step 4
Go to Step 11
.. Go to Step 10
..
4
;
Important: The green POWER lamp of the tester should

remain illuminated while the tester is being used.
1. Turn OFF the ignition.
Connect the red lead of the J 41450-8 Generator
Electronic Tester to the generator output terminal.
2. Connect the black lead of the J 41450-8 Generator
Electronic Tester to the metal generator housing.
Does the green POWER lamp on the tester illuminate?
Measure the. voltage from the output terminal of the

generator to the generator metal housing.
Does the voltage measure equal to the specified value?
B+
Measure the voltage from the output terminal of the

generator to the battery negative terminal.
Does the voltage measure equal to the specified value?
8+
Caution: Batteries produce explosive gasses. Batteries

contain corrosive acid. Batteries supply levels of
electrical current high. enough to cause burns.
Therefore, to reduce the risk ofpersonal injury while
working near a battery:
Always shield your eyes
.. Avoid leaning over the batterywhenever possible;
Do not expose the battery to open flames or
sparks.
Do not allow battery acid to contact the eyes or
the skin.
- Get medical help.
Turn OFF completely the load tool before connecting or
disconnecting a carbon pile load tester to the battery.
Otherwise, sparking at the terminals could cause battery.
gasses to explode and cause personal injury.
1. Connect a carbon pile tester to the vehicle
Important: Ensure that all generator output circuit wires
pass through the. inductive probe.
2. Connect an inductive ammeter to the output circuit of
the generator.
3. Disconnect the generator harness connector.
4. Locate the matching harness connector on the
J 41450,8, and connect the connector to the
generatqr.
Does the red DIAGNOSTIC lamp on the tester illuminate?
1. Start the engine and allow it to idle for 30 seconds.
2. Increase the engine speed to 2500 RPM.
Go to Step 6
Go to Step 12
Go to Step 14
Go to Step 7.
Engine Electrical
Engine
6-705
Generator Not Operating Properly (cont'd)

Value(s)
Step
Action
1. Maintain the engine speed at 2500 RPM.

Important: If the generator is not capable of producing the
Load Test amps, operate the generator at it's maximum
possible output.
2. Turn ON the load of the carbon pile tester and
increase the load until the generator output is equal
to the Load Test value given in Generator Usage.
1. Maintain the engine speed at 2500 RPM and

continue to operate the generator at the load
test value.
2. Measre the voltage drop from the output terminal of
the generator to the positive terminal on the battery.
Refer to Circuit Testing and Connector Repairs in
Wiring Systems.
Does the voltage measure greater than the
specified value?
0 ..5V
1. Maintain the engine speed at 2500 RPM and

continue to operate the generator at the load
test value.
2. Measure the voltage drop from the battery negative
terminal to the metal housing .of the generator. Refer
to Circuit Testing and Connector Repairs in Wiring
Systems.
Does the voltage measure greater than the
specified value?
0.5V
Go to Step 14
Go to Step B
Go to Step 10
Go to Step 9
Goto Step 11
Go to Step 15
10
11
Repair the high resistance or open in the ground circuit of

the generator. Refer to Circuit Testing and Connector
1. Disconnect the J 41450-8 tester harness connector

from the generator, but leave the alligator clips
connected so that the green POWER lamp remains
illuminated.
2. Connect a jumper lead, with an in-line 100-ohm
resistor between the J 41450-8 tester harness
connector terminal B and a good ground.
Does the red DIAGNOSTIC lamp illuminate?
13
There is a problem with the J 41450-8. Refer to the

manufacturers instructions, how to test the J 41450-8 for
proper operation.
Has the J 41450-8 tester been replaced?
14
Replace the generator. Refer to Generator Replacement

(3.8 L) or Generator Replacement (5.7 L).
Operate the vehicle in order to verify the repair.

15
No
Repair the high resistance or an open in the output circuit

of the generator. Refer to Circuit Testing and Connector
12
Yes
Go to Step 1.5
Go to Step 15
Go to Step 14
Go to Step 13
Go to Step2
Go to Step 15
System OK
Go to Step2
6-706
Engine Electrical
Engine
Generator Assembly Check
Diagnosis
On Vehicle Inspection Procedure
Tool Required
To diagnosis the CS-1300 charging system, use the
following procedure .
1. Inspect the accessory drive belt for damage or
wear. Service or replace as necessary.
2. Inspect the wiring.
3. Check for an undercharged or overcharged
battery condition (voltage lower than 11 volts
or higher than 16 volts), refer to Generator Not
Operating Properly.
Detach the wiring harness connector from the
generator.
With the ignition switch in the ON position and
the engine not running, connect the J 39200 as
a voltmeter from a ground to the L terminal in
the wiring harness connector. Connect the F or
the I terminal for the. gauge equipped vehicles.
At least one terminal should have battery
voltage.
Zero volts indicates an open circuit between the
terminal and the battery. Connect as required.
Reconnect the wiring harness connector to the
generator.
When the charging system is operating normally, the

voltmeter will read between 11-16 volts when the
engine is running. If the voltmeter operates abnormally,
.or if an undercharged or overcharged battery
condition occurs, the following procedure may be used
to diagnosis the chargin~ system.
An undercharged batteiy is often caused by
accessories being left on overnight, or by a hood or
instrument panel compartment lamp that stays on.
Noise from a generator may be ca[Jsed by a
loose drive pulley, loose mounting bolts, worn or dirty
bearings, faulty diode or faulty stator. A magnetic
whining noise may be heard from the CS-130D
generator. This is considered a normal condition.
Precautions
To avoid damage to the electrical equipment, always
observe the following precautions:
Do not reverse the connections to the generator.
Do not short across or ground any of the
terminals in the charging circuit, unless otherwise
directed by instructions.
Never disconnect the generator BAT terminal while
the generator is. operating.
When connecting a battery charger or a booster
battery, follow the procedure in Jump Starting
in Case of Emergency.
Do not attempt to disassemble CS-130D
generator. Damage to the generator could result.
Trouble in the charging system will show up as one or
more of the following conditions:
An abnormal voltmeter reacling
An undercharged battery condition (with slow
cranking or a dark hydrometer)
An overcharged battery condition (with electrolyte
leaks or a yellow hydrometer). Refer to Battery
Hydrometer Displays Dark or Yellow Dot.
Important: Disconnect the negative battery cable

before removing or installing a series-type ammeter at
the generator battery terminal.
Install an ammeter at the generator output
terminal. With the load off, install .a carbon pile
load test across the battery terminals. Start
the engine and run at 2500 RPM. Make sure
this is done at ambient temperature.
, Measure the voltage across the battery, using
the J 39200 If the voltage is above 16 volts,
replace or repair the generator.
Turn on the accessories and place a load on
the battery with the carbon pile to obtain
maximum generator output. Maintain voltage at
13 volts or above. Use an ammeter to check
amperage. Compare output to amperage rating
in Generator Usage.
Engine Electrical
Engine
6-707

Worn or dirty plugs give satisfactory operation at idling
speed, but under operating conditions they frequently
fail, Faulty plugs are indicated in a number of ways:
., Poor fuel economy
" Power loss
O
Loss of speed
Hard starting
., Poor engine performance

Spark plugs may also fail due to the following
conditions:
e
Carbon fouling
" Excessive plug gap

" Broken insulators
Fouled plugs are identified by black carbon deposits.
The black deposits are usually the result of
slow-speed driving and short runs where sufficient
engine temperature is seldom reached. Worn pistons,
rings, faulty ignition, over-rich air/fuel mixture and
spark plugs which are too cold will also result in carbon
deposits. Excessive gap wear, on plugs of low
mileage usually indicated the engine is operating at
high speeds or loads that are consistently greater than
.normal or that a plug which is too hot is being used.
Electrode wear may also be the result of plug
) overheating due to insufficient spark plug torque or too
much spark plug torque. An excessively lean air/fuel
mixture will also result in excessive electrode wear.
Broken insulator are usually the result of improper
installation or carelessness when regapping the plug.
Broken upper insulators usually result from a poor
fitting wrench or an outside impact. The cracked
insulator may not show up right away, but will as soon
as oil or moisture penetrates the crack. The crack
may not be visible. Broken lower insulators usually
result from carelessness when regapping and
generally are visible. This type of break may result
from the plug operating too hot, which may happen in
periods of high-speed operation or under heavy
loads. When regapping a spark plug, always make the
gap adjustment by bending the ground (side)
electrode. Spark plugs with broken insulators should
always by replaced.
Resistor type spark plugs with tapered seats are used.
No gasket is needed on these plugs. These spark
plugs are a High Efficiency (HE) spark plug that has a
fine wire electrode, nickel plated shell and a platinum
pad across from the electrode.
1053
1. Normal service is a mixture of idling, low speed,

and high speed operation.
O Occasional high speed driving is essential to
good spark plug.performance.
Increased combustion heat burns away excess
carbon deposits, which accumulate from
frequent idling or stop~and~go driving .
2. The heat resistant, insulating boot covers the
spark plug terminal.
The boot extends over a portion of the spark
plug insulator.
These boots prevent engine misfiring.
3. Corona discharge is a steady blue light appearing
(in darkness) around the insulator, just above the
shell crimp.
O Do not mistake this for a shorted insulator.
This is visible evidence of a high-tension field.
This has no effect on ignition system
performance.
This discharge repels dust particles.

This leaves a clear ring on the insulator just
above the shell.
This is not evidence that combustion gases

are escaping.
6-708
Engine Electrical
Engine
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 3
DEFINITION: A visual inspection of the spark plug firing end.
1. Remove the spark plug from the engine.

2. Note which cylinder the plug is from.
Do you see a brown to grayish tan deposit with a slight
electrode wear?
1. This is normal wear.

2. Clean, regap and reinstall the plug.
3. Tighten the plug, refer to Fastener Tightening
Specifications.
Do you see dry, fluffy, black carbon deposits?
This indicates poor ignition output, refer to. Spark Plug

Wire Resistance.
1.524 mm
(0.060 in)
System OK
Go to Step 4
Go to Step 6
Is the ignition coil(s) to the spark plug connections.OK?
Go to Step 5
Repair or install new parts as necessary.

Do you see wet, oily deposits with very little

electrode wear?
1. This results from either the break-in of a new or

recently overhauled engine.
2. Or from failed piston rings.
Degrease, gap and reinstall the spark plug.
System OK
Go to Step 7
Go to Step B
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 2
1.524 mm
0.060 in
Do you see. red, brown, yellow and/or white colored

coatings on the insulator?
These are the by-products ofcorribustion.

Is the insulator heavily coated?
10
1. Gap and install new spark plug(s),

2. Tighten the spark plug, refer to Fastener Tightening
Specifications.
1.524 mm
(0.060 in)
System OK
11
Are there heavy deposits of dark colored coatings,

especially on the side of the plug facing the intake valve?
12
1. This is the result of failed intake valve seals.

2. Or from excessive valve stem to valve guide
clearances.
3. This may not occur in all cylinders.
4. Repair or install new parts as necessary.
13
Is there a shiny, yellow glaze coating on the spark plug

insulator?
14
1. These are the melted by-products of combustion.

2. Avoid wide open throttle after long periods of low
speed operation.
3. Gap and install new spark plug(s). Refer to Fastener
Tightening Specifications.
Go to Step 12
Go to Step 13
System OK
Go to Step 14
1.524 mm
(0.060 in)
Go to Step 15
System OK
15
Are the insulator tips blistered or burned?
Go to Step 17
16
Are the electrodes badly eroded?
Go To Step 17
Engine
Engine Electrical
6-709
Spark Plug Visual Diagnosis (cont'd)

Step
Action
17
1. This is the result of overheating.

2. The spark plug heat range may be too hot.
3. The fuel octane rating may be to low for the
application, refer the customer to the Owners Manual
for correct fuel rating.
Is the plug heat range correct?
18
Check the torque value to ensure good spark plug seat

contact. Refer to Fastener Tightening Specifications
Are the spark plugs tightened according to specifications?
19
Check for a misfiring engine, refer to OTC P0230 Fuel

Pump Relay Control Circuit for V6 or OTC P0300 Engine
Misfire Detected for V8 in Engine Controls.
Is the vehicle operating properly?.
20
1. Check for a lean/rich fuel mixture, refer to Fuel

System Diagnosis for V6 or Fuel System Diagnosis
for V8 in Engine Controls.
2. Repair or install new parts as necessary.
21
Gap and install the correct spark plug(s). Refer to Spark

Plug Usage.
$park Plug Wires Not Operating Properly

1. Inspect the spark plug gap. Adjust the gap as
needed.
2. Inspect the spark plug wires for any obvious cuts,

burns, or damage. Replace the wires as needed.
Value(s)
Yes
No
Go to Step 18
Go to Step 21
Go to Step 19
Go to Step 10
Go to Step 20
Go to St(:Jp 10
System OK
System OK
3. With the engine ON, inspect for any arcing to

ground or othe.r components. Replace the
spark plug wires as needed.
4. Check the spark plug wires for proper resistance.
Refer to Spark Plug Wire Resistance.
6-710
Engine Electrical
Engine
Repair Instructions
Starter Motor Relay Replacement
Removal Procedure
1. Open .and remove the cover to the numbe~ 2
underhood electrical center.
2. Remove the starter motor relay. Heter to Electrical

Center Identification \(~ews in \1\/iring systems.
401242
1. Install the starter motor relay. Refer to Electrical
Center Identification. Views in Wiring Systems.
2. Install and close the cover on the number 2
underhood electrical center.'
401242
Engine
Engine Electrical
6~711
Starter Motor Replacement (3.8 L)

Removal Pro,cedure
Important: This engine was designed for starter motor
mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
Procedure.
Information.
3. Remove the starter motor shield. Refer to Starter
Shield Replacement (3.8 L).
4. Remove the starter motor bolt.
5. Remove the starter motor stud.
6. Lower the starter motor from the engine block.
7. Remove the positive cable to starter motor nut (1 ).
8. Remove the positive cable from the starter motor.
43571
211604
6-112
Engine
Engine Electrical
9. Remove the wiring harness starter lead nut from

the starter.
10. Remove the starter lead and washer.

11 . Remove the starter motor.
211623
1. Lift the starter motor i_nto position~
2. Install the starter lead. and washer to the .starter.
Notices.
3 . Install the wiring harness starter lead nut.
Tighten
Tighten the wiring harness starter lead nut to
2 N-m (17 lb in).
211623-
4. Install the positive cable to the starter.

5. Install the positive cable to starter motor nut (1).
Tighten
Tighten the positive cable to starter motor nut (1)
to 1O Nm (89 lb in).
6. Raise the starter motor to the engine block.
211604
Engine Electrical
Engine
6-713
7. Install the starter motor bolt.

Tighten
Tighten the starter motor bolt to 47 Nm (35 lb ft).
8. Install the starter motor stud.
Tighten
Tighten the starter motor stud to 45 Nm (33 lb ft).
9. Install the starter motor shield. Refer to Starter
11. Connect the negative battery cable. Refer to
Procedure.
43571
Staner Motor Replacement. (5. 7 L)

Removal Procedure
Important: This engine was designed for starter motor
mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
Procedure.
Information.
3. Remove the left side oxidation catalytic converter.
Replacement (5. 7 L Left) in Engine Exhaust.
4. Remove the starter motor bolts:
5. Lower the starter motor from the engine block.
550622
6-714
Engine Electrical
Engine
6. Remove the wiring harness starter lead n1..1tfrorri
the starter.
7, Remove the wiring harness starter lead and
washer from the starter.
211617
8. Remove the positive cable to starter motor

nut (3).
9. Remove the positive cable (4) from the
starter motor.
10. Remove the starter motor.
4
211595
11. Remove the starter motor shield, if necessary.
550624
Engine
Engine Electrical
6-715
1. Install the starter motor shield, if necessary.
550624
2. Lift the starter motor into position.

3. Install the positive cable (4) to the starter motor.

Notices.
4. Install the positive battery cable to starter motor
nut (3).
Tighten
Tighten the positive battery cable to starter motor
nut (3) to 10 N-m (89 lb in).
4
211595
5. Install the wiring harness starter lead and washer

to the starter motor.
6. Install the wiring harness starter lead nut.
Tighten
Tighten the wiring harness starter lead nut to
2 N-m (18 lb in).
7. Raise the starter motor to the engine block.
211617
6-716
Engine
Engine Electrical
8. Install the starter motor bolts.
Tighten
Tighten the starter motor bolts to 50 N-m (37 lb ft).
9. Install the left side oxidation catalytic converter.
Replacement (5. 7 L Left) In Engine Exhaust.
Procedure.
.~
550622
Starter Pinion Clearance Check

The pinion clearance cannot be adjusled. Improper
indication of worn parts. In order
clearance is
to check the pinion clearance, perform the following
procedure:
1. Disconnect the starter motor field connector from
the solenoid M terminal.
2. ,lns1,1late the starter motor field connector, carefully.
3. Connect a 12 V battery from the solenoid switch
terminal to the solenoid frame.
4. Momentarily flash a jumper lead from the solenoid
motor terminal to the solenoid frame. This will
shift the pinion into the cranking position.
The pinion will remain in the cranking position
until the battery is disconnected.
5. Push the pinion back toward the commutator end
to eliminate thrust movement.
an
1038
6. Measure the distahcebetween the'piriion and the

pinion stop collar.
The clearance should be from
0.25-4.06 mm (0.010-0; 160 in).
1039
Engine
Engine Electrical
6-717
Starter Shield Replacement (3.8 L)

Removal Procedure
Information.
2. Remove the starter motor shield bolts (1 and 3)
and nut (2).
3. Remove the starter motor shield from the vehicle.
211622
1. Install the starter motor shield to the vehicle.
and Notices.
2. Ins.tall the starter shield nut (2) and

bolts (1 and 3).
Tighten
Tighten to starter motor shield bolt (1) to
30 N-m (22 lb ft).
Tighten the starter motor shield bolt (3) to
10 N-m (89 lb in).
Tighten the starter motor shield nut (2) to
1O N-m (89 lb in).
211622
Starter Shield Replacement (5.7 L)

Removal Procedure
. Replacement (5. 7 L).
2. Unsnap the starter motor shield from the starter
solenoid.
550624
6-718
Engine
Engine Electrical
1 . Snap the starter motor shield to the starter

solenoid.

550624
Battery Charging
Before Charging
Notice: Turn OFF the ignition when connecting or
disconnecting the battery cables, the battery charger
or the jumper cables: Failure to do so may damage the
PCM or other electronic components.
Important: Do not use the boost, the jump start or the
crank setting for prolonged charging of batteries if
the charger is equipped with these settings. Using any
of these settings for a prolonged period may cause
gassing or spewing of electrolyte through the
vent hole.
1. Ensure that the electrolyte and the plates are at
room temperature before charging the battery. An
extremely cold battery may not accept the
current for several hours after the charger is

started,
2. Always stop charging, or reduce the charging
rate, if either of thefollowing conditions exists:
.. The battery temperature .is. .52C (125F)
orh~he~

O
Electrolyte spews or gasses violently 'through

the vent holes.
.
3. Replace the baUery when either of the following

conditions exist:
" The hydrometer is clear or yellow.
The battery is frozen.
Engine
Charge Time Required
The time required to charge a battery will vary
depending on the following factors:
The size of. the battery; A. higher capacity battery
which is completely discharged requires more
time to charge than a smaller capacity battery.
The battery temperature; The colder the battery,
the more time it takes to charge.
The battery charger capacity (in Amperes); The
higher the charger amperage, the less time it
will take to charge the battery.
The battery state-of-charge; A completely
discharged battery requires more than twice as
much charge as a half~charged battery.
While Charging
Tools Required
GM PIN 12303040 Battery Terminal Adapters
1. Do not charge a battery with a green hydrometer
dot unless it has just been discharged, such as in
cranking.
'
2. When charging, the adapters should be snug
against the battery t~rminals to keep resistance
to a minimum.
3. Make sure all battery terminals are clean and tight.
4.
5.
6.
7.
8.
Tighten
Tighten the battery side terminal adapters to
15 Nm (11 lb ft).
Best results occur when charging a battery that is
at room temperature. A battery that is extremely
cold may not accept current for several hours.
Charge the battery until the hydrometer has a
green dot.
Inspect the battery every half hour after starting
the battery charger.
Tap the hydrometer lightly to dislodge any air
bubbles. The bubbles may cause a false
indication.
After charging, load test the battery.
Charging Procedure
1. Measure the battery voltage:
Measure the voltage at the battery
terminals using a voltmeter.
A reading of less than 11 Volts indicates that
the charge current is low.
The battery will take longer to accept a current
higher than 2 milliamps.
2. Set the battery charger on the highest setting.
3. If necessary, disable the polarity protection
circuitry:
This circuitry, available on most chargers,
prevents charging unless the charger leads are
properly connected to the battery terminals.
A completely discharged battery may not have
enough voltage to activate this circuitry, even
though the leads are properly connected,
implying that the battery will not accept
a charge.
Engine Electrical
5;.719
Most chargers have an override or a bypass

function so that the charger will turn on and
charge a low voltage battery.
4. The required battery charge time varies according
to the voltage capabilities of the battery charger.
Replace the battery only if the charge current
is not measurable after the following charge times.
16 Volts or more - up to 4 hours
14-15.9 Volts - up to 8 hours
Less than 13.9 Volts - up to 16 hours
5. Reserve capacity rating:
The reserve capacity rating on the battery
label is the n,umber of Ampere-hours of charge
required in order to produce the green
hydrometer dot.
For example, if the battery has a reserve

capacity rating of 90 (expressed in
Ampere-hours), the battery would be recharged
as follows:
- 10 Ampere charge x 9 hours =
90 Ampere hours
- 30 Ampere charge x 3 hours =
90 Ampere hours
.. If the green hydrometer dot is not visible after
an Ampere-hour charge equal to twice the
reserve capacity rating, replace the battery.
6. After charging, load test the battery. Refer to
Battery Electrical Drain/Parasitic Load Test.
Battery Charge low or Completely

Discharged
1. Measure the battery voltage at the battery
terminals using a digital multimeter (DMM).
O A reading of less than 11 V indicates that the
initial charging will be very low.
It could take some time before the battery
accepts current in excess of a few
milliamperes.
2. Set the battery charger on the highest setting.
3. If necessary, disable the polarity protection
circuitry:
This circuitry, available on most chargers,
prevents charging unless the charger leads are
properly connected to the battery terminals.
A completely discharged battery may not have
enough voltage to activate this circuitry, even
though the leads are properly connected,
implying that the battery will not accept
a charge.
Most chargers have an override or a bypass
function so that the charger will turn ON
and charge a low voltage battery.
4. The required battery charge time varies according
to the voltage capabilities of the battery charger.
A charger of less than 14 volts could take up
to 16 hours before it appears to be accepting
current, followed up by several hours of the
appearance of charging.
6-720
Engine El.ectrical
5. To determine the amount of hours. the battery

may need to be charged, the following calculation
can be made:
The reserve capacity rating on the battery
label is the number of ampere2hours of charge
required iri order to produce the green
hydrometer dot.
After the meter on the charger starts to show
current flow, note the number of amps being
accepted.
Determine the reserve capacity of the battery.
Refer to Battery Usage.
Divide the reserve capacity by the number of
amps shown on the meter to determine how
many hours of charging is needed.
6. When the green dot appears in the hydrometer,
discontinue charging.
7. If the green hydrometer dot is not visible after an
ampere-hour charge equal to twice the reserve
capacity rating, replace the battery. Refer to
Battery Replacement.
8. After charging, load test the battery. Refer to
Battery Electrical Drain/Parasitic Load Test.
Engine
Jump Starting in Case of Emergency
Caution: Batteries produce explosive gasses.
Batteries contain corrosive acid. Batteries supply
levels of electrical current high enough to
cause burns. Therefore, to reduce the risk of
personal injury while working near a battery:
.. Always shield your eyes.

" A void leaning over the battery whenever
possible. '
O
Do notexpose the battery to open flames or

sparks.
Do not allow battery acid to contact the eyes

or the skin.
- Get medicaf help.
Notice: Push starting the vehicle can, .under some

conditions, cause damage to the catalytic converter
and an automatic transmission.
This vehicle has a 12 Volt, negative ground electrical
system. Make sure the vehicle or equipment being
used to jump start the engine is also 12 Volt, negative
ground. Use of any other type of system will damage
the vehicle's electrical components.
Engine
Engine Electrical
6-721
1. The following procedure is a typical battery to

battery hookup for jump starting.
2. The booster battery (4) and the discharged
battery (3) should be treated carefully when using
jumper cables. Do not cause sparks.
3. Position the vehicle with the charged (booster)
battery (4) so that the jumper .cables will reach.
Do not let the vehicles touch.
4. Attach the end of one jumper cable (6) to the
positive terminal of the booster battery (4).
5. Attach the other end of the same cable (2) to the
positive terminal of the discharged battery (3).
6. Attach one end of the second jumper cable (5) to
the negative terminal of the booster battery (4).
Caution: Do not connect a jumper cable directly to

the negative terminal of a discharged battery to
prevent sparking and possible explosion of
battery gases.
7. Attach the other end of the second jumper
cable (1) to a good engine ground (engine lift hook
or generator bracket) at the discharged battery (3).
405500
8. Start the engine of the vehicle that is providing

the boost (4).
9. Start the engine of the vehicle with the discharged
battery (3).
10. Disconnect the negative jumper cable (1) from the
engine ground of the battery (3) that was boosted.
11. Remove the other end of the negative jumper
cable (5) from the booster battery (4).
12. Remove the positive jumper cable (6) from the
booster battery (4).
Important: Do not let the cable end touch any metal

while the other cable end is still connected.
13. Remove the positive jumper cable (2) from the
other battery (3).
405501
6-722
Engine
Engine Electrical
Battery Negative Cable
Disconnec1:/Connect Procedure
Removal Procedure
Caution: Refer to SIR Caution in Cautions and

Notices.
1. Record all the vehicle preset radio stations.
2. Record the customers's radio Theftlock code (if

applicable).
3. Turn all the lamps and accessories off ..

4. Turn the ignition switch to the OFF position (3).
341078

5. Disconnect the negative battery cable bolt.
208241
Notice: Refer to Fastenef'Notice in Cautions and
Notices.
Important: Clean any existing oxidation from the

contact face of the battery terminal and battery cable
using a wire brush before installing.
1. Install the negative battery cable bolt.
Tighten
Tighten the negative battery cable bolt to
15 N-m (11 lb ft).
208241
Engine
Engine Electrical
6-723
2. Turn the ignition switch to the ACC position (1).
3. Unlock the Theftlock radio (if applicable). Refer

)
to Radio/Audio System Operation-Theftlock in

Entertainment.
4. Reprogram the radio stations to the previous
settings.
5. Set the clock to the current time.
6. Turn the ignition key to the LOCK position (2) and
remove the key.
341078
Battery Cable Replacement (3.8 L Positive)

Removal Procedure
1. Remove .the battery. Refer to Battery

Replacement.
2. Remove the positive cable from the stud on the
fuseblock:
Open the positive cable cap.
Remove the positive cable to fuseblock
stud nut.
Remove the positive cable from the
fuseblock stud.
211614
3. Remove the positive cable from the rosebud clip

at the power steering reservoir.
211610
6-724
Engine Electrical
Engine
4. Remove the wiring harness ground bolt and radio
frequency (RF) ground strap and cruise control
ground lead from the front rail.
346034
5. Remove the positive cable from the generator:

Slide the boot down revealing the positive
terminal stud.
Remove the positive cable nut from the
generator input stud.
Remove the positive cable.

6. Remove the positive cable rosebud clip from the
engine lift bracket.
43670
7. Remove the positive cable rosebud clips from the

cooling fans.
Information.
211607
Engine
Engine Electrical
6-725
9. Remove the positive/negative cable from the

engine mount stud:
Remove the positive cable RF ground nut (2).
Remove the RF ground strap.
1O. Remove the starter motor shield. Refer to Starter
11 . Remove the positive cable from the starter
solenoid:
Remove the positive cable to starter motor
nut (1).
Remove the positive cable from the harness
conduit.
211604
1. Install the positive cable to the harness conduit.
Notices.
2. Install the positive cable to starter motor nut (1 ).
Tighten
to 10 N-m (89 lb in).
3. Install the starter motor shield. Refer to Starter
4. Install the positive/negative cable to the engine
mount stud:
Install the RF ground strap.
Install the positive cable RF ground nut (2).
Tighten
Tighten the positive cable RF ground nut to
25 N,m (18 lb ft).
5. Install the wiring harness bolt and RF ground
strap and cruise control ground lead to the
front rail.
211604
Tighten
12 Nm (106 lb in).
346034
6-726
Engine Electrical
Engine
6. Install the positive cable rosebud clip at the power
steering reservoir.
211610
8. Install the positive cable rosebud clips at the

.cooling fans.
211607
9. Install the positive cable rosebud clip to the

engine lift bracket.
10. Install the positive cable to the generator.
9 Install the positive cable to the stud.
Install the positive cable nut to the generator
output stud.
Tighten
output stud to 22 N-m (16 lb ft).
Slide the boot over the generator output stud.
43670
Engine
Engine Electrical
6~727
11. Install the positive cable to the stud on the

fuseblock:
Install the positive cable to the fuseblock stud.
0
Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable to fuseblock stud
nut to 14 N-m (10 lb ft).
~ Close the positive cable cap.
12. Install the battery. Refer to Battery Replacement.
211614

(3.8 l Negative)
Removal Procedure
1. Remove the battery. Refer to Battery

Replacement.
2. Remove the negative cable nut at the ground
terminal.
3. Remove the ground lead from the
wheelhouse stud
211588
4. Remove the battery cable rosebud clip from the

accumulator bracket.
211593
6-728
Engine
Engine Electrical
5. Remove the negative cable nut from the engine

block stud.
6. Remove the negative cable from the harness
conduit.
43679
1. Install the negative battery cable to the harness
conduit.
2. Install the negative cable to the engine block stud.
Notices.
3. Install the negative cable nut to the engine
block stud.
Tighten
Tighten the negative cable nut to engine block
stud to 22 N-m (16 lb ft).
43679
4. Install the battery cable rosebud clip to the

211593
Engine
Engine Electrical
6-729
5. Install the ground lead to the wheelhouse stud.

6. Install the negative cable nut at the ground
terminal.
Tighten
Tighten the negative cable nut at the ground
terminal to 6 N-m (53 lb in).
211588
Battery Cable Replacement (5.7 L Positive)

Removal Procedure
Replacement.
2. Remove the positive cable from the stud on the
fuseblock.
Open the positive cable cap.
Remove the battery cable to fuseblock
stud nut.
Remove the positive cable from the
fuseblock stud.
Intormation.
211614
4. Remove the conduitrosebud clips at the

cooling fans.
211602
6-730
Engine Electrical
Engine
5. Remove the wiring harness ground bolt and radio
frequency.(RF) ground strap and cruise control
ground lead at the front rail.
346034
6. Remove the positive cable from the generator..

terminal stud.
generator output stud.
211599
7. Remove the positive cable to starter motor

nut (3).
8. Remove the positive cable (4) from the
starter motor.
9.. Remove the positive cable from the harness
conduit.
4
211595
Engine Electrical
Engine
6-731
1. Install the positive cable to the harness conduit.
2. Install the positive cable (4) to the starter motor.

Notices.
3. Install the positive cable to starter motor nut (3).
Tighten
to 10 N-m (89 lb in).
4
211595
4. Install the positive cable to the generator:

Install the positive cable.
Install the positive cable nut to the generator
output stud.
Tighten
Tighten the positive cable nut to the
generator output stud to 22 N-m (16 lb ft).
)
Slide the boot over the positive terminal stud.
211599
5. Install the wiring harness ground and RF ground

strap and cruise control ground lead bolt to the
front rail.
Tighten
Tighten the wiring harness groundand RF ground
strap and cruise control ground lead bolt to
12 N-m (106 lb in).
346034
6-732
Engine Electrical
Engine
6. Install the conduit rosebud clips .at the
cooling fans.
211602
8. Install the positive cable to the stud onthe

fuseblock:
.Install the positive cable to the fuseblock stud.
Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable to fuseblock stud
nut to 14 N-m (10 lb ft).
Close the positive cable cap.
211614

(5.7 L Negative)
Removal Procedure
Replacement.
2. Remove the negative cable nut at the ground
terminal.
3. Remove the ground lead from the
wheelhouse stud.
211588
Engine
Engine Electrical
6-733
4. Remove the battery cable rosebud clip from the

211593
5. Remove the negative cable to.e11gine block

bolt (1 ).
6. Remove the ground lead (2) from the
engine block.
7 .. Remove the negative battery cable from the

harness conduit.
211595
Installation Proce.dure
1. Install the negative cable to the harness conduit.
2. Install the ground lead (2) to the engine block.
Notice:. Refer to Fastener Notice in Cautions and

Notices.
3. Install the negative cable to engine block bolt (1 ).
Tighten
Tighten the negative cable to engine block bolt (1)
4'
211595
6-734
Engine Electrical
Engine
4. Install the battery cable rosebud clip at the
211593
5. Install the ground lead to the wheelhouse stud.

6. Install the negative cable nut at the ground
terminal.
Tighten
Tighten the negative at cable ground terminal nut
to 6 N-m (53 lb in).
211588
Battery Hold Down Retainer Replacement

Removal Procedure
1. Loosen the battery hold down retainer bolt.
2. Remove the battery hold down retainer and bolt.
43660
Engine
Engine Electrical
6Q735
1. Install the battery hold down retainer and bolt.

and Notices.
2. Tighten the battery hold down retainer bolt.
Tighten
Tighten the battery hold down retainer bolt to
18 N,m (13 lb ft).
43660
Battery Replacement
Removal Procedure
Procedure.
208241
2. Disconnect the positive battery cable bolt.
211587
6-"736
Engine
Engine Electrical .
3. Remove the battery hold down retainer bolt.

4. Remove the battery hold down retainer.
43660
5. Remove the battery from tile battery tray/coolant

recovery reservoir.
221643
1. Install the battery to the battery tray/coolant
recovery reservoir.
221643
Engine
Engine Electrical
6-737
2. Install the battery hold down retainer.

Notices.
3. Install the battery hold down retainer bolt.
Tighten
Tighten the battery hold down retainer bolt to
18 Nm (13 lb ft).
43660
4. Connect the positive battery ca.ble bolt.

Tighten
Tighten the positive battery cable bolt to
15 N-m (11 lb ft).
211587

Procedure.
208241
6-738
Engine Electrical
Engine
Battery Tray Replacement
Removal Procedure
Replacement.
the radiator.
221645
3. Remove the accelerator and cruise control

servo cable adjuster bolts, if equipped with a
5.7 L engine.
4. Reposition the accelerator and cruise control
servo cable adjuster.
221646
5. Remove the coolant recovery reservoir bolt.
(
221653
Engine
Engine Electrical
6-739
6. Remove the wiring harness rosebud clip from the

reservoir neck.
7. Remove the coolant recovery
reservoir/battery tray.
221650

the reservoir/battery tray.
221663
reservoir/battery tray.
2. Install the coolant recovery reservoir/battery tray.
221663
s. 740
Engine Electrical
Engine
3. Install the wiring harness rosebud clip to the
reservoir neck.
221650
Notice:Refer to Fastener Notice in Cautions and

Notices.
4. Install the coolant recovery reservoir bolt.

Tighten
Tighten the coolant recovery reservoir bolt to
12 N-m (106 lb in).
221653
5. Position the accelerator and cruise control servo

cable adjuster, if equipped with a 5.7 L engine.
6. Install the accelerator and cruise control servo
cable adjuster bolts.
Tighten
Tighten the accelerator and cruise control servo
cable adjuster bolts to 7.5 N-m (66 lb in).
221646
Engine Electrical
Engine
6-741

radiator.
9. Add engine coolant to the FULL COLD mark
on the reservoir.
221645
Underhood Fuse Block Replacement

Removal Procedure
The underhood electrical center is part of the forward
lamp wiring harness. The underhood electrical
center and harness must be replaced as a complete
assembly.
Procedure.
2. Starting inside the vehicle, disconnect the
accel/cruise servo cable adjuster electrical
connectors (1 ).
407641
3. Disconnect the following connectors from the

steering column (1 ):
Ignition switch (2)
Wiper/washer (3)
Cut the insulator from around the connector.
Dimmer switch (4)
.1
407643
5q42
Engine Electrical
Engine
4: Disconnect the electronic throttle control (ETC)
electrical connector (1 ), if equipped with a
3,8 L engine.
5. Disqonnect the rosebud clips (2) from the
dash mat.
Information.
407645
7. Disconnect the secondary air injection (.AIR) pump

connector, if equipped with a 5.7 L engine.
,:5J
550628
8. Disconnect the vacuum tank hose from the

vacuum tank.
/
282928
Engine
Engine Electrical
6-743
9. Remove the park/turn signal (3) and marker

lamp (1) connector from the lamp (2).
10. On Pontiac, disconnect the side marker lamp
connector.
407630
11. Remove the side repeater lamp (Export only).
379374
12. Remove the harness clips (1) from the fender rail.
(Export only)
1
407632
6-744
Engine
Engine Electrical
13. On Chevrolet, disconnect the connector from the

fog lamp.
14. Remove the rosebud clip from the front
bumper beam.
550635
15. On Pontiac, disconnect the connector from the

fog lamp.
16. Remove the clip from the front bumper beam.
' 550631
17. Remove the secondary lock retainer.(3).

18. Disconnect the headlamp jumper harness (2) from
the forward lamp harness (1 ).
---
(
2
407626
Engine Electrical
Engine
6-745
19. Disconnect the inline headlamp connector (1)

from the forward lamp harness.
20. Disconnect the rosebud clip (5) from the front

end panel.
21. Route the following through the front end
panel hole.
Fog lamp connector (2)
Park/turn signal connector (3)
Side marker connector (4), Pontiac only
1
407623
23. Remove the captured secondary lock (1') from the

connector.
24. Disconnect the ETC connector (2) from the
throttle body, if equipped with a 3.8 L engine.
407647
25. Disconnect the washer pump.electrical

connector (1 ).
26. Disconnect the windshield washer fluid hose (2)
from the pump.
407637
6-746
Engine Electrical
Engine
27. Disconnect. the forward lamp wiring harness
rosebud clips (1) from the tie bar.
407640
28. Disconnect the cooling fan electrical connectors,

29. Disconnect the harness rosebud clips.
Replacement.
550332
31. Remove the right front ground bolt .(2).

32. Remove the forward lamp wiring ground (3) from
the tie bar.
33. Remove the harness from the outboard of the)
battery tray (1 ).
34. Remove the forward lamp harness headlamp
branch through the hole in the front panel.
407633
Engine
Engine Electrical
6-747
35. Remove the forward lamp harness ground

stud (1 ).
36. Remove the forward lamp harness ground (2).
37. Disconnect the electronic throttle actuator
electrical connector (3), if equipped with a
5.7 L engine.
407622
38. Disconnect the secondary captured locks.

engine harness.
40. Disconnect the forward lamp harness vacuum
tube from the top of the vacuum check valve.
346047
41. Remove the speed sensor connector (1) from the

mid rail.
42. Disconnect the harness rosebud (2) clip at the
coolant fill neck.
407621
6-748
Engine Electrical
Engine
43. Remove the positive battery cable from the stud
on the fuseblock:
43.1. Open the positive cable cap,
43.2. Remove the po$itive cable.to fuseblock
stud nut
43.3. Remove the positive cable from the
fuseblock stud.
211614
44. Remove the ABS/SIR electrical ground stud (1)

from .the wheelhouse panel.
45. Remove the ABS/SIR electrical grounq
terminal (2) from the wheelhouse.
407616
46. Disconnect the 30 way connect9r ( 1) from the

brake pressure module valve.
407617
Engine
Engine Electrical
6-749
47. Disconnect the brake fluid level sensor

connector (1) from the master cylinder.
48. Remove the wheel speed sensor connector (2)
from the mid rail.
407618
49. Remove the underhood electrical center from the

wheelhouse bracket.
50. Remove the air inlet grille panel. Refer to Air Inlet
Grilfe Panel Replacement in Body Front End.
51. Disconnect the wiper motor electrical connector.
406433
52. Remove the wipe motor harness branch from the

plenum extension.
53. Remove the windshield washer fluid hose from
the plenum extension.
54. Remove the forward lamp wiring harness grommet
bolt (2).
55. Remove the harness rosebud clip at the left
wheelhouse panel.
56. Gently, remove the forward lamp harness from
inside the vehicle through the front of dash
opening.
57. Remove the forward lamp wiring harness from the
vehicle.
407620
6-750
Engine Electrical
Engine
1. Install the forward lamp wiring harness to the
vehicle.
2. Route the forward lamp harness through the front
of dash in the interior of the vehicle.
3. Install the harness rosebud clip to the left
wheelhouse panel.

Notices.
4. Install the forward lamp wiring harness grommet
bolt (2).
5.
6.
407620
7.
8.
9.
Tighten
Tighten the forward lamp wiring harness grommet
bolt (2) to 2 N-m (18 lb in).
Install the windshield washer fluid hose to the
plenum extension.
Install the wiper motor branch to the plenum
extension.
Connect the wiper motor electrical connector.
Install the air inlet grille panel. Refer to Air Inlet
Grille Panel Replacement in Body Front End.
Perform the following to install the underhood
electrical center to the wheelhouse bracket:
9.1. Tilt the forward lamp harness bracket
outboard.
9.2. Insert the tab on the bracket into the hole in
the wheelhouse bracket.
9.3. Roll bracket back inboard.
9.4. Secure bracket by sliding down into tabs on
tie bar.
406433
Engine
Engine Electrical
6-751
10. Install the wheel speed sensor connector (2) to

the mid rail.
11. Connect the brake fluid level sensor connector (1)
to the master cylinder.
407618
12. Connect the 30 way connector (1) to the brake

pressure module valve.
407617
13. Install the ABS/SIR electrical ground terminal (2)

to the wheelhouse.
14. Install the ABS/SIR electrical ground stud (1) to
the wheelhouse panel.
Tighten
Tighten the ABS/SIR electrical ground stud (1) to
14 N-m (10 lb ft).
407616
6-752
Engine Electrical
Engine
15. Install the harness ground wire (2) to the tie bar.
16. Install the left front forward lamp wiring ground
bolt (1 ).
Tighten
Tighten the left front forward lamp wiring ground
bolt (1) to 1O N-m (89 lb in).
407614
17. Install the positive battery to the stud on the

fuseblock:
17 .1. Install the positive cable to the
fuseblock stud.
17.2. Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable nut to fuseblock
stud to 14 Nm (10 lb ft).
17.3. Install the positive battery cable cover.
211614
18. Connect the harness rosebud (2) clip to the

coolant fill neck.
19. Install the speed sensor connector (1) to the
mid rail.
407621
Engine
Engine Electrical
5,.753
20. Connect the forward lamp harness vacuum tube

to the top of the vacuum check valve.
harness.
22. Connect the secondary captured locks.
346047
23. Connect the electronic throttle actuator electrical

connector (3), if equipped with a 5.7 L engine.
24. Install the forward lamp harness ground (2).

25. Install the forward lamp harness ground stud (1 ).
Tighten
Tighten the forward lamp harness ground stud (1)
to 16 N-m (12 lb ft).
407622
26. Route the forward lamp harness headlamp branch

through the hole in the front panel.
27. Tuck the harness into the opening forward of the

battery tray (1 ).
28. Install the forward lamp wiring ground (3) to the
tie bar.
29. Install the right front ground bolt (2).

Tighten
Tighten the right front ground bolt (2) to
1ONm (89 lb in).
407633
6-754
Engine
Engine Electrical
31 . Connect the rosebud clips.

32. Connect the cooling fan electrical connectors.
550332
33. Connect the forward lamp wiring harness rosebud

clips (1) to the tie bar.
407640
34. Connect the windshield washer fluid hose (2) to.

the pump.
35. Connect the washer pump electrical connector (1 ).
407637
Engine
Engine Electrical
6-755
36. Connect the ETC connector (2) to .the throttle

body, if equipped with 3.8 L engine.
37. Install the captured secondary lock (1) to the
connector.
Information.
407647
39. Route the following through the front end

panel hole:
Side marker connector (4), Pontiac only
Park/turn signal connector (3)
Fog lamp connector (2)
40. Connect the rosebud clip (5) to the front
end panel.
41. Connect the inline headlamp connector (1) to the
forward lamp harness.
1
407623
42. Connect the headlamp jumper harness (2) to the

forward lamp harness (1 ).
43. Install the secondary lock retainer (3).
--
2
407626
6-756
Engine
Engine Electrical
44. On Pontiac, install the clip (3) to the front

bumper beam.
45. Connect the fog lamp connector (2) to the lamp.
407629
46. On Chevrolet, install the rosebud clip to the front

bumper beam.
47. Connect the fog lamp connector to the lamp.
550635
48. Install the harness clips (1) to the fender rail.

(Export only)
(
1
407632
Engine
Engine Electrical
6-757
49. Install the side repeater lamp. (Export only)
379374
50. Install the park/turn signal (3) and marker (1)

connector to the lamp (2).
51. On Pontiac, connect the side marker lamp
connector.
407630
52. Connect the vacuum tank hose to the

vacuum tank.
/
282928
6-758
Engine Electrical
Engine
53. Connect the AIR pump connector; if equipped
with a 5.7 L engine.
550628
55. Con.nect the rosebud clips (2) to the dash mat

56. Connect the ETC electrical c6nnector~(1 ), if
equipped with a 3.8 L engine.
407645
57. Connect the following connector to the steering

column (1):
Dimmer switch (4)
Wiper/washer (3)
Install a tie strap around the connector
between the black and pink wires.
Ignition switch (2)
(
407643
Engine
58. Connect the accel/cruise servo cable adjuster
electrical connectors (1 ).
Engine Electrical
6-759
407641

Procedure.
208241
Ground Strap Replacement

Removal Procedure
1. On the 3.8 L engine, remove the positive/negative
cable from the engine mount stud.
" Remove the positive cable radio
frequency (RF) ground nut (2).
" Remove the harness clamp from the stud.
" Remove the RF ground strap.
211604
6-760
Engine
Engine Electrical
2. On the 5.7 L engine, remove the engine wiring

harness ground bolt from the block (1 ).
3. Disconnect and reposition the oxygen sensor
353688

ground strap and cruise control ground lead from
the frame rail.
5. Remove the tape attaching the ground strap to
the wiring harness.
6. Remove the ground strap from the vehicle.
346034
1. Install the ground strap to the vehicle.
2. Wrap new tape around the ground strap and the
wiring harness.

Notices.
3. Install the wiring harness ground bolt and RF
ground strap and cruise control ground lead to
the frame rail.
Tighten
12 Nm (106 lb in).
(
346034
Engine
Engine Electrical
6-761
4. On the 5.7 L engine, connect and position the

oxygen sensor electrical connector.
5. Install the engine wiring harness ground bolt (1) to
the block.
Tighten
Ti,ghten the engine wiring harness ground bolt (1)
to 25 N-m (18 lb ft).
353688
6. On the 3.8 L engine, install the p9sitive/negative

cable to the engine mount stud.
Install the RF ground strap.

Install the harness clamp from the stud.
Install the positive cable RF ground nut (2).
Tighten
Tighten the positive cable RF ground
nut (2) to 25 N-m (18 lb ft).
211604
Generator Bracket Replacement (3.8 L)

Removal Procedure
1. Remove generator rear brace. Refer to Generator
Brace Replacement.
2. Remove the fuel rail from the upper intake
manifold. Refer to Fuel Rail Assembly
Replacement in Engine Controls - 3.8 L.
3. Remove the generator brace bracket bolts.
4. Remove the generator bracket from the
cyl,inder head.
165246
6-762
Engine
Engine Electrical
1. Install the generator bracket to the cylinder head.

Notices.
2. Install the generator brace bracket bolts.
Tighten
Tighten the generator brace bracket bolts to
50 Nm (37 lb ft).
3. Install the fuel rail to the upper intake manifold.
Refer to Fuel Rail Assembly Replacement in
4. Install the generator rear brace. Refer to
Generator Brace Replacement.
165246

(5.7 L Front)
Removal Procedure
1. Remove the accessory drive belt idler pulley.
Refer to Drive Belt Idler Pulley Replacement Accessory in Engine Mechanical - 5.7 L.
3. Remove the generator bracket bolt and bracket.
550637
Notices.
1. Install the generator bracket and. bolt.
Tighten
Tighten the generator bracket bolt to
50 Nm (37 lb ft).
Replacement(5.7 L).
3. Install the accessory drive belt idler pulley. Refer
to Drive Belt Idler Pulley Replacement - Accessory
in Engine Mechanical - 5.7 L.
(
550637
Engine
Engine Electrical
6-763

(5.7 L Rear)
Removal Procedure
1. Remove the generator rear mounting bolt (to
generator) (1 ).
2. Remove the generator rear mounting bolt (to
engine) (2).
3. Remove the generator rear bracket.
-~
2
211626
1. Install the generator rear bracket.
2. Install the generator rear mounting bolt (to
generator) (1) hand tight.
Notice:. Refer to Fastener Notice in Cautions and

Notices.
3. Install the generator rear mounting
bolt (to engine) (2).
)
Tighten
O
Tighten the generator rear mounting bolt (to

generator) (1) to 25 N-m (18 lb ft).
Tighten the generator rear mounting bolt (to
engine) (2) to 50 N-m (37 lb ft).
-~
2
211626
Generator Brace Replacement

Removal Procedure
1 . Remove the generator. Refer to Generator
2. Remove the canister purge solenoid. Refer to
EVAP Canister Purge Valve Replacement in
Engine Coritrols - 3.8 L.
3. Remove the generator rear brace bolts (5).
4. Remove the generator rear brace (4) from the
vehicle.
487452
6-764
Engine
Engine Electrical
1. Install the generator rear brace (4) to vehicle.

and Notices.
2. Install generator rear brace bolts (5).

Tighten
Tighten the generator rear brace bolts (5) to
25 N-m (18 lb ft).
3. Install the canister purge solenoid. Refer to EVAP

Canister Purge Valve Replacement in Engine
Controls - 3.8 L
487452
Generator Replacement (3.8 L)

Removal Procedure
Procedure.
Belt Replacement in Engine Mechanical - 3.8 L.
3. Disconnect the generator electrical connector.
211637

.. Slide the boot down revealing the positive
terminal stud.
5. Remove the canister purge solenoid. Refer to

EVAP Canister Purge Valve Replacement in
(
43670
Engine
Engine Electrical
6-765
6. Remove the generator rear brace bolt (6).

7. Remove the generator bolts (2, 3).
8. Remove the generator (1) from the drive belt
tensioner:
487452
1. Install the generator (1) to the drive belt tensioner.
Notice:. Refer. to Fastener Notice in Cautions and

Notices.
2. Install the generator bolts (2, 3).
Tighten
Tighten the generator bolt (2) to
30 Nm (22 lb ft).
Tighten the generator bolt (3) to
50 Nm (37 lb ft).
3. Install the generator brace bolt (6).
Tighten
Tighten .the generator brace bolt (6) to
30 N-m (22 lb ft).
4. Install the canister purge solenoid. Refer to EVAP
Canister Purge Valve Replacement in Engine
Controls-3.8 L.
487452
5. Install the positive cable to the generator.

Install the positive cable to the generator
output stud.
Install the positive cable to the generator
output stud nut.
Tighten
output stud to 22 N-m (16 lb ft).
Slide the boot over the generator output stud.
43670
6-766
Engine
Engine Electrical
6. Connect the electrical connector to the generator.

Replacement in Engine Mechanical-3.8 L.
Procedure.
211637
Generator Replacement (5. 7 L)

Removal Procedure
Procedure.
Belt Replacement - Accessory in Engine
Mechanical-5.7 L
Information.
terminal stud.
211599
5. Remove the generator rear bracket mounting

bolt (1 ).
6. Remove the transmission oil cooler lines from the
oil cooler clip.
(
211626
Engine
Engine Electrical
6-767
7. Remove the front generator mounting bolts and oil

cooler clip.
211628
8. Disconnect the generator electrical connector (3).

9. Remove the generator from the vehicle.
211624
1. Install the generator to the vehicle.
2. Connect the generator electrical connector (3).
211624
6:-768
~ngine Electrical
Engine
Notice: Refer to Fa.stener Notice in Cautions and
Notices.
3. Install the front generator mounting bolts and oil
cooler clip.
Tighten
Tighten the generator mounting bolts to
50 N-m (37 lb ft).
4. Install the transmission oil cooler lines to the oil
cooler clip.
5. Install ttie generator rear bracket mounting

bolt (1 ).
Tighten
Tighten the rear bracket mounting bolt (1) to
25 Nm (18 lb ft).
211626
6. Install the positive cable tothe generator:

Install the positive cable.
lnstall.ttie ppsitive cable nut to the generator
output stud.
Tighten
Tighten the positive cable nut to the
generator output stud to 22 Nm (16 lb ft).
Slide the boot over the positive terminal stud.
Replacement - Accessory in Engine
Mechanical-5. 7 L.
Procedure.
211599
Engine
Engine Electrical
6-769
Generator Splash Shield Replacement

Removal Procedure
1. Remove the generator splash shield from the tie
strap on the steering rack.
211633
2. Reniove the generator splash shield nuts.

3. Remove the generator splash shield.
211632
1. Install the generator splash shield.
2. Install the generator splash shield nuts.
211632
5;..770
Engine Electrical
Engine
3. Install the generator.splash shield to the tie s1rap
on the steering rack.
211633

(3.8 L Right Bank)
Removal Procedure
1. Turn the ignition to OFF (3) or to LOCK (2).

Information.
341078
Notice: Twist the spark plug boot one-half turn in

order to release the boot. Pull on. the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged.
3. Disconnect the number 4 and number 6 plug

wires from the spark plugs.
5. Disconnect the number 2 plug wire from the
spark plug.
(
211645
Engine
Engine Electrical
6-771
6. Disconnect the even (2, 4, 6) spark plug wires

from the ignition coils.
7. Remove the spark plug wire harness.
43661
Important: The lower tabs of the heat shield must

extend over the hex on the spark plug in order
to complete installation of the heat shield and the boot
on the spark plug.
1. Install the spark plug wire harness.
2. Connect the even (2, 4, 6) spark plug wires to the
ignition coils.
3. Connect the number 2 plug wire from the
spark plug.
Information.
43661
5. Connect the number 4 and number 6 plug wires

. to the spark plugs.
6. Lower the vehicl.e.
211645
5;;772
Engine Electrical
Engine
(3.8 L Left Bank)
Removal Procedure
1. Disconnect the odd numbered plug wires (1, 3, 5)
from the ignition coils.

order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged.
Information.
43661
3. Remove the plug wires from the spark plugs.

4. Remove the spark plug wire harness from .the
vehicle.
211642
Important: The lower tabs of the heat shield must
extend over the hex on the spark plug in order
to complete installation of the heat shield and the boot
on the spark plug.
1. Install the spark plug wire harness to the vehicle.
(
211642
Engine
Engine Electrical
6-773
4. Connect the odd numbered plug wires (1, 3, 5) to

the ignition coils.
43661
Spark Plug Wire Harness

Replacement
7 L)
cs:
Removal Procedure
order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plugwire or the wire
could be damaged,
1. Disconnect the spark plug wire at each spark plug.
Twist each spark plug 1/2 turn.
Pull only on the boot in order to remove the
wire from each spark plug.
2. Disconnect the spark plug wire from the
ignition coil.
Twist each spark plug boot 1/2 turn.
Pull only on the boot in order to remove the
wires from the ignition coil.
211641'
1. Install the spark plug wires at the ignition coil.
2. Install the spark plug wire to each spark plug.
3. Inspect the wires for proper installation:
Push sideways on each boot in order to inspect
the seating.
Reinstall any. loose boot.
211641
6-774
Engine
Engine Electrical
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wires. Refer to Spark Plug

Wire Harness Replacement (3.8 L Right Bank),
(3.8 L Left Bank) or Spark Plug Wire Harness
Notice: Allow the engine to cool before removing the

spark plugs. Attempting to remove the spark plugs
from a hot engine may cause the plug threads to seize,
causing damage to cylinder head threads.
14324
Notice: Clean the spark plug recess area before

removing the spark plug. Failure to do so could result
in engine damage because of dirt or foreign material
entering the cylinder head, or by the contamination of
the cylinder head threads. The contaminated
threads may prevent the proper seating of the new
plug. Use a thread chaser to clean the threads oi any
contamination.
2. Loosen each spark plug one or two turns.
3. Brush or use compressed a:ir to)emove any dirt
from around the spark plugs.
4. Remove the spark plugs one at a time an.d place
each plug in tray markE?d with the corresponding
cylinder numbers;
1. Inspect each spark plug gap. Adjust each plug as
needed.
Specification
Spark plug gap: 1 ,524 mm (0.060 in):,
2. Hand start the spark plugs in the corresponding
cylinders.
Notices.
3. Tighten the spark plugs.
Tighten
Tighten the 3.8 L engine spark plugs to
27 N,m (20 lb ft).
Tighten the 5. 7 L engine spark plug on aNEW'.
cylinder head to 20. Nm (15. lb ft).
Tighten the 5.7.L engine spark plug on
subsequent
installations ,to 15 Nm (11 lb 'ft).
.
,,
4. Install the spark.plug wires. Refer to Spark Plug
Wire Harness Replacement (3.8 L. Righi Bank),
(3.8 L Left Bank) or Spark Plug Wire Harness
'
14824
and.
'
'
Engine
Engine Electrical
6-775
lgniUon Coil Replacement (3.8 L)

Removal Procedure
control module.
2. Disconnect the spark plug wires from the coil
being serviced.
211652
3. Remove the ignition coil bolts (2).

4. Remove the ignition coil (1) from the module (4).
5. Remove the ignition coil seal (3), if required.
379371
1. Install the ignition coil seal (3), if removed.
2. Install the ignition coil (1) to the module (4).

Notices.
3. Install the ignition coil bolts (2).
Tighten
Tighten the ignition coil bolts (2) to
4 N-m (35 lb in).
379371
6-776
Engine
Engine Electrical
4. Connect the spark plug wires to.the coil.

5. Connect the electrical connector from the control
module.
Tighten
Tighten the ignition control module bolt to
2.5 N:m (22 lb in).
211652
Ignition Coil Replacement (5.7 L)

Removal Procedure
1. Disconnect the main electrical connector feeding
the ignition coils.
2. Disconnect the ignition coil harness connectors.
3. Disconnect the spark plug wire at the ignition coil.
211648
4. Remove the ignition coil mounting bolts.

5. Remqve the ignition coiL
309850
Engine
Engine Electrical
6-777
lnstaNation Procedure
1'. Install the ignition coil.
Notices.
2. Install the ignition coil mounting bolts.
Ti,ghten
Tighten the ignition coil mounting bolts to
12 N-m (106 lb in).
309850
3. Connect the spark plug wire at the ignition coil.

4. Connect the ignition coit harness connector.
5. Connect the main electrical connector feeding the
ignition coils.
211648
Ignition Coil Module Replacement (3.8 L)

Removal Pro,cedure
1. Loosen the control module electrical
connector bolt.
2. Remove the control module electrical connector
from the module.
3. Remove the spark plug wires from the ignition
control module.
211652
6-778
Engine Electrical
Engine
4. Remove the ignition control module nuts.
5. Remove the engine lift bracket to ignition control
module bolt.
6. Remove the ignition control module/coils.
43664
7. lay the module/coils on a clean work surface.
8. Remove the ignition coil bolts (2) from all the

coils (1 ):
9. Remove the ignition coils (1) from the module (4).

10. Remove the ignition coil seals (3).
11. Remove the module (4) from the module

bracket (5).
379371
1. Install the module (4) to the module bracket (5).
2. Install the ignition coil seals (3):
3. Install the ignition coils (1) to the module (4).
Notice: Refer. to. Fastener Notice in Cautions

and Notices.
4. Install the. ignition coil bolts (2).

Tighten
Tighten the ignition coil bolts (2) to
4 N-m (35 lb in).
379371
Engine
Engine Electrical
6-779
5. Install the ignition control module/coils.

6. Loosely install the engine lift bracket to ignition
control module bolt.
7. Install the ignition control module nuts.
Tighten
Tighten the ignition control module nuts to
30 N-m (22 lb ft}.
Tighten the engine lift bracket to ignition
control module bolt to 25 N-m (18 lb ft).
43664
8. Install the spark plug wires to the ignition control

module.
9. Install the control module electrical connector to

the module.
10. Tighten the control module electrical

connector bolt.
\)
Tighten
Tighten the ignition control module bolt to
3 Nm (27 lb in).
211652
6-780
Engine
Engine Electrical

Starting System Description
When the ignition switch is turned to tbe START
position, the battery voltage is applied to the starter .
motor solenoid, and both of the starter motor solenoid
windings are energized. The pull-in windings work
together magnetically in order to puU in and hold the
plunger. The plunger then move~ the shift lever..
This action causes the starter dnve to rotate as 1t
engages with the flywheel on the engine. At.th.a same
time, the plunger also closes the starter moto~
.
solenoid switch contacts. Full battery voltage 1s applied
directly to the starter motor, whi.ch iii tum cranks the
engine.
As soon as the coritacts close, the voltage is no
longer applied through the pull-in windings, since the
battery voltage is applied to both ends of the
windings. The hold-in winding remains energized, and
the magnetic field is strong enough to hold the
plunger, the shift lever, ~nd the st~rter drive c_ontacts
in place in order to continue cranking the engine.
When the ignition switch is moved from the START
position, the battery voltage is removed from th~ .
starter motor solenoid and the junction of the windings.
Voltage is applied from the contacts through both .
windings in order to ground at the. end of the hold-in
windings. However, thevoltageapplied to the .
pull-in winding is now opposing the voltage applle~
when the winding was first energized. The magnetic
fields of the pulHn and hold-in windings now
oppose each other. The return spring then causes the
starter drive to disengage and the contacts to open
simultaneously. As soon as the contacts open,
the starter circuit is turned off.
Starting System Operation

When the ignition switch is turned to the start position,
battery voltage is sent to the starter solenoid
contacts. This_ energizes the solenoid windings and
causes movement of the solenoid plunger and
shift lever which causes the drive pinion to engage the
engine flywheel ring gear and the solenoid switch
contacts to close. When the solenoid switch contacts
close, the starter motor is energized and cranking
takes place. As the engine starts, the pinion overrun
clutch protects the motor armature from excessive
speed until the ignition switch is op~ned. Once
the solenoid windings are de-energized, the return
spring causes the pinion to disenQag~_. In or?er
to prevent excessive overrun, the 1grnt!on switch should
be opened immediately when the engine starts.
Starting System Circuit Description
Starter Circu'it Operation

When the ignition switch is moved to the START
position voltage is applied to the normally open
contact~ of the starter relay. Voltage is also applied
through .either the park neutral position switch..
(automatic transmi\3sion) when _in park or neutra_l o~
the clutch pedal position switch (manual transm1ss1on)
when the clutch pedal is depressed, to the starter
relay coil. The body control module (BCM) energizes
the starter relay by grounding one side of the relay
coil only when the theft deterrent system has not been
activated.
When the starter relay is energized, the normally open
contacts close completing the circuit to the starter
solenoid. When the starter solenoid circuit is
completed, both the hold-in windings and the pull-in .
windings are energized. The circuit through the pull-in
winding is complete~ through the st~rter motor. .
The windings work together magnetically to pull in and
hold in the p_lunger. The_ plungern1oves the shift .
lever. This action causes the drive assembly to rotate
as it engages the flywhe~I ring gear on the engine: .
At the same time the plunger also closes the solenoid
switch contacts in the starter solenoid. Full battery
voltage is then applied directly to the starter _motor and
it cranks the engine.
As soon as the solenoid switch contacts close, voltage
is no longer applied to the pull-in winding since. .
battery voltage is applied to both ends of the w1~ding.
The hold-in winding remains energized and c~ntinues
to hold the plunger, the shift lever, ~nd the dnve .
assembly solenoid switch contacts in place to continue
cranking the engine.
When the ignition switch is released from the START
position, battery voltage is removed from the
two windings. Voltage is applied through the motor
contacts and both windings to ground. However,
the direction of current flow through the windings is
reversed. The magnetic fields of the two windings now
oppose one another. The return spring, aided by
the opposing magnetic fields of the windings,
disengages the drive assembly which opens the
solenoid switch contacts. Once the contacts open, the
starter circuit is turned off.
Engine Electrical
Engine
Battery Description
Battery Diagnosis
Caution: Batteries generate hydrogen gas which is

extremely flammable and may explode violently
if ignited by a spark or a flame. Battery acid
is extremely corrosive and causes severe personal
injury if the acid comes into contact with the
skin- blindness if the acid comes into contact with
the eyes. In order to avoid severe personal
injury, use extreme precaution when servicing the
battery or battery-related components.
If the battery tests good but still fails to perform

satisfactorily, the following are some of the more
common causes:
A vehicle accessory was left on overnight.
The driving speeds have been slow with frequent
stops (stop-and-go driving).
The electrical load has exceeded the generator
output (particularly with the addition of aftermarket
equipment).
Existing conditions in the charging system,
including the following possibilities:
- An electrical short
- A slipping belt
- A bad generator
- A bad generator voltage regulator
O The battery has not been properly maintained,
including the following situations:
- A failure to keep the terminals tight
- A failure to keep the terminals clean
- A loose battery hold-down
Existing mechanical conditions in. the electrical
system, such as any short or pinched wires,
attributing to power failure.
The car is in storage for extended periods of time.
Plug fouling, causing extended cranking periods.
The hydrometer has been read incorrectly.
There has been an insufficient Ampere-hour
charge rate for a discharged battery.
There is a burned out charge indicator bulb
causing a NO CHARGE condition.
" There is a continuous current draw on the battery
through excessive parasitic drain.
The battery is old.
4
)
6-781
3
405476
A maintenance free battery is standard on all vehicles.

There are no vent plugs in the cover. The battery is
completely sealed except for two small vent holes
in the side. These vent holes allow the small amount
of gas that is produced in the battery to escape.
The battery consists of the following components:
Hydrometer lens (1)
" Negative terminal (2)
Hold-down ramp (3)
Positive terminal (4)
" Battery grids (5)
The battery has three functions in the electrical
system:
Provides electrical current when the vehicle's
electrical nee.ds exceed the generator's output.
Stabilizes current surges in the charging system in
order to protect electrical systems.
Stores electrical energy for the starting system.
The battery specification label contains important
information about the following:

The test ratings
The original model number
The recommended replacement model number
The cold cranking Amps (CCA)
Battery Operation
The battery supplies current to operate the starting
motor and the ignition system when the engine is being
started. The battery has three major functions in the
electrical system:
1. Provides a source of energy for cranking the
engine
2. Acts as a voltage stabilizer for the electrical
system
3. For a limited time, it can provide energy when the

electrical load used exceeds the output of the
generator
The battery is an electrochemical devise.. This means

the battery uses chemicals to produce electricity.
The amount of electricity it can produce is limited. As
the chemicals in the battery are used up, the
battery runs down, or is discharged. It can be
recharged by supplying it with electric current from a
battery charger, or from the vehicle generator.
The used up chemicals are then returned to their
original condition, so the battery becomes recharged.
5.,752
Engine Electrical
Engine
Charging System Operation.
Battery Tray and Hold-Down Retainer

Description
Clean any corrosion from the battery tray/coolant

recovery reservoir and the hold down clamp prior to
installing the battery: Ensure the carrier is in good
condition in order to hold the battery securely and keep
the battery level. Ensure there are no parts or tools
in the battery tray/coolant recovery reservoir
before installing the battery. lnorder to prevent the
battery from shaking in the tray, tighten the hold down
bolt to the specification noted. Refer to Fastener
Tightening Specifications
Charging System Description

The charging system consists of the following
components:
.. The battery
The generator (CS-1300)

A voltage regulator
O
405471
Indicator lamp or voltmeter circuitry
CS-Series Generators
405469
Model CS-Series generators (1) feature a high

ampere output per pound of weight. The CS stands
for charging systems. The 130 is the measurement, in
millimeters, of the outside diameter of the stator
laminations and the D is for dual internal fans. The
delta stator, rectifier bridge, and the rotor with slip rings
and brushes, are electrically similar to other
CS series generators. The CS-1300 generator uses a
conventional pulley and dual internal fans to cool
the slip ring end frame, rectifier bridge and voltage
regulator.
The generator's rotor shaft (2) is rotated by the engine
drive belt. The rotor shaft rotates the generator's
rotor. The generator produces the electrical current
that charges the battery. The generator also provides
energy to the vehicle's electrical systems when the
engine is running.
The charging system provides voltage to the

battery and to the vehicle electrical systems. The
generator's voltage regulator controls the rotor's field
current to meet these needs.
Current flows (1) through the ~lip rings (8) to the rotor
winding (2) in order to create a magnetic field (3).
The engine-driven rotor (4) is rotated by the engine
within the stator (5). This rotation creates an
alternating current (AC) voltage in the stator
windings (6). The AC voltage go1s to the rectifier
bridge (7). The rectifier bridge converts this AC voltage
to direct current (DC) voltage. The DC voltage is
delivered from the generator's output terminal to the
battery and the electrical systems through a fusible
link (11). Theregulator grounds circuit 225 (10) when
the charging system voltage is abnormal: This
information causes the PCM to send a class 2
message to the instrument panel cluster, which
activates the CHECK GAGES lamp.
The voltage regulator limits system voltage by
controlling the rotor field CLJrrent. When the field
ccurrent is on, the regulator switches the rotor field on
and off at a fixed rate of about 400 cycles per second.
By varying the overall on/off time, correct average field
current for proper system voltage control is maintained.
At high speeds, the on time may be 1o percent .and the
off time may be 90 percent. At low speeds, and with
high electrical loads, the on/off time may be 90 percent
and 1Opercent respectively. The voltmeter reads
battery voltage when the engine is not running and
reads charging system voltage when the engine is
running. The normal indication is between 11 and
16 volts.
Engine
The generator uses only two connections-battery

positive and the L terminal, in addition to the ground
path through the generator bracket. Use of P, I, and
S terminals is optional. The P terminal is connected to
the stator and may be connected externally to a
tachometer or other devise. The I terminal can be
connected directly to battery voltage to power
the generator instead of, or in addition to, the
L terminal which must be stepped down. This
S terminal may be connected to an external voltage
source, such as voltage near the battery, for voltage
control. If the S terminal is not used, internal generator
voltage is used for control.
The CS-130D generator must be replaced. Do not
disassemble the CS-130D generator.
Charging System Operation

The charging system has two jobs:
1. To put back into the battery the current used to
start the engine
2. To handle the load ofthe lights, ignition, radio,
and other electrical and electronic equipment
while the engine is running.
The charging system includes the generator, regulator,
and battery, with connecting wires.
The generator converts mechanical energy from the
engine into electrical energy. It keeps the battery
in a charged condition and handles electrical loads
while the engine is running. The alternator produces
alternating current (ac) inside the stator windings.
Diodes convert this ac into direct current (de).
Charging System Circuit Description

Charging Circuit Operation
The generator provides voltage to operate the
electrical system and to charge the battery. A magnetic
field is created when current flows through the rotor
windings. This field rotates as the rotor is driven by the
engine, creating an AC voltage in the stator windings.
The AC voltage is then converted to a DC voltage
by a rectifier bridge. This DC voltage is then supplied
through circuit 1 to the electrical system at the
battery terminal.
The amount of output voltage is controlled by the
current supplied to the rotor. The solid state regulator
in the generator controls the current supplied to
the rotor. The rotor current is a series of electrical
pulses supplied by the regulator. When the ignition
switch is first placed in the RUN position, the
pulse width is very narrow. This causes the rotor to
produce a weak magnetic field. This will produce
a lower output voltage to the vehicle's electrical
system. Once the engine is running, the regulator
monitors the output voltage through an internal wire
and changes the pulse width accordingly.
Engine Electrical
6-783
Ignition System Description (3.8 l)

The electronic ignition system controls fuel.combustion
by providing a spark to ignite the compressed
air/fuel mixture at the correct time. To provide optimum
engine performance, fuel economy, and control of
exhaust emissions, the PCM controls the spark
advance of the ignition system. The electronic ignition
system does not use the conventional distributor
and coil. The electronic ignition system has the
following advantages over the conventional. mechanical
distributor system:
O
No moving parts
Less maintenance required
" Remove mounting capability
O
No mechanical load on the engine
More coil cool down time between firing
Elimination of mechanical timing adjustments
" Increased available ignition coil saturation time
The electronic ignition system consists of
three twin-tower ignition coils, an ignition control
module, a dual Hall-effect crankshaft position sensor,
an engine crankshaft balancer with interrupter
rings attached to the rear, related connecting wires,
and the Ignition Control (IC) and fuel metering portion
of the PCM.
The three twin-tower ignition coils are individually
mounted to the ignition control module. Each end of a
coils secondary winding is attached to a spark
plug. Each cylinder is paired with the cylinder that is
opposite it. These two spark plugs are on top
dead center at the same time. When the ignition coil
fires, both plugs fire at the same time to complete
the circuit. The cylinder on compression is said to be
the event cylinder and the one on exhaust is the
waste cylinder. The cylinder on the exhaust stroke
requires very little of the available energy to fire
the plug. The remaining energy will be used as
required by the cylinder on the compression stroke.
The same process is repeated when the cylinders
reverse roles. This method of ignition is called a waste
spark ignition system.
The electronic ignition system consists of the following
components:
~ Crankshaft position sensor
~ Crankshaft balancer interrupter rings
~ Camshaft position sensor
Ignition coils
Ignition control module
Powertrain control module (PCM)
For a more complete and detailed description of the
above information refer to Electronic Ignition (El)
System Description in Engine Controls-3.8 L
6-784
Engine Electrical
Ignition System Description (5.7 l)

The electronic ignition system controls fuel combustion
advance of the ignition system. The electronic ignition
system does not use the conventional distributor
and coil. The electronic ignition system has the
following advantages over a conventional mechanical
distributor system:
Engine
The electronic ignition system consists of the following
components:
.. Crankshaft position sensor

.. Crankshaft position sensor reluctor wheel
.. Camshaft position sensor
" Ignition coils
For a more complete and detailed description of the
above information refer to Electronic Ignition (El)
System.Description in Engine Controls-5.7.L
No moving parts
Ignition System Operation
Less maintenance required
The ignition system supplies high-voltage surges to

the spark plugs in the engine cylinders. These surges
produce electric sparks across the spark plug gaps.
The heat from the sparks ignites, or sets fire to,
the compressed air-fuel mixture in the combustion
chambers. When the engine is idling, the spark
appears at the plug gap just as the piston nears top
dead. center (TDC) on the. compression .stroke.
When the engine is operating at higher speeds, or
with part throttle, the spark is advanced. It is moved
ahead and occurs earlier in the compression
stroke. This gives the compressed mixture more 1ime
to burn and deliver its energy to the pistons.
Remove mounting capability

No mechanical load on the engine
More coil cool down time between firing
Elimination of mechanical timing adjustments
Increased available ignition coil saturation time
The ignition system on this vehicle feature a multiple
coil ignition and is known as coil near plug. The
secondary ignition wires are short compared with a
distributor ignition system wire. Eight ignition
coils/module are individually mounted above each
cylinder on the rocker cov.ers. The coil/mo.dules
are fired sequentially. There is ah Ignition Control (IC)
circuit for each ignition coil/module. The eight ignition
control circuits are connected to the PCM. All
timing decisions are made by the PCM, which triggers
each coil/module individually.
Engine
Engine Electrical
6-785

Illustration
Illustration
GM P/N 12303040
Battery Side
Terminal Adapters
3431
J 38758
Parasitic Draw Test Switch
3432
J 21008
Self Powered Test Light
J 39200
Digital Multimeter
J 35590
Current Clamp
J 41450-8
CS Electronic Generator
Tester
8439
95591
162176
J 35616-A
Connector.Test Adapter Kit
8917
J 42000
Digital Battery Tester
404758
6-786
Engine
Engine.Controls- 3.8L
Engine Controls - 3.8l

(
Specifications
oc
Temperature vs Resistance
OF
OHMS
Temperature vs Resistance Values (Approximate)
,.
100
212
177
90
194
241
80
176
332
70
158
467
60
140
667
50
122
973
45
113
1188
40
104
35
95
1459
1802
30
86
2238
25
77
2796
20
68
3520
15
59
4450
iO
50
5670
41
7280
32
9420
-5
23
12300
-10
14
16180
-15
21450
-20
-4
28680
-30
-22
52700
-40
-40
100700

Specification
Metric
English
A/C Refrigerant Pressure Sensor
6N-m
53 Lb In
Camshaft Position Sensor (CMP) Retaining Bolt
10 N-rri
89 Lb In
150 Nm + 114
111 Lb Ft+ 114
Crankshaft Position Sensor (CKP) Bolts
20 N-m
15 Lb Ft
Engine Coolant Temperature Sensor (ECT)
25 N-m
18 Lb Ft
Engine Oil Level Switch
20 N-m
15 Lb Ft
Exhaust Gas Recirculation Valve (EGR) Bolts
25 N-m
18 Lb Ft
Fuel Filter Fitting
30 Nm
22 Lb Ft
Fuel Pipe Front Clip Bolt
4.5 Nm
40 Lb In
Fuel Pipe Rear Clip Bolt
5.5 N-m
49 Lb In
Application
Fuel Pipe Shield Bolt
5 N-m
44 Lb In
Fuel Pipe Shield Nuts
5 N-m
44 Lb In
Fuel Pipe Shield Studs
5N-m
44 Lb In
Fuel Rail Attaching Nuts or Bolts
10 N-m
89 Lb In
Fuel Sender Assembly Attaching Nuts
6.5 Nm
58 Lb In
Fuel Tank Retaining Strap Bolts
33 Nm
25 Lb Ft
42 N-m
31 Lb Ft
Engine
Engine Controls - 3.SL
6-787

Specification
Metric
English
Ignition Coil Retaining Bolts
4.5 Nm
40 Lb In
Ignition Control Module Retaining Bolts
30 Nm
22 Lb Ft
Application
Knock Sensor
19 Nm
14 Lb Ft
Spark Plug
2.7 N-m
20 Lb Ft
Throttle Body Nuts or Bolts
10 N-m
89 Lb In
Fuel System Specifications

If you have the 3800 V6 engine (VIN Code K), use
regular unleaded gasoline rated at 87 octane or higher.
If you have the 5.7L V8 engine (VIN Code G), use
premium unleaded gasoline rated at 91 octane
or higher for best performance. You may use middle
grade or regular unleaded gasolines, but your
vehicl,e may not accelerate as well.
It is recommended that the gasoline meet specification
which have been developed by the American
Automobile Manufactures Association (AAMA) and
endorsed by the Canadian Motor Vehicle
Manufacturers Association for better vehicle
performance and engine protection. Gasolines
meeting the AAMA specification could provide
improved driveability and emission control system
performance compared to other gasolines. For more
information, write to: American Automobile
Manufacturer's Association, 7430 Second Ave,
Suite 300, Detroit Ml 48202.
Be sure the posted octane for premium is at least 91
(at least 89 for middle grade and 87 for regular). If
the octane is less than 87, you may get a heavy
knocking noise when you drive. If it's bad enough, it
can damage your engine.
If you're using fuel rated at the recommended octane

or higher and you hear heavy knocking, your
engine needs service .. But don't worry if you hear a
little pinging noise when you're accelerating or driving
up a hill. That's normal, and you don't have to buy
a higher octane fuel to get rid of pinging. It's the heavy,
constant knock that means you have a problem.
Notice: Your vehicle was not designed for fuel that
contains methanol. Do not use methanol fuel
which can corrode metal parts in your fuel system and
also damage plastic and rubber parts. This kind of
damage would not be covered under your warranty.
If your vehicle is certified to meet to meet California
Emission Standards (indicated on the under hood
emission control label), it is designed to operate on
fuels that meet Califomia specifications. If such
fuels are not available in states adopting California
emissions standards, your vehicle will operate
satisfactorily on fuels meeting federal specifications,
but emission control system performance may be
affected. The malfunction indicator lamp on your
instrument panel may turn on and/or your vehicle may
fail a smog-check test. If this occurs, return to your
authorized dealer for diagnosis to determine the cause
of failure. In the event it is determined that the
cause _of the condition is the type of fuels used, repairs
may not be covered by your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask your service station operator
whether or not the fuel contains MMT.
6-788
Engine Controls - 3.8L
Engine
Emission Hose Routing Diagram

226742
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Fuel Pressure Regulator

To Vacuum Brake Booster
EVAP Servi9e Port
Intake Manifold
To EVAP Caniste.r (Behind the Left
Rear Tire)
Throttle Body
PCV Valve
To Accessory
Manifold Vacuum Source
Engine
sqag
Emission Hose Routing Diagram (EVAP Control System Overview)

1
20
17
16
14
12
13
19
18
200517
Legend
(1) EVAP Vent Valve/Solenoid
(2) EVAP Vent Valve/Solenoid Ignition Feed
Circuit Terminal
(3) EVAP Vent Valve/Solenoid Control Circuit
Terminal
(4) EVAP Vent Valve/Solenoid Filter
(5) EVAP Vapor Lines
(6) Fuel Tank Pressure Sensor
(7) Fuel Tank Pressure Sensor Ground Circuit
Terminal
(8) Fuel Tank Pressure Sensor Signal Circuit
Terminal
(9) Fuel Tank Pressure Sensor Circuit 5 Volt
Reference Circuit Terminal
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Fuel Filler Pipe

Check Valve (Spitback)
Modular Fuel Sender Assembly
Fuel Limiter Vent Valve (FLVV)
PressureNacuum Relief Valve (Optional)
EVAP Canister
EVAP Canister Purge Valve/Solenoid
Ignition Feed Circuit Terminal
Control Circuit Terminal
Intake Manifold Vacuum Source
EVAP Service Port
6-790
Engine

Engine Controls Schematic Icons
Icon
Icon Definition
Refer to ESD Notice in Cautions and Notices.
19384
Refer to 080 II Symbol Description Notice in Cautions and N'otices.
19385
Engine Controls Schematics (Power and Ground)
::s
cc
s
Cl)
IHol In AUN, Bulb Teal And START!
.. - -
- - - .,IP
GAUGES :Fuse
Fuse 9
Block
1
G3
H3
10A
H4
I
~-----'
0.5PNK 39
0.50RN 340
0.5 PNK/BLK 439
8206
- - - - - -,..
0.35 PNK 39
0.8 PPLJWHT 1035

0.8
C101
0.5PNK 439
A3
... - - - - - - - - - - - - ., Instrument
I Instrument~ Malfunction
I Cl st
I Cluster
# Indicator
I U er
Power
Distribution
Schematics In
Wiring Systems
8170 --~O-P3_':_H_T_
I Schematics In
~=~~t~~~ges
101
C
20
I
Lamp (MIL)
~:~~~~OON) I
I
Ignition Positive
Voltage
O.S p p ~ ~:- ___________________

-
lgnttion Posmve
Voltage
.J
~:~-~N~tr
1----- - - - - .,
MIL
Control
56
57
60
0.8 BLK/WHT 451

0.8 BLK/WHT 451
C1
Powertrain
I Control
PCM
C1=BLU
I Module
C2=CLEAR I
PCM
PCM
PCM
PCM
.,,.
I
~_Ground_:-_-:"_-:~:-_-:"_-:_-::-_':" Ground-~=---:-- Ground :-_-:-_-::_-:.:-:.:-_-:"_-::_-: _ _G~ound _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .J
16
>
B C230
_____________________ !~ C1
- Battery - Positive
Voltage (B+)
:.35 BRN/W~~1419
0.5 ORN 340
... -
I
I and Console
0.8 PPLJWHT 1035
Power
Distribution
Schematics In
Wiring Systems
(PCM)
>
:::,
cc
::s
0.8 BLK/WHT 451
0.8 BLK/WHT 451
Cl)
8110
''
' '-----~
3 BLK 451
0
Ground
Distribution
Schematics In
Wiring Systems
.,.....
__
0
:::,
' ""!
8101
2.
Cl)
(,,)
coI""'
3 BLK
G110
451
(I')
I
......i
4_99303
en
I
Engine Controls Schematics (Class 2 Serial Data line)
....g
iHot At All Tlmesj

r -
1Power
I Distribution
Schematics
I in
Wiring
I Systems
03
C3
CIG/ACCY
~~s;
11
C4
"'IP
" - - - - - - - - c~ - "'Powertrain
I
I
P
I
I Fuse I
7V C1-BLU
I Control
c2:cLEAR I Module
1Block I
(PCM)
1
I
L--------- '----.I
SerialData
(Class 2)
...------
Distribution
Schematics In
Wiring Systems
8240
L----- ----J~
59
1 ORN 540
Power
1
I
C1
P110
K
[SJc
~
[B
0.35 DK GRN 1049
1 ORN 540
'1llf
IL 0 c
c.o
N
:::,
(Q
:::,
Cl)
0
:::,
" "I
2..
(/)
(,)
QO
r-
C230
0.35 DKGR:1'049
E
C220
0.8 BLK/WHT 451

P110
r---1
0.8 BLK/WHT 451
Ground
Distribution
Schematics in
Wiring Systems
~-----'---.;...
~ Splice
, , 1 Pack
Ia., Communications
_____
1 SP200
-.aI
0.5 BLK/WHT 451
- - .J
r ...,.
3 BLK 451
I
I
8110
8215
-1!c~:~:
... o-:1au; : Connector
I
I
Ground
Distribution
Schematics in
Wiring Systems
I
I
I
3BLK
650
8216
0.35 PPL 1132
~,
8217
3 BLK 451
3 BLK 650
0.8 BLK 650
4
G110
5
------
----------16
2 Data Link
-----------------------Connector
(DLC)
G200
:::!
(Q
:J
499304
(1)
Engine Controls Schematics (Ignition Controls, Knock Sensors)

Electronic Brake ,._
Camshaft
Control Module P"4

(EBCM)
~
Position (CMP)
Sensor
1"-----,
I
I
...
_____ .,I
Tachometer
Input
50
C
0.8
WHT/ 644
BLK
$144
0.8 RED/BLK 645
0.35
WHT 121
:r
(I)
Position (CKP)
Sensor
!__
A
cc
Crankshaft
I....__ .t _ _Wl_
:~_
~ 11
~ --E~_"'r--=-
11 C1
::s
1
D
1~-i-W l\
C
0.8
WHT/ 644
BLK
Lr,- -
8182
0.8
LT BLU/ 1800
WHT
0.8 RED/BLK 645

S14~--.JJ'-_.;._ _ _ _ _ ____,
_ _o_.5_P_N_K~
239
Power
Distribution
Sc~emat1cs In
Wmng Systems
0.5 PNK 239

G C100
0.8 RED/BLK 645

633
G
C105
12V
+
.1
Electronic
Ignition
Control
Module
~
(ICM)
>
O.BPNK 239
p
CKP 18x
Signal
CMP/CKP
Sensor Ignition
Positive Voltage
CMP
Sensor
Signal
0.5 PNK!239
$107 - - - - -
0.8YEL 573
0.8
WHT/ 644
BLK
..I
0.5 PNK 239
Ignition
Positive
Voltage
CKP
Sync
Signal
5V
,l
camshaft
Position
Sensor
Signal
18x
Reference
Signal
3x
Reference
Signal
Bypass
Control
Ignition
Control (IC)
Ref Low
Ground
K
0.8
BLK 450
0.8 BLK 630

0.8
PPL/WHT 430
0.8WHT 423
0.35
DK BLU 496
0.35
LT BL~ 1876
2
Bank 1
Engine
I KS Signal KS Signal Speed
B
Output
I"Bank
Knock
~ Knock
Sensor, _
Sensor,
Left
Right
..
B
-=-
341 __ _3_3 C1 8 C2 7
0.8
TAN/BLK 424
0.8LT
BLU/BLK 647
--------~
______ !3
Camshaft 18x
Position
Reference
S~nsor
Signal
0.8
RED/BLK 453
------~~ _________ ?~ _____'!~
3x
Reference
Signal
Bypass
Control
. PCM
C1=BLU
Ignition
Control (IC)
C1
Ref Low
cc
::I
Ground
Distribution
Schematics In
Wiring Systems
0.35 WHT 121
::s
S108
C2=CLEAR
::s
1 BLK 450
- ,:
112
~G
, Powertram
I Control
I Module ..
I (PCM) ~
_____________________________________________
.,
~
Signal
(I)
-=499305
(n
.I
Engine Controls Schematics (Fuel Pump Controls)
O')
I
........
IL 0 c
1 GRY
120
GR:[
C200D
C200A
Fuel
Pump
Motor
I
I
I
I
Fuel
Level
Sensor
Ii
.
Fuel
: UTa~tk
Tank
rn
Pressure I
. Sensor I
1 I

Automatic
Transmission
-O~;~
In Wiring
systems
BLK
3 BLK
1450
1050
~~11;~~;- -r---~~; H31Jl

03
C405B
-_:-~;;_~~
" 'I
ffl
c:,.)
co
4~~~~? ~9~----_-_--_-_-
~~:al
0.5
GRY
72;
~~ngerant
Pressure
senfr
3
=--~-~~-=--~ci11gn~3- - ~(B~M)
0.5
~
0.35 DK BLU 229
DK GRN 220
A9
GAY
::DKD
C101
0.35
0.35 GRY
GRN/WHT
LT BLU/BLK 1688
305
G
B
g~~RN 890
0.35 PPL 1589 NC Refrigerant
0.35 GRY 720
69 ____ ~~~r~ ~n~~ ____ .?.? ________ ?? __________________ ~
r - 5V - - - - - - Fuel - - - - - - - - Sensor - - - - - - - - ..
I
Fuel
Tank
Ground
PCM
\
I
Level
Pressure
C1=BLU
J_
I
Signal
Signal _
C2=CLEAR
v
12
lJ
r- Theft- - - - - - - - - - - - "II Body

1Deterrent
Starter
Control
I Fuel Enable
Enable
I Module
-Cr~-~::~-~~1-[~~;~ 4~6-0;- - - - .,
1 BLK 150 0.5 PPL 30
DK GRN s9o
C
A
D
H C405A
--
0
:,
- - - - - - - - - ., Fuel
!,,
C3
(D
ORN/BLK 469
A
:::I
cg
:,
Throttle
Actuator
Control (TAC)
Module
465
0.35 GRY 720
,,,
[B
.s::,.
r-
- - _.,
01
Harness Junction
I
Block 2
0.35 BLK/WHT 451
I
I
I
I
I
ji:~T:.,- ------------
~~::!fc~
- - - "I Engine Wiring

I
--....-----...--. Fuel
86 Pump
Relay
0.35GRY 720
0.35 GRY 720
F3
G3 C405B
C405A
Ground
~c
~
1 GRY 120
$244
B3
A8
::r
EC::O
C200D
tC200A
~~GAN
465
;:ooo
K C101
35
0.35 DK BLU 229
DK GRN 220
C2.
70 C1
.
76 C2
Fuel - - - - Fuel - - - - Starter - "I Powertram
Pump
i~nable
Enable
I Control
Control
l.Control
I Module jJ,
sv
I (PCM) ~
L------------- ----------------- --------- -----------'
::I
CD
499306
(D
Engine Controls Schematics (Fuel Injectors)
II-lot In AUN, Bulb Test And START!
.-------~-,E~Qlne
.
I Power
Distribution
I Schematics
I
lnWiring
~ 8!,51~m:_
iL 0 c
1
INJ 1
Wmng
MiniFuse 1 Harness
I
15A
Junction
Cl)
~
~
0.8 PNK/WHT 639
0.8 PN
3'
5J
_ _ _ ___ ~ Block 2
A
m
::J
cc
C100
639
0
S102
0.5 PNK 639
0.5 PNK 639
0.5 PNK 639
0.5 PNK 639
0.5 PNK 639
0.5 PNK 639
[]Fuel
[1r~
[]Fu~
[I]FLim
[]Fuel
~njector
~jector
[]Fuel
~jector
~jector
~jector
~jector
::J
cc
::J
Cl)
0.5 BLK 1744
0.5 LT GRN/BL
79
~
I
I
I
I
---1
-=-
Injector 2
Driver
0.5 PNK/BLK 1746
0.5 LT BLU/BLK 844
! ------;u;; - - l- - - - - - -
73
- ;u; - ;- - - - - -F:I - Injector 1

Driver
1745
42
C1
---1
-=-
lnj~ctor 3
Driver
46
C2
---1
-=-
0.5 BLK/WHT 845
lnj~ctor 4
Dnver
r---1-----
47
;el- - - , -
---1
-=-
-Fi:I - lnj~ctor 5
Driver
(')
0
0.5 YEUBLK 846

43
;u; - - !- - ~ Powertrain
lnj~ctor 6
Driver
-=-
PCM
C1=BLU
---1
-=-
::J
C1
1 Control
1 Module
I (PCM)
I
.&..
~--------------------------------------------------~~~~-------~~
499307
" "I
ti)
O')
Engine Controls Schematics (MAP, ECT, IAT Sensors)
Powertram .. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
Module~~~~~ :
j.
JSV
ECT JSV
C1~~L~
5 Volt
Sensor
C2=CLEAR
1. _ _ _ _ _ _ _ ReferenceA _
_ _ _ _ _ _ _ _ _ _ - - _ _ _ _ _ _ _ _ _ Signal_
_ _______
I
33
----------------------------------------26
4f
IAT
Sensor
I
Signal _ _ _ _ _ _ ~
50
C2
C2.
0.35GRY 598
Exhaust Gas
Recirculation
(EGR)
Valve
Al---0""',;;;,35;;;,,,,;;G..;,,R..;,,Y;......;..__..__ _ _ _ __
598
$117
0.35TAN 472
0.5 YE
IL 0c
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en
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m
:::s
c.c
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:::s
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410
(A)
00
r
0.35GRY 598
B
Engine '"
Coolant I
Temperature I
(ECT) Sensor 1. A
rn
t-.,
I
I
..1
Intake Air
Temperature
(IAT) Sensor
0.35 ORN/BLK 469

0.35 LT GRN 432
0.5 BRN 718

0.35 PPL 719
13 C1
..
I
MAP
Sensor
.Ground
I
I
L
25 C2
12
17
C1
----------------- --------------------,
.
-
MAP
Sensor
.Signal.
-..
ECT
Sensor
Ground
PCM
C1 =BLU
C2=CLEAR
-=-
-.- -
IAT
Sensor
Ground
I Module (PCM)
I
.
Powertram
I Control
j.
:::s
<e.
:::s
.I~
499308
(I)
Engine Controls Schematics (Heated.Oxygen Sensors)
::::,
(,Q
!Loe j
!Hot In RUN, Bulb Test And START 1
Engine
I W',
ENG SEN
I
mng
MiniFuse I Harness
20 A
Junction.
_ ___ ...I Block 2
r - - - - - I Power
I Distribution
I Schematics
in Wiring
I.. Systems
_ _ _ _ _ _
Power
Distribution
Schematics in
Wiring Systems
' ._ -
1. -
Signal
-
12
C2 -
H02S 1
H02S 1
Low
. .
Lew
C1 - - - - - - - -
29
0.8
PPL/WHT 1665
0.8
PNK 539
~
~
. - - - - - - - - - - - - - - - - - - - :
.
PCM
c 1=BLU
H~2S 1
. ..
... Signal
C1 -
10
Bank 1
C2=CLEAR
. I
H02S 2,
H02S 2
Low
C2 - - . - - - - - - - - - - 28
- ., Powertrain
1Control
Signal
C1
. 11
Module
(PCM)
.&..
C2
0.8.PPL 1666
0.8 GRY 1981
0.8 TAN 1667
0.8
CD
[SJc
0.8 PNK 539
0.8 PNK 539
0.8
DK BLU 1980
TAN/WHT 1653
D
8104
Bank 2
27
.,
......
Bank 1
H02S 1
+- - - -... ......0.8 PNK 539
- : - - - - - - - - - - - - - - - - - - - -
I
I
0.8 PNK 539

B C105
...... -...
D
Heated Oxygen
Sensor Bank 1,
Sensor2
Heated Oxygen
Sensor Bank 2,
Sensor1
H.eated Oxygen
Sensor Bank 1,
Sensor 1
::::,
(,Q
::::,
CD
c
0.8
BLK 450
::::,
0.8 BLK 450
' "'I
0.8.BLK 450
8108
.
1 BLK
450' '-- - - - - - - -a
-=- G112
in
.Ground
Distribution
Schematics In
Wiring Systems
en
I
......
499309
(,I)
......
Engine Controls Schematics (MAF Sensor, EVAP System, EGR Valve)
!Hot In RUN, Bulb Test And START

iHot In RUN, Bulb Test And START
;o:er- - - - - - - - - - - - - - - - Po;r - - - - - - - ~ Engine
I Distribution
J7
ENG SEN
Distribution
G9 ENG CTRL I Wiring
Schematics In
MiniFuse
Schematics In
MiniFuse Harness
1 Junction
: Wiring Systems J6 20 A
Wiring Systems GB 15 A
~
L, -
0.8 PNK 539
Block 2
P100
_ _ _ .,
.... ;G; : va1ve

I lgniti.on
Positive
I Voltage
12v - - - - - "' Powertrain

PCM
C1=BLU
C2=CLEAR
:::s
: Control
Module (PCM)
I
I
(Q
:::s
Ai.
11111'
CD
!.----------"~
4 C2
()
0
Power
0.5 PNK 239
Distrlbulion
B C105
Schematics In
0.35 LT BLU 697
Manifold Air
Wiring Systems 0.5 PNK 239
Pressure
8182
(MAP)
-Po_w_e_r- - - .
G C100
0.5 PNK 239
Sensor
0.8 PNK 539
02 C200B
Distribulion
A
Schematics In
0.5 PNK 239
C200D
8104
!,. _ _ _ _ _ _
Wiring Systems
0.5 PNK 239
8107
0.8 PNK 539
A2 C405B
0.35 GRY 598
0.35 YEL 492
AIC405D
0.5 PNK 239
c
A
A
0.35 PNAK 239
Mass Airflow
Ignition
MAF
Positive
Sensor (MAF) Sensor
E
D
Voltage
Signal
Evaporative
[ ] ] Evaporative
Ground
Emission
Emission (EVAP)
(EVAP)
B
I...___J,..-_-_-_-_-_-_-_-_-1__--_ _____ l
[ ] Canister
Purge
Canister
A
B
B
Solenoid
Bl Vent
Valve
Solenoid
Valve
0.35 WHT 1310
0.35 BLK/WHT 451
0.35 BRN 1456
B C4050
0.35
B2IC405B
BLK 552
0.35 DK
GRN/WHT 428
0.5WHT 1310
8110
3BLK
451
ui'
I
II
3 BLK 451
-c
~-----
Ground
Distribution
Schematics In
Wiring Systems
:::s
69 '-------76
Powertrain ~ MAF Control I S~nsor

Module (PCM) 1 Signal
jJ,
I
I
I
C1
C230
0.35GRY 435
0.5WHTt310
P110
2 C2
EVAP canister - - - - - EVAP Canister - -

Purge Valve
vent Valve
T Driver
T Driver
-,
Ji.
~
Ji.
~
1. . 5l?J;;
28 C2 31 C1
C1
EGR - EGR - - - - - Sensor - - - - - - - - ~
Valve Pin~~
Ground
I
T Control Posmon
PCM
Ji.
Signal
I
~
~
C1=BLU
I
C2=CLEAR
I
32
L------------------------------------------------J
499312
:::s
'!:!.
:::s
CD
___/
Engine Contr.ols .Schematics (VSS, Cruise, Generator, Engine. Oil Level)
l:l.
. ~ ~:ut
~--- -=- SV
:)*::i~!f~ :
i--
PCM
C1=BLU
C1
0.35 TAN/BL~r464 - - - - - - - - - - - - - - - - - - - 61
Instrument
I vss I Cluster
~1"!!.ut ~-- ~ .
r """". .,
0.35 DK GRN/WHT 817

P110
K C220
88
I Input
I Control Module
1 TPS Position I (EBCM)
1 Output
I
.. _ _ -
27
1~
C2
o.35 RED 225
r TPSP;it;n .,Electronic B.rake
0_35 DK GRN/WHT 817
____
>
r-T;;;non., Generator
I 1nput I
.----<11
L.--.1
..;.Ii,-.~.
C1
(D
~c
~
~
}J
C105
0.35 TAN/81.:K 464

9 C1
0.35 DK GRN/WHT 817
~!~~~:;CM)
Output
- - - - - - - - - - C2=CLEAR - - - - - - - - ~~t~:iltlon---------=- - - -
55
!L c I
::s
5
(Q
~.
Ground
Distribution
Schematics
In Wiring
Systems
3 BLK 451
0.35 DK.GRN/WHT 817.
A1
sno
0_35 ORN/BLK 463

0.35. BLK/WHT 451
C200D
C200A
0.35 D~GRN/W: 817

r -
I
I
... -
D C105
., Cruise
I Control
I Module
..I
ii---3---il :!;:~
-------A C2
Speed
Engin.e
Oil
Level
Switch
::s
3 BLK 451
C.Q
::s
(D
0.35 ORN/BLK 463
0.35 YEL 400.
0.35 PPL 401
~-------~~i1~-- ~~165
64
I
I
sv
71
1~~~e1
58
C1
- - - - - - - - - - - - - - - - - - - P C M ____
C1 =BLU
C2=CLEAR
-=-
0.35 BRN 1174
::s
" "'I
'vi
C2
Signal
5V
-----~6~~~~~a,n
(.,)
()0
Module
I (PCM) A
I
PJ>
1.-----------------------------------------------------J
Cl')
I
499313
"""
Engine Controls Schematics (TAC Module, Brake Switch, Cruise)

0.35 BRN
Atlc:::o
aa
- - - PCM
I C1=BLU
I C2=CLEAR
Serial
Signal
Serial
~a!! _ _ _ _ _ _
-----15
14
TAC
1. -'!-~ ___
1,,; -
Cruise
Control
Release
TAC
I
I Release (Brake)
I J; I Switch
0.5 BRN 86
- - - 2~ - ~, p
- - -
~is:
C230
~-
~
I
- TAC- Serial
Data
TAC Serial
Data
::I
co
r
0.8 ORN 1540
- - - - - - - - - - -
______ ~
20
-
-a Multi-
!~"
9~ - -
____________ ~
- Cruise' On/Off ,
Signal
Exterior
Lights
Schematics
In Lighting
Systems
0.8 LT BLU 20
8243
- - - - -
0.8 LT BLU 20
A4
C2~.; PNK
5
339
C200D
C200A
P100
0.8 LT BLU 20
0.8 LT BLU
8154
20
0.8 LT BLU 20
0.5 GAY/BLK 87
P100
Cruise Control
Schematics In
Cruise Control
P100
21
8
- Cruise - Set/Coast
Signal
: Switch
~- C,
0.5
DKBLU 84
P100
18
-
C A/C Compressor
Relay
OFFe ... -~1/A :
0.5GRY 397
:::,
(D
1.---------.11
-----.11
::I
(C
___ ___ =1s~,~~T- ___ ~

L
0.35
ORN/ 1061
BLK
16
8
C
'" - , Stop Lamp(rCC
R/A
ON
C200D
C200A
------
JB
Loe
ti)
! 7--~;;----------- --
0.35 TAN 800
I Systems
I I
1E I
" "I
.1
: OFFe_____
0.35
ORN/ .1061
BLK
A5
I Schema.tics J9
I In Wiring
Engine
W'.
1nng
I
TCS BATT Harness
MiniFuse 1 Junction
20 A
I Block 1
0
0
owe rain
I Control
B C250
I Module
: (PCM) 0.5 PNK 139
0.5 PNK
I JI.
~
139
r- -
P110
D
!.------
(Closed w/o
Hot At All Timesl

r - - - - - - - - - ,
I Power
I
Distribution
, Engine
I Wiring
I Harness
i Junction
I Block 2
I
co
MIC215
0.35
ORN/ 1061
BLK
C220
.!I
B
brake
rt 0:5 PNK 139 depressed)
C1
0.35TAN 800
'" ,- , Cruise Control
0.5 BRN 86
F C100
r- -
Hot In RUN, Bulb Test Or ST@

r-Power
I Distribution
I Schematics
ETC
I lnWirlng
MiniFuse
I Systems
10A
O')
Cruise - - Resume/Accel
Signal
Ignition Positive
Voltage
7
-
Brake - Switch ..
Signal
Battery Posttlve
Voltage
., Throttle
I
Actuator
Control
1(TAC)
I
1.------------------------------------------------------------~M~
JI.
~
499314
s
(I)
Engine Controls Schematics (TAC Module, TAC).
---------------------------------------------------------- ~ l~~~:!~r !L0cI
I
I
I
I
TP
Sensor 2
Signal
,
TAC
IL.
TAC
G.!_O~d _ _
17
TI
_
2r~n! ______-_
5
P100
sv
TP.
Sensor2
_ __ ~~d- _
22
24
TP
_ _ _
MotorDriver
~or! _
23
. 13
TI
.
T
P.
Sensor1
~n_:or_: _ !~~ ___
=_
12
10
TP
MotorDriver
_ _ _ _ _ _
.:: ___ ~i _
TP
Sensor1
Ground
11
I Control
J
1 (TAC)
I Module
>~
+
I+ I
I 1 ,._..,.
A.
~
0.35 BLK 476
o.35
BLK/WHT
451
gfl<JWHT 451
8 171
0.8
BLKIWHT 451
B
H C101
0.35 DK GAN 485
0.8BRN 582
D
ES
~~
0.8
BLKJWHT 451
P100
[S]
Fuel
Pump
Relay
0.35 GRY/BLK 1687

P100
0.35GRY 597
0.35 BLK 470
0.8 YEL 581
0.8
BLKJWHT 451
0.8
BLKJWHT 451
0.35 PPL 486
Throttle
Position
Sensor2
5V
5V
RTN
REF
Motor
Drive
Low
Motor
Drive
Hi
5V
5V
REF
RTN
Throttle
Position
Sensor1
TPS1
Throttle
Actuator
Control
Ji
::,
(.Q
::,
(f)
0.8 BLKJWHT
451
Ground
Distribution
Schematics
::I
In Wiring
Systems
Cf)
3 BLK 451
G110
3BLK
451
en
I
QO
0
499316
..r,.
Engine Contrpls Schematics (Secpnd Gear Start, Cruise Control Switches)
!Loe I
IHotln RUN!
r------,1p
I G3 GUAGES 1Fuse
I H3 Fuse 9
I Block
I
10 A
H4
L.- -
!oEsc!
.......... .I
~
[B
0.5 PNK 39
Power
Distribution
Schematics In
Wiring Systems
0.35GRY 48
'" -}- - - "' Cruise Control
(Anticipate) I (Clutch)
____
._I l:--
+----
8206
0.8 PNK 39
....I Switch
--i- --- ~:~~nd

B
I
I
I
0.35 BLK/WHT 451
C270
- ---rwltch) -
~te;or- -
~~:ing
Schematics In
Ughlfng
f!\ 2nd
W Gear
Systems -
Indicator
0
N
::::s
C.C.
::::s
CD
0
::::s
'"'Ii
cir
(,.)
cor
I Start
I Switch
I (Chevroletw/o NW9)
0.35
BRN/ 1571
WHT
A13
0.35GRY 48
0.35 BLK!WHT 451
(Momentary
~-
en
co
.I
0.35 PPL/WHT 1572

C200D
C200B
C4
----------------C200A
P100
,--,-------
:
1
0.35 BLK/WHT
451
0.35 GRY 48
B C220
-----------.i
0.8 BLK/WHT 451
.!
5215
0.8 BLK!WHT 451
..... -
Systems
8110
3 BLK 451
3 BLK
451
~G110
1
P 10
_ GRY
0 35
48
18
Ground
Distribution
~c:~n~ics
0.35
BRN/ 1571
WHT
~.:ate
I Swhch
1 Ignition
I F
0.35 PPL/WHT 1572
--------'--------~
0.35 BRN/WHTf 157.1

.
.
C105
0.35 PPL/WHTf .1572

.
1------ 1---------!l
21
C2
C1
::rtG;:i;ch
Si nal
9
12V
..
-=-
---
-=-
2n~.Gear
lnd1cator
control
- PCM
.
C1=BLU
C2=CLEAR
~6~~~~ram
IM d I
O Ue
I
I {PCM)
~------~-------------------------------.1
A.
,-
::::s
(Q
::::s
499318
CD
.. _ /
Engine Controls.Schematics (Automatic Transmission, Brake Switch) ....

lHot In RUN, Bulb T""t And START
r -
...... -
~~~f
l
- .- - - ., Engine
PoWer - - - -
ENG CTRL I Wiring

MiniFuse I Harness
15 A
I

ENG SEN
MlnlFuse
20 A
1..
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Distribution
Schematics In
Wiring Systems
0.8 PNK 539

B 0105
0.8 PNK 539
$104 - - - - - - - P110
0.8 PNK 539
-+
-J- - - - .,switch
Stop Lamp/TCC
I (Open with
I
I
II
I....
TCC/Shift I brake pedal

Interrupt I depressed)
Switch
II
______ ...
D 02
G 0100
0.5 PNK 239
r-.
- - - - - - - - -. . . -~--. ..-
I
I
I
0.5 RED 839
0.5 RED 839
: I
6~~~':rter
Clutch
Solenoid
(TCC SOL.)
[J]
0.5 RED 839
0.5 RED 839
[]1. []1 ~~f~:1: . []1 ~~fe~~:
..
6~n~~~er
Clutch
Pulse Width
Modulation
;~fe~.:i:
(3-2 SS)
Valve
Assembly
(2-3 SS)
Valve
(1-2 SS)
Valve
~5~ :-=~- MT1"8:~1~~~-~- 05~1m~-~ MLTG+~ -__j

T
P110
0.5 WHT 687
0.5 TAN/BLK 422
30 01
79
_________ ?~
:::,
cc
:::,
01
(D
-a
0.5 YELJBLK 1223
0.5 BRN 418

0.8 PPL 420
[_
D 0220
Module I
~ (PCM) I
t
.-----...J
Automatic
Transmission
I
I
0.8 PPL 420
PowCeortnrat:onl ~
Power
Distribution
Schematics In
Wiring Systems
---
C C2
1
[B
0.5 PNK 239
0.8 PNK 539
__________ ~~
02
0
:::,
0.5 LT GRN 1222

44
__________ 1 01
=eh,- -----------:. . ---- -,-;c~ ;:- - - -t. -.T.~;;~ ;o~ -, -3.:; ss - - - .~,- 2-3-SS - - -} ~-;s; - -~: - )
. c
Signal
Valve
----T Control
! .
/
Valve
----Teontrol
'
. Valve
--T Assembly . .
Control
. Valve
, Assembly
Control
Valve
---T Control
C1=BLU
C2=CLEAR
ui"
I
I
.. - - - - - - - - - - - - --- - -- - - - - - - - - - - - - - - - - - - ---- -- ........ - - - --- - -- - --- - - - - .,

=
(D
0.5 PNK 239

Power
Distribution
Schematics In
Wiring Systems
5'
lbEsc!
Junction
- __ ...:. ...,. Block
2
CIC220
r -
!Loe I
lHot In RUN, Bulb T<><:t And START
I
~ution
I Schematics In
I Wiring Systems JS
_ _ _ _ _ _
:::,
cc
0)
I
ex,
Q
499319
Engine Controls Schematics (Automatic Transmission,. Park Neutral. Position Switch)
0)
I
CC)
..r -
I
I
Transmlsi,lon
Range A
Input
I
I
L -
22 C1
Transmission
Range B
Input
.
-
0.5 PNK 1224
57
Transmission
Range c
Input
- - - - - - - - - -17
0.5 DK BLU 1225
0.5 RED 1226
-.- -
Powertram
Control .
Module
(PCM)
I
.,
C2
Jll1*
.J
~"--6.
~
oc
~
~
~
Auto
Trans Shift
Lock Control
Schematics In
Automatic
Transmission
PCM
C1=BLU
C2=CLEAR
TFT
Sensor
Signal
- - -- - --- -- - --68
0.5 YELJBLK 1227

0.5 ORN/BLK 434
8234
__o_.5_0_R_N_/_B_LK
_ _,
434
N . ______________ f:I
r - 0.5PNJ-1224
0.5DKBLU~225 -
~1
. __
__________ .F _____________ ~
-
0.50RNr1226 -
El
0.5BRNt227 -
Ar
Switch
LO
Switch
, Switch
- .- -
. -
CD
00
::s
' "'I
in"
w
r - ;-;---
I
I
1.
1
l
I ~
. R,,_,. ,
.-" 2
4
I
N if D
I
.
.,Park
'Neutral
I Position
Iswitch
(Automatic
I Transmission)
I
I
L--------.l
A
0.5 LT BLU 1229
BY.
-- -
.-
0.5 PPL.1228
0.35 BLK/WHT 451

8215 - - - - - .,
(TFT)
=
-
Transmission
Flu Id
Temperature
.02
Sensor
Automatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
switch
04
03
Swttch
Switch
ol
REV
,
C1
m
::s
c.e.
::s
[B
0.5 ORN/BLK 434

Automatic
Transmission
Q
;1::1,
;.~~~-~:~;~
0.5GRY'k.452 -
-------------c
C1
0.35
1229
ORN/BLK 434
0.8 BLK/WHT 451
-----------0.5
RED/BLK 1228
------~.?
46
r -
I
I
I
..
L - -
3BLK
451
r-. ---:r..:-. .
------'-_1_6 C2
PC SOL
va1ve High .
PNP - - - - - - - - .,Powertrain
SWitch
PCM
I Control
c 1=BLU
I Module (PCM)
C2=CLEAR
..-
- - - - - -
P110
_ _ _ _ ...J
;;-;0-;:.,-.. - - - - -. 1Valve Low
Ground
Distribution
Schematics
In Wiring
Systems
E C220
0.5 GRY 720

E
Fuel Tank
Unit
H C220 0.8 BLK/WHT 451
12V
- - - -- - -
12V
- -
- - -
- - - -
- - -
A.
,-
.J~
.
.
::s
::s
u;i
499321
CD
Engine Controls Schematics (A/C HVAC Control)
IHot In RUN, Bulb TestAnd STARTI

,. -P;;-w; -
..,.. -
Distribution
Schematics
In Wiring
G7
GS
A/C CRUISE
MlnlFuse
15
A
.. _s~t~:_ _ _
.. - - - - - -
Engine
I Wiring
Power
Distribution
Schematics
In Wiring
.Systems
1 Harness
:
_ ____
Junction
Block 2
.. -
Multifunction
Lever
-----,1p
I
HVAC
Fuse
I
Fuse 6
Block
.I
1 BRN 241
139
Power
Distribution
Schematics In
Wiring Systems
0.5 PNK 139

I
I
I
[(gJ
08
010
~~pressor
Relay
:
I
I._
_______ _
c10
.,
[B
Engine
[ill
B
0.5 BLK 450
:ci= 1__.I
-----J
l
C
_,
Ground
Distribution
Schematics In
Wiring Systems
.__~~~~~-e--~-0~~5_B_LK~~~-<1111I 8108
450
8115
i BLK 450
~ G112
Switch
o~
I
I
DEF
- ~ .HTR
MAX .
NORM B/L
VENT
;K GRNIW~ :
I
I
I
- - - - - - '
35
1688
F 0230
$111
:::,
(.Q
P110
:::,
Cl)
0.35 DK GRN/WHT 762
0.35 LT BLU/BLK 1688
T
I
HVAC
Control I
Selector I
unit
LT BLU/
BLK
Fuel
Tank
Unit
0.
I Control
I
I
I
1:T.-.
0.35
A/C
C2 - - - - - - - , HVAC
- C
/.....
OG.3R5Y 720
0.35 DK GRN/WHT 459
Compressor
Clutch
A Sensor
0.35
RED/BLK 380
.____
..,.. -
A/C
I
Refrigerant I
Pressure I
0.35 LT BLU/BLK
0.5 DKGRN 59
,. -
B. 0100
0.5 DK GRN 59
8114
1 BRN 241
Harness
I Junction
: Block 2
0.35
DKGRN/ 459
WHT
0.5 DKGRN 59
_ _..;..1..;::B"""R;;;;..N'------11111 S248
241
I Wiring
I
C8
(D
~c
~
20 A
E2
C1--------11----~
r -
Clutch Diode
-,- -
0.5 PNK 139

0.5 PNK
S165
0.5 PNK 139
A/C
!Loe l
IHotlnRUNi
m
:::,
c.c
5
39
- - ---l
____ ?-J
A/C -
___________ ?~ _______________________?2
1
-
Volt
- - 5
Ref
. erenc1
B.
NC -
0
::I
.""'0.....
C2
Powertram
u,
1
1.------------------------------------J >
NC
I Relay
I Control -
Sensor
Signal
5V
PCM
C1=BLU.
C2=CLEAR
Requesi
Signal
I Control
Module
PCM)
i(
O')
I
ClO
499323
0
01
en
I
Engine Controls Schematics (Engine Cooling Fans)
QC)
en
3RED
402
IHot At All Times!
:s
i"-----------------------------.E
.
I
.
Power
COOL
I ~Qln0
(Q
:s
Distrlbuti?n
J7
FAN
I Wmng
Schematics
MiniFuse
Harness
1
K
In Wiring
J6
10 A
Junction
Systems
_____________
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...I Block 1
L1
I
I
L
COOL FAN
MaxlFuse
40 A
3 RED 402
(I)
-a
0
:s
0.35 ORN 1640
Cl)
8169
3RED 402
$179
0.35 ORN 1640 3 RED 402
3 WHT 504
Engine
Wiring
Harness
J~7;'~~
&" -
I C3
83
I l~
B9
Engine
5~.,
'.'.'. 3LTBL:1409 --------
ri I
-. -
C6
JJ---4 :i:.t:.,
c,
"'
Engine
~':,~~
~,~., :
-~;5:~~:,:---------- ----------- --3~T ~%?___ )
a,o
0.35 DK BLU 473 3 WHT 504
g;::U- ----------------,----,--~
3
-
47
Fans
C100
B8
0.35DKGRN 335 ~~:~g
LtJ
0.35 ORN 1640
0.35 ORN 1640
H C100
~~~~
LtJ
Fans
3 GRY 532
3 BLK 150
.'".::'"::-:--:-::~'.l----:::-~~~~~~----:3~B~L_K~~-;::=======:::;-~~~--:-~S113
0.35 DK GAN 335
0.35 DK BLU 473
150
Ground
/
Distribution
Ii>- - - - -"
6 _________________________________________ 5 C1
Schematics In
Wiring Systems
I"
Cooling - - - - - - - - - - - - - - - - - - - - , -Cooling - - - .. Powertram
3 BLK 150
I
Fan Relay 1
.
PCM
Fan Relay
I Control
1 BLK
I ----T Control
C1=BLU
----T 2 and 3
I Module (PCM)
I
$.
C2=CLEAR
! Control
I ~
150
. -
. ''..- -
.J
::::J
(Q
499325
:s
(I)
Engine
6-807
Component locator
Engine Controls Components
Name
NC Clutch Diode
A/C Compressor Clutch
A/C Refrigerant
Pressure Sensor
Location
Sealed in a harness, approximately 3 cm
(1.2 in) from the injector 2 qreakout
HVAC Component Views

in HVAC with A/C Manual
Engine Controls
Connector End Views
Above the right front wheelhouse, attached

to the refrigerant line

Engine Controls
Connector End Views

blower motor
..
ABS Component Views in lnline Harness Connector
ABS Traction Control
End View in Automatic
Transmission
Body Control Module
Component Views in
Body Control Module

ConnectorEnd Views in
Camshaft
Position (CMP) Sensor
Mounted in the top rear center of the

engine
Engine Controls
Component Views
Engine Controls
Connector End Views
Crankshaft
Position (CKP) Sensor
In the lower front of the engine
Engine Controls
Component Views
Engine Controls
Connector End Views
Cruise Control (Clutch)

Switch
Mounted in the clutch pedal bracket
Cruise Control
Component Views in
Cruise Control
Cruise Control Connector

End Views in Cruise
Control
Cruise Control Module
Mounted to the left frame rail, forward of

the wheelhouse
Cruise Control
Component Views in
Cruise Control

End Views in Cruise
Control
Cruise Control Release

(Brake) Switch
Mounted in the upper hole of the brake .

pedal. bracket
Cruise Control
Component Views in
Cruise Control

End Views in Cruise
Control
Under the IP, right of the steering column
Data Link
Communications
Component Views in
Data Link
Communications
Data Link
Communications
Data Link
Communications
ABS Component Views in

ABS Connector End

Views in Antilock Brake
System
On the top front left side of the engine
Engine Controls
Component Views
Engine Controls
Connector End. Views
Engine Coolant
Temperature (ECT)
. Sensor
Under the throttle body, on the front side

of the engine
Engine Controls
Component Views
Engine Controls
Connector End Views
Engine Cooling Fans
Behind the radiator
Cooling System
Component Views in
Engine Cooling
Cooling System
Engine Cooling
Engine Controls
Component Views
Engine Controls
Connector End Views
Connector End View
In the. front of the engine, on the lower

right side
Automatic Transmission Behind the engine
Body Control
Module (BCM)
Locator View
Data Link
Connector (DLC)
Electronic Brake Control Mounted with brake pressure modulator

Module (EBCM)
valve on the top of the left front frame rail
Electronic Ignition
Control Module {ICM)
On the lower left .side of the engine, in the

oil pan

Junction Block 1

compartment
Power and Grounding

Component Views in
Wiring. Systems

Junction Block 2

compartment
. Power and Grounding

Component Views in
Wiring Systems
..
Evaporative
Emission (EV AP)
Canister Purge
Solenoid Valve
On the right side of the engine next to

injector 2
Engine Controls
Connector End Views
..
6-808
Engine

Engine Controls Components (cont'd)
Name
Evaporative
Emission (EV AP)
Canister Vent
Solenoid Valve
Location
On the top right side of the engine, part of

the EVAP canister
On the front left side of the engine, in front

Exhaust Gas
Recirculation (EGR) Valve of the ignition control module
Locator View
Connector End View

Engine Controls
Connector End Views
Engine Controls
Component Views
Engine Controls
Connector End Views
Engine Controls
Component Views
Engine Controls
Connector End Views
Fuel Injectors
Mounted on the intake manifold, part of

the fuel rail
Fuel Tank Unit
Under the rear of the vehicle
Engine Controls
Connector End Views
Forward of the left front wheelhouse,

behind the underhood electrical center 2
Fusible Links
Generator
On the front right side of the engine
Engine Electrical
Component Views in
Engine Electrical
Mounted in the left exhaust manifold
Engine Controls
Component Views
Engine Electrical
Engine Electrical
..

Bank 1, Sensor 1

At the rear of the catalytic converter
Bank 1, Sensor 2
Mounted in the right exhaust manifold
Bank 2, Sensor 1
HV AC Control
In the center of the IP, above the radio
Instrument Cluster
On the.left side .of the IP
Intake Air
Temperature (IAT)
Sensor
Mounted on the air duct, in front of the

intake manifold
IP Fuse. Block
Knock Sensor, Left

Knock Sensor, Right
On the left end of the IP carrier
In the bottom left side of the engine block

In the bottom right side of the engine block
Mounted to the right side of the intake

Manifold Absolute
Pressure (MAP) Sensor manifold
Mass Air Flow (MAF)
Sensor

intake manifold
Multi-function Lever
On the left side ,of the steering column
Switch

Powertrain Control
Module (PCM)
On the rig~t side of the engine

Second Gear Start

Switch (Chevrolet
w/o NW9)
In the center of the IP, above the HVAC

control
Engine Controls
Connector End Views
Engine. Controls
Connector End Views
Engine Controls
Component Views
Engine Controls
Connector End Views

in HVAC. with A/C Manual
HVAC Connec.tor End

Views in HV AC with A/C
Manual
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Instrument P?nel,
Gauges, and Console
Connector End Views in '
Instrument Panel,
Gauges and Console
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Component Views
Engine Controls
ConnectorEnd Views
Engine Controls
Connector End Views
Engine Controls
Connector EndViews
Cruise Control
Component Views in
Cruise Control
Wiper/Washer System .
Wipers/Washer System
Shift Lock Control
Component Views in
Engine Controls
Conflector End Views
Power and Grounding

Component Views in
Wiring Systems
PCM Connector
End Views

Engine Controls
Connector End Views
Engine
6-809

Name
Stop Lamp/TCC Switch
(Automatic)
Locator View
Location
Cruise Control
Component Views in
Cruise Control
Mounted on the brake pedal bracket
Throttle Actuator Control On the plenum, with throttle body

Throttle Actuator
Control (TAC) Module
Vehicle Speed Sensor

(Automatic)

(Manual)
Splice Pack SP200
Connector End View
Mounted on the accelerator pedal bracket
Lighting Systems
Connector EndViews in
Lighting Systems
Engine Controls
Connector End Views
Engine Controls
Connector End Views
On the rear right side of the transmission
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges a,nd Console
Engine Controls
Connector End Views
On the rear left side of the transmissfon
Instrument Panel,
Gauge,s, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Connector End Views
Under the left side of the IP, near the DLC
Lighting Systems
Component Views in
Lighting Systems
Data Link
Communications
Data Link
Communications
C100 '(10 cavities)

wheelhouse

Wiring Systems

End Views in Wiring
Systems
C101 (10 cavities)

wheelhouse

Wiring Systems

End Views in Wiring
Systems
C105 (8 cavities)

wheelhouse

Wiring Systems

End Views in Wiring
Systems

Harness Routing. Views in

Wiring Systems

End Views in Wiring
Systems
C200B (18 cavities)


Wiring Systems

End Views in Wiring
Systems
C200D (48 cavities)


Wiring Systems

End Views in Wiring
Systems
C200A (17 cavities)
'
C220 (10 cavities)


Wiring Systems

End Views in Wiring
Systems
C230 (10 cavities)


Wiring Systems

End Views in Wiring
Systems
C250 (2 cavities)
Forward lamp harness of the cruise control

harness, near th.e brake/clutch pedal
bracket

Wiring Systems

End Views in Wiring
Systems
C270 (2 cavities)
IP harness of the cruise control harness,

near the brake/clutch pedal bracket
Harness. Routing Views in

Wiring Systems

End Views in Wiring
Systems
C405A (7 cavities)
Fuel tank harness to the IP harness pass

through connector, forward of the rear axle

Wiring Systems
lnfine Harness Connector

End. Views in Wiring
Systems
C405B (16 cavities)
IP harness pass through connector,

forward of the rear axle

Wiring Systems

End Views in Wiring
Systems
.
;
6-810
Engine

Name
.Location
Locator View
Connector End View
C405D (4 cavities)

Harness Routing Views if]

Wiring Systems

End Views in Wiring
Systems
G106

support
Harness Routing Views ir]

Wiring Systems
In the front of the engine, bolted to the

pulley above the A/C clutch connector

Wiring Systems
G112
Attached to the rear of the left

cylinder head

Wiring Systems
G200
Near the left A-pillar, bolted to the IP

mounting stud behind the ki.ck panel

Wiring Systems
G305
Bolted to the left rocker panel at the floor

pan bar

Wiring Systems
P100
Left side.in the dash panel, engine to the

Harness Routing Views in 1'

Wiring Systems
P110
Rightside in the dash panel, engine to the


Wiring Systems
8101
In the engine harne.ss main branch,

approximately 15 cm (6 in) from the.
powertrain control .module (PCM) breakout
8102
In the engine harnesE., approximately

21 cm (8.3 in) from G211 breakout
8104
In the engine harness, approximately 7 cm

(2.3 in) from the. right knock sensor
breakout
In the engine harness, main branch,

approximately 21 cm (8.3 in) from the
powertrain confrol module (PCM) breakout
G110 (V6 VINK)
8107
..
8108

approximately 15 cm (6 in) from G112
breakout
8110
In the. engine: harness, approximately 4 cm

(1.6 in) from the powertrain control
module (PCM) breakout
8111
In the forwardli:i.mp harness,

powertrain control module (PCM) breakout
8113
In the forwarc:l lamp harness approximately

7 cm (2:8 in) from the electronic throttle
module breakout
8114

(1.2 in) from the generator breakout
8115
In the engine harness at the generator

breakout
8117

(1.2 in) from fuel injector 5 breakout
8121

8144

8145

8154 (Chevrolet)

approximately 7 cm (2.8 in) from the C120
(left front wheel speed sensor) breakout
--
'
Engine
6-811

Name
Location
Locator View
Connector End View

C120 (left front wheel speed sensor)
breakout
8165

junction block 2 breakout
8166

breakout
8167

electronic brake control module (EBCM)
breakout
8169

8170

breakout
8171

approximately 10 cm (4 in) from G102
breakout
8179

25 cm (9.8 in) from the engine wiring
8182

8206
In the IP harness, at the rear compartment

lid release relay breakout
8215
In the IP harness, main branch,

approximately 11 cm (4 in) from the
antenna cable breakout
8216

instrument cluster breakout
8217

approximately 18 cm (6.8 in) from the body
control module (BCM) breakout

approximately 5 cm (2 in) from the body
8240

8242
In the IP harness, approximately 4 cm

(1.6 in) from the data link connector (DLC)
breakout
8243

(3.5 in) from G200 breakout
8244 (Convertible)

(18 in) from C405
8244 (Coupe)

(15.8 in) back from C405
8248

(0.8 in) from DRL module breakout
8154 (Pontiac)
8234 (Automatic)
6-812
E11gine
Engine Controls Component Views

Engine Component Locator View (Left Side)
(
1
370231
Legend
(1) MAP Sensor
(2) Oil Level Sensor
(3) H02S Sensor
(4) EGR Valve

(5) Throttle Body
Engine
6-813
Engine Component locator View (Right Side)
370232
Legend
(1)
(2)
(3)
(4)
(5)

Ignition Coils/Module
Throttle Body
Engine Coolant Temperature (ECT) Sensor
CAM Sensor
(6)
(7)
(8)
(9)
Crank Position (CKP) Sensor

Oil Pressure Sensor
H02S Sensor
Fuel Injectors
6-814
Engine Controls -
:t8l
Engine
PCM Connector End Views

Powertrain Control Module Connector C1 (BLU) End View
41
. 60@ 61
@@@@@@@@@@@@@@@@@@@@
:i~@@@@@@@@@@@@@@@@@@~J
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20
80 ,
.."\
@@@@@@@@@@@@@@@@@@@@
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21
c ]:
40
15026
Connector Part
Information
Pin
BLU PCM Connector C1

80 Pin Connector
Circuit No.
Wire Color
-
PPUWHT
1572
3
4
LT GRN
Function
Not Used
211d Gear. Start Indicator (4L60E only)
Not Used
1222
1 - 2 Shift Solenoid Control (4L60E only)
DKBLU
473
Cooling Fan 2 a:nd. 3 Relay Control
DKGRN
335
Cooling Fan .Relay 1 Control
BLK
630
Camshaft Position Sensor (CMP) Signal
PPUWHT
430
3X Reference
LT BLU/BLK
647
18X Reference
10-11
Not Used
12
BRN
718
Engine Coolant Temperature Sensor (ECT) Ground
13
ORN/BLK
469
Manifold Air Pressure Sensor (MAP) Ground
14
ORN/BLK
1061
Throttle ActuatorControl (TAC) Serial Data
15
TAN
800
Throttle Actuator Control (TAC) Serial Data
16
BLK/WHT
451
PCM Ground
17
PPL
719
ldlke Air Temperature Sensor (IAT) Ground
Not Used
18
19
PNK
439
PCM Ignition Fe~d
20
ORN
340
PCM Battery Feed
21
22
23-26
PNK
1224
-
Not Used
Transmission Range A Input (4L60E only)
Not Used
27
TAN/WHT
1653
Bank 1 H02S 1 Low
28
GRY
1981
Bank 1 H02S 2 Low
29
TAN
1667
Bank 2 H02S 1 Low
30
PPL
420
Brake Switch 2 Signal
31
BLK
552
Exhaust Gas Recirculation Sensor (EGR) Ground
32
GRY
435
EGR Valve Ground
33
DK/BLU
496
Bank 1 Knock Sensor Signal
34
LT/BLU
1876
Bank 2 Knock Sensor Signal
35-42
Not Used
43
YEUBLK
846
Injector Control Cylinder #6
44
YEUBLK
1223
2 - 3 Shift Solenoid Control (4L60E only)
Engine
6~815
Powertrain Control Module Connector C1 (BLU) End View (cont'd)
~~
41
60
1i1111
.61
@@@@@@@@@@@@@@@@@@@@
80
111111
@@@@@@@@@@@@@@@@@@@@
:ilil>@@@@@@@@@@@@@@@@@@~l c[@:ili!>@@@@@@@@@@@@@@@@@@~l L
\..: 1
20
21
40
15026
Connector Part
Information
Pin
Function
Not Used
LT BLU/BLK
844
47
BLK/WHT
845
48
RED/BLK
453
Reference Low
49-52
TAN/BLK
424
Bypass Control
54
WHT
423
Ignition Control (IC)
55
DKGRN/WHT
817
Vehicle Speed Sensor (VSS) Output
56
BLK/WHT
451
PCM Ground
57
BLK/WHT
451
PCM Ground
Not Used
59
DKGRN
1049
Class 2 Serial Data
60
BLK/WHT
451
PCM Ground
61-63
Not Used
64
YEL
400
VSS High
65
PPL
401
VSS Low
Not Used
66-68
69
YEL
492
Mass Air Flow Signal
70
DKBLU
229
Theft Deterrent Fuel Enable
71
ORN/BLK
463
72
73
74.75
76
77-78
79
80
LT GRN/BLK
-
DKGRN/WHT
BLK
1745
Requested Torque Input

Not Used
Not Used
428
EVAP Canister Purge Control
1744
Not Used
53
58
Circuit No.
46
45
Wire Color
BLU PCM Connector C1

80 Pin Connector
Not Used
Not Used
6-816
Engine
Powertrain Control Module Connector C2 (CLR) End View
(
/
~\..'
41
60@ 61
@@@@@@@@@@@@@@@@@@@
::i(~@@@@@@@@@@@@@@@@@@Jlc
20
BO l
@@@@@@@@@@@@@@@@@@
of~@@@@@@@@@@@@@@@@@@J)c
21
40
15026
Connector Part
Information
Pin
1
Wire Color
CLR PCM Connector C2

80 Pin Connector
Circuit No.
-
Function
Not Used
WHT
1310
EVAP Canister Vent Valve Control
DKGRN/WHT
465
Fuel Pump Relay Control .
LT BLU
697
EGR Valve Control
BRN/WHT
419
MIL Control
6-7
Not Used
WHT
121
Engine Speed Output
TAN/BLK
464
Delivered Torque Output
10
PPL
1666
Bank 2 H02S 1 Signal
11
DKBLU
1980
Bank 1 H02S 2 Signai
12
PPL/WHT
1665
Bank 1 H02S 1 Signal
13-15
Not Used
ORN/BLK
434
PNP Switch Signal
17
RED
1226
Transmission Range C Input (4L60E only)
18
GRY
48
16
19-20
21
BRN/WHT
Clutch Anticipate Switch

Not Used
1571
2nd Gear Start Signal
22
DK GRN/WHT
762
A/C Request Signal
23
PPL/WHT
1035
Crank Signal
24
BRN
86
Cruise. Control Release Signal
25
LTGRN
432
MAP Sensor Signal
26
YEL
410
ECT Sensor Signal
27
RED/BLK
380
A/C Refrigerant Pressure Sensor Signal
28
BRN
1456
EGR Pintle Position Signal
29-32
Not Used
33
GRY
598
5 Volt Reference A
34
LT BLU/BLK
1688
5 Volt Reference B
35
GRY
720
Sensor Ground
36-38
39
40-41
42
43-44
DKGRN/WHT
PNK/BLK
-
459
1746
-
Not Used
A/C Compressor Clutch Relay Control
Not Used
Not Used
45
RED/BLK
1228
Pressure Control Solenoid High (4L60E only)
46
LT BLU/WHT
1229
Pressure Control Solenoid Low (4L60E only)
Engine Controls.;. 3;8L
Engine
6-817
Powertrain Control Module Connector C2 (CLR) End View (cont'd)
)
{
41
u
.
60
@@@@@@@@@@@@@@@@@@@@
tJ[@@@@@@@@@@@@@@@@@@@~) c
~1
~
=l
Ig]
O
61
80
15026
Connector Part
Information
Pin
47
48
Wire Color
-
WHT
Circuit No.
49
TAN
472
51-54
55
DKGRN
Function
Not Used
687
50
3-2 Shift Solenoid Control (4L60E only)

Not Used
Intake Air Temperature Sensor Signal
' Not Used
Fuel Tank Pressure Sensor Signal
890
56
CLR PCM Connector C2

80 Pin Connector
Not Used
57
DKBLU
1225
Transmission Range E3 Input (4L60E only)
58
BRN
1174
Engine Oil Level Switch Signal
5960
61
62-67
68
69
70-75
76
77
RED
YEL/BU~ .
PPL
-
DKGRN
-
Not Used
225
Generator Control
..
1227
.... 1589
220
Not Used
Transaxle Fluid Temperature Sensor (4L60E only)
Fuel Level Signal
Not Used
Starter Enable (If Equipped)
Not Used
78
BRN
418
TCC PWMSolenoid.Control (4L60E only)
79
TAN/BLK
422
TCC Enable Solenoid Control (4L60E only)
80
Not Used
ur
@@@@@@@@@@@@@@@@@@@@
of@@@@@@@@@@@@@@@@@@@~) c
~
~~
..
6-818
Engine
Engine Controls Connector End Views

(
n
~ c::::J
M~
73223
62440
Connector Part
Information
0
1216-2017
2-Way F Metri-pack
150 Series (GRY)
Connector Part
Information
Pin
Pin
Wire Color
Circuit
No.
DKGRN
59
A/C Compressor Relay

Fuse Feed Input
BLK
450
Ground
Function
Wire Color
1216-2279
. 3-Way F Metri-pack
150 Series (GRY)
Circuit
No.
Function
BRN/WHT
633
Camshaft Position (CMP)

Sensor Signal
RED/BLK
645
CMP/CKP Sensor Ground
WHT/BLK
644
CMP/CKP Sensor Ignition

12V Reference
i::::::::J
~DICIBIA~
280765
258299
Connector Part
Information
1211-0192
3-Way F Metri-pack
150.Series Pull To Seat
Sealed (BLK)
Pin
Wire Color
Circuit
No.
GRY
720
Fuel Tank Unit Feed Input
LT BLU/
BLK
1688
5V Reference Input
RED/BLK
380
A/C Sensor Signal
Function
Connector Part
Information
1216-2834
4-Way F Metri-pack
150 Series (GRY)
Circuit
No.
Pin
Wire Color
LT BLU/
WHT
1800
Crankshaft Position (CKP)

Sync Signal
YEL
573
CKP 18x Signal
RED/BLK
645
644

12V Reference
WHT/BLK
Function
Engine
Electronic Ignition Control Module (ICM)
I
~
l.
([@N IMI <f@JEJ@rr@lo IcI@]
l~I
'-
'
518983
516619
Connector Part
Information
1212-4379
14-Way F Metri-pack
150 Series Sealed P2S (BJ.K)
Pin
Wire Color
Circuit
No.
WHT
423
Ignition Control,
TAN/BLK
424
Bypass Control
LTBLU/
BLK
647
18x Reference Signal
PPL/WHT
430
3x Reference Signal
Not Used
6-819
Function
Connector Part
Information
Pin
Wire Color
BRN
BLK
630

Signal
YEL
573
CKP 18x Signal
LT BLU/
WHT
1800
CKP Sync Signal
BRN/WHT
633
CMP Signal Sensor
BLK
450
Ground
RED/BLK
453
Reference Low
RED/BLK
645
WHT/BLK
644

12V Reference
PNK
239
Fused Input Feed
YEL
1216-2194
2-Way F Metri-pack
150 Series Sealed P2S (BLK)
Circuit
No.
Function
718
Engine Coolant
Tenperature (ECT) Sensor
Ground
410
Engine Coolant
Temperature (ECT)
Sensor Signal 5V
Reference
'C,'
35437
Connector Part
Information
1205-2641
2 Way F Metri-pack
150 Series (BLK)
Pin
Wire Color
Circuit
No.
BLK/WHT
451
Ground
BRN
1174
Oil Level Switch Signal 5V

Reference
Function
6-820
Engine
Engine Oil Pressure Sensor
Evaporative Emission (EVAP) Canister Vent

Solenoid Valve
516616
Connector Part
Information
Pin
Wire Color
35437
1206-5400
4-Way F Metri-pack
150 Series (GAN)
Circuit
No.
TAN
31
BLK/WHT
451
C-D
Connector Part
Information
Function
Oil Pressure Indicator
Lamp Output
Ground
Not Used
1205-2643
2 Way F Metri-pack
150 Series (RED)
0
Pin
Wire Color
Circuit
No.
PNK
239
Fused Input Feed
WHT
1310
EVAP Canister Vent

Valve Driver Ground
Function
Exhaust Gas Recirculation (EGR) Valve
Evaporative Emission (EV AP) Canister

Purge Solenoid Valve
I c::::::J
~-~
68773
35437
Connector Part
Information
Pin
Wire Color
1205-2643
2-Way F Metri-pack
150 Series Sealed (RED)
Circuit
No.
Function
PNK
239
Fused Input Feed
DK GRN/
WHT
428
EVAP Canister Purge

Valve Driver Ground
Connector Part
Information
Pin
Wire Color
0 1218-6056
5 Way F Metri-pack
150 Series Pull to Seat
Sealed (BLK)
Circuit
No.
Function
GRY
435
Exhaust Gas
Recirculation (EGR) Valve
Control Ground
BLK
552
Sensor Ground
BRN
1456
Exhaust Gas
Recirculation (EGR) Pintle
Position Signal
GRY
598
MAP Sensor Input
LT BLU
697
Exhaust Gas
Recirculation (EGR) Valve
12V Reference
Engine
Engine Controls - 3,8l 6-821

Fuel Injector #1
Fuel Injector #3
334635
Connector Part
Information
e 1532-6181
2-Way F Micro-pack
64 Series (BLK)
Pin
Wire Color
Circuit
No;
PNK
639
BLK
1744
334635
Connector Part
Information
1532-6181
2-Way F Micro-pack
64 Series (BLK)
Pin
Wire Color
Circuit
No.
Fused Input Feed
PNK
639
Fused Input Feed
Fuel Injector #1 Driver

Ground
PNK/BLK
1746

Ground
Function
Fuel Injector #2
Function
Fuel Injector #4
Ir'
~A
m_
-:h
--a
334635
Connector Part
Information
Pin
Wire Color
PNK
LT GRN/
BLK
0 1532-6181
2-Way F Micro-pack
64 Series (BLK)
Circuit
No.
Function
334635
Connector Part
Information
Pin
Wire Color
PNK
LT BLU/
BLK
639
Fused Input Feed
1745

Ground
1532-6181
2-Way F Micro-pack
64 Series (BLK)
Circuit
No.
Function
639
Fused Input Feed
844

Ground
6-822
Engine

Fuel Injector #5
Fuel Tank Unit (Fuel Pump Motor and Fuel

level Sensor)
--'-
/'
r@J
[~:f
00
[QJ [[I
334635
Connector Part
Information
r
518981
1532-6181
2-Way F Micro-pack
64 Series (BLK)
Connecte>r Part
. Information
Pin
Wire Color
Circuit
No.
PNK
639
Fused Input Feed
BLK/WHT
845

Ground
Function
Pin
Fuel Injector #6
Wire Color
1216-0482
4-Way F Metri-pack j
Circuit
No.
Function
PPL
30
PCM Fuel Level

Signal Input
GRY
120
Fuel Pump Relay Fuse

Feed Input
BLK
150
Ground
BLK/WHT
651
PCM Sensor
Ground Input
Fuel Tank Unit (Fuel Tank Pressure Sensor)
334635
Connector Part
Information
1532-6181
2-Way F Micro~pack
64 Series (BLK)
Pin
Wire Color
Circuit
No.
PNK
639
Fused Input Feed
YEUBLK
846

Ground
516611
Function
Connector Part
Information
1205-9595
3-Way F Metri-pack
Pin
Wire Color
.Circuit
No.
ORN/BLK
469
PCM Sensor
Ground Input
DKGRN
890
Fuel Tank Pressure

Signal Input
GRY/BLK
416
A/C Refrigerant Pressure

Sensor Output
Function
Engine
Heated Oxygen Sensor Bank 1, Sensor 1
"
/'.
~@]0
:500
~00
[QJ I]]:I
,.....
[QJ []],,,,,
ti
'
/'
'@] ~'
6-823
1 t:I
r
518981
518981
Connector Part
Information
Pin
A
B
Wire Color
TAN/WHT
PPL/WHT
1216-0482
4-Way F Metri-pack
150 Series Sealed (BLK).
Circuit
No.
Connector Part
Information
Pin
Function
1653
Left Front Heated Oxygen

Sensor (H02S) - Low
1665
Left Front Heated Oxygen

Sensor (H02S) - High
Wire Color
1216-0482
4-Way Metri-pack 150 Series
Sealed (BLK)
Circuit
No.
Function
TAN
1667
Right Front
Heated Oxygen
Sensor (H02S) - Low
PPL
1666
Right Front
Heated Oxygen
BLK
450
Ground
PNK
539
Fused Input Feed
BLK
450
Ground
PNK
539
Fused Input Feed
Intake Air Temperature (IAT) Sensor
F Fl
00
c:=
00
280751
Connector Part
Information
1216-0825
4 Way M Metri-pack
150 Series (BLK)
68719
Connector Part
Information
1216-2199
2-Way F Metri pack
150.2 Series Sealed (GRY)
Pin
Wire Color
Circuit
No.
GRY
1981
Heated Oxygen
Sensor (H02S) - Low
Pin
Wire Color
Circuit
No.
DKBLU
1980
Heated Oxygen
PPL
719
Intake Air
Temperature (IAT) Sensor
Ground
TAN
472
Intake Air
Signal 5V Reference
Function
BLK
450
Ground
PNK
539
Fused Input Feed
Function
6~824
Engine

Second Gear Start Switch
(Chevrolet w/o NW9)
~CVCSJ
mrnm
68740
Connector Part
Information
Pin
Wire.Color
304345
1212-9946
3-Way F Metri pack
150 Series (GRV)
Circuit
No.
Connector Part
Information
Function
Manifold Absolute
Pressure (MAP) Sensor
Ground
ORN/BLK
469
LTGRN
432
Manifold Absolute
Signal
598
Manifold Absolute
Pressure (MAP)
Sensor 5V Reference
GRY
62453
1205-9595
3-Way F Metri-pack
150 Series (BLK)
Pin
Wire Color
Circuit
No.
YEL
492
Mass Air Flow (MAF)

Sensor Signal
BLK/WHT
451
Ground
PNK
539
Fused Input Feed
Function
A.
B
Wire Color
Circuit
No.
Function
Second Gear Indicator
Control Ground
PPUWHT
1572
PNK
39
Fused Input Feed
Interior Lights Dimming

Ground Output
GRY
Not Used
Mass Air Flow (MAF) Sensor
Connector Part
Information
Pin
" 1217-7195
6-Way F Metri-pack
150 Series (BLK)
B.RN,/WHT
1571
Second Gear Start Switch

Signal Ground
BLK/WHT
451
Ground
Engine
Throttle Actuator Control Module
Throttle Actuator Control

/'
-,
-...,
--
+Yi+ 13
2 ~)I';= 14
.,
:... >- jii: 1
3 I=!,)!:!
IE 5
1
I'
4 .. ,:li,! .... 16
'\
51:1:!),!i" 17
//
w W~W~lliJ,
w WWW
[[
6-825
6 i:, ~);., 18
7 .., ,:),! 19
8::i~tllC 20
9 "' +) + 21
10 ::, ~ll~ !C 22
[IJ
11
1;1;
!>i;: 11:
23
12 .. +c)st = 24
\.\.
')
""-='
130644
Connector Part
lntormation
1204-7937
8-Way F Metri-pack
150 Series (BLK)
39784
Connector Part
Information
Pin
Wire Color
Circuit
No.
BLK
476
TP Sensor 2 Ground
PPL
486
TP Sensor 2 Signal
GRY
597
TP Sensor 2 5V
Reference
3.
BRN
582
Not Used
YEL
581
Motor Driver-High
Function
GRY/BLK
1687
TP Sensor 1 5V
Reference
DKGRN
485
TP Sensor 1 Ground
BLK
470
TP Sensor 1 Ground
Pin
8
1212-9225
24-Way F Micro-pack
100 Series (NAT)
Wire Color
Circuit
No.
YEL
581
ORN
1540
Function
Motor Driver-High
Not Used
Fused Input Feed

Not Used
BLK/WHT
451
Ground
Not Used
PNK
DKBLU
84
.Cruise Set/Coast Signal
LT BLU
20
Brake Switch Signal
10
DKGRN
485
TP Sensor 1 Ground
11
GRY/BLK
1687
TP Sensor 1 5V
Reference
339
Fused Input Feed
12
BLK
470
TP Sensor 1 Ground
13
BRN
582
Motor Driver-Low
Not Used
14-15
16
ORN/BLK
1061
TAC Serial Data
17
BLK/WHT
451
Ground
18
TAN
800
TAC Serial Data
20
GRY
397
Cruise On/Off Signal
21
GRY/BLK
87
Cruise Resume/Acee!
Signal
Not Used
19
~.~--l~~~~--11---~~-1-_..:;~~~~~~~~~
22
PPL
486
TP Sensor 2 Signal
23
GRY
597
5V Reference
24
BLK
476
TP Sensor 2 Ground
6-826
Engine
Vehicle Speed Sensor Connector C2

Procedures
A Diagnostic Starting Point
~)
'518983
. Connector .Part
Information
Pin
Wire Color
1216-2195
2 Way F Metri-pack
150.2 Series Sealed
P2S (BLK)
Circuit
No.
Begin the system diagnosis with the A Powertrain On

Board Diagnostic (080) System Check. The
Powertrain OBD System Check will provide the
following information:
The identification of the control module(s) w~ich
command the system.
The ability of the control module(s) to
communicate through the serial data circuit.
The identification of any stored diagnostic trouble
codes (DTCs) and their status.
The use of the Powertrain OBD System Check will
identify the correct procedure for diagnosing the
system and where the procedure is located.
Function
PPL
401
Vehicle Speed
Sensor (VSS)
Signal - Low
YEL
400
Vehicle Speed
Sensor (VSS) Signal High 5V Reference
Engine
6-827
A Powertrain On Board Diagnostic (OBD) System Check
Refer to Engine Controls Schematics.
Circuit Description
The Powertrain On-Board Diagnostic System Check
must be the starting point for any driveability complaint
diagnosis. Before using this procedure, you should
perform a careful visual/physical inspection of the PCM
and engine grounds for clean and secure connections.
The Powertrain On-Board Diagnostic System Check
is an organized approach to identifying a problem
created by an electronic engine control system
malfunction.
Diagnostic Aids
Important: Remove any debris from the connector

surfaces before servicing a component. Inspect
the connector gaskets when diagnosing or replacing a
component Ensure that the gaskets are installed
correctly .. The gaskets prevent contaminate intrusion.
Poor terminal connection.
Inspect the harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
faulty terminal to wire connection. Use a
corresponding mating terminal to test for proper
tension. Refer to Testing for Intermittent and Poor
Connections and Connector Repairs in Wiring
Systems.
" Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the display
on the scan .tool while moving connectors
and wiring harnesses related to the sensor. A
change in .the display may indicate the location of
the fault. Refer to Wiring Repairs in Wiring
Systems.
" Inspect the PCM and the engine grounds for
clean and secure connections.
If the OTC is determined to be intermittent, reviewing

the Failure Records can be useful in determining
when the OTC was last set.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
1. The MIL should be ON steady with the key ON,
engine OFF. If not, the No Malfunction Indicator
Lamp table should be used to isolate the
malfunction.
2. This test ensures that the PCM is capable of
transmitting Class 2 serial data to the DLC
and that the Class 2 data circuit is not open or
shorted. If a problem is encountered and a
malfunctioning scan tool is suspected, try the scan
tool on another vehicle to verify operation. If a
DLC problem exists, the DLC Diagnosis table
should be used to diagnose the condition.
3. IUhe engine will not start, the Engine Cranks But
Will Not Run table should be used to diagnose
the condition.
4. The scan tool may display DTCs which are
diagnosed in Automatic Transmission/Transaxle
Diagnosis. If multiple DTCs are stored, diagnose
each OTC according to the following priority:
PCM Error DTCs.
System Voltage DTCs.
e Component Level DTCs (Switches, sensor
range/performance, sensor high voltage,
sensor low voltage, ODMs, etc.).
O
System level DTCs (Fuel trim, Misfire, EGR
flow, TWC System, Idle Control System,
H02S Response or H02S Transition Time
Ratio).
5. A scan tool parameter which is not within the
typical range may help to isolate the area which is
causing the problem.
6-828
Engine

Step
Action
Value(s)
1. Install a scan tool.

2. With a scan tool, attempt to display PCM data.
Does the scan tool display PCM data?
Attempt to start the engine.

Does. the engine start and continue to run?
Yes
No
Important:
Check for applicable service bulletins before
proceeding with the diagnosis.
Do not turn OFF the ignition when performing this
diagnostic table.
Do not perform this test if no drivability condition
exists.
Unless instructed, do not clear any DTCs.
1. Turn ON the ignition, with the engine OFF.
2. Observe the Malfunction Indicator Lamp (MIL).
Is the MIL illuminated?
Go to Step 2
Go to
Malfunction
Indicator
Lamp (MIL)
Inoperative
Goto Step 3
Go to Data Link
Connector
Diagnosis
Go to Step 4
Go to Engine
Cranks but Does
Not Run
Go .to the
applicable
DTC table
Go to Step 5
System OK
Go to
Component
System Checks
;;,
Important: If the scan tool indicates any DTCs set, record

Freeze Frame/Failure Records.
Use the scan tool in order to display Diagnostic Trouble
Codes (DTCs).
Does the scan tool indicate any DTCs set?
With a scan tool, compare the PCM data to the Scan Tool
Data List.
Does the scan tool indicate PCM values equal or within
the typical values?
Scan Tool Data List

The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool.
The list is arranged in alphabetical order. A given
parameter may appear in any one of the data lists, and
in some cases may appear more than once, or in
more than one data list in order to group certain
related parameters together.
Use the Engine Scan Tool Data List only after the
following is determined:
Powertrain On-Board Diagnostic System Check is
completed.
No Diagnostic Trouble Codes (DTCs) are active.
On-board diagnostics are functioning properly.
Scan tool values from a properly running engine may
be used for comparison with the engine you are
diagnosing. The Engine Scan Tool Data List
represents values that would be seen on a normally
running engine.
Important: A scan tool that displays faulty data should

not be used. The scan tool concern should be
reported to the manufacturer. Use of a faulty scan tool .
can result in misdiagnosis and unnecessary parts
replacement.
Only the parameters listed below are referenced in
this service manual for use in diagnosis. If all values
are within the typical range described below, reier
to Symptoms for diagnosis.
The column labeled Data List indicates where a
parameter can be located on the scan tool. Refer to
the scan tool operating manual for the exact locations
of the data lists. The following is a description of
each term listed:
Eng 1: Engine Data 1 List
EGR: Exhaust Recirculation Valve Data
EVAP: Evaporative Emissions Data
Cat: Exhaust Catalyst Data
H02S: Heated Oxygen Sensor Data
Misfire: Cylinder Misfire Data
Cruise: Cruise Control Data
TAC: Throttle Actuator Control Data
ODD: Output Driver Data
Engine
6-829
Scan Tool Data List

Scan Tool Parameter
Data list
Units Displayed
Typical .Data Value
Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off/Brake Pedal Released
.
. ..
Misfire
3X Crank Sensor
RPM
Varies
Misfire
RPM
Varies
. t8X Crank Sensor
1-2 Sol.
OK/Fault/Invalid State
OK
2-3 Sol.
ODD
OK
3-2 Downshift Sol.
ODD
OK
Varies
A/C High Side Pressure
Eng 2
Volts
A/C Press Out of Range
Eng 2
Yes/No
No
A/C Relay
ODD
OK
A/C Request
Eng 2, Cat, Misfire
Yes/No
No
Actual EGR Position
Eng 1, 2, EGR, Misfire
Percent
0
14.2:1 - 14.7:1
Air Fuel Ratio
Eng 1, Cat, H02S
Ratio
APP Average
Eng 1, 2, EGR, Cat,

H02S, Cruise, TAC
Counts
.Varies
APP Indicated Angle
Eng 1, 2, EGR, Cat,

H02S, Cruise, TAC
Percent
ODD
..
APP Sensor 1
TAC
Volts
0.8 - 1.0
APP Sensor 2
TAC
Volts
0.8 - 1.0
APP Sensor 3
TAC
Volts
0.8 - 1.0
APP Sensor 1 Angle
TAC
Percent
APP Sensor 2 Angle
TAC
Percent
APP Sensor 3 Angle
TAC
Percent
APP.Sen. 1 and 2 Disagree
TAC
Yes/No
No
APP Sen. 1 and 3 Disagree
TAC
Yes/No
No
APP Sen. 2 and 3 Disagree
TAC
Yes/No
No
APP Sen. 1 Out of Range
TAC
Yes/No
No
TAC
Yes/No
No
TAC
Yes/No
No
BARO
Eng 1, 2, E:GR,
EVAP, Cat
kPa/Volts
65-110 kPa I
3.5-4.5 Volts
Brake Switch
Cruise, TAC
Applied/Released
Released
Cam Signal Present
Misfire
Yes/No
Yes
Clutch Anticipate Switch
Cruise (w/ Manual

Transmission)
Applied/Released
Commanded A/C
Eng 2, Cat,. Misfire
On/Off
Released
Off
. Cornmanded Gen
Eng 1
On/Off
On
cruise
Cruise, TAC,
Engaged/Disengaged
Disengaged
Cruise Disengage Hist.1 ~6
Cruise
Cruise Control Diagnosis
Varies
Cruise Release Sw.
Cruise, TAC
Applied/Released
Released
Cruise Resume/Acee!
Cruise, TAC
On/Off.
Off
Cruise Set/Coast
Cruise, TAC
On/Off
Off
Cruise Switch
Cruise, TAC
On/Off
Off
Current Gear
Eng 1
Transmission Gear
Position
Cyl. 1-6 .Ckt Hi~tory
ODD
OK/Stuck Low
(open)/Stuck High/Fault
OK
Cyl. 1-6 Ckt. Status
ODD
OK/Stuck Low
(open)/Stuck High
OK
Decel Fuel Mode
Eng 1, 2, Cat, H02S,

Misfire, Cruise, TAC
Active/Inactive.
Inactive
6-830
Engine
Scan Tool Data List (cont'd)
Scan Tool Parameter
Data List
Units Displayed
Typical Data Value
E:ngine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Acc~ssories Off/Brake Pedal Released
Desired EGR Position
Eng 1, 2, EGR, Misfire
Percent
Desired Idle Speed
Eng 1, 2, EVAP,
Cruise, TAC
RPM
PCM Controlled (varies)
Driver Module 1 Status
ODD
Enabled/Off-High
Volts/Off High
Temp/Invalid State
Enabled
ODD
Enabled/Off-High
Volts/Off High
Temp/Invalid State
Enabled
ODD
Enabled/Off-High
Volts/Off High
T emp/lnvalid State
Enabled
ODD
Enabled/Off-High
Volts/Off High
Temp/Invalid State
Enabled
ECT
Eng 1, 2, EGR, EVAP,

Cat, H02S, Misfire
oc;oF
Varies
0.14-1.0
EGR Closed Val. Pintle
EGR
Volts
EGR Duty Cycle
EGR
Percent
EGR Feedback
EGR
Volts
0.14-1.0
EGR Flow Test Count
EGR
Counts
0-10
EGR Position Error
EGR
Percent
Engine Load
Eng 1, 2, Cat, Misfire,

Cruise, TAC
Percent
2-5
Engine Run Time
Engine 1, 2, EV AP,
Cat, Cruise, TAC
Hr: Min: Sec
Varies
Engine Speed
Eng 1, 2, EGR, EVAP,

Cat, H02S, Misfire,
Cruise, TAC
RPM
Varies
EVAP Canister Purge
EVAP, H02S
Percent
Low and Varying
EVAP Fault History
EVAP
No Fault/Excess
Vacuum/Purge Valve
Leak/Small Leak/Weak
Vacuum
No Fault
EVAP Purge Sol.
ODD
OK
EVAP Vent Sol.
.0-100
--
EVAP
Open/Closed
Varies
EVAP Vent Sol.
ODD
OK
Fans High Speed
Eng 2, Cat
On/Off
Off
Fans Low Speed
Eng 2, Cat
On/Off
Off
FC Relay 1
ODD
OK
ODD
OK
FC Relay
2 and 3
--
Fuel Level
EVAP
Percent
Fuel Pump
Eng 2
On/Off
On
Fuel Pump Ckt. History
ODD
OK/Stuck Low
OK
Fuel Pump Ckt. Status
ODD
OK/Stuck Low
OK
Fuel Tank Pressure
EVAP
in H20Nolts
Varies
Fuel Trim Cell
Eng 1, Misfire
0-4
Fuel Trim Learn
Eng 1, Cat
Enabled/Disabled
Varies
H02S Bank 1 Sensor 1
Eng 1, H02S
Ready/Not Ready
Ready
Eng 1, H02S
Ready/Not Ready
Ready
0-100
Engine Controls - 3.8L 6.;831
Engine
Scan Tool Data list (cont'd)
Data List
Scan Tool Parameter
Units Displayed
Typical Data Value
Ehgine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed loop/Accessories Off/Brake Pedal Released
Eng 1, Cat, H02S
millivolts
Eng 1, Cat, H02S
millivolts
0-1000 and Varying
H02S Bank 1.Sensor 2
Eng 1, Cat, H02S
millivolts
0-1000 and Varying
H02S Warm-Up Bn1 Sen 1
H02S
Min:Sec
Varies (under
2 minutes)
H02S Warm-Up Bn2 Sen .i
H02S
Min: Sec
Varies (under
2 minutes)
H02S Warm-Up Bn1 Sen 2
H02S
Min: Sec
Varies (under
2 minutes)
H02S
Counts
Varies
H02S XCounts Bank 2
H02S
Counts
Varies
IAT
Eng 1, 2, EVAP,
Cat, H02S
oc/oF
Varies
Ignition 1
Eng 1, 2, EGR, H02S,

Cruise, TAC
Volts
Varies
,,,
,,
,,
H02S XCounts Bank 1
,'
Ignition Mode
Eng 2
IC/Bypass
IC
Injector Pulse Width
Eng1, Cat
milliseconds
Varies (1.5-3.5)
Knock Retard
Eng 2
Degrees
Long Term FT Bank 1
Eng 1, Misfire
Percent
-10-10
Long Term FT Bank 2
Eng 1, Misfire
Percent
-10-10
Loop Status
Eng 1, Cat, H02S,

Misfire
Open/Closed
Closed
>
,,
'
Eng 1, 2, Cat,
H02S, TAC
Grams per Second
3-6 (depends on
altitude)
MAF Frequency
Eng 1
Hz
1200-3000 (depends on
altitude)
MAP
Eng 1, 2, EGR,
EVAP,TAC
kPa/Volts
20-48 kPa/0.75-2 Volts

(depends on altitude)
MIL
Eng 2
On/Off
Off
MIL
ODD ..
,OK/Fault/Invalid State
OK
Misfire Current Cyl. 1-6
Misfire
Counts
0
0
'
Misfire History Cyl. 1-6
Misfire
Counts
Misfiring Cylinder Prim.
Misfire
0-6
Misfiring Cylinder Sec.
Misfire
0-6
Power Enrichment

Active/Inactive
Inactive
Reduced Engine Power
'
'
MAF
,,
0-1000 and Varying
'
Eng 1, 2, EGR, Cat,

H02S, Misfire,
Cruise, TAC
'
Active/Inactive
Inactive
',
Rich/Lean Bank 1
Eng 1
Rich/Lean
Constantly Varying
Rich/Lea:n Bank 2
Eng 1
Rich/Lean
Constantly Varying
Short Term FT Bank 1
Eng 1, Cat, Misfire
Percent
-10-10
Eng 1, Cat, Misfire
Percent
-10~10
Degrees
20 (varies)
Spark
Eng 2
Starter E:nable Relay

. Starter Inhibit
ODD
Eng 2
St~rt Up ECT
EVAP, H02S
Start Up IAT
EVAP, H02S
"
Active/Inactive
oc/oF
OK
Inactive
Varies
ocjoF
Varies
'
TAC Brake Switch
Cruise, TAC
Applied/Released
Released
TAC/PCM Communication
Eng 1, 2, EGR, Cat,

H02S, Cruise, TAC
OK/Fault
OK
6-832
Engine
Scan Tool Parameter
Data List
Units Displayed
Typical Data Value
Engine Idling/Radiator .Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off/Brake Pedal Released
TCC Enable Sol.
ODD
OK
TCC Sol.
ODD
OK
Total Misfire Current Count
Misfire
Counts
Total Misfire Failures Since First Fail.
Misfire
Counts
Totai Misfire Passes. Since First Fail
Misfire
Counts
TP Desired Angle
Eng 1, 2, EGR, Cat,

H02S, Cruise, TAC
Percent
1-4
TP Indicated Angle
Eng 1, 2, EGR, Cat,

H02S, Misfire,
Cruise, TAC
Percent
1-4
TP Sensor 1
TAC
Volts
0.5-1.2
..
TP Sensor 2
TAC
Volts
0.5-1.2
TP Sensor 1 Angle
TAC
Percent
2-4
TP Sensor 2 Angle
TAC
Percent
2-4
TP Sensors Disagree
TAC
Yes/No
No
TP Sensor 1 Out of Range
TAC
Yes/No
No
TP Sensor 2 Out of Range
TAC
Yes/No
No
Traction Control
Eng 2, Cruise
Active/Inactive
Inactive
Traction Control Desired Toque
Eng 2, Cruise
Percent
100%
Traction Control Torque
Eng 2, Cruise
Percent
65-80%
Transmission Range
Eng 2, Cruise (w/

automatic transmission)
Transmission Gear
Position
Park
TR Switch A
Eng 2, Cruise (w/

Low/High
High
TR Switch B
Eng 2, Cruise (w/

Low/High
Low
TR Switch C
Eng 2, Cruise (w/

Low/High
High
TWC Protection

Active/Inactive
Inactive
Vehicle Speed
Eng 1, 2, EGR, Cat,

MPH/Km/h
VTD Fuel Disable
Eng 2
Active/Inactive
Scan Tool Data Definitions

The Engine Scan Tool Data Definitions contain a brief
description of all engine related parameters available
on the scan tool. The list is in alphabetical order.
A given parameter may appear in any one of the data
lists. In some cases, the parameter more than
once or in more than one data list in order to group
certain related parameters together.
3X Crank Sensor: Scan tool displays 1200 to
10,000 RPM. This signal is calculated from the
18X pulses and is fed to the PCM by the ignition
control module. This is used by the PCM to calculate
RPM at engine speeds above 1200 RPM. and to
initiates injector pulses.
18X Crank Sensor: Scan tool displays
Oto 1200 RPM. This signal is produced by the ignition
control module and is fed to the PCM to calculate
engine RPM below 1200 RPM.
Inactive
1-2 Sol.: Scan tool displays OK, Faulfor Invalid

state. These parameters describe the condition of the
control circuit.
2-3 Sol.: Scan tool displays OK, Fault or Invalid
control circuit.
3-2 Downshift Sol.: Scan tool displays OK, Fault or
Invalid state. These parameters describe the
condition of the control circuit.
A/C High Side Pressure: Scan tool displays
0.00 to 5.00volts. Represents the A/C refrigerant
pressure sensor signal. The amount of pressure
indicates the amount of load that the A/C compressor
is placing on the engine. The PCM uses this
information to adjust idle and to control the
cooling fans.
Engine
A/C Pressure Out Of Range: Scan tool displays
YES or NO. YES displayed indicated that the PCM is
monitoring an A/C refrigerant pressure signal
voltage which is too high or too low to allow the A/C
compressor clutch to engage.
A/C Relay: Scan tool displays OK, Fault or Invalid
state. These parameters describe the condition of
the control circuit.
A/C Request: Scan tool displays YES or NO.
Indicates the state of the A/C request input circuit from
the HVAC controls. The PCM uses the A/C request
signal 10 determine whether A/C compressor operation
is being requested.
Actual EGR Position: Scan tool displays O percent
to 100 percent Represents the actual position of
the EGR pintle in percent. O percent displayed
indicates a fully extended pintle (EGR valve closed).
Air/Fuel Ratio: Scan.tool displays 0.0 to 25.5.
Air Fuel Ratio indicates the PCM commanded value.
In closed loop, Air Fuel Ratio shoul.d normally be
around 14.2-14.7. A lower Air Fuel Ratio indicates a
richer commanded mixture, which may be seen during
Power Enrichment or TWC Protection modes. A
higher Air Fuel Ratio indicates a leaner commanded
mixture. This can be seen during Decel Fuel Mode.
APP Average: Scan tool displays
0-150 counts. When the accelerator pedal is fully
depre$sed the scan tool will display approximately
\ 122 counts. The TAC module takes the voltages from
J the 3 AP~ sensors, averages the readings and
converts the readings into counts. The scan tool
displays the average. The average is different on every
vehicle.
APP Indicated Angle: Scan tool displays
0-100 percent. The scan tool displays the Accelerator
Pedal Position in percentage. When the APP is at
rest, the display shows O percent. When the APP is
fully depressed, the display shows 100 percent.
APP .sensor 1 /2 /3: Scan tool displays
0-5.0 volts. When the accelerator pedal is at
O percent (pedal at rest), the display shows
approximately 1 Volt. When the accelerator pedal is at
100 percent (pedal fully .depressed), the display
shows approximately 3.6 volts.
APP Sensor1 / 2/ 3 Angle: Scan tool displays
0-100 percent.. When the accelerator pedal is at rest,
display shows O percent. When the accelerator
pedal is fully depressed, display shows 100 percent.
This percentage indicates to the TAC module the
actual pedal position.
APP Sen. 1 and APP Sen. 2 Disagree: Scan tool

displays YES or NO. When the TAC module receives a
signal voltage from APP sensor 1 not in proper
relationship to APP sensor 2, the scan tool displays
YES. The scan tool displays NO under the normal
operating conditiol'ls.
6-833

YES. The. scan tool displays NO under the normal
operating conditions.
YES. Th.e scan tool displays NO under the normal
operating conditions.
APP Sensor 1 I 2 I 3 Out of Range: Scan tool
displays YES or NO. If the APP sensor voltage is not
within the specifications, the scan tool displays
YES. If the APP sensor voltage is within the
specifications, the scan tool displays No.
BAR.O: Scan tool displays 10 to 105 kPa I
0.00 to 5.00 volts. The barometric pressure reading is
determined from the MAP sensor signal monitored
during key up and wide~open throttle (WOT)
conditions. Barometric pressure is used to adjust fuel
delivery and spark advance to compensate for
altitude changes.
Brake Switch: Scan tool displays APPLIED or
RELEASED. Indicates the brake pedal position. When
the brake pedal is depressed a signal voltage is
sent to the PCM. If a fault occurs on this circuit known
as the cruise control brake switch 2 Circuit, a P1586
will set and cruise will not function.
Cam Signal Present: Scan tool displays YES or
NO. If the PCM does not receive a cam signal from the
ignition control module the scan tool displays NO.
Clutcp Anticipate Switch: Scan Tool Displays
APPLIED or RELEASED. The PCM monitors the clutch
pedal switch input; if a low voltage is monitored, the
PCM considers the. clutch anticipate switch closed
to ground (clutch pedal released). This is done to avoid
a possible RPM flare caused by the sudden change
in engine load.
Commanded A/C: Scan tool displays ON or OFF.
Represents the PCM commanded state of the A/C
compressor clutch relay driver circuit. The A/C
compressor clutch should be engaged when
Commanded A/C displays ON.
Commanded Gen: Scan tool displays ON or OFF.
OFF displayed indicates that the PCM has
commanded the generator control circuit OFF.
Cruise: Scan t.ool displays ENGAGED or
DISENGAGED. Represents the state of the Cruise
Status Input from the PCM module. Cruise should not
display DISENGAGED unless t.hevehicle is operatihg
in cruise control.
Cruise Disengage History 1-6: Scan tool displays
the last 6 cruise control disengages in order from
1 to 6..There are 30 possible causes for the cruise
control to disengage.
6-834
Cruise Release Switch: Scan tool displays

RELEASED or APPLIED. This circuit has the cruise
brake switch and the cruise clutch switch wired in
series on manual transmission vehicles. Represents
the position of the brake pedal and clutch as seen
by the PCM. If the brake or clutch pedal is applied the
PCM will not allow the cruise to engage. If a fault
occurs on this circuit known as the cruise control brake
switch Circuit, a P0571 will set and cruise will not
function.
Cruise Resume/Accel: Scan tool displays ON or
OFF. When the Cruise control switch is in the on
position and the Resume/Accel switch is activated, the
scan tool displays ON. The switch, when in the ON
position, sends a signal voltage to the TAC module,
that signal is then sent to the PCM across .serial data.
When the Resume/Accel switch is released the.
scan tool displays OFF.
Cr.uise Set/Coast: Scan tool displays ON or OFF.
When t.he Cruise control switch is in the on position
and the Set/Coast switch is activated, the scan
tool displays ON. The switch, when in the ON position,
sends a signal voltage to the TAC module, that
signal is then sent to the PCM across serial data.
When the Set/Coast switch is released the scan tool
displays OFF.
Cruise Switch: Scan tool displays ON or OFF.
When you activate th.e cruise control switch, the scan
tool displays ON. The switch, when in the ON
position, sends a signal voltage to the TAC module,
that signal .is then sent to the PCM across serial data.
This allows all other functions of the Cruise Control.
When you turn off the cruise control switch, the
scan tool displays OFF.
Current Gear: Scan tool displays 0-4. The scan tool
display the gear that the transmission is in. An
illegal transmission position displays 9.
Cyl. 1-6 Ckt. History: Scan tool displays OK, Stuck
Low (open) or Stuck High. These Parameters
describe the condition of each injector control circuit. If
a fault is detected the scan tool will list which the
fault type with the. corresponding cylinder.
Cy!. 1-6 Ckt. Status: . Scan tool displays OK, Stuck
Low (open) or Stuck High. These Parameters
describe the condition of each injector control circuit.
Decel. Fuel Mode: Scan tool displays ACTIVE
or INACTIVE. ACTIVE is displayed if the PCM has
detected conditions appropriate to operate in
Deceleration Fuel Mode. The PCM will command
deceleration fuel mode when a sudden decrease in
throttle position has been detected while the vehicle is
traveling over 25 mph. While in Deceleration Fuel
mode, the PCM will decrease the amount of fuel
delivered by entering Open Loop and decreasing the
injector pulse width.
Desired EGR Position: Scan tool displays
O percent to 100 percent. Represents the EGR pintle
position that the PCM is commanding. Desired
EGR Position should stay close to Actual EGR
Position.
E11gine
Desired Idle Speed: Scan tool displays
Oto 3187 RPM. Represents the idle speed that is
commanded by the PCM. The PCM will compensate
for various engine loads based on engine coolant
temperature to keep the engine at the desired
idle speed.
Driver Module 1 I 2 I 31 4 Status: Scan tool

displays Enabled, Off-High volts, Off High Temp or
Invalid state. This parameter describes the internal
PCM driver module condition. This module controls all
the relays/solenoids listed below the Driver Module
parameter in the .scan tool Output Driver Data List up
to the next driver module.
ECT: Scan tool displays -40C to 151 C, -40F to
304F. The engine coolant temperature (ECT) sensor
is mounted in the coolant stream. The PCM applies
5 volts to the ECT sensor circuit. The sensor is a .
thermistor which changes interna.1 resistance as
temperature changes. When the sensor is cold
(internal resistance high), the PCM monitors a high
signal voltage and interprets it as a cold engine. As the
sensor warms (internal resistance decreases), the
voitage signal decreases and the PCM interprets the
lower voltage as a warm engine.
EGR Closed Valve. Pintle Position: Scan tool
dispiays 0.0 to 5.0 volts. Represents the learned
voltage that the PCM uses to determine whether or
not the EGR valve is fully closed (0 percent pintle
position). If the Desired EGR Position is O percent and
a difference of more than 0.4 volt between EGR
Feedback and EGR Closed Valve Pintle Position is
detected, OTC P1406 will set.
EGR Duty Cycle: Scan tool displays O percent to

100 percent. Represents the EGR valve driver
PWM signal from t.he PCM. A duty cycle of O percent
indicates that no EGR flow is being commanded; a
100 percent duty cycle indicates maximum EGR flow
commanded.
EGR Feedback: Scan tool displays
0.00 to 5.00 volts. Indicates the EGR pintle position
sensor signal voltage being monitored by the PCM. A
low voltage indicates a fully extended pintle (closed
valve); a voltage near 5 volts indicates a fully retracted
pintle (open valve)
EGR Flow Test Count: Scan tool displays O10 255.
Indicates the number of EGR flow test samples
collected during the current ignition cycle. The
maximum number of samples allowed is 1 during
normal operation. If the PCM battery feed has been
disconnected or a OTC P0401 has been cleared,
several EGR flow test samples will be allowed during
the next ignition cycle. This is to allow repair
verification during a single ignition cycle.
EGR Position Error: Scan tool displays O percent to
100 percent. Indicates the difference between
Desired EGR Position and Actual EGR Position
currently being monitored by the PCM. If the.EGR
Position Error reaches an unacceptable level,
OTC P1406 will set.
Engine
6-835
Engine Load: Scan tool displays O percent to

100 percent. Engine load is calculated by the PCM
from engine speed and MAF sensor readings; Engine
load should increase with an increase in RPM or
air flow.
Fuel Tank Pressure: Scan tool displays in

Oto 5.00 volts or -32 to 32 (in/H20). This parameter
indicates the pressureNacuum insi.de of the fuel
tank. A negative value indicates a vacuum. A positive
value indicates .a pressure.
Engine Run Time: Scan tool displays

00:00:00 to 99:99:99 Hrs:Min:Sec. Indicates the time
elapsed since the engine was started. If the engine
is stopped, ENGINE RUN TIME will be reset to
00:00:00.
Fuel Trim. Cell: Scan tool displays Oto 9 fuel trirn

cell is dependent upon engine speed and MAF sensor
readings. A plot of RPM vs. MAF is divided into
10 cells .. Fuel trim cell indicates which cell is currently
active.
Engine Speed: Scan tool displays Oto 9999 RPM.

Engine speed is computed by the PCM from the
3X reference input. It .should remain close to desired
idle under various engine loads with engine idling
Fuel Trim Learn: Scan tool displays YES or NO.

When conditions are appropriate for enabling long term
fuel trim corrections, FUELTRIM LEARN will display
yes. This indicates that the long term fuel trim is
responding to short term fuel trim. If the Fuel Trim
Learn displays NO, long term fuel trim will not respond
to changes in short term fuel trim.
EVAP Canister Purge: Scan tool displays O percent

to 100 percent Represents the PCM commanded
PWM duty cycle of the EVAP Purge valve. O percent
displayed indicates no purge; 100 percent displayed
indicates fullpurge.
EVAP Fault History: Scali tool displays NO FAUL:.T,
EXCESS VACUUM, PURGE VALVE LEAi( SMALL
U::AKor WEAKVACUOM. The EVAP Fault History
indicates the status of the EV AP system dia.gnpstics
performed by the PCM.
EVAP Purge S.ol.: Scan tool displays OK, Fault8/
Invalid state. Thes.e parameters describe the condition
of the control circuit.
EVAP Vent Sol.: Listed. in the EVAP Data List ) Scan tool displpys Open or Closed, The.scan
tool displays Open when the.PCM.commands. the
EVAP system to purge. The. scan tool will show Closed
when the system is not purging:
Fans High Speed: Scan tool displays ON ofOFF.

Represents the PCM .commanded state of both fans.
Fans Low Speed: .. Scan tool displays ON or .
OFF. Represents the PCM co.mmanded state of
both fans.
Fan Control Relay 1: Scan tool displays,OK, Fault

or Invalid state. These parameters describe the
Fan Control Relay 2 and 3: Scan tool displays OK,
Fault or Invalid state. These parameters describe
the condition of the control circuit.
Fuel Level: Scan tool displays 0-100 percent The
scan tool displays in percentage the amount of
fuel in the fuel tank.
Fuel Pump: Scan tool displc1.ys ON or Of'F: Indicates
the PCM commanded state of the fuel pump relay
control circuit.
Fuel Pump Ckt. History: Scan tool displays OK,

Stuck Low (open) or Stuck High". These Parameters
describe the .condition of the fuel pump control circuit.
Fuel Pump Ckt. Status: Scan tool displays OK,
Stuck Low (open) or Stuck High. These Parameters
describe the condition of the fuel pump control
circuit. If a fault is detected the scan tool will list which
the fault type.
H02S Bank 1 Sen. 1 I Bank 2 Sen. 1: Scan tool

displays READY or NOT READY. Indicates the status
of the fuel control exhaust oxygen sensor. The
scan tool will indicate that the exhaust oxygen sensors
are ready when the PCM detects a fluctuating H02S
voltage sufficient to allow closed loop operation.
This will not occur unless the exhaust oxygen sensors
are warmed up;
H02S Bank 1 Sen. 1 I Bank 2 Sen. 1 I Bank 1
Sen. 2: Scan tool displays Oto 1132 mV. Represents
thEl fuel control exhaust oxygen sensor output
voltage. Should fluctuate constantly within a range
between 10 mV(lean exhaust) and 1000 mV
(rich exhaust) while operating in Closed Loop.
H02S Warm-Up Sensor Bank 1 Sen. 1 I Bank 2
Sen. 1 I Bank 1 Sen. 2: Scan tool displays
00:.00 to 99:99 MIN:SEC; Indicates time to warm-up
for each H02S. The H02S warm up time is used
for the H02S heater test. The PCM will run the heater
test only after a cold start (determined by engine
coolant and intake air temperature at the time
of startup) and only once during an ignition cycle.
When the engine is started the PCM will monitor the
H02S voltage. When the H02S voltage indicates
a sufficiently active sensor, the PCM looks at
how much time has elapsed since startup. If the.PCM
determines thattoo much time was required for the
H02S to become active, a DTC will set. If the engine
was warm when started, H02S Warm-Up will
display the. value that was stored last time the test
ran. If info has. been cleared, H02S Warm-Up
will display .00:00.
H02S XCounts Bank 1 I Bank 2: Scan tool
displays to 255. Indicates the number of times the
H02S 1 signalhas crossed the 450 mV bias
voltage during a .1 second interval. A H02S 1 signal
that almost never crosses the bias voltage could
indicate a fuel trim problem, a faulty H02S 1 circuit, or
a faulty H02S 1.
6.:836
IAT: Scah tool displays -40C to 151C, ~40F to

304F .. The. PCM converts the resistance of the ihtake
air temperature sensor to degrees. The PCM uses
Intake air temperature (IAT) to adjust fuel delivery and
spark timing according to incoming air density. IAT
is also compared to ECT at startup to identify
cold starts for the H02S heater and the EVAP
diagnostics.
Ignition 1: Scan tool displays O to 25.5 volts.
Represents the system voltage measured by the PCM
at its ignition teed.
Ignition Mode: Scan tool displays BYPASS or IC.
Indicates the commanded state of the Bypass
signal output from the PCM. When BYPASS is
displayed, the ignition control module is controlling the
spark advance at a fixed 10 degrees BTDC (Bypass
mode). IC displayed indicates that the PCM has
requested control of the spark advance (IC mode).
The ignition control module determines the correct
operating mode based on the level .of voltage that the.
PCM applies to the ignition control module bypass
circuit. The PCM provides 5 volts to the ignition control
module bypass circuit when conditions are appropriate
for PCM control of spark timing (IC mode). If the
PCM does not apply 5 volts to the bypass circuit, or if
the ignition control module does not receive it, the
module will control spark timing.
Injector Pulse Width: Scan tool displays

Oto 1000 msec. Indicates. the amount of time the PCM
is commanding each injector ON during each engine
cycle. A longer injector pulse width will cause more fuel
to be delivered. Injector Pulse Width should increase
with increased engine load,
Knock Retard: Scan tool displays 0.0 degrees to
25.5 degrees. Indicates the. amount of spark the PCM
is removing from IC spark advance in response to
the signal from the knock sensors. The Traction
Control system Desired Torque signal.from the EBTCM
may cause knock retard to display a value greater
than 0.0 degrees if Traction Control is active.
long Term Fuel Trim Bank 1 I Bank 2: Scan tool
displays -23 percent to 16 percent.Long Term Fuel
Trim is derived from the Short Term Fuel Trim value
and represents a long-term correction of fuel
delivery. A value of O percent indicates that fuel
delivery requires no compensation to maintain the
PCM commanded air/fuel ratio. A negative value
significantly below O percent indicates that the fuel
system is rich and fuel delivery is being reduced
(decreased injector pulse width). A positive value
significantly greater than O percent indicates that. a
lean condition exists and the PCM is compensating by
adding fuel (increased injector pulse width). Because
Long Term Fuel Trim tends to follow Short Term
Fuel Trim; a value in the negative range due to
canister purge at idle should not be considered
unusual. The PCMs maximum authority to control long
term fuel trim allows a range between -23 percent
and + 16 percent. Fuel trim values at or near maximum
authority may indicate an excessively rich or lean
system.
Engine
loop Status: Scan tool displays OPEN or CLOSED.
Closed loop indicates that the PCM is controlling
fuel delivery according to oxygen sensor voltage. In
Open Loop', the PCM ignores the oxygen sensor
voltage and bases the amount of fuel to be delivered
on TP sensor, engine coolant, and MAF sensor
inputs only.
MAF: Scan tool displays 0.0-512 g/s. Mass air
flow (MAF) is the MAF Input Frequency converted to
grams of air per second. This indicates the amount
of air entering the engine.
MAF Frequency: Scan tool displays O to 32000 Hz.
The mass air flow sensor input signal to the PCM
is a frequency which varies from around 3000 Hz at
idle to above 7000 Hz.at wide-open throttle. The PCM
converts this frequency signal to grams per .second to
be displayed 911 .the scan tool as MAF.
MAP: Scan tool displays
10-105 kPa/0.00 to 4.97 volts. The manifold absolute
pressure (MAP} ~ensor measures the. change in
.
the in.take manifold pressure from engine load, EGR
flow, and speed changes. As intake manifold pressure
increases, Jntake vacuum decreases resulting in a
higher MAP sensor voltage and kPa reading. The MAP
sensor signal is used to monitor intake manifold
pres9urechanges during the EGR flow test, to update
the BARO reading, and as an enabling factor for
many of the diagnostics.
MIL: Listed in Eng 2 Data list O Sc.an tool displays
ON or OFF. Indicates the PCM commanded state
of the malfunction indicator lamp.
MIL: Scan tool displays OK, Fault or Invalid state'.

These parameters describe the condition of the control
circuit..
Misfire Current Cyl 1~6: . Scan tool displays Oto

198 Counts. The Misfire Current counters indicate the
number of cylinder firing events detected as possible
misfires on each cylinder during the last
200 crankshaft revolutions. The number that the
counters display are twice the actual number of misfire
events detected. The counters may normally display
some activity, but the activity should be very low
and nearly equal for all the cylinders .
Misfire History Cyl 1-6: Scan tool displays
O to 65535 Counts. The Misfire History counters
indicate the total level of misfire thathas been detected
on each cylinder. The number that the counters
display are.twice the actuc;1I number of misfire events

detected. The Misfire History counters will not
update or show any activity until a misfire OTC (P0300)
has become active. The Misfire History counters will
be updated every time a 200 crankshaft revolution
misfire test failure is detected.
Misfiring Cylinder (Primary) I Misfiring Cylinder
(Secondary): Scan tool displays O or Cylinder#. If a
misfire is being detected, Misfiring Cylinder displays
the misfiring cylinder numbers.
Engine
\,
I
Power Enrichment: Scan tool displays ACTIVE or

INACTIVE. ACTIVE displayed indicates that the
PCM has detected conditions appropriate to operate in
Power Enrichment mode. The PCM will command
Power Enrichment mode when a large increase
in throttle position and load is detected. While in Power
Enrichment, the, PCM will increase the amount of
fuel delivered by entering Open Loop and increasing
the injector pulse width. This is done to prevent a
possible sag or hesitation from occurring during
acceleration.
Reduced Engine Power: Scan tool displays
ACTIVE or INACTIVE. The scan tool displays Active
when the PCM has diagnosed a ETC problem or
during drivetrain abuse protection. The PCM limits the
engine power.
Rich/Lean Bank 1 I Bank 2: Scan tool displays
RICH or LEAN. Indicates whether oxygen sensor
voltage is greater than a 600 mV threshold voltage
(rich) or less than a 300 mV threshold voltage (lean).
Should change constantly while in closed loop,
indicating that the PCM is controlling the air/fuel
mixture properly.
Short Term Fuel Trim Bank 1 I Bank 2: Scan tool

displays -11percent to 20 percent. Short Term
Fuel Trim represents a short-term correction to fuel
delivery by the PCM in response to the amount of time
the fuel control oxygen sensor voltage spends
above or below the 450 mV threshold. If the oxygen
sensor voltage has mainly remained less than 450 mV,
indicating a lean air/fuel mixture, short term fuel trim
will increase into the positive range above O percent
and the PCM will add fuel. If the oxygen sensor
voltage stays mainly above the threshold, short term
fuel trim will decrease below O percent into the
negative range while the PCM reduces fuel delivery to
compensate for the indicated rich condition. Under
certain conditions such as extended idle and high
ambient temperatures, canister purge may cause Short
Term Fuel Trim to read in the negative range during
normal operation. The PCMs maximum authority
to control fuel trim allows a range between - i 1 percent
and +20 percent. Fuel trim values at maximum
authority may indicate an excessively rich or lean
system.
6-837
Starter inhibit: Scan tool displays ACTIVE or

INACTIVE. Indicates if the PCM has received the
correct inputs for startup. If ACTIVE is displayed a fault
exists in the Theft Deterrent System.
Start-Up ECT: Scan tool displays -40C to 151 C,
-40F to 304F. Indicates the engine coolant
temperature at the time that the vehicle was started.
Used by the H02S diagnostic to determine if the
last startup was a cold start.
Start-Up IAT: Scan tool displays -40C to 151C,
-40F to 304F. Indicates the intake air temperature at
the time that the vehicle was started. Used by the
H02S diagnostic to determine if the last startup was a
cold start.
TAC Brake Switch: Scan tool displays APPLIED or
RELEASED. Indicates the brake pedal position.
When the brake pedal is depressed a signal voltage is
sent to the TAC module, that signal is then sent to
the PCM across serial data. If a fault occurs on
this circuit known as the Stoplamp Switch Circuit, a
P1574 will set.
TAC/PCM Communication: Scan tool displays OK
or FAULT. If the communication between the TAC
module and the PCM is interrupted the scan tool
displays FAULT. The scan tool displays OK under the
normal operating conditions.
TCC Enable Sol.: Scan tool displays OK, Fault or
Invalid state. These parameters describe the conditiori
of the control circuit.
TCC Sol.: Scan tool displays OK, Fault or Invalid
control circuit.
Total Misfire Current Count: Scan tool displays
Oto 99. Indicates the total number of cylinder
firing events that were, detected as being misfires
during the last 200 crankshaft revolution sample
period.
Total Misfire Failures Since First Fail: Scan tool
displays Oto 65535 Counts. Indicates the number
of 200 crankshaft revolution sample periods during
which the level of misfire was sufficiently high to report
a failure.
Total Misfire Passes Since First Fail: Scan tool
displays Oto 65535 Counts. Indicates the number
of 200 crankshaft revolution sample periods during
which the level of misfire was sufficiently low to report
a pass.
Spark: Scan tool displays -64 degrees to

64 degrees. Displays the spark timing being
commanded by the PCM on the IC circuit. A negative
(-) value indicates degrees Before Top Dead
Center (BTDC) or spark advance; a positive value
indicates degrees After Top Dead Center (ATDC) or
spark retard. Because the ignition control module sets
spark advance at a fixed value of 10 BTDC while
opera1ing in Bypass mode, the displayed Spark
advance only reflects true spark timing when the PCM
has commanded IC mode.
TP Desired Angle: Scan tool displays

0-100 percent. The PCM indicates the desired throttle
angle for conditions present at that time.
Starter Enable Relay: Scan tool displays OK, Fault

or Invalid state. These parameters describe the
TP Sensor 1 / 2: Scan tool displays 0-5 volts. The

scan tool displays the amount of throttle opening
in volts. Closed throttle displays approximately 1 volt
and wide open throttle displays approximately 4 volts.
TP Indicated Angle: Scan tool displays

0-100 percent. The TP Indicated angle displays in
percentage the amount of throttle opening.
6-838
Engine
TP Sensor 1 I 2 Angle: Scan tool displays

0-100 percent. The scan tool displays the amount of
throttle opening in percentage. Closed throttle
displays O percent and wide open throttle displays
near 100 percent.
TP Sensors Disagree: Scan tool displays YES or
NO. When the TAC module receives a signal
voltage from one of the throttle position sensors not in
proper relationship to the other, the scan tool
displays YES. The scan tool displays NO under
TP Sensor 1 Out of Range: Scan tool displays YES
or NO. If the TAC module detects that the voltage is
below.37 volts at closed throttle or above 4.7 volts
at wide open thrpttle, the scan tool displays YES. If the
voltages are within specifications, the scan tool
displays NO.
TP Sensor 2 Out of Range: Scan tool displays YES
or NO. If the TAC module detects that the voltage is
below.37 volts or at closed throttle or above 4.7 volts at
wide open throttle, the scan tool displays YES. If the
voltages are within specifications, the scan tool
displays NQ.
Traction Control: Scan tool displays ACTIVE or
INACTIVE. Active will be displayed if a message
is received from the EBTCM requesting torque
reduction.
Traction Control Desired Torque:
Scan tool range
O percent to 100 percent. Represents the PWM

signal from the electronic brake and traction control
module. The EBTCM reduces th.e Traction Control
Desired Torque signal pulse width when a drive wheel
slippage situation is detected. The PCM monitors
the Traction Control Desired Torque signal and
reduces drive wheel slippage as necessary by
retarding spark timing, or increasing air/fuel ratio. The
PCM can also turn OFF up to three fuel injectors if
the Traction Control Desired Torque signal indicates a
large enough amount of drive wheel slippage. A
problem with the Traction Control Desired Torque
signal should cause a OTC to set.
Traction Control Torque: Scan tool range
O percent to 100 percent. Represents the PWM signal
which indicates the percent of available torque the
engine is delivering to the drive wheels. The EBTCM
monitors the Traction Control Torque signal to
ensure that the PCM is responding properly to the
Traction Control Desired Torque signal.
Transmission Range: Scan tool displays INVALID,
PARK/NEUTRAL, REVERSE, DRIVE 4, DRIVE 3,
DRIVE 2, or LOW. Transmission Range represents the
decoded status of the four inputs from the Transaxle
Range Switch Assembly. The combination of transaxle
range inputs indicates the position of the transaxle
manual valve.
TR Switch A I BI C: Scan tool displays HIGH or.

LOW. The TR switch A I B I C display represents the
states of the four inputs from the transaxle range
switch. HIGH displayed indicates a B+ voltage signal
being monitored at the PCM, LOW displayed
indicates a grounded input signal. The combination of
transaxle range inputs indicates the position of the
transaxle manual valve.
TWC Protection: Scan tool displays ACTIVE or

INACTIVE. ACTIVE displayed indicates that the PCM
has detected conditions appropriate to operate in
TWC Protection mode. This is determined based on
engine load and engine coolant temperature. While in.
TWC Protection, the PCM will decrease Air/Fuel
Ratio to a value that depends on mass air flow (higher
Mass Airflow= lower Air/Fuel Ratio).
Vehicle Speed: Scan tool displays 0-255 km/h,
0-155 mph. The vehicle speed sensor signal is
converted into mph and km/h for display.
VTD Fuel Disable: Scan tool displaysACTIVE or
INACTIVE. The Theft Deterrent Fuel Enable circuit is
an input from the vehicle theft deterrent control
module that signals the PCM to enable the injectors if
the proper signal is.received. The scan tool will
normally display INACTIVE. If the vehicle theft,
deterrent control module does not sent the correct
Theft Deterrent Fuel Enable signal to the PCM,
the display will switch to ACTIVE and the fuel system
may be disabled. Refer to DTCsP1626,P1629,.or
Vehicle Theft Deterrent diagnosis for further
information.
Diagnostic Trouble Code (DTC) Type

Definitions
Diagnostic Trouble Codes (DTCs) ar,e categorizec\ into
emissions and non-emissions related types. V\Jhen
a OTC is set, the MIL and Failure data are utilizecl.by.
the control modules diagnostic executive accgrding
to the OTC type. Each OTC is set based upon
the individual DTCs running and setting criteria, It is
important to read the Action Taken When the .
OTC Sets and Conditions for Clearing the MIUDTC in
the supporting text for taking appropriate acJion to
each OTC.
Emissions Related DTCs

Type A
The following actions.occur at the time of the
first failure:
Turns on the MIL
Stbres OTC in memory
" Stores Freeze Frame/Failure records data
Updates the Failure Records after each ignition
cycles first failure
Some Type A DTCs will not perform the above actions
when the OTC first detects a failure. Two consecutive
failures are required. This allows systems, such as
EVAP, to accurately identify what failure exists before
setting a OTC and requesting MIL illumination.
Engine
Engine Controls - 3.8l 6-839
TypeB
The following actions occur at one of the
following times:
First failure:
- Does not turn on the MIL
- Stores the DTC in memory as Failed
Last Test
- Stores Failure Records data
O Second consecutive drive cycle with a failure:
- Turns on the MIL
- Stores the DTC in memory as a history DTC
- Stores Freeze Frame data
:-- .Updates Failure. Records data
" Second non-consecutive drive cycle with a failure:
- Stores the DTC in memory as Failed
Last Test
- Updates Failure Records data
Non-Emissions Related DTCs

Type C
The following actions occur at the time of a failure:
a Does not turn on the MIL
.. Stores the DTC in memory as a history OTC
" Stores Failure Records data
" Some Type C DTCs may also cause an auxiliary
service lamp to be illuminated, and/or display a
message to the vehicle operator.
Type X
No actions occur. These DTCs are coded into the
control modules software, but will not run because
one of the following reasons:
" Associated hardware is not installed with the
vehicles emission package
" The diagnostic is not required for the vehicles
emission package
Diagnostic Trouble Code (DTC) list/Type

Description
Domestic
RPO L36
Export
Unleaded Fuel
European .
Export
Unleaded Fuel
OTC P0101 Mass Air Flow (MAF) Sensor Performance
OTCP0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
OTC PO 103 Mass Air Flow (MAF) Sensor Circuit High Frequency
OTCP0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low

Voltage
OTCP0108 Manifold Absolute Pressure (MAP) Sensor Circuit High

Voltage
OTC POt 12 Intake Air Temperature (/AT) Sensor Circuit Low Voltage
OTCPOt 13 Intake Air Temperature (!AT) Sensor Circuit High Voltage
OTC POt 17 Engine Coolant Temperature (ECT) Sensor Circuit Low

Voltage
OTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High

Voltage
OTCP0125 Engine Coolant Temperature (ECT) Excessive Time to

Closed Loop Fuel Control
OTCP0131 H02S Circuit Low Voltage Bank 1 Sensor 1
OTCP0132 H02S Circuit High Voltage Bank 1 Sensor 1
OTCP0133 H02S Slow Response Bank 1 Sensor 1
OTCP0134 H02S Circuit Insufficient Activity Bank 1 Sensor 1
OTCP0135 H02S Heater Performance Bank 1 Sensor 1
OTCP0153 H02S Slow Response Bank 2 Sensor 1
OTCP0171 Fuel Trim System Lean Bank 1
'
6-840
Engine
Diagnostic Trouble Code (DTC) List/Type (cont'd)

I
European
Export
Unleaded Fuel
Domestic
RPO L36
Export
Unleaded Fuel
DTC P0172 Fuel Trim System Rich Bank 1
DTC P0174 Fuel Trim System Lean Bank 2
DTC P0201 Injector 1 Control Circuit
Description
B
B
DTC P0230 Fuel Pump Relay Control Circuit
.c
DTC P0300 Engine Misfire Detected
DTC P0327 Knock Sensor (KS) Circuit Bank 1
DTC P0336 Crankshaft Position (CKP) Sensor Circuit
DTC P0341 Camshaft Position (CMP) Sensor Performance
DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient
DTC P0403 Exhaust Gas Recirculation (EGR) Solenoid Control Circuit
DTC P0404 Exhaust Gas Recirculation (EGR) Open Position

Performance
DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit

Low Voltage
DTC P0420 Catalyst System Low Efficiency
DTC P0440 Evaporative Emission (EVAP) System
DTC P0442 Evaporative Emission(EVAP) System Small Leak Detected
DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Control

Circuit
DTC P0446 Evaporative Emission (EVAP) Vent System Performance
DTC P0449 Evaporative Emission (EVAP) Vent Solenoid Control Circuit
DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage
DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage
DTC P0462 Fuel Level Sensor Circuit Low Voltage
c
c
c
c
c
c
DTC P0463 Fuel Level Sensor Circuit High Voltage

DTC P0480 Cooling Fan Relay 1 Control Circuit
DTC P0481 Cooling Fan Relay 2 and 3 Control Circuit
DTC P0500 Vehicle Speed Sensor (VSS) Circuit

DTC P0502 Vehicle Speed Sensor (VSS) Circuit Low Input (3.BL)
'.
DTC P0503 Vehicle Speed Sensor (VSS) Circuit Intermittent (3.BL)
DTC P0506 Idle Speed Low
DTC P0507 Idle Speed High
DTC P0530 Air Conditioning (AIC) Refrigerant Pressure Sensor Circuit
DTC P0571 Cruise Control Brake Switch Circuit
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
DTC P0601Control Module Read Only Memory (ROM)
DTC P0602 Control Module Not Programmed
DTC P0560 System Voltage

DTC P0567 Cruise Control Resume Switch Circuit
DTC P0568 Cruise Control Set Switch Circuit
Engine
Engine Controls - 3.Sl 6-841

Diagnostic Trouble Code (DTC) Listrrype (cont'd)
Description
OTC P0604 Control Module Random Access Memory (RAM)
European
Export
Unleaded Fuel
A
OTC P0620 Generator Performance
OTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit
OTC P0704 Clutch Switch Circuit
c
c
c
c
c
c
c
c
c
OTC P0724 Brake Switch Circuit High Input (3.BL)
c
c
c
c
c
c
c
c
c
OTCP0740 TCC Enable Solenoid Circuit Electrical (3.BL)
OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low

Input (3.BL)
OTCP0713 TransmissionFluidTemperature (TFT) Sensor Circuit High
Input (3.BL)
OTCP0719 Brake Switch Circuit Low Input (3.BL)
rec System Stuck On (3.BL)
OTCP0748 Pressure Control Solenoid Circuit Electrical (3.BL)
OTC P0751 1-2 Shift Solenoid Valve Performance - No First or

Fourth Gear (3.BL)
OTCP0752 1-2 Shift Solenoid Valve Performance - No Second or

Third Gear (3.BL)
OTC P0753 1-2 Shift Solenoid Circuit Electrical (3.BL)
OTC P0756 2-3 Shift Solenoid Valve Performance - No First or

Second Gear (3.BL)
OTC P0757 2-3 Shift Solenoid Valve Performance - No Third or

Fourth Gear (3.BL)
OTC Pt 106 Manifold Absolute Pressure (MAP) Sensor Circuit

Intermittent High Voltage
OTC Pt 107 Manifold Absolute Pressure (MAP) Sensor Circuit

Intermittent Low Voltage
OTC Pt 111 Intake Air Temperature (/AT) Sensor Circuit Intermittent

High Voltage
OTC Pt 112 Intake Air Temperature (IA T) Sensor Circuit Intermittent

Low Voltage
OTC Pt 114 Engine Coolant Temperature (ECT) Sensor Circuit


OTC Pt 120 Throttle Position (TP) Sensor 1 Circuit
OTC Pt 125 Accelerator Pedal Position (APP) System
OTC Pt 133 H02S Insufficient Switching Bank 1 Sensor 1
OTCP0742
Export
Unleaded Fuel
OTC P0606 Control Module Internal Performance
OTC P0711 TFT Sensor Circuit Range/Performance (3.BL)
Domestic
RPO L36
OTC Pt 134 H02S Transition Time Ratio Bank 1 Sensor 1
OTC P1220 Throttle Position (TP) Sensor 2 Circuit
OTC P1221 Throttle Position (TP) Sensor 1- 2 Correlation
OTC P1271 Accelerator Pedal Position (APP) Sensor 1-2 Correlation
c
c
c
c
c
c
c
c
c
c
c
c
OTC Pt 272 Accelerator Pedal Position (APP) Sensor 2-3 Correlation

OTC P1275 Accelerator Pedal Position (APP) Sensor 1 Circuit
6-842
Engine
Engine Controls - 3.81:.

Diagnostic Trouble Code (DTC) list/Type (cont'd)
Domestic
RPO L36
Export
Unleaded Fuel
European
Export
Unleaded Fuel
OTC P1286 Accelerator Pedal Position (APP) Sensor3 Performance
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
OTC P1336 Crankshaft Position (CKP) System Variation Not Learned
A.
OTC P1351 Ignition Coil Control Circuit High Voltage
Description
OTC P1276 Accelerator Pedal Position (APP) Sensor 1 Performance
OTC P1281 Accelerator Pedal Position (APP) Sensor 2 Performance
OTC P1352 Ignition Bypass Circuit High Voltage
OTC P1361 Ignition Control (IC) Circuit Low Voltage
OTC P1362 Ignition Bypass Circuit Low Voltage
OTC P1374 Crankshaft Position (CKP) High to Low Resolution

Frequency Correlation
.B
c
c
x
x
x
x
OTC P1404 Exhaust Gas Recirculation (EGR) Closed Position

Performance
OTC P1441 Evaporative Emission (EVAP) System Flow During

Non-Purge
OTC P1514 Throttle Body Performance
A
A
OTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator

Position Performance
OTC P1517 Throttle Actuator Control (TAC) Module Performance
OTC P1518 Throttle Actuator Control (TAC) Module Serial Data Circuit
OTC P1519 Throttle Actuator Control (TAC) Module Internal Circuit
c
c
c
c
c
c
c
c
OTC P1380 Misfire Detected - Rough Road Data Not Available

OTC P1381 Misfire Detected - No Communication with Brake Control
Module
OTC P1515 Control Module Throttle Actuator Position Performance
OTC P1523 Throttle Closed Position Performance

OTC P1546 Air Conditioning (A/C) Clutch Relay Cohtro/ Circuit
OTC P1571 Traction Control Torque Request Circuit
OTC P1574 Stop/amp Switch Circuit
OTC P1586 Cruise Control Brake Switch 2 Circuit
OTC P1626 Theft Deterrent Fuel Enable Signal Lost
OTC P1629 Theft Deterrent Fuel Enable Signal Not Received
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
c
OTC P1635 5 Volt Reference 1 Circuit
OTC P1639 5 Volt Reference 2 Circuit
OTC P1689 Traction Control Delivered Torque Output Circuit
OTC P1810 TFP Valve Position Switch Circuit (3.BL)
OTC P1860 TCC PWM Solenoid Circuit Electrical (3.BL)
OTC P1870 Transmission Component Slipping (3.BL)
Engine
6-843
Malfunction Indicator Lamp (MIL) Inoperative

Diagnostic Aids
Circuit Description

If the engine runs OK, test for a malfunctioning
MIL, an open in the MIL control circuit, or an
open in the instrument cluster ignition feed.
If the engine cranks but will not run, test for an
open PCM ignition or battery feed or a poor
PCM to engine ground.
There should be a steady MIL with the ignition ON

and the engine not running. Ignition feed voltage
is supplied directly to the MIL. The powertrain control
module (PCM) turns the MIL ON by grounding the
MIL control circuit. No MIL with the key ON, engine not
running and the MIL DTC set suggests an open in
the MIL control circuit.
MIL Operation
The malfunction indicator lamp (MIL) is located on the
instrument panel (CHECK ENGINE) or (SERVICE
ENGINE SOON). The MIL performs the following
functions:
It informs the driver that a problem has occurred
and that the vehicle should be taken for service
as soon as possible.
As a system check, the MIL will illuminate with the
ignition switch ON and the engine not running.
when the engine is started, the MIL will turn OFF.
If the MIL remains ON, the self-diagnostic
system has detected a problem. If the problem
goes away, the MIL will turn OFF in most cases,
but a diagnostic trouble code will remain stored.
If the MIL is illuminated, then the engine stalls, the
MIL wm remain IUuminated so long as the ignition
switch is ON.
Now, if the MIL is not illuminated and the engine
stalls, the MIL will not illuminate until the ignition
switch is cycled OFF, then ON.
Perform the Powertrain On-Board Diagnostic System
Check first, when.the following conditions are
present:
When the MIL does nofturn ON when the ignition
switch is turned to the RUN position.
When the MIL remains ON while the engine is
running.
When you suspect a driveability problem.

component. Ensure that the gaskets are installed
correctly; The gaskets prevent contaminate intrusion.
Systems.
Damaged harness.
on the scan tool while moving connectors
change in the display may indicate the location of
Systems.
Inspect the PCM and the engine grounds for
. clean and secure connections.
If the DTC is determined to be intermittent, reviewing
when the DTC was last set.
Test Description
The numbers below refer to the step numbers on the
diagnostic table:
2. If the MIL OTC is set, the MIL Control Circuit table
will better diagnose the condition.
6. Using a test lamp connected to B+, probe each of
the PCM ground terminals to ensure that a good
ground is present.
6-844
Engine

Malfunction Indicator Lamp (MIL) Inoperative
Step
Yes
Values
Action
Did you perform the Powertrain On-Board
Diagnostic (OBD) System Check?
Go to Stf)p 2
Does the scan tool indicate the MIL DTC set?
Inspect the PCM feed fuses.

Are the fuses OK?

2. Disconnect the PCM.
3. Turn ON the ignition.
4. Probe the PCM ignition feed circuit using a test lamp
that is connected to a good ground.
Probe the PCM battery feed circuit using a test lamp that
is connected to a good ground.
Test for faulty PCM grounds or poor PCM ground

connections. Refer to Testing for Intermittent and Poor
Important: The replacement PCM must be programmed.

Replace the PCM.
Refer to PCM Replacement/Programming.
Repair open in PCM battery feed circuit or the PCM

ignition feed circuit. Refer to Wiring Repairs .in Wiring
Systems.
Repair short to ground in PCM ignition feed circuit or the

PCM battery feed circuit. Refer to Wiring Repairs in Wiring
systems.
No
Go to A
Povvertrain On
Board.
Diagnostic (OBD)
.. System Check
Go to
DTCP0650
Malfunction
Indicator
Lamp (MIL)
Control Circuit
Go to Step 3.
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step B
Go to Step 6
.Go to Step B
..
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to A
Powertrain On
Board
.Diagnostic (OBD)
System Check
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
-.--.
Go to Step 7
..
(
.
..
..
Engine
Engine Controls - 3.SL 6..;845
Data link Connector Diagnosis

CircuiJ Description
The Class 2 serial data circuit to the DLC allows
bi-.directional communication between the PCM and
the .scan tool. If communication between the scan tool
and the PCM cannot be established, the procedure
in the DLC Diagnosis table should be used to diagnose
the condition.
Diagnostic Aids
lnsp~ct for, the following: .
For the PCM to establish communication with the
scan tool; system voltage must be between
9.0 and 16.0 volts. If system voltage is not within
this range, refer to Symptoms - Engine Electrical
Ensure that the correct application (model year,
carline, VIN code) has been selected on the
span tool. If communication still cannot be
established try tfie scan tool on another vehicle to
ensure that the scan tool or cables are not the
cause of the condition.
component Ensure that the gaskets are installed
correctly. The ga~kets prevent contaminate intrusion.
improperly formed.or damaged terminals, and
Connections .and Connector Repairs in Wiring
Systems.
Damaged. harness.
Systems.
Test Description
The number below refers to the step number on the
diagnostic table:
4. The serial data circuit voltage will constantly vary

and should measure between 0.5 and 3.0 volts.
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is replaced,
the new PCM must be programmed.
6-:846
Step
Action
Engine
Data Link Connector Diagnosis
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 9
Go to Step 10
Go to Step 5
Goto Step 7

2. Connect a test lamp to the battery feed circuit of the

Data Link Connector.
3. Using the .test lamp, probe each of the DLC ground
circuits.
Does the test lamp illuminate while probing both circuits?
Connect a test lamp between the battery feed circuit of the

Data Link Connector and a good ground.
1. Turn ON the ignition,'with the engine OFF.

2. Connect a DMM between the Class II serial data
circuit of the DLC and a good ground.
4.5V
Does the voltage measure less than the specified value?

5

4. Connect a DMM between the Class II serial data
circuit of the DLC and battery positive voltage.
Does the voltage measure at or near the specified value?
o.ov
Go to Step 6
Repair the open in the Class II serial data circuit. Refer to

Wiring Repairs in Wiring Systems.
Repair the short to voltage in the Class II serial data

circuit. Refer to Wiring Repairs in Wiring Systems.
10
Repair open or short to ground in the DLC battery feed

circuit. Replace the fuse, if necessary. Refer to Wiring
11
Go to Step 11
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

Replace the PCM.
Goto A
Powertrain On
Board
Diagnostic (080)
System Check.
Repair the open in the DLC ground circuits. Refer to

Go to Step 11
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Repair the short to ground in the Class II serial data

Go to Step 8
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Engine
6-847
Engine Cranks but Does Not Run

Camshaft
Position (CMP).
Sensor
Crankshaft
!Hot In Ri.m,.Bulb Test And Start!
Position (CKP)
., Engine
Sensor ..e Power ~ -
I Distributi~n G9
Schematics
I in Wiring
GB
I Systems
1
__
PNK 239
RED/ 645
BLK
RED/ 645
BLK
WHT/ 644
BLK
BRN/WHT 633
J
M
N
CrvlP/CKP
_____
LT BLU/ 1800
WHT
Sensor Ignition
Positive Voltage
PNK 239
p
CKP18x
Signal
CrvlP/CKP
Sensor
Ground
Power
Distribution
Schematics
In Wiring
Systems
PNK 239
YEL 573
G
LJil
L--------J
PNK 239
WHT/ 644
RED/ 645
BLK
BLK
WHT/ 644 ____,
BLK
Crv1P1
Sensor
. Signal
ENG CTRL I'w

,nng
M' 'F
Harness
m, use
I
.
15 A
I Junction
1 Block 2
_]
~
4
Ignition
Control (ICM)
Module
Ignition
Positive
Voltage
CKP
Sync
Signal
5V
Camshaft 12V
Position
'18x
Sensor
Reference
"---- Signal
Signal
F
BLK 630
Powertrain
Control
~ Module
~ (PCM)
I .
I
I _
3x
Reference
Signal
D
Bypass
Control
Ignition
Control (IC) Ref Low
PPL/ 430
WHT
LT
BLU/ 647
BLK
Ground
L
RED/ 453
BLK
K
BLK 450
Ground
Distribution
Schematics
In Wiring
Systems
WHT 423
TAN/BLK 424
8
53
54
C-;m;ha-; IBx- - - - 3x - - - Bypas7 - l[1it;;;n - Position Reference

Reference Control Control (IC)
s~nsor Signal
Signal
Signal
48
C1
~1 Low-
- - - - CONN ID
C1=BLU
C2=CLEAR
L-----------------------. ---
,
I
I
I
11- "."
v
BLK 450
L. - - -
'
--J
548502
Circuit Description
The Electronic Ignition system uses a waste spark

method of spark distribution. In this type of ignition
system, the ignition control module triggers the correct
coil based on the sync signal received from the
crankshaft position sensor, resulting in both spark
plugs connected to the coil firing at the same time. The
spark plug for the cylinder on the exhaust stroke
requires a lower energy requirement to fire, leaving
the remaining high voltage to fire the spark plug for the
cylinder on the compression stroke.
During crank, the ignition control module monitors the
CKP sync signal. The CKP sync signal is used to
determine the correct cylinder pair to fire first. The CKP
sync signal is used only by the ignition control
module to initiate ignition coil firing sequence. It is not
passed to the PCM. After the ignition control module
processes the CKP sync signal, the ignition control

module monitors the 18X CKP signal and sends
18X and 3X reference pulses to the PCM. When the
PCM receives these pulses, the PCM will command all
six injectors to allow a priming shot of fuel for all the
cylinders. After the priming, the injectors are left
OFF during the next six 3X reference pulses from the
ignition control module. This allows each cylinder a
chance to use the fuel from the priming shot. During
this waiting period, the PCM receives a camshaft
position signal pulse. The camshaft position signal
allows the PCM to operate the injectors sequentially
based on camshaft position. If the camshaft position
signal is not present at start-up, the PCM will
begin fuel delivery with a 1 in 6 chance that fuel
delivery is correct.
6-848
Engine
Diagnostic Aids
Test Description

Malfunctioning engine coolant temperature sensor.
Using a scan tool, compare engine coolant
temperature with intake air temperature on a
completely cool engine. engine coolant
temperature should be within 10c of intake air
temperature. If not, replace the ECT sensor.
Throttle position sensor.
If the TP angle is more than 80 percent, the PCM
may operate in clear flood mode. The PCM will
not allow fuel delivery while operating in clear
flood mode.

diagnostic table:

correctly. The gaskets prevent contaminate intrusion.
Systems.
Damaged harness.
Systems.
5. Determines if the ignition control module (ICM) is

receiving the 18X CKP Reference signal. If the
18X CKP signal to the ICM is not present,
there will be no RPM, spark, or fuel injector
pulses.
6. Ensures that the ICM has the proper voltage
supply and ground.
8. Verifies that the ICM is supplying the proper
sensor feed voltage.
24. Test for the proper operation of the CKP Sync
signal, ICM and related spark system components.
Without the CKP Sync signal the ICM is unable
to properly sequence the ignition coils.
35. If the 18X and CKP Sync signals to the ICM or
the 18X and 3X reference signals to the ICM
short together the vehicle will not start and run.
However, there will be spark and fuel injector
pulses.
Engine
Engine Controls - 3.Sl
6-849
Engine Cranks .but D.oes Not Run

Step
Action
Values

No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 5
Go to Step 4
Go to Fuel
System
Pressure Test
Go to Fuel Pump
Electrical Circuit
Diagnosis
Go to Step 17
Go to Step .6
Go to Step 8
Go to Step 7
Go to Step 39
Go to Step 40
Go to Step 9
Go to Step 11
Yes
Important: Before proceeding with this table, ensure that

the vehicle battery is fully charged.
Important: If the engine cranks and does not run and
multiple DTCs are present, test the ignition relay feed
circuits to and from the ignition relay. Refer to Power
Distribution Schematics and Circuit Testing in Wiring
Systems.
Important: If any DTCs are stored as failed since code
clear (except P1374, P0336, or P0341), diagnose the
DTCs before continuing with this table.
1. Inspect the fuses which supply ignition positive
voltage to the following components:
Electronic ignition control module.
Fuel injectors.
2. If either fuse is open, repair the short to ground in the
affected ignition positive voltage circuit. Refer to
2. Install a J 34730-1A fuel pressure gauge.

3
333-376 kPa
(48-55 psi)

4. Observe the fuel pressure gauge.
Does the fuel pressure measure within the specified
values and holding?
Is any fuel pressure indicated?
4
2. Remove the fuel pressure gauge.

5

4. With a scan tool, observe the engine RPM while
cranking the engine.
Does the scan tool indicate an engine RPM?
2. Disconnect the ignition control module (ICM).

6

4. Connect a test lamp between the ignition positive
feed and ground circuits in the ICM connector.
1. Leave the ICM disconnected.
2. Probe the ignition positive feed circuit at the ICM
connector using a test lamp that is connected to a
good ground.
2. Reconnect the ICM.

8
3. Disconnect the 18X crankshaft position (CKP) sensor.

5. Measure the voltage between the sensor feed arid
sensor ground circuits in the 18X sensor connector
using a DMM.
Does the voltage measure near the specified value?
B+
s.:aso
Step
Action
Engine
Engine Cranks but Does Not Run (cont'd)
Measure the voltage between the sensor signal and

sensor ground circuits in the 18X sensor connector using
a DMM.
Does the voltage measure within the specified values?
Values
Yes
No
(
6V-9V
Go to Step 10
Go to Step 14
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 41
Go .to Step 12
Go to Step 13
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 38
13
Test the 18X sensor feed circuit for an open or a short to

ground. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 41
14
1. Leave the DMM connected.

3. Disconnect the ICM.
Does the DMM indicate any voltage?
Go to Step 15
Go to Step 16
10
11
12
15
16
17
18
19
20
Inspect for poor connections at the 18X sensor. Refer to

Measure the voltage on the sensor feed circuit at the

18X sensor connector using a DMM that is connected to a
good ground.
B+
Test the 18X sensor ground circuit for an open. Refer to

Circuit Testing and Wiring Repairs in Wiring Systems.
Repair the short to voltage on the 18X sensor signal

Test the 18X signal circuit for an open or a short to
Wiring Systems.
1.
2.
3.
4.
Turn OFF the ignition.

Disconnect all fuel injectors.
Turn ON the ignition.
Observe the J 34730-2C fuel injector test lamp when
installed in each injector connector.
Did the injector test lamp illuminate for any of the
injectors?
1.
2.
3.
4.
5.
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 38
Go to Step 18
Go to Step 19
Go to Step 43
Go to Step 46
Go to Step 24
Go to Step 20
Go to Step 21
Go to Step 22
.
-
Leave the fuel injectors disconnected.

Disconnect the PCM.
Observe the injector test lamp when installed in the
each injector connector.
Did the injector test lamp illuminated for any of the
injectors?
1. Leave the fuel injectors disconnected.

2. Leave the injector test lamp installed in a injector
connector.
3. Observe the injector test lamp while cranking the
engine (repeat for each injector).
Did the injector test lamp blink for each injector?
Did the injector test lamp blink for any of the injectors?
Engine
6-851

Values
Yes
No
Test for an open in the fuel injector control circuits

associated with the injector test lamp that did not blink.
Systems.
Did you find and correct.the condition?
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 44
1. Leave the fuel injectors .disconnected.

3. Probe the ignition positive feed circuit at each injector
connector using a Test Lamp that is connected to a
good ground.
Does the test lamp i_lh.Jminate?
Go to Step 24
Go to Step 23
Step
Action
21
22
Repair the open ignition positive feed circuit to the fuel

injectors. Refer to Wiring Repairs in Wiring Systems.
23
24
'
25
26
27
28

2. Disconnect a spark plug wire from the spark plug.
3. Install J 26792 spark tester in the end of the spark
plug wire.
4. Jumper the companion cylinder ignition wire to engine
ground. The companion,cylinder is the cylinderthat
shares the same ignition coil (i.e. 1/4, 2/5, 3/6).
..
5. Crank the engine while observing the spark tester.
Spark should be observed.
6. Repeat the above test for each ignition wire, noting
any cylinders that do not have spark.
Did you observe spark at all cylinders?
Did you observe spark at any cylinder?
1.
2.
3.
4.

Disconnect the 18X sensor.
Measure-the voltage on the CKP Sync signal circuit
using a DMM that is connected to a good ground.
Inspect for poor connections at the 18X sensor. Refer to
Did you find and correcfthe condition?
Testthe CKP Sync signal circuit for a short to voltage or a
short to the 18X sensor feed circuit. Refer to Circuit
GOtoA
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 34
Go to Step25
Go to Step 30
Go to Step 26
Go.to Step27
Go to Step 28
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 41
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 29
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 38
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 31
6V-9V
29
Test the CKP Sync signal circuit for an open or a short to

Wiring Systems.
30
1. Remove a_nd visually/physically inspect the ignition

coils and the ignition wires associated with the
cylinders that did not have spark.
2. Ensure that the ignition wires, boots, coils, and coil
towers are free of cracks and carbon tracking.
If a problem is found, replace the damaged ignition
components. Refer to Ignition Coil(s) Replacement.
6-852
Engine

Step
31
Action
Measure the ignition coil secondary resistance using
aDMM.
If any resistance is outside the specified values; replace
the malfunctioning ignition coils as necessary. Refer to
Ignition Coil(s) Replacement.
32
Measure the resistance of the ignition wires associated

with the cylinders that did not have spark using a DMM.
Replace the ignition wires that measure more than the
specified value. Refer to Spark Plug Wire Harness
Replacement (3.8 L Right Bank).
33
1. Connect a test lamp across the ignition module

primary circuit (between the electronic ignition control
module terminals) for the coils associated with the
cylinders which did not have spark.
2. Observe the test lamp while cranking the engine.
Does the test lamp blink continuously while the engine is
cranking?
34
1. Remove the spark plugs from all of the cylinders.

Refer to Spark Plug Replacement in Engine
Electrical.
2. Visually/physically inspect the spark plug electrodes.
Did the spark plug inspection reveal excessive fouling?
Values
Yes
5K-8K ohms
(5000 8000 ohms)
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 32
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 33
Go to Step 45
Go to Step 42
Go to Base
Engine Misfire
Diagnosis in
Engine
Mechanical
Go to Step 35
3280-4921
ohms/meter
(10001500 ohms/ft)
1. Test for the following conditions:

A short between the 18X CKP and CKP Sync
signal inputs to the ICM
O A short between the 18X and 3X reference signal
inputs to the PCM
Skewed ECT sensor
Skewed or unresponsive MAP sensor
Faulty MAF sensor
Faulty IAC valve
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs in Wiring Systems
36
1. Test the fuel for contamination. Refer to

Alcohol/Contaminants-in-Fuel Diagnosis.
2. If a problem is found, clean the fuel system and
correct the contaminated fuel conditions as
necessary.
37
Repair the engine mechanical problem. Refer to Base

Engine Misfire Diagnosis in Engine Mechanical to
diagnose the following conditions:
Bent push rods
Malfunctioning or incorrect camshaft
Leaking or sticky valves or rings
0
Excessive valve deposits
Loose or worn rocker arms
Weak valve springs
Incorrect valve timing
Leaking head gasket
35
38
Inspect for poor connections at the ICM. Refer to Testing

for Intermittent and Poor Connections and Connector
No
(
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 36
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Goto Step 37
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 42
Engine
Engine .Controls - 3.8L 6-853

Step
Action
39
Repair the open in the ICM ground circuit. Refer to Wiring

40
Repair the open in the ignition positive feed circuit to the

ICM: Refer to Wiring Repairs in Wiring Systems.
41
Replace the 18X CKP sensor. Refer to Crankshaft

Position (CKP) Sensor Replacement.
42
Replace the ICM. Refer to Ignition Control Module

Replacement.
43
Repair the short to ground in the fuel injector control

circuits associated with the injector test lamps that stayed
illuminated. Refer to Wiring Repairs in Wiring Systems.
44
Inspect for poor connections at the PCM. Refer to Testing

45
Replace the ignition coils associated with the cylinders that

did not have spark. Refer to Ignition Coil(s) Replacement.
Values
Yes
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Pbwertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Powertrain On
Bbard
Diagnostic (080)
System Check

46
Replace the PCM.

No
Go to Step 46
,,
6-854
Engine Controls - 3.81..
Engine
Fuel Pump Electrical Circuit Diagnosis

!Hot At All Times
;.;w;r - - - - - - - .,I Engine Wiring
Distribution
I Schematics
I in Wiring
I Systems
FUEL PUMP Harness

rvliniFuse I Block 1
20 A
I
H9
HS
Junction
uJ
----.1
L.-----
ORN 1340
BLK/WHT 451
Throttle
GRY~
GRY 120
,.Theft- - ., Body
'--~~-~--~-~-_,
- - - ., Fuel
Fuel
Pump
Motor
I Pump
I
I Motor
I
DK
: Deterrent :
Fuel Enable
BLK 1050
BLK
1450
Control
Module
~ s~n':!_ _ ~ (BCM)
DKBLU 229
GRN/WHT 465
Ground
Distribution
Schematics
In Wiring
Systems
BLK/WHT
451
BS
GRY 120
Actuator
Control
Module
DK BLUI229
3 C2
70 C1
Powertrain ,. - - - - - - - - - - - - - .,
Control I .
~~~p CONN ID 1:~:1ble I
~ Module I \
Control
control 1
1
~ (PCM) I -L
I 12v
sv
I
L-------....;.-----.1
--1
BLK/WHT 451
BLK/WHT 451
Ground
Distribution
Schematics
In Wiring
Systems
BLK 451
g:it~AR
(
548508
Circuit Description
When the ignition switch is first turned on, the PCM
energizes the fuel pump relay which applies power to
the in-tank fuel pump. The fuel pump relay will
remain on as long as the engine is running or cranking
and the PCM is receiving reference pulses. If no
reference pulses are present, the PCM de-energizes
the fuel pump relay within 2 seconds after the
ignition is turned on or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and
injectors, then to the fuel pressure regulator. The fuel
pressure regulator controls fuel pressure by allowing
excess fuel to be returned to the fuel tank.
Diagnostic Aids

Systems.
Oamagedtiamess.
Systems.
Test Description
diagnostic table:
2. Tests the ignition feed circuit to the fuel
pump relay.
3. Verifies that the fuel pump feed circuit is OK
between the fuel pump relay and the fuel pump,
and that the fuel pump can deliver adequate
pressure to the fuel rail.
Engine
6-855
4. Tests the fuel pump feed circuit for a short to

battery positive voltage.
8. Tests whether the problem is caused by an open

in the fuel pump feed circuit or the fuel pump
ground circuit.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 7
Go to Step 4
Go to Step 8
Go to Step 5
Go to Step 6
Did you Perform the Powertrain On-Board

.2
1. Disconnect the fuel pump relay.

2. Replace the fuel pump fuse, if necessary.
3. Connect a test lamp between the relay switch feed
circuit at the fuel pump relay connector and a good
ground.
2. Connect a 10 amp fused jumper wire between the
fuel pump feed circuit and the relay switch feed circuit
at the fuel pump relay connector.
Caution: Wrap a shop towel around the fuel pressure
connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel/eakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
3. Install a J 34730-1A fuel pressure gauge.
4. Turn ON the ignition, with the engine OFF'.
Does the pressure measure within the specified range?
338-380 kPa
(49-55 psi)
1. Disconnect the jumper wire.

2. Connect a test lamp between the fuel pump feed
circuit and a good ground.
Test the fuel pump feed circuit for a short to voltage. Refer
to Circuit Testing and Wiring Repairs in Wiring Systems.
Go to Step 14
.
Inspect for a poor connection at the fuel pump relay. Refer

to Testing for Intermittent and Poor Connections and
Repair the open or short to ground in the fuel pump relay

switch feed circuit. Refer to Wiring Repairs in Wiring
Systems.
1. Leave the fused jumper wire connected.

2. Disconnect the fuel pump.
3. Connect a test lamp between the fuel pump feed
circuit at the fuel sender harness connector and a
good ground.
Go to Step 14
Go to Step 11
Go to Step 14
Go to Step 10
Go to Step 9
6-856
Engine
Fuel Pump Electrical Circuit Diagnosis (cont'd)

Step
Action
1. Repair the open or short to ground in the fuel pump

feed circuit. Refer to Wiring Repairs in Wiring
Systems.
Values
11
Repair the open in the fuel pump ground circuit. Refer to

12
13
Replace the fuel pump. Refer to Fuel Sender Assembly

Replacement.
Fuel Metering System

Some failures of this system will result in an Engine
Cranks But Will Not Run symptom. If this condition
exists, Refer to Engine Cranks but Does Not Run. This
will determine if the problem is caused by the ignition
system, the PCM, or the fuel pump electrical circuit.
Refer to Fuel Pump Electrical Circuit Diagnosis for the
fuel system wiring schematic.
If there is a fuel delivery problem, Refer to Fuel
System Pressure Test. This diagnoses the fuel
injectors, the fuel pressure regulator, and the fuel
pump. If a malfunction occurs in the fuel metering
system, it usually results in either a rich H02S signal
or lean H02S signal. This condition is indicated by
the H02S voltage, causing the PCM to change the fuel
calculation (fuel injector pulse width) based on the
H02S reading. Changes made to the fuel calculation
will be indicated by a change in the long term fuel
trim values which can be monitored with a scan tool.
Go to Step 14
Go to Step 12
-
Go to Step 14
Repair the fuel pump harness for an external open or short

between the fuel pump connector and the fuel tank. Refer
to Wiring Repairs in Wiring Systems.
Fuel System Diagnosis
Go to Step 12
14
Go to Step 14
Replace the fuel pump relay. Refer to Fuel Pump Relay

Replacement.

Does the fuel pressure measure within the
specified range?
No
2. Replace the fuse if necessary.

10
Yes
Goto Step 14
Go to Step 13
-
Go to Step 14
338-380 kPa
(49-55 psi)
System OK
Go to Step 2
Ideal long term fuel trim values are around O percent;

for a lean H02S signal, the PCM will add fuel,
resulting in a fuel trim value above O percent and for a
rich H02S signal the PCM will take away fuel,
resulting in a fuel trim value below O percent. Some
variations in fuel trim values are normal due to
powertrain design. If the fuel trim values are
excessively greater or lower then O percent Refer to
OTC P0171 Fuel Trim System Lean Bank 1 or
OTC P0172 Fuel Trim SystemRich Bank 1.
(
\

The MAF sensor is mounted to the front of the throttle
body, and is used to measure the amount of air
entering the engine. The PCM uses this information to
determine the operating condition of the engine and
to control fuel delivery. For further information, refer to
Information Sensors/Switches Description.
Fuel System Pressure Test

A fuel system pressure test is part of several of the
diagnostic charts and.symptom checks. To perform this
test, referto Fuel SystemPressure Test.
Engine
6-857
DTC P0101 Mass Air Flow (MAF) Sensor Performance
!Hot In Run. Bulb Test And Start
~ - Po;er- - - - - - - - I
Distribution
Sch~'!'atics
1nWmng
Systems
J7
I
~Engine Wiring
Harness
I
Junction Block 2
ENG SEN
MiniFuse
20 A
L-------------..1
PNK 539
~----
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
YEL 492
PNK 539
Ignition
Positive
Voltage
MAF
Sensor
Signal
Mass Airflow
(MAF) Sensor
Ground
Ground
Distribution
Schematics
B
BLK!WHT 451
It>-----
In '11\nring
Systems
BLK 451
69 C1
'" - - - -;,,; - - - - - - - ., Powertrain
I
Sensor
CONN ID
I Control
I
Signal
C1=BLU
I. Module
C2=CLEAR
I (PCM)/.
L------------~
~
548513
Circllit Description
Conditions for Setting the DTC
The mass air flow (MAF) sensor measures the amount

of air which passes through it into the engine. The
PCM uses the mass air flow information to monitor
engine operating conditions for fuel delivery
calculations. A large quantity of air entering the engine
indicates an acceleration or high load situation,
while a small quantity of air indicates deceleration
or idle.
The MAF sensor produces a frequency signal which
can be monitored using a scan tool. The frequency will
vary within a range of around 2000 Hertz at idle to
near 10,000 Hertz at maximum engine load.
OTC P0101 will be set if the signal from the MAF.
sensor does not match a predicted value based on
barometric pressure, air density, manifold pressure,
throttle position and engine RPM.
The difference between actual airflow and predicted

airflow is more than a calibrated value.
Conditions for Running the OTC
The engine is running.

Ignition voltage between 9.0 and 18.0 volts.
Throttle is steady and less than 30 percent.
EGR duty cycle is less than 100 percent.
EGR pintle position is less than 100 percent.
MAP is steady and less than 80 kPa.
EV AP canister purge is less than 100 percent.
Action Taken When the DTC Sets

The PCM will illuminate the malfunction indicator
lamp (MIL) during the second consecutive trip in
which the diagnostic test has been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame/Failure
Records data.
Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the
third consecutive trip in which the diagnostic has
been run and passed.
The History OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using a scan tool.
6~858
Engine
Diagnostic Aids
lnspectfor the following:
" Skewed or stuck TP sensor. A faulty TP sensor or
TP sensor circuit can cause the PCM to incorrectly
calculate the predicted mass air flow value.
Observe throttle angle with the throttle closed. If
the throttle angle reading is not O percent, test for
the following conditions and repair as necessary:
If none of the above conditions are noted and the
throttle angle reading at closed throttle is not
O percent, replace the TP sensor.
" Skewed MAP sensor. A skewed MAP sensor can
cause the BARO reading to be incorrectly
calculated. To test the MAP sensor, compare the
MAP/BARO reading on the vehicle being
diagnosed to the MAP/BARO reading on a
normally operating vehicle. If a large difference is
noted replace the MAP sensor.
.. Plugged intake air duct or dirty air filter element.
" The actual mass air flow is compared to a
calculated Mass Air Flow based on the MAP, TP,
and engine RPM readings (speed density). A
skewed/unresponsive MAP sensor at key ON will
cause the calculated mass air flow value to be
inaccurate. When the engine is started a
calculated difference between actual Mass Air
Flow and Calculated mass air flow occurs.
OTC P0101 will set, the vehicle will stall, a default
mass air flow based on the MAP sensor will
occur. Because the MAP sensor is
skewed/unresponsive the default mass air flow
values are incorrect and vehicle may not restart. If
a fault occurs which causes the MAP sensor
value to be incorrect (poor vacuum connections,
damaged vacuum source, or defective vacu.um
hoses, air entering the engine without passing
through the MAF), DTC P0101 will set and
the default mass airflow value will be substituted.
Because the MAP sensor value is incorre.ct
the vehicle may not start and run.
Important: Remove any debris from the c<;>nnector

cornponent. Ensure that the gaskets are installed
" Poor terminal connection.
Systems.
.. Damaged harness.
change ih the display may indicate the location of
Systems.
Test Description
diagnostic table:
3. Only, if sent here from the Engine Cranks But

Does Not Run, continue to follow diagnostic table
even if OTC P0101 has NOT failed this ignition.
4. This step tests the MAP. sensor. By disconnecting
the MAF sensor, the vehicle is forced into speed
density. Speed density is based on the MAP,
TP, and engine RPM readings. With a
skewed/unresponsive MAP sensor, the speed
density calculation is incorrect and vehicle may not
start. For further information refer to
diagnostic aids.
5. This step tests for skewed 6r sticking MAP
sensor. MAP sensor should respond smoothly and
gradually as RPM. is increased. Compare MAP
sensor of affected vehicle to that of a normally
operating vehicle if a large difference is noted
replace the MAP sensor.
9. Verifies that ignition feed voltage and .a good
ground are available at the MAF sensor.
Engine
Engine Controls- 3.8L
6-859
l:;tep
Action
Values
Yes
No.
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
applicable DTC
Go to Step 3
Did you perform the Powertrain On Board

With a scan tool, select the Diagnostic Trouble

Codes (DTCs).
Does the scan tool indicate any other DTCs set?
Operate the vehicle within Fail Records conditions.

Does the scan tool indicate DTC P0101 failed this ignition?
Go to Step
.Go to
Diagnostic Aids
4.
Important: DO NOT CLEAR DTC.s.
1. Disconnect the MAF sensor.
2. Attempt to start engine.
'
Does engine start and continue to run?
Go to.Step 5
Go to Step 6
Go to Step 7
Go to Step 6
Go to Step 20
Go to Step 7
Go to Step B
Go to
OTC P1221
Throttle
Position (TP)
Sensor 1- 2
Correlation
Go to Step 9
Go to Step 10
Go to Step 13
Go to Step 12
Go to Step 14
Go to Step 11
Go to Step 20
Go to Step 17
Go to Step 15
Go to Step 16
Go to Step 20
Go to Step 18
2. Reconnect the MAF sensor.

3. Start the engine.
5
4. With a scan tool, observe the MAP sensor parameter

while slowly increasing engine speed to 3000 RPM.
Does the parameter value change as engine speed

increases?
6
Diagnose the MAP sensor. Refer to MAP Sensor Circuit

Diagnosis.
1. Turn ON the ignition, with the throttle closed.
2. With a scan tool, observe throttle angle parameters.
Does the scan tool indicate both parameter less than the
specified value?
4%

8
2. Disconnect the MAF sensor.

4. Connect a DMM between the signal circuit of the
MAF sensor and a good ground.
5.0V
Connect a test lamp between the ignition feed and ground

circuits of the MAF sensor.

10
4.5V
11

4. Connect a DMM between the signal circuit of the
o.ov

12
Connect a test lamp between the ignition feed circuit of the

)
13
Inspect for a poor connection at the MAF sensor. Refer to

6-860
Engine

DTC P0101 Mass Air Flow (MAF) Sensor Performance (cont'd)
Step
14
Action
Inspect the MAF sensor circuits for the following
conditions:
1. Excessive resistance in the signal circuit of the MAF
sensor.
2. Excessive resistance in the ground circuit of the MAF
sensor.
3. Short to ground in the signal circuit of the MAF
sensor.
4. Poor connection at the PCM.
Refer to Testing for Intermittent and Poor Connections,
Connector Repairs or Wiring Repairs in Wiring Systems.
Values
15
16
Repair the open or excessive resistance in the ignition

feed circuit of the MAF sensor. Refer to Wiring Repairs or
Testing for Intermittent and Poor Connections in Wiring
Systems.
17
Repair the short to voltage in the signal circuit of the MAF

sensor. Refer to Wiring Repairs in Wiring Systems.
18
Replace the MAF sensor. Refer to MAF Sensor

Replacement.

Replace the PCM.
20
1. Use the scan tool in order to clear the DTCs.

2. Operate vehicle within the Fail Record conditions.
Does the DTC reset?
No
Go to Step 20
.. Go to Step 19
Repair the open or excessive resistance in the ground

circuit of the MAF sensor. Refer to Wiring Repairs or
Testing for Intermittent and Poor Connections il"I Wiring
Systems.
19
Yes
Go to Step20
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step
System OK
Engine
Engine Controls - 3~8L
6-861
DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
!Hot In Run, Bulb Test And Start
'" - -Power
- - -,... . Distribution
Schematics
i,:iWiring
Systems
L
~ -
- - - - - "'E
. Wr'ng
I ngme
I I
ENG SEN
Harness
I
MiniFuse
Junction Block 2
20 A
I
I
,':- -
L...2.til
PNK 539
~----
PNK 539
Power
Distribution .
Schem~tics
In Wiring
Systems
YEL 492
AA
PNK 539
c .
A
lgni!lon
Positive
Voltage..
MAF
Sensor
Signal
Mass Airtlow
(MAF) Sensor
Ground
Ground
Distribution ..
Schematics
In Wiring
Systems
B
BLK/WHT 451
.,..__ -
-. -
.-.
69 C1
r -
I
I
BLK. 451
L: -
~A-;; - - - - - - - , Powertrain
Sensor
Signal
CONN ID
C1=BLU
C2=CLEAR
-- - - - . - - -
I Control
I Module
I (PCM) ,6
'
..I
548513
Circui.t De~cription
of air which passes through it into the engine. The
PCM uses the mass air flow information to monitor
.
engine operating conditions for fuel delivery
calculations. A large quantity of air entering 'the engine
indicates an acceleration or high load situation,
while a small quantity of air indicates deceleration or
idle. The MAF sensor produces a frequency signal
which can be monitored using scan tool. The
frequency will vary within a range of around 2000 Hertz
at idle to about 10,000 Hertz at maximum engine
loc1.d; DTC P0102 will be $et if the signalJrequency
from the MAF sensor is lower than the possible range
of a normally operating MAF sensor.
Conditions for Running the DTC

Throttle angle is less than 1.5 percent.
Ignition voltage is more than 8.0 volts.
lac is. more than 5 counts:
MAF signal frequency is less' than 800 Hertz.

Above conditions are present for over 0.5 seconds.
Action Taken When the OTC Sets

. The PCM will store conditions which were present
Records ,data.

'been run and passed.
warm-up cycleshave occurred without a
malfunction.
The DTC can be cleared by using a scan tool.
6-862
Engine
Diagnostic Aids
Plugged intake air duct or filter element. A wide-open
throttle acceleration from a stop should cause the
mass air flow displayed on a scan tool to increase from
about 4-6 gm/s at idle to 100 gm/s or more at the
time of the 1-2 shift. If not, inspect for a restriction.
Systems.
Damaged harness.
and wiring harnesses related to the sensor: A

Systems.

Test Description
The numbers below refer to the Step numbers on the
diagnostic table:
2. This step verifies that the problem is present
at idle.
5. A voltage reading of less than 4 or over 6 volts at
the MAF sensor signal circuit indicates a
malfunction in the wiring or a poor connection.
6. Verifies that ignition feed voltage and a good
ground are available at the MAF sensor.
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.
Step
Action
Important: If OTC P0108 is set diagnose it first. Refer to

OTC P0108 Manifold Absolute Pressure (MAP) Sensor
Circuit High Voltage.
2. With a scan tool, observe the MAF Frequency
parameter.
Does the scan tool indicate the parameter is less than the
specified value?
Values
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
Goto
Diagnostic Aids
Go to Step 15
Go to Step 5
1200 Hz
(1.2 kHz)
Inspect for the following conditions:

1. Objects blocking the MAF sensor inlet screen.
2. Vacuum leaks around the intake manifold.
3. Vacuum leaks at throttle body.
4. Vacuum leaks at the EGR valve flange and pipes.
5. Crankcase ventilation valve malfunctioning, missing,
or incorrectly installed.

Disconnect the MAF sensor.
Turn ON the ignition, with the engine OFF.
Connect a DMM between the signal circuit of the
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

2. Operate the vehicle within Fail Records conditions.
Does the scan tool indicate OTC P0102 failed this ignition?
1.
2.
3.
4.
Yes
5V
Go to Step 6
Go to Step 9
Engine Controls - 3..8l
Engine
6-863
DTC P0102 Mass Air Flow (MAF) Sensor Circuit low Frequency (cont'd)
Step
Values
Action
Connect a test lamp between the ignition feed circuit and

the ground circuit of the MAF sensor.
Connect a test lamp between the ignition feed circuit of the

MAF sensor and a good ground,

Testing for Intermittent and Poor. Connections.and
Did you find and correctthe condition?
Test the signal circuit of the MAF sensor for an open,

short to ground, or a short to voltage. Refer to Wiring
10
Repair the open in the ground circuit cit the MAF sensor.
Refer to Wiring Repairs in Wiring Systems.
Repair the open or short to ground in the ignitiori feed

circuit of the MAF sensor. Refer to Wiring Repairs in
Wiring Systems.
11
12
Replace the MAF.sensor: Refer to MAFSehsor

Replacement.
Did you complete t.he replacement?
No
Go to Step 8
Go to Step 7
Go to Step 10
Go to Step 11
Go to Step 15
Go to Step 12
Go to Step 15
Go to Step 13
-
Go to Step 15
Go to Step 15
Go to Step 15
,'
13

14

Replace thePGM.
Refer to .PCM Replacement/Programming.

2. Operate ttie vehicle within the Fail Record conditions.
Does the OTC reset?
15
Yes
Go to Step 15
Go to Step 14
Go toStep 15
Go to Step2
System OK
.
6-864
Engine
DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
!Hot In Run, Bulb Test And Start!
-;:: ;er0
J7
Distribution
Schematics
in Wiring
Systems
~ Engine Wiring
ENG SEN
MiniFuse
20 A
I
I
I
Harness
Junction Block 2
L-------------J
PNK 539
~-----
PNK 539
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
YEL 492
C,..
A,.,_
,---lg-n-111-on_ _ _ _ _
M_AF--,
Positive
Voltage
Sensor
Signal
Mass Airflow
(MAF) Sensor
Ground
Ground
Distribution
Schematics
In Wiring
Systems
B"
BLK/WHT 451
69 G1
'" - - - -;;,A-; - - - - - - - , Powertrain

I
I
BLK 451
Sensor
Signal
CONN ID
C1=BLU
C2=CLEAR
I Control
I Module
I (PCM)~
L------------..1I
M.
(
548513
Circuit Description
of air which passes through it into the engine during
a given time. The PCM uses the mass air flow sensor
information to monitor engine operating conditions
for fuel delivery calculations. A large quantity of
air entering the engine indicates an acceleration or
high load situation, while a small quantity of air
indicates deceleration or idle.
The MAF sensor produces a frequency signal which
can be monitored by using a scan tool. The frequency
will vary within a range of around 2000 Hertz at idle
to near 10,000 Hertz at maximum engine load.
DTC P0103 will be set if the signal from the MAF
sensor is more than the possible range of a normally
operating MAF sensor.

"
.,
"

The throttle angle is less than 1.5 percent
ignition voltage is more than 8.0 volts.
IAC is more than 5 counts.

.. MAF signal frequency is more than
11,500 Hertz (11.5 kHz).
" The condition are present for 0.5 seconds.

" The PCM will illuminate the malfunction indicator
lamp (MIL.) during the second consecutive trip in
" The PCM will store conditions which were present
when the DTC set as Freeze Frame/Failure
Records data.
Conditions for Clearing the Mll/DTC

.. The PCM will turn the MIL OFF during the
., The History DTC will clear after 40 consecutive
malfunction.
" The DTC can be cleared by using a scan tool.
Engine
6-865
Diagnostic Aids
Test Description

diagnostic table.

Systems.
Damaged harness.
Systems.
2. This step verifies that the problem is present

at idle.
4. A frequency reading with the MAF sensor
connector disconnected indicates an
Electromagnetic Interference (EMI) related
malfunction or a poor connection.
9. This vehicle is equipped with. a PCM which utilizes
the new PCM must be programmed. Refer to
PCM Replacement/Programming.
6-866
Engine

Step
Action

1

2. With a scan tool, observe the MAF Frequency
parameter.
Does the scan tool indicate the parameter more than the
specified value?

1.
2.
3.
4.

Disconnect the MAF sensor.
Start the engine.
With a scan tool, observe the MAF Frequency
parameter.
Does the scan tool indicate the parameter at or near the
specified value?
Values
Go to Step 2
Go to A
PowertrainDn
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 7
Go toStep 10
Go to Step 6
10,500 Hz
O Hz

Replacement.
Inspect the MAF sensor harness for incorrect routing:

1. Inspect near the secondary ignition wires or coils.
2. Inspect near the other high voltage components
(solenoids, relays, motors).


Replace the PCM.

2. Operate the vehicle within the Fail Record conditions.
Does the OTC reset?
10
No

Connector. Repairs in Wiring Systems.
Yes
Go to Step 10
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
Go to Step 2
System OK
Engine
Engine Controls - 3.8L 6-867
DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
J.
'" - - - - - - - - - - -. Powertrain
I Control
sv
I
1
Module J;,
I
5 Volt
I (PCM)
I
Reference A
[M;-1
M.
L.1il
'"------33 C2
---..!
EGR
.Valve
GRY 598
GRY
.598
I~
.. I
r-Y~ _
-------~
1 1
,----------------------.
GRY 598
~bas~i~!~
Pressure_
(MAP) Sensor A
...
ORN/BLK 469
13" C1
CONN ID
C1 = BLU
C2=CLEAR
MAP
Sensor
Ground
LT GRN 432
25 C2
MAP
Sensor
Signal
Powertrain
Control
Module
(PCM)~
>
~--------------------J
368338
Circuil Description
The manifold abs.elute pressure (MAP) sensor
,responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from less than 2 volts at idle (high vacuum)
to more than 4 vo.lts with the key ON, engine not
running or at wide-open throttle (low vacuum). The
MAP sensor is used to determine manifold pressure
changes while the EGR flow test diagnostic is
being run, refer to OTC P0401 Exhaust Gas
'Recirculation (EGR) Flow Insufficient. Also to update
the barometric pressure reading (BARO), as an
enabling factor for other diagnostics. The PCM
.monitors the MAP signals for voltages outside the
normal range of the MAP sensor. If the PCM detects a
MAP sensor signal voltage that is excessively low,
OTC P0107 will set.
.

No TP sensor DTCs present.
Ignition voltage is more than 8 volts.
O
Throttle angle is more than or equal to 1O percent,

when engine speed is less than or equal to
900 RPM.
Gonditions for Setting the DTC

The MAP sensor indicates less than 12 kPa.

O
The .PCM will illuminate the malfunction indicator


Records data.

The PCM will turn the MIL OFF during tl)e
The History DTC will clear after 40.consecutive
malfunction.
Diagnostic Aids

faulty terminal to wire connection. l:Jse a
Systems.
Damaged harness.
and wiring har.nesses related to the sensor. A
Systems.
6-868
Engine Controls
Engine
3.8l
Test Description
diagnostic table:

DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids

1
Important: Refer to OTC P1635 5 Volt Reference 1 Circuit

or DTC Pt 639 5 Volt Reference 2 Circuit first, If set:
, 1. Turn ON the ignition, with the engine OFF.
2. With the scan tool and the throttle closed, observe
the MAP voltage parameter.
Does the MAP voltage measure less then the
specified value?
0.1 volt
Operate the vehicle within Fail Record conditions.

Does the scan tool indicate DTC P0107 failed?
1. Disconnect the MAP sensor.

2. Connect a 3 amp jumper between the 5 volt reference
circuit and the MAP signal circuit.
3. With a scan tool, observe the MAP voltage
parameter.
Does the scan tool indicate voltage at near the
specified value?
4.95V
1. Disconnect the jumper wire.

2. Connect a test lamp between battery positive voltage
and the MAP sensor signal circuit.
parameter.
Does the scan tool indicate voltage at or near the
specified value?
4.95V
..

2. Test the 5 volt reference circuit of the MAP sensor for
high resistance or an open.
3. Repair as necessary. Refer to Circuit Testing and
Inspect the 5 volt reference circuit of the MAP sensor for a

poor connection at the PCM. Refer to Testing for
Intermittent and Poor Connections and Connector Repairs.
Test the signal circuit of the MAP sensor for an open,

short to ground, or short to the sensor ground. Refer to
CircuitTesting and Wiring Repairs in Wiring Systems.
Test the signal circuit and the 5 volt reference circuit of the
MAP sensor for a poor connection at the MAP sensor.
Connector Repairs.
Go to Step 9
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 13
Go to Step 7
Go to Step 13
Go to Step12
Go to Step 13
Go to Step 10
(
Go to Step 13
Go to Step 11
Engine
6-869
DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage (cont'd)
Step
Action
Values
10
Test the signal circuit and the 5 volt reference circuit of the
MAP sensor for a poor connection at the PCM. Refer to
Connector Repairs.
11
Replace.the MAP sensor. Refer

MAP Sensor
Replacement.
Did you compl,ete the replacement?
to
Yes
No
Go to Step 13
Go to Step 12
Go to Step 1.3
Important: Perform the set up procedure for the PCM.

12
13
Replace the PCM.

Did you complete th!;! replacement?
1. Use a scan to in order to clear the DTCs.
2. Operate the vehicle within the Fail Record cond.itions.
Does the DTC reset?
Go to Step 13
Go to Step 2
System OK
Engine
6-870
DTC P0108 Manifold AbsolotePressute.(MAP) Sensor 1Circuit High Voltage
J.
t 0~I
r~N1
'" - - - - - - - - - - , Powertrain
I Control
sv
:
L.- -
EGR
Valve
SVolt
Reference A
-
..
.., . . . - . - -
Module
I (PCM)
I
J,
~
=~;:r~,
C
.I
33 C2
GRY 598
GRY
598
GRY 598
(MAP) S.ensor Ar
ORN/BLK 469
LT GRN 432
13AC1
'"
...
25 C2
MAP
MAP
Sensor
.Sensor. :
Signal
.,
.Powertrain
Control
Module )#,
1
(PCM) I,.~
1
~--------------------J
Ground
.. .
.
368338
Circuit Description
The manifold absolute pressure (MAP) sensor
responds to changes in intake manifold pressure
to more than 4 volts with the key ON, engine not
Recirculation (EGR) Flow Insufficient. Also to update
monitors the MAP signals for voltages outside the
MAP signal voltage that is excessively high,
DTC P0108 will set.

No TP sensor DTCs present.
Engine is running.
Throttle position is less than or equal to
0.5 percent when engine speed is less than or
equal to 900 RPM.

The MAP sensor indicates more than 85 kPa.

O

Records data.

" The History OTC will clear after 40 consecutive
malfunction.
.. The DTC can be cleared by using a scan tool.
Diagnostic Aids
component. Ensure that the gaskets are instal!ed
Systems.
Damaged harness.
Systems.
Engine Controls.~ 3.8L
Engine
6-871
DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage
Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids

-
Important: Refer to OTC P1635 5 Volt Reference 1 Circuit

or OTC Pt 639 5 Volt Reference 2 Circuit first, If set.
1. If the engine idle is rough, unstable or incorrect,

repair the idle problem before continuing with this
table. Refer to Rough, Unstable, or Incorrect Idle and
Stalling in Symptoms.
4.2 V
2. With the engine idling, observe the MAP voltage

parameter on a scan tool.
Does the scan tool indicate the parameter is more than the
specified value?
Does the scan tool indicate OTC P0108 failed this ign?

parameter.
Does the scan tool indicate the parameter is
specified value?
ov
1tt the
Inspect for a plugged or leaking vacuum supply to the

MAP sensor.
Go to Step 5
Replace the MAP sensor. Refer to MAP Sensor

Replacement.
Go to Step
Go to Step 12
Go to Step 11
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 10

10
Go to Step 12

Inspect the ground circuit of the MAP sensor at the MAP
sensor for poor connections at the harness connector.
Go to Step 6

Inspect the ground circuit of the MAP sensor for a poor
connection at the PCM. Refer to Testing for Intermittent
and Poor Connections and Connector Repairs in Wiring
Systems.
Go to Step 12

Test the signal circuit of the MAP sensor for a short to
voltage or short to 5 volt reference circuit. Refer to Circuit

Test the ground circuit of the MAP sensor for an open or
high resistance. Refer to Circuit Testing and Wiring
Go to.Step
Go to Step 12

11
Replace the PCM.

Go to Step 12
1. Use tlie scan tool in order to clear the DTCs.

12

Does the OTC reset?
Go to Step 4
System OK
6-872
Engine
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit low Voltage
.- - - ,-- - -,,v- - - ., Powertrain
:
r :~~~t~~~
IAT
Sensor.{
s,~a~ ____
__
.J
(PCM)
j,,
L.1il
M,
50IC2
TA~ 472
rn
pptr
Intake Air
Temperature
(IAT) Sensor
719
l Ci
,- - - - - - iA.1- - - - - - - - .,
n
I
I
~-
Sensor
PCM
Ground
c1 = BLU
- - - - - - - -C~=:L~A~
Powertrain
I Control
I Module (PCM)
,I,,
M
221729
Circuit Description
The intake air temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering
the engine. The PCM applies 5.0 V through a pull up
resistor. When the intake air is cold, the sensor
resistance is high and the PCM will monitor a high
signal voltage on the IAT sensor signal circuit. As the
intake air warm, the sensor resistance becomes
lower causing the PCM to monitor a lower voltage. If
the PCM detects an excessively low IAT sensor
signal voltage (high temperature indicated),
DTC P0112 will set.

No active ECT sensor or VSS DTCs present.
Engine running for over 10 seconds.
Vehicle speed is more than 40km/h(25 mph).

IAT signal voltage indicates an intake air
temperature more than 135C (275F).
The above conditions are present for more than
10 seconds.

Records data.
Conditions for Clearing .the MIL/OTC

.. The History DTC will clear after 40 consecutive
malfunction.
" The OTC can be cleared by using a scan tool.
Diagnostic Aids
Important: Rernove any debris from the connector
Systems.
Damaged harness.
Systems.
Engine
Test Description
)
may be shorted above or below a certain

temperature. If this is the case, replace the IAT
sensor. If the IAT sensor appears to be OK,
the fault is intermittent refer to Diagnostic Aids.
The number below refers to the step number on the

diagnostic table:
2. Verifies that the fault is present.
3 .. If DTC P0112 can be repeated only by duplicating
the Fail Records conditions. Refer to Temperature
vs Resistance table. The table may be used to
test the IAT sensor at various temperatures
to evaluate the possibility of a shifted sensor that
6-873

DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids

-
2. With a scan tool, observe the IAT parameter.
135"C (275F)
Does the scan tool indicate the parameter is more than

specified value?
Operate vehicle within Fail Records conditions.

Does scan tool indicate DTC P0112 failed this ignition?

2. Disconnect the IAT sensor.
4
3. Turn ON the ignition, with the engine OFF ..
-37C (-34F)

specified value?
Go to Step 6 .
Go to Step 5
Go to Step 8
Go to. Step 7

5
2. Test the signal circuit of the IATsensor for a short to

Wiring Systems.

6
Replace the IAT sensor. Refer to /AT Sensor

Replacement.
Goto Step 8

Replace the PCM.

,,
,,
Go toStep 8

Does the DTC reset?
Go to Step 2
System OK
6-874
Engine Controls - .3.8L
Engine
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
J :
.- - - - ""'~v- - - , Powertrain
1
1 Control
:
IAT
S~nsor
Signal ,
Module (PCM)
~
~--------J~
50IC2
TA~
J,,.4.
..
.,
!Loe
'
'
I (
-"
472
rn
Intake Air
Temperature
(IAT) Sensor
Al
PPL 719
17 "C1
r -
iAr- - - - - - - - ., Powertrain
Sensor
Ground
~-
PCM
C1=BLU
-
- -C~=:L~~
I
I
Control
Module (PCM) ~
M.
221729
Circuit Description
the engine. The PCM applies 5.0V through a pull
up resistor. When the intake air is cold, the sensor
resistance is high and the PCM will monitor a
high signal voltage on the IAT sensor signal circuit. As
the intake air warm, the sensor resistance becomes
lower causing the PCM to monitor a lower voltage.
If the PCM detects an excessively high IAT sensor
signal voltage (low temperature indicated), OTC P0113
will set.
Conditions for Running The DTC

No active ECT sensor or VSS DTCs present.
" The engine has be.en running for more than
3 minutes.
" Vehicle speed is less than 8km/h(5mph).
Mass air flow is less than 8 gm/s.
Engine coolant temperature is more than
60C (140F),

IAT signal voltage indicates an intake air temperature
less than -38C (-36F).

Records data.

O The History DTC will clear after 40 consecutive
malfunction.
Diagnostic Aids
Systems.
Damaged harness.
Systems.
Engine
Test Description .

diagnostic table:
3. If OTC P0113 can be repeated only by duplicating
the Fail Records conditions. The Temperature vs
Resistance table may be used to test the IAT
sensor at various temperatures to evaluate
the possibility of a shifted sensor that may be
open above or oelow a certain temperature. If this
is the case, replace the IAT sensor. Refer to
IAT Sensor Replacement. If the IAT sensor
appears to be OK, the fault is intermittent. Refer
to Diagnostic Aids.
Engine Controls - 3.8L . 6-875

5. Use a fused jumper during this test. If the IAT
signal circuit.is shorted to battery or ignition
positive voltage the fuse in the jumper will open,
indicating a short in the signal circuit.
6-876
Engine
Action
Step
Values
Yes
'

1
'
Go,to Step 2
',

2. With a scan tool, observe the 1AT parameter.
Does the scan tool indicate the parameter is less than the.
specified value?
~37~C (-34F)
Powertrain On
Board
Diagnostic (080)
System Check
'
Gq to $fep 4
:,
'

2. Disconnect the IAT sensor.
3. Connect a 3 amp fused jumper between the signal
circuit of the IAT sensor and the ground circuit of the
IAT sensor.
specified value?
135C (275F)
1. Jumper the IAT signal circuit to a good ground.

specified value?
135C (275F)
Test the signal circuit of the IAT sensor for a short to

voltage. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the ground circuit of the IAT sensor for a high

resistance or an open. Refer to Circuit Testing and Wiring
Test the signal circuit of the IAT sensor for an open. Refer
Inspect for faulty IAT sensor ground or signal circuit

connections at the PCM. Refer to Testing for Intermittent
Systems.
10
Inspect for a faulty connections at the IAT sensor. Refer to


Replacement.
12

Replace the PCM.
13

Does the DTC reset?
11
No
Go to A.
''

Does scan tool indicate DTC P0113 failed this ignition?
Go. to Step 4
Go to Step 3
.Go fo
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 7
Go to Step 8
Goto Step 13
Go to Step 10
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 13
Go to Step 2
System OK
Engine
6;.877
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
'" - - - - '-v- - - - , Powertrain
:.
ECT
Sensor
JS
L -
!g~I -
:
I
26IC2
'"f-
~~~~f~
(PCM)
,6
~
iM7l
~
Y~L 410
,Engine
I Coolant
I Temperature
LA- J (ECT) Sensor
BRN 718
12 "C1
- - ECT- - ~ Powertrain
Sensor
I Control
Ground
I Module (.PCM)
I
I
'" - - - - - I
I
L -
CONN ID
c1 = BLU
C2=CLEAR
-~
,-
~
368395
Circuit Description
Diagnostic Aids

thermistor mounted in the engine coolant stream. Tlie
PCM applies a voltage (about 5.0V) through a pull
up resistor to the ECT signal circuit. When the engine
coolant is cold, the sensor (thermistor) resistance
is high, therefore the PCM will measure a high signal
voltage. As the engine coolant warms, the sensor
resistance becomes less, and the ECT signal voltage
measured at the PCM drops. With a fully warmed
up engine, the ECT signal voltage should measure
about 1.5 to 2.0V,


The ECT indicates an engine coolant temperature
more than 140C (284F).

Records data.
Conditions for Clearing the MIL/DTC

malfunction.

the connector gaskets when diagnosing or replacirig a
Systems.
" Damaged harness.
Systems.
6-878
Engine
Test Description
certain temperature. If this is the case, replace the

ECT sensor, refer to ECT Sensor Replacement.
If the ECT sensor appears to be OK, the fault
is intermittent refer to Diagnostic Aids.

diagnostic table:
3. If OTC P0117 can be repeated only by duplicating
the Fail Records conditions, refer to the
Temperature to Resistance Value table. The table
may be used to test the ECT sensor at various
temperatures to evaluate the possibility of a shifted
sensor that may be shorted above or below a

the new PCM must be programmed. Refer to
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit low Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go.to Step 6
Go to $tep 5
Go to Step 8
Go to Step 7


2. With a scan tool, observe the ECT parameter.
specified value?

Does scan tool indicate OTC. POl 17 failed this ignition?

2. Disconnect the ECT sensor.
specified value?
139C (282F)
'
-38C (~36F)
Test the ECT sensor signal circuit for a short to ground or

a short to the sensor ground circuit. Refer to Circuit
Replace the ECT sensor. Refer to ECT Sensor

Replacement.

Replace the PCM.
1. Use the scan tool in order .to clear the DTCs.

2. Operate the vehicle within the Fail Record conditions ..
Does the OTC reset?
Go to Step 8
Go to Step 8
Go.to Step 2
System OK
Engine
Engine Controls - 3;8l
H379
DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
.- - - - - - - - - - , Powertrain
. Jsv.
ECT
Sensor
:
I
~g~I -
...,. -
~~~t~.f~
Jt,,
(PCM)
26IC2
YELi 410
.BA
- t-,Engine
Coolant
I
I
I
I Temperature
LA- J (ECT) Sensor
BRN 718
12,.,.C1
'" - - - - - - - - fcr- I
I
L -
CONN ID
C1 =BLU
C2=CLEAR
-
Sensor
Ground
-
Powertrain
Control
Module
(PCM)
I
4
,-
~.
368395
Circuit Description
Diagnostic Aids

thermistor mounted in the engine coolant stream. The
PCM applies a voltage (about 5.0V) through a pull
up resistor to the .ECT signal circuit. When the engine
coolant is cold, th.e sensor (thermistor) resistance
is high, therefore the PCM will measure a high signal
voltage. As the eAgine coolant warms, the sensor
resistance becomes less, and the ECT signal voltage
measured at the PCM drops. With a fully warmed
up engine, the ECT signal voltage should measure
about 1.5 to 2.0V.

The engine is running for longer than 15 seconds.

The ECT sensor signal indicates an engine coolant
temperature less than -39C (-38F).

Records data.

malfunction.

the connector gaskets when diagnosing or. replacing a
Poor terminal connection;
faulty terminal to wire connection'. Use a
Connections and Connector Repairs. in Wiring
Systems.
Damaged harness.
Inspect the wiring harness for damage. If the ,
harness appears to be OK, 'observe the display
Systems.
Inspect the.PCM and the engine grounds for
6-880
Test Description
Engine
t 1. This vehicle is equipped with a PCM which utilizes

diagnostic table:
2. Verifies that the malfunction is present.
Step
Action
Values
Yes
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
1. Turn ON the ignition, with the engine OFF. .

2
2. Observe the ECT parameter displayed on the

scan tool.
Is ECT below the specified value?
..
No
Go to A
Powertrain On
Board
Diagnostic /080)
System Check

-38C or -36F
1. Verify that the ignition is ON, with the engine OFF.

2. Review and record scan tool Failure Records data.
3. Operate the vehicle within Failure Records conditions
as noted.
4. Using a scan tool, monitor specific OTC info for
OTC P0118.
Does the scan tool indicate OTC P0118 failed?

Important: It the 3 amp fuse blows, locate and repair the
short to voltage on the sensor signal wire and verity that
the sensor was not damaged.
3. With a 3 amp fused jumper, connect the ECT signal
circuit and the sensor ground circuit together at the
ECT sensor harness connector.
5. Observe the ECT parameter displayed on the
scan tool.
Is ECT at the specified value?
140C or 284F
Important: It the 3 amp fuse blows, locate and repair the

short to voltage on the sensor signal wire and verity that
the sensor was not damaged.
1. With a 3 amp fused jumper, connect the ECT signal
circuit at the ECT sensor harness connector to a
good ground.
2. Observe ECT displayed on the scan tool.
Is ECT at the specified value?
140C or 284F
1. Test tor poor connections at the ECT sensor.

2. It a problem is found, replace terminals as necessary.
Refer to Testing for Continuity, Testing for Intermittent
and Poor Connections, Repairing Connector
Terminals and Connector Repairs in Wiring Systems.
Was a problem found?
1. Turn OFF the ignition switch.

3. Test the ECT sensor ground circuit for an open or a
short to voltage.
Go to Step 6
Go to Step 5
Go to Step 7
Go to Step B
Go to Step 12
Go to Step 10
(
Go to Step 12
Go to Step 9
Engine
Step
6-881
DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage (cont'd)
Action
Values
Yes
No
1. Turn OFF the ignition switch.

3. Test the ECT signal circuit for an open or a short to
8
voltage.
4. If a problem is found, repair as necessary and verify

thaf. the sensor was not damaged. Refer to Wiring
1.' Test for a poor sensor ground or ECT signal circuit

terminal connection at the PCM
2. If a problem is found, replace terminals as necessary.
Refer to Testing for Continuity, Testing for Intermittent
and Poor Connections, Repairing Connector
Terminals, Connector Repairs and Wiring Repairs in
Wiring Systems.
Replacement.
11
12
1. Review and record s9an tool Failure Records data.

2. Clear DTCs
3. Operate the vehicle within Failure Records conditions
as noted.
Go to Step 12
Go to Step 11
Is action complete?
Replace the PCM. Refer to PCM
Replacement/Programming.
Is action complete?
Go to Step 9

10
Go to Step 12
Go to Step 12
Go to Step 12
4. Using a scan tool, monitor specific DTC info for

OTC P0118.
Does the scan tool indicate OTC P0118 failed?
Go to StepZ
System OK
6-882
Engine
DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed Loop Fuel
Control
J. :
'" - - - - - - - - - , Powertrain
I Control
I
sv
:
I
L
ECT
Sensor
-
~g~I -
- - -
Module (PCM)
~
[1vi;l
LlJ
26! C2
YELi 410
rtBr-
,Engine
I coolant
I Temperature
(ECT) Sensor
BRN 718
12AC"1
r - - - - - - - - ECT - ~ Powertrain
I
I CONN ID I
Sensor
Control
I
= BLU I
Ground
: Module (PCM)
I
I
.
1
A-
1c1C2=CLEARI
L-----------~
A
fS'
~
368395
Circuit Description
To provide the best possible combination of
driveability, fuel economy, and emission control, a
closed loop air/fuel metering system is used. When the
vehicle is first started, the PCM controls fuel delivery
in open loop, ignoring the H02S signals and
calculating air/fuel ratio based on inputs from the
engine coolant temperature, throttle position, and mass
air flow sensors. The PCM will begin using the
H02S 1 signal for controlling fuel delivery {Closed
Loop). when the following conditions have been met:
The H02S output signal is varying, indicating
that the sensor is hot enough to operate properly.
.. The engine coolant temperature sensor indicates
coolant temperature more than 40C (104F)
with manual transmission vehicles or more than
20C(68F) with automatic transmission vehicles.
Time since start-up is at least 15 seconds
for a warm engine or 90 seconds for a cold
engine.
The PCM monitors the amount of time for the cooling
system to achieve closed loop operating temperature.
This diagnostic is broken into three temperature
regions. The diagnostic uses the ECT and IAT sensors
to determine which region to operate in. The time to
achieve closed loop temperature is monitored. A
time based decision is made depending on the
temperature region. The diagnostic will monitor the
following conditions prior to setting the DTC:
O Total airflow must exceed a calibrated amount.
" Engine idle time must be less than a calibrated
amount.

No active IAT or ECT DTCs present.
Minimum air temperature is more
than -7C (19F).
Start0 up engine coolant temperature is less than
40C (104F) with manual transmission vehicles.
Start-up engine coolant temperature is less than
20C (68F) with automatic transmission vehicles.
Region 1-air temperature more than 10C (50F)
and the start up coolant temperature more than
10C (50F).
Region 2-air temperature more than -7C (20F)
and the start up coolant temperature between
-7C (20F) and 10C (50F).
Region 3-air temperature more than -7C (20F)
and the start up coolant temperature between
-40C (-40F) and -7C (20F).

Region 1 (Automatic Transmission):
Engine run time over 139 seconds to achieve
closed loop temperature of 20c (68F).
Calibrated minimum amount of total airflow has
been exceeded.
Maximum idle time less than 104 seconds.
Region 1 (Manual Transmission):
closed loop temperature of 40C (104F).
been exceeded.
Engine
been exceeded.
.Maximum idle time less than 188 seconds.
been exceeded.
Engine run time over 324 seconds to .achieve
been exceeded.
Maximum idle time more than 243 seconds.
been exceeded.

Records data.

The PCM will turn the MIL OFF during the.
malfunction.
Engine Controls 3.8l
6-883
Diagnostic Aids
DTC P0125 set indicates a skewed ECT sensor.
Comparing the engine coolant temperature displayed
on a scan tool with actual coolant temperature
measured with a thermometer may isolate this
condition. If the displayed engine coolant temperature
is not close to the actual coolant temperature,
replace the ECT sensor.

Systems.
Damaged harness,
and wiring .harnesses related to the sensor. A
Systems.
Inspect the PCM a.nd the engine grounds for
Test Description
The numbers below refer to the Step numbers on the
diagnostic table:
. Memory (EEPROM). When the PCM is being
6-884
Engine
DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed Loop Fuel Control
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to applicable
DTC. Go to
Diagnostic
Trouble
Code(DTC)
List/Type.
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 5
Go to Step 7
Was the Powertrain ON-Board Diagnostic System Check

performed?
1
Are any ECT sensor DTCs set?

3. Install a fused jumper wire between the
two terminals at the sensor harness connector.
Is the ECT parameter near the specified value?
1. Check for high resistance in the wiring related to the

ECT sensor.
2. Check for poor connections at the E.CT. sensor and
the PCM. Refer to Testing for Intermittent and Poor
Systems.
Replace the faulty terminals or repair the faulty wiring as

necessary. Refer to Testing for Intermittent and Poor
Connections and Wiring Repairs in Wiring Systems.
Replace ECT sensor. Refer to ECT Sensor Replacement.

Important: The new PCM must be reprogrammed.

Replace the PCM.
1. Allow the engine to cool until the ECT and IAT sensor
parameters are within 5 degrees of each other.
2. Clear DTCs.
3. Start engine.
4. With the engine idling, monitor the ECT parameter on
the scan tool.
Does ECT increase to above the specified value within
9 minutes?
140C or 284F
Go to Step 8
Go to Step 8
Go to Step 8
-10C or 14F
System OK
Go to Step 2
Engine
}j ---"'
6-885
DTC P0131 H02S Circuit low Voltage Bank 1 Sensor 1

'" "p0-;;;er
I Distribution
J7
Engine Wiring
I Harness
ENG SEN
MiniFuse
20A
I ~chE;mat1cs
I Junction Block 2
I inWmng
J6
I
L__8y!!e~s _ _ _ _ _ _ _ _.
L1J
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
-<II- -
PNK 539
------ ------------
---------,
'" - - - - - - - - - - - - - - - - , Powertrain I
Bank 1
CONN ID
I Control
I
I
I
C1=BLU
I Module
I
I
H02S 1
H02S 1
C2=CLEAR
I (PCM)
'f
S1gn,il
PNK 5~9
12
C2
Low
27
C1
PPL/WHT 1665
TAN/WHT 1653
.J
A
"'
,...,1,----+------i-, Heated Oxygen
....
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
Sensor Bank 1
Sensor1
----------------------~
t
, _ _ _ _ _ _ _ _ -<Ill
_ _ _ _ _ _ _ _ -<Ill
Ground
Distribution
Schematics
In Wiring
Systems
548532
Circuit Description
The PCM supplies a bias voltage of about 450 mV

between the H02S signal and low circuits. When
measured with a digital voltmeter, this may display as
low as 350 mV. The oxygen sensor varies the
voltage within a range of about 1000 mV when the
exhaust is rich, down through about 100 mV
when exhaust is lean. The PCM constantly monitors
the H02S signal during closed loop operation and ..
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If
the H02S voltage remains excessively low for
p.n extended period of time, this DTC will be set.
H02S signal voltage remains less than 175 mV during

normal closed loop operation
OR
H02S signal voltage remains less than 600 mV during
power enrichment.

No Misfire, CKP, Fuel injector, MAF, TP, EVAP,
IAT, MAP, Fuel trim, EGR or ECT DTCs are
present.
The vehicle is in closed loop.
The Air/Fuel Ratio is more than or equal to
14.5 but less than or equal to 14.8
Throttle angle is between 5 percent and
40 percent

Records data.

The History DTC will clear after 40 consecutive
malfunction.
6-886
Engine
Diagnostic Aids
.. Throttle body inlet screen blockage
Low fuel pressure - The system will go lean if
pressure is too low. The PCM can compensate
for some decrease. However, if fuel pressure
is too low, a H02S OTC may set. Refer to Fuel
System Pressure Test.
Fuel injectors contaminated or faulty - Refer to
Fuel Injector Balance Test
" Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the. H02S, causing the system to
appear lean. Inspect for exhaust leaks that
may cause a false lean condition to be indicated.
~ Faulty MAF sensor - Disconnect the MAF sensor
and see if the lean condition is corrected. If so,
replace the MAF sensor.
.. Fuel contamination - Water, even in small
amounts, can be delivered to the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis for
procedure to test for fuel contamination.
If none of the conditions are present, replace the

affected H02S.
the Fail Records can be useful in determining
Test Description
The numbers below refer to step numbers on the
diagnostic table:
3. This OTC failing during power enrichment
operation (TP angle above 60 percent) may
indicate a condition described in Diagnostic Aids.
If this OTC test passes while the Fail Records
conditions are being duplicated, an intermittent
condition is.indicated. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition that caused the OTC to be set
occurs .
.Memory (EEPROM). When the PCM is replaced,
DTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1

Step
Action
Values
Yes
Go to Step 2
Important: During this step, observe all H02Svoltage

parameters. If all parameters remain below the specified
value refer to Diagnostic Aids.
1. Operate vehicle within the Conditions for Setting
parameters.
2. With a scan tool, observe H02S voltage parameter.
Does the H02S voltage remain below the specified value?
Operate vehicle within Fail Records co.nditions.
Does the scan tool in.dicate this OTC failed this ignition?
1. Disconnect the H02S.
Does scan tool indicate H02S voltage less than the
specified v.alue?
Test the H02S signal circuit for a short to ground or a
short to the sensor ground circuit. Refer to Circuit Testing
and Wiring Repairs in Wiring Systems.
Replace the H02S. Refer to Heated Oxygen
Sensor (H02S) Replacement.
Does the DTC reset?
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
400mV
. Go to Step 4
Go to Step 3
Go to Step 4
Go'to
Diagnostic Aids
Goto Step 5
Go toStep 7
Go to Step 8
Go to Step 6
400mV
Go to Step 8
Go to Step 8
Go to Step 2
System OK
Engine
6-887
DTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1
-i- - ,

.. Po-;;;e;I Distribution
J?
Engine Wiring
Harness
I Junction Block 2
I
ENG SEN
~che~atics.
MiniFuse
I m\Mnng
J6
20A
I
L_sy~e~s _ _ _ _ _ _ _ _.
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
PNK
..,. _________
_ 539
----------------------
.- - - - - - - - - - - - - - - - - , Powertrain I
I
Bank 1
CONN ID
I Control
I
I
C1=BLU
I Module
I
I
H02S1
H02S1
C2=CLEAR
I (PCM)
'f
Signal
Low
121 C2 271
PNK 5;9
C1
PPLJWHT 1665
TAN/WHT 1653
B ,,._
.J
A ,,._
....4----+----+-, Heated Oxygen
,.64
Heated Oxygen
Sensor (H02S)
Bank2Sensor1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
Sensor Bank 1
Sensori
----------------------~
t
,
. , _ _ _ _ _ _ _ _ _.,.
_ _ _ _ _ _ _ _ _.,.
/
/
Ground
Distribution
s.chematics
In Wiring
Systems
548532
Circuit Description

between the H028 signal and low circuits. When
measured with a digital voltmeter, this may display as
low as 320 mV. The oxygen sensor varies the
voltage within a range of about 1000 mV when the
exhaust is rich, down through about 10 mV when
exhaust is lean. The PCM constantly monitors
the H028 signal during closed loop operation and
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If
the H028 voltage remains excessively high for
an extended period of time, this OTC will be set.
H028
during
OR
H028
during

" No Misfire, CKP, Fuel injector, MAF, TP, EVAP,
IAT, MAP, Fuel trim, EGR or ECT OTCs are
present.
" The vehicle is in closed loop.
" Throttle angle is between 5 percent and
40 percent
signal voltage remains more than 975 mV

signal voltage remains more than 200 mV
decel fuel cutoff.

Records data.

malfunction.
6".888
Engine
Diagnostic Aids
High fuel pressure - The system will go rich if
pressure is too high. The PCM can compensate
for some increase. However, if fuel pressure is too
high, a H02S OTC may set. Refer to Fuel
Fuel Injector Balance Test.
Inspect the EVAP Canister for Fuel Saturation. If
the EV AP Canister is full of fuel, inspect canister
control and hoses. Refer to EVAP Control
System Diagnosis.
Disconnect the MAF sensor and see if the rich
condition is corrected. If so, replace the MAF
sensor.
Inspect for a leaking fuel pressure regulator
diaphragm by inspecting the vacuum line to the
fuel pressure regulator for the presence of fuel.
An intermittent TP sensor output will cause
the system to go rich due to a false indication of
the engine accelerating.
Shorted H02S - If the H02S is internally shorted
the H02S voltage displayed on the scan tool will
be over 1 volt. Disconnect the affected H02S
and jumper the H02S low circuit to ground with
the key ON. If the displayed H02S voltage
changes from over 1000 mV to around 450 mV,
replace the H02S. Silicon contamination of
the H02S can also cause a high H02S voltage to
be indicated. This condition is indicated by a
powdery white deposit on the portion of the H02S
exposed to the exhaus.t stream. If contamination
is noticed, replace the affected H02S.
Open H02S Signal or Low Circuit or Faulty H02S

- A poor connection or open in the H02S signal
or low circuit can cause the OTC to set during
deceleration fuel mode. An H02S which is faulty
and not allowing a full voltage swing between
the rich and lean thresholds can also cause this
condition. Operate the vehicle while monitoring the
H02S voltage with a scan tool. If the H02S
voltage is limited within a range between 300mV
to 600mV, inspect the H02S signal and low
circuit wiring and associated terminal connections.
If the wiring and connections are OK, replace
the H02S.
Test Description
diagnostic table:
3. This OTC failing during deceleration fuel mode
operation (vehicle speed above 25 mph, TP
angle below 3 percent) may indicate a condition
described in Diagnostic Aids. If this DTC test
passes while the Fail Records conditions are being
duplicated, an intermittent condition is indicated.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help
determine how often the condition that caused the
OTC to be set occurs.
Engine

DTC P0132 H02S Circuit .High Voltage Bank 1 Sensor 1
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 7

Important: During this step, observe all H02S voltage

parameters. If all parameters remain above the specified
1. Operate the vehicle within the Conditions for Setting
parameters.
2. With a scan tool, observe the H02S voltage
parameter.
Does the H02S voltage remain above the specified value?
600mV
Operate vehicle in Decel fuel mode (vehicle speed above .

25 mph, TP angle below 3 percent) while observing the
H02S voltage parameter on the scan tool.
Does the H02S voltage remain above the specified value
while in Decel fuel mode?
110 mV
Operate the vehicle within the Fail Records conditions.

Does the scan tool indicate this OTC failed this ignition?
Disconnect the H02S.

Does scan tool indicate H02S voltage more than the
specified value?
Test for a short to voltage on the H02S signal circuit.

Refer to Circuit Testing and Wiring Repairs.

Replace the PCM. Refer to PCM Replacement/
Programming.


Does the OTC reset?
500 mV
Go to Step 9
Go to Step 9
Go to Step2
System OK
6-890
Engine
1 -,
DTC P0133 H02S Slow Response Bank 1 Sensor 1

'" Power
I
Distribution
J7
.~ch~r:natlcs
inWmng
J6
MiniFuse
L _?Y;,!6'.;:S - _ _
Engine Wiring
Harness
I Junction Block 2
ENG SEN
20A
_ - _ -
PNK 539
Power
Distribution
Schematics
In Wiring
PNK 539
~---------
----------------------,
'" - - - - - - - - - - - - - - - - , Powertrain I
I Control
I
Bank 1
CONN ID
I
I
C1 =BLU
I Module
I
H.02s 1
Ho2s 1
c2=CLEAR
.i..
1 (PCM)
I
Signal
Low
'I'
Systems
12IC2 -
-27I-C1 .- - - - -
PNK 5~9- PPL/WHT 1665

TAN/WHT 1653
.J
,&
Heated Oxygen
Sensor (H02S)
Bank2Sensor1
Heated Oxygen
Se.nsor (H02S)
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 1
---------- __________ )
t
Sensor"1
, __ - - - - - - ~
/- _______ ~
Distribution
Schematics
In Wiring
Systems
(
548532
Circuit Description
The PCM continuously monitors the heated oxygen

sensor (H02S) activity, The PCM counts the number
of times that a rich to lean and a lean to rich
response is indicated. Then, the PCM adds the
amount of time it took to complete all transitions for a
100 second test period. With this information, an
average time for each transition can be determined. If
the average response time is too slow, this DTC
will set. A lean to rich transition is indicated when the
H02S voltage changes from less than 300 mV to
more than 600 mV. A rich to lean transition is indicated
when the H02S voltage changes from more than
600 mV to less than 300 mV. An H02S that responds
too slowly is likely to be faulty and should be
replaced.
H02S lean to rich average transition response time

was longer than 63 milliseconds. The rich to lean
average transition response time was longer than
190 milliseconds.

., No Misfire, CKP, Fuel injector, MAF, TP, EVAP,
present.
" The engine coolant temperature is more than
50C (122F).
" Engine speed is between 1000 RPM and
3000 RPM .
.. Mass air flow is between 10.0 g/s and 30 g/s.

Records data.

malfunction.
Engine
Diagnostic Aids
Test Description

diagnostic table:

correc11y. The gaskets prevent contaminate intrusion.
Systems.
Damaged harness,
Systems.
0
2. When the system is operating correctly the H02S

voltage should toggle above and below the
specified values.
5. If the low circuit is shorted to ground the H02S
voltage will be less than 400 mV when the
signal circuit is jumped to ground.
6. The specified value is what is measured on a
correctly operating system.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids

Important: If any other DTCs are set (except H02S

DTCs), refer to other DTCs first before proceeding with.
this table.
1. Engine at operating temperature.
2. Operate engine above 1200 RPM for two minutes.
parameter.
Does scan tool indicate H02S voltage varying outside the
specified values?

Inspect and test for the following:

Exhaust leak. Refer to Exhaust. System Inspection and
Exhaust Leakage in Engine Exhaus(
The H02S is installed correctly.
Damaged wiring. Refer to Wiring Repairs in Wiring
Systems.
400-500 mV
Go to Step 15
Go
to
Step 5
6-892
Engine Controls 3.8L
Engine
DTC P0133 H02S Slow Response Bank 1 Sensor 1 (cont'd)

Step
Action
Values
Yes
No

3. Jumper the signal circuit (PCM side) to a good

ground.
400mV

Does the scan tool indicate H02S voltage more than the
specified value?
Goto Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Goto Step 15
Go to Step 12
1. Remove the jumper wire.
2. Measure the voltage on the H02S signal circuit (PCM

side) using a DMM that is connected to a good
ground.
4.5V

7
Measure the voltage on the H02S low circuit (PCM side)

Test the low circuit for an open or high resistance. Refer to
5V
10
11
Test the signal circuit for an open or high resistance. Refer

Test the low circuit for a short to ground. Refer to Circuit

Test for poor connections at the H02S. Refer to Testing

Important: Determine the cause of contamination before

replacing the sensor.
12
13

e Fuel Contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis
Engine oil or coolant consumption. Refer to Oil
Consumption Diagnosis in Engine Mechanical.
O
Use of improper RTV sealant. Refer to Silicon
Contamination of Heated Oxygen Sensors Notice in
Replace the effected H02S sensor. Refer to Heated
Oxygen Sensor (H02S) Replacement.
Test for poor connections at the PCM. Refer to Testing for
Intermittent and Poor Connections and Connector Repairs
in Wiring Systems.
Go to Step 15
14

Go to Step 15
Go to Step 14
Go to Step 15
1 . Use the scan tool in order to clear the DTCs.

15
Does the OTC reset?
Go to Step 2
Go to Step 16
Go to
applicable OTC
System OK
Use. the scan tool in order to check for DTCs.

16
Does the scan tool indicate any DTCs that you have not
diagnosed?
Engine
6-893
DTC P0134 H02S Circuit lnsOfficientActivity Bank 1 Sensor 1

'" Po-;;;e~ - ] - ' -. - ..;;. - .... ,
I,.. Distribution }, . ENG SEN I
5
JI
~ch~l'!lal.lc. . . . J6
: . MiniF.use
II
mW1nng
20A
._ ~y~e~s _: _ _ , . :.:,; .:.. __ _.
. PNK 539.
~ower
,,
Distribution
Schematics
In Wiring
Systems
..,._
'
'
-'
'
PNK
~
539'
'
Engine Wiring
Harness
.
-
.
- -
[SJ
Junction Block 2
.
-
'
'
-,
'" - - - - - - - - - - - - -- - - - , Powertrain I
Bank 1
CONN ID
I Control
I
I
I
C1=BLU
I Module
I
I
H02S 1
H02S 1
C2=CLEAR I (PCM)
.J.
'- _ _ _ Signal _ _ _ Low_ _
. _ _ _ .J
121 C2 27-l
>
PNK.. 53. g.. ...

C1
PPL/WHT 1665
'
TAN;WHT 1653
D'
B ,,...
A ,,...
Heated Oxygen
Sensor (H02$)
Bank 2 Sensor 1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
-+..---------H~at~d Oxygen
Sensor Bank i
Sensor.1
,--------t
Gro",d -
, _ - - - - - - - ---<II Distribution
/ - _ _ _ _ _ _ _ _.,. Schematics
/

1nWiring
Systems ..
- -
- ;
548532
Circuit Descrir>,tion
measured with<a OMM, this may display as low as
320 tnV. The oxygen sensor varies the voltage within
a range of about1000 mV when the exhaust is
.
rich, down through about 10 mV when exhaust is lean.
The PCM constantly monitors the H02S signal
during closed loop operation and compensates for a
rich or lean condition by decreasing or. increasing
injector pulse width as necessary. If the H02S voltage
remains at or near the 450 mV bias for an extended
period of time, this OTC will be set, indicating an open
sensor signaLor sen~or.k>w circuit.
Condjtions for Running the OTC

IAT; MAP, Fuel trim, EGR orECT OTCs are
present.
Engine has been running for longer than
4 minutes.
Conditions for ;Setting the OTC

)
H02S signal voltage remains betwE;)en 400 mV

and500mV.

..Records data.
Conditions for. Clearing the Mll/DTC

The PCM will turn the MIL OFF c:luring the
. third consecutive trip in which the. diagnostic has
The History OTC. will clear after 40 consecutive
malfunction.
The OTG~an be cleared by using a scan tool.
6.;894
Engine
Diagnostic Aids
Test Description

diagno~tic table:

Systems.
Damaged harness.
Systems.

specified values.
voltage will be less than 400 m\/ when the
DTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor 1

Step
Action
Values
Yes
No
Go to Step 2
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check .
..

DTCs), refer to other DTCs first before proceeding with
this table.
2

parameter.
specified values?
400-500 mV
Go to Step 3
Go to Step 4
Goto Step 4
Go to
. Diagnostic Aids
Go to Step 15
Go to Step 5

Exhaust leak. Refer to Exhaust System Inspection and
Exhaust Leakage in Engine Exhaust.
O

Systems.
Engine Controls.3.8L 5.;395
Engine
DTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor 1 (cont'd)

Values
Action
Step

. 2. Disconnect the H02S .
3. Jumper the. signal circuit (PCM side) to a good
ground.
4 . With a. scan tool, observe H02S voltage parameter.
Doe.s t.he scan tool indicate H02S voltage more than the
specified value?
5
. .
ly1easure t.he voltage on the H02S low circuit (PCM side)

using ,,1 DMM that is connected to a good ground.
Dqes the.voltage measure near the. specified value?
5V
Test the iow circuitfor an open or high resistance. Refer to

11
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
. Go to Step 15
Go to Step 12

Go to Step 10
4.5V

10
Go to Step 6
400mV

No

side) using aDMM that is connected tci a good
,ground.
Does the voltage measure near the specified vaiue?
Yes

Fuel Contamination. Refer to
Engine .oil or. coolant consumption. Refer to. Oil
Consumption Diagnosis-in Engine Mechanical.
Contamination of Heate.d Oxygen Sensors Notice in
12
13
..
14
,,

in Wiring Systems.

:Repiace the PCM. Refer to PCM Replacement/
Programming.
'
Go to Step 15
.
-
16
Go to Step 15
Go to Step14
Go to Step 15

15

Does the OTC reset?
;
Use the scan tool in order to check for DTCs.

Does the scan toof indicate any DTCs that you have not
diagnosed?
Go to Step 2 .
Go to
applicable OTC
Go to Step 16
System OK
6-896
Engine
DTC P0135 H02S Heater Performance Bank 1 Sensor 1
-i-----,
Engine Wiring
I Harness
I Junction Block 2
J6
I
.__8Y!,!e~s _ _ _ _ _ _ _ _.
... Po-;;;e,:I Distribution

I ~ch~f!latlcs
I in w,nng
J7
ENG SEN
MiniFuse
20 A
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
PNK 539
~---------
----------------------,
r -
I
I
Bank 1
CONN ID
C1=BLU
I
H02S1
H02S1
C2=CLEAR
._ _ _ _ Signal _ _ _ Low _ _ _ _ _ _ _
P6wertrain I
I Control
I Module
I {PCM)
271
.1..
..1
Jb
PNK 539
121 C2
C1
PPL/WHT 1665
TAN/WHT 1653
Heated Oxygen
Sensor (H02S)
Bank2Sensor1
A
"'
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
"'
Heated Oxygen
Sensor Bank 1
Sensor1
,---------t
Ground -
, __ - _ - _ - - -'<Iii
/ - _ _ _ _ _ _ _ -<fl
I
I
- - -
Distribution
Schematics
In Wiring
Systems
(
548532
Circuit Description
Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors to
become active. An Oxygen sensor heater is also
required by catalyst monitor sensor to maintain a
sufficiently high temperature which allows accurate
exhaust oxygen content readings further from
the engine. The PCM will run the heater test only after
a cold start (determined by engine coolant and
intake air temperature at the time of startup) and only
once during an ignition cycle. When the engine is
started the-PCM will monitor the H02S voltage. When
the H02S voltage indicates a sufficiently active
sensor, the PCM looks at how much time has elapsed
since startup. If the PCM determines that too much
time was required for the H02S to become active, this
DTC will set. The time it should take the H02S to
reach operating temperature is based on the engine
coolant temperature at start-up and the average mass
air flow since startup (higher average airflow or
higher startup engine coolant temperature = shorter
time to H02S activity).

present.
Intake air temperature (IAT) is less than
35C (95F) at startup
O Engine coolant temperature (ECT) is less than
35C (95F) at startup.
IAT and ECT are within 6C (11 F) of each other
at start-up.
e
Average mass air flow for the sample period is

less than 20 g/s.
O
The system voltage is between 9 and 18 volts.

H02S voltage remains within 150 mV of the bias
voltage (about 450 mV) for a longer amount of time
than it should. The amount of time ranges between
42 seconds and 2 minutes.

.. The PCM will store conditions which were present
Records data.
Engine

malfunction.
Diagnostic Aids

Connections .and Connector Repairs in Wiring
Systems.
Damaged harness.
change in the display may indicate the location. of
Systems.
6-897
Test Description
diagnostic table:
2. The H02S should be allowed to cool before
performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the H02S
signal will remain near the 450mv bias voltage.
4. This step ensures that the ignition feed circuit to
the H02S is not open or shorted. The test lamp
should be connected to a good ground, in case the
H02S low or H02S heater ground circuit is
faulty.
5. This step tests the H02S heater ground circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a
hot H02S heater element will measure a much
higher resistance .than a H02S heater element at
room temperature). It is important to allow the
H02S to cool before measuring H02S heater
element resistance.
OTC P0135 H02S Heater Performance Bank 1 Sensor 1

Step
Action
Important: If engine has just been operating, allow engine

to cool for about one half hour before proceeding.
parameter.
Does H02S voltage go from bias voltage to more than the
first specified value or less than the
second specified value?
Inspect the H02S ignition feed fuse.
Is the fuse open?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 13
Go to Step 4
600mV
300mV
6-898
Engine

DTC P0135 H02S Heater Performance Bank 1 Sensor 1 (cont'd)
Step
Action
Important: Use a known good ground. Do not use the

H02S heater ground or low circuit.
1. Disconnect the .H02S.
2. Probe the ignition feed circuit (PCM harness side)
using a test lamp that is connected to a good ground
Does. the test lamp illuminate?
Connect the test lamp between the H02S ignition feed

circuit and the H02S heater ground.
Does test lamp illuminate?
1. Allow the H02S to cool for at least 10 minutes.

2. Measure the resistance between the H02S ignition
feed and H02S heater ground at the pigtail using
a DMM.
Does the resistance measure within the specified range?
Repair the open H02S ignition feed circuit. Refer to Wiring

Repair the open H02S heater ground circuit. Refer to

1. Inspect for a poor connection at the H02S.

Test the H02S signal and low circuits for an open. Refer
Inspect the H02S signal or low circuits for a poor

connection at the PCM and H02S. Refer to Testing for
in Wiring System.

13
Repair the short to ground in H02S ignition feed circuit

and replace faulty fuse. Refer to Wiring Repairs in Wiring
Systems.
14

1. Use the scari tool in order to clear the DTCs.
3. With a scan tool, observe the H02S voltage for at
least 2 minutes.
10
11
12
Values
Yes
No
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 12
5 -10 ohms
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 11
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 14
600mV
300 mV
System OK
Go to Step 2
Engine
6-899
DTC P0137 H02S Circuit lowVoltage Bank 1 Sensor 2
-i----
siart]
,Engine Wiring
ENG SEN . .I Harness
Min1.F_u_
lJ.unction Block 2
A se. .I.
!Hot In Run, Bulb Test And

r Po;;erI Di~tribution
J?
Sch. ematics
I 1~W1r1ng
, c;ystems
L------
Power,
Distribution
Schematics
In Wiring
Systems
.,.__ _,
.... ,
r.-------------,
Powertrain
Control
J Module II
M(PCM)
CONN ID
C1,eBLU
C2=CLEAR
I.
J6 .
20
. .
PNK 539
, .
' , PNK 539
'
---
-- __ .:.
.-
- - . . -.,
H02S 21
Signal
Low
G~~r1~~1 . 11
. .
A
----.J
Bank1
~-~~-~I
H02S 2
[SJ.
C2 .
DKBLU 198,0,
l;3
"
PNK 539
Heated Oxygen
Sensor (H02S)
'Bank 1 Sensor 1
Heated Oxygen
Sensor (H02S)
Heated Oxygen
Sensor. Bank 1
Sensor2
Bank 2 Sensor,1
_ _ _ _ _ _ _ _ _ _ _ _ _ _ .J
BLKt50
._. . .
. .
'
BLK 450' ......._ ______

-<II
_ - -
.;:.:_ -
-<OS
.I
Ground
Distribution
Schematics
In Wiring
Systems
)
548539
Circuit Description
Conditions. for. Setting the DTC
To control emissions of Hydrocarbons (HC), Carbon

Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The PCM has the ability
to monitor this process using the post-catalyst H02S.
This H02S produces an output signal which
indicates the oxygen storage capacity of the catalyst;
this in turn indicates the catalysts ability to convert
exhaust gases efficiently. If the post H02S signal
voltage remains excessively low for an extended
period of time, this DTC will set.
Post H02S signal voltage remains less than 60 mV

during normajdosed loop operation.
OR
Post H02S signal voltage remains less than 600 mV
during power enrichment mode.

No Misfire, Transmission, Fuel injector, MAF, TP,
EVAP, IAT, MAP, Fuel trim, EGR or ECT DTCs
are present.
" Closed loop commanded air/fuel ratio is
between 14.5 - 14.8.
" Throttle angle is between 5 percent and
40 percent.
O
The engine coolant temperature is more than

75C (165F).
Action Taken. When the DTC Sets

Records data.

malfunction.
6-900
Engine
Diagnostic Aids
.. Fuel pressure low - A condition which causes a
lean exhaust can cause this OTC to set. The
system will go lean if pressure is too low.
The PCM can compensate for some decrease.
However, if fuel pressure is too low, this OTC may
set. Refer to Fuel System Pressure Test.
~ Fuel injectors faulty - Refer to Fuel Injector
Balance Test.
O Vacuum leaks - Inspect for a disconnected or
damaged vacuum hoses and for vacuum leaks at
the intake manifold, throttle body, EGR system,
and crankcase ventilation system.
Exhaust leaks - An exhaust leak may cause
stream past the H02S, causing this OTC to set.
Inspect for exhaust leaks near the oxygen
sensors.
., MAF sensor faulty - Disconnect the MAF sensor
and see if the condition is corrected. If so,
replace MAF sensor.
Fuel contamination - Water, even in small
Systems.
Damaged harness.
Systems.
Test Description
diagnostic table:
3. This OTC setting during power enrichment mode
conditions may indicate a condition described in
the Diagnostic Aids above. If this OTC test passes
while the Fail Records conditions are being
duplicated, an intermittent condition is indicated.
Engine
6-901

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 7

Important: During this step, observe the pre-catalyst

H02S voltage parameters. If the pre-catalyst parameters
remain below 400mV refer to Diagnostic Aids.
parameters.
parameter.
Does the H02S voltage remain less than the
specified value?

Does the scan tool indicate this DTC failed this ignition?
Disconnect H02S and jumper the low circuit (PCM side) to

a good ground.
Does scan tool indicate H02S voltage near the
specified value?
75mV
450 mV

in Wiring Systems.
Did you find a problem?
Repair the H02S signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Go to Step 8
Replace the PCM.

Go to Step 8

8

Does the DTC reset?
Go to Step 2
System OK
6~902
Engine
-:i ,
IHot In Run, Bulb Test And Start!

'" Power
I Distributi?n
Schematics
1n Wiring
Systems
Power
Distribution
Schematics
In Wiring
Systems
>
CONN ID
C1=BLU
C2 = CLEAR
Bank 1
H02S 2
______
ENG SEN
J6
MiniF. use
20 A
L------
...,.__ -,
L0c
Engine Wiring
I Harness .
I Junction Block 2
',
PNK 539
'
[SJ
----.!
- -
- - - - - - - -
I
I
H02S 2 I
L::'..w ____ ~n~
I I
PNK 539
'
.--------------,
Powertrain
Control
Module II
~(PCM) L
J?
- - -,,
.1
G:1,~~K B~;Fo
PNK 539
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1
Heated Oxygen
Sensor Bank 1
Sensor2
BLKf 50
-.-
,. .
BLK 450' '- ____ -. _

_ - -
- -
-<14
-<II
_,'
.Ground
Distribution
Schematics
In Wiriog
Systems
(
548539
Circuit Description
Conditions for Setting the DTC .

This sensor produces an output signal which
this in turn indicates the catalysts ability to convert
exhaust gases efficiently. If the post H02S voltage
remains excessively high for an extended period
of time, this OTC will set.
Post H02S signal voltage remains more than 999 mV

during normal closed loop operation.
OR
Post H02S signal voltage remains more than 200 mV
during deceleration fuel mode operation.

IAT, MAP, Fuel trim, EGR or ECT OTCs are set.
Closed loop with commanded Air/Fuel ratio
between 14.5 and 14.8.
The throttle position is between 5 percent and
40 percent.

0

Records data.

malfunction.
Engine
Diagnostic Aids

Fuel pressure high - An excessively rich fuel
mixture can cause this DTC to set. Refer to Fuel
System Pressure Test
Fuel injectors faulty - Refer to Fuel Injector
Balance Test
the EVAP Canister is full of fuel, inspect canister
System Diagnosis
sensor. Refer to MAF Sensor Replacement
the system to go rich, due to a false indication of
Shorted H02S "CC. If the H02S is internally shorted
be over 1 volt. Try disconnecting the affected
H02S and jumper the H02S low circuit to ground
with the key ON. If the displayed H02S voltage
changes from over 1OOOmV to around 450mV,
be indicated. This condition is. indicated by a
exposed to the exhaust stream. If contamination
is evident, replace the affected H02S. Refer
to Heated Oxygen Sensor (H02S) Replacement
Open H02S Signal or Low Circuit or Faulty H02S
condition. Operate the. vehicle while monitoring the
the H02S. Refer to Heated Oxygen Sensor
(H02S) Replacement
6;.903

Systems.
Damaged harness.
Systems.
Test Description
diagnostic table:
3. This OTC setting during deceleration fuel mode
operation may indicate a condition described
in the Diagnostic Aids above. If this OTC
test passes while the Fail Records conditions are
being duplicated, an intermittent condition is
indicated. Review the Fail Records vehicle
mileage since the diagnostic test last failed. This
may help determine how often the condition
that caused the OTC to be set occurs.
6;;904
Engine

Step
Action
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5

Diagnostic (080) System Check?
Important: During this step, observe the pre-catalyst

H02S voltage parameters. If the pre-catalyst parameters
remain above 600mV refer to Diagnostic Aids.
1. Operate .the vehicle within the Conditions for Setting
parameters.
parameter.
Does the H02S voltage remain more than the
specified value?


2. Jumper low circuit to a good ground.
Does scan tool indicate H02S voltage near the
specified value?

Disconnect the PCM.
Measure the voltage of the H02S signal circuit at the
PCM harness connector using a DMM that is
connected to a good ground.
Does the voltage measure more than the specified value?
999mV
'
..
450mV
1.
2.
3.
4.
500mV
,.
Repair short to voltage in the H02S signal circuit. Refer to


Replace the PCM.
1. Use the scan tool in order to clear DTCs.

Does the OTC reset?
Go to Step 6
Go to Step 7
Goto Step 8
Go to Step B
Go to Step 2
System OK
Engine
6-905
-i- -.,
r- Power
Distribution
I
Power
Distribution
Schematics
In Wiring
Schematics .
in Wmng
...__ -,
.....
r--------------.,
J.
(PCM)
L -
CONN ID
C1=BLU
C2 = CLEAR
-
H02S 2
-
L~w -
H02S 2
-
l...J:!.I
..I
.....
',
.....
PNK 539
--------------,
r,:
- Sjn~
Engine Wiring
I Harness
I Junction Block 2
PNK 539
I
I
Bankl
ENG SEN
MlnlFuse
20 A
J6
Systems
L -. -
Systems
Powertrain
Control 1.
Module II
Jl
.1
G7I'~6K B:;
PNK 539
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1
Heated Oxygen
Sensor Bank 1
Sensor 2
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1
I
I
BLKt50
-----------.
'
BLK
' "- _ _ _ _ _ _
450
~
_-----------<Ill
-
__ J
Ground
Dlstribu.ti?n
Schematics
lnWiring
Systems
548539
Circuit Description

This sensor produces an output signal which
this in turn indicates the catalyst's ability to convert
exhaust gases efficiently. If the post H02S signal
voltage remains at or near the 450mV bias for
an extended period of time, this OTC will set.
Post H02S signal voltage remains between 412 mV

and 490 mV during normal closed loop operation.

No Misfire, CKP, Fuel Injector, MAF, TP, EVAP,
IAT, MAP, Fuel Trim, EGR or ECT OTCs
are set.
Engine has been running for more than 4 minutes.

Records data.

malfunction.
6-906
Engine
Diagnostic Aids
., Damaged harness.

Corroded exhaust flange bolts - Using a J 39200
Digital Multimeter, ensure that continuity exists
between the engine block and the heated oxygen
sensor shell. If resistance is excessively high, ,
replace corroded exhaust flange attaching
hardware as necessary.
Faulty H02S heater or heater circuit - With the
ignition ON the H02S voltage displayed on a
scan tool should gradually drop to less than
300mV or rise to more than 600mV. If not,
disconnect the H02S and connect a test lamp
between the H02S ignition teed and heater
ground circuits. If the test lamp does not illuminate,
repair the open ignition feed or sensor ground
circuit as necessary. Refer to Wiring Repairs in
Wiring Systems. If the test lamp illuminates
and the H02S signal and low circuits are OK,
replace the H02S. Refer to Heated Oxygen

Sensor (H02S) Replacement
Systems.

Systems.
Inspect the PCM ancl the engine grounds for

the Failure. Records can be useful in determining
Test Description
diagnostic table:
2. When the system is operating correctly the
H02S voltage should toggle above and below the.
specified values.
5.
1.f the low circuit is shorted to ground the

H02S voltage will be less than 400 mV when the

. correctly operating system.

Step
Action
Values

.,
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check.,
Go to Step 3
Gdto Step 4
G.o to Step 4
Go to
Diagnostic Aids
1
.
Yes

this table.
parameter.
specified values?
400~500 mV


0
Systems.
(
Go to Step 15
Go to Step 5
Engine
6~907

Step
Action
ground.
specified value?
Values
Yes
No
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 12
400mV

6
10
11
12
13
14
15
16

ground.
Did you find ahd correct the condition?
Replace the. effected H02S sensor. Refer to Heated
Oxygen Sensor (H02S) Replacement. .
in Wiring Systems.
Replace ~he PCM. Refer to PCM Replacement!
rogrammmg.
1. Use the scan tool iri order to clear the DTCs.
Does the OTC reset?
Use the scan tool in order to check for DTCs'.
Does th.e scan tool indicate any DTCs that you have not
diagnosed?
4.5V
5V
Go toStep 15
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step2
Go to Step 16
Go to
applicable OTC
System OK
6-908
Engine
DTC P0141 H02S Heater Performance Bank 1 Sensor 2.
l I
r Po;er-
Distributi?n
I
I
Schematics
in
Wiring
Distribution
Schematics
~ -,
Control
(PCM)
,.-------------,I
I
I
... -
ENG SEN
MiriiFuse
J6
20 A
Engine Wiring
I Harness
.
I Junction Block 2
I
'
',
.....
[SJ
N
.~
PNK 539
-
Bank1
-,,
-- .
'
~----~I
C1=BLU
C2=CLEAR
-
PNK 539
.....
Systems
> Module
J?
.
Systems
In Wiring
CONN ID
L------ ----.J
Power
Powertrain
H02S 2 I
H02S 2
Low
-
Signal
-
28IC1
1981
GRY
- , - .I
11IC2
DKBLU 1980
'f
PNK 539
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1
Heated Oxygen
r-+-----+-------t---. Heated Oxygen
Sensor(H02S)
Bank 2 Sensor 1
Sensor Bank 1
sensor 2
C
I
I
. .
BLKt50
----'
..
BLK
'
'
450
_ - -
"'-- _
- -
,. - - - - - -
_ _ _ _
- - - -
...
.
-'-<II
-- - -411
G~~
Distrlbutl?n
Schematics
In Wiring
Systems
(
548539
Circuit Description
amount of time required for the pre-catalyst oxygen
sensors to become active. An oxygen sensor heater is
required by catalyst monitor sensor to maintain a
exhaust oxygen content readings further from
the engine. The PCM will run the heater test only after
a cold start (determined by engine coolant and
intake air temperature at the time of startup) and only
started the PCM will monitor the H02S voltage. When
the post H02S voltage indicates a sufficiently active
time was required for the post H02S to become active,
this OTC will set. The time it should take the H02S
to reach operating temperature is based on the engine
coolant temperature at start-up and the average
Mass Air Flow since startup (higher average airflow or
Conditions for Running ttie DTC

IAT, MAP, Fuel. trim, EGR or ECT OTCs.
System voltage is between 9 and 18 volts.
.
" Engine coolant temperature (ECT) is less than
IAT and EC.Tare within 6C (11 F) of each other
at start~up.
" The average mass air flow for the sample period
is less than 22.Tgm/s.

Post H02S voltage remains within 150 mV of the
bias voltage (aboutA50;mV).
The.amount of time depends on engine coolant
temperature atstartup and the average air flow
since startup.

lamp (MIL) during the second cohsecutive trip in
which the diagnostic test has been run and failed .
Records data.
Engine

The PCM will turn the MIL .OFF during the
malfunction.
Diagnostic Aids
surfaces before servicing a component Inspect
Systems.
Damaged harness.
Systems.
the Failure Records can be useful in aetermining
6-909
Test Description
diagnostic table:
warms. If the heater is. not functioning, the H02S
signal will remain near the 450mV bias voltage.
4. This step ensures that the. ignition feed circuit to
should be connected to a good chassis ground, in
case the H02S low or H02S heater ground
circuit is faulty.
6. This step tests for an open or shorted H02S
heater element. The heater element resistance will
vary according to H02S temperature (a hot
H02S heater element will measure a much higher
resistance than a H02S heater element at
element resistance.
11. An open H02S' signal or low circuit can cause the
H02S heater to appear faulty. inspect these
circuits before replacing the sensor.

Step
Action

parameter.
Does H02S voltage vary from bias voltage to more than
the first specified value or less than the
Inspect ignition feed fuse for the H02S.
Is the fuse open?
Values
Yes
No
Go to Step 2
Go to A
Powettrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
,Go to Step 15
Go to Step 4
..
600 mV
300mV
6-9.1 O Engine Controls - 3.8L
Engine

Step
10
11
12
13
14
15
16
Action
H02S heater ground circuit or the H02S low circuit.
2. Probe the H02S ignition feed circuit (PCM side)
using a test lamp that is connected to a good ground.
Connect a test lamp between H02S ignition feed and
H02S heater ground.
2. Measure the resistance between the ignition feed
circuit and the heater ground circuit at the H02S
pigtail using a DMM.
Repair open H02S heater ground circuit. Refer to Wiring
Inspect for poor connections at the H02S. Refer to Testing
1. Test for continuity of the H02S signal circuit and the
H02S low circuit. Refer to Circuit Testing in Wiring
Systems.
2. If either circuit measures over 5 ohms, repair open or
poor connection as necessary. Refer to Testing for
Intermittent and Poor Connections and Connector
Repairs or Wiring Repairs in Wiring Systems.
Inspect for a poor H02S signal or low circuit connection at
the H02S. Refer to Testing for Intermittent and Poor
Inspect for a poor H02S low circuit connection at the
PCM. Refer to Testing tor Intermittent and Poor
Did you find and correct the conditiori?
Inspect for a poor H02S signal circuit connection at the
PCM. Refer to Testing tor Intermittent and Poor
Sensor (H02S) Replacement
and replace the faulty fuse. Refer to Wiring Repairs in
Wiring Systems.
1. Clear the DTCs
3. Wi.th a scan tool, observe the H02S voltage
parameter.
Values
Yes
No
(
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 14
5-10 ohms
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 10
'
(
Go to Step 16
Go to Step 11
Go to Step 16
Go to Step 12
Go to Step 16
Go to Step 13
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 16
600mV
300mV
(
System OK
Go to Step 2
Engine
-i
6-911
r Po;er-
I
I
I
Power
Distribution
Schematics
In Wiring
Systems
._
J?
Distribution
Sche,:natics
1n Wmng
~y~e~
~--
J6
-
ENG SEN
MinlFuse
20 A
.,Engine
1HarnessWiring
I Junction Block 2
pv;;-,
Llli
PNK 539
' ' , PNK 539

'
1-------------------------I
I
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1
Powertrain r
Control I
I
Module
(PCM) I
J.
M
CONN ID
.,
I
I
I
Bank 2
C1=BLU
C2=CLEAR
H02S 1
H02S 1
L----------------.29I.C1 10IC2
Low
TA: 16f>7
Signal
P~L 1666
.1
PNDK 539
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 2
Sensor 1
y
I
I
I
________________________ !~Kt50
"'
.
. BLK=4~0- ~----_-_-_-_
.
---==
Ground
Distribution
Schematics
In Wiring
Systems
548543
Circuit Description

measured with a OMM, this may display as low as
350 mV. The oxygen sensor varies the voltage within
a range of about 1000 mV when the exhaust is
rich, .down through about 100 mV when exhaust. is
lean. The PCM constantly monitors the H02S signal
during closed loop operation and compensates for
a rich or lean condition by decreasing or increasing
injector pulse width as necessary. If the HO~S voltage
remains excessively low for an extended penod of
time, this OTC will be set.
H02S signal voltage remains less than 175. mV during

OR
H02S signal voltage remains less than 6000 mV
during power enrichment.

present.
40 percent

lamp (MIL) during the second consecutive trip. in
Records data.

.. The History OTC will clear after 40 consecutive
malfunction.
6-912
Engine
Diagnostic Aids
Throttle body inlet screen blockage
Low fuel pressure - The system will go lean if
pressure is too low. The PCM can compensate
for some decrease. However, if fuel pressure
is too low, a H02S DTC may set. Refer to Fuel
stream past the H02S, causing the system to
Faulty MAF sensor - Disconnect the MAF sensor
and see if the lean condition is corrected. If so,
replace the MAF sensor.
Alcohol/Contaminants-in-Fuel Diagnosis for
procedure to test for fuel contamination.
If none of the above conditions are present, replace

the affected H02S.
Test Description
diagnostic table:
3. This DTC failing during power enrichment
operation (TP angle above 60 percent) may
indicate a condition described in Diagnostic Aids.
If this DTC test passes while the Fail Records
conditions are being duplicated, an intermittent
condition is indicated. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition that caused the DTC to be set
occurs.

Step
Action
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 7
Go to Step 8
Go to Step 6
Values

parameters. If all parameters remain below the specified
1. Operate vehicle within the Conditions for Setting

parameters.
Does the H02S voltage remain below the specified value?
Does scan tool indicate H02S voltage less than the
specified value?
Important: The replacementPCM must be programmed.
Does the OTC reset?
400mV
400mV
Goto Step 8
Go to Step 8
Go to Step 2
System OK
Engine
l_ -
6-913
OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1
!Hot In Run, Bulb Test And Startl

Power_
I Distribution
J7
I Sche'!'atics
I
POIAer
Distribution
Schematics
In Wiring
Systems
J6
1nW1nng
._ ~y:!_e';;; -
ENG SEN
MlnlFuse
20A
,Engine Wiring
I Harness
I Junction Block 2
[M;"l
LJ.I
..,
PNK 539
...---- .....
' , PNK 539
r---------------------I
Heated Oxygen
Sensor (H02So
Bank 1 Sensor 1
Powertrain ' - - - - . - - - - - - - - - - - - ,
Control I
CONN ID
Bank 2
I
I
C1=BLU
I
Module ._
C2=CLEAR
H02S_1
H02S 1
I
..,
(PCM) I
Low
Signal
_________________
j)
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 2
I I
29 C1
T~ 1667
10 C2
P~ 1666
PN; 539
,......j..----'---1----+-, Heated Oxygen
Sensor Bank 2
Sensor 1
Ground
Distribution
Schematics
In Wiring
Systems
548543
Circuit Description

rich down through about 10 mV when exhaust is lean.
Th~ PCM constantly monitors the H02S signal
during closed loop operation and_ comp~nsate~ for a
rich or lean condition by decreasing or increasing
injector pulse width as necessary. If the H02~ voltage
remains excessively high for an extended penod of
time, this OTC will be set.
H02S signal voltage remains more than 975 mV

during normal closed loop operation
OR
H02S signal voltage remains more than 200 mV
during decel fuel cutoff.

No Misfire, CKP, Fuel ii:ijector; MAF; TP, EVAP,
present.
40 percent

lamp (MIL) during the second consecutive trip. in
Records data.

" The PCM will turn the MIL OFF during the
malfunction.
6-914
Engine
Engine Controls - 3J.ll
Diagnostic Aids
High fuel pressure - The system will go rich if
high, a H02S OTC may set. Refer to Fuel
Fuel Injector Balance Test.
System Diagnosis.
sensor.
the system to go rich due to a false indication of
Shorted H02S - If the H02S is internally shorted
be over 1 volt. Disconnect the affected H02S
and jumper the H02S low circuit to ground with
the key ON. If the displayed H02S voltage
changes from over 1000 mV to around 450 mV,
be indicated. This condition is indicated by a
exposed to the exhaust stream. If contamination
is noticed, replace the affected H02S.
Open H02S Signal or Low Circuit or Faulty H028

condition. Operate the vehicle while monitoring the
the H02S.
Test Description
The numbers below refer to step numbers on the .
diagnostic table:
3. This OTC failing during deceleration fuel mode
operation (vehicle speed above 25 mph, TP
angle below 3 percent) may indicate a condition
described in Diagnostic Aids. If this OTC test
passes while the Fail Records conditions are being
duplicated, an intermittent condition is indicated. .
anElectrically Erasable Programmable Read Only
Engine
6-915

Action
Step
Values
Yes
Did you perform the Powertrain on~Board

Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go toStep5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 7
No

parameters. If all parameters remain above the specified

parameters.
parameter.
Does the H02S voltage remain above the specified vl'!lue?
Operate vehicle in Decel fuel mode (vehicle speed above

25 mph, TP angle below 3 percent) while observing the
H02S voltage parameter on the scan tool.
Does the H02S voltage remain above the specified value
while in Decel fuel mode?
Operate the vehicle within the Fail Records conditions.

Disconnect the H02S.

Does scan tool indicate H02S voltage more than the
specified value?
Test for a short to voltage on the H02S signal circuit.

Refer to Circuit Testing and Wiring Repairs.
110mV
500 mV
)
7

Sensor (H02S} Replacement.
Does the DTC reset?
600 rriV
Go to Step 9
-
.
-
Go to Step 9
Go to Step 2
System OK
..
6-916
Engine
-i----
r Po;er-
I
I1
Power
Distribution
Schematics
In Wiring
Systems
..,...._
Sche.. ,:natics
__
a.
J?
Distribution
1nW1r1ng
~y~e~
J6
- -
20A
,Engine
1HarnessWiring
IIJunction Block 2
- - - -
..,
ENG SEN
rvliniFuse.
PNK 539
'
'--.... PNK 539
' --....
,-------------------------Powertrain ... - - - - - - - - - - - - - - - - - ,
Control I
MO d UIe I
(PCM) I
v
Heated Oxygen
Sensor (H02So
Bank 1 Sensor 1
CONN ID
C1=BLU
C2=CLEAR
Bank2
I
H02S 1
H02S 1
Low
Signal
> . - - - - - - - 29'""' c1 . . -10 - e2 ~

r-rJ,667 P~Lr,666
I
.1
PNt 539
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 2
Sensor 1
I' -
- - - - - - - - - - - - - - - - - - - - - - -
BLKt50
BLK .,;,' ~ - -
- - - - --<
--- .. --------..
Ground
..
Distribution
s'ctiematics
In Wiring
Systems
(
548543
Circuit Description

sensor (H02S) activity. The PCM counts the number
of times that a rich to lean and a lean to rich
response is indicated. Then, the PCM adds the
amount of time it took to complete all transitions for a
100 second test period. With this information, an
average time for each transition can be determined. If
the average response time is too slow, a DTC P0133
will be set. A lean to rich transition is indicated
when the H02S voltage changes from less than
300 mV to more than 600 mV. A rich to lean transition
is indicated when the H02S voltage changes from
more than 600 mV to less than 300 mV. An H02S that
responds too slowly is likely to be faulty and should
be replaced.
H02S lean to rich average transition response time

was longer than 63 milliseconds. The rich to lean
average transition response time was longer than
190 milliseconds.

present.
50C (122F).
Engine speed is between 1000 RPM and
3000 RPM.
Mass air flow is between 10.0 g/s and 30 g/s.

Records data.

malfunction.
Engine
6-917
Diagnostic Aids
Test Description

diagnostic table:

Systems.
Damaged harne.ss.
on the scan tool while r:noving connectors
Systems.
.clean and secure connections.
.

specified values.
14. This.vehicle is equipped with a PCM which utilizes
\)

''
Step
Action

this table.
parameter.
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 15
Go to Step 5
400-500 mV

specified values?
,'



. , Damaged wiring. Refer to Wiring Repairs in Wiring
Systems.
6-918
Engine

Step
Action
.3. Jumper the signal circuit (PCM side) .to a good
ground.
4. With. a scan tool, observe H02S voltage parameter.
specified value?
Values

5V


10

12

Go to SteptO
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step B
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
.Go to Step 14
4.5V
Go to Step 15
Go to Step 12
Go to Step 15
13

in Wiring Systems.
14

Replace the PCM. Refer to PCM Replacement!
Programming.
15

Does the DTC reset?

diagnosed?
16
Go to Step 6
400mV
11
No
..

ground.

Yes
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 2
Go to Step 16
Go to
applicable OTC
System OK
Engine
6-919

r _ _ !Hot lnlRun:.=3u1bTest And Startl
Power
I Distributi?n
I
Schernat,cs
I .,n wrri ng
J7
ENG SEN
.
J6
rvi,mFuse
. .
20 A
Engine Wiring
1Harness
.
1
I Ju. nct1on Block 2
Systems
Power
Distribution
L,
+- _ _
Schematics
.-
'
PNK 539
'
In Wiring
Systems
' , PNK 539

......
1--------------------------'
I
v
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1
Powe.rtrain r
Control I
Module I
.I
(PCM)
~
CONN ID
1 =BLU
C2=CLEAR
H02S 1
Low
I
I
I
Bank 2
H02S 1
Signal
L-----------------~
r!H~7
Heated Oxygen
~F~
PN K 539
0
Sensor (H02SO
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 2
Sensor 1
~ ______ . _ . _______________ BLKt4:0

.
BLK=
'
450 '- - - - - - - -:::
Ground
Distribution
Schematics
In Wiring
Systems
548543
Circuit Description

rich, i:lown through about 10 mV when exhaust is lean.
The PCM constantly monitors the H02S signal
during closed loop operation and compensates for a
rich or lean condition by decreasing or increasing
injector pulse width as necessary. If the H02S voltage
remains at or near the 450 mV bias for an extended
perioi:l of time, this OTC will be set, indicating an open
sensor signal or sensor low circuit.
H02S signal voltage remains between 400 mV

and 500 mV.

present.
Engine has been running for longer than
4 minutes.

. 0 The PCM will store conditions which were present
Records data.

" The History DTC will clear after 40 consecutive
malfunction.
O The OTC can be cleared by using a scan tool.
6-920
Engine
Diagnostic Aids
Faulty H02S heater or heater circuit - With the
ignition ON the H02S voltage displayed on a scan
tool should gradually drop to less than 250 mV or rise
to more than 600 mV. If not, disconnect the H02S
and connect a test lamp between the H02S ignition
feed and heater ground circuits. If the test lamp
does not illuminate, repair the open ignition feed or
sensor ground circuit as necessary. Refer to
Wiring Repairs in Wiring Systems. If the test lamp
illuminates and the H02S signal and low circuits are
OK, replace the H02S.
.. Poor terminal connection.
Systems.
Damaged harness.

Systems.
Test Description
diagnostic table:
2. When the system .is operating correctly the H02S
specified values.

Step
Action

this table.
parameter.
specified values?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 15
Go to Step 5
400-500 mV


Systems.
Engine
6-921

Action
Step
Values
Yes
No
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 12


5
ground.
specified value?
400mV

6

ground.
4.5V

5V


10

11


12
13
Inspect ahd test for the following:

Alcohol!Contaminants-in,Fuel Diagnosis
in Wiring .Systems.
Go to Step 15
Go to Step 15
Go to Step 14
14

Programming.
Go to Step 15

15
Does the OTC reset?
Go to Step2
Go to Step 16
Go to
applicable OTC
System OK
16
diagnosed?
6-922
Engine
IHot In Run, Bulb Test And Start!

.- Power- ] I Distribution
J?
ENG SEN
I Schematics
MlnlFuse
I 1n Winng
J6
20 A
Systems
,.___ L-----__ PNK 539----..1
Power
Distribution
Schematics
In Wiring
Systems
r -
,Engine Wiring
I Harness
I Junction Block 2
'
' , PNK 539

-
'-
Powertrain .- - - - - - - - - - - - - - - - - - ,
Control I
CONN ID
C1=BLU
C2=CLEAR
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1
M O d U Ie
(PCM} I
J.
bf;,
Bank 2
H02S 1
Low
I
H02S 1
Signal
29- C1 - -10 - C2 -
'
I
J
T~r,667 P~Lr,666 PN; 539
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 2
Sensor 1
I
I
I
IL-------------------------BLKt50
~,
Ground
BLK 450 "- - - - - - -
- "
Distribution
-<1
Schematics
'-<fl
In Wiring
Systems
(
548543
Circuit Description
amount of time required for fuel control sensors to
become active. An Oxygen sensor heater is also
required by catalyst monitor H02S to maintain a
exhaust oxygen content readings further from the
engine. The PCM. will run the heater test only after a
cold start (determined by engine coolant and intake
air temperature at the time of startup) and only
started the PCM will monitor the H02S voltage. When
the H02S voltage indicates a sufficiently active
time was required for the H02S to become active, this
OTC will set. The time it should take the H02S to
reach operating temperature is based on the engine
coolant temperature .at start-up and the average mass
air flow since startup (higher average airflow or

present.
" Engine coolant temperature (ECT) is less than
IAT and ECT are within 6C (1 iF) of each other
at start-up.
Average mass air flow for the sample period is
less than 20 g/s.
.. The system voltage is between 9 and 18 volts.
Conditions for Setting the OTC

H02S voltage remains within 150 mV of the bias
voltage (about 450 mV) for a longer amount of time
than it should. The amount of time ranges between
42 seconds and 2 minutes.

" The PCM will illuminate the. malfunction indicator
Records data.
Engine

malfunction.
Diagnostic Aids

the connector gaskets when diagnosing. or replacing a
terminals, impropermating, broken locks,
Systems.
O Damaged harness.
change in the display may indi.cate the location of
Systems.
6-923
Test Description
diagnostic table:
warms. If the heater is not functioning, the H02S
signal will remain near the 450 mv bias voltage.
4. This step ensures that the ignition feed circuit to
should be connected to a good ground, in case the
H02S low or H02S heater ground circuit is
faulty.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a
hot H02S heater element will measure a. much
higher resistance than a H02S heater element at
element resistance.

Step
Action

parameter.
Inspect the H02S ignition feed fuse.
Is the fuse open?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 13
Go to Step 4
600mV
300mV
6-924
Step
Engine

Action
Values
Yes
(
-
Connect the test lamp between the H02S ignition feed

circuit and the H02S heater ground.

2. Measure the resistance between the H02S ignition
feed and H02S heater ground at the pigtail using
aDMM.
10
Test the H02S signal and low circuits for an open. Refer
11
Inspect the H02S signal or low circuits for a poor

connection at the PCM and H02S. Refer to Testing for
in Wiring System.
12

13

and replace faulty fuse. Refer to Wiring Repairs in Wiring
Systems.

Go to Step 8'
Go to Step9
Go
to Step
12
1. Inspect for a poor connection at the H02S.

14
Go to Step 6
, Go to Step 14

3. With a scan tool, observe the H02S voltage for at
least 2 minutes.
Go to Step 7

Go to Step 5
5'-10 ohms
No
'.

H02S heater ground or low circuit.
2. Probe the ignition feed circuit (PCM harness side)
using a test lamp that is connected to a good ground
Go
to Step 14
Go to Step 14 ..
1
'.,
Go tb Step 10
(
Go.toStep 14
Go to Step 11
'!
Go to Step 14
Go. to Step 12
Go to Step 14
.,
Go to Step 14
600mV
300mV
System OK
Go to Step 2
Engine
6-925
DTC P0171 Fuel Trim System lean Bank 1

Circuit Description
closed loop air/fuel metering system is used. While in
closed loop, the PCM monitors the pre-catalyst
H02S signals and adjusts fuel delivery based upon
thesevoltages. A change made to fuel delivery will be
indicated. by the long and short term fuel trim values
which .can be monitored with a scan tooL Ideal fuel trim
values. are around O percent; .if the H02S. signals
are indicating a lea.n condition the PCM will add fuel,
resulting in fuel trim values more than O percent. If
a rich condit.ion is detected, the fuel trim values will be
less than O percent, indicating that the PCM is
reducing the amount of fuel delivered: If an excessively
lean condition is detected, the PCM will set.this
OTC. The. PCM s maximum authority to control long
term fuel trim allows a range between -20 percent and
+20 percent. The PCM s maximum authority to
control short term fuel trim allows a range between
-20 percent and+2Q percent. The PCM monitors fuel
trim under various operating conditions (fuel trim
cells) before determining the status of the fuel trim
diagnostic. The fuel trim cells are as follows:
.).
Purge OFF
Cell
Purge ON
. Idle (Cell 0)
Decel (Cell 1)
Accel (Cell 3)
x
x
x
x
High Flow (Cell4)
Normal (Gell 2)
.-
The vehicle may have to be operated in an ofthe

above conditions (marked with X) before the PCM
determlnes fuel trim status.The amount of fuel
trim deviates from O percent in each cell and the
amount that each cell is used directly affects whether
or not the vehicle must be operated in all of the
cells described above to complete the diagnostic.
Important: Some. conditions can cause multiple cells
to indicate lean.
Below are sonie examples of why each eel.I could

indicate a lean condition in each cell.
Idle (Purge ON) - An EVAP system leak, manifold
vacuum leak, severe' lack of fuelsupply, fuel
contamination or an exhaust leak.
Id.le (Purge OFF) - A ~anifoJd vacuum Jea:k,
severe lack of fuel supply, fuel contamination or an
exhaust leak.

Decel (Purge ON) - An EVAP system leak,.

manifold vacuum leak, fuel contamination or an
exhaust leak.
Decel (Purge OFF) - A manifold vacuum leak, fuel
" Normal (Purge ON or OFF) - A lack of fuel supply,

fuel contamination or an exhaust leak.
Acee! (Purge ON or OFF) - A lack of fuel supply,
fuel contamination or a:n exhaust leak;
" High FloVI( (Purge ON or OFF) - A lack of .fuel
supply, fUel contamination or an exhaust leak.
Below are some reasons for a lack of fuel supply.
A faulty or restricted fuel injector.
. A restricted fuel line.
A faulty or restricted fuel pump.
A faulty or restricted fuel regulator.
A restricted .fuel filter.

No VSS, EST, CKP, CAM, TP, Misfire, Fuel
injector, MAF, 02, MAP, EGR, EVAP, ECT or IAT
OTCs are set.
Engine coolant temperature between 20c (68F)
and 110C (230F).
Intake' air temperature is .between -18.C (0F) and
70C (158F).
.
Manifold absolute pressure is between 15 kPa
' and 85 kPa.
Throttle angle is steady .and less than 90. percent.
Vehicle speed is. less than 132 km/h (82 mph) .
Engine speed is between 600 and 4000 RPM.
Baro is more than 70 kPa .
Air flow is between 3 gm/s and 150 gm/s.
Conditions for Setting the.OTC

Long term fuel trim average is more than
+ 17 percent and the short term fuel trim average
is more than .+2 percent of the indicated cells
in .the Fuel Trim Cell Table..
All of the conditions described above have been
met in the Fuel Trim Cells for more than
1 second.
Acti<m Taken When the OTC Sets

lai:np (MIL) during the second consecutive trip in
O The PCM will store conditions which were present
whEm the OTC set as Freeze Frame/Failure
Records data.

The PCM w.ill turn the MIL OFF during the
third cons.ecutive trip in which the diagnostic has
malfunction.
6-926
Engine
Diagnostic Aids
Fuel pressure/flow low - The system will go lean
and add fuel during high fuel demand. The
Accel and the High Flow cells will increase to
more than O percent if this condition is present.
The PCM can compensate for some dec.rease.
However, if fuel pressure is too low, both
DTC P0171 and P0174 may be set. Refer to Fuel
Fuel injectors faulty - The system will go lean and
add fuel if a fuel injector is not suppling enough
fuel. All cells could increase to more than
O percent depending on the severity of the
problem. In most cases high fuel demand cells
such as Accel and High Flow will be more likely to
show the problem. Refer to Fuel Injector
Balance Test.
Vacuum leaks - Inspect for disconnected or
the intake manifold, throttle body, EGR system
and crankcase ventilation system. The Idle
cells (Purge ON or OFF) will increase to more
than O percent if this condition is present.
EVAP system leaks - Inspect for disconnected or
damaged EVAP lines and hoses. The Idle cell
with (purge ON) will increase to more than
O percent if this condition is present.
All cells could increase to more than O percent
depending on the severity of the problem.
Alcohol/Contaminants-in-Fuel Diagnosis. All cells
could increase to more than O percent depending
on the severity of the problem.

Systems.
Damaged harness.
Systems.
Test Description
diagnostic table.
2. This step determines whether the fault is present.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit. Using this kit prevents damage
to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.
4. If both lean DTCs are set, both banks of the
engine are operating lean. Inspect the items that
would cause both banks to operate lean.
5. A vacuum leak causes DTCs P0171 and P0174 to
set at the same time. Inspect all areas of the
engine for a vacuum leak. Also inspect the PCV
.valve for being thecorrect one for this application.
Make sure the engine oil fill cap is in place and
that it is tight. Insure the engine oil dip stick is fully
seated.
Engine
6-927

Values
Action
Step
Did you perform the Powertrain On-Board.

Qjagnostic (OBD) System Check?
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
.Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 7
Go to Fuel
System
Pressure Test
Go to Step 7
Go to Fuel
System
Diagnosis
Important: If any DTCs are set, except P0171 and P0174

refer to those DTCs before proceeding with this table.
1. Idle the engine at the normal operating temperature.
2. Fuel system in Closed Loop.
Yes
+17% LT
3. With a scan tool, observe th~ Long Te.rm FT

parameter.
Does the scan tool indicate fuel trim less than the
specified value indicated?
2. Turn OFF the ignition for 15 seconds.
3. Sfartthe engine.
3

the OTC, and as close to the Failure Record~
conditions as possible.
Does the scan tool indicate that this OTC failed this
ignition?
Is the other Lean OTC also set?
Visually/physically inspect the following items:

O
Vacuum hoses for splits, kinks, and proper

connections. Refer to Under Hood Vacuum Hose
Routing Diagrams..
Crankcase ventilation valve and/or system for leaks.

Refer to Crankcase. Ventilation System inspection.
e
Contaminated f.~el. Refer tp

Alcohol/Contaminants~in-Fuel Diagnosis:
PCMand sensor grounds are clean, tight and in the

proper locations. Refer to Testing for Intermittent and
Poor Connections in Wiring Systems.
Engine mechanical failure. Refer to Base Engine

Misfire Diagnosis in Engine Mechanical.
Did you find any problems in any of the above areas?
Visually/physically. inspect the following items:
Exhaust leaks, missing or loose exhaust hardware.
H02S is installed securely and the electrical connector
not contacting exhaust system or ignition wires.
..
Vacuum leaks that will only affect this bank, such as

the intake manifold, the injector 0-rings, ,etc ..
Was a problem found in any of the above areas?

Repair or replace any faulty items found.

.
-
Go to Step 8
Does this OTC reset?
diagnosed?
Go to Step 2
Go to Step 9
Go to
applicable OTC
System OK
6-928
Engine

Conditions for Running .the DTC
Circuit Description
these voltages. A change made to fuel delivery will be
indicated by the long and short term fuel trim values
which can be monitored with a scan tool. Ideal fuel trim
values are around O percent; if the H02S signals
are indicating a lean condition the PCM will add fuel,
a rich condition is detected, the fuel trim values will be
reducing the amount of fuel delivered. If an excessively
rich condition is detected, the PCM will set this
DTC. The PCM maximum authority to control long
-20 percent and +20 percent. The PCM monitors fuel
Cell
Purge ON
Idle (Cell O}
x
x
x
x
x
Decel (Cell 1)
Normal (Cell 2)
Accel (Cell 3)
High Flow (Cell 4)
Purge OFF
The vehicle may have to be operated in all of the

determines fuel trim status. The amount of fuel
trim deviates from O percent in each cell and the
Important: Some conditions can cause multiple cells

to indicate rich
Below are some examples of why a rich condition
could exist in the above cells.
A saturated EVAP canister - This will affect the
purge ON cells
" A faulty fuel regulator
., Gas in the oil pan
.. A fuel return restriction
O
A engine misfire
.. A faulty fuel injector
O
A restricted exhaust
No VSS, EST, CKP, CAM, TP, Misfire, Fuel

injector, MAf, 02, MAP, EGA, EVAP, ECT or IAT
DTCs are set.
Engine coolant temperature between 20c (68F)
and 110C (230F).
" Intake air temperature is between ~18C (0F) and
70C (158F).
and 85 kPa.
.. Throttle angle is steady and less than 90 percent.
Vehicle speed is less than 132 km/h (82 mph).
E:ngine speed is between 600 .a,nd 4000 fiPM.
O Baro is more than 70 kPa.

The long term fuel trim average is at or near
maximum authority of -:-18 percent and the
short term average fuel trim is at or near.maximum
authority of -2 percent of the indicated cells in
the Fuel trim table.
.. All conditions have been mehn the Fuel trim cells
for more than 1 second.
Action Taken When the DTC Sets .

lamp (MIL) during the. second consecutive trip in ,
which the diagnostic test has. been run and failed.
The PCM will store conditions which. were present
Records data.

The History DTC willclear after 40 consecutive
malfunction.
Engine
Diagnostic Aids
Fuel pressure high - The system will go rich if
high, a OTC P0172 and P0175 may set. Refer
. to Fuel System Pressure Test
Balance Test.
System Diagnosis.
Inspect for a leaking. fuel pressure regulator
fuel pressure regulator for the presence of
fuel. If there is fuel in the vacuum line, refer to
Fuel System Pressure Test.
Fuel in the oil pan - The system will go rich if the
large amounts of fuel are purged from the
oil pan.
Engine misfire - The sill go rich due to the lack of
complete combustion.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
Restricted exhaust - The system could indicate a
rich condition. Refer to Restricted Exhaust
System Check.


Systems.
6-929
" Damaged harness.

Inspect the wiring harness for damage. If the .
Systems.
If the ~TC is determined to be intermittent, reviewing
Test Description
The numbers .below refer to the step numbers on the
diagnostic table.
If you cannot duplicate the OTC, the information
~ecords data can help determine how many miles
since the OTC set. The Fail Counter and Pass
will isolate when the OTC .failed. For an
4. If the both rich OTCs are set, both banks are
operating rich. Inspect items that would cause both
banks to operate rich.
5. Excessive fuel in the oil will cause DTCs P0172
and P0175 to set at the .same time. Remove
the PCV valve from the intake manifold and plug
with a suitable stopper. Also disconnect the
fresh air pipe from the rocker cover and plug using
a suitable stopper. If the long terrn and short
term fuel trim values increase, indicates there is
fuel in the oil.
6-930
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check

Important: If any DTCs are set, except POi 72 and P0175,

3. With a scan tool, observe the Long Term FT Bank
parameter.
Does the scan tool indicate fuel trim more than the

the DTC, and as close to the Failure Records
Does the scan tool indicate that this DTC failed this
ignition?
Is the other Rich DTC also set?

Collapsed air intake duct.
The air filter element for being restricted. Refer to Air
Cleaner Element Replacement.
MAF sensor for being installed in the proper direction
and for foreign objects blocking the inlet screen. Refer
to MAF Sensor Replacement.
For fuel in the pressure regulator hose. Refer to Fuel
Pressure Regulator Replacement.
For excessive fuel in the crankcase. Change oil as
necessary.
Important: When the fuel system check is finished, return

to this table.
Inspect the injectors for leakage, refer to Fuel Injector
Balance Test.
Are any injectors leaking?

Replace the faulty H02S. Refer to Heated Oxygen


Does this DTC reset?
10
diagnosed?
-18% LT
Go to Step 3
. Go to Step4
Go to Step4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 7
Go to Fuel
System
Pressure Test
Go to.Step 9
Go to Step B
Go to Step 9
Go to Step 9
Go to Step 2
Go to Step 10
Go to
applicable DTC
System OK
Engine
6-931'

Circuit Description
these Voltages. A change made to fuel delivery will be
indicated by the long and short termfuel trim values
less than O percent, indicating that the PCM is .
lean condition is detected, the PCM will set this
DTC. The PCM s maximum authority to control long
cells) before c::letermining the status of the fuel trim
Cell
Idle (Cell 0)
becel (Cell 1)
.Norn;ial (Cell 2)
...
Acee! (Cell 3)
High Flow (Cell4)
Purge ON
Purge OFF
x
x
-
x
x
x
The vehic.le may have to be operated in all of the

trirndevia,te~from .0 percent in each cell and the
cells described' above to complete the diagnostic.
Important: .So.me conditions can cause multiple cells
to indicate lean.
Below are some examples of why each cell could
indicate a lean condition in each cell.
Id.le (P.urgeON) - An E.VAP system leak, manifold
vacuum foak, severe lack of fuel supply, fuel
" .Idle (Purge OFF) - A manifold vacuum leak,
severe.lack of fuel supply, fuel contamination or an
exhaust leak.
" Decel (Purge ON) - An EVAP system leak,
manifold vacuum leak, fuel contamination or an
exhaust leak.
Decel (Purge OFF) - A manifold vacuum leak, fuel
" Normal (Purge ON or OFF) - A lack of fuel supply,

fuel contamination or an exhaustleak;
., Accel (Purge ON or OFF) - A lack of fuel supply,
fuel contamination or an exhaust leak.
" High Flow (Purge ON or OFF) - A lack of fuel

supply, fuel contamination or an exhaust leak.
Below are some reasons for a lack of fuel supply.
" A faulty or restricted fuel injector
O A restricted fuel line
" A faulty or .restricted fuel pump
O
A faulty or restricted fuel regulator
A restricted fuel filter

.. No VSS, EST, CKP, CAM, TP, Misfire, Fuel
injector, MAF, 02, MAP, EGR, EVAP, ECT. or IAT
DTCs are set.
" Engine coolant temperature between 20c (68F)
and 110C (230F).
Intake air temperature is between -18C (0F) and
70C (158F).
and 85 kPa.
Throttle angle is steady and l~ss than 90 percent.
Vehicle speed is less than 132 km/h (82 mph).
e Engine speed is between 600 and 4000 RPM.
Baro is more than 70 kPa .
" Air flow is between :3 gm/s and 150 gm/s.
@

" Long term fuel trim average is more than
+ 17 percent and the short term fuel trim average
is more than +2 percent of the indicated cells
in the Fuel Trim Cell Table.
All of the conditions described above have been
met in the Fuel Trim Cells for more than
1 second.

which the diagnostic test has been run and fa,iled.
O The PCM will store conditions which were present
Records data.

malfunction.
., The DTC can be cleared by using a scan tool.
6-932
Engine
Diagnostic Aids
Fuel pressure/flow low - The system will go lean
and add fuel during high fuel demand. The
Accel and the High Flow cells will increase to
more than O percent if this condition is present.
The PCM can compensate for some decrease.
However, if fuel pressure is too low, both
OTC P0171 and P0174 may be set. Refer to Fuel
Fuel injectors faulty - The system will go lean and
add fuel if a fuel injector is not suppling enough
fuel. All cells could increase to more than
O percent depending on the severity of the
problem. In most cases high fuel demand. cells
such as Accel and High Flow will be more likely to
show the problem. Refer to Fuel Injector
Balance Test.
Vacuum leaks - Inspect for disconnected or
the intake manifold, throttle body, EGR system
and crankcase ventilation system. The Idle
cells (Purge ON or OFF) will increase to more
than O percent if this condition is present.
EVAP system leaks - Inspect for disconnected or
damaged EV AP lines and hoses. The Idle cell
with (purge ON) will increase to more than
O percent if this condition is present.
All cells could increase to more than O percent
depending on the severity of the problem.
Alcohol/Contaminants-in-Fuel Diagnosis. All cells
could increase to more than O percent depending
on the severity of the problem.


Systems.
Damaged harness.
harness appears to be OK, o.bserve the display
Systems.
Test Description
diagnostic table.
Test Adapter Kit. Using this kit prevents damage
to the harness connector terminals.
will isolate when the OTC failed. For an
4. If both lean OTCs are set, both banks of the

5. A vacuum leak causes OTCs P0171 and P0174 to
valve for being the correct one for this application.
that it is tight. Insure the engine oil dip stick is fully
seated.
Engine
6-933

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids

Important: If any DTCs are set, except P0171 and P0174

refer to those DTCs before proceeding IIVith this table.
2. Fuel.system in Closed Loop.
3. With a scan tool, observe the Long Term FT
paramet13r.
Does the scan tool indicate fuel trim less than the
+17% LT
1. Turn ON the ignition, with 'the engine OFF.

the DTC, and as .close to the Failure Records
ignition?
Is the other Lean DTC also set?

connections. Refer to Under Hood Vacuum Hose
Routing Diagrams.
Refer .to Crankcase Ventilation System Inspection.
Contaminated fuel. Refer to
PCM and sensor grounds are clean, tight and in the
proper locations. Refer to TestirJg for Intermittent and
Did you find any problems in any of. the above areas?

Exhaust leaks, missing or loose exhaust hardware.
H02S is installed securely and the electrical connector
not contacting exhaust systern or ignition wires.
Engine. mechanical failure. Refer to B?se Engine
Vacuum leaks that will only affect this bank, such as
the intake manifold, the injector 0-rings, etc.


diagnosed?
~)
Go to Step 5
Go to Step 6
Go to Step 7
Go to Fuel
System
Pressure Test
Go to Step 7
Go to Fuel
System
Diagnosis
Go to Step 8
Go to Step 2
Go to Step 9
Go to
applicable DTC
System OK
6-934
Engine Controls .,. 3.8L
Engine
DTC P0175 Fuel Trim System Rich Bank:2

Circuit Description
Conditions. for Running the DTC

these voltages. A change made to fuel delivery will be
indicated by the long and short term fuel trim values
rich condition is detected, the PCM will set this
DTC. The PCM maximum authority to control long
Cell
Purge ON
Purge OFF
Idle (Cell 0)
x
x
-
Decel (Cell 1)
Normal (Cell 2)
Accel (Cell 3)
High Flow (Cell 4)
x
x
x
The vehicle may have to be operated in all of the

trim deviates from O percent ineach cell and the
amount thafeach cell is used directly affects whether
Important: Some conditions can cause multiple cells

to indicate rich
Below are some examples of why a rich condition
could exist in the above cells.
A saturated EVAP canister - This will affect the
purge ON ceUs
A faulty fuel regulator
" Gas in the oil pan
A fuel return restriction
A engine misfire
A faulty fuel injector
A restricted exhaust
No VSS, EST, CKP,CAM, TP, Misfire, Fue.1

injector, MAF, 02, MAP, EGR, EVAP, ECT
IAT
DTCs are set.
Engine coolant temperature between 20C (68F)
arid 110C (230F).
Intake air temperature is between-18C (0F) and
70C (158F).
and 85kPa.
Throttle angle is steady and less than 90 percent.
Vehicle speed is les; than 132 km/h (82 mph).
E:rigine speed is between 600 a.ndAdOO RPM.
Baro Js more than 70 kPa.
or
Conditions :for Setting the DTC

The io~g te;m fuel trim average is at or near
maxim.um authqrity of -18 percent and the
short term average fuel trim is at or near maximum
authority of -2 percent of the indicated cells in
the Fuel trim fable.
All conditions .have been met in the Fuel trim cells
for more than 1 second.
Action Taken When the DTC Sets ,

lamp (MIL) during the second cbnsecutive trip in
The PCM will store conditions ~hichwere present
when the DTC set as. Freeze Frame/Failure
Records. data.
.
. '
Conditionsfor.Clearing the Mil/OTC

The PCM will turn the MIL OFF du-ring the
th.ird consecutive trip in which the diagnostic has
malfunction.
The DTC cari be cleared by using a scan tool.
Engine
Diagnostic Aids
Fuel pressure high - The system will go rich if
high, a DTC P0172 and P0175 may set. Refer
to Fuel System Pressure Test.
Balance Test.
System Diagnosis.
fuel pressure regulator for the presence of
fuel. If there is fuel in the vacuum line, refer to
Fuel System Pressure Test.
Fuel in the oil pan - The system will go rich if the
large amounts of fuel are purged from the
oil pan.
Engine misfire - The sill go rich due to the lack of
complete combustion.
Restricted exhaust - The system could indicate a
rich condition. Refer to Restricted Exhaust
System Check.

Systems.
6-935
Damaged harness.
Inspect the wiring harness for damage. If the.
Systems.

Test Description
The. numbers below refer to the step numbers on the
diagnostic table.
2. This step determines whether the. fault is present.
included in the .Freeze Frame and/or Failure
since the DTC set The Fail Counter and Pass
will isolate when the DTC failed. For an
4. If the both rich DTCs are set, both banks are
and P0175 to set at the same time. Remove
fresh air pipe from the rocker cover and plug using
a suitable stopper. If the long term and short
fuel in the oil.
6-936
Step
Action
Engine

Values
Yes
No
Go to Step 2
.. Goto A
PowertrainOn
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to.Step6
Did you perform the Powertrain .On-Board

Important: If any DTCs are set, except P0172 and P0175,

3. With a scan tool, observe the Long Term FT Bank
parameter.
-18 % LT
Does the scan tool indicate fuel trim more than the

the OTC, and as close to the Failure Records
ignition?
Is the other Rich OTC also set?

For fuel in the pressurei regulator hose. Refer to Fuel
For excessive. fuel in the crankcase. Change oil as

necessary.
Go to Step 7
Go to. Fuel
System
Pressure Test
Go to Step 9
Go to Step 8
Important: When the fuel system check is finished, return

.to this table.
Inspect the injectors for leaki3,ge, refer to Fuel Injector

Balance Test.



10
diagnosed?
Go to Step 9
Go to Step 9
Go to Step 2
Go to Step 10
Go to
applicable OTC
System OK
Engine
6-937

!Hot In Run, Bulb Test And Start)
I"----Power
I
I
Distribution
. Schematics
I in Wiring
----, Engine Wiring

I
IN_J _1
1Harness
M1rnFuse Junction
15 A
I
J9
JS
I __ Systems
L.-----
Block 2
LJil
____ . .I
Al
PNK/WHT 639
A
fliil
~
Fuel
~njector
BL~r1744
79 C1
.- ----- ---------.
11
F~el
lnJ~ctor 1
Driver
I
I
CONN ID
C1 =BLU
C2=CLEAR
. -
"'::.. -
Powertrai n
I Control
I
A
I Module Jiii!'
.... (PCM) ~
548547
Circuit Description
Diagnostic Aids
The PCM controls the fuel injector control circuit using

a Multi Function Driver (MFD). The MFD has the
ability to detect an electrical malfunction. If an electrical
malfunction is detected, the MFD signals the PCM
to set this OTC.
Monitor the injector fault parameter in the scan tool.

Move the electrical harnesses for the effected electrical
circuit. If the status changes .on the scan tool, that
may be an indicator where an intermittent faulf may be
located.

The ignition is ON.

An incorrect voltage level is being detected on the
injector driver circuit.
Above condition for over 30 seconds.

Records data.

malfunction.
Important: Remove any debris from .the connector

corresponding mating terminal.to testfor proper
Systems.
Damaged harness.
Systems.
6-938
Engine
Test Description
The .. numbers below refer to the step numbers on the
diagnostic table:
4. If the scan tool indicates STUCK HIGH there is a
short to battery positive voltage on the fuel
injector control circuit.
5. If the scan tool indicates STUCK LOW there is an
open or a short to ground on the fuel injector
control circuit.
6. If the scan tool indicates a STUCK HIGH while
cranking, the short to battery positive voltage
is between the injector connector and the PCM. If
the scan tool indicates STUCK LOW while
cranking the problem is within the injector.
9. This step is testing for a short. to ground in the

circuit.
10. The fuel injector in this circuit will need to be
tested after the short to ground is r~paired or after
the PCM is replaced.
11. This step is testing the function of thePCM. If the

test lamp flashes then the PCM is able to supply
the ground.
13. This step will find a open between the splice and
the injector.
an Electronically Erasable Programmable Read
Only Memory (EEPROM). When the PCM is

Step
A~tion
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System. Check
.Go to Step 4
.Go to Step 3

Start and idle the engine.

Does scan tool indicate this OTC failed this ignition? .

Does scan tool indicate this OTC failed this ignition?
2. With a scan tool, observe the Cylinder Injector Ckt.

Status parameter for this injector.
Does the scan tool indicate this parameter STUCK LOW?
Go toStep 4
Goto
Diagnostic Aids
Go.to Step 6
Go to Step 5
Go toStep 9
Go.to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 17
Go to Step 16
Does scan tool indicate this parameter STUCK HIGH?

5
.-

2. Disconnect the fuel injector connector .
6

Status parameter for this injector while cranking the
engine.
Does the scan tool indicate this parameter STUCK HIGH

when the engine is cranking?
Test for a short to voltage on the control circuit for this

injector. Refer to Circuit Testing and Wiring Repairs.

Does the scan tool indicate this parameter STUCK LOW
while cranking the engine?
1. Disconnect the fuel injector connector.

2. Probe the control circuit using a test lamp that is
connected to battery positive voltage.
10
Did you find and correct the conditions?

Test for a short to ground on this injector control circuit.
Refer to Circuit Testing and Wiring Repairs
Go to Fuel lnj
Coil Test - ECT
Between 10-35
Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test - ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16
Engine

DTC P0201 Injector 1 Control Circuit (cont'd)
Action
Step
Values
1. Leave the test lamp connected.

2. Crank the engine.
Does the test lamp flash?
12
Test for an open in the injector control circuit. Refer to

Testing for Intermittent and Poor Connections or Circuit
Testing and Wiring Repairs.
13
Test for an open or poor connection in the fuel injector

feed circuit. Refer to Testing for Intermittent and Poor
Connections or Circuit Testing and Wiring Repairs.
11
Yes
No
Go to Step 13
Go to Step 12
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 17
Go to Step 16
Inspect the injector control circuit for a poor connection at

the fuel injector. Refer to Testing for Intermittent and Poor
Connections and Connector Repairs.
14
Inspect the injector control circuit. for a poor connection at

the .PCM. Refer to Testing for Intermittent and Poor
16

17

3. Operate the vehicle within the Fail Records
conditions.
Does the OTC reset?
15
Go to Step 17
Go to Step 2
System OK
6-940
Engine
rel
~w:r - - - - - - -
I Distribution
Schematics
I in Wiring
I Systems
INJ 1
J\JliniFuse
15 A
~ Engine Wiring
I
Harness
. Junction Block 2
Ll<l
I
I
L----- ----J
Al
PNK/WHATY.._6-39_ _ _ _ _ _ _
PN_K__.l639 .
r1iJFuel
tjector.
LtJ
LT ~.~N/B~~r~~5
- ;u;- -,- ~ -:~N~D- -,~ 6~~:~rain.
lnjector2
Driver
.
-
"".
"';;... -
.C1=.BLU
C2=CLEAR
-
. I
-
...
..6.
Module,,..
(PCM)~
548552
Circuit Description
Diagnostic Aids

to set this DTC.
Monitor the injector fault parameter ih the scan tool.

Move the ele.ctrical harnesses for the effected electrical
circuit. If the status changes on the scar:i tool, that
may be an indicator where a:n intermittent fault rnay be
located:

The ignition is ON.


Records data.

malfunction.
Important: Remove any debris from the connec1or

surfaces before servidng a. component, Inspect
correctly. The gaskets prevent contah)inate intrusion.
corresponding .mating terminal to test for proper
Systems.
Damaged harness.
Systems.
Engine
Test Description
9; This step is testing for a short to ground in the

circuit.

diagnostic table:
10. The fuel injector in this circuit will need fo be

tested after the short to ground is repaired or after

11 .. This step is testing the function of the PCM. If the

testlamp flashes then the PCM is able to supply
the ground.

control circuit.
13. This step wiU find a open between the splice and
the. injector.



Action
Step
..
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Goto Step 9
Go to
Diagnostic Aids

-
1
'
2
3
Does scan tool indicate this DTC failed this ignition?

.
.

Does. scan tool indicate this fff,G failed this ignition?

Does scan tool indicate this parameter STUCKHIGH?
cc;

6

engine.


Go to Step 8
Go to Step 17
Go to Step 16

Go to Step 7
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)

10

Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16
6-942
Engine

Step
11
Action
Values

Yes
No
Go to Step 13
Go to Step 12
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
12
Test for an open in .the injector c.ontrol circuit. Refer to

13

Inspect the injector control circuit for a: poor connection at

the fuel injector. Refer to Testing for Intermittent arid Poor
14
15

..
..
,,
Did_ you find and correct the condition?
16

..
. Go to Step 17
Go to Step 16
..
.Go to Step 17

17

conditions.
Does the OTC reset?
''
Go to Step 2
System OK
Engine
5.;.943

!Hot In Run, Bulb Test And
Start!
;,,.;r - - - - - - -
Distribution
I Schematics
I inWiring
I Systems
~ Engine
INJ 1
MiniFuse I
15A
I
I
Wiring
Harness
Junction Block 2
L2lil
--~-..I
L-----
Al
PNK/WHT 639
fliil
Fuel
~~jector
'(
PNK/BL~,1746
42,,.C2
,. - - - - - , - - - - - - - - ., Powertrai n
I
Fuel
lnJector3
Driver
CONN ID
C1=BLU
C2=CLEAR
-.1
-
I Control
I
I Module p
... (PCM)~
548554
Circuit Description
Diagnostic Aids

a Mul1i Function Driver (MFD). The MFD has the
malfunction is detected, the MFD signals the PCM ,
to set this OTC.

circuit. If the status changes on the scan tool, that
may be ah indicator where an intermittent fault may be
located.

The ignition is ON.


Records data.

been run and passep.
malfunction.

Systems.
Damaged harness.
Systems.
6-944
Engine Controls ;. 3.8L
Engine
Test Description
diagnostic table:
. 5. If the scan tool indicates STUCK LOW there is an ..
control circuit.
9. This step is testing for a short to ground in the

circuit.
tested after the short to ground. is repaired or after
the PCM i.s replaced.
11. This step is testing the function of the PCM. If the

test lamp flashes then th.e PCM is able to supply
the ground.
13. This. step will find a open between the splice and
the injector.

Action
Step
Values

..
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3

Does scan tool indicate this DTC failed .. this ignition?

No
Yes
Go to Step
Go to
Diagnostic Aids
(
Go to Step 6
Go to Step 5
Go to Step 9
Go to
Diagnostic Aids
Go to Step 7
Go to Step B
Go to Step 17
Go.to Step 16
1; Turn OFF the ignition.
2. Disconnect the fuel injector .connector.

Status parameter for.this injector while.cranking the
engine.

Go to Fuel /nj
Coif Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16

9
10

Engine

Action
Step
11

Values
13
No
Go to Step 13
Go to Step 12
Go to Step 17
Go to Step 15
12
Yes

Test for an open or poor connection .ih the fuel injector

'
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)

Did you find and correct the, c.ondition?
14
15

Go to Step 17
16

Go to Step 16
'
Go to Step 17

17

3. Operate the vehicle within .the Fail Records
conditions.
Does the OTC reset?
Go to Step 2
System OK
6-946
Engine

~
!Hat In Run, Bulb Test And rt]

;:;;,,:;r - - - - - - - ~ Engine Wiring
Distribution
I Schematics
I in Wiring
I Systems
L-----
INJ 1
MiniFuse
15 A
Harness
1Junction Block 2
I
----..S
Al
PNK/WHT 639
A
'(
fliil
LlJ
Fuel
~jector
LT BLU/BL~l844
4alc1
.- - - - - -,. - - - - - - - - ., Powertrain
I
I
Fuel
lnJector 4
Driver
CONN ID
c1=,BLU
I Control
(
I
--..
C2=CLEAR
I Module p
,_ ______ "':.. _______ _, (PCM) ~
548556
Circuit Description
Diagnostic Aids

to set this OTC.

may be an indicator where an intermittent fault may be
located.

The ignition is ON.

" An incorrect voltage level is being detected on the
" Above condition for over 30 seconds.

Records data.
O

malfunction.

Systems.
Damaged harness.
Systems.
O Inspect the PCM and the engine grounds for
Engine
Test Description
diagnostic table:
4. If 1he scan tool indicates STUCK HIGH there is a
short to battery positive. voltage on the fuel
5. If 1he scan tool indicates STUCK LOW there is an
control circuit.

circuit.


the ground.
the injector.

replaced,. the new PCM must be programmed.

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 9
Go to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 17
Go to Step 16
Did yo perform the Powertrain On-Board

1'
.,
Start and. idle the engine.




engine.



10

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test - ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16
s:.943
Engine
Engine .Controls - 3.8L

Step
11
Action

Values
Yes
(
-
12
13


Go to Step 13
Go to Step 12
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel In} Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 17
Go to Step 16

14
No
15

16

Go to Step 17

17

conditions.
Does the OTC reset?
Go to Step 2
System OK
Engine
Engine Controls - 3.Sl 6-949

;;;w;r - - - - - - - ~ Engine Wiring
Distribution
Schematics
I in Wiring
I Systems
L-----
INJ 1
1\/1.iniFuse
15 A
Harness
1Junction Block 2
UJ
I
I
----.J
PNK/WHT 639
A
'(
Al
PNKl639
~Fuel
~jector
LlJ
BLK/W:i-1845
47 ,,.C1
'" - - - - - 1 - - - - - - - - ., Powertrain
I
F~el
lnJector5
Driver
I
L
/
. .
--1 .
I Control
CONN ID
Cj=BLU
C2=CLEAR
-
I Module Jlffl'
-
.J
(PCM)
~
548560
Circuit Description
Diagnostic Aids

to set this OTC.

located.
') Conditions for Running the DTC

The ignition is ON.


Records data.

malfunction.

Systems.
Damaged harness.
Systems.
6-950
Engine
Test Description
diagnostic table:
control circuit.

9. This step is testing for a shortto ground in the

circuit.

the ground.
the injector.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
.Go to Step 3
Go toSt~p 4
Go to
Diagnostic Aids

-

Operate the vehicle within Fail Record conditions:


1. Tum OFF the ignition.

engine.

Does the scan tool indicate. this parameter STUCK LOW

10


(
Go to Step 6
Go to Step 5
Go to Step 9
Go to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 17
Go to Step 16
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel. lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16
Engine
6-951

Action
Step
11

Values
Yes
12

13

Go to Step .13
Go to Step 12
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)

14
15

Connections and ConnectorRepairs.

16
.. Did you complete the replacement?
17

conditions.
Does the DTC reset?
No
.
Go to Step 17
Go to Step 16
Go to Step 17
Go to Step 2
System OK
6-952
Engine
,_:r - - -
---IN_J _1
tvlimFuse
15 A
Distribution
Schematics
I in Wiring
I Systems
~ Engine Wiring
1 Harness
Junction Block 2
fM':I
L1il
I
I
L--------..1
PNKJWHT 639
A.
Al
fliiJ
LlJ~jector
Fuel
A'(
YEL/BL~y846
4sic1
r - - - - - , - ..,.. - - - - - ...., ., P6wertrain
Fuel
I
I
lnj~ctor 6
Driver
I .Control
CONN ID
--1
I
lir.
I Module JfJII'
C1 = BLU.
C2=CLEAR
.J
(PCM)
~
548563
Circuit Description
Diagnostic Aids

to set this OTC.

circuit. If the_ status changes on the scan tool, that
located.

The ignition is ON.


lamp (MIL} during the second consecutive trip in
Records data.

malfunction.

Systems.
Damaged harness.
Systems.
If the OTC is determined to be intermittent, revi,ewing
Engine
Test Description
)

circuit.

diagnostic table:


control. circuit
cranking .the problem is within the injector.
6-953

the ground.
the injector.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 9
Go to
Diagnostic Aids
Go to Step 7
Go to Step B
Go to Step 17
Go to Step 16

1

..

Does scan tool. indicate this DTC failed this ignition?


engine.


)
10


Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 16
Engine
6954 Engine Controls - 3.8L

Step
Action
Values
Yes
No
Go to Step 13
Go to Step 12
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 14
Go to Step 17
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
or Fuel In) Coil
Test - ECT
Outside
10-35 Degrees C
(50-95Degrees F)

11
2. crank the engine.

Does the. test lamp flash?
12

13


the fuel injector. Refer to Testing for Intermittent.and Poor
14
15

"
Go to Step 17
Go to Step 16
..
16
17


conditions.
Does the OTC reset?
Go to Step. 17
Go to Step 2
System OK
Engine
6-955

! Hot At All Times!
'" - - - - I Power
~~~:~~:c~
I inWiring
I Systems
- - - - ., Engine Wiring
FUEL PUMP I Harness Junction
llillnlFusa I Block
20A''
I
,
I
H9
HS
&..----ORN
U!J
1340
BLK/WHT 451
'
I
Throttle
GAY~
GAY 120
GAY 120
Actuator
I ,____......._______........___.
BS
I
Motor
~~~-L_-_,_-_-~
: Deterrent
:
Fuel Enable
DK
DKBLU 229
Schematics
In Wiring
Systems
BLK 1050
BLK
1450
Powertrain
Control
j}4 Module
, ~ (PCM)
3
r -
C2
-
70
-
j_--J ~~~p
I .
I
I, ,
I
C1
-
CONN ID
1~~:lble
Control Ci=BLU
Control
C2=CLEAR
,...._
____.
12V
-
DK BLUI229
GRNNVHT 465
Ground
Distribution
Control
Module
~ s~n~ _ ~ (BCM)
I Motor
I
BLK/WHT
451
,. Theft- '.""" ., Body
- - - ., Fuel
Fuel
I Pump
Pump
Control
Module
5V
-
-,- -
BLKJWHT 451
BLK/WHT 451
Ground
Distribution
Schematics
In Wiring
Systems
-,
BLK 451
I
1
1
I
~
)
548508
Circuit Description
The PCM provides ignition positive voltage to control
the fuel pump relay. The PCM has the ability to
detect an electrical malfunction on the relay control
circuit When the ignition switch is first turned ON, the
PCM energizes the fuel pump relay which applies
power to the fuel pump. The fuel pump relay will
remain ON as long as the engine is running or
cranking and the PCM is receiving reference pulses. If
no reference pulses are present, the PCM
de-energizes the fuel pump relay within 2 seconds
after the ignition is turned ON or the engine is stopped.
With the engine stopped, the fuel pump can be
turned ON by using the scan tool output controls
function. If an electrical malfunction is detected, the
PCM will set OTC P0230.

The ignition is ON.

The PCM detects an electrical malfunction on the
fuel pump relay control circuit.
The condition is present for more than 30 seconds.

The PCM will not illuminate the malfunction
indicator lamp (MIL).
when the OTC set as Failure Records data only.
This information will not be stored as Freeze
Frame data.

A history OTC will clear after 40 consecutive
malfunction.
6-956 . Engine Controls - 3.8L
Engine
Diagnostic Aids
Test Description
!nspect tor the following:

diagnostic table.
2. Listen for an audible click when the relay operates.
Com111and both the ON and OFF states. Repeat
the commands as necessary.

surtaces before servicing a component. Inspect
the ~onnector gaskets when diagnosing or replacing a
faulty 1erminal to wire connection. Use a

Systems .
., Damaged harness.
Inspect the. wiring harness for damage. If the
hamess appears to be OK, observe the display
and wiring har.nesses related to the sensor. A
Systems.
Inspect the PCM and th engine grounds for clean
and secure connections.
3, Verifies that the PCM is providing voltage to

the relay.
4. Tests for an open in the ground circuit to the relay.
5. Tests if voltage is constantly being applied to
the relay.
12. The PCM utilizes Electrically Erasable

Programmable Read Only Memory (EEPROM).
When the PCM is replaced, the new PCM must be
programmed.
Engine
6-957
OTC P0230 Fuel Pump Relay Control Circuit

Values
Action
Step
Did you perform the. On-Board (OBD) Diagnostic

Sy$tern
Check?
I
'
1. Turn ON the ignition; with the engine OFF.

2. With a scan tool, command the fuel pump relay ON
and OFF.
Does the relay turn ON and OFF with each.command?
..
5,
Dqes the test lamp remain illuminated with each

command?
Test the control ci.r.cuit of the relay for a short to ground or

an open. Refer fo Circuit Testing and Wiring Repairs in
Wiring Systems. .
.

Test the control circuit of the relay for a short to voltage.
Refer to CircuitTestingand Wiring Repairs in Wiring
Systems:
Inspect for poor connections at the relay. Refer to Testing

Did you ,find and.correct the.condition?
Inspect for poor connectiOns at the PCM. Refer to Testing

Repair the ground circuit of the relay. Refer to Wiring

11
Replace the relay.

12

Replace the PCM.
13

Does the OTC reset?
10
Go to
. Diagnostic Aids
Go to Step 3
Go to Step.4
Go to Step 5
Go to Step 8
Go to Step 10
Go to Step 7
Go to Step 6
Go to Step 13
Go
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
Go toStep2
,.
1. Connect a tesUamp between the control circuit of the

relay and the ground circuit of the relay.
2. With scan tool, command the relay ON and OFF.
Does the test lamp turn ON and OFF with each
command?
No
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check

2. .Disconnect the r!;)lay.
3, Turn ON the ignition.with the engine OFF.
. 4. .Probe the control' circuit of the relay with a test lamp
3
connected to a ~ood ground.
5 . With a scan tOol, command the relay ON and OFF.
.
Ode$ ihe test lamp turn ON and OFF with each''
..
command?
Yes
to
Step 9
Go to Step 13
Go to Step 13
Go
to
Step 13
Go to Step 2
System OK
6-958
Engine

Circuit Description
The PCM has the ability to detect a misfire by
monitoring the 3X reference and camshaft position
input signals from the ignition control module.
The PCM monitors crankshaft speed variations
(reference period differences) to determine if a misfire
is occurring. If 2 percent or more of all cylinder
firing events are misfires, emission levels may exceed
mandated standards. The PCM determines misfire
level based on the number of misfire events monitored
during a 200 engine revolution test sample. The
PCM continuously tracks 16 consecutive
200 revolution test samples. If 11 or more misfires are
detected during any 10 of the 16 samples, DTC P0300
will set. If the misfire is large enough to cause
possible three-way catalytic converter damage,
DTC P0300 may set during the first 200 revolution
sample in which the misfire was detected. In the case
of a catalyst damaging misfire, .the MIL will flash to
alert the vehicle operator of the potential of catalyst
damage.

" No VSS, CKP, TP, MAP, ECT, CAM or MAF
DTCs are set.
Engine has been running for more than 5 seconds.
., Engine speed between 550 and 5800 RPM.
System voltage between 9 and 18 volts.
.. The ECT sensor indicates a temperature between
-6C (21F) and 120C (248F).
.. Fuel cutoff is not active.
" Fuel level is more than 10 percent.
.. Throttle angle is steady.

The PCM detects a crankshaft RPM variation
indicating a misfire sufficient to cause three-way
catalytic converter damage or emissions levels that
exceed the mandated standard.

warm-up cycles have .occurred without a
malfunction.
Diagnostic Aids
The scan tool provides information that can be useful
in identifying the misfiring cylinder. If the DTC P0300
is currently stored as DTC status Failed Since
Code Clear, the misfire history counters .(Misfire
History Cyl #1 - #6) will still contain a value that
represents the. level of misfire detected on each
cylinder. The scan tool displayed misfire counter
values (Misfire History Cyl. #1 through #6) can
be useful in determining whether the misfire affects a
single cylinder, a cylinder pair (cylinders that share
an ignition coil - 1/4, 2/5, 3/6), or is random. If.
the largest amount of activity is isolated to a cylinder
pair, inspect for the following:
Secondary ignition wires.
Inspect the secondary wires associated with the
affected cylinder pair for disconnected ignition
wires or for excessive resistance. The wires
should measure less than 30,000 ohms
(30K ohms) .
Damaged or malfunctioning ignition co.ii.
Inspect for cracks, carbon tracking or other
damage. Also test coil secondary resistance.
Secondary resistance should be between
5000 ohms and 8000 ohms (5K ohms and
8K ohms).
Substitute a known good coil.
Switch ignition coils and retest. If the misfire
foHows the coil, replace the ignition coil. .

The PCM will illuminate the MIL during the
second consecutive trip in which the diagnostic
has been run and failed unless three way
converter damage is possible in which case the
light will illuminate after the first failure.
" If equipped with traction control, the PCM will
command the EBTCM via the serial data circuit to
turn OFF traction control, and the EBTCM will
illuminate the TRACTION OFF lamp.
when the DTC set as Freeze Frame .and Failure
Records data'.
Engine
If the misfire is random, inspect for the following

conditions:
Crankshaft Position System Variation.
Refer to CKP System Variation. Learn Procedure.
The crankshaft position system variation
compensating values are stored in the PCM
non-volatile memory after a learn procedure has
been performed. If the actual crankshaft
position variation is not within the crankshaft
position system variation compensating values
stored in the PCM, OTC P0300 may set. The
crankshaft position system variation learn
procedure is required when any of the following
service procedures have been performed:
- PCM replacement or reprogramming
- Engine replacement
- Crankshaft replacement
- Crankshaft balancer replacement
- Crankshaft position sensor replacement
Any engine repairs which disturbs
crankshaft/harmonic balancer to crankshaft
.position sensor relationship.
System grounds.
Ensure all connections are clean and properly
tightened.
" Mass air flow sensor.
A Mass air flow (MAF) sensor output that causes
the PCM to sense a lower than normal air flow
will cause a lean condition. Try operating the
vehicle within. t.he fail records conditions with t.he
MAF sensor disconnected. If the lean or
misfiring condition is not present with the MAF
sensor disconnected, replace the MAF sensor.
" Loss of EBCM/EBTCM Serial Data.
If the PCM stops receiving data from the
EBCM/EBTCM, OTC P0300 can set due to a loss
of rough road data. Check for stored ABS/TCS
DTCs, especially DTCs related. to a serial
data malfunction. Refer to Self-Diagnostics in
ABS/TCS.
Air Induction System.
Vacuum leaks that cause intake air to bypass the
MAF sensor will cause a lean condition. Inspect
for disconnected or damaged vacuum hoses,
incorrectly installed or malfunctioning crankcase
ventilation valve, or for vacuum leaks at the
throttle body, EGR valve, and intake manifold
mounting surfaces.
Fuel Pressure.
Perform a fuel system pressure test. A
malfunctioning fuel pump, plugged filter, or
malfunctioning fuel system pressure regulator will
contribute to a lean condition.
Refer to Fuel System Pressure Test.
Fuel injectors
Refer to Fuel lnj Coil Test - ECT Between
10-35 Degrees C (50-95 Degrees F).
Refer to Fuel lnj Coil Test - ECT Outside
6-959
" Contaminated Fuel.

Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
EGR System.
Inspect for leaking valve, adapter, or feed pipes
which will contribute to a lean condition or
excessive EGR flow.
Extended Idle,
Excessive open loop operation caused by
extended idling or short trip driving may leave
deposits on the heated oxygen sensors. The
deposits cause oxygen sensors to respond slowly
to exhaust oxygen content, affecting fuel control
and causing a misfire to be indicated at idle. This
condition is not permanent. To determine if this
condition is causing the DTC P0300 to be
set, review the freeze frame and fail records data
for DTC P0300. If the OTC P0300 occurs at
high engine speeds, the condition described
above did not cause the OTC P0300 to set. If the
OTC P0300 occurs at idle or very low engine
speeds and at engine coolant temperatures less
than 80C (176F), the condition described
above is very likely the cause of the OTC P0300
being set. The deposits on the heated oxygen
sensors can be eliminated by operating the vehicle
fully warm at mass air flows more than 15 gm/s.
Important: If the level of misfire was sufficient to

cause possible catalyst damage (if the MIL was
flashing), ensure that the OTC P0420 test is completed
and passed after verifying the misfire repair.
Reviewing the Freeze Frame/Fail Records vehicle
mileage since the diagnostic test last failed may help
determine how often the. condition that caused the
OTC to be set occurs. This may assist in diagnosing
the condition.
Test Description
diagnostic table.
2. A condition that sets a OTC other than P0300
may also cause a misfire ..If any of the indicated
DTCs are set with OTC P0300, diagnose and
repair the other OTC before using the
OTC P0300 table.
3. The Misfire Current Cyl # parameter may normally
indicate a small amount of activity (0 - 1O counts)
but should not steadily increment during an
entire 200 revolution test sample period.
4. Depending on the cause of the misfire, the Misfire

History Cyl # counter will indicate a very large
number for the misfiring cylinders; values for the
non-misfiring cylinders will be less than
1/2 as great as the misfiring cylinders. When
investigatirig a misfire, always start with the
components associated with the cylinders that has
the largest number of counts stored in the
Misfire History Cyl # counter.
5. Steps 5 through 12 test for conditions that can
cause a random cylinder misfire.
13. Steps 13 through 22 test for conditions that can
cause a non-random or single cylinder misfire.
6.;.960
Engine

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P1380
Misfire Detected Rough Road
Data Not
Available
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 13
Go to Step 25
Go to Step 6
Go to Step 25
Go to Step 7
Go to Step 25
Go to Step 8
Go to Step 25
Go to Step 9
Go to Step 25
Go to Step 10
Go to Step 25
Go to Step 11
Go to Step 25
Go to Step 12

Is DTC P1380 also set?
1. Start and idle the engine.

3
10
11
3. With a scan tool, observe the Misfire Current Cyl #

parameter for each cylinder.
Does the scan tool indicate a current misfire?
With a scan tool, observe the Misfire History Cyl #
parameter.
Does the scan tool indicate a large value for more than
one cylinder?
Visually and physically inspect the vacuum hoses/lines for

splits, kinks, and improper connections. Refer to Emission
Hose Routing Diagram.
Visually and physically inspect the PCV valve for improper

installation and for damaged 0-rings. Refer to Crankcase
Ventilation System Inspection.
Inspect the throttle body inlet screen for damage or for the
presence of foreign objects that may partially block the air
flow sample.through the MAF sensor. Refer to Throttle
Body Assembly Replacement or Throttle Body Air Inlet
Screen Replacement.
Test the fuel pressure. Refer to Fuel System

Pressure Test.
Test the fuel for excessive water, alcohol, or other

contaminants. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Visually and physically inspect the PCM injector grounds,

power grounds and sensor grounds to ensure that they are
clean, tight, and in their proper locations. Refer to Ground
Distribution Schematics in Wiring Systems.
Visually and physically inspect the following areas for

vacuum leaks:
Intake manifold
Injector 0-rings
EGR adapter
EGR valve
EGR feed pipes
Engine
6-961
DTC P0300 Engine Misfire Detected (cont'd)

Step
Action
12
1. Remove the EGR valve. Refer to EGR Valve

Replacement.
2. Visually/physically inspect the valve to ensure that the
pintle is not sticking partially open. Also, inspect the
EGR valve pintle and seat for carbon deposits or
burrs that may interfere with the pintle closing
completely.
13
Test for proper fuel injector operation. Refer to Fuel lnj

Coil Test - ECT Between 10-35 Degrees C
(50-95 Degrees F) or Fuel lnj Coil Test. - ECT Outside
1.0-35 Degrees C (50-95 Degrees F).
14
Visually and physically inspect the spark plug wires

associated with the cylinders which were misfiring to
ensure that they are not damaged and are connected to
the proper cylinders at the coils and at the spark plugs.
Did you find and co.rrect the condition?
15
1. lnst1:1II a J 26792 spark tester at the spark plug end of

the spark plug wire for the cylinder that is indicated
by the Misfire Current Cyl # counters or Misfire
History Cyl # counters as having the most severe
misfire (largest number of counts).
2. Jumper the spark plug end of the companion cylinder
spark plug wire to engine ground. The companion
cylinder is the cylinder that shares the same ignition
coil (i.e., 1/4; 2/5; 3/6).
3. Crahk the engine while observing the spark tester.
Spark should be observed.
Is spark present?
16
Important: If carbon tracking or terminal discoloration is

apparent at the ignition coil end of any of the spark plug
wires, replace the affected ignition wire and the associated
ignition coil. Refe(to Ignition Coil(s) Replacement.
1. Remove and visually/physically inspect the spark plug
wires associated with the cylinders that were
indicated as misfiring. Ensure that the wires and
boots are free of carbon tracking and the insulation is
not damaged.
2. If a problem is found, replace malfunctioning spark
plug wires as necessary. Refer to Spark Plug Wire
Harness Replacement (3.8 L Right Bank) .or Spark
Plug Wire Harness Replacement (3.8 L Left Bank) in
Engine Electrical.
17
.t. Measure the resistance of the spark plug wires

associated with the cylinders that were indicated as
misfiring.
2. Replace any spark plug wires that measure more
than the specified value. Refer to Spark Plug Wire
Harness Replacement (3.8 L Right Bank) or Spark
Engine Electrical.
Values
Yes
No
Go. to Step 25
Go to Step 13
Go to Step 25
Go to Step 14
Go to Step 25
Go to Step 15
Go to Step 20
Go to Step 16
Go to Step25
Go to Step 17
Go to Step 25
Go to Step 18
3280-4921
ohms/meter
(1000-1500
ohms/ft.)
6-.962
Engine

Step
Action
Values
Yes
No
1. Remove and visually/physically inspect the ignition
18
coils associated with the cylinders that were indicated

as misfiring. Ensure that the coils and coil towers are
free of cracks and carbon tracking.
2. If a problem is found, replace damaged ignition coils

as necessary. Refer to Ignition Coil(s) Replacement.
19
1. Measure the ignition coil secondary resistance.

2. If resistance is not between the specified values,
replace the faulty ignition coils as necessary. Refer to
Ignition Coil(s) Replacement.
Go to Step 25
Go to Step 24
Go to Base
Engine Misfire
Diagnosis in
Engine
Mechanical
Go to Step 21
Go to Step 25
Go to Step 22
(50008000 ohms)
1. Remove the spark plugs from the cylinders that were

indicated as misfire.
2. Visually inspect the spark plug electrodes for
excessive fouling. Refer to Spark Plug Replacement
21
Go to Step 19
5K-8Kohms
20
Go to Step 25
1. Visually inspect spark plug insulators for cracks,

carbon tracking, or other damage. Also, inspect
electrodes for incorrect gap. Refer to Spark Plug
Visual Diagnosis in Engine Electrical.
2. If a problem is found, replace affected spark plugs as
necessary. Refer to Spark Plug Replacement in
Engine Electrical.

Inspect for an engine mechanical problem .. Refer to Base
Engine Misfire Diagnosis in Engine Mechanical.
22
1. Damaged accessory drive belt or pulley.

2. Damaged driven accessory (generator, water pump,
drive belt tensioner, etc.).
3. Loose or broken motor mount.

23
Test for a transmission TCC problem. Refer to Diagnostic

Trouble Code (OTC) List/Type in Transmissionrrransaxle.
Replace the ignition control module. Refer to Ignition
Control Module Replacement.
Go to Step 23
Go to Step 25
Go1o
Diagnostic Aids
Did you find and correct the condition?,.

24
Go to Step 25
Go to Step 25

25
3. With a scan tool, observe the Misfire Current

Cylinder # parameter for each cylinder.
Does the scan tool indicate a current misfire?
Go to Step 2
Systen:i OK
Engine
6-.9.63
I I
L0 c
LJ!.I
- - - - - - - - ~ L T BLU11.876
LT BLU 1876
1
.i
DK.~LU1~96.
1
Knock
Sensor
Right
-=-
. .
33
Knock
Sensor
Left
-=-
l __ ?~
C1
r - Bank 1- Ba;k2 - - - - - - , Powertnii n

KS Signal KS Signal
CONN ID
I Control
I
c1 '.'._BLU
I Module ,6
I
c2-CLEAA
I (PCM)~
L-------------.1
548568
Circuit Description
'The PCM .contains integrated knock sensor (KS)
:diagnostic circuitry. The PCM uses the circuitry to
diagnose the KS ~ensors and related wiring. The PCM
calculates an average voltage of each knock sensors
signals and takes instantaneous signal voltage
readings. The PCM uses the instantaneous signal
voltage readings to determine the state of the knock
sensor circuitry. If the knock senso'r system is
operating normally, the PCM shoul.d monitor
instantaneous KS signal voltage readings varying
outside a voltage range is more than and less than the
calculated average voltage. If the PCM malfunctions
in a manner which will not allow proper diagnosis
.of the KS circuit OTC P0325 will set.

No TP, VSS, CKP sensor, CMP sensor, MAF
. sensor, or ECT sensor OTCs are set.
Engine speed is between 1000 and 2500 RPM:
O Throttle angle is more than 10 percent.
e Engine load is more than 45 percent.
O
Engine coolant temperature. is .more than
60C (140F).
Maximum spark retard is less than 15 degrees.
System voltage is more than 9 volts.

The PCM detects a malfunction in the integrated
knock sensor diagnostic circuitry which will not
allow proper diagnosis of the knock sensor
circuits.
The condition is present for 300 3X reference
periods (100 crankshaft revolutions).
Action Taken VVhen the DTC Sets

The PCM will store conditions whic:h were present
Records data.

The PCM will tum the MIL OFF during the
... The History OTC will clear after 40 consecutive
warm~up cycles have occurred without a
malfunction.
6-964
Engine
Diagnostic Aids

Systems.

Systems.
Damaged harness.

Test Description
The numbers. below refer to the step numbers on the
diagnostic table.
2. Ensures that the malfunction is present.

Step
Aetion
Did you perform the Powertrain On-Boa.rd
Values

2. Operate vehicle within Fail Records conditions.

Replace the PCM.
Refer to PCM Replacernent!Programming,

Does the DTC reset?
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Important: If an engine knock can be heard repair the

engine mechanical problem before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis (Base Engine)
in Engine Mechanical.
1. Operate the vehicle within Conditions for Setting
the DTC.
2. With a scan tool, observe Specific DTC info for this
DTC until the test runs.
Yes
Go
io Step 4
Go to Step 4
Go to Step 3
Go to
Diagnostic Aids
Go to Step 5
Go to Step 2
System OK
Engine
Engine Controls - 3.SL 6-965
LI.I
.---------....,LT
LT BL~ .1876
DK BL~
Knock
Sensor
Right
~
1496
~
--
BLU11876
331
__ 3~
Bank1- sa";;"k2 - - - - - ~.,
C1
Knock
r I
KS Signal KS Signal
Left
CONN ID
g:~t~AR
Sensor
..
Powertrain
I Control
I Module~
I (PCM)~
L-------------.1
548568
Circuit Description
The PCM contains integrated knock sensor (KS)
diagnostic circuitry. The PCM uses the circuitry to
diagnose the KS sensors and related wiring. The PCM
sensor circuitry. If the knock sensor system is
operating normally, the PCM should monitor
outside a voltage range above and below the
calculated average voltage. If the PCM detects a
knock sensor 1 s1gnal voltage within the calculated
average voltage range, OTC P0327 will set.

No TP, VSS, CKP sensor, CMP sensor, MAF
sensor, or ECT sensor DTCs are set.
Engine speed is between 1000 and 2500 RPM:
Throttle angle is more than 1O percent.
Engine load is more than 45 percent.
60C (140F).

The PCM detects a knock sensor 1 signal voltage
within the calculated average voltage range.
The condition is present for 300 3X reference

Records data.

'
malfunction.
Diagnostic Aids

Systems.
Damaged harness.
on the scan tool While moving connectors
Systems.

6-966
Engine Controls -3.Sl
Test Description
diagnostic table.
2. This verifies the malfunction is present. The scan
tool will indicate OTC Ran=Yes and Pass=lnt if
the failure is intermittent. This indicates the
diagnostic passed this ignition cycle and failed this
Jgnition cycle. At this point the resistance of the
knock sensors should be verified to be in the
correct range. If the knock sensor resistances are
correct, test the KS system wiring connections.
When inspecting the KS system connections, start
at the KS system jumper harness connector
Engine
located behind the intake manifold. Then.insp~ct
the connections at the PCM. Refer to the.
wiring schematic for the correct connector and
terminal. Then inspect the connections at
the appropriate knock sensor. Failure Records
data does not include the parameter KS Activity,
however other parameters may aid in locating
the conditions under which an intermittent
occurred.
3. This test will isolate the knock sensor from the
rest of the circuit.
4. Tap ori the engine block in the location of the
appropriate knock sensor.
Engine
6-967
OTC P0327 Knock Sensor (KS) Circuit Bank 1

Step
Action
Values
Yes
No
Go to Step2
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7

1 '
Important: If an engine knock can be heard, repair the

diagnostic.
4. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Fail Records as possible. Special
operating conditions that you need to meet before the
PCM will run this diagnostic, where applicable, are
listed in Conditions for Running the DTC.
ignition?
1. Disconnect the knock sensor.

2. Measure the resistance of the appropriate knock
3
sensor by connecting a DMM between the knock

sensor signal circuit on the sensor side and the
engine block.
3. Set the DMM to the 400K ohm scale.
Does the resistance measure within.the specified range?
93-107KQ
1. Connect a DMM between the appropriate knock

engine block.
2. Set the DMM to the AC voltage scale.
3. Tap on the engine in the area of the appropriate
knock sensor while observing the DMM.
Does the scan tool indicate a signal while tapping on the
engine near the knock .sensor?
Test the KS signal circuit for an open, a short to voltage or

a short to ground. Refer to Circuit Testing and Wiring
Replace the knock sensor. Refer to Knock Sensor (KS)

Replacement.
Inspect the KS signal circuiffora poor connection at the

PCM. Refer to Testing for Intermittent and Poor
Go to Step 9
Go to Step 9

Programming.

2. Operate the Fail Record conditions.
Does the DTC reset?
10
diagnosed?
Go to Step 8
Go to Step 9
Go to Step2
Go to Step 10
Go to
applicable DTC
System OK
6-968
Engine
Engine Controls - 3.8L.
~-------~LT BLU11876.
LT BLU 1876
1
~"'
DK BLU
Knock
Sensor
Right
1496
1
~
_
-
33
Knock
Sensor
Left
l __
3~ C1
1- sa-;;-k
2r - Bank
I
KS Signal KS Signal
I
I
._
- - - - - ., Powertrain
CONN 10
c1:BLU
_____________
C2-CLEAR
.1 Control
I Module>,
I (PCM)~
_.
548568
Circuit Description
The PCM contains integrated knock sensor (KS)
diagnostic circuitry. The PCM uses the circuitry to
diagnose the KS sensors and related wiring. The PCM
calculated average voltage. If the PCM detects a
knock sensor 2 signal voltage within the. calculated
average voltage range, OTC P0332 will set.

No TP, VSS, CKP. sensor, CMP sensor, MAF
sensor, or ECT sensor OTCs are set.
" Engine speed is between 1000 and 2500 RPM:
O
Throttle angle is more than 10 percent.
" Engine load is more than 45 percent.
60C (140F).

" The PCM detects a knock sensor 2 signal voltage
within the calculated average voltage range.
The conditions is present for 300 3X reference

.. The PCM will illuminate the malfunction indicator
Records data.
Conditions .for Clearing the MIUDTC

warm-up cycles have occurred .without a
malfunction.
Diagnostic Aids
Poortermirial. connection.
faultyterminal to wire connection. Use a
Connections and .Connector Repairs in Wiring
..Systems.
Damaged harness.
on the scan tool while. moving connectors
.the fault. Refer to Wiring Repairs in Wiring
Systems .
Engine
Test Description

diagnostic table.
tool will indicate OTC Ran=Yes and Pass=lnt if
ignition cycle. At this point the resistance of the
correct, test the KS system wiring connections.
When inspecting the KS system connections, start
6-969
located behind the intake manifold. Then inspect

the connections at the PCM. Refer to the
wiring schematic for the correct connector and
terminal. Then inspect the connections at
the appropriate knock sensor. Failure Records
data does not include the parameter KS Activity,
however other parameters may aid in locating
the conditions under which an intermittent
occurred.
3. This test will isolate the knock sensor from the
rest of the circuit.
4. Tap on the engine block in the location of the
6-970
. Engine
DTC P0332 Knock Sensor (KS) Circuit Bank-2

Step
Action
Values
Yes
No
Go to Step 2
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check

Diagnostic (OBD) System C.heck?

diagnostic.
recorded in Fail Records as possible. Special
operating conditions that you need to meet before the
PCM will run this diagnostic, where applicable, are
listed in Conditions for Running the OTC.
ignition?
..
-
1. Disconnect the knock sensor.

2. Measure the resistance of the appropriate knock
sensor by connecting a DMM between the knock
engine block.
1. Connect a DMM between the appropriate knock

engine block.
3. Tap on the engine in the area of the appropriate
knock sensor while observing the DMM.
Does the scan tool indicate a signal while tapping on the
engine near the knock sensor?
Test the KS signal circuit for an open, a short to voltage or

a short to ground. Refer to Circuit Testing and Wiring
Replace the knock sensor. Refer fo Knock Sensor (KS)

Replacement.
Inspect the KS signal circuit for a poor connection at the



Does the OTC reset?
10
diagnosed?
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 6
93-107KQ
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 9
'
Go.to Step g
Go to S(ep 8 ..
Go to Step f}
Go to Step 2
Go to Step 10
Go to
applicable OTC
System OK
Engine
6~971

,. -P - -
ower
- - -
Distributi9n
Systems
- -
- ., Engine
ENG CTRL
~cher:natics
1 mWinng
MiniFuse
15 A
Wiring
I Harn~ss
1Junction Block 2
I
.. __________ ...I
PNK 239
PN K 239
Power
Distribution
PNK!239
~c~:i;:ics
..
Systems
-----..J
PNK 239
p
.
Ignition
Control (ICM)
ignition
SV
Positive
Camshaft
Voltage
----T
Position
J,
Signal
18x
Reference
3x
Reference
Signal
Signal
F} CT Cl
9
BLK 630
BLU/BLK 647
Dl
Module
J.
Ground
PPL/WHT 430
----------- ----------. ----i-----------------------,

Powertrain
I
CMP
Sensor
1ax
Reference
sx
Reference
Signal
Signal
Signal
I Control
CONN ID
C1=BLU
I Module
.. _____________________________ ..
:
C2=CLEAA
: (PCM)
548570
Circuit Description
The 1BX reference signal is produced by the ignition

control module. The ICM calculates .the 18X reference
signal by filtering the crankshaft position (CKP)
sensor 18X pulses when the engine is running and
CKP sync pulses are also being received. The
PCM uses the 18X reference signal to calculate engine
RPM and crankshaft position at engine speeds less
than "1200 RPM. The PCM constantly monitors
the number of pulses on the 18X reference circuit and
compares the number of 18X reference pulses to
the number of 3 X reference pulses and CAM signal
pulses being received. If the PCM receives an
incorrect number of pulses on the 18X reference
circuit, OTC P0336 will set and the PCM will use the
3X reference signal circuit for fuel and ignition
control. The engine will continue to start and run using
the 3X reference and CAM signals only.
No 18X reference pulses are not received in

one engine cycle (720 degrees of crankshaft rotation).

The engine is running (3X reference pulses are being
received).

which the diagnostic has been run and failed.
If equipped with traction control, the PCM will
command the electronic brake and traction control
module (EBTCM) via the serial data circuit to
turn OFF traction control, and the EBTCM
will illuminate the TRACTION OFF lamp.
when the OTC set as Freeze Frame and Failure
Records data.

been run. and passed ..
malfunction.
5:.972
Engine
Diagnostic Aids

- Conn.ections and Connector Repairs in Wiring
Systems.

Incorrect harness routing near secondary ignition
,
components.
Faulty Ignition Coil - Remove the :ignition coils and
inspect the ignition control module and coils for
cracks, carbon tracking, or other signs that
indicate that the coil secondary circuit is arcing to
the ICM or ICM wiring harness. Refer to Ignition
Coil(s) Replacement
Secondary ignition wires arcing to wiring harness Inspect secondary ignition wires for carbon
tracking or other signs of damage.
lnspectthe wiring harness for damage. If the

Systems.
Test Description
diagnostic table.

Step
Action
Go to Step 2
. Goto Step 3
Go to Engine
Cranks but Does
Not Run

Does the engine start?
No
Go to A
Powertrain On
Bo.a rd
Diagnostic (080)
System Check
!'
..
Yes
Values

Damaged harness.
1. Clear the DTCs.

2. Start the engine and idle for 1 minute.
Test for an open, a .short to voltage, or a short to ground
in the 18X reference circuit between the ICM and the
PCM. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
<3o to Step 4
Go to
Diagnostic Aids
Go to Step 1.1
Go to Step5
1. Turn .OFF the ignition.

2. Reconnect th!=) ICM.
3. Disconnect the crank sensor.
4. Connect a test lamp to a good ground.
5. Connect a DMM between the 18X. refer~nce .circuit at
the PCM connector and a good ground.
7. Repeatedly touch the test lamp to the'18X signal
circuit at the crank sensor connector while observing
the DMM.
Does the measured voltage change?
Test for a short to voltage or poor connections at the ICM.

Refer to Circuit Testing and Wiring Repairs or Testing for
in Wiring Systems.
.
!
..
Go to Step 8
Go to Step 6
Go to Step 11
Go to Step 7
Engine
6-973
DTC P0336 Crankshaft Position (CKP) Sensor Circuit (cont'd)
Step
Values
-

1. Incorrect harness routing near secondary ignition
components.
2. Ignition coil arcing to the wiring harness or to the
ignition control module (inspect the ignition coils for
cracks, carbon tracking, or other signs of damage).
Refer to Ignition Coil(s) Replacement.
3. Spark plug wires arcing. Refer to Spark Plug Wire
Harness Replacement (3.8 L Right Bank) or Spark
Engine Electrical.

10

Replace the PCM.
11

Does the DTC reset?
Action

Replacement.
Yes
No
Go to Step 11
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 11
Go to Step 2
System OK
5;.974
Engine

r.=====::;-------, Crankshaft
Camshaftr-------;::======~
Position (CKP)
Position (CMP)
Sensor
Sensor
A
LTBLU/
WHT
RED/ 645
BLK
WHT/ 644
BRN/WHT 633
BLK
fM7I
Uil
1800
YEL 573
-----~
RED/BLK 645
RED/ 645
BLK
WHT/ 644
BLK
1
J
CKP 18x
Signal
GMP/CKP
Sensor Ignition
Positive Voltage
CMP
Sensor
Signal
CKP
Sync
Signal
5V
12V
x~---
Ignition
Control
(ICM)
Module
>
Camshaft
Position
Sensor
Signal
stKI630
r----.,-r----, ..
7
C1
CONN ID
I
I
C1 = BLU
C2=CLEAR
. camshaft
Position
sensor
Signal
I Powertra1n
Control
I
.
Module
jJ.
'(PCM)~
L----------.J
(
548574
Circuit Description
The camshaft position PCM input is produced by the
ignition control module or ICM. The ICM produces
the camshaft position PCM input by filtering the
camshaft position (CMP) sensor pulses when the
engine is running and CKP sync pulses are also being
received. The PCM uses the camshaft position
PCM input pulses to initiate sequential fuel injection
and to determine crankshaft position for the misfire
diagnostic. The PCM constantly monitors the number
of pulses on the camshaft position PCM input
circuit and compares the number of camshaft position
PCM input pulses to the number of 18X reference
pulses and the number of 3X reference pulses being
received. If the PCM receives an incorrect number
of pulses on the camshaft position PCM input circuit,
OTC P0341 will set and the PCM will initiate injector
sequence without the camshaft position PCM
input with a one in six chance that injector sequence is
correct. The engine will continue to start and run
normally, although the misfire diagnostic will be
disabled.

The engine is running (3X reference pulses are being
received).

No cam sensor reference pulses are not received in
one engine cycle (720 degrees of crankshaft rotation).

Records data.
0

malfunction.
Diagnostic Aids
Secondary ignition wires arcing to wiring harness Inspect secondary ignition wires for carbon
tracking or other signs of damage.
Faulty Ignition Coil - Remove the ignition coils and
inspect the ignition control module and coils for
cracks, carbon tracking, or other signs that
indicate that the coil secondary circuit is arcing to
the ICM or ICM wiring harness. Refer to Ignition
Coil(s) Replacement
Engine

Systems.
.. Damaged harness.
Systems.
6-975

Test Description
diagnostic table.
2. Ensures that the fault is present.
21. Determines whether the fault is caused by a
missing camshaft magnet or a faulty PCM.
The voltage measured in this step should read
around 4 volts, toggling to near O volts when
the CMP sensor interfaces with the camshaft
magnet.

Step
Action
Values
Important: If the engine cranks but will not run, refer to

Engine Cranks but Does Not Run.

Does the scan tool indic!:lte this OTC failed this ignition?

3. Probe the camshaft position input signal circuit at the
PCM connector using a Digital Multimeter that is
Important: If voltage measures 0, bump over engine to
insure cam sensor magnet is not located under the cam
sensor at the time of this test.
5. Observe the voltage indicated on the DMM.
5V
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 16
Goto Step B
Go to Step 7
Go to Step 6

2. Without disconnecting the CMP harness connector,
remove the CMP sensor from the engine front cover.
Important:
4
)
5
The magnet used must have sufficient power and the

correct polarity.
0
If the voltage remains at 5 volts, retest using the
opposite end of the magnet.
4. Place a magnet on the CMP sensor.
Does the voltage toggle from 5 volts to O volts as the
magnet is placed on the sensor?
Does the voltage on the camshaft position input signal
circuit measure more than the specified value?
5V
6-976
Engine

DTC P0341 Camshaft Position (CMP) Sensor Performance (cont'd)
Step
Action
1. Turn OFFthe ignition.
2. Leave the PCM disconnected.
5. Probe the camshaft position input signal circuit and
the CMP sensor signal circuit .at the ICM using a test
lamp that is connected to B+.
Values
Yes
No
Go to Step 24
Go to Step 13
Go to Step 24
Go to Step 18
Go to Step 9
Go to Step 12
Go to Step 10
Go to Step 11
Go to Step 15
Go to Step 14
Go to Step 24
Go to Step 14
Go to Step24
Go to Step 14
Go to Step 24
Go to Step 14
6. If the test lamp is illuminates, repair the short to

ground in the camshaft position input signal circuit or
the CMP sensor signal circuit. Refer to Wiring
7
5. Probe the camshaft position input signal circuit using

a test lamp that is connected to a good ground.
6. If the test lamp is illuminates, repair the short to
voltage in the camshaft position input signal circuit.
Refer to Wiring Repairs in Wiring Systems:
1. Disconnect the CMP sensor.

2. Measure the voltage on the sensor feed circuit using
a DMM that is connected to the CMP ground circuit.
Is the voltage at the specified value?
B+
Measure the voltage on the CMP sensor signal circuit

using a DMM that is connected to the CMP ground circuit.
Does the voltage measure within the specified range?
5-7V
1. Measure the voltage on the CMP input signal circuit

at the PCM connector using a DMM that is connected
to a good ground.
2. Observe the voltage while repeatedly touching the
CMP sensor signal circuit at the CMP sensor
connector using a test lamp that is connected to a
good ground.
Does the voltage switch between O and 5 volts when the
test lamp is repeatedly touched to the CMP signal circuit?
Test for the following conditions:

1. The CMP sensor signal circuit for an open, a short to
voltage or a short.to ground.
2. The camshaft position input signal circuit for a short
to voltage.
Systems.
12
Test the following circuits for an open between the ICM

and the CMP sensor:
1. The sensor feed circuit.
2. The sensor ground circuit.
Systems.
13
Test for an open in the camshaft position input signal

circuit between the PCM and the ICM. Refer to Circuit
10
11
Engine
6-977
DTC P0341 Camshaft Position (CMP) Sensor Performance (cont'd)

Step
Action
Values
Inspect for poor connections at the ICM. Refer to Testing

15
Inspect for poor connections at the CMP sensor. Refer to

16

17

components.
2. Ignition coil arcing to the wiring harness or to the
ignition control module. Inspect ignition coils for
cracks, carbon tracking, or other. signs of damage.
Refer to Ignition Coil(s) Replacement.
3. Secondary ignition wires arcing to the wiring harness.
Refer to Spark Plug Wire Harness Replacement
(3.8 L Right Bank) in Engine Electrical.
18

Replacement.
Replace the CMP sensor. Refer to Camshaft

Position (CMP) Sensor Replacement.

components.
2. Ignition coil arcing to wiring harness or ignition control
module. Inspect ignition coils for cracks, carbon
tracking, or other signs of damage. Refer to Ignition
Coi/(s) Replacement.
Secondary
ignition wires arcing to wiring harness.
3.
(3.8 L Right Bank) in Engine Electrical.
14
19
20
21
1. Reinstall the CMP sensor to the engine front cover.

2. Probe the camshaft position input signal circuit using
a DMM that is connected to a good ground.
3. Observe the voltage while repeatedly bumping the
engine with the starter.
Does the voltage toggle between the specified values?
Yes
No
Go to Step 24
Go to Step 17
Go to Step 24
Go to Step 19 .
Go to Step 24
Go to Step 20
Go to Step 24
Go to Step 18
-
Go to Step 24
Go to Step24
Go to Step24
Goto Step 21
Go to Step 22
Go to Step 23
5V /OV
22
Replace the PCM.

Go to Step 24
23
Replace faulty or missing CMP sensor magnet.

24

Does the OTC reset?
Go to Step 24
Go to Step 2
System OK
6-978
Engine

Circuit Description
The PCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open
while monitoring the manifold absolute pressure (MAP)
sensor signal. When the EGR valve is opened, the
PCM should see a proportional increase in MAP. If the
expected increase in MAP is not seen, the PCM
notes the amount of error that was detected and
adjusts an internal fail counter towards a fail threshold
level. When the fail counter exceeds the fail threshold
level, the PCM will set DTC P0401. The number of
test samples required to accomplish this may
vary according to the amount of detected flow error.
Normally, the PCM will only allow one EGR flow
test sample to be taken during an ignition cycle. To
aid in verifying a repair, the PCM a!!ows a specified
number of test samples during the first Ignition
cycle following a scan tool Clear Info or a battery
disconnect. Between nine and twelve samples should
be sufficient for the PCIVI to determine adequate
EGR flow and pass the EGR test if the system is
operating correctly.

malfunction.
Diagnostic Aids
Important: If the EGR valve shows signs of excessive
heat, inspect the exhaust system for blockage
.(possibly a plugged catalytic converter). Refer to
Restricted Exhaust System Check.
To verify a repair, cle.ar the information with the scan
tool and run the EGR flow test keeping the following
items in mind:
will
The PCM
only run the EGR flow test during a
gradual deceleration.
The PCM will only run the EGR test during a
closed throttle condition.
RPM is between 900 and 1400 RPM.
The PCM will only run the EGR test at vehicle

speeds more than 40 km/h (25 mph).
.. Several deceleration cycles will be necessary to
run a sufficient number of EGR flow test
samples (9-12).
BARO is more than 70 kPa.

Vehicle speed is more than 40 km/h (25 MPH).
" If the engine speed increases more than 100 RPM

from the enabling RPM (refer to Conditions for
Running the DTC), the PCM will reset the test.
A/C clutch status is unchanged.
If the engine speed decreases more than

300 RPM from the enabling RPM (refer to
Conditions for Running the DTC), the PCM will
reset the test.
When the PCM commands the EGR valve open
engine speed will drop. If the engine speed
drops below the following RPM values, the test
will not run:
No Fuel Injector, CKP, TP, MAP, VSS, IAT, ECT,

IAC, EGR Pintle, Misfire or MAF DTCs set.
75C (167F).
Transmission status is unchanged.

Throttle angle is less than 1 percent
EGR position is less than 1 percent
MAP, TP, RPM and VSS are steady.

MAP changes monitored during the EGR flow test
indicate insufficient EGR flow.

The PCM will iiluminate the malfunction indicator
lamp (MIL) during the first trip in which the
diagnostic test has been run and failed.
The PCM wi!l store conditions which were present
Records data.
- Manual Transaxle - 800 RPM.

- Automatic Transaxle - 700 RPM.
The EGR TestCounter displayed on the scan tool
can b.e useful in determining that the EGR flow
test is running and to keep track of the number of
test samples taken. The counter will increment
each time a test sample is taken.
Engine
Engine Controls
A Vacuum restriction to the MAP sensor - A restriction

to the M.AP sensor can cause the EGR flow test to
fail due to insufficient MAP changes being monitored
during the test. Inspect for objects blocking the
vacuum to the MAP sensor. Also inspect for kinked or
pinched MAP sensor vacuum hoses (if equipped.)

terminals, improper mating, bro.ken locks,
corresponding mating terminal to test for proper .
Systems.
a~aL
6-979
Damaged harness.
Systems.

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 5
Go to Step 3
Did you perl'orm the Powertrain On-Board

1
.
2
)
> .
..
lnspecttlle exhaust system for modification of original

installed parts or leaks.
Replacement.
2. Visually and physically inspect the 'following items:
. The pintle, the valve passages and the adapter for
excessive deposits or any kind. of a restriction.
1:,
the EGR valve gasket and pipes for leaks.
.
Go to Step 5
Go to Step 4
.',
1. Remove the EGR inlet and outlet pipes from the
exhaust manifold and the intake manifold. Refer to

EGR Valve Replacement.
.
2. Inspect the manifold EGR ports arid. the EGR inlet
arid outlet pipes for a blockage caused by excessive
I>
deposits or other damage.
1. With a scan fool, observe the EGR Test Count
parameter.
2. Operate the vehicle within the conditions specified in
Diagnostic Aids:
3. Continue operating the vehicle until 9 -12 EGR Test .
Count test samples have been taken.
Does the DTC reset?
'i
..
Go to Step.5
Go to
Qiagnostic Aids.
Go to Step 2
System OK
6-980
Engine

MAP Sensor _. -
lSJoc
[S]
N
al
GAY 598
D
GRY 598
BLK 552
LT BLU 697
BAN 1456
GRY 435
~= -
C2
~ -~~~: -f_
:
32
~~~tr:
Control ..f
__.....
28
C1
Ground
~-
C2
31
C1
33
C2
~~fa -1- --- ~~i -. ---- -r- i~~~=e~ ~ :6~~:~~ain

Position
Signal
-=-
I
I
Position
Ground
PCM
C1=BLU.
C2=CLEAR
Module
(PCM)
I ~
I ~
L-----------------------------~------J
(
480730
Circuit Description
The PCM monitors the EGR valve pintle position input
to ensure that the valve responds properly to
commands from the PCM. The Linear EGR valve is
controlled by using an ignition positive driver and
ground circuit within the PCM. The driver has
the ability to detect an electrical malfunction in the
ignition positive or ground circuit. If an electrical
malfunction occurs, the driver signals the PCM to set
DTC P0403.

The engine is cranking or running.

The PCM detects an electrical malfunction in the
control circuit for the EGR valve.

Records data.

The PCM will turn the MIL OFF du~ing the
third consecutive trip in which the. diagnostic has
warm-up cycles have occu'rred without a
malfunction.
The DTC can be cleared by using a scan tooL
Engine
s~.981
Diagnostic Aids
Test Description

diagnostic table.

component.. Ensure that the gaskets are installed
correctly. The gaskets preveritcontaminate intrusion.
.
Poor terminal connectior,.
Systems.
Damaged harness.
Inspect the wiring harm~ss for damage. If the
the scan tool while moving connectors
Systems.
clean and secure. connections.
the Failure Records cah be useful in determining
on
2. Listen for an audible click when the solenoid

operates. Command the EGR between O percent
to 1O percent. Repeat the commands as
necessary.
3. Verifies that the PCM is providing voltage to the
solenoid.
4. Tests for an open in the ground circuit to the
solenoid.
5. Tests if voltage is constantly being applied to the
solenoid.
programmed.
6-982
Engine

Step
Action
Yes
,No
Go to Step~
Goto A
Powertrain On
.Board
Diagnostic (080)
Sysfem Check
Go to
Diagnostic A.ids
(3-Q to Step 3
Values
Did you perform the On-Board Diagnostic (OBD)

System Check?
,
2
.1. Turn ON the ignition, with th,e engine OFF .

2. With a scan tool, command the EGA from O percent
to 1O percent.
Does the solenoid turn ON and OFF with each command?
1. Connect a test lamp between the control circuit of the

solenoid and the ground circuit of the solenoid.
2. With a scan tool, command the EGA between
O percent and 10 percent.
command?
Does the test lamp remain illuminated with each

command?
Test the control circuit of the solenoid for a short to ground

or an open. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the control circuit of the solenoid for a short to

voltage. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Inspect for poor connections at the EGA. Refer to Testing

Repairs in Wiring systems.

Repair the ground circuit of the solenoid. Refer to Wiring

11
Replace the EGA. Refer to EGR Valve Replacement.

12

Replace the PCM.
13

conditions.
Does the OTC reset?
10

2: Disconnect the EGA.
4. Probe the control ci.rcuit ofthe solenoid using a test
lamp that is connected to a good ground.
5. With a scan tool, command ,the EGA between
O percent and 10 percent.
command?
'.
Go to Step4
Go to Step 5
G.o to Step 8
.Gp to St<3p 10
Go to Step 7 .
Go to Step q
(
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 13
Go to Step 13
(
Go to Step2
System OK
Engine
Engine Controls - 3;8L 6-983
DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

MAP Sensor -<f -
IL 0 c
GRY 598
D
GRY 598
BLK 552
LT BLU 697
BRN 1456
GRY 435
32 C1
28 C2 31 C1
33 C2
4 C2
,. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .., Powertrain
I
EGR
t
EGR
EGR.1
EGA
5Volt
i
Valve
/- __ ___,-i__n_
Control
Pint!e
Pint!~
Reference A
l Control
I
Control --j_Ground
Pos1t1on
Pos1t1on
Module
:
Signal
-=Ground
PCi\il
: (PCM)
I
Cl = SU.:
C2=CLEAR
l
.,,6
I ~
L------------------------------------J
480730
Circuit Description
commands from the PCM. The PCM compares Actual
EGR position with Desired EGR position when the
valve is commanded open. If Actual EGR position
varies more than 15 percent from Desired EGR
position when the PCM is commanding the EGR valve
opened, DTC P0404 will set.

System Voltage is between 10 volts and 16 volts.

Desired EGR does not equal 0.
Actual EGR position varies more than 15 percent
from Desired EGR position.
The above conditions are present for more than
20 seconds.

lamp (Mil) during the second consecutive trip in
The .PCM will store conditions which were present
Records data.

The PCM wm turn the MIL OFF during the
malfunction.
6-984
Engine
Diagnostic Aids
Excessive deposits on the EGR Pintle or seat.
Remove the EGR valve and inspect for deposits
that may interfere with the EGR valve pintle
extending completely or cause the pintle to stick.
A EGR valve over temperature or icing condition
could have caused this DTC to set.

Systems.
" Damaged harness.

Systems.
Test Description
diagnostic table.
3. If DTC P0404 will only set under certain
conditions, the malfunction may be intermittent;
refer to Diagnostic Aids. If an intermittent
wiring problem is not present, check for a poor
connection at the PCM or the EGR valve. If
the connections are OK and DTC P0404 continues
to set, replace the EGR valve.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Was the Powertrain On-Board Diagnostic (OBD)

System Check?
-
Important: If any of the following DTCs are set, diagnose

the other OTC first.
OTC P0403 Exhaust Gas Recirculation (EGR)
Solenoid Control Circuit
O OTC P0405 Exhaust Gas Recirculation (EGR) Position
Sensor Circuit Low Voltage
1. Turn ON the ignition switch.
2. Select the scan tool EGR valve output control
function.
3. Increment the EGR valve through all positions while
comparing desired EGR position to actual EGR
position.
Does desired EGR position remain within 15 percent of
actual EGR position at all commanded positions?

2. Operate the vehicle within Failure Records conditions.
OTC P0404.

2. Disconnect the EGR valve.
Does the pintle position displayed on the scan tool equal
the specified value?
0%
(
Go to Step 5
Go to Step 7
Engine
Step
Engine Controls - 3~8l
6-985
DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance (cont'd)
Action
Yes
Values
No
Connect a DMM to measure voltage between the sensor
ground circuit and the 5 volt reference A circuit at the
harness connector.
5V
Go to Step 6
Go to Step 8
Go to Step 12
Go to Step 10
Go to Step 16
Go to Step 15
Go to Step 9
Go to Step 11
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 14
Go to Step .16
Go to Step 14
Go to Step 13
Go to Step 15
Important: If the 3 amp fuse blows, locate and repair a

short to ground in the signal circuit. Refer to Wiring
6
Install a 3 amp fused jumper between the 5 volt reference

circuit and the signal circuit at the EGR valve harness
connector.
Does the pintle position displayed on the scan tool equal
Test the Signal Circuit for a short to voltage and repair as
necessary. Refer to Wiring Repairs in Wiring Systems.
Connect the DMM between the 5 V reference circuit and a

good ground.
100%
5V
10
Test the sensor ground circuit for an open or short to

voltage. Refer to Wiring Repairs in Wiring Systems.
Test the signal circuit for high resistance or a high
resistance short to ground. Refer to Wiring Repairs in
Wiring Systems.

Test the 5 V reference circuit for an open, short to ground,
or a short to voltage and repair as necessary. Refer to
)
11
1. Check for poor terminal connections at the
12
EGR valve.
Testing for Continuity, Testing for Intermittent and
Poor Connections, Repairing Connector Terminals,
1. Check the circuits related to the EGR valve for poor

terminal connections at the PCM.
13
14

Testing for Continuity, Testing for Intermittent and
Poor Connections, Repairing Connector Terminals,
Replace the EGR valve. Refer to EGR Valve
Replacement.
Go to Step 16
Is action complete?
15
Replace the PCM.

Is action complete?
Go to Step 16
16
2. Clear DTCs.
3. Operate the vehicle within Failure Records conditions.
OTC P0404.
Does the scan tool indicate OTC P0404 failed this ignitjon?
Go to Step 2
System OK
6-986
Engine
DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit low Voltage
MAPSensor ..,. -
-,- -
GRY 598
D
GRY 598
BLK 552
LT BLU 697
BRN 1456
GRY 435
C2
r - - - - - - - - - I
EGR
}
Valve
___ ____n___rL_
I Control
"j_
32
-
I
J
28
C1
- - EGR
Control
Ground
- - EGR
Pintle
Position
Signal
C2
31
-
C1
- - EGR
Pintle
Position
Ground
33
-
'""'. ..
C2
- - - - 5Volt
Reference A
PCrvJ
Powertrain
Contial
I Module
I (PCM)
I
=
C1 = BLU
C2=CLEAR
j/J;
I
I .~
~-----------------------.-----------~-J
(
480730
Circuit Description
commands from the PCM and to detect a fault if the
pintle position sensor circuit is open or shorted. If
the PCM detects an excessively low EGR Feedback
signal voltage, DTC P0405 will set.

The PC.M will turn the MIL OFF during the
malfunction.
Diagnostic Aids

A EGR valve icing or over temperature condition could
have caused this DTC to set.
EGR Feedback is less than 0.14 volts at any time.

.. The condition is present for longer than
20 seconds.

Records data.

Systems.
Engine
" Damaged harness.
Systems.
6.-987
Test Description
diagnostic table:
3. If OTC P0405 will only set under certain
refer to Diagnostic Aids. If an intermittent
wiring problem is not present, inspect for a poor
connection at the PCM or the EGR valve.
DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage
Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Steps
Go to Step 9
Go to Step 8
Go to Step 6
Go to Step 13
Go to Step 7
Go to Step 19
Go to Step 17
Go to Step 12
Go
Go to Step 10
Go to Step 11

1
2. With a scan tool, increment the EGR valve through all

2
positions while comparing Desired EGR position to

Actual EGR position.
Does Desired EGR position remain close to Actual EGR
position at all commanded positions?
1. Disconnect the EGR.
2. Measure the voltage between the EGR pintle position

4
sensor ground circuit and the 5 volt reference circuit

using a DMM.
Probe the EGR valve pintle position signal circuit with a
test lamp that is connected to B+.
1. Connect a jumper between the 5 volt reference circuit
and the pintle position signal circuit.
2. With a scan tool, observe the Actual EGR position
parameter.
Does the scan tool indicate Actual EGR position at the
specified value?
Test for an open in the EGR valve pintle position signal
circuit. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
5V
100%

8
3. Probe the EGR valve pintle position signal circuit

using a test lamp that is connected to B+.
Probe the 5 volt reference circuit using a test lamp that is
connected to B+.
to Step
15
6-988
Engine
DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage (cont'd)
Step
Action,
Values
Yes
No
Go to Step 16
Go to Step 18
Go to Step 19
Go toStep 17
10
11
12
13
14
15

3. Probe the 5 volt reference circuit using a test lamp
that is connected to B+.
Test for an open in the 5 volt reference ci.rcuit. Refer to

Repair the short to ground in the EGA valve pintle position

signal circuit. Refer to Wiring Repairs in Wiring Systems.

1. Poor connections at the EGA valve.
2. The EGA pintle position signal circuit shorted to the
EGR valve control circuit.
If a problem is found, repair as necessary. Refer to
Wiring Repairs or Testing for Intermittent and Poor
Systems.
Important: If the EGR valve shows signs of excessive

heat, check the exhaust system for blockage (possibly a
plugged converter) using the procedure found in the
Restricted Exhaust System Check. If the exhaust system
is restricted, repair the cause; one of which might be an
injector which is open due to one of the following reasons:
Stuck
Grounded driver circuit
Possible faulty control module
If this condition is found, the oil should be checked for
possible fuel contamination.
Replace the EGA valve. Refer to EGR Valve
Replacement.
Test the EGR valve pintle position signal circuit for a short
to the sensor ground circuit. Refer to Circuit Testing and
Go to Step 19
Go to Step 14
Go to Step 19
Go to Step 19
Repair short to ground in the 5 volt reference circuit. Refer

17
Inspect the circuits related to the EGA valve for a poor

Systems.
18

Replace the PCM.

Does the OTC reset?
19
Go to Step 19

16
Go to Step 18
Go to Step 19
Go to Step. 19
Go to Step 18
Go to Step 19
Go to Step 2
System OK
Engine
DTC P0420 Catalyst System
low Efficiency
Circuit Description
three-way catalytic converter is.used. The .catalyst
within the converter promotes a ch.emical reaction
and carbon dioxide. The catalyst also redu,ces NOx,
converting it to nitrogen; The converter also has
the ability to store excess oxygen and release the
stored oxygen to promote these reactions. This oxygen
storage capacity, (OSC) is a measurement ofthe
catalysts ability to control emissions. T.he PCM.
monitors t.his process using a h.eated oxygen
sensor (H02$) located in the exhaust stream past the
three-way converter. When the catalyst is functioning
properly, .the r;I02S 2 is slow to respond to a large
change in the H02S 1 signal: When the H02S 2
responds quickly to a large change in the H02S 1
signal.the OSC and efficiency of the catalyst is
consideredfo be bad and the MIL will be illuminated if
subsequerittests also indicate a fail~re.
6-989

1. Meet conditions for engine warm up. Use the
scan tool catalyst data list in order to verify the
following.
No VSS, EVAP, Mis{ire, H02S, EGR, Ec;r,
MAF, ETC, IAT, NIAP!. CMP, CKP sensqr,
Fuel Trim, or Fuel Injector, DTCs set.
Engine has been running longer than
1O minutes ...
Engine coolant temperature (ECT) is rnore
than 76C (169F) and less thanJ24~{255F)..
Baro is more than 75 kPa.
Vehicle is in Closed Loop.
Intake air temperature (IAT) is more than
-20C (-4F) and less than 100C (212F).
Battery voltage more than 10. 7 volts.
2. Warm up the catalyst.
Fully open hood.
Transmission is in park (automatic) or neutral
(manual).
Set the parking brake.
Press and hold service brake.
Each time the engine is started the diagnostic
can run up to 18 times. After the ten minute
run time, and before the diagnostic runs
the first time, the engine must run an additional
5 minutes between 1500 and 2000 RPM.
Any additional tests on the same key cycle,
the RPM must be between 1500 and
2000 RPM for 1 minute.
To activate the diagnostic; Return to idle and
put the vet;iicle in drive (automatic) or depress
the clutch (manual).
3. Test the catalyst.

.Place.the transmission. in drive (automatic) or
neutral and depress the clutch (manual):
Within 60 seconds the air fuel ratio will go rich
below 14.1 for up to 5 seconds, then it may
go lean above 15.3 for up to 6 seconds.
Using the scan tool check and see if
DTC P0420 has passed orfailed this key cycle

The PCM determines that the catalysts oxygen
storage capacity is less than a threshold considered
acceptable.

Records. data.

malfunction.
The DTC ca_n be cleared by using a scan tool.
Diagnostic Aids
The PCM WILL NOT ENABLE the catalyst test
until following conditions are met:
- Engine speed is plus or minus 250 RPM

from desired idle.
- Throttle position (TP) is less than .5 percent
- Short term integrator is between
-20 percent and +20 percent.
The catalyst test WILL ABORT if the vehicle falls
out side the conditions listed below while the
test is running:
- Engine speed is plus or minus 250 RPM
from desired idle.
- Throttle position (TP) is less than .. 5 percent.
- Short term integrator is between
-20 percent and +20 percent.
The catalyst test may abort due to a change in
engine load (i.e., A/C, coolant fan). If this
problem occurs use the scan tool to force the
cooling fans on return to step 3 in the table then
repeat the test
Important: When using the scan tool to force the
cooling fans .on use the next list and previous list soft
keys to enter the catalyst data list. If the. catalyst
data list is not entered this way the cooling fan control
will be canceled.
The number of attempted tests is limited to
18 per key cycle.
6-990
Engine
More than 6 tests may have to be attempted to

get 6 completed tests. An aborted test counts
as an attempted test.
If 18.tests have been attempted, and a decision
has not been made this key cycle then turn the
key OFF for 30 seconds. Start the engine
and perform the Conditions for Running the DTC including the 10 minute run time.
After returning to an idle the H02S 1 signal may
stay rich or lean for several seconds causing
the test to be delayed.
Systems.
Damaged harness.
Inspect the wiring harness for damage. If .the
Systems.

Test Description
diagnostic table:
1. The powertrain OBD system check prompts the
technician to complete some basic tests and
store the freeze frame and failure records data on
the scan tool if applicable.
2. If any other DTCs are set, diagnose those DTCs
first. A fault in a component can cause the
converter to appear degraded or may have caused
its failure.
3. Clearing the DTCs allows the catalyst test to be

attempted 18 times and completed up to 6 times
this key cycle. If the A/C is ON the diagnostic may
not run. The engine must be warmed-up. The
converter needs to be warmed-up by raising the
engine speed more than idle for the specified tim.e
prior to each attempted test. Check and see if
OTC passed or failed this key cycle. If the
DTC does not pass or fail look for a possible
reason that would cause the test to abort.
4. This step includes tests for conditions that can
cause the three~way converter to appear
degraded. Repair any problems found before
proceeding with this table.
9. If the three-way converter needs to bereplaced,
make sure that another condition is not present
which could damage the converter. These
conditions may include: misfire, high engine oil or
coolant consumption, retarded spark timing,
weak spark or a plugged/leaking injectors. Correct
any possible causes of converter damage
before replacing the converter.
OTC P0420 Catalyst System Low Efficiency

Step
Action
Values
Yes
No
Go to Step 2
Go.to A
Powertrain On
Board
Diagnostic (OBD)
. System Check
Go to applicable
OTC first
Go to Step 3

Are any other DTCs set?

Important: If the A/C is left on the following diagnostic
may not run.
1. With a scan tool, review and record Fail Records and
clear DTCs.
2. Turn the A/C OFF.
3. Fully open the hood;
Important: If more than 6 tests have been attempted and
the OTC has not passed or failed this key cycle the test
may be aborting. Go to diagnostic aids.
5. The test may need to be completed up to 6 times in
order to pass or fail.
Does the scan tool indicate the OTC ran and passed this
key cycle?
(
System OK
Go to Step 4
Engine
5..;991
DTC P0420 Catalyst System Low Efficiency (cont'd)

Step
Values
Action
Yes
No
Go to step 9
Go to step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
1. Visually and physically inspect the three-way catalytic

.
converter for damage.
2. lnspecttorthe following:
Dents.
Severe discoloration caused by excessive
temperatures.
Holes.
..
Internal rattle caused by damaged catalyst

substrate.
3. Also, ensure that the three-way catalytic converter is
a proper original equipment manufacturer part.
Did you find damage?
5
Visually and physically. inspect the. exh?USt system

for leaks.
Did you find.a prob,lem?

Visually inspect for .the follbwing:
Oxygen sensors for damage

Oxygen sensors wiring harness for damage
. .
Repair the exhausLsystem as necessary,

Did you complete the repair? .
Replace the oxygen sensor or repair the wiring as
necessary. Refer to Heated Oxygen Sensor(H02S)
Replacement or Wiring Repairs in Wiring Systems.
Go to Step 10
Go to Step 10
Di.d you complete the replacement?
Notice: A misfiring condition may damage the replacement
three-way catalytic converter. Check for a misfiring

condition. If a misfire is present, repair the misfiring
condition before replacing the three-way qatalytic
converter.
Replace the three way catalytic converter. Refer to

Catalytic Converter Replacement (3.8 L) in Engine
Exhaust.
10
Important: If the A/C is left on the following diagnostic

may not run,
1. With a scan tool, clear DTCs.
2. Turn OFF the A/C.
3. Fully open the hood.
4. Operate the vehicle withi11 the Fail Record c.onditions.
Important: If more than 6 tests have been attempted and
the OTC has not passed or failed this key cycle the test
may be aborting. Go to Diagnostic Aids.
.
5. The test may need to be completed up to 6 times in
order to pass or fail.
Does the scan tool indicate the OTC ran and passed this
key cycle?
11
diagnosed?
Go to Step 10
Go to Step 11
Go to Step 4
Go to
applicable DTC
System OK
6-992
Engine Controls - 3.BL
Engine

Refer to EVAP System Overview.
System Description
The EVAP LARGE LEAK TEST Is based on applying
vacuum to the EV AP system and monitoring
vacuum decay. The PCM monitors vacuum level via
the fuel tank pressure sensor input. At an appropriate
time, the EV AP canister purge valve and the EV AP
vent valve/solenoid are turned on, allowing engine
vacuum to draw a small vacuum on the entire
evaporative emission system. If a sufficient vacuum
level cannot be achieved, a large leak or a faulty EVAP
canister purge valve is. indicated. This can be caused
by the following conditions:.
Disconnected or faulty fuel tank pressure sensor
Missing, not completely installed or faulty fuel
fill cap
" Disconnected, damaged, pinched, or blocked
EV AP purge line
" Disconnected or damaged EVAP vent hose
" Disconnected, damaged, pinched, or blocked fuel
tank vapor line
Disconnected or faulty EVAP canister purge valve
" Disconnected or faulty EVAP vent valve
" Open ignition feed circuit to the EVAP vent or
purge valve
Damaged EVAP canister
" Leaking fuel sender assembly 0-ring
Leaking fuel tank or fuel filler neck
Any of the above conditions can set DTC P0440.

No TP sensor, ODM, IAT sensor, or MAP sensor
DTCs set.
" Startup engine coolant temperature is between
4C and 30C (40F and 86F).
O Startup engine coolant temperature is not more
than 8C (14F) greater than startup intake air
temperature.
.. Startup Intake air temperature is between 4C and
30C (40F and 86F).
" Startup intake air temperature not more than
2C (4F) greater than start-up engine coolant
temperature.
Fuel tank level is between 15 percent and
85 percent.
BARO is more than 75kPa.
Conditions For Setting the OTC

The EV AP system is not able to achieve or maintain
vacuum during the diagnostic test.

first trip in which the diagnostic runs and fails.
turn OFF traction control and .illuminate the
TRACTION OFF lamp.
Records data.
Important: Although this diagnostic is considered type

A, it acts like a type B diagnostic. Whenever the
EVAP diagnostics report that a system has passed, or
if the battery has been disconnected, the diagnoslic
must fail during 2 consecutive cold start trips
before setting a DTC. The initial failure is not reported
to the diagnostic executive or displayed on a scan
tool. A passing system always reports to the diagnostic
executive immediately.
Conditions for Clearing the MIL/OTC

third consecut.ive trip in which the diagnostic has
malfunction.
Diagnostic Aids
Cracked or punctured EVAP canister.
Damaged or disconnected source vacuum line,
EVAP purge line, vent hose or fuel tank
vapor line.
Poor connection at the PCM.
Inspect harness connectors for backed out
poor terminal to wire connection.
Damaged harness. Inspect the wiring harness to
the EVAP vent valve, the EVAP purge valve,
and the fuel tank pressure sensor for an
intermittent open or short circuit.
Kinked, pinched or plugged vacuum source,
EVAP purge, or fuel tank vapor line. Verify that the
lines are not restricted.
Use the following procedure to test for a carbon
release condition that could plug the system.
1. Turn off the ignition switch.
2. Remove the EVAP canister purge valve. R1;3fer
to EVAP Canister Purge Valve Replacement.
3. Lightly tap the canister purge valve on a clean
work area looking for carbon particles exiting
either of the vacuum ports.
Engine
4. If no carbon release is evident, reinstall the

components and continue with the. OTC P0440
diagnostic table. If carbon is being released
from either component, continue with this
service procedure.
5: Remove the charcoal canister from the vehicle.
6. Ensure that the main cylinder valve is turned
off on the J 41413 EVAP purge/pressure
diagnostic station.
7. Disconnect the black hose that connects the
nitrogen cylinder to the EV AP purge/pressure
diagnostic station at the pressure regulator
by unscrewing the knurled nut on the regulator.
No too.ls are required to remove the black
ho$e from the regulator.
8. Using a section of vacuum line, connect
one end over the open threaded fitting of
the EVAP purge/pressure diagnostic station
pressure regulator.
9. Connect the remaining end to the purge valve
end of the EVAP purge line at the vehicle and
turn on the main nitrogen cylinder valve.
Continue to blow any debris. from the purge
line for 15 seconds.
10. Return the EVAP pressure/purge diagnostic
station to its original condition by reinstalling
the black hose that was disconnected in
step 7.
11 . Replace the following components:
The EVAP canister purge valve. Refer to
Replacement.
The EVAP canister. Refer to EVAP
Canister Replacement EV AP Canister.
12. Proceed with the DTC P0440 diagnostic table.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assistin diagnosing the condition.
Test Description
diagnostic table:
1. The Powertrain On-Board Diagnostic (OBD)
System Check prompts you to complete some of
the basic checks and store the Freeze Frame
and Failure records data on the scan tool if
applicable.
2. If a vent valve or EVAP purge valve electrical
malfunction 'is present, the purge system will
not operate correctly. Repairing the electrical
malfunction that caused the additional DTC tb set
will very likely correct the condition that set
this DTC.
6-993
3. Inspects for a fuel tank pressure sensor stuck

high condition. Th.e fuel tank pressure must
be relieved by removing the canister line from the
fuel tank or EVAP canister. The fuel fill cap will
not relieve the fuel tank pressure due to a
check valve in the filler neck. The check valve
seals when pressure is applied to prevent vapors
from escaping through the filler neck. The
scan tool should read within 1.0 inch H20 of the
specified value.
4. Inspects for a large leak in the EVAP system.
5. Verifies that the fuel tank pressure sensor
accurately reacts to EVAP system pressure
changes.The EV AP station is pressurizing a
sensor that normally reads vacuum. The scan tool
reads high pressure at O volts and high vacuum
at 5 volts. The scan tool can only read a max
pressure of 6.0 inches of H20 (0 volts), however
the EVAP service station can pressurize the
system to much higher pressures. The scan tool
value should be within 0.5 inch H20 of the
specified value.
.6. lnspectsJor a leaking EVAP canister line, or
vent valve.
8. Inspects for a stuck closed or plugged EVAP
canister purge valve.
9. Inspects for a leaking or stuck open EVAP

canister purge valve, the scan tool should read
within 1.0 inch HG of the specified value.
12. Inspects for a leaking or stuck open EV AP
canister purge valve. The valve should be within
1.0 in HG of the specified value.
14. Inspects for a plugged EVAP system.
18. Ensures that sufficient source vacuum is present
at the EV AP canister purge valve.
21. The EVAP station is pressurizing a sensor that
normally reads vacuum. The scan tool reads
high pressure at O volts and high vacuum
pressure of 6.0 inches of H20 (0 volts), however
specified value.
6-994
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Applicable OTC
Go to Step 3
Did you Perform the Powertrain On-Board

Important: Visually/physically inspect for the following

conditions:
Vacuum or purge lines disconnected. Refer to
Emission Hose Routing Diagram.
Loose or missing fuel fill cap.
Did the OTC P0443 Evaporative Emission (EVAP) Purge
Solenoid Control Circuit or OTC P0449 Evaporative
Emission (EVAP) Vent Solenoid Control Circuit also set?

2. Disconnect the canister .purge line from the EVAP
4. With a scan tool, observe the fuel tank pressure
parameter.
Does the scan tool indicate the fuel tank pressure near the
specified value?
Important: Before continuing, zero the EVAP pressure

and vacuum (inches of H20) gauges on the J 41413
EVAP pressure/purge diagnostic station.
2. Reconnect all EV AP hardware that was previously
disconnected.
3. Install the J 41415-40 fill tank cap adaptor to the fuel
fill neck and fuel fill cap.
4. Connect the EV AP station to the fuel tank cap
adaptor.
5. Turn ON the ignition, with the engine OFF
6. With a scan tool, capture Fail Records data for
OTC P0440 and clear DTCs.
7. With a scan tool, select Seal option to seal the EVAP
System.
Important: Do not exceed the pressure in the
specified value.
8. Attempt to pressurize the system to the specified
value by slowly turning the EVAP service station
rotary switch to the PRESSURE position. Monitor the
pressure with the gauge on the cart with the rotary
switch in the OFF/HOLD position.
Did you achieve the specified value?
O in. H20
Go to Step
Go to Step20
(
5 in. H20
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 7
1. With the EVAP station, maintain the fuel tank
pressure at the specified value. Monitor the pressure

with the gauge on the cart with the rotary switch in
the OFF/HOLD position.
parameter.
Does the scan tool indicate fuel tank pressure near the
specified value?
5 in. H20
6-996
Engine

OTC P0440 Evaporative Emission (EVAP) System (cont'd)
Step
13
14
15
16
17
18
19
20
21
Action
specified value.
1. Reconnect all EVAP hardware that was previously
disconnected.
3. With a scan tool, EVAP purge/seal, select the seal
option to seal the EVAP system.
4. With the EVAP station connected to the EVAP
service port, continuously attempt to pressurize the
EVAP system to the specified value by leaving the
EVAP pressure/purge diagnostic station control knob
in the pressurize position
5. Using the ultrasonic leak detector J 41416 locate and
repair leak in EVAP system. It may be necessary to
partially lower the fuel tank to examine the tank
connections.
Important: Inspect for carbon release into the EVAP
system.
Disconnect the purge line from the canister side of the
purge valve.
Does the vacuum level on the EV AP station vacuum
gauge measure near the specified value?
Replace the EVAP canister purge valve. Refer to EVAP
Canister Purge Valve Replacement.
Inspect for no source vacuum to the EVAP purge .valve.
Replace the EVAP vent valve. Refer to EVAP Vent Valve
Replacement.
1. With a scan tool, increase purge to 100 percent.
2. Run the engine from 12.00-1500 RPM and observe
the vacuum level.
Does .the vacuum level on the EVAP station vacuum
gauge measure above the specified value?
Inspect for a kinked or restricted canister purge line
between the EVAP canister purge valve and EVAP
canister.
Did you find and complete the repair?
2. Disconnect the EVAP canister line from the fuel tank
or EVAP canister to relieve the fuel tank pressure.
4. With a scan tool, observe fuel tank pressure
parameter.
specified value?
disconnected.
'
3. With a scan tool, select the Seal option to seal the
EVAP system.
specified value.
4. With the EVAP station, pressurize the system to the
first specified (higher) value by slowly turning the
EVAP servi.ce station rotary switch to the PRESSURE
position. Monitor the pressure with the gauge on the
cart with the rotary switch in the OFF/HOLD position .
.Does the EVAP pressure decrease to less than the
second specified (lower) value within 2 minutes with the
rotary switch in the OFF/HOLD position?
Values
Yes
No
5 in H20
Go to Step 21
O in Hg
Go to Step 15
Go to
Diagnostic Aids
Go to Step 21
Go to Step 21
Go .to Step 15
Go to Step 21
15 in Hg
Go
Diagnostic Aids
Go to Step 16
O in. H20
Go.to Step21
O in. H20
Go to Step 19
Go to
OTC P0453 Fuel
Tank Pressure
Sensor CiFCuit
. High Voltage
15 in. H20
10 in. H20
(
Go to Step 3
System OK
Engine
Engine Controls - 3.8L 5.;.997
DTC P0442 Evaporative Emission (EVAP) System Small Leak Detected

)
System Description
The EVAP SMALL LEAK TEST is based. On applying
vacuum to the EVAP.system and monitorihg
vacuum decay. The PCM monitors vacuum level via
the Fuel Tank Pressure sensor input. Atan appropriate
time, the EVAP canister purge valve and the.EVAP
vent valve are turned on allowing engine vacuum
to draw a small vacuum on the entire evaporative
emission system. After the desired vacuum level has
been achieved, the EVAP purge valve is turned
off, sealing the system. A leak is detected by
monitoring for a decrease in vacuum level over a
given time period, all other variables remaining
constant. A small leak in the system will cause
OTC P0442 to be set.
Conditions f.or Running the DTC

No TP sensor, ODM, IAT sensor, or MAP sensor
DTCs set.
The OTC P0440 diagnostic test has passed.
Startup engine coolant. temperature is not more
t.han 4C and 30C (40F and 86F).
Startup engine is not more than 8C (14F).
Startup Intake air temperature not more than 2c
and 30C (40F and 86F).
Startup intake air temperature not more than
2C (4F).
85 percent.

A vacuum decay condition indicating a small leak is
detected during the diagnostic test.

turn OFF traction control and illuminate the
TRACTION OFF lamp.
when the OTC set as Freeze Frame/Farlure
Records data.
Important: Although this diagnostic is considered type
A, it acts like a type B diagnostic. Whenever the
EVAP diagnostics report that a system has passed, or
if the battery has been disconnected, the diagnostic
must fail during 2 consecutive cold start trips
before setting a OTC. The initial failure is not reported
to the diagnostic executive or displayed on a scan
tool. A passing system always reports to the diagnostic

The History OTC will clear after 40 consecutive.

malfunction.
..
Diagnostic Aids
Cracked or punctured EVAP canister.
Damaged source vacuum line, EVAP purge line,
EVAP vent hose or fuel tank vapor line.
Poor connection at PCM.
Inspect harne.ss connectors for backec:l out
Damaged harnes.s.
Inspect the wiring harness to the EVAP vent valve.
EVAP canister purge valve and the fuel tank
pressure sensor. for an intermittent open or short
ci~~
.
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.
Test Description
diagnostic table:
1. The powertrain On-Board Diagnostic (OBD)
and Failure Records data on the scan tool
if applicable .
. .2. If a vent valve or EVAP purge valve electrical
malfunction is present, the purge system will
malfunction that caused the additional OTC to set
will very likely correct the condition that set
this OTC.
high condition: The.fuel tank pressure must
fuel t.ank or EVAP canister. The fuel fill cap will
not relieve the tank due to a check valve in
the filler neck. the check valve seals when
pressure is applied to prevent vapors from
escaping through the filler neck. The scan tool
should read within 1.0 inch H20 of the
specified value.
changes. The EVAP station is pressurizing a
sensor that nc:irrnally reads vacuum.The scan tool
at 5 volts; The scan tool can only read a max
pressure of 6.0 inches of H20 (0 volts). However
system to much higher pressures: The scan tool
specified value.
5.;999
Engine Controls - 3.8t
5. Inspects for a small leak in the EVAP system.

6. Inspects. for a leak in the canister, vent line,. or a
leaking EVAP vent valve ..
canister purge valve. The scah tool should read
Engine
high pressure at O volts and high vacuum
pressure of 6.0inches of H20 (0 volts), however
the EVAF,' service .station can pressurize the
system to much. higher pressures. The sc~rn tool
V,alue should. be within 0.5 inqh H20 of the
specified value.
OTC P0442 Evaporative Emission (EVAP) System Sm~II Leak Detected

Step
No
.Go to A
Action
1
Go to Step 2
Important: Visually/physically inspect for the following

conditions:.
. Vacuum or purge lines disconnected. Refer to
Did the DTC P0443 Evaporative Emission (EVAP) Purge
SolenoidControl Circuit or OTC P0449 Evaporative
Emission (EVAP) Vent Solenoid Contr9/ Circuitalso set?
2. Disconnect the EVAP canister line from the EVAP
canister purge valve. This will relieve the fuel.tank
pressure:
4. With a scan tool observe the fuel tank pressure
. parameter.
Goto
applicable OTC
Powertrain Dn
Board
Diagnostic (OBD)
System Check
Go to Step 3
O in. H20
Does.the scan.tool indicate fuel tank pressure near the

specified value?
Gq to Step 4
Go to Step 15
Important: Before continuing with diagnosis, zero the

EVAP Pressure and Vacuum (inches of H20) gauges on
.the J41413 EVAP pressure/purge diagnostic station.
2. Reconnect all hardware that was previously
disconnected.
3 .. Install the J 41415-40 Fill Tank Cap Adaptor to the
. fuel fill ne.ck and fuel fill cap.
4. Connect the. EV AP station to. the fuel tank cap

adaptor.
5. Turn ON the igoition, with the engine OFF.

6. Capture Fail Record data for DTC .P0440 and
clear DTCs.
7. With a scan tool, select seal option to seal the EVAP
system.
specified value.
8. Attempt to pressurize the system to the specified
value. by slowly turning the EVAP service station
rotary switch to the PRESS\JRE: pC>sition. Monitor the
pressure with the gauge. on the cart with the rotary
9. With a scan tool observe fuel tank pressure
parameter.
specified value?
5 in. H20
(
Go to Step 5
Go to Step 7
Engine
Engine Controls - .3.8l
6-999
OTC P0442 Evaporative Emission (EVAP) System Small leak Detected (cont'd)
Step
Action
Values
Yes
No
Go to Step 6
Goto
Diagnostic Aids
Go to.Step 9
Go to Step B
Go to Step 16
Go to
DTCP0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage
Important: Do not exceed the pressure in the specified
(higher) value Increase pressure to the first specified

(higher) value by slowly turning the EVAP service station
Does the EVAP pressure decrease to less than the
1. Disconnect the fuel tank vapor line and the EVAP
purge line from the EV AP canister.
2. Block the canister fitting for the fuel tank vapor line.
3. Connect a hand vacuum pump to the canister port for
the EVAP purge line.
4. With a scan tool, ensure that the EVAP System is still
sealed.
5. With a hand held vacuum pump attempt to appiy
vacuum to the EVAP canister. The EVAP canister is
large and may take time to achieve specified level.
Can vacuum be maintained at the specified value?
1. Visually/physically inspect for the following conditions:
O Restricted fuel tank vapor line
Restricted EVAP purge line
2. If a problem is found, repair as necessary.
15in.H20
10 in. H20
5 in. Hg
..
10
11
1. Visually/physically inspect for the following conditions:

Damaged fresh air vent hose
Damaged EV AP canister
2. If a problem is found, repair as necessary.
Visually/physically inspect for the following conditions:
Leaking fuel tank vapor line.
Damaged EVAP purge line.
1. Disconnect the engine vacuum purge line from the
EVAP canister purge valve.
2. With the EVAP service station, connect the EVAP
service station (Hg) vacuum gauge hose to the
canister side of the purge valve.
EVAP system.
6. Run the engine from 1200 -1500 RPM and observe
vacuum level.
Does vacuum level measure near the specified value?
Replace the EVAP canister purge valve. Go to EVAP
Canister Purge Valve Replacement.
Go to Step 16
Go to Step
Go to Step 16
Go to Step 10
Go to Step 12
Go to Step 11
13
O in. Hg
Go to Step 16
6-1000
Engine
DTC P0442 Evaporative Emission (EVAP) System Small Leak Detected (cont'd)
Step
Action
Values
12

disconnected.
system.
Important: Do not exceed the 15 inches H20 pressure in
the specified value.
3. With the EVAP station connected to the EV AP
service port, continuously attempt to pressurize the
EVAP system to the specified value by leaving the
EVAP pressure/purge diagnostic station control knob
in the pressurize position
4. With the ultrasonic leak detector J 41416 locate and
repair any leak in EVAP system. It may be necessary
to partially lower the fuel tank to examine the top tank
connections.
15 in. H20
13

Replacement.
Yes
No
Go to Step 16
Go to Step 16
14

between the EV AP canister purge valve and EVAP
canister.
Did you find and complete the repair?
O in. H20
15

2. Remove the EV AP canister line from the fuel tank or
EVAP canister. This will relieve the fuel tank
pressure.
parameter.
specified value?
O in. H20
16

disconnected.
EVAP system.
specified value.
4. Pressurize the system to the first specified (higher)
value by slowly turning the EVAP Service station
Does the EV AP pressure decrease to less than the
rotary switch in the 'Off/Hold' position?
15 in. H20
10 in. H20
Go to Step 16
Go to Step 14
Goto
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage
Go to Step 3
System OK
6-1 oot
Engine
DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Control Circuit

IHot In RUN, Bulb Test And START
~
:
~ E~Qine
Distribution
G9
ENG CTRL
Wmng
Schematics In
MinlFuse : Harness
Wiring systems Gs
15 A
Junction
___
_ _ _ _ _ _ _ JI Block 2
~P;e;- -
..... -
0.35 PNK 239
0.5 PNK 239

0.5 PNK 239
II
P100
8182
0.5PNK 239
G
0.5 PNK 239
~-
Solenoid
Valve
C2008
, IC200D
0.5 PNK 239
8107
A2
C405D
B2IC405B
C4058
0.5 WHT 1310
A C405D
0.5 PNK 239
81 Vent
Solenoid
Valve
0.35 WHT 1310
C100
02
Power
Distribution
Schematics In
Wirtng Systems
Evaporative
[ ] Evaporative
E.m.ission. (EVAP) .
Emissio.n
. [ ] Canister
(EVAP)
Purge
. Canister
0.35 DK
GRN/WHT 428
C230
0.5 WHt1310
P110
76 C1
2 C2
Powertrain '" - , - - - - - - - - - - - - - - - .,
Control I
EVAP Canister
EVAP Canister I
I
Module (PCM) 1
---.1
-=-
~ I
I
Purge Valve
Driver
.PCM
C1=BLU
C2=CLEAR
"---1
Vent Valve
Driver
-=-
I
i
I
~-----------------J
594232
Circuit Description
Output driver modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various engine and Transmission
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
.
device which the PCM is commanding ON. Unlike the
quad driver modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. DTC P0443 set indicates an
improper voltage level has been detected on the
output circuit which controls the EVAP canister purge
solenoid valve.

The ignition is ON.

An improper voltage level has been detected on
the output circuit which controls the EVAP
canister purge solenoid valve.
The above conditions are present for at least
30 seconds.

Records data.

malfunction.
6-1002
Engine
Diagnostic Aids
Test Description

Damaged harness.
harness appears to be OK, disconnect the PCM,
turn the ignition ON and observe a voltmeter
connected between the solenoid control circuit and
ground at the PCM harness connector while
moving connectors and wiring harnesses related
to the solenoid. A change in voltage will
indicate the location of the malfunction.
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

diagnostic table.
1. The powertrain OBD System Check prompts you
to complete some basic checks and store the
freeze frame and failure records data on the
scan tool.
2. Listen for an audible clicking when the purge
solenoid operates: Command both the Increase
and Decrease states. Repeat the commands
as necessary.
3. Tests for voltage at the feed side of the solenoid.

4. Verifies that the PCM is providing ground to the
.solenoid.
5. Tests if ground is constantly being applied to the
solenoid.
programmed.
Engine
6-1003

Ste!)
Action

1
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to.
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to 'Step 10
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
2. With a scan tool, Increase and Decrease the purge

solenoid up _and down.
Does the solenoid respond with each command?
1.
2.
3.
4.

Disconnept the solenoid.
Probe the feed circuit of the solenoid with a test lamp


solenoid and the feed circuit cif the sole.noid.
2. With a scan tool, command the purge solenoid ON
and OFF.
command?
.

command?

voltage or an open. Refer to Wiring Repairs in Wiring
Systems.
)
7

ground. Refer to Wiring Repairs in Wiring Systems.
.8
lrispect for poor connections at the solenoid. Refer to


Repairs iri Wiring Systems.
Repair the -feed circuit of the solenoid. Refer to Wiring

Repairs in Wiringsystems.
10
11
Replace the solenoid. Refer to EVAP Canister Purge

ValveReplacement.
Go to Step 13
Go to Step 13
12
13
Replace the PCM .

2. Operate the vehicle within the. Fail Record conditions.
Does the OTC reset?
Go to Step 13
Go to Step2
System OK
6-1004
Engine

System Description
A RESTRICTED or BLOCKED EVAP VENT PATH is
detected by monitoring fuel tank pressure during
normal operation (EVAP vent .valve/solenoid open, .
EVAP canister purge valve normal). With the
EVAP vent valve open, vacuum level in the system
should be very low unless the vent path is blocked. A
blockage can be caused by the following conditions:
Faulty EVAP vent va!ve (stuck closed)
Plugged kinked or pinched vent hose
Shorted EVAP vent valve driver circuit
Plugged EV AP canister
If any of the conditions described above are present,
DTC P0446 will set.

.. No TP sensor, ODM, IAT sensor, or MAP sensor
DTCs set.
., All conditions for P0440 and P0442 have been
met and passed.
Startup engine coolant temperature is not more
than 40 and 300 (40F and 86F}.
" Startup engine is not more than 80 (14F).
Startup Intake air temperature not more than 2C
Startup intake air temperature not more than
20 (4F).
85 percent.

" Fuel tank pressure is less than -10 inch H20.
" The condition is present for at least 30 seconds.

The PCM will jlluminate the MIL during the
TRACTION OFF lamp.
Records data.
Important: Although this diagnostic is considered
type A, it acts like a type B diagnostic. Whenever the
EVAP diagnostics report that a system has passed,
or if the battery has been disconnected, the diagnostic
must fail during 2 .consecutive cold start trips before
setting a DTC. The initial failure is not reported to the
diagnostic executive or displayed on a scan tool. A
passing system always reports to the diagnostic
Conditions for Clearing the Mil/OTC


warm-up cycles have occurred Without a
malfunction.
Diagnostic Aids
Kinked, pinched or plugged vent hose
Reviewing the Fail Records vehicle mileage since
the diagnostic test last failed may help determine
how often the condition that caused the DTC
to be set occurs. This may assist in diagnosing
the condition.
Test Description
The numbers below refer to t.he step numbers oh the
diagnostic table:
1. The Powertrain On-Board Diagnosis (OBD)
System Check prompts you to the basic checks
and store the Freeze Frame and Failure Records
Data on the scan tool if applicable.
2. If a EVAP vent valve or EV AP purge valve
electrical malfunction is present, the purge system
Will not operate correctly .. Repairing the electrical
malfunction that caused the additional DJC to
set will very likely correct the conqition that
set this DTC.
3. Inspects for a fuel tan.k pressure sensor stuck

high condition. The fuel .tank pressure must
be relieved by removing the canister .line from the
. fuel tank or EVAP canister. l"he fuel fill cap will
not relieve the tank pressure due to a check valve
in the filler neck. The check. valve seals when
pressure is appHed to prevent vapor from escaping
through the filler neck.. The scan tool should
read within 1.0 inch H20 of the specified value.
sensor that normally reads vacuum.. The scan tool
at 5 volts. The scan tool can only read .a max
pressure of 6:0 inch of H20 (0 volts). However the
EVAP service station can pressurize the system
to much higher pressures. The scan tool value
should be within 0.5 inch H20 of the
specified value.
5. Inspects for a plugged or stuck closed EVAP vent
valve. The value should decrease to within
1.0 inch HG of the specified value.
Engine
6-1005

Step.
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Applicable DTC
Go to Step 3
Go to Step 4
Go to Step 11
Go to Step 5
Go to Step 7
Go to
Diagnostic Aids
Go to Step 6
Important: Visually/Physically inspect for the following

conditions:

or EVAP canister. This will relieve the fuel tank
pressure.
parameter.
specified value?
O in. H20

EVAP pressure and vacuum (inches of H20 gauges on
the J 41413 EVAP pressure/purge diagnostic station.
disconnected.
3. Install the J 41415-40 fuel fill cap adapto'r to the fuel
4. Connect the EVAP station to the fuel tank cap
adaptor.
6. With a scan tool, capture Fail Records data for
DTC P0446 and clear DTCs
7. With a scan tool, command the vent valve ON
(closed) to seal the system.
specified value.
8. With the EVAP station, attempt to pressurize the
EVAP system to the specified value by slowly turning
the rotary switch to the PRESSURE position. Monitor
the pressure with the gauge on the cartwith the
rotary switch in the OFF/HOLD position.
parameter.
Does the scan tool indicate fuel tank pressure at the
specified value?
5 in. H20
1. With the EVAP station, maintain EVAP pressure at

the first specified (higher) value.
2. With a scan tool, command the vent valve OFF
(open) to relieve the pressure through the vent valve.
Does the EVAP pressure decrease to near the
Second specified (lower) value within 2 minutes with the

Did OTC P0443 Evaporative Emission (EVAP) Purge
5 in. H20
O in. H20
6-1006
Engine

DTC P0446 Evaporative Emission (EVAP) Vent System Performance (cont'd)
Step
Action
Values
1. Disconnect the large vent hose (marked AIR) from

the EVAP canister.
2. With the EVAP station, switch the rotary switch
to purge.
3. Start the vehicle and allow to reach operating
temperature
4. With a scan tool, increase EVAP purge to
100 percent. The scan tool will abort the test if the
vacuum is above 15 inches H20.
5. With the EVAP station, monitor the vacuum (inches
H20) gauge on the for 5 seconds while holding the
engine speed at 2,500 RPM.
Does the vacuum rem.ain less than the specified value?
Inspect the vent hose between the EVAP canister and the
EVAP vent valve/solenoid for being kinked, pinched, or
otherwise blocked.

Replacement
'
Replace the EVAP canister. Refer to EVAP Canister

Replacement.
No
Go to Step 7
Go to Step 9
Go to Step 12
Go to Step 8
10 in. H20
Go to Step 12
Go to Step 12

canister.
O in. H20
11

2. Disconnect the EV AP canister line from the fuel tank
pressure.
parameter.
specified value?
O in. H20
12

disconnected.
2. Turn ON the ignition, With the engine OFF.
4. With the EVAP station, pressurize the EVAP system
to the first specified (higher) value by slowly turning
the rotary switch to the PRESSURE position. Monitor
the pressure with the gauge on the cart with the
5. With a scan tool, command the EVAP vent valve OFF
(open) to relieve the system pressure.
Does the pressure decrease to less than the
10
Yes
Go to Step 12.
Go to Step 10
Go to
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage
Go to Step 3
System OK
5 in. H20
O in. H20
Engine
Engine Ccmtrols - 3.8L
6~1007
IHot In RUN, Bulb Test And START l

~ -P;e-;- - I Distribution
I
G9
Schematics In
.
Wiring Systems Gs
..., -
~ E~Qine
..I ___________ ..I Block 2

0.5 PNK 239
0.5 PNK 239
rn
P100
8182
0.5 PNK 239

G
A2 C4058
A
Bl
Evaporative A
Emission
~
(EVAP)
Canister
Vent
Solenoid
Valve
C405D
B2IC405B
0.5 PNK 239

8107
II
0.35 WHT 1310
C200B
C200D
0.5 PNK 239

Power
Distribution
Schematics In
Wiring Systems
A
Evaporative
Emi~sion (EVAP)
Canister
Purge
Solenoid
Valve
C100
02
rn
0.35 PNK 239
ENG CTRL I Wmng

MinlFuse I Harness
1s A
Junction
C405D
0.35 DK
GRN/WHT
0.5 PNK 239
428
0.5 WHT
1310
C230
0.5WHtT310
P110
--------------.
J -..,
1
-_1
1
76
Powertrain .. Control I
I
Module (PCM) 1
..
~ I
I
Ci
EVAP Canister
Purge Valve
Driver
-=-
PCM
C1;BLU
C2;CLEAR
C2
F:VAP Canister I
Vent Valve
I
Driver
I
"
...-
I
I
I
~-------------~---J
594232
Circuit Description
are needed to control various engine and Transmission
output circuit individually. DTC P0449 set indicates an
output circuit which controls the EVAP canister vent
solenoid valve.

The ignition is ON.

the output circuit which controls the EVAP
canister vent solenoid valve.
30 seconds.

Records data.

malfunction.
6-1008
Engine
Diagnostic Aids
Test Description

" Damaged harness.
harness appears to be OK, disconnect the PCM,
turn the ignition ON and observe a voltmeter
connected between the solenoid control circuit and
ground at the PCM harness connector while
moving connectors and wiring harnesses related
to the solenoid. A change in voltage will
indicate the location of the malfunction.
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

diagnostic table.

scan tool.
2. Listen for an audible click when the vent solenoid
operates. Command both the ON and OFF
states. Repeat the commands as necessary.
3. Tests for voltage at the feed side of the solenoid.
solenoid.
solenoid.
programmed.
Engine
Step
Action
Values
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 10
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12

2. With a scan tool, command the vent solenoid ON
and OFF.
Does the solenoid turn ON and OFF with each command?

2. Disconnect the solenoid.
3. Turn ON the ignition, with the engine OFF,
4. Probe the feed circuit of the solenoid with a test lamp

solenoid and the feed circuit of the solenoid.
2. With a scan tool, command the vent solenoid ON
and OFF.
command?

command?

voltage or an open. Refer to Wiring Repairs in Wiring
Systems.

Inspect for poor connections at the solenoid. Refer to

Inspect for poor connections at the harness connector of

10
Repair the feed circuit of the solenoid. Refer to Wiring

Replace the solenoid. Refer to EVAP Vent Valve

Replacement.
11
12
13
Yes


Replace the PCM.
Does the OTC reset?.
Go to Step 13
Go to Step 13
Go to Step 13
Go to Step2
System OK
6-1010
Engine
DTC P0452 Fuel Tank Pressure Sensor Circuit low Voltage

8244
!Loe
0.35GRY 720
0.35 GRY 720
F3
G3 C405B
r------
0.5
BLK/WHT 651
C405A
0.35GRY 720
ORN/BLK 469
II
A
,---+-,
'-----!>-'
~ ~
Fuel
level
Sensor
.I
-
Fuel
Fuel
Tank
Sensor
1 Pressure I
UTa~tk
n!
~fv;~r~a-i~ ::Jl~ -)
Automatic
Transmission
-A j O.o PPli 30
o.
35
lS]
0.5
D
P~l~i-~;r::ii;l~
NC
0.5
GRY 720
G C230
Refrigerant
Pressure
Sensor
~-~-_-_-_-_-_-_-T_-_-_-_-_-_-_-_- - -_-_-_-_-_-_-_-_-_0.35 GRY
,0.35
lT BlU/BlK 1688
PPLl.
0.35
0.35 GRY 720
DKGRN 890
i 589
69
l" -
I
I
i
A/C Refrigerant
Pressure Sensor
0.35
0.35
GRY 720.
-1----- ----,
_________________ ??
I'u--
.,,,_ -5V. - -
Fuel
Level
Signal
_______ _?~
-Fuel
Tank
Pressure
Signal
_
PCM
C1=BLU
C2=CLEAR
C2
Sensor
Ground
~--------------------
Powertrain
I Control
I Module , '
I (PCM) . ~
_J
594230
Circuit Description
The PCM monitors the fuel tank pressure sensor
signal to detect vacuum decay and excess vacuum
during the enhanced EV AP diagnostic. The fuel
tank pressure sensor measures the difference between
the air pressure (or vacuum) in the tank and the
outside air pressure. The PCM applies a 5.0 volt
reference and ground to the sensor. The sensor will
return a signal voltage between 0.06 and 4.9 volts.
If the PCM detects a fuel tank pressure sensor signal
that is excessively low, DTC P0452 will set.

The ignition is ON.

The fuel tank pressure sensor signal is less than
0.06 volts .
.. The conditions is present for 5 seconds.

. The PCM will illuminate.the malfunction indicator
The PCM will store conditions which were present.
Records data.
Conditions for Clearing the MILIDTC

malfunction.
Engine
. Engine Controls - 3.8L
6-1011
Diagnostic Aids
Test Description

Poor connection at the PCM or fuel tank pressure
sensor.
terminals, improper mating broken locks,
Damaged harness.
harness appears to be OK, observe the fuel tank
pressure sensor display on the scan tool while
moving connectors and wiring related to the
sensor. A change in the display will indicate the
location of the malfunction.

diagnostic table.
a.
12. This vehicle is equipped with PCM which utilizes

DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage

Step
Action
Values
Yes
No
Go to SttJp 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 9
Go to Step 6
Go to Step 13
Go to Step 7
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 11

Important: If OTC P1639 is set refer to DTC Pt 639 5 Volt

Reference 2 Circuit.
1. Turn ON the Ignition, with the engine OFF.
2. With a scan tool, observe fuel tank pressure sensor
voltage parameter.
Does the scan tool indicate voltage less than the
specified value?
0.3V

1. Disconnect the fuel tank pressure sensor connector.

2. Connect a jumper between the signal circuit and the
5 volt reference A circuit.
voltage parameter.
Does the scan tool indicate voltage near the
specified value?
5V
Using a DMM, measure voltage between the 5 volt

reference A circuit and the ground circuit.
5V

3. Inspect the 5 volt reference A circuit for a poor
connection at the PCM. Refer to Testing for
Intermittent and Poor Connections and Connector
Test the 5 volt reference A circuit for an open or high

resistance. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Inspect for poor connections at the fuel tank pressure

sensor. Refer to Testing for Intermittent and Poor
6-1012
Engine

DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage (cont'd)
Step
Action
Values

3. Inspect the signal circuit for a poor connection at the
Systems.
10
Test the signal circuit for an open, short to ground, or

Replace the fuel tank pressure sensor. Refer to Fuel Tank

Pressure Sensor Replacement.
12

Replace the PCM.
13

2. Operate the vehicle within Fail Record conditions.
Does the OTC reset?
11
Yes
No
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 13
Go to Step 2
System OK
Engine
6-1013

8244
0.35GFW 720
0.35GRY 720
F3
G3 C405B
C405A
gCK.NV~i~~:----G
D
,. - - -
- - - - ;
. - - - - . Fuel
~~~~or
0.35GRY 720
0.5
ORN/BLK 469
- - - - - - - - - ., Fuel
I!
Fuel
Tank
1I~~~~~:e :Unit
~ ---AI- ~fv;:Kr4~6-~~::Nr8~ _)
0.5 PPL 30
A
Automatic
Transmission
p~l;~-~;F:ii~;1::
D
C405A
NC
0.35
0.5
GRY 720
-_-_----------r-- _-_-_-_-_-_-- -_-_-_-_-_-_-_-_-_~
0.35
P110
720
LT BLU/BLK 1688
Refrigerant
Pressure
Sensor
0.35
GAY 720
NC Refrigerant
Pressure Sensor
0.35 PPL 1589
69
0.35
0.35 GRY 720
DKGRN 890
55
35 C2
,. .. 1j5V- - - -- - - Fuel,- - - - - -Se-;;s;;; - ,Powertrain

I
I Control
I
I
Fuel
Level
Signal
Tank
Pressure
Signal
_
PCM
C1=BLU
C2=CLEAR
Ground
I Module /I,
I (PCM) ~
L--------------- -------J
594230
Circuit Description
The PCM monitors the fuel tank pressure sensor
signal to detect vacuum decay and excess vacuum
during the enhanced EVAP diagnostic. The fuel
tank pressure sensor measures the difference between
the air pressure (or vacuum) in the tank and the
outside air pressure. The PCM applies a 5.0 volt
reference and ground to the sensor. The sensor will
return a signal voltage between 0.1 and 4.9 volts. If the
PCM detects a fuel tank pressure sensor signal that
is excessively high, OTC P0453 will set.

The ignition is ON.
) Conditions for Setting the DTC

The fuel tank pressure sensor signal is more than
4.9 volts.
The conditions is present for 5 seconds.

when the OTC set a.s Freeze Frame/Failure
Records data.

malfunction.
6-1014
Engine
Diagnostic Aids
Inspect fo the following:
Poor connection at the PCM or fuel tank pressure
sensor.
terminals, improper mating broken locks,
Damaged harness.
harness appears to be OK, observe the fuel tank
pressure sensor display on the scan tool while
moving connectors and wiring related to the

sensor. A change in the display will indicate the
location of th_e malfunction.
Test Description
diagnostic table,
1o. This vehicle is equipped with a PCM which utilizes.
DTC P0453 Fuel Tank Pressure Sensor CircuitHigh Voltage

Step
Action

voltage parameter.
Does the scan tool indicate voltage more than the
specified value?
Operate the vehicle within the Fail Record conditions.
1. Disconnect the fuel tank pressure sensor. connector .
sensor voltage parameter.
specified value?
Test the signal circuit for a short to voltage or a short to
the 5 volt reference A circuit. Refer to Circuit Testing and
Did you find and correct the,condition?
.
3. Inspect the ground circuit for a poor connection at the
Systems.
Test for an open or high resistance in the ground circuit.
Systems.
Inspect for poor connections atthe fuel tank pressure
sensor. Refer to Testing for: Intermittent and Poor
Did you find and correct the condition_?
Replace the fuel tank pressure sensor. Refer t9 Fuel Tank
Replace the PCM.
Does the DTC reset?
10
11
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 11
Go to Step 10
Go to Step 11
Go to Step 7
Go to Step 11
Go to Step B
4.7V
ov
Go to Step 11
Yes
Values
Go to Step 9
..
Go to Step 11
.,
Go to Step 11
.
Go to Step 2
System OK.
.,
Engine
6-1015
OTC P0462 Fuel Level Sensor Circuit Low Voltage

8244
0.35GRY 720
0.35GRY 720
G3 C405B
F3
gtK/W:T1~~
C405A
0.35 GRY 720
0.5
ORN/BlK 469
----1
Level
Sensor
- - - - - - - - - ., Fuel
ITan k
Fuel
I{.
A
--+-. Fuel
~ ---AI-
l I~~~:re :Unit
T
Automatic
Transmission
~fv;:Kt4~6-~~:!f: - )
0.5 PPL 30
p~t1 ~i~i5-~~:1~;: i ~~~11::5B

A
0.35
H C405A
1
H
A .
-_-_-_-_------:r,--_-_-_-__-_-_-- -_-_-_-_-_-_-_-_-_G-
C230.
0.5
GRY 720
P110
0.35 GRY 720
0.35
LT BLU/BLK 1688
NC
Refrigerant
Pressure
Sensor
0.35
GRY 720
A/C Refrigerant
Pressure Sensor
0.35 PPL 1589
0.35
0.35 GRY 720
DKGRN 890
35 C2
55
Fuel
~Sensor
'". -u---------,--------,
69
I
I
I
SV
Fuel
Level
Signal
Tank
Pressure
Signal
PCM
Ci=BLU
C2=CLEAR
Ground
Powertrain
I Control
I Module ~
I (PCM) ~
L-------------=---------~
594230
Circuit Description
The fuel level sensor changes resistance based on
fuel level. The fuel level sensor has a signal circuit and
a ground circuit. The PCM applies a voltage (about
5.0 volts) on the signal circuit to the sensor. The PCM
monitors changes in this voltage caused by changes
in the resistance of the sensor to determine fuel level.
When the fuel tank is full, the sensor resistance is

high, and the PCMs signal voltage is only pulled down
a small amount through the sensor to ground.
Therefore, the PCM will sense a high signal voltage
(fuel tank full). When the fuel tank is empty, the sensor
resistance is low, and the signal voltage is pulled
down a greater amount. This causes the PCM to sense
a low signalvoltage (fuel tank empty).
The PCM uses inputs from the fuel level sensor to
calculate the total fuel remaining in the fuel tank. This
information is then sent to the fuel gauge.
This DTC sets when the PCM senses a signal voltage

lower than the normal operating range of the sensor.

The ignition switch is in the RUN position.

The fuel level sensor voltage is below 0.39 volts.
All conditions present for 6.0 minutes.

The PCM wi.11 .store conditions which were present
Records data.
6-1016
Engine

malfunction.
the Freeze Frame and/or Failure ,Records data can aid

in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining hovv many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
Diagnostic Aids
Test Description
The vehicle fuel gauge displays empty with this

DTC set:
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in

diagnostic table.
2. This step determines if the fault is present.
DTC P0462 Fuel level Sensor Circuit low Voltage

Step
Action
10
11

2. With a scan tool, observe the fuel levelsensor
parameter.
Does the scan tool indicate fuel levelabove the
specified value?
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Disconnect the fuel levelsensor.
parameter.
specified value?
Test the signal circuit for a short to ground. Refer to Circuit
Test the fuel sender pigtail circuits for a short together or a
short to ground. Refer to Circuit Testing and Wiring
Replace the fuel levelsensor. Refer to Fuel Sender
Assembly Replacement.
Repairs in y./iring Systems.
Replace the PCM.
Does the DTC reset?
Does the scan tool display any DTCs that you have not
diagnosed?
Values
Yes
No
Go to A
Go to Step 2
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 10
Go to Step B
Go to Step 10
Go to Step 7
0%
0%
Go to Step 10
Go to Step 10
Go .to Step 9
Go to Step 10
Go toStep 2
Go to
applicable DTC
Go to Step 11
System OK
Engine
6-1017

8244
IL0 c
0.35GRY 720
0.35GRY 720
F3
G3 C405B
C405A
rs]
N
gi_;[~,----"G
D
0.35GRY 720
0.5
ORN/BLK 469
Automatic
Transmission
NC
0.5
GRY 720
Refrigerant
Pressure
Sensor
0.35
GRY 720
)
0.35 PPL 1589
0.35
0.35 GRY 720
DKGRN 890
35 C2
55
'" -u5V- --.. --.. Fuel

69
I
I
I
Fuel
Level
Signal
1-----
Tank
Pressure
Signal
_
PCM
C1=BLU
C2=CLEAR
-S;;;s; Ground
Powertrain
I Control
I Module >,
I (PCM) ~
L-----------------------J
594230
Circuit Description
The fuel level sensor changes resistance based on
fuel level. The fuel level sensor has a signal circuit and
a ground circuit. The PCM applies a voltage (about
5.0 volts) on the signal circuit to the sensor. The PCM
monitors changes in this voltage caused by changes
in the resistance of the sensor to determine fuel level.
high, and the PCMs signal voltage is only pulled down
a small amount through the sensor to ground.
Therefore, the PCM will sense a high signal voltage
(fuel tank full). When the fuel tank is empty, the sensor
resistance is low, and the signal voltage is pulled
down. a greater amount. This causes the PCM to sense
a low signal voltage (fuel tank empty).
The PCM uses inputs from the fuel level sensor to
calculate the total fuel remaining in the fuel tank. This
information is.then sent to the fuel gauge.

higher than the normal operating range of the
sensor.


O
The fuel level sensor voltage is above 2.9 volts.
The condition present for 6 minutes.

" The PCM will illuminate the malfunction indicator
lamp (MIL) during the second cOnsecutive trip in
Records data.
6-1018
Engine

.The History DTC will clear after 40 consecutive
malfunction.
Diagnostic Aids
DTC set.
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
determining how many ignition cycles the diagnostic
This will isolate when the DTC failed.
Test Description
diagnostic table.
3. Using the Freeze Frame a.nd/or Failure Records
will isolate when the DTC failed. For an
intermittent condition.
12. Inspect the fuel sender pigtail for damage, if
damage is found on the pigtail outside of the tank
repair as necessary before replacing the sender.
14. Inspect for proper terminal tension/connections at
the PCM harness for all connections before
replacing the PCM:
(
\

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic .Aids
Go to Step 5
Go to Step 7
Go to Step 11
Go to Step6
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 14

1

parameter.
specified value?
ignition?
100%
1. Disconnect the fuel level sensor.

2. Measure the voltage on the signal circuit using a
DMM that is connected to a good ground.
5.5V
1. Connect a fused Jumper between the signal and

ground circuits.
parameter.
Does the scan tool indicate fuel level less than the
specified value?
100%
1. Disconnect the jumper from the fuel level sensor

ground circuit.
2. Jumper the fuel levelsensor signal circuit to a known
good ground.
Does the scan tool indicate fuel levelless than the
specified value?
100%
Test the signal circuit for a short to voltage. Refer to

Engine
6-1019
DTC P0463 Fuel Level Sensor Circuit High Voltage (cont'd)
Step
Action

to Circuit Testing in Wiring Systems.
Values
Repair the signal circuit. Refer to Wiring Repairs in Wiring

Systems.
Test the ground circuit for an open or high resistance.
Replace the fuel levelsensor. Refer to Fuel Level Sensor
Replacement.
Repair the ground circuit. Refer to Wiring Repairs in Wiring
Systems.
Go to Step 12
13
Go to Step 13
Go to Step 15
Go .to Step 15

12
Go to Step 13
Go to Step 15

11
Go to Step 9
-

10
No
Yes
Go to Step 15
Go to Step 14
14
Replace the PCM.

Go to Step 15
15
)
16

Does the OTC reset?
diagnosed?
.
Go to Step 2
Go to Step 16
Go to
applicable OTC
System OK
6-1020
Engine

!Hot At All Times
!Hot At All Times!
,. - - - - - - - -Power - - - - - - - - L1
COOL FAN
Distribution
J7
Schematics
Ma)(J.Fuse
K1
in Wiring
J6
40 A
.. _ _ _ _ _ _ _ _ systems---Power
Distribution
Schematics
In Wiring
Systems
RED 402
~ -
COOLING
FAN
MiniFuse
1~A___
"'Engine Wiring
I Harness
.
I J unc. tion Bl ock 1
I
ORN 1640
-.-----------~i~----~,=::;:;:Po=w=er===;il
r------a,,
RED 402
Powertrain
Control
Module
(PCM)~
ORN 1640
Ji.
WHT 504
,I C3
Y:Lr~1:
'. ~' LT r.09- ---Blc~1
'"tI
,Engine
I Coolant
I
..
I Temperature
-' (ECl) Sensor
cs
s10
c10
------,
- - - - - -
DK BLU 473
~~
Cooling
~
- - -
ECT
Sensor
Ground
B
~ Right
- - -
Cooling
Fan Relay 1
Control
BLK
150
DK BLU 473
CONN ID
C1 "'.. 8LU
C2 - CLEAR
'-
BLK 150
--,
-. - - , Powertrain
Cooling
Fan Relay
2 and 3
Control
I Control
Module A
(PCM) ~
T
:l_
I
I
I _ _ _ _ _ _ _ _ _ _.!It
..
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
J
~
~
.
l_ _____________________________ ~ C1
- - - -. - - - - - - - - - - - - - - - - -
~~
Cooling
DK BLU 473
BLK 150
DK GANT335
-
WHT 504
12 . _________ .?.
r -
- -
DK BLU 473
GAY 532
I
I
~ ~~ ;O~ ----
~ Left
DKGRN 335
BAN 718
Engine
Wiring
Harness
Junction
R.ED 402 Block 1
88
89
83
Distribution
Schematics
In Wiring
Systems
ORN 1640
ORN 1640
l~~J_J iGJ]p~:, I\1- -ct I~;,

r-----,
ITT
Llw
Ground
Distribution
Schematics
In Wiring
Systems
548579
Circuit Description
Output driver modules (OOMs) are used by the PCM
are needed to control various engine and Transaxle
functions. Each OOM is capable of controlling up to
quad driver modules (QOMs) used in prior model
years, OOMs have the capability of diagnosing each
output circuit individually. OTC P0480 set indicates an
output circuit which controls the Fan 1 Relay.

The ignition is ON.

the output circuit which controls the low
speed fans.
The above conditions present for at least
30 seconds.

Records data.
Engine
. The History DTC will clear after 40 consecutive
warm 0 upcycles have occurred without a
malfunction.
Diagnostic Aids
tension. Refer to Testingfor Intermittent and Poor
Systems.
Damaged harness.
on the scan tool While moving connectors
Systems.
6-1021
Test Description
diagnostic table.
to complete .some basic tests and store the
Failure Records data on the scan tool.
Command both the ON and OFF states. Repeat
3. Tests for voltage at the coil feed side of the relay.

4. Verifies that the PCM is providing ground to
the relay.
5. Tests if ground is constantly being applied to
the relay.
programmed.
6-1022
Engine

Step
Action

1
Values
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step3
Go to Step 4
Go to Step 10
Go to Step 8
Go toBtep5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12

2. With a scan tool, command the Low Speed Fans ON
and OFF.
Does the relay turn ON and OFF with each command?

Disconnect the relay.
Probe the coil feed circuit of the relay using a test

relay and the coil feed circuit of the relay.
2. With a scan tool, command the Low Speed Fans ON
and OFF.
command?

command?
Test the control circuit of the relay for a short to voltage or

an open. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the control circuit of the relay for a short to ground.

Systems.
Inspect for poor connections at the relay. Refer to Testing

Did you find and c.orrect the condition?

10
Repair the feed circuit of the relay. Refer to Wiring Repairs

in Wiring Systems.
11
Replace the relay.

12

Replace the PCM ..
13

Does the OTC reset?
1.
2.
3.
4.
Yes
Go to Step 13
Go to Step 13
Go to Step 13
Go to Step2
System OK
Engine
6-1023
IHot At All Times I
.. - -
K1
L
Power
Distribution
Schematics
In Wiring
! Hot Ab~II Times!
- - - - - - Power - - - - -
COOL FAN
Distribution
J7
Maxi Fuse
Schematics
A
in Wiring
JG
_40 _ _ _ _ _ Systems
_ _ _ _
RED 402
- - - - , Engine Wiring
I Harness
COOLING
FAN
~~~use
_
___
ORN "1640
.r - - - - - -~
.-----'!'------------------
.- _ _
I ECT Jsv
I Sensor
~Si~na~
RED 402
.- t-
Distribution
Schematics
Engine
Wiring
Harness
In Wiring
Systems
ORN 1640
I
[IJ]l I) -l QI O \
C3
Junction
WHT 504
ORN 1640
ORN 1640
RED 402 Block 1
- - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
... -
v:61::
83
89
'. ~, __
I
L
-'
88
Fan
~1-_____
~ ----- -
Relay #1
C4
~~~il~:g
Fan
- -
~~ay
- - - - - - -~--
c~
_0~
__
LT BLU 409
8
~o
_____ ~
__ - ; : ;
DK BLU 473
DK BLU 473
-----------"
~ Left
~g~e
(ECT) Sensor
C6
~~~lrneg
----~-
,Engine
I Coolant
I Temperature
l.--2il
+- - - -.-----------'['------.::===;,
Power
Systems
Powertrain
Control
Module ft,
(PCML~
I Junction Block 1
J
Cooling
~ Right
~~M
Cooling
Fan
A
BLK 150
BLK
DK GRN 335
DK BLU 473
iSO
I
r-----------~--------------------,p
rt
I
J f:~
J ~;~ I C~~iora,n
12 . _________ .?.
. _____________________________
1
~i!ay 1
~;~sor
I
I
Ground
L -
jt
-~ -
"'-- -
C1
BLK 150 '- - - ~
:e1ay
-.,12and3
CONN ID
C1=BLU
C2 = CLEAR
----TControL
WHT 504
B
DK BLU 473
GAY 532
BRN 718
Relay #2
;o~ ____
Fan
DKGRN 335
~~;\~neg
Fan
Control
-~ -
I.Module
JI,
(PCM)~
Ground
Distribution
Schematics
In Wiring
Systems
548579
Circuit Description
output circuit individually. DTC P0481 set indicates
an improper voltage level has been detected on
ODM B output 2, which controls the high speed and
series/parallel cooling fan relays.
) Conditions for Running the DTC

The ignition is ON.

" An improper voltage level has been detected on
the output circuit which controls the high
speed fans.
30 seconds.

Records data.
6;.1024
Engine
C<:lnditions for Clearing the MIUDTC

Th.e PCM will turn the MIL OFF during the
malfunction.
O
Diagnostic Aids
surfaces. before servicing a component. Inspect
Systems.
" Damaged harness.
Systems.
Test Description
The numbers below. refer to the step numbers on the
diagnostic table.
(.

to complete some basic tests and store the
Failure Records data on the scan tool.
2. Listen for an audible click whe.n the relay operates.
3. Tests for voltage at the coil feed side of the
relays.
relays.
relays.
programmed.
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powe,train On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 10
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12

Important: If you cannot determine if the relays are
responding to the command, observe the fans. When the

High Speed Fans are commanded ON, Both fans should
operate in low speed and after several seconds both fans
should switch to high speed. If the fans are not operating
properly continue with step 3 of this table.
2. With a scan tool, command the High Speed Fans ON
and OFF.
Do both relays turn ON after several seconds and OFF
with each command?

2. Disconnect the Fan 2 and Fan 3 relays.
4. Probe the coil feed circuits of each relay using a test
Does the test lamp illuminate for both circuits?
1. Connect a test lamp between the control circuits of

each relay and the coil feeds circuit of each relay.
2. With a scan tool, command the High Speed Fans ON
and OFF.
Does the test lamp turn ON after several seconds and
OFF with each command for both relays?

command?
Test the control circuits of each relay for a short to voltage

or an. open. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the control circuits of each relay for a short to ground.

Systems:
10
11
Inspect for poor connections at the relays. Refer to Testing

Repair the feed circuit of the effected relay. Refer to

Replace th.e effected relay.

Go to Step 13
Go to Step 13

12
13
Replace the PCM.

Does the DTC reset?
Go to Step 13
Go to Step2
System OK
6-1026
Engine
DTCP0500 Vehicle Speed Sensor (VSS) Circuit
I
I
!Loe
Vehicle Speed
~ Sensor (VSS)
YEL 400
64
PPL 401
I
I
1-----
65
High
Low
Ci
Powertrain
I Control
I Module
I (PCM) >,
-i
PCM
5V
Av
'" - ---vssi- - -vss
I
I
[SJ
_
-
C1=BLU
C2=CLEAR
.M.
L------------------~
223029
Circuit Description
Vehicle speed information is provided to the PCM by
the vehicle speed sensor (VSS). The VSS consists
of a magnetic pickup sensor mounted to the
transmission case which interfaces with a rotor
pressed onto to the transmission output shaft. The
VSS produces a frequency signal that is proportional
'to vehicle speed. The PCM converts the VSS
signal to vehicle speed, displayed on the scan tool in
miles per hour and kilometers per hour. The PCM
also uses the VSS signal to generate the 4000 pulses
per mile vehicle speed signal used by the instrument
cluster and the TAC module.

~
Engine speed is more than 1250 RPM.

.. Engine load and engine speed acceleration
indicate that the vehicle is in gear.

Vehicle speed sensor indicates a speed of less than
5 km/h (3 MPH) for more than 20 seconds.

which the diagnostic has been run and failed.
command the electronic brake and traction control
module (EBTCM) via the serial data circuit to
turn OFF traction control, and the EBTCM
will illuminate the TRACTION OFF lamp.
when the DTC set as Freeze Frame and Failure
Records data.

The History DTC will clear after 40 .consecutive

malfunction.
Diagnostic Aids
Inspect for a Loose or damaged VSS rotor - A
damaged VSS rotor may cause an erratic or incorrect
vehicle speed to be displayed. Refer to Manual
Transmission section for on-vehicle service.

correctly. The gaskets prevent contaminate intrusion .
.
Systems.
.. Damaged harness.
Systems.
., Inspect the PCM and the engine grounds for

Engine
6-1027
Test Description
The numbers below refer to the step numbers on the .
) diagnostic table:
2. If the condition that caused the OTC to set cannot
be duplicated, inspect the items refemed to in
Diagnostic Aids may isolate the cause of an
intermittent fault
DTC POSOO Vehicle Speed Sensor (VSS) Circuit

Step
'
Action
Yes
No
Go to Step 2
Goto A
Powertr~in On
Board
Diagnosti (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Valu.es
Did you perform the Powertrain .On-Board

1
',
1.. Turn.OFF the ignition.

2.. Raise the drive wheels.
3. Start the engine and idle in gear.
'
4. With a scan tool, observe the vehicle speed
parameter.
'
Doe.s the .scan tool indicate vehipl,e speed more than the
specified value?
'
Observe the cluster speedometer with. the engine still
idling in gear.
Does the speedometer indicate vehicle speed more than
the specified val.ue?
'
,,'
,'
',.
0
,'
0
i
Go to Step l
'

2. Disconnect the VSS ..
~-.Connect J 33,431-8 signal generator and instrument

pp.nel tester. to .the VSS, conneqtor.
5. Turri ON the signal genera.tor, set signal generator to
generate a VSS signal.
6. With a scan tool, observe the vehicle speed
parameter.
Does the scan tool indicate vehicle speed.more than the
specified value?
', <
'
Test for the following conditions,
1. VSS High circuit open, shorted to ground, or shorted
to voltage.
2. VSS Low circuit open or shorted to voltage. Refer to
Replace the VSS. Refer to Vehicle Speed Sensor in
Transmission/Transaxle,
,.
'
'
Go to Step 6
GotoStep 5
'
Go to Step B
Go to Step 7
Go to Step 8
1.s the action complete?

Important: The Replacement PCM must be programmed.
Go to Step
Go to Step 8
1: Turn OFF the ignition.

8
2. Raise the drive wheels.

3. Start the engine and idle in gear.
4. With a scan tool, observe vehicle speed parameter.
Does the scan tool indicate vehicle speed more than the
specified the specified value?
0
System OK
Go to Step 3
6-1028
Engine
DTC P0506 Idle Speed Low

Circuit Description
The throttle actuator motor is controlled by the TAC
module using various inputs from the PCM which
are communicated across serial data. The DC motor
located on the throttle body drives the throttle plate. In
order to decrease idle speed, the TAC module
commands the throttle closed reducing air flow into
the engine and the idle speed decreases; In order to
increase idle speed, the TAC module cornmands
the throttle plate open allowing more air to bypass the
throttle plate. If the Actual idle RPM does not match
the Desired idle RPM within a calibrated time, this
OTC sets.

No Misfire, EGR, TP, VSS, ECT, MAP, IAT, Fuel
trim, Fuel injector, CKP or MAF DTCs set.
Engine is operating for at least 2 minutes.
ECT is more than -40C (-40F)
IAT is more than -40C (-40F)
BARO is more than 65 kPa
System voltage is between 9.0 and 18.0 volts
Vehicle speed is less than 3 mph
APP indicated angle is less than 0.25 percent

The Actual idle speed is approximately 150 RPM
lower than the Desired idle speed.
All above conditions present tor 15 seconds.

The .PCM will store conditions which were present
Records data.

malfunction:
The OTC can be cieared by using a scan tool.
Diagnostic Aids
improperly formed m damaged terminals, and
fa.ulty terminal to wire connection. Use a
Systems.
Damaged harness.
harness appears to be OK, observethe display
Systems.
Test Description
diagnostic table.
2. This test determines whether or not the engine

can achieve the commanded RPM, and if not,
whether the RPM is too high or too low.
Engine
6-1029
DTC P0506 Idle Speed low

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5


2. With a scan tool, command the engine speed up to
1500 RPM, down to 500 RPM, up to 1500 RPM.
3. Exit the RPM control function.
Does the engine speed correspond, within 100 RPM, with
each command?
Is the engine RPM more than 100 RPM more than or less
than the Desired RPM?

Excessive deposits in the throttle body.
A faulty PCV valve.
Go to Step 6

5
Excessive deposits in the .throttle body.

Parasitic load on the engine (i.e. transmission
problem etc.).

Does the DTC reset?
Does the scan tool indicated any DTCs set that you have
not diagnosed?
Go to Step 6
-
Go to Step 2
Go to Step 7
Go to applicable
DTC table
System OK
6-1030
Engine

Circuit Description
The throttle actuator motor is controlled by the TAC
module using various inputs from the PCM which
are communicated across serial data. The DC motor
located on the throttle body drives the throttle plate. In
order to decrease idle speed, the TAC module
commands the throttle closed reducing air flow into
the engine and the idle speed decreases. In order to
increase idle speed, the TAC module commands
the throttle plate open allowing more air to bypass the
throttle plate. If the Actual idle RPM does not match
the Desired idle RPM within a calibrated time, this
OTC sets.

No Misfire, EGR, TP, VSS, ECT, MAP, IAT, Fuel
trim, Fuel injector, CKP or MAF DTCs set.
Engine is operating for at least 2 minutes.
ECT is more than -40C (-40F)
IAT is more than -40C (-40F)
BARO is more than 65 kPa
System voltage is between 9.0 and 18.0 volts
Vehicle speed is less than 3 mph
APP indicated angle is less than 0.25 percent

The Actual idle speed is approximately 175 RPM
higher than the Desired idle speed.
All above conditions present for 15 seconds.

Records data.

'" The History OTC will clear after 40 consecutive
malfunction.
.. The OTC can be cleared by using a scan tool.
Diagnostic Aids
Connections and Connector.Repairs in Wiring
Systems.
" Damaged harness.
Systems.
.. Inspect the PCM and the engine grounds for
Test Description
diagnostic table.
Engine
Step
Action
Values
No
Go to Step 2
Go to A
Powertrain. On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5

2. With a scan tool, command the engine speed up to
1500 RPM, down to 500 RPM, up to 1500 RPM.
3. Exit the RPM control function.
each command?
Is the engine RPM more than 100 RPM more than or less
than Desired RPM?

Vacuum leaks
A faulty PCV valve
Yes
Go to Step 6

5
6
7

e Parasitic load on the engine (i.e. transmission
problem etc.).
Go to Step 6

Does the DTC reset?
not diagnosed?
Go to Step 2
Go to Step 7
Go to applicable
DTC table
System OK
6-1032
Engine
DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit
rel
L.::'.J
~---i~~ig:Cant
I_l
l _Pi-essure
c'""""'----8 """v--A--=--' Sensor
LJ.I
GRY 720
RED/BLK 380
LT BLU/ 1688
BLK
FTP
__ -<1 Fuel Tank

Unit
Sensor
GRY 720
LT BLU/ i688
~
I
27 _ ~ ~-L~- _3:l _ ~9 J_ C2
- NC - - - - ;v; - ; - - s-;n;;r - - - - - Sensor
Signal
1 1
Reference
B
Ground
SV
CONN ID
C1 - BLU
C2-CLEAR
~--------------------~
Powertrain
Control
Module
(PCM) ,A~
548583
Circuit Description
The A/C system uses an A/C refrigerant pressure
sensor mounted in the high pressure side of the A/C
refrigerant system to monitor A/C refrigerant pressure.
The PCM uses this information to turn ON the
engine coolant fans when the A/C refrigerant pressure
is high and to keep the compressor disengaged
when A/C refrigerant pressure is excessively high or
low. The AJC refrigerant pressure sensor operates like
other 3-wire sensors. The PCM applies a 5.0 volt
reference and a sensor ground to the sensor. Changes
in the A/C refrigerant pressure will cause the A/C
refrigerant pressure input to the PCM to vary.
The PCM monitors the A/C refrigerant pressure signal
circuit and can determine when the signal is outside
of the possible range of the sensor. When the signal is
out of range (high or low) for a prolonged period of
time, the PCM will set OTC P0530. When OTC P0530
is set, the PCM will not allow the A/C compressor
clutch to engage. This is done to protect the
compressor.

.. The engine is running.
" The A/C is requested.

The A/C refrigerant pressure sensor signal voltage
is less than 0.1 volt (9 psi).
OR
" The A/C refrigerant pressure sensor signal voltage
is more than 4.9 volts (472 psi).
.. Either of the above conditions are present for
more than 20 seconds.
0

" The PCM will not illuminate the malfunction
Frame data.

" A history OTC will clear after 40 consecutive
malfunction.
Engine
Diagnostic Aids
)

Systems.
Damaged harness.
6-1033

Systems.
Test Description
diagnostic table.
3. If the A/C refrigerant pressure signal voltage stays
high after disconnecting the A/C refrigerant
pressure sensor electrical connector, the signal
circuit is shorted to voltage or the PCM is faulty.
6. Tests for a high resistance or an open in the
ground circuit.
Memory (EPROM). When the PCM is being

Action
Step

Diagnostic (OBD) nostic System Check?
1

2. With a scan tool, observe the A/C pressure sensor
parameter.
Does the scan tool indicate the parameter is within the
specified range?

2. Connect a 3 amp fused jumper wire between the
5 volt reference circuit and the signal circuit.
4. With a scan tool, observe the A/C pressure sensor
parameter.
specified value?
4.9V
1. Disconnect the fused jumper wire.

2. Measure the voltage between the 5 volt reference
circuit and the ground circuit.
5.1V
1. Disconnect the negetive battery cable.

2. Measure the resistance from the ground circuit of the
A/C pressure sensor to a good ground.
Does the resistance measure less than the
specified value?
5Q
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 11
0.1V to 4.9V
0.1V
Yes

Disconnect the A/C pressure sensor
With a scan tool, observe the A/C pressure sensor
parameter.
specified value?
1.
2.
3.
4.
Values
6-1034
Engine

DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit (cont'd)
Step
Action
Values
Test the 5 volt reference circuit for a high resistance, or an

open. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Test the signal circuit for a short to ground; high

resistance, or an open. Refer to Circuit Testing and Wiring
10

11
Test the ground circuit for high resistance or an open.

Systems.
12
Inspect for poor connections at the A/C pressure sensor

Connector Repairs .in Wiring Systems.
13

14
Replace the A/C pressure sensor.

15

Replace the PCM.
16

Does the DTC reset?
Yes
No
Test the 5 volt reference circuit for a short to voltage.

Systems.
Go to Step 16
Go to Step 13
Go to Step 16
Go to Step 9
Go to Step 16
. Go to Step 13
Go to Step 16
Go to Step 13
Go to Step 16
Go to Step 13
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 15
Go to Step.16
,-
Go to Step 16
Go to Step 2
System OK
Engine
6-1035
'" - - - - - - - - - - - - , Powertrain
I
I Control
I
CONN ID
I Module (PCM)
I
I
I
C1=BLU
C2=CLEAR
Generator
Terminal L
Output
I
I
I
L------------.1
61 C2
Ji>
.l,. ~
~
IMAl
Llil
RED 225
B
'" - - .. Generator
I Tum on!
jlnput
I
L -
.I
369145
Circuit Description
Diagnostic Aids
The PCM monitors system voltage on the PCM

ignition feed circuit. If the system voltage is out of
tolerance, DTC P0560 will be set. When the conditions
that set DTC P0560 are present, operation of some
vehicle systems and components may be affected.


System voltage monitored at the PCM ignition
feed circuit is less than 10 volts or more than
16 volts.
" Above conditions must be present for more than
25 seconds.
0

0

when the DTC set as Failure Records data only.
Frame data.
Com:litions for Clearing the Mll/DTC

A history DTC will clear after 40 consecutive
malfunction.
c

Systems.
.. Damaged harness.
Systems.
O Inspect the PCM and the engine grounds for
6-1036
Engine
Test Description
diagnostic table.


Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
OTC P1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 5
Go to
Diagnostic Aids

10
1. Start and run engine above 1000 RPM.

2. With a scan tool, observe the ignition 1 voltage
parameter.
Does the scan tool indicate voltage within the
specified range?
10-16V
1. Connect a J 39200 DMM between the battery

terminals.
2. Observe the voltage while running the engine above
1000 RPM.
10-16V
1. Load the electrical system by turning ON the

headlamps and the HVAC high blower.
2. Observe the DMM voltage while running the engine
above 2000 RPM.
10-16V

2. Disconnect the generator.
3. Measure the voltage on the generator control circuit
5. With a scan tool, command the Gen. L Term. ON.
Does the voltage measure near the specified value with
the Gen. L Term. commanded ON?
5V
Compare the ignition 1 voltage parameter on the scan tool

with the actual battery voltage read with the DMM.
Do the voltages match?
Inspect the PCM ignition feed circuit for a poor connection

between the ignition switch and the PCM. Refer to Testing
Test the generator control circuit for an open or a short to

Wiring Systems.
(
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 7
Go to Step 12
Go to Step 10
Go to
Diagnostic Aids
Go to Step 9
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 11
Engine
6-1037
DTC P0560 System Voltage (cont'd)

Step
11
12
Action
Inspect the generator control circuit for a poor connection

at the PCM. Refer to Testing for Intermittent and Poor
Inspect the generator control circuit for a poor connection
at the generator. Refer to Testing for Intermittent and Poor
Values
Yes
No
Go to Step 14
Go to Step 13
Go to Step 14
Go to Generator
Assembly Check
in Engine
Electrical

13
14

1. Start and run the engine above 1000 RPM.
2. With a scan tool, observe ignition 1 voltage
parameter.
specified range?
Go to Step 14
10-16V
System OK
Go to Step 5
6~1038
Engine
Engine Controls -3.SL
[l]
!Hot In RUN And STARij

B
.. - - - -ENG - , Engine Wiring
Cruise
I
J7
SEN
I Harness
Clutch
I
Js
~~nltuse I Junction Block 2
---- Switch
L - - - - - - .I
BRN11
(Manual
Trans Only)
PNK 539
C C2
WHJ 379
[l]
Brake
Switch
[ZJ
"
P~1~:0
-P.;e~ - , Engine Wiring

Distribution I Harness
Schematics I Junction Block 2
I
NC Cruise in Wiring
Systems I
Minifuse
15A
Cruise
Brake
Switch
BR~186
30 C1
24 C2
,. - &ake - - - - - - - - - - -c;;;;s; ., Powertrain
I
Switch
CONN ID
Control I Control
I
Signal
C1=BLU
R~lease I Module
I
C2=CLEAR
Signal I (PCM)
I .&.
IP
11.----------------J~
-------..1
PNK 139
PNK 139
M
Headlamp And
- - - - - ,cruise Turn Signal
Control Switch
.. - - - - - -
I
I
i Hot In ON And START I
I OFF
Q
I
I
:~~~:~1
OFF
-----
----- I
--------- I
ON
---
11.------GRY
I
#
SET/COAST I
R/A
DK BLU
BLK
------r------1
I
DKBLU 84
GRY 397
GRY/BLK 87
20 ______ ? ______2_1
Cruise On/Off
Signal
Cruise
SeVCoast
Signal
Cruise
Throttle Actuator A.
Resume/Accel Control (TAC) ...,..A
Signal
Module
~
,..._------~------~-------'
(
548587
Circuit Description
The throttle actuator control (TAC) module is a
communication link between the cruise switches and
the PCM. The cruise Resume/Acee! switch is an
input to the TAC module. This input is then
communicated from the TAC module to the PCM
across serial data, allowing the PCM to control and
hold a requested speed. The Cruise Resume/Acee!
switch sends an ignition voltage to the TAC module
when the switch is closed (ON). If the PCM receives an
input when the module does not expect it, this
OTC sets.

The Cruise switch is ON.

The Resume/Acee! switch is ON for more than
90 seconds.

Frame data.

malfunction.
Diagnostic Aids
e Poor terminal connection.
Systems.
Engine
O
6-1039
Damaged harness.
Test Description

Systems.

diagnostic table.
2. This step determines if the Resume/Accel signal
circuit is shorted to voltage.
3. This step determines if the TAC module or the
switch is at fault.
4. Inspect for a resume/accel switch stuck in the
engaged position or for the signal circuit shorted to
voltage.
7. This OTC will not report a pass. The scan tool
status for this OTC will never report a pass.
The scan tool will only indicate the OTC when the .
diagnostic fails. The repair is not complete if
the scan tool indicates that the diagnostic ran and
failed.

when the OTC was lasf set.

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 7
Go to Step 6

1

2. Turn OFF the cruise switch.
3. With a scan tool, observe the Cruise Resume/Acee!
switch parameter.
Does the scan tool indicate the Cruise Resume/Acee I
switch ON?
1.
2.
3.
4.

Disconnect the TAC module.
Probe the Resume/Acee! switch signal circuit at the
TAC module harness using a J 34142-8 test lamp
Repair the short to voltage on the Resume/Acee! switch

Replace the. TAC module. Refer to Accelerator Controls
Pedal Replacement (TAC Module and Bracket Assembly).
Replace the multifunction lever. Refer to Multifunction Tum

Signal Lever Replacement - On Vehicle in Steering
Column.

Does the DTC reset?
not diagnosed?
Go to Step 7
Go to Step 7
Go to Step 2
Go to Step 8
Go to
applicable DTC
System OK
6~1040
Engine
DTC P0568 Cruise Control Set Switch Circuit
[ZJ
IHot In RUN And STAR11

B
" - ... - -ENG - , Engine Wiring
Cruise
I
J7
SEN
I Harness
Clutch
I
Js
~~n_:use I Junction Block 2
___.. Switch
1.. _ _ _ _ _ _ J
BRN'I
(Manual
Trans Only)
PNK 539
C C2
WHJ 379
Brake
Switch
PP~1~:0
[l]
'" - - - -P~e7" - , Engine Wiring
I
I
I . A/C Cruise
I Minifuse
PNK 139
Cruise
Brake
Switch
I Harness
I Junction Block 2
I
I
L2w
PNK
BR:186
30 C1
24 C2
" - er'ai; - - - - - - - - - - -c;;:;is; ., Powertrain
I
Switch
CONN ID
Control . Control
I
Signal
C1=BLU
R~lease I Module
1.
C2=CLEAR
Signal I (PCM)
A
_ ____
I
I
Distribution
Schematics
in Wiring
Systems
. 15A
_______ ...
r _ _ _ _ _ _
I
I
I Hot In ON And START!
__ _ _ __ .- _ _ .
10FF
I .....
,cruise Headla.mp And

1Control Turn Signal
: switch Control Switch
OF~
.
I
. . .......... I
--------- I
ON
. ....
.. ______
_ SET/COASTR/A I
o
lfllll'
1.----------------~~
GRY
DKBLU
BLK
------r------I
I
DKBLU 84
GAY 397
GRY/BLK 87
20 . ____ J.;3 . _____2_1

Cruise On/Off Cruise
cruise
Throttle Actuator.._
Signal
Set/Coast
Resume/Acee!
Control (TAC) p
,__
.......,
4
Signal
Signal
Module
~
____________________
(
548587
Circuit Description
The throttle actuator control (TAC) module is a
communication link between the cruise switches and
the PCM. The cruise Set/Coast switch is an input
to the TAC module. This input is then communicated
from the TAC module to the PCM across serial
data, allowing the PCM to control and hold a requested
speed. The Cruise Set/Coast switchsends a.n
ignition voltage to the TAC module when the switch is
closed (ON). If the PCM receives an input when
the module does not expect it, this OTC sets.

The Cruise switch is ON.

The Set/Coast switch is ON for more than 90 seconds.

., The PCM will store conditions which were present
Frame data.

malfunction.
.. The .DTC can be cleared by using a scan tool.
Diagnostic Aids
A set/coast switch stuck in the engage position or the
signal circuit is shorted to voltage.
lmpol'tant: Remove any debris from the connector
Systems.
Engine

Test Description
Damaged harness.
Systems.

diagnostic table.
2. This step determines if the Resume/Acee! signal
circuit is shorted to voltage.
3. This step determines if the TAC module or the
switch is at fault.
4. Inspect for a resume/accel switch stuck in the
engaged position or for the signal circuit shorted to
voltage.
7. This OTC wjll not report a pass. The scan tool
status for this OTC will never report a pass.
The scan tool will only indicate the DTC when the
diagnostic fails. The repair is not complete if
the scan tool indicates that the diagnostic ran and
failed.
OTC P0568 Cruise Control Set Switch Circuit

Action
Step

1

2. Turn OFF the cruise switch.
3. With a scan tool, observe the Cruise Set/Coast switch
parameter.
Does the scan tool indicate the Cruise Set/Coast
switch ON?
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 7
Go to Step 6

Disconnect the TAC module.
Probe the Set/Coast switch signal circuit at the TAC
module harness using a test lamp that is connected
to a good ground.
Repair the short to voltage on the Set/Coast switch signal

Replace the TAC module. Refer to Accelerator Controls

Replace the multifunction lever. Refer to Multifunction Turn

Signal Lever Replacement - On Vehicle in Steering
Column.
1.
2.
3.
4.
Values
Go to Step 7
Go to Step 7
1: Use the scan tool in order to clear the DTCs.

Does the OTC reset?
not diagnosed?
Go to Step 2
Go to Step 8
Go to
applicable OTC
System OK
Engine
6~1042. Engine Controls- 3.8l

.. - - I
I
J7
J6
L -
.a
PNK 539
C C2
BRN,
Brake
Switch
[]
,.
(Manual
Trans
Only)
L
WHJ 379
PNK 139
Cruise
Brake
Switch
.j; 0
- - - -P:::e7 - ., Engine Wiring

Distribution
Schematics
in Wiring
Systems
A/C Cruise
Minifuse
15A
M
-
I
30 C1
24 C2
aOFF
,. - s";a1<"; - - - - - - - - - - -c;;;is; ., Powertrain
. I
-I
Switch
CONN ID
Control .. I Control
I
Signal
C1=BLU
Release I Module
:
ON
I
C2=CLEAR
Signal I (PCM)
IP
Ai.
L----------------..1~
., Cruise
I Control
1Switch
Headlamp And
Turn Signal
Control Switch
I
I
PNK 139
BR: 86
I Harness
I Junction Block 2
-------..&
PP~1~:0
! H~t In ON And START!
B
-ENG - ., Engine Wiring [ ] Cruise
SEN
I Harness
Clutch
~~nlfuse I Junction Block 2
---- Switch
IHot In RUN And STAR"l!
---~---
-
---~ -SET/COAtfA :
L------- ---GRY
DK BLU
BLK
------1------1
I
DKBLU 84
GRY 397
GRY/BLK 87
20 . _ _. __ _l;I . ____ -~1
Cruise
Cruise
Resume/Acee!
Set/Coast
L.._ _ _ _ _ _ _ _Signal
_ _ _ _ _ _ _ _Signal
_ _ _ _ _ __ .
Cruise On/Off
Signal.
Throttle Actuator ...

Control (TAC) .....
Module
~
(
548587
Circuit Description
The cruise control brake switch and the cruise clutch
switch are normally closed switches. When the
.Cruise Brake switch or the cruise clutch switch are
closed, the PCM senses ignition voltage on the cruise
control release signal circuit. The PCM compares
this signal to the signal received from the other clutch
and brake switches. If these switches do not agree
this DTC will set.

The engine speed is more than 1000 RPM for
1 second.
The wheel speed is more than 20 mph in order to
enable the diagnostic. The diagnostic disables
when the wheel speed is less than 5 mph.

The vehicle speed decreases 1. MPH in
0.5 seconds without the PCM sensing a switch
transition.
~ The cond.ition is present for 1O accel/decel cycles.

Frame data.

malfunction.
Engine
Diagnostic Aids
)
Perform the following in order to adjust the cruise

control brake switch:
1. With the brake pedal depressed, insert the cruise
control brake switch into the retainer until the
switch body seats in the retainer. You can hear
clicks as you push the threaded portion of
the switch through the retainer.
2. Slowly pull the brake pedal fully rearward against
the stop until you can no longer hear the clicks.
faulty terminal to wire .connection. Use a
Systems.
6-1043
Damaged harness.
Systems.
Test Description
diagnostic table.
4: This step tests for a cruise control release circuit
for a short to B+.
6,-1044
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 17
Go to Step 5
Go to Step 26
Go to Cruise
Control
Diagnosis
Go to Step 27
Go to Step 7
Go to Step 27
Go to Step 8
Go to Step 9
Go to Step 18
Go to Step 10
Go to Step 19
Go to Step 11
Go to Step 20
Go to Step 13
Go to Step 21

..

2. With a scan tool, observe the cruise release switch
parameter.
3. Depress the brake pedal approximately half-way.
Does the scan. tool parameter switch from Released to
Applied?
Inspect the A/C Cruise fuse.

Is the fuse open?
Important: Only do this step if the vehicle has a manual

transmission. Otherwise go to step 5.
1. Disconnect the cruise clutch switch.
2. Probe the clutch switch feed circuit at the clutch
switch connector using a J 34142-8 Test Lamp that is
connected to B+.
..
1. Disconnect the cruise brake switch.
2. Probe the brake switch feed circuit at the brake

5
switch connector using a test lamp that is connected

to B+.
3. Probe the brake switch signal circuit at the brake
switch connector using a test lamp that is connected
to B+.
Does the test lamp illuminate when probing either circuit?
Test the adjustment of the cruise control brake switch. Go

to Diagnostic Aids.
Did you find a correct the condition?
Important: Only do this step if the vehicle has a manual

transmission. Otherwise go to step 12.
Test the adjustment of the cruise clutch switch. Go to
Diagnostic Aids.
1. Disconnect the cruise clutch switch.

2. Probe the cruise clutch switch feed circuit at the
cruise clutch switch connector using a test lamp that
is connected to a good ground.
Probe the brake switch feed circuit at the clutch switch

connector using a DMM that is connected to a good
ground.
OV
10
1. Remove the cruise clutch switch.

2. Measure the continuity across the switch while
toggling it by hand.
Does the DMM toggle from open to continuity.
11

2. Measure the brake switch feed circuit for continuity
between the clutch and the brake switch.
Does the DMM indicate continuity?
12

2. Probe the cruise brake switch feed circuit at the
brake switch connector using a test lamp that is
(
Go to Step 13
Go to Step 22
Engine
6-1045
DTC P0571 Cruise .Control Brake Switch Circuit (cont'd)

Step
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Action
Probe the cruise control release switch signal circuit at the
brake switch connector using a DMM that is connected to
a good ground.
1. Remove the cruise brake switch.
2. Measure the continuity across the switch while
toggling it by hand.
Does the DMM toggle from open to continuity?
Test for an open in the cruise control release switch signal
circuit. Refer. to CircuitTestirig and Wiring Repairs in
Wiring Systems.
Inspect for poor connections. Refer to Testing for
in Wiring Systems.
Repair the short to ground in the clutch switch feed circuit.
Did you complete.the repair?
Repair the open in the clutch switch feed circuit. Refer to
Test for a short to voltage between the clutch switch and
the PCM. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Replace the cruise clutch switch.
Repair the open in. the brake switch feed circuit between
the clutch and brake switch. Refer to Wiring Repairs in
Wiring Systems.
Repair the oper;i in the brake switch feed circuit. Refer to
Repair the short to voltage in the cruise control release
Replace the cruise brake switch.
Replace the PCM.
Repair the short to ground on the circuit which illuminated
the test lamp. Refer to Wiring Repairs in Wiring Systems.
Did you c9mplete the repair?
Does the OTC reset?
not diagnosed?
Values
Yes
No
Go to Step 14
Go to Step 23
Go to Step 15
Go to Step 24
Go to Step 27
Go to Step 16.
Go to Step 27
Go to Step 25
OV
Go to Step 27
Go to Step 27
Go to Step 27
-
Go to Step 27
Go to Step 25
. Go to Step 27
Go to Step 27
Go to Step 27
-
Go to Step 27
Go to Step 25
-
Go to Step 27
Go to Step 27
Go to Step 25
Go to Step 2
Go to applicable
OTC table
Go to Step 28
System OK
6-1046
Engine
DTC P0601 Control Module Read Only Memory (ROM)
Circuit Description

Records data.
The PCM used in this vehicle utilizes an Electrically

Erasable Programmable Read-Only
Memory (EEPROM). The EEPROM contains program
information and the calibrations required for
powertrain diagnostics operation.
Unlike the PROM used in past applications, the
EEPROM is not replaceable. When the PCM is
replaced or a calibration update is required, the PCM
must be programmed using approved Techline
equipment.
Diagnostic Aids
OTC P0601 indicates that the contents of the

EEPROM have changed since the PCM was
programmed. The only possible repair is PCM
replacement. Remember to program the replacement
PCM with the correct software and. calibration for
the vehicle.
The ignition is in the crank or run position.
Test Description

The PCM does not contain the correct program
required to operate the vehicle.

diagnostic table.
an Electrically Erasable ProgrammablEl Read Only

Step
Action
Values
Yes
'

Go to Step 2

Go to A
Powertrain On
Board
Diagnostic (080)
System Check
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Engine
6'."1047

Circuit Description
The PCM used in this vehicle utilizes an Electrically

Erasable Programmable ReadaOnly
Memory (EEPROM). The EEPROM contains program
information and the calibrations required for
powertrain diagnostics operation.
Unlike the PROM used in past applications, the
EEPROM is not replaceable. When the PCM is
replaced or a calibration update is required, the PCM
must be programmed using approved Techline
equipment.
The PCM will illuminate the malfunction indicator.

lamp (MIL) during the. first trip in..which the
Records data.
Test Description
diagnostic table.

the new PCM. must be programmed.

The PCM does not contain the correct program
required to operate the vehicle.

Step
Action
Values
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
1. Program the PCM with the correct software. Refer to

2
)
3
2. Retest for DTC P0602.
Did DTC P0602 reset?
Go to Step 3
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
System OK
DTC P0604 Control Module Random Access Memory (RAM)

Circuit Description

Records data.
The PCM performs an internal self-test on its Random

Access Memory (RAM) or read/write memory. If this
self-test fails, this OTC sets.

The ignition voltage is more than 10 volts.
The ignition is ON for 5 seconds.

The internal RAM test fails.
Test Description
diagnostic table.
2. This OTC indicates an internal PCM problem.

Step
Action
Values
Yes

Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
6-1048
Engine
DTC P0606 Control Module Internal Performance

Circuit Description

diagnostic test has been run and. failed.
Records data.
This diagnostic indicates that the PCM detects an

internal microprocessor integrity fault.

The PCM is powered-up.

The PCM detects an internal microprocessor
integrity fault.
Test Descriptiqn
diagnostic table.
2. This OTC indicates an internal PCM problem.
DTC P0606 Control Module Internal Performance

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check


Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Engine
6-1049
DTC P0620 Generator Performance

'" - - - - - - - - - - - - ., Powertrain
I Control
CONN ID
I Module (PCM)
I
I
I
I
I
C1=BLU
C2=CLEAR
Generator
Terminal L
Output
I
i
I
~
~
L2lli
L------------..1
61 C2
RED 225
B
r - - , Generator
I Turn On I
11nput
L- -..1
369145
Circuit Description
Diagnostic Aids
The PCM Output (L) terminal to the alternator

determines when the alternator will be turned off. It is
on under all normal vehicle operating conditions
except during low RPM conditions. The alternator is
turned off during low RPM conditions to remove excess
load from the engine.

Systems.
Damaged harness.
Systems.
The alternator telltale lamp

ignition is on and engine is
will go out after the engine
alternator is putting out the
will illuminate any time the

not running. The telltale
is running and the
desired amperage.

" The voltage telltale is ON.

The above condition is present for more than
30 seconds.

Frame data.

0

malfunction.
Test Description
diagnostic table:
and Electrically Erasable Programmable Read
Only Memory (EEPROM). When the PCM
is replaced, the new PCM must be programmed.
6-1050
Engine

OTC P0620 Generator Performance
Step
Action
Values


2. Disconnect the Generator harness connector.
3. Connect a J 39200 DMM between the
(L} terminal and a good ground.
Yes
No
Go To Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
I'
o.ov
Go To Step3
5.0V
Command the Generator on with the scan tool while

observing the DMM.
Go To Starting
and Charging
Does the voltage change from the first indicated value to the
second indicated value?
Test the (L) circuit for an open or short to ground. Refer to

Test the (L) circuit for a short to voltage. Refer to Circuit

Inspect for a poor connection at the PCM. Refer to Testing

Go To Step 7
Go To Step4
Go To Steps
Go To Step 7
Go To Step 7
Go To Step 7
Go ToStep2
System OK
Go To Step 6

6

Programming.
Does the OTC reset?
Engine
6-1051
DTC P0650 Malfunction Indicator Lamp (Mil) Control Circuit

!Hot In Run, Bulb Test And Startj
r - - - - - - - - , IP
I
I Power
I Distribution
G3
GAUGES I Fuse
Schematics
Fuse 9
Block
I in Wiring
H3 10 A
I
I Systems
H4
L------
---.1
------II>
PNKI 39
PNK 39
A51
,.
......____::t - - - - - -,
I Instrument
,;;:
A Malfunction
I Cluster Schematics0
Indicator
I
Lamp (MIL)
I
I in Instrument
~ (SERVICE
I
I Panel, Gauges
(!)
I and Console
- -
r'
ENGINE SOON) I
Power
DistribuUon
Schematics
In Wiring
Systems
L:lli
Instrument
Cluster
A
~
A4I
BRN/WHT 419
BRN/WHTI419
5 C2
,
- -t
1
L-----------------~
'
I
I
I
MIL
Control
CONN 10
c1 :_ BLu
C2-CLEAR
Powertrain
I Control
I Module
I (PCM)&~
>
548589
Circuit Description
Diagnostic Aids

improper voltage level on the output circuit that
controls the malfunction indicator lamp (MIL).

Ignition is ON.

the output circuit which controls the malfunction
Above conditions for at least 30 seconds.

Records data.
The PCM wiH turn the MIL OFF during the

warrn-up cycles have occurred without a
malfunction.
O The DTC can be cleared by using a scan tool.

O Poor terminal connection.
faulty ter.minal to wire connection. Use a
Systems.
O
Damaged harness.
harness appears to.be OK, observe the display
Systems.
.
6-1052
Engine
Test Description
4. Tests for a short to voltage on the control circuit.

diagnostic table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.

Memory (EEPROM}. When the PCM is replaced,
DTC P0650 Malfunction Indicator lamp (MIL) Control Circuit

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step11


2

4. Measure the voltage on the MIL control circuit using a
J 39200 DMM that is connected to a good ground.
Does the voltage measure at or near the specified valu.e?
Probe the MIL control circuit using a test lamp that is
connected to ground.
B+

Leave the PCM disconnected.
Disconnect the instrument panel.
Measure the voltage on the MIL control circuit using a
ov
Repair short to voltage in the MIL control circuit. Refer to

Inspect the ignition feed fuse for the instrument panel

indicators.
Is the fuse open?
1. Repair the short to ground in ignition feed circuit for

the instrument panel indicators. Refer to Wiring
2. Replace the fuse.
1. Disconnect the instrument cluster.

3. Measure the voltage on the ignition feed circuit for
the instrument cluster indicators using a DMM that is
B+
Test the MIL control circuit for an open or a short to

Wiring Systems.
10
1.
2.
3.
4.
5.
Inspect the MIL control circuit and the instrument panel

indicators ignition feed circuit for a poor connection at the
instrument panel and the PCM. Refer to Testing for
in Wiring Systems.
(
Go to Step 10
Go to Step 5
Go to Step 15
Go to Step 7
Go to Step B
Go to Step 15
Go to. Step 9
Go to Step 13
Go to Step 15
Go to Step 10
Go to Step 15
Go to A
Diagnostic
System Check Instrument
Cluster in
Instrument
Panel, Gauges
and Console
Engine
6-1053
DTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit (cont'd)

Action
Step
Values
Yes
No
Go to
Diagnostic Aids
Go to Step 12
Go to Step 15
Go to Step 14
2. Reconnect the PCM.

3. Disconnect the instrument cluster.
11
5. Connect a J 34142-B. test lamp between the MIL
control circuit and the 1/P ignition feed circuit.
6. With a scan tool, command the MIL ON and OFF.

Does the test lamp flash ON and OFF with each
command?
12
Inspect the MIL control circuit for a faulty connection at the

13
Repair the open in the ignition feed circuit to the 1/P

indicators. Refer to Wiring Repairs in Wiring Systems.
Go to Step 15
14
15

1. Use the scan tool in order to clear the DTCs

Does the DTC reset?
Go to Step 15
Go to Step 2
System OK
6-1054
Engine Controls - 3.Bl
Engine
GRY 48
Cruise Control/
Clu.tch Anticipate
Switch
___
Grou~d
f: ~ -----------
BLK/WH~ 451
~~~~~
BLK/WHT ;~ - - - - - - - - - - -
Distribution
Schematics
~ -
lnWiring
Systems
BLK/WHT 451
'- - - - - - - -
14_S___~-~_K/W~H_T_.,i ~~~rt~~~;';ch
~-~;r
GRY
r Clut;
48
18 C2
-1-- -----,
1 Anticipate
..
CONN ID
I Swi.tch
C1 =BLU
I IFgrnt,on . . . C2=CLEAR
I
12v
Powertrain
I Control
I Module
I PCM
I(
L----------.J
i,..
~
548590
Circuit Description
The clutch anticipate switch input allows the PCM to
adjust the idle when the manual transmission clutch is
being disengaged. The PCM monitors the Clutch
Anticipate Switch input; if a low voltage is monitored,
the PCM considers the Clutch Anticipate Switch
closed to ground (clutch engaged). When the ground
at the Clutch Anticipate Switch input is interrupted
(clutch being disengaged), the PCM will immediately
decrease idle. This is done to avoid a possible
RPM flare caused by the sudden change in
engine load.

Engine load and engine speed acceleration indicate
that the vehicle is in gear and moving.

O
The Clutch Anticipate Switch PCM input indicates

that the clutch is engaged. (clutch switch closed
to ground).
Above conditions must be present for more than

3 minutes.
OR
" Changes in the vehicle speed to engine speed

ratio indicate that more than 70 gear changes
have occurred.
The state of the Clutch Anticipate Switch did not
change.

Frame data.

" A history DTC will clear after 40 consecutive
malfunction.
Diagnostic Aids
Systems.
" Damaged harness.
Systems.
Engine
Test Description
diagnostic table:
2. This step tests the true state of the clutch pedal
switch.
6-1055

7. This step tests the integrity of the Clutch Anticipate

Switch input circuit.
DTC P0704 Clutch Switch Circuit

Step
Action
Values

Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 6
Go to
Diagnostic Aids
Go to Step 4
Go to Step 13
Go to Step 5
Go to Step 9
Go to Step 15
Go to Step 7
Go to Step 10
Go to Step 11
Go to Step 8
Go to Step 16
Go to Step 14
2. With a scan tool, observe the Clutch Anticipate
Switch parameter.
Does the scan tool indicate Released?
"
Depress the clutch pedal while observing the Clutch

Anticipate Switch parameter on the scan tool.
Does the parameter change to Applied?
Disconnect the Clutch Anticipate Switch.

Does the scan tool indicate Applied?
2. Disconnect the PCM
3. Probe the signal circuit at the PCM harness

connector using a J 34142-8 test lamp that is
connected to B+.
1. Disconnect the clutch pedal switch.
10
11
)
12
2. Probe the ground circuit using a test lamp that is

connected to B+.
1. Connect a fused jumper between the signal circuit

and the ground circuit.
2. With a scan tool, observe the clutch anticipate switch
parameter.
Test the signal circuit for an open or a short to voltage.

Systems.
Repair the short to ground in the signal circuit. Refer to

Repair open in the ground circuit. Refer to Wiring Repairs

in Wiring Systems.
Test the Clutch Anticipate Switch adjustment. Refer to

Clutch Anticipate Switch Replacement in Clutch.
Inspect for poor connections at the Clutch Anticipate

Switch. Refer to Testing for Intermittent and Poor
Go to Step 16
-
Go to Step 16
Go to Step 16
Go to Step 12
Go to Step 16
Go to Step 13
6-1056
Engine

DTC P0704 Clutch Switch Circuit (cont'd)
Step
13
14
15
16
17
Action
Values
Replace the Clutch Anticipate Switch. Refer to Clutch

Anticipate Switch Replacement in Clutch.
Inspect for poor connections at PCM. Refer to Testing for

in Wiring Systems.


2. With a scan tool, observe the clutch anticipate switch
parameter.
Does scan tool indicate Released?
Depress the clutch pedal while observing the Clutch

Anticipate Switch display on the scan tool.
Does the parameter change to Applied?
Yes
No
Go to Step 16
Go to Step 16
Go to Step 15
Go to Step 16
Go to Step 17
Go to Step 6
System OK
Go to Step 4
Engine
6-1057
DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage
,. - - - - - - - - - - ., Powertrain
I
sv
I Control
1
I
.
Module Jt,
I
5Volt
.
I (PCM) ~
I
Reference A
!..------33 C2
---.J
EGR
Valve
L.2ril
GRY 598
GAY
.
598
I}==t>---11
C
GRY 598
Manifold
Absolute
Pressure
(MAP) Sensor
Al
ORN/BLK 469
13AC1
LT GRN 432
25 C2
r---------------------,
CONN ID
MAP
Sensor
Ground
Cl = BLU
C2=CLEAR
MAP
Sensor
Signal
6--------------------J
Powertrain
Control
Module J,,
(PCM)~
368338
Circuit Description
.MAP signal voltage that is intermittently high,
DTC P1106 will set.

.. The MAP sensor intermittently indicates a voltage
more than 4.2 volts.
.. The above conditions are present for more than
5 seconds.

Frame data.
O

O

No TP sensor DTCs are present.
The engine has been running for a length of time
that is determined by startup coolant temperature.
The length of time ranges from 2 minutes at
less than -30C(-22F) to 0.5 second at more than
30C (86F).
O The throttle position is less than 2 percent when
the engine speed is less than 900 rpm.
OR
The throttle position is O percent when the engine
speed is more than 900 rpm.
warmsup cycles have occurred without a

malfunction.
6-1058
Engine
Diagnostic Aids
Damaged harness.

Systems.

Systems.

OTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage
Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0108
Manifold Absolute
Pressure (MAP)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 9
Go to Step 8
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step B
Go to Step 9
Go to
Diagnostic Aids
Go to Step 2
System OK

1
Is OTC P0108 also set?

2
Is OTC P11 i 1 or P1115 also set?
Inspect the MAP ground for a poor connection at the MAP

Inspect the MAP ground for a poor connection at the PCM.

Test the signal circuit of the MAP sensor for an intermittent

short to voltage. Refer to Circuit Testing and Wiring
Test the 5 volt reference A circuit of the MAP for an

intermittent short to voltage. Refer to Circuit Testing and
Test the ground circuit for an intermittent open. Refer to



Does the OTC reset?
Engine
5:.1059
DTC P1107 Manifold Absolute Pressure {MAP) Sensor Circuit Intermittent Low Voltage
~- - - - - - - - - - - , Powertrain
I Control
sv
I
I
Module J;.
: .svolt
I (PCM) ~
Reference A
~------33 C2
---.!
EGR
Valve
GRY 598
GRY
I}==c>--1~
GRY 598
Manifold
Absolute
Pressure
...
(MAP) Sensor A
598
~------'
1 1
ORN/BLK 469
LTGRN 432
13"C1
r-
I.
25 C2
---~----------~-,
CONN ID
MAP
MAP
Cj = BLU
Sensor
Sensor
C2 =CLEAR
Ground
Signal .
~----------- .--------J
Powertrain
Control
Module ,&
(PCM)~
368338
Circuit Description
changes _while the EGR flow test diagnostic is
MAP signal voltage that is intermittently low,
DTC P1107 will set.

No TP sensor DTCs are present.
" The ignition is ON.
Throttle angle is steady more than O percent if
engine speed is less than 1000 rpm.
OR
Throttle angle is steady more than 1O percent if
engine speed is more than 1000 rpm.

The MAP sensor intermittently indicates a voltage
less than 0.1 volt.
O The above conditions are present for more than
5 seconds.

Frame data.

malfunction.
Diagnostic Aids
Important: Rernove any debris from the connector
Systems.
" Damaged harness.
Systems.
when the OTC was last set
6-1060
Engine
DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent Low Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP0107
Manifold Absolute
Pressure (MAP)
Sensor Circuit
Low Voltage
Go to Step 3
Go to Step 7
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 9
Go to Step 6
Go to Step 9
Go to Step 7


2
Are any TP DTCs also set?
Inspect for poor connections at the harness connector of

the MAP sensor. Refer to Testing for Intermittent and Poor
Inspect the 5 volt reference A circuit of the MAP sensor for

a poor connection at the PCM. Refer to Testing for
in Wiring Systems.
Inspect the signal circuit of the MAP sensor for a poor

Systems.
Test the 5 volt reference A circuit of the MAP sensor for

an intermittent open or short to ground. Refer to Circuit
Test the Signal circuit of the MAP sensor for an

intermittent open or short to ground. Refer to Circuit

Does the OTC reset?
(
Go to Step 9
Go to Step 8
Go to Step 9
Go to
Diagnostic Aids
Go to Step 2
System OK
Engine
6-1061
DTC Pt111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage
: J :
'" - - - - ~v- - - ., Powertrain

Control
I
I
I Module (PCM)
IAT
Sensor
s,~a.'._ ____
__
.J
}>,
50IC2
TA~ 472
rn
Intake Air
Temperature
(IAT) Sensor
pptl 719
11
r -
I
I
l C1
iAr- - - - - - -::: - ., Powertrain

Sensor
Ground
PCM
I I
Control
IC1=BLU
I I Module
C2=CLEARI I
Jt,
(PCM)
L---------------J
221729
Circuit Description
the engine. The PCM applies 5.0 volts through a
pull up resistor to the IAT sensor. When the intake air
is cold, the sensor resistance is high and the PCM
will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. OTC P1111 will set when the PCM detects
an intermittently high signal voltage on the intake
air temperature sensor signal circuit.

" No active ECT, MAF sensor or VSS DTCs.
The engine has been running for more than
3 minutes.
Vehicle speed is less than 56 km/h(35 mph).
The mass air flow is less than 12 g/s.
60C (140F).

IAT signal voltage indicates an intake air
temperature intermittently less than -34C (-29F).
The above conditions are present for more
than 5 seconds.

Frame data.

malfunction.
DiagnosUc Aids
Systems.
Damaged harness.
Systems.
6-1062
Step
Engine
DTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0113
Intake Air
Temperature (IA T)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 10
Go to Step.B
Go .to Step 10
Go to Step

1
With a scan tool, select Diagnostic Trouble Codes (OTC).

2
Is OTC P1106 or P1115 also set?
Inspect for a faulty ground circuit connection at the IAT

Inspect for a faulty signal circuit connection at the IAT

Connections in Wiring Systems.
Test the signal circuit of the IAT sensor for an intermittent

open. Refer to Testing for Intermittent and Poor
Test the signal circuit of the IAT sensor for an intermittent

short to voltage. Refer to Testing for Intermittent and Poor
Inspect for a faulty sensor ground circuit connection at the

-.

Test the ground circuit of the IAT sensor for an intermittent
open or a faulty splice. Refer to Testing for Intermittent
Systems.
9.
Go to Step 10
Ge to
Diagnostic Aids
Go to Step 2
System.OK

10
2. Operate .the vehicle within the Fail Record conditions.

Does the OTC reset?
Engine
6-1063
DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage
: J :
..- - - - - -;,v- - - ., Powertrain
IAT
Control
I Module (PCM)
Sensor
L -
_S1.'.!_na.'._ -
50IC2
.J
j;.
Lill
TA~ 472
rn
Intake Air
Temperature
(IAT) Sensor
pptI719
17 C1
r -
iAT- - - - - - - - ., Powertrain
Sensor
(;round
PCM
I I
1c1C2=CLEARI
= BLU I
Control
I Module
(PCM)
L---------------J
...
Ji1il>~
221729
Circuit Description
Diagnostic Aids

the engine. The PCM applies 5.0 volts through a
pull up resistor to the IAT sensor. When the intake air
is cold, the sensor resistance is high and the PCM
will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. DTC P1112 will set when the PCM detects
an in1ermittently low signal voltage on the intake
air temperature sensor signal circuit.

No active ECT, MAF sensor or VSS DTCs.
lhe engine has been running for over 10 seconds.
Vehicle speed is more than 25 mph.

lhe IAT sensor indicates an intake air temperature
intermittently more than 135C (275F).
lhe conditions is present for up to 5 seconds.

Frame data.
Conclitions for Clearing the MIUDTC

malfunction.

Systems.
Damaged harness.
Systems.
6-1064
Engine
DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
OTC P0112
Intake Air
Temperature (!AT)
Sensor Circuit
Low Voltage
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 2
System OK


Does the scan tool indicate OTC P0112 also set?
Test the signal circuit for an intermittent short to ground.


Does the DTC reset?
Engine
6-1065
DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent low Voltage
r -
v- - - - , Powertrain
: ~~~t~f~ (PCM)
: ECT JS
I
. L
Sensor
-
~g~I -
::- -
>
LJil
261 C2
YELi 410
Brr
r -
I
I
CONN ID
C1 =BLU
C2=CLEAR
f- ,Engine
I Coolant
~Temperature
A
(ECn Sensor
BRN 718
12,,,C1
- - ECT - ~ Powertrain
'
Senso~
I Control
Ground
I Module (PCM) .st.
-I
L-----------~
p,,
~
368395
Circuit Description
Diagnostic Aids

PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high therefore the PCM will measure a
high signal voltage. As the engine coolant warms, the
sensor resistance becomes less, and the ECT
signal voltage measured at the PCM drops. With a
fully warmed up engine, the ECT signal voltage should
measure about 1.5 to 2.0 volts. If the PCM detects
an ECT signal that is intermittently below the range of
the ECT sensor, OTC P1114 will set.

15 seconds.

The ECT sensor is intermittently more than
140C (284 F)
The condition is present for at least 3 seconds.

Frame data.

malfunction.

Systems.
Damaged harness.
Systems.
6-1066
Engine
DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
OTC P0117
Engine Coolant
Temperature (ECT)
Sensor Circuit
Low Voltage
Go to Step 3


Does the scan tool indicate OTC P0117 also set?
Test the signal circuit of the ECT sensor for an intermittent

short to ground. Refer to Testing for Intermittent and Poor

Does the OTC reset?
Go to Step 4
Go to
Diagnostic Aids
Go to Step 2
System OK
Engine Controls . ; 3.8l
Engine
6-1067
DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage
r -
-v- - - - , Powertrain
5
ECT
Sensor
L -
!g~I -
I
.J
~~~~f~
>
I cI
L0
(PCM).
. 261 C2
YELi 410
Brr
f- ,Engine
Coolant
I
r -
I
I
CONN ID
C1 =BLU
C2=CLEAR
~Temperature
A- (ECT) Sensor
BRN 718
.
12,,,,C1
- - ECT- - ~ Powertrain
.
Sensor
I Control
.
Ground
I Module (PCM) .
L-----------.J
>.
368395
Circuit Description
Diagnostic Aids

PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high; therefore the PCM will measure a
high signal voltage. As the engine coolant warms,
the sensor resistance becomes less, and the
ECT signal voltage measured at the PCM drops. With
a fully warmed up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. If the PCM
detects an ECT signal that is intermittently above the
range of the ECT sensor, OTC P1115 will set.

15 seconds.

.. The ECT sensor is intermittently less
than -34C (-29F)
" Above conditions present for more than 5 seconds.

Frame data.
0

malfunction .

Systems.
Damaged harness .
Systems.
6"'.1068
Engine
Step
Action
Values
Is DTC P1106 or P1111 also set?
Inspect for a faulty ground circuit connection at the ECT

Inspect for a faulty signal circuitconnection at the ECT

Go to Step 3
Go to Step 8
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
Go to
Diagnostic Aids
Go to Step 2
System OK

open. Refer to Testing for Intermittent and Poor

short to voltage. Refer to Testing for Intermittent and Poor
Inspect for a faulty sensor ground circuit connection at the

Test the ground circuit of the ECT sensor. for an

intermittent open or a faulty splice. Refer to Testing for
in Wiring Systems.
1. Use the scan tool in order to clear the. DTCs.

2. Operate the vehicle within the. Fail Record conditions.
Does the DTC reset?
10
Go to
OTC P0118
Engine Coolant
Temperature (ECT)
Sensor Circuit
High Voltage
With a scan tool, select Diagnostic Trouble Codes (DTC).

Does the scan tool indicate DTC P0118 also set?
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Yes
Engine
6~1069
DTC P1120 Throttle Position (TP) Sensor 1 Circuit
r -
I.
I
I
I
Pol"webr 1 ~
Dstrl uton
Schematics
in Wiring
Systems
GlO
Engine Wiring
'" -
I Harness
THROT 1. Junction Block 1
CONT I
Minifuse I
ElEC
..; - - - - - - ..,,;11;._A_
!Loe I
IHot At Ali Times I
! Hot In RUN Or START!
- - - - - - - ~E;ngine Wiring
TCS BATT
Harness
Junction Block 1
: J9
LJil
JB
I, -
.I
Power
Distribution
Schematics
In Wiring
Systems
ORN
'-----(l>-
PNK 339
1540
ORN 1540
==---------------. Throttle
.-------------:-"""7-".;;...;;..;;_-;;_-:..;;-:..;;-;.;;-..:.-..:.-..:.-..:..-..:..-=---;;_-:....;-:....;-:..;;-;.;;-;.;;-..:.-..:.-..:..-~Ignition
Positive
Voltage
Battery
Positive
Voltage
Actuator
Control:
(TAC}
TP
Senso~
TAC
TAC
TP
Sensor 2
TP
Sensor 2 Motor Driver Motor. Driver
Module
TP;i
TP
TP
. Sensor 1
Sensor 1 Sensor 1 Signal
"1:,-
:iT;~~iT~-~ ~~'-:::J.:V,1, ~~:r.:~~'i1=;.~- -:~:J ~~l~~~~"~:1,~~::~~1 ~

5
5
:~
BLK/
WHT
BLK/
WHT
JsLK/WHTr451
451
451
BLK/W-HT
,.. _ -
.,.
Ground
Distribution
Schematics
In Wiring
Systems
C
----
TPS 2
A
D
;~--- - -;----
-M-o~;---
REF
Drive
Throttle
Position ...___ ____.
Sensor2
RTN
E.
H
~o~o~
Drive
Hi
H Bridge
Motor Driver
;~---RTN
C1
-;;---REF
TPS 1
Throttle
Position
Sensor 1
L-~~~~~~~~~~~~~~~~~~~~---'
Throttle
Actuator
Control
~
548593
Circuit Description
The throttle position (TP) sensor is mounted on the
throttle bodyffAC assembly. The sensor is actually
two individual throttle position sensors within
one housing. Two separate signal, ground and
reference circuits are used in order to connect the TP
sensor assembly and the throttle actuator
control (TAC) module. The TP sensor signal voltage
increases as the throttle opens. The signal circuit
for TP Sensor is pulled up to reference voitage.

OTCs P0606, P1517, P1518 are not set.
The ignition switch is in the crank or run position.
The ETC serial data is operational.

TP sensor 1 voltage is less than 0.34 volts or more
than 4.4 volts as observed on the scan tool.

TRACTION OFF lamp.
Records data.

malfunction.
6-1070
Diagnostic Aids
When the TAC module detects a problem within the
ETC System the PCM receives a message across
serial data and more than one ETC System related
DTC may set. This is due to the many redundant tests
run continuously on this system. Locating and
repairing one individual problem may correct more
than one DTC. Keep this in mind when reviewing
captured DTC info.

Systems.
Engine
Damaged harness.
Systems.
Engine
6-1071
DTC.P1120 Throttle Position (TP) Sensor 1 Circuit
Step
Action
1. With a scan tool, observe the TP sensor voltage

parameter.
2. Depress the throttle to wide open throttle (WOT) and
release.
Does the scan tool indicate voltage at or near the specified
value throughout throttle travel?
1V
Does scan tool indicate voltage below the specified value

throughout throttle travel?
1V

parameter.
2. Disconnect the TAC throttle body.
value when the TAC is disconnected?
5V

3. Measure the voltage on the reference circuit using a
3.9-4.6V
1. Disconnect the TAC I throttle body.

parameter.
4. Connect a test lamp between the signal and return
circuits.
Does the scan tool indicate voltage at the specified value
when the test lamp is installed?
OV
1. Remove the test lamp from the return circuit.

2. Connect the test lamp to a good ground.
OV
Did. the test lamp illuminate when the it was connected

between the signal circuit and ground?
10

11
Inspect the ELEC THROT CONT and TCS BAIT fuses.

Are the fuses OK?
Yes
No
Go to Step 2
Go to A
Powertrain Dn
Board
Diagnostic (OBD)
System Check
Go to Step 3..
Go to Step 11
Go to Step 21
Go toStep 4
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step 23
Go to Step 17
Go to Step 10
Go to Step 8
Go to Step 14
Go to Step 9
Go to Step 15
Go to Step 16
Go to Step23
Go to Step 18
Go to Step 12
Go to Step 19
Important: If the code does not set this ignition, refer to

Diagnostic Aids.
2. With a scan tool, observe the TP sensors, Disagree
parameter.
Does the scan tool indicate YES?
Values
3.9-4.6V
6-.1072
Engine Controls
3.8l
Engine
DTC P1120 Throttle Position (TP) Sensor 1 Circuit (cont'd)

Step
Action
1. Disconnect the TAC module.
2. Probe the feed circuits using a test lamp with a test
Does the test lamp illuminate when probing the feed
circuits?
Values
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Test the return circuit for an open. Refer to Circuit Testing
Test the signal circuit for an open. Refer to Circuit Testing
Test the reference circuit for an open or short to ground...
Systems.
Test the reference circuit for a short to voltage. Refer to
..
Repair the short to ground in the feed circuit. Refer to
Repair the open in the feed circuit. Refer to Wiring Repairs
in Wiring Systems.
Test the return circuit for a short to ground. Refer to Circuit
..
Test for continuity between the reference circuit in the TAC
and ground. Refer to Circuit Testing in Wiring Systems.
Is continuity indicated?
Inspect for a poor connection at the TAC. Refert6 Testing
Replace the throttle body/TAC assembly. Refer to Throttle
Body Assembly Replacement.
Inspect for a poor connection atthe TAC module. Refer to
Does the DTC reset?
diagnosed?
No
Yes
Go to
DTCP1515
Control Module
Throttle Actuator
Position
Performance or
OTC P1516
Throttle Actuator
Control (TAC)
Module Throttle
Actuator Position
Performance
Go to Step 20
Go to Step 27
Go to Step26
..
\
Go to Step 27
Go to Step 25
Go to Step 27
Go to Step26
Go to Step 27
Go to Step 25
Go to Step 27
Go to Step 25
Go to Step27
Go to Step 26
Go to Step 27
Go to Step 27
Go to Step 27
Go to Step 22
Go to Step24
Go to Step 26
Goto Step 27
Go to Step 24
Go to Step 27
-
Go to Step 2]
Go to Step 26
-
Go to Step 27
Go to Step 2
Go to
applicable DTC
Go to Step 28
System OK
Engine
6-1073
DTC P1125 Accelerator Pedal Position (APP) System

Diagnostic Aids
) Circuit Description
The accelerator pedal position (APP) sensors are
mounted on the accelerator pedal/TAC module
assembly. There are three individual Accelerator Pedal
Position sensors within one housing. Three separate
signals, a ground, and reference circuits. If only
one APP sensor DTC is set, the redundant APP
systems allow the Electronic Throttle Control (ETC)
system to continue operating normally. This OTC sets if
the PCM detects a problem with more than one APP
sensor. One APP sensor OTC will not cause the
Reduced Engine Power message to be displayed.
Two APP sensor DTCs for the same sensor also will not
cause the Reduced Engine Power message to be
displayed. However, if two or more DTCs are set
involving more than one APP sensor, this OTC will set
and the Reduced Engine Power message is displayed.

DTCs P0606, P1517, P1518 are not set.
The ignition is ON.

Two or more APP sensors are out of range or all
three APP sensors disagree or one APP sensor is out
of range and the other two APP sensors disagree.

TRACTION OFF lamp ..
Records data.

The PCM will turn the MIL. OFF during the
The History OTC will .clear after 40 consecutive
malfunction.
If a repair is completed and the OTC was cleared

using a scan tool on the same ignition cycle, the
default action will not clear until an ignition
cycle has occurred.
When the TAC module detects a problem within
the ETC System the PCM receives a message
across serial data and more than one ETC System
related OTC may set. This is due to the many
redundant tests run continuously on this system.
Locating and repairing one individual problem
may correct more than one OTC. Keep this in mind
when reviewing captured OTC info.
Systems.
Damaged harness.
harness appears to be OK, observe the display on
the scan tool while moving co.nnectors and wiring
harnesses related to the sensor. A change in.the
display may indicate the location of the fault. Refer
Inspect the PCM and the engine grounds for clean
and secure connections.
the Failure Records can be useful .in determining
Test Description
diagnostic table.
2. When the problems are corrected which are
causing the APP sensor DTCs to set, the status
of this OTC will change to History.
DTC P1125 Accelerator Pedal Position (APP) System

Step
Action
Did you perform the. Powertrain On-Board
Values
Yes
Go to Step 2
This OTC indicates that two or more APP sensor DTCs

are also set.
Review the DTCs.
Go to the APP sensor DTCs that are set and perform
those diagnostic tables.
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
6-1074
Engine
DTC P1133 H02S Insufficient Switching Bank 1 Sensor 1
-QI---- ,
,. Power
.I
Engine Wiring
Distribution
~cher:,iatics
mWirmg
Systems
.
J7
J6
L------
I Harness
1Junction Block 2.
I
ENG SEN
MiniFuse
20A
----..1
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
..,.._
- - -
PNK 539
. -
------------
--~---,
,. - - - - - - - - - - - - - - - - , Powertrain I
I
I
sank 1
H02S 1
Signal
CONN ID
C1=BLU
C2=CLEAR
H02S 1
Low
12-lC2 - -271-C1 - - - - -
PNK 5;9- PPL/WHT 1665

.
TAN/WHT 1653
D
I Control
I Module
I (PCM)
.J.
Heated Oxygen
J.
I
I
.1.
v
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1
H.eated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
Sensor Bank 1
Sensor1
---------------------~
.t
,
, - - - - - - - - -4
/- _______ ~
/
.
Ground
Distribution
Schematics
In Wiring
Systems
(
548532
Circuit Description
The PCM monitors the heated oxygen sensor (H02S)
activity. The PCM counts the number of times that
the H02S signal voltage crosses the rich to lean and
lean to rich thresholds during a 100 second test
period. If the PCM determines that the H02S did not
switch enough times, DTC P1133 will be set. A
lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to more than
600 mV. A rich to lean switch is determined when
the H02S voltage changes from more than 600 mV to
less than 300 mV.

No Fuel injector, MAF, TP, EVAP, IAT, MAP, Fuel
trim, EGR or ECT DTCs are set.
DTC P0135 is not set.

Records data.

malfunction.
O

The PCM monitors less than 55 lean to rich and
rich to lean switches for this H02S.
The H02S voltage remains between 300 and
600 millivolts,
The conditions are present for a 2 minute after
closed loop enable.
Engine
6-1075
Diagnostic Aids
Test Description

diagnostic table:

Systems.
O Damaged harness.
Systems.

specified values.
voltage will be less than 400 mV when. the

Step
Action

this table.
parameter.
specified values?
Systems.
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 15
Go to Step 5
400-500 mV
6-1076
Engine

DTC P1133 H02S Insufficient Switching Bank 1 Sensor 1 (cont'd)
Step
Action

3. Jumper the.signal circuit (PCM side) to a good
ground.
specified value?

ground.
Values
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
4.5V
5V


10

11

12

~ Fuel Contamination. Refer to
13

in Wiring Systems.
14

15

Does the OTC reset?
16

diagnosed?
No
400mV

Yes
(
Go to Step 15
Go to Step 12
Go to Step 15
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 2
Go to
applicable DTC
Go to Step 16
(
System OK
Engine
DTC P1134 H02S Transition Time Ratio Bank 1 Sensor 1
-i-----,
'" 'p0-;;;e;:I Distribution

I ~ch:r:natics
I
.
.
J?
J6
Wmng
Systems
in
ENG SEN
MiniFuse
20 A
Engine Wiring
I Harness
I Junction Block 2
fM;-J
LJiJ
L---------J
PNK 539
Power
Distribution
Schematics
In Wiring
Systems
<ii---- ..
PNK 539
---
-------------
'" - - - - - - - - - - - - - - - - , Powertrain I
I
Bank 1
CONN ID
I Control
I
I
C1=BLU
I Module
I
I
H02S 1
H02S 1
C2=CLEAR
I (PCM)
..1.
Signal
Low
v
PNK 5~9- ..J
~
Heated Oxygen
PPL/WHT 1665
~
Sensor (H02S)
TAN/WHT 1653
Bank2Sensor1
12-rC2 - -271-C1 - - - - -
B ,,.,
A ,...
Heated Oxygen
Sensor Bank 1
Sensor1
Ct
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 2
______________________ J
, _ _ _ _ _ _ _ -.-<Ill
_ _ _ _ _ _ _ _ -<iii
/
/
Ground
Distribution
Schematics
In Wiring
Systems
)
548532
Circuit Description
sensor (H02S) activity. The PCM counts the number
of times that the H02S responds from rich to lean
and from lean to rich and adds the amount of time it
took to complete all transitions during the 100 second
test period. With this information, an average time
for all transitions can be determined. The PCM then
divides the rich to lean average by the lean to rich
average to obtain a ratio. If the H02S transition time
ratio is not within range, OTC P1134 will be set,
indicating that the oxygen sensor is not responding as
expected to changes in exhaust oxygen content.

trim, EGR or ECT OTCs are set.
OTC P0135 is not set.

The PCM detects the H02S transition time ratio is
less than 0.6 or more than 3.3.
The conditions are present for a 2 minutes after
closed loop enable.
O

Records data.

malfunction.
6-1078
Engine
Diagnostic Aids
Test Description

diagnostic table:

Systems.
Damaged harness.
Systems.

specified values.
6. The specified value is what is m.easured on a

Step
Action

this table.
parameter.
specified values?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 15
Go to Step 5
400-500 mV
Operate vehicle within Fail Records conditions:


Systems.
Engine
6-1079
DTC P1134 H02S Transition Time Ratio Bank 1 Sensor 1 (cont'd)

Step
Action
Values
Yes
No
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 12


ground.
400mV

specified value?

ground.
4.5V

7

5V

to Circuit Testing and Wiring Repairs in Wiring.Systems.

10

11


12
13

I,
Replace the. effected H02S sensor. Refer to Heated
in Wiring Systems.
Go to Step 15
Go to Step 15
Go to Step 14
14

Go to Step 15

15
Does the OTC reset?
Go to Step 2
Go to Step 16
Go to
applicable OTC
System OK

16
diagnosed?
6-1080
Engine
-i -
JHot In Run, Bulb Test And Start!
r Po;er
I Distribution
J7
I
I
J6
ENG SEN
.. lvlinlFuse
Schematics.
In Wiring
Systems
20 A
,Engine Wiring
I Harness
I Junction Block 2
I
L---------..1
PNK 539
Power
Distribution
Schematics
In Wiring
....--- '
'
' , PNK 539
Systems
r-------------------------I
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1
Powertrain r
Control I
M d I I
O Ue I
(PCM)
}.
CONN ID
C1=BLU
C2=CLEAR
Bank2
I
I
H02S 1
Low
H02S 1
TA: 1667
P~L 1666
I I
Signal
L-----------------~
29 C1
10 C2
PN K 539
0
Heated Oxygen
Sensor (H02SO
Heated Oxygen
Sensor Bank 2
Sensor 1
Bank 1 Sensor 2
I
I
BLK150'-,'
I
L
- - - - - - - - - - - - - - - - - - - - - - - - .-
Ground
BLK 450 '-- - - - - - - ......,.

-----
-----<II
Distribution
Schematics
In Wiring
Systems
(
548543
Circuit Description
The PCM monitors the heated oxygen sensor (H02S)
activity. The PCM counts the number of times that
the H02S signal voltage crosses the rich to lean and
lean to rich thresholds for a 100 second test period.
If the PCM determines that the H02S did not
switch enough times, DTC P1153 will be set. A lean to
rich switch is determined when the H02S voltage
changes from less than 300 mV to more than 600 mV.
A rich to lean switch is determined when the H02S
voltage changes from more than 600 mV to less
than 300mV.


.The PCM will store conditions which were present
Records data.

The PCM will tum the MIL OFF during the
third.consecutive trip in which the diagnostic has
malfunction.
The DTC .can be cleared by using a scan tool.

The PCM monitors fewer than 55 lean to rich and
rich to lean switches for Bank 2 H02S 1.
The H02S voltage remains between 300 and
600 millivolts .
.. The conditions are present for a 2 minute after
closed loop enable.
Engine
6-1081
Diagnostic Aids
Test. Description

diagnostic table:
) Important: Remove any debris from the connector

Systems.
Damaged harness.
Systems.
) when the DTC was last set.

specified values.
5. If the 1ow circuit is shorted to ground the H02S
ari Electrically Erasable Programmable Read Only
DTC P1153 H02S Insufficient.Switching Bank 2 Sensor 1

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 15
Go to Step 5


this table.
parameter.
specified values?
400-500 mV
..


Systems.
6-1082
Engine

Step
Action
ground.
Values
10
11
No
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 12
4.5V

Does the voltage measure hear the specified value?
5V




(
..
12
13
14

in Wiring Systems.

16
Go to Step 15
Go to Step .15
Go to Step 14
Go to Step 15

15
400mV
specified value?
ground.
Yes

Does the OTC reset?

diagnosed?
Go to Step 2
Go to Step 16
Go to
applicable DTC
System OK
Engine
4---
6-1083

'"Po;erDistribution
Sche'!latics .
I In Wmng
Systems
I
I
Power
Distribution
Schematics
In Wiring
Systems
J?
.
J6
ENG SEN
MlnlFuse
20 A
,Engine
Wiring
1
Harness
I Junction Block 2
I
L2w
L---------.I
PNK 539
1 - - - ......
' , PNK 539
r-------------------------Powertrain '" - - - - - - - - - - - - - - - - - ,
Control I
CONN ID
Bank 2
I
M d I I
I
t
Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1
O LI
C1 = BLU
C2=CLEAR
(PCM) .1
).
H02S 1
Low
I
I
H02S 1
Signal
I I
L-----------------~
29
C1
TA: .1667
.10
C2
PPBL 1666
PN; 539
Heate~ Oxygen
Sensor (H02SO
Bank 1 Sensor 2
Heated Oxygen
Sensor Bank 2
Sensor 1
I
I
I
I
I
BLKt50
L--------------------------.
',
BLK 450 "-- - - - - - - __,,.
----------~
Ground
Distribution
Schematics
In Wiring
Systems
548543
Circuit Description
The. PCM continuously monitors the heated oxygen
sensor (H02S) activity. The PCM counts the numbe.r
of times that the H02S responds from rich to lean
and from lean to rich and adds the amount of time it
took to complete all transitions for a 100 second
test period. With this information, an average time for
all transitions can be determined. The PCM then
average to obtain a ratio. If the H02S transition time
ratio is not within range, DTC P1154 will be set
indicating that the oxygen sensor is not responding as
expected to changes in exhaust oxygen content.

.. No Fuel injector, MAF, TP, l::VAP, IAT, MAP, Fuel
" DTC P0155 is not set.

.. The PCM detects the H02S transition time ratio is
less than 0.6 or more than 3.3 ..
.. The conditions are present for a 2 minutes after
closed loop enable.

The PCM will store condit.ions which were present
w.hen the DTC set as Freeze Frame/Failure
Records data.

malfunction .
6-1084
Engine
Diagnostic Aids
Test Description

diagnostic table:

the connector gaskets ~hen diagnosing or replacing a

Systems.
" Damaged harness.
Systems.
l.f the DTC is determined to be intermittent, reviewing
when the DTC was. last set.

specified values.
5. If. the low .circuit is shorted to ground the H02S
signalcircuit is jumped to ground.
7. The specified value.is what is measured on a
ari Electrically Erasable Programmable Read Only

Step
Action
Values
Yes
No
Go to Step.2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to.
Diagnostic Aids
Go to Step 15
Go to Step 5

1

this table.
parameter.
Doe.s scan tool indicate H02S voltage varying outside the
specified values?
400-500 mV


Systems.
Engine
6-1085

Step
Action
ground.
specified value?
ground.
Values



11

12

10
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 12
Go to Step 15
13

in Wiring Systems.
14

Replace the PCM. Referto PCM Replacement!
Programming.
15

Does the OTC reset?

diagnosed?
16
Go to Step 6
4.5V
5V
No
400 mV
flileasure the voltage on the H02S low circuit (PCM side)

Yes
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 2
Go to Step 16
Go to
applicable OTC
System OK
5,.1086
Engine
DTC P1220 Throttle Position (TP) Sensor 2 Circuit
r - Power
~
Distribution
Schematics
in Wiring
Systems
810
ELEC
I
I
I
I
IHot At All Times j
i Hot In RUN Or START!

Engine Wiring
I Harness
THROT I Junction Block 1
CONT I
~1:use I
r -
: J9
TCSBATT
rvlinifuse
20 _
A __
_
JBL
1.---------J
-:- -
..., _ _
ORN
1540
PNK 339
---ll>-
ORN 1540
'Engine Wiring
[M;'"l
'Harness
1
Junction Block 1
1
J
LJil
Power
Distribution
Schematics
In Wiring
Systems
3
.-------------:~;.;;...;;;..;;..;;~.:.;;..:;,..;;..:;..;;.;;..;;;.;;..;-;..;;-:..::-:..::-:..::-:..::-:..::-.;:..-.;:..-- ;;;..;-~-:;::::-;------------i Throttle
7
Ignition
Positive
Voltage
TAC
.1
~=nsor'h
Si nal
TAC
BL;olu:~~~H:;ot::~
WHT
-~. g
:u~p
451
- -11>
. B_L_Kj~~_! 451
e
BU</ BLK/WHT 451
WHT 451
.r -
"'4
Battery
Positive
Voltage
TP
Sensor 2
(TAC)
G_r~u:~~.L1.~-8~-
Ground
Distribution
Schematics
In Wiring
Systems
TPS 2
BLK 476
A
D
..
;;--- - -;---- -,; ;
REF
Module
~
TP:l
TP
.
.
.
. lTP
TP
Sensor 1
Sensor 2 Motor Driver M_otor Driver Sensor 1 Sensor 1 Signal .
221-G~{1v::> 24I.
PPL 486
B
C
----
Actuator
Control
0 0
5
RTN
-.H~11
sl.tl;;;:~ .~~1Re_1DK~~. ~1"'.485 ~
YEL 581
E . H
;---
GRY/BLK 1687
F ____
~o~o~
;~-
Drive
Hi
RTN
--
Cf
TPS 1
><1rT-h-ro~ttl-e-
H Bridge
Motor Driver
Posilion
Sensor 1
Throttle
Actuator
Control
~
~
(
548593
Circuit Description
throttle body/TAC assembly. The sensor is actually
sensor assembly and the throttle .actuator
control (TAC) module. The TP sensor signal voltage
increases as the throttle opens, The signal circuit
for TP Sensor is pulled up to reference voltage.

The ignition switch in the crank .or run position.

The TP sensor 2 voltage is less than 0.25 volts or
more than 4.49 volts.

If equipped with traction control,the PCM will
turn OFF traction conVol and illuminate the
TRACTION OFF lamp.
The PCM will store conditions which were present .
Records data.
o

e The History DTC will clear after 40 consecutive
. warm-up cycles have occu.rred without a
malfunction.
Engine
Diagnostic Aids
)
6-1087

Systems.

ETC System the PCM receives a message across
captured DTC info.
Damaged harness.

component. Ensure that t.he gaskets are installed
correctly .. The gaskets prevent contaminate intrusion.

Inspect the wiring harness for damage. If t.he

Systems.

DTC P1220 Throttle Position (TP) Sensor 2 .Circuit

Step
Action

parameter.
2. Depress the throttle to wide open throttle (WOT) and
release.
value throughout throttle travel?
1V
Does scan tool indicate voltage below the specified value

throughout throttle travel?

parameter.
2. Disconnect the TAC throttle body.
value when the TAC is disconnected?

Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 11
Go to Step 21
Go to Step 4
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13
Go to Step 23
Go to Step 17
Important: If the code does not set this ignition, refer to

Diagnostic Aids.
2. With a scan tool, observe the TP sensors Disagree
parameter.
Does the scan tool indicate YES?
Values
1"
5V
.
3.9-4:6V
6-1088
Engine
DTC P1.220 Throttle Position (TP) Sensor 2 Circuit (cont'd)

Step
Action
1. Disconnect the TAC I throttle body.
parameter.
4. Connect a test lamp between the signal and return
circuits.
Values
Yes
No
(
ov

Go to Step 10
Go to Step 8
qo to Step 14
Go to Step 9
Go to Step 15
Go to Step 16
Go to Step 23
Go to Step 18
to Step 12
Go to Step 19
1. Remove the test lamp from the return circuit.

2. Connect the test lamp to a good ground.
Does the scan tool indicate voltage at tile specified value
ov
Did the test lamp illuminate when the it was connected

between the signal circuit and ground?
10

11
Inspect the ELEC THROT CONT and TCS BATT fuses.

Are the fuses OK?
3.9-4.6V

2. Probe the feed circuits using a test lamp with a test
Does the test lamp illuminate when probing the feed
circuits?
12
13
14
15
16
17
18
19

Test the return circuit for an open. Refer to Circuit Testing


Test the signal circuit for an open. Refer to Circuit Testing

Test the reference circuit for an open or short to ground.

Refer.to Circuit Testing and Wiring Repairs in Wiring
Systems.
Test the reference circuit for a short to voltage. Refer to

Repair the short to ground in the feed circuit. Refer to

Go
Go to
OTC P1515
Control Module
Throttle Actuator
Position
Performance or
OTC P1516
Throttle Actuator
Control (TAC)
Module Throttle
Actuator Position
Performance
Go to Step 20
Go to Step 27
Go to Step 26
Go to Step 27
Go to Step 25
Go to Step 27
Go to Step 26
Go to Step 27
Go to Step 25
Go to Step 27
Go to Step 25
Go to Step 27
Go to Step 26
Go to Step 27
Engine Controls -
Engine
a.al
6-1089
DTC P1220 Throttle Position (TP) Sensor 2 Circuit (cont'd)

Values
Step
Action
20

in Wiring Systems.
21
Test the return circuit for a short to ground. Refer to Circuit

22
Test for continuity between the reference circuit in the TAC

and ground. Refer to Circuit Testing in Wiring Systems.
Inspect for a poor connection at the TAC. Refer to Testing

23
. Repairs in Wiring Systems.
. :.
. Did you find and correct the condition?

24
.. Did you complete the replacement?
Inspect for a poor connection at the TAC module. Refer to

Did yqu find and correct the condition?

27

Does the DTC reset?
28
Does the. scan tool display any DTCs that you have not
diagnosed?
25
26
Yes
No
-
Go to Step 27
Go to Step 27
Go to Step 22
Go to Step 24
Go to Step 26
Go to Step 27
Go to Step 24
-
Go to Step 27
Go to Step 27
Go to Step 26
Go to Step 27
Go to Step 2
Go to Step 28
Go to
applicable DTC
System OK
6-1090
Engine
DTC P1221 Throttle Position (TP) Sensor 1- 2 Correlation
r -
I
I
I
I
Engine Wiring
I Harness
THROT I Junction Block 1
CONT I
:111use...I
Power . -<Cl
Distribution
Schematics
in Wiring
Systems
GlO
IHot At All Times I

ELEC
. _________
,. : Jg
- - - - - - - .,Engine Wiring
TCS BATI
I Harness
Mini!use
Junction Block 1
1
. _ -------J
I J8
20A
ORN
PNK 339
'---p,.
1540
ORN 1540
3
Power
Distribution
Schematics
In Wiring
Systems
.------------;;..;;;..;;..;;..;;-;.;.;-_-.;;;-.;;;-;.;.;-_----------------------.,..-------;::---::-:-:------------, Throttle
Ignition
Battery
Actuator
Positive
Positive
Voltage
Voltage
Control
(fAC)
T
TP=l
Module
s:nsor~
TP
TP
. _ j TP
TP
Sensor 1
TAC
TAC
s 1
Sensor 2
Sensor 2 Motor Driver Motor Dnver Sensor 1 Sensor 1 Signal
>
~&T:li ______~t:~rr:i ~ :.~ ~: 1.~:{1v:~ B::1.:::~i1~;.~- -:~:1:~i1~;:~: 1":~:7~~~1485 ~

BLKJ BLK/WHT 45i
WHT 451
- -
.ce;
Ground
Distribution
Schematics
In Wiring
Systems
C
----
TPS2
----sv
D
EH
- - - - - - - - - - - - "'" --Motor
Motor
sv
REF
RTN
Throttle
Position
Sensor 2
Drive
Drive
Hi
H Bridge
Motor Driver
F
GC1
- - - - - - -- - - - - -
5V
RTN
TPS1
Throttle
Position
Sensor 1
Throttle
Actuator
Control
~
(
548593
Circuit Description
throttle body!TAC assembly. The sensor is actually
sensor assembly and the throttle actuator
control (TAC) module. Each TP sensor signal voltage
increases as the throttle opens. The signal circuit
for TP sensors are pulled up to reference voltage.

.. The ignition switch is in the crank or run position.
., The ETC serial data is operational.

TRACTION OFF lamp.
e The PCM will store conditions which were present
Records data.

TP sensor 1 and TP sensor 2 disagree by more than
0.17 volts.

been run and passed .
malfunction.
Engine
Diagnostic Aids
) ETC System the PCM receives a message across
captured DTC info.
tension. Refer to Testing for Intermittent and. Poor
Systems.
6-1091
" Damaged harness.

change in the. display. may indicate the location of
Systems.
Test Description
diagnostic table.
18. When the TAC module detects a problem within
related DTC may set. This is due to the many
may correct more than one DTC. Keep this
in mind when reviewing captured DTC info.
DTC P1221 Throttle Position (TP) Sensor 1- 2 Correlation

Step.
Action
Did you perform the .Powertrain On-Board
Values
Yes
No
Go to Step 2
Go to A
Powerlrain On
Board
Diagnostic (OBD)
System Check
Important: If DTC P1518, 1120 or 1220 are also set, refer

to those DTCs first for further diagnosis.
2

2. With a scan tool, observe the TP Disagree
parameter.
.Go to Step 3
Does the scan tool indicate NO?
Go
to Step 4
1. With a scan tool, select Diagnostic Trouble

Code (DTCs).
2. Move the harness and related connectors while

observing the OTC information.
Does the harness movement cause this DTC to fail this

ignition?
Go to Step 10
Go to
Diagnostic Aids
Go to Step 5
Go to Step 11
Go to Step 6
Go to Step 12
Go to Step 13
Go to Step 7

2. Disconnect the TAC.

4. Measure the voltage on both the TP 1 and TP 2
3.9-4.6 V
reference circuits using a digital multimeter that is

5
Measure the voltage on both the TP 1 and TP 2 signal

circuits using a DMM that is connected to a good ground.
3.9-4.6 V
Measure for continuity between the TP 1 reference and

the TP 2 reference at the TAC using a DMM.
6-1092
Engine

DTC P1221 Throttle Position (TP) Sensor 1- 2 Correlation (cont'd)
Step
Action
Values
Measure for continuity between the TP 1 signal and the

TP. 2 signal at the TAC using a DMM.
Does the DMM .indicate continuity?

2. Leave the TAC disconnected.
3. Measure for continuity between the TP 1 reference
and the TP 2 reference at the TAC module harness
connector using a DMM.
Measure for continuity between the TP 1 signal and the

TP 2 signal at the TAC module harness connector using
a DMM.
10
Repair the harness/connections as necessary. Refer to

Wiring Repairs and Connector Repairs in Wiring Systems.
11
Repair the short to voltage in the reference circuit. Refer to

12
Repair the short to voltage in the signal circuit Refer to

i3


Pedal Replacement (TAC Module anc/ Bracket Assembly).
Did you compleite the replacement?
Repair the TP 1 and TP 2 reference circuits shorted

together. Refer to Wiring Repairs in Wiring Systems.
Repair the TP 1 and TP 2 signal circuits shorted together.


conditions.
Does the OTC reset?
Does the scan tool indicate any DTCs set that you have
not diagnosed?
14
15
i6
i7
18
Yes
No
(
Go to Step 13
Go to Step 8
Go to Step 15
Go to Step 9
Go to Step 16
Go to Step 14
Go to Step 17
Go to Step 17
Go to Step 14
Go to Step 17
Go to Step 14
Go to Step 17
Go to Step 17
Go to Step 17
Go to Step 17
Go to Step 2
Go to Step 18
Go to
applicable OTC
System OK
Engine
6-1093
'!
Circuit Description
Diagnostic Aids

assembly. There are three individual accelerator pedal
position sensors within one housing. Three separate
signal, ground and reference circuits are used
which are contained within the throttle actuator
control (TAC) module. The APP sensor signal voltage
increases as the Accelerator pedal is depressed.
The signal circuits pull to ground within the TAC
module.


OTCs P0606, P1517, P1518, P1276, P1281 are
not set.

APP sensor 1 disagrees with APP sensor 2 by more
than 10.5 percent or the APP 1 signal is shorted to the
APP 2 signal.

This. information will not be stored as Freeze
Frame data.

malfunction.

the ETC System the PCM receives a message across
OTC may set. This is due to the many redundant tests
than one OTC. Keep this in mind when reviewing
captured OTC info.
Test Description
diagnostic table.
may correct more than one OTC. Keep this
in mind when reviewing captured OTC info.
DTC P1271 Accelerator Pedal Position (APP) Sensor 1-2 Correlation

Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Diagnose these
DTCs first
Go to Step 3

-


conditions.
Does the OTC reset?
not diagnosed?
Go to Step 4
Go to Step 2
Go to Step 5
Go to
applicable DTC
System OK
6.;1094
Engine Controls .,. 3.8l
Engine
DTC P1272 Accelerator Pedal Position (APP) Sensor 2..3 Correlation

Circuit Description
Diagnostic Aids

module.


DTCs P0606, P1517, P1518, P1281, P1286 are
not set.

10.5 percent or APP sensor 1 signal is shorted to APP
sensor 3 signal.

Frame data:

malfunction.

captured DTC info.
Test Description
diagnostic table.
across .serial data and more than one ETC System
in mind when reviewing captured DTC info,

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Diagnose these
DTCs first
Go to Step 3


Go to Step 4

4

conditions.
Does the DTC reset?
not diagnosed?
Go to Step 2
Go to Step 5
Go to
applicable DTC
System OK
Engine
6-1095
DTC Pi 273 Accelerator Pedal Position {APP) Sensor 1-3 Correlation

Circuit Description
Diagnostic Aids

mounted on the. accelerator pedal!TAC module
contrqi (TAC) modul.e. The APP sensor signal voltage
increa.ses as the. Accelerator pedal is depressed.
module.

surfaces before seNicing a component. Inspect

DTCs P0606, P1517, P1518, P1276, P1286 are
not set.

than 10.5 percent or the APP sensor 2 signal and APP
sensor 3 signal are shorfed together.

Frame data.

malfunction.

than. one OTC. Keep this in mind when reviewing
captured OTC info.
Test Description
diagnostic table.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Diagnose these
DTCs first
Go to Step 3

1


conditions.
Does the DTC reset?
not diagnosed?
Go to Step 4
Go to Step 2
Go to Step 5
Go to
applicable DTC
System OK
6-1096
Engine
DTC P1275 Accelerator Pedal Position (APP) Sensor 1 Circuit

Circuit Description
Diagnostic Aids

module.

When the TAC. module detects a problem within
than one OTC. Keep this.in mind when reviewing
captured OTC info.

" OTCs P0606, P1517, P1518 are set.

APP sensor 1 voltage is less than 0.68 volts or more
than 4.5 volts.

Frame data.

malfunction.
Test Description
diagnostic table.
(.
.
6-1097
DTC P1275 Accelerator Pedal Position (APP) Sensor t Circuit

Step
Action
. Diagnostic (OBD) System Check?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 5
Go to
Diagnostic Aids
Important: If any other DTCs are aJso set, refer to the
appropriate OTC for f_urther diagnosis.

1. Turn ON the ignition, with your foot OFF the
accelerator pedal and the engine OFF.
2. With the scan tool, observe the APP sensor voltage
parameter for this APP.
Does the scan tool. indicate voltage within the
specified range?
Fully depress the accelerator pedal.
Does the scan tool indicate the voltage within the
specified range?
0.7-1.1V
2.7-4.2 V
1. With the scan tool, select Diagnostic Trouble

4
Codes (DTCs).
2. Depress the accel.erator pedal to wide open .
throttle (WOT) and then return it to closed throttle.
Did this OTC fail this ignition?

2 .. Operate the vehicle within the Fail Records
conditions.
Does the OTC reset?
not diagnosed?
Go to Step 6
.Go to Step 2
Go to Step 7
Go to
applicable OTC
System OK
6-1098
Engine Controls,. 3.8L
Engine
DTC P1276 Accelerator Pedal Position (APP) Sensor 1 Performance

Circuit Description
mounted on the accelerator pedal!fAC module
module.

" The ignition switch is in the crank or run position.

than 10.5 percent and APP sensor 1 disagrees
with APP sensor 3 by more than 10.5 percent.

Frame data.
Diagnostic Aids

component. Ensure that.the gaskets are installe.d
captured OTC info.
Test Description
diagnostic table.

malfunction.
Engine
6-1099

Step
Action
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 4
0.5-1.3 V


conditions.
Does the DTC reset?
not diagnosed?
Yes
1. With a scan tool, observe the APP disagree

parameters.
2. Slowly depress the accelerator pedal to WOT
. stopping briefly at approximately 25 percent,
50 percent, and 75 percent. .Then slowly return to a
closed throttle position stopping briefly at
approximately 75 percent, 50 percent, and
25 percent.
Does the scan tool indicate NO for all APP disagree
parameters?
Important: If any other DTCs are set, refer to the

appropriate DTC for .further diagnosis.
2. With a scan tool, observe the APP sensor voltage
specified range?
Values
Go to Step 5
Go to Step 2
Go to Step 6
Go to
applicable DTC
System OK
6-1100
Engine

Circuit Description
Diagnostic Aids

mounted on the accelerator pedal!fAC module
module.

When the TAC module detects a probiem within
than. one DTC. Keep this in mind when reviewing
captured DTC info.
Condjtions for Running the DTC

DTCs P0601, P0602, P0606, P1517, P1518 are
not set.

The APP sensor 2 voltage is this less than 0.68 volts
or more 4.5 volts

indicator lamp (MIL}.
The PCM will store condi,tions which were present
Frame data.
Con,ditions for Clearing the Mll/DTC
Test Description
diagnostic table.
A history DTC will cl.ear after 40 consecutive

malfunction.
Engine
6;.1101

Step
Action

1
Values
Yes
No
Go to Step 2
Go to A
Powertrain Oh
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 5
Go to
Diagnostic Aids
Important: If any other DTCs are also set, refer to the

appropriate OTC for further diagnosis.
specified range?
'
0.7-1.1V
3.

specified range?
2.7-4.2 V

Codes (DTCs).
4
2. Depress the accelerator pedal to wide open

Did this OTC fail this ignition?

1:. Use the scan tool in order to clear the DTCs.

2. Operate the. vehicle within the Fail Records
conditions.
Does the OTC reset?
not diagnosed?
Go to Step 6
Go to Step2
Go to Step 7
Go to
applicable OTC
System OK
6-1102
Engine

Circuit Description
Diagnostic Aids
The accel.erator pedal position (APP) sensors are

module.

captured OTC info.

OTCs PCJ606, P1517, P1518 are not set.

than 10.5 percent and APP sensor 2 disagrees

Frame data.
Test Description
diagnostic table.
may correct more than one OTC'. Keep this

malfunction.
Engine
6-1103

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 4

-

appropriate OTC for turther diagnosis.
2
2. With a scan tool; observe the APP sensor voltage

specified range?
0.5-1.3 V

parameters.

stopping briefly at approximately 25 percent,
50 percent, and 75 percent. Then slowly return to a
closed throttle position stopping briefly at
25 percent.

parameters?
Replace the TAC. module. Refer to Accelerator Controls

Pedal Replacement (TAC Module an.d Bracket Assembly).

conditions.
Does the OTC reset?
not diagnosed?
Go to Step 5
Go to Step 2
Go to Step 6
Go to
applicable OTC
System OK
6-1104
Engine

Circuit Description
Diagnostic Aids

assembly ..There are three individual accelerator pedal
module.

run .continuously on this system. Locating and
captured DTC info.

DTCs P0606, P1517, P1518 are not set.

APP sensor 3 voltage is less than 0.68 volts or more
than 4.5 volts.

Frame data.

malfunction.
Test Description
diagnostic table.
the. ETC Systein the PCM receives a message
Engine
Engine.Controls - 3.8l 6-1105

Step
Action
Values
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 5
Go to
Diagnostic Aids
Important: If any other DTCs are also set, refer to the

appropriate DTC for further diagnosis.
specified range?
Q;?-1.1 V

specified range?
2.7-4.2 V

Codes (DTCs).
2. Depress the accelerator pedal to wide open
Did this DTC fail this ignition?


conditions.
Does the DTC reset?
not diagnosed?
Yes
Goto Step 6
Go to Step 2
Go to Step?
Go to
applicable DTC
System OK
6.-1106
Engine

Circuit Description
Diagnostic Aids

module.
Important: Remove any debris from the connec1or

cornponent. Ensure that the gaskets are installed
OTC may set. This is due to the many redundan! tests
repairing one individual .problem may correct more
captured OTC info.
when the OTC was. last set.

" OTCs P0606, P1517, P15i8 are not set.
" The ignition switch is in the crank or run position.

than i 0.5 percent and APP sensor 3 disagrees

., The PCM will not illuminate the malfunction
when the OTC set as Failure Records data oniy.
Frame data.
Test Description
The nurnbers below refer to the step numbers on the
diagnostic table.
6. When the TAC module detects. a problem within
across serial dc:lta and.more than one ETC System

malfunction.
Engine
Step

Action
Values
Yes

appropriate OTC for further diagnosis.
2. With a scan tool, observe the APP sensor voltage
specified range?

parameters.
stopping briefly at approximately 25 percent,
50 percent, and 75 percent. Then slowly return to a
closed .throttle position stopping briefly at
. 25 percent.
parameters?
Pedal Replacement (TAC Module andBracket Assembly).
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step4
0.5-1.3 V
Go to Step 5
6-1107

conditions.
Does the DTC reset?
not diagnosed?
Go to Step 2
Go to Step 6
Go to
applicable DTC
System OK
6-1108
Engine
DTC P1336 Crankshaft Position (CKP) System Variation Not learned

Circuit Description
The crankshaft position system variation learning

feature is used to calculate reference period errors
caused by slight tolerance variations in the crankshaft,
the crankshaft balancer interrupter rings, and the
crankshaft position sensor hall effect switches. The
calculated error allows the PCM to accurately
compensate for reference period variations. This
enhances the ability of the PCM to detect misfire
events over a wider range of engine speed and load.
The crankshaft position system variation values
are. stored in the PCM non-volatile memory after a
learn procedure has been performed. DTC P1336 set
indicates that the crankshaft position system
variation values have not been stored in the PCM and
the crankshaft position system variation learn
procedure must be performed. The learn procedure is
required after the following seNice procedures
have been performed, regardless of whether or not
OTC P1336 is set:
PCM replacement
Engine replacement
Crankshaft replacement
e Crankshaft balancer replacement
" Crankshaft position sensor replacement
Any engine repairs which disturbs
crankshaft/harmonic balancer to crankshaft
position sensor relationship


malfunction.
The OTC can be cleared by using a .scan tool.
Diagnostic Aids
The crankshaft position system variationcompensating
values are stored in the PCM non-volatile memory
after a learn procedure has been performed. If
the actual crankshaft position variation is not within
the crankshaft position system variation compensating
values stored.in the PCM, DTCP0300 may set,
refer to Diagnostic Aids for OTC P0300.
If the crankshaft position system variation learn
procedure. cannot be performed successfully, check
for the following conditions and correct as necessary:
The engine ,coolant temperature less than
70C (158F).
Allow the engine to warm to more than
70C (158F).
Powertrain DTCs set
The scan tool crankshaft position system variation
learn function will be disabled if any powertrain
DTCs other than OTC P1336 are sto.red.
Camshaft position signal problem detected

Crankshaft position system variation values are not
stored in the PCM memory.

Records data.
Refer to OTC P0341 Camshaft Position (CMP)

Sensor Performance.
.. 3X reference signal problem detected
Refer to OTC P1374 Crankshaft Position (CKP)
High to Low Resolution Frequency Correlation
18X reference signal problem detected
Refer to OTC P0336 Crankshaft Position (CKP)
Sensor Circuit.
DTC P1336 Crankshaft Position (CKP) System Variation Not Learned

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check

Perform the crankshaft position system variation learn

procedure. Refer to CKP System Variation Learn
Procedure.
Did you complete the procedure?
System OK
Engine
6-1109
DTC P1351 Ignition Coil Control Circuit High Voltage

Ignition
Control (ICM)
Module
Ignition
Control (IC)
Ji,
M,
WHT 423
54
'" -
I
I
-1
CONN 10
C1
-;;;t;;; - - - - ,
9
Control (IC)
c1 = BLU
G2=GLEAR
Powertrain
I Control
I Module Ji,
I (PCM) ~
L------------.1
548594
Circuit Description
The ignition control module (ICM) sends signals that
the PCM requires for fuel control and spark advance
calculations. At the start of engine crank, the ICM
controls spark advance (Bypass mode). When
the second 3X reference pulse is recognized by the
PCM, the PCM applies 5 volts to the Bypass
circuit. The 5 volts on the Bypass circuit commands
the ICM to switch spark advance to PCM control
(IC mode). At this time, The ICM will remove
the ground it has applied to the IC circuit. If the PCM
.detects a open in the IC circuit, DTC P135i will
set. The engine may be started but will run on Bypass
mode timing.


The PCM detects an open in the IC circuit.

lamp {MIL) during the second consecutive trip in
Records data.

The PCM will. turn the MIL OFF during the
third consecutive trip in which tht3 diagnostic has
.. The History. DTC will clear after 40 consecutive
malfunction.
Diagnostic .Aids
. Inspect for the following:
the conriector gaskets when diagnosing or replacing a
Systems.
Damaged harness.
Systems.
6-1110
Engine
DTC P1351 Ignition Coil Control .Circuit High Voltage

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 8
Go to Step 5
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 6


2
3. Connect a DMM between the IC and Reference Low

Circuits.

Disconnect the ignition control module (ICM).
Test for an open in the IC circuit. Refer to Wiring
Inspect for faulty connections at the PCM. Refer to Testing

Inspect for faulty connections at the ICM. Refer to Testing


Replacement.

Replace the PCM.
1.
2.
3.
4.
20mV-40mV

conditions.
Does the DTC reset?
Go to Step 8
Go to Step 8
Go to Step 2
System OK
Engine
Engine Controls
3.8L
6.-1111
DTC P1352 ignition Bypass Circuit High Voltage
Ignition
Control (ICM)
Module
Bypass
Control
I I
L
~
N
TAN/BLK 424
53 ""C1
r - - - - - - By~s;- - - - ,
I
I
L -
CONN ID
c1 = BLU
C2 = CLEAR
-
Powertrain
I Control
I Module ).
I (PCM) - ~
Control
.
-
- -
..I
548596
Circuit Description
Diagnostic Aids

controls spark advance (Bypass mode.) When
circuit, commanding the ICM to switch spark advance
to PCM control (IC mode). If the PCM detects an
open in the Bypass circuit, OTC P1352 will set. The
engine will start and may run in Bypass mode timing.


The PCM detects an open in the Bypass circuit.
" The conditions is present for 300 3X reference

Records data.

malfunction.

O

Systems.
Damaged harness.
Systems.
6-1112
Engine

OTC P1352 Ignition Bypass Circuit High Voltage
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 8
Go to Step 5
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 6


3. Connect a DMM between the IC and Reference Low
Circuits.
5. Probe the BYPASS circuit using a test lamp that is
connected to B+.
Test for an open in the BYPASS circuit. Refer to Circuit


Inspect for faulty connections at the ICM. Refer to Testing


Replacement.

Replace the PCM.

conditions.
Does tile DTC reset?
150mV-250mV
Go to Step 8
(
-
Go to Step 8
Go to Step 2
System OK
Engine
6-1113
DTC P1361 Ignition Control (IC) Circuit Low Voltage
Ignition
Control (ICM)
Module
,Ii>
Bypass
Ignition
..._~_c_an_1r_a1~_co_n_1ro_1(_1c_)~__, ~
A
WHT 423
53
r -
I
I
I
- - - CONN ID
C1=BLU
C2=CLEAR
- Bypa7s Control
54
C1
lgnitio; - Control (IC)
Powertrain
I Control
I Module );
( (PCM) ~
L-----------------~
548599
Circuit Description
controls spark advance (Bypass mode). When
circuit. The 5 volts on the Bypass circuit commands
the I.CM to switch spark advance to PCM control
(IC mode). At this time, The ICM will remove
the ground it has applied to the IC circuit. When the
IC pulses are not grounded, the PCM can use
the IC pulses to control spark advance. A short in the
IC circuit or an open or short to ground in the
Bypass circuit will cause the PCM to monitor no IC
pulses after the PCM has switched the Bypass circuit
ON. The PCM will set DTC P1361 under either of
these conditions. The engine may be .started but will
run on Bypass mode timing.

Engine is running.

" The PCM does not monitor IC pulses while IC
mode spark advance is commanded.
" The conditions is present for 300 3X reference

O


Records data.

been run and pas$ed.
" The History DTC will clear after 40 cons.ecutive
malfunction.
Diagnostic. Aids
Inspect for the follovying:
Systems.
O Damaged harness.
Systems.
6-1114
Engine
DTC P1361 Ignition Control (IC} Circuit low Voltage

Action
Step

1
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 13
Go to Step 5
Go to Step 12

3
3. Tum ON the ignition.

4. Probe the IC circuit using a test lamp that is

4

5
Repair the short to voltage in the IC circuit. Refer to Wiring

Go to Step 14

6

connected to B+
Go toStep 7
Repair the short to ground in the IC circuit. Refer to Wiring

Go to Step 8
Go to Step 14

2. Leave the PCM and the ICM disconnected.
8

connected to B+.
Repair the short to ground in the BYPASS circuit. Refer to

Go to Step 9
10
Go to Step 14

Test for a short between the IC and the BYPASS circuits.
Systems.
Go to Step 10
Go to Step 14
Go to Step 11
Go to Step 13
Go to Step 12

3. Reconnect the ICM.
11

5. With a DMM connected between the IC and the
Reference Low circuits, probe the BYPASS circuit
Does the voltage toggle between the specified ranges?
20mV-40mV
150mV-250mV
Engine
6-1115
DTC P1361 Ignition Control (IC) Circuit low Voltage (cont'd)

Step
12
Action
Replacement.
Values
Yes
No
-
Go to Step 14
13
14
Replace the PCM.


conditions.
Does the OTC reset?
Go to Step 14
Go to Step 2
System OK
6-1116
Engine
DTC P1362 Ignition Bypass Circuit Low Voltage
I I
L
Ignition
Control (ICM)
Module
Control
Ignition
Control (IC)
8 ;
A'
Bypass
>
[S1
N
WHT 423
53 ,_ - - - -54
C1
- r -
CONN ID
- Bypa;s - lgriliio; - - Control
C1=BLU
C2=CLEAR
Control (IC)
Powertrain
I Control
I Module
I (PCM) ~
>
L-----------------~
548599
Circuit Description
controls spark advance (Bypass mode.) When
circuit, commanding the ICM to switch spark advance
to PCM control (IC mode). If the PCM detects a
short to voltage in the Bypass circuit, OTC P1362 will
set. A short to ground in the IC circuit or Bypass
circuit will cause both OTC P1361 and DTC P1362 to
set. The engine will start and may run in Bypass
mode timing.


The PCM detects a short to voltage in the Bypass
circuit.

Records data.

malfunction.
Diagnostic Aids
Systems.
Damaged harness.
Systems.
Engine
6-1117
DTC P1362 Ignition Bypass Circuit Low Voltage

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 13
Go to Step 5
Go to Step 12

-
Is DTC P1361 set also?

Disconnect the PCM.
Probe the BYPASS circuit using a test lamp that is

connected to a ground.
Repair the short to voltage in the BYPASS circuit. Refer to


connected to B+.
Repair the short to ground in the IC circuit. Refer to Wiring

Repairs in Wiring System.

connected to B+.
Repair the short to ground in the BYPASS circuit. Refer to

10

4. Test for a short between the IC and BYPASS circuits.
11

Reconnect the ICM.
With a DMM connected between the IC and
Reference Low circuits, probe the BYPASS circuit
Does the voltage toggle between the specified ranges?
1.
2.
3.
4.
1.
2.
3.
4.
5.
Go to Step 14
Go to Step 7
Go to Step 8
Go to Step 14
Go to Step 9
Go to Step 10
Go to Step 14
Go to Step 14
Go to Step 11
Go to Step 13
Go to Step 12
20mV-40mV
150mV-250mV
6-1118
Engine
DTC P1362 Ignition Bypass Circuit Low Voltage (cont'd)

Step
Action
Values
12

Replacement.
13

Replace the PCM.

conditions.
Does the OTC reset?
14
Yes
No
Go to Step 14
Go to Step 14
Go to Step 2
System OK
Engine
6-1119
DTC P1374 Crankshaft Position (CKP) High to low Resolution Frequency Correlation
~ -;;
I
;:;e;- - - - - - - - j E.ngine Wiring
Distribution
ENG CTRL
1 . ~c~~r'::i~tics
Systems
L------
Harn~ss .
1 Junction Block 2
I
Mini Fuse
15
A
----.J
PNK 239
-----,
PNK 239
Power
Distribution
P.N Kt239
~c~~~.ln~tics
Systems
_____
..
.J
PNK 239
PA
Ignition
Ignition
Positive
Voltage
5V
Wx
Reference
Signal
Camshaft /
Position
....f
Signal
J,
F}630
BLK
cf
LT
BLU/BLK
647
-----------
Control (ICM)
3x
Reference
Signal
ol
Module>
Ground
PPL/WHT 430
r----1-----------------------,
I
I
I
CMP
sensor
Signal
-----------
18x
Reference
Signal
3x
Reference
Signal
CONN ID
Ci = BLU
C2=CLEAR
I
I
I
Powertrain
Control
M. d I
O U
1~C~
L-----------------------------J
>~
548570
Circuit Description
The 3X reference signal is produced by the ignition
control module. The ICM calculates the 3X reference
signal by dividing the crankshaft position (CKP)
sensor 18X pulses by 3 when the engine is running
and CKP sync pulses are also being received.
The PCM uses the 3X reference signal to calculate
engine rpm and crankshaft position at engine speeds
more than 1200 rpm. The PCM also uses the
pulses on this circuit to initiate injector pulses. The
PCM constantly monitors the number of pulses on the
3X reference circuit and compares the number of
3X reference pulses to the number of 18 X reference
pulses and CAM signal pulses being received. If
the PCM receives an incorrect number of pulses on
the 3X reference circuit, DTC P1374 will set and
the PCM will use the 18X reference signal circuit for
fuel and ignition control. The engine will continue
to start and run using the 18X reference and camshaft
position PCM input signals only.


'" The ratio of 18X reference pulses to CAM signal
pulses received by the PCM equals 36:1.
.. The ratio of 18X reference pulses to 3X reference
pulses received by the PCM does not equal 6:1.
The condition is present for more than 1O seconds.

Records data.

The PCM wiU turn the MIL OFF during the
malfunction.
6-1120
Engine
Diagnostic Aids
Damaged harness.

Malfunctioning ignition coil - Remove the ignition
coils and inspect the ignition control module and
coils for cracks, carbon tracking, or other signs
that indicate that the coil secondary circuit
is arcing to the ICM or ICM wiring harness. Refer
to TBD.
.. Secondary ignition wires arcing to wiring harness
- Inspect the secondary ignition wires for
carbon tracking or other signs of damage.
Systems.
Inspect the wiring harness for damage. If the'

Systems .

If the OTC is determined to be intermittent, revie,ving
Test Description
diagnostic table.
DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation
Action
Step
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Engine
Cranks but Does
Not Run
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5

1

Does the engine start and continue to run?


3. Install a J 34730-2A injector test lamp at any injector
harness connector.
5. Connect a test lamp to B+.
6. Repeatedly touch the test lamp to the 3X reference
circuit at the ICM connector while observing the
injector test lamp.
Does the injector test lamp blink?
1.
2.
3.
4.
Turn OFF the ignition:

Disconnect the PCM.
Test for the following cdnditions:
3X reference circuit open
3X reference circuit shorted to ground
3X reference circuit shorted to voltage
5. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
(
Go to Step 11
Go to Step 6
Engine
6-1121
DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation (cont'd)
Step
)
6
Action
Inspect the 3X reference circuit for a faulty connection at

Connections and Connector Repairs ih Wiring Systems.
Values
Inspect for poor conne.ctions at the ICM. Refer to Testing

Go to Step 11
Go to Step 7
Go to Step 11
Go to Step 10
Go to Step 11
Go to Step 9
Did youfind and correct the condition?

Replace the ICM. Refer to Ignition Coil(s) Replacement.
No

components.
2. Ignition coil arcing to the wiring harness or to the ICM.
3. Ignition coils for cracks, carbon tracking, or other
signs of damage. Refer to Ignition Coil(s)
Replacement.
4. Secondary ignition wires arcing to the wiring harness'.
(3.8 L Right Bank) or Spark Plug Wire Harness
Replacement (3.8 L Left Bank) in Er:igine Electrical.
Yes
Go to Step 11
10
11


conditions.
Does the DTC reset?
Go to Step 11
Go to Step 2
System OK
6-1122
Engine.
DTC P1380 Misfire Detected - Rough Road Data Not Available

Refer to ABS Schematics.
Circuit Description
The PCM receives rough road information from the
EBCM I EBTCM on the serial data circuit (CKT 800).
The PCM uses the rough road information to
enhance the misfire diagnostic by distinguishing
crankshaft speed variations caused by driving on rough
road surfaces from variations caused by true misfires.
The EBCM I EBTCM transmits rough road information
based on inputs from the wheel speed sensors. If
the EBCM I EBTCM detects a condition which will not
allow it to properly identify rough road situations
while a misfire condition is being detected by the PCM,
DTC P1380 will be set.
CondiUons for Running the DTC

.,
..
..
..
Engine load is less than 87 percent.

Engine speed is less than 5000 RPM.
A misfire DTC is occurring and requesting the MIL
to be illuminated.


Frame data.

A history DTC will clear after 40. consecutive
malfunction.
Diagnostic Aids
DTC P1380 set indicates that the ABS I TCS system
has detected a malfunction which will not allow
the EBCM I EBTCM to transmit correct rough road
data to the PCM. Refer to Self-Diagnostics in
ABS Brakes should be used to diagnose this condition.

The PCM has detected a EBCM I EBTCM rough road
sensing error.
DTC P1380 Misfire Detected - Rough Road Data.Not Available

Step
Action
Values
Yes
No
Go to
Self-Diagnostics
ABS/TCS
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

1
Engine
6-1123
DTC P1381 Misfire Detected - No Communication with Brake Control Module

Refer to ABS Schematics.
Diagnostic Aids
Circuit Description
The PCM receives rough road information from the

EBCM I EBTCM on the Class 2 serial data circuit. The
PCM uses the rough road information to enhance
the misfire diagnostic by distinguishing crankshaft
speed variations caused by driving on rough
road surfaces from variations caused by true misfires.
The EBCM I EBTCM transmits rough road info"rmation
based on inputs from the wheel speed sensors. If
a loss of communication occurs which causes the PCM
not to receive rough road information while OTC P0300
is requesting the MIL, OTC P1381 will set.

faulty terminal to wire connection, Use a
Systems.
" Damaged harness.
harness appears to be OK,. observe the display
Systems.
clean and secure connections .

"

Engine speed is less than 5000 RPM.
A misfire OTC is occurring and requesting the MIL
to be illuminated.

The PCM is detecting a loss of communication with
the EBCM I EBTCM for at least 10 seconds.
.. The PCM will not illuminate the malfunction

Frame data.

malfunction.
Test Description
diagnostic table.
2. Ensures that the EBCM/EBTCM is capable of
transmitting serial data on the UART serial
data circuit.
4. Tests the UART serial data circuit at the
EBCM/EBTCM for correct voltage.
6-1124
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
System OK
Go to
Diagnostic /\ids
Go to Step 5
Go to Step 6
Go to Step7
Go to Step 6
Go to Step 7
Go to
Se/f~Diagnostics
in ABS/TCS
System OK
Go to Step 4


2. With a scan tool, attempt to display ABS data.
Can ABS data be displayed?
Test the serial data circuit for an open or a faulty

connection. Refer to Circuit Testing and Wiring Repairs or

2. Disconnect the EBTCM.
4. Measure the voltage on the serial data circuit using a
Does the voltage vary within the specified range?
Inspect for a poor connection at the EBTCM. Testing for

in Wiring Systems.
Test for an open in the serial data circuit to the EBTCM.

Systems.

2. With a scan tool, attempt to display ABS data.
Can ABS data be displayed?
1-5V
Engine
6-1125
DTC P1404 Exhaust Gas Recirculation (EGR) Closed Position Performance

MAPSensor ... -
IL 0 c
GAY 598
D
GAY 598
BLK 552
LT BLU 697
BAN 1456
GAY 435
28 C2 31 C1
33 C2
4 C2
32 C1
,. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Po ert an
I
I
:
EGR
Valve
___ ___r,_r,_
Control ----'f
_.__
EGA
Control
Ground
EGA
Pintle
Position
Signal
-::-
I
I
EGA
Pintle
Position
Ground
5 Volt
Reference A
I
I
PCM
Control
Module
: {PCM)
C1=BLU
C2=CLEAA
I
I ~
>
L------------------------------------J
480730
Circuit Description
commands from the PCM. When the ignition is turned
ON, the PCM learns the EGR closed valve pintle
position. The PCM compares the learned EGR closed
valve pintle position to the actual EGR position
when the EGR valve is commanded closed. It the
actual EGR position indicates that the EGR valve is
still open when the PCM is commanding the EGR
valve closed, DTC P1404 will set.

System voltage is more than or equal to 1O volts.

EGR Feedback is 0.2 volt more than the EGR
Closed Valve Pintle Position when the Desired

EGR Position is commanded to O percent
The above condition is present tor more than

20 seconds.

diagnostic test has been run and tailed.
Records data.

The PCM vvill turn the MIL OFF during the
malfunction.
6-1126
Engine
Diagnostic Aids
Test Description

diagnostic table:

Inspect the harness connectors for. backed out
Systems.
Damaged harness.
and wiring harnesses related to the sensor. A.
Systems.

(.

4. If DTC P1404 will only set under certain
refer to DTC P1404 Diagnostic Aids. If an
intermittent wiring problem is not present, check
for a poor connection at the PCM or the EGR
valve. If the connections are OK and DTC P1404
continues to set, replace the EGR valve.
14. This vehicle is equipped with a PCM which uti.lizes


Step
. Action
Values
Did you perform the Powertrain .on-Board

Diagnostic (OBD)Systemctieck?
1
.
,.
Go.to Step 2
Important: If OTC P0403 is set, diagnose it first.

With a scan tool and the engine idling, observe actual
EGR position parameter.
Does the scq.n tool indicate actual EGR position at the
specified value?
0%
1. Turn ON the ignition ..

.
2. With. a scan tool, increment the. EGA.valve through all
positions while comparing Desired EGR .Position to
actual EGR position parameters.
Does the Desired EGR Position remain close to actual
EGR position at all commanded positions?
Does the scan tool. indicate OTC P1404 failed this ignition?
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Yes
1. Disconnect the EGR valve.

2. With a scan tool, observe actual EGR position
parameter.
Does the scan tool indicate actual EGR position at the
specified value?
0%
Probe the EGR pintle position sensor ground circuit using

a test lamp that is connected to B+.
Go'to Step 3
Go to Step 5
Go to Step 4
..
.
Go to Step 6
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 8
Engine
DTC P1404 Exhaust Gas Recirculation (EGR) Closed Position Performance (cont'd)
Action
Step
Values
Yes
No
Go to Step 12
Go to Step 11
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 10

4. Measure the voltage on the EGR valve pintle position
OV
signal circuit using a DMM that is connected to a

good ground.
Tes.t the .EGR pintle position sensor ground circuit for an

open. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Inspect for poor connections at the EGR valve. Refer to


Replacement.
10
Notice: If the EGR valve shows signs of excessive heat,

inspect the exhaust system for blockage-possibly a
plugged converter-,-using the procedure .found on the
Restricted Exhaust System Check. If the exhaust system
is restricted, repair the cause. Inspect for an open injector
caused by one or more of the following conditions:
Stuck
Grounded driver circuit
Possible faulty control module
If one of the above conditions is found, inspect the oil for
possible fuel contamination.
Go to Step 15

11
Repair short to voltage in the EGR pintle position signal

Go to Step 15

The EGR valve pintle position signal circuit for a
short to the 5 volt reference circuit.
12
The EGR valve pintle position signal circuit for a

short to the EGR valve control circuit.

13
Inspect the circuits related to the EGR valve for poor

connections at the PCM. Refer to Testing for Intermittent
Systems.
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 14

14

Go to Step 15

15

Does the OTC reset?
Go to Step 2
System OK
6-1128
Engine Controls;. 3.8L
Engine
DTC P1441 Evaporative Emission (EVAP) System Flow During NonmPurge

Refer to EVAP SystemOverview.
System Description
THE powertrain control module (PCIVI) supplies a
ground to energize the EVAP purge valve (purge on).
The EVAP purge valve control is pulse width
modulated (PWM) or turned on and off several times a
second. The duty cycle (pulse width) is determined
by engine operating conditions including load, throttle
position, coolant temperature and ambient
temperature. The duty cycle is calculated by the PCM
and the output is commanded when the appropriate
conditions have been met. The system checks
for conditions that cause the EV AP system to purge
continuously by commanding the EV AP vent valve ON
(Closed) and the EVAP canister purge valve OFF
(Closed). If vacuum level in the fuel tank increases
during the test, a continuous purge flow condition
is indicated. This can be caused by any of the
EV AP canister purge valve leaking internally
EVAP purge and engine vacuum lines switched at
the EV AP canister purge valve
EVAP canister purge valve control circuit grounded
If any of these conditions are present, OTC P1441
will set.

No ECT, IAT, MAP, TP, MAF sensor, VSS,
H02S, Misfire, Fueltrim, Injector circuit,
EGR pintle position DTCs set.
All conditions for OTC P0440, P0442 and P0446
diagnostic tests have be~n met and passed.
Startup engine coolant temperature is not more
than 4C and 30C (40 F and 86F).
Startup engine is not more than 8C (14F).
Startup Intake air temperature not more than 2c
Startup intake air temperature riot more than
2C (4F).
85 percent.

A continuous open purge flow condition is detected
during the diagnostic test (fuel tank pressure
decreases to less than -11 inch H20.

" The PCM will illuminate the MIL during .the
command the EBTCM via the serialdata circuit to
TRACTION OFF lamp.
.
" The PCM will store condition.s which were present
when the OTC setas Freeze Frame/Failure
Records data.
Important: Although this diagnostic is considered

type A, it acts like a type B diagnostic. Whenever the
EVAP diagnostics report that a system has passed,
or if the battery has been disconnected, the diagnostic
must fail during 2 consecutive cold sta.rt trips.before
setting a OTC. The initial failure is not reported to the
diagnostic executive or displayed on a scan tool. A
passing system always reports to the diagnostic

..
malfunction.
The OTC can be cleared.by using a scan .tool.
Diagnostic Aids
Check for the following conditions:

terminals, improper mating, brokenlocks,
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to .be OK, c::orinect the
J 41413 to the EVAP service.port, pressurize
the EVAP system to "10 inch H20 and observe the
fuel tank pressure display on the sc.an tool
while moving connectors and wiring harnesses
related to the EVAP purge valve. A sudden
change in the display will indicate.the location of
the malfunction.
Engine
Engine Controls - 3.8l .6-1129
Incorrect vacuum line routing.
Verify that the source vacuum line routing to the

EVAP purge valve is correct and that the
EVAP purge and source vacuum lines to the
EVAP canister purge valve are not switched.
Malfunctioning or damaged canister.
Use the following procedure to check for a carbon
release condition:
2. Remove the EVAP purge valve. Refer to

EVAP Canister Purge Valve Replacement.
3. Lightly tap the EVAP purge valve on a clean

either of the vacuum ports,
components and continue with the OTC P1441
table. If carbon is being released from either
component, continue with this se,rvice
procedure.
5. Remove the charcoal canister from the vehicle.

OFF on the J 41413 EVAP purge/pressure
diagnostic station.

nitrogen cylinder to the EVAP purge/pressure
diagnostic station at the pressure regulator
by unscrewing the knurled nut on the regulator.
No tools are required to remove the black
hose from the regulator.
one end over the open threaded fitting of
the EVAP purge/pressure diagnostic station
pressure regulator.
9. Connect the remaining end to the EVAP purge
valve end of the EVAP purge line at the
vehicle and turn on the main nitrogen cylinder
valve. Continue to blow any debris from the
purge line for 15 seconds.
10. Return the J 41413 EVAP pressure/purge
diagnostic station to its original condition by
re-installing the black hose that was
disconnected in step 7.
11. Replace the following components:
The EV AP purge valve. Refer to
Replacement.
The EVAP canister. Refer to EVAP
Canister Replacement.
12. Proceed with the OTC P1441 diagnostic table.
often the condition that caused the OTC to set occurs.
This may assist in diagnosing the condition.
Test Description
diagnostic table:
1. The Powertrain On-Board Diagnostic (OBO)
System Check promps you to complete some of
the basic check and store the Freeze Frame
and Failure Records data on the scan tool
if applicable.
2. If an EVAP purge valve electrical malfunction is
present, the purge system will not operate
correctly. Repairing the electrical malfunction will
very likely correct the condition that set
this OTC.

high condition. The fuel tank pressure must
fuel tank or EV AP canister. The fuel fill cap will
not relieve the tank due to a check valve in
the filler neck. The check valve seals when
pressure is applied to prevent vapors from
escaping through the filler neck. The scan tool
should read within 1.0 inch H20 of the
specified value.
canister purge valve/solenoid. the scan tool should
read within 1.0 inch HG of the specified value.
changes. the EVAP station is pressurizing a
pressure of 6.0 inches of H20 (O volts). However
value should be within 0.5 in H20 of the
specified value.
6. If the EVAP purge and engine vacuum lines are
switched at the EVAP purge valve/solenoid, the
valve/solenoid will leak vacuum.
High pressure at O volts and high vacuum
pressure of 6.0 inches of H20 (O volts). However
specified value.
6-1130
Engine
DTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

Step
Action
Did you perform the Powertrain On'-Board
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
applicable DTC
Go to Step 3
Go to Step 4
Go to Step 12

conditions:

Emission Hose Routing Diagram Emission hose
routing Diagram.

. Emission (EVAP) Vent Solenoid Control Circuit also set?
r.
Turn OFF the. ignition;

2. Disconnect the EVAP canister Line from the EVAP
canister purge valve. This will relieve the fuel tank
pressure.
O in. H20
4. With a scan tool, observe the fueltank pressure

parameter.
Does the scan tool indic(:lte fuel tank pressure near the
specified value?
..

EVAP pressure and vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station, refer
to tool operating instructions.

disconnected
3. Install the J 41415-40 fill tank cap Adaptor to the fuel

4. Connect the EVAP station to the fuel tank cap
adaptor.
6. With a scan tool, capture Fail Record data for
5 in. H20
DTC P1441 and clear DTCs.

system.
specified value.
system to the specified value by slowly turning the
rotary switch to the PRESSURE position. Monitor
1. With the EVAP station, maintain tank pressure at the

specified value. Monitor the pressure with the gauge
on the cart with the rotary switch in the OFF/HOLD
position.
parameter.
Go to Step 6
Go to
Diagnostic Aids
Go to Step 9
5 in. H20
specified value?
Inspect the EVAP purge and source vacuum line routing
and connections at the EVAP purge valve. Refer to
Go to Stf;!p 5
(
Go to Step 12
Go to Step 7
Engine
6-1131
DTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge (cont'd)
Step
Action
Values
1. Connect the inch HG vacuum hose on the EVAP

service station to the canister side of the purge valve.
EVAP system.
5. Run the engine from 1200-1500 RPM and observe
vacuum level.
Does the vacuum measure near the specified value?
O in. Hg
Important: Check for carbon release into the EVAP

system. Refer to Diagnostic Aids.
Replace the EVAP c;:tnister purge valve. Refer to EVAP
CanisterPurge Valve Replacement.
Visually/physically inspect for the following conditions:

Restricted fuel tank vapor line
Restricted EVAP purge line
10
Check for a kinked or restricted canister purge line

canister.
Did you find and correct the .condition?
O in. H20
11

2. Disconnect the EV AP canister line from the f1,1el tank
pressure.
parameter.
Do.es the scan tool indicate fuel tank pressure near the
specified value?
O in. H20
12

disconnected
3. With a scan tool, select the seal option to seal the
EVAP system.
first specified (higher) value by slowly turning the
D.oes the EVAP pressure decrease to less than the
15 in. H20
10 in. H20
Yes
No
Go to
Diagnostic Aids
Go to Step 8
Go to Step 12
Go to step 12
Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage
Go to Step 12
Go to Step 10
Go to
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage
Go to Step 3
System OK
6-1132
Engine
DTC P1514 Throttle Body Performance

Circuit Description
The PCM uses the TP, BARO, IAT and engine RPM
in order to calculate an expected mass airflow
.
rate. The PCM compares this value to the mass airflow
value and the speed density calculation in order to
verify the proper throttle operation.

No other ETC DTCs are present.
No PCM processor DTCs are present.
Engine is running and engine speed is more
than 600 RPM.

The PCM detects that the actual airflow (MAF) and
Speed Density is .much more than the expected
(calculated) airflow rate.
Action Ta.ken When the DTC Sets

The PCM will illuminate. the MIL during the
TRACTION OFF lamp.
Records data.

warm-up cycles have occurred. without a
malfunction.
Diagnostic Aids
Inspect the throttle blade for being broken, bent,
or missing.
Skewed cam sensor Signal - Intermittently shorted
to ground, causing a fluctuating RPM as seen on
the scan tool.

surfaces before seNicing a component. Inspect
correctly. The gaskets preventcontaminate intrusion.
terminals, improper mating, broken locks
improperly formed or damaged terminals,' and
corresponding mating terminal to te~! for.proper
tension. Refer to. Testing for Intermittent and Poor
Systems.
Damaged harness.
lnspectthe wiring harness for damage, If the
harness appears to be OK,. obseNe the display
change in .. the display may indicate the location of
Systems.
clean and'secureconnections.
'
the Failure Records tan be useful in determining
Test Description
diagnostic table.
3. Physically/visually inspect the throttle body

assembly and correct any problems that .
you obseNe. Manually move the throttle blade
from closed to wide open throttle (WOT).
You should not need to use excessive force. The
throttle blade should move smoothly through
the full range and should return to a slightly open
position on its own.
5. When the PCM detects a problem within the ETC
System other DTCs may set due to. the many
redundant tests rnn continuously on this svstem.
Engine
Engine Controls - 3~8L
5.;1133
DTC P1514ThrottleBody Performance

Step
Action
Did you perform the Powertrain On-13oard

Diagnostic (OBD) System Ch.eek?
1
Values
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Diagnose these
DTCs first
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 2
Go to the
applicable DTC
System OK
Caution: Turn OFF the ignition before inserting fingers

into the throttle bore. Unexpected movement of the
throttle blade could cause persona( injury.
Important: If any of the conditions listed below exist,
replace the throttle body!TAC assembl.y; Refer to Throttle
Inspect the throttle body for the following while modulating
the throttle using the scan tool:
O Loose or damaged throttle blade
Broken throttle shaft
Drive mechanism damage
1. Use the scan tool ii;i order to clear the DTCs.

2. Operate the vehicle within Faii Records conditions.
Does the DTC reset?
not diagnosed?
Yes
..
6-1134
Engine
OTC P1515 Control Module Throttle Actuator Position Performance
r -
I
I
I...
- -
- -
~~~f~ution _..
Schematics
in Wiring
Systems
810
- -
Engine Wiring
Harness
ELEC
THROT I Junction
CONT I
~'11use I
rc:"l
!Hot At All Times J
Block 1
_________ ...
- - - - - - - .,Engine Wiring
TCS BATI
I Harness
Minituse
20A
_______ ... Junction Block 1

Power
ORN~
PNK 339
1540
7
L2J
ORN 1540
3
Distribution
Schematics
In Wiring
Systems
(
548593
Circuit Description
The commanded throttle position, based on accelerator
pedal position and possibly other limiting factors, is
compared to the actual throttle position. The PCM
monitors the Commanded and actual throttle position.
This OTC sets if the PCM detects the problem.
No other ETC DTCs are set.

No PCM processor DTCs are present.
The ignition voltage is more than 8.5 volts with
key ON engine OFF.
The ETC system is not in the battery saver mode.

The PCM detects that the commanded and actual
throttle positions are not within a calibrated range of
each other.

command the EBTCM via the serial data Gircuit to
TRACTION OFF lamp.
Records data.

malfunction.
Engine
Diagnostic Aids

Important: Ensure that the starting and charging
systems are operating properly. Low system voltage
causes this DTC to set.
If you do not find any trouble, check for mechanical
problems or binding that may be temperature related.
Components may not move freely in extreme heat
or cold due to the presence of contaminants or
ice formation ..
corresponding mating terminal to testfor proper
Systems.
Damaged harness.
Systems.
Test Description
diagnostic table.
3. If the TP indicated angle does not follow the
movement of the throttle blade, and no TP sensor
DTCs are set, there is a mechanical problem
with the throttle shaft or the TP sensor. Replace
the throttle body assembly. Re-install the air
inlet duct after repairs are completed.
System other DTCs may set due to the many
may correctmore than one DTC. Keep this
DTC P1515 Control Module Throttle Actuator Position Performance

Step
Action
Important: If you came from one of the following OTC

tables continue with this table and go to step 3.
Is OTC P1120, P1220 or P1221 set?

3. With a scan tool, observe the TP sensor 1 and 2
angle parameter.
4. Slowly depress the accelerator pedal to wide open
throttle (WOT) and then slowly retum it to closed
throttle.
Does the TP sensor 1 .and 2 angle increase to near the
specified value as the pedalis depressed and decrease as
the pedal is released?
1.
2.
3.
4.

Disconnect the TAC.
Measure. the voltage across the Throttle Actuator
circuits (Motor Hi and Motor Low) using a DMM.
Does the voltage measure specified range?
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
. Board
Diagnostic (OBD)
System Check
Diagnose these
DTCs first
Go to Step 3
,.
100%
Go to
Diagnostic .Aids
Go to Step 4
Go to Step 15
Go to Step 5
7.5-8.5 V
'
6;.1136
Engil1e
DTC P1515 Control Module Throttle Actuator Position Performance (cont'd)

Step
Action
Values

2. Measure the voltage on each Throttle Actuator circuit
.
(Motor Hi and Motor Low) using a DMM that is
Is any voltage present?
Test for an open in each Throttle Actuator circuit (Motor Hi

and Motor Low). Refer to Circuit Testing in Wiring
Systems.
Test for a short to ground on each Throttle Actuator circuit

(Motor Hi and Motor Low). Refer to Ci,:cuit Testing in
Wiring Systems.
Test for continuity between each Throttle. Actuator circuit

(Motor Hi and Motor Low) and all other circuits in the TAC
module connector. Refer to Circuit Testing in Wiring
Systems.
Repair the short to voltage on the affected Throttle

Actuator circuit. Refer to Wiring Repairs in Wiring
Systems.
10
Repair the open or high resistance on the affected Throttle

Systems.
11
Repair the short to ground on the affected Throttle

Systems.
Repair the circuits that are shorted together. Refer to

13
Inspect for poor connections at the TAC module. Refer to

14

Inspect for poor connections at the TAC. Refer to Testing


17

Does the OTC reset?
18
not diagnosed?
12
15
16
Yes
No
Go to Step 9
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 11
Go to Step 8
Go to Step 12
Go to Step 13
Go to Step 17
Go to Step 17
Go to Step 17
Go to Step 17
Go to Step 17
Go to Step 14
Go to Step 17
Go to Step 17
Go to Step 16
-
Go to Step 17
Go to Step 2
Go to Step 18
Go to
applicable OTC
System OK
Engine
6-1137
DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator

Position Performance
r -
I
I
I
I...
- - ,
Power
"'11
.
. lb u!Jon
D1str
Schematics
in Wiring
Systems
810
IL 0 c
IHot At All Times I
Engine Wiring
IH
ELEC
arnes.s
THROT I Junction
CONT I
~11fuse I
Block 1
_________ .
r -
: J9
TCS BATI
Mlnifuse
20 A
I JB
L-
[M;'l
Llli
-------.!
ORN 1540
3
~Engine Wiring
1Harness
Junction Block 1
1
ORN
'-------~
1540
PNK 339
I.
Power
Distribution
Schematics
In Wiring
Systems
......- - - - - - - - - - - l g - n i - t i o _ -------------------------n_ _ _ _ _ _ _ _ _ _ _ _B _ a t - t e - r y - - - - - - - - - - - - . Throttle

Positive
Voltage
TAC
Ground
!:nsor~
Signal
TAC
Ground
BL~1~:;/~-J;l~~1-~~:~
BLK/
-F~~ - -
WHT
WHT
BLI<!
WHT
451
- -~
451
~L_K!':""~_:
BLK/WHT 451
451
451
,.. _ _ _ _ .,,.
TP
Sensor2
sv Ref
TP
Sensor2 Motor Driver Motor Driver
Ground Low
Hi
Control
(TAC)
~=n:o, 11
Module
TP
TP
Sensor1 Sensor1 Signal
Ground 5V Ref
221-.~~~15~~-241--~~~1;8~----11-B1i.1-;7~- --111- ~~-~~~1485
PPL 486
B
C
----
Ground
Distribution
Schematics
In Wiring
Systems
Actuator
Positive
Voltage
TPS 2
BLK 476
YEL 581
A
D
E
H
- - - - -- - - - - - -- - - - - ---
sV
sV
REF
RTN
Motor
Drive
Motor
Drive
GRY/BLK 1687
F
G C1
- - - - - -- - - - - 5V
RTN
5V
REF
TPS 1
Hi
________________________
Throttle
Position ....__ __.
..._Sensor 2
H Bridge
Motor Driver
Position
Sensor1
__,
Throttle
Actuator
Control
~
548593
Circuit Description
The commande.d throttle position, based on accelerator
pedal position and possibly other limiting factors, is
compared to the actual throttle position. The TP values
should be within a calibrated range of each other.
The TAC module monitors the Commanded and actual
throttle position. This DTC sets if the TAC module
detects the problem and send the message to
the PCM across serial data.

OTC P1518 is not present.
Conditions for Setting the. OTC

The TAC module detects that the commanded and
actual throttle positions are not within a calibrated
range of each other or the TAC module cannot
determine throttle position or both TP sensors are
invalid.

turn OFF traction control and illuminate the.
TRACTION OFF lamp.
Records data.


malfunction.
6-1138
Diagnostic Aids
Important: Ensure that the starting and charging

systems are operating properly. Low system voltage
causes this DTC to set.
If you do not find any trouble, check for mechanical
problems or binding that may be temperature related.
Components may not move freely in extreme heat
or cold due to the presence of contaminants or
ice formation.

Systems.
Engine
Damaged harness.
the .fault. Refer to Wiring Repairs in Wiring
Systems.
Test Description
diagnostic table.
3. If the TP indicated angle does not follow the
movement of the throttle blade, and no TP sensor
DTCs are set, there is a mechanical problem
with the throttle shaft or the TP sensor. Replace
the throttle body assembly. Re-install the air
inlet duct after repairs are completed.
OTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Diagnose these
DTCs first
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4

1
Important: If you came from one of the following DTC

tables continue with this table and go to step 3.
Is DTC P1120, P122Cl or P1221 set?
3. With a scan tool, observe the TP sensor 1
and 2 angle parameter,
4. Slowly depress the accelerator pedal to wide open
throttle (WOT) and then slowly return it to closed
throttle.
Does the TP sensor 1 and 2 angle increase to near the
specified value as the pedal is depressed and decrease as
the pedal is released?
1.
2.
3.
4.

Disconnect the TAC.
Measure the voltage across the Throttle Actuator
circuits (Motor Hi and Motor Low) using a DMM.
Does the voltage measure specified range?
2. Measure the voltage on each Throttle Actuator circuit
(Motor Hi and Motor Low) using a DMM that is
Is any voltage present?
'
100%
'
7.5-8.5 V
Go to Step 15
Go to Step 5
(
-
Go to Step 9
Go to Step 6
Engine
6-1139
DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance
(cont'd)
Values
Step
Action
Test for an open in each Throttle Actuator circuit (Motor Hi

and Motor Low). Refer to Circuit Testing in Wiring
Systems.
Test for a short to ground on each Throttle Actuator circuit

(Motor Hi and Motor Low). Refer to Circuit Testing in
Wiring Systems.
Test for continuity between each Throttle Actuator circuit

(Motor Hi and Motor Low) and all other circuits in the TAC
module connector. Refer to Circuit Testing in Wiring
Systems.
Repair the short to voltage on the affected Throttle

Systems.
Repair the open or high resistance on the affected Throttle

Systems.
.
Repair the short to ground on the affected Throttle

Systems.
10
11
12
13

..
Go to Step8
Go to Step 12
Go to Step 13
..
Go toStep 17
Go to Step 17
16

Go to Step 14
-
Go to Step 17
Go to Step 17
Go to Step 16
-
Go to Step 17
Does the DTC reset?
18
Go to Step 11
15
not diagnosed?
Go to Step 7
Go to Step 17
Inspect for poor connections at the TAC. Refer to Testing

17
Go to Step 10
Go to Step 17

No
Go to Step 17

14
Yes
Go to Step 2
Go to Step 18
Go to
applicable DTC
System OK
6-1140
Engine
DTC P1517 Throttle Actuator Control (TAC) Module Performance

Circuit Description
The throttle actuator control (TAC) module contains

data which is essential for proper ETC System
operation. The TAC module continuously checks the
integrity of this data. When the TAC module is
unable to write or read data to and from RAM or the
TAC module is unable to correctly read data from
the flash memory or an internal TAC module processor
fault is detected. This communicated to the PCM
across serial data and this OTC sets.

" OTC P1518 is not present.

The TAC module determines that an internal data test
did not pass.

e If equipped with traction control, the PCM will
TRACTION OFF lamp.
Records data.


malfunction.
Diagnostic Aids
the connector gaskets when diagnosing/replacing a
Test Description
diagnostic table.
DTC P1517 Throttle Actuator Control {TAC) Module Performance

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

appropriate DTC first for further diagnosis.

not diagnosed?
Go to Step 3
Go to Step 2
Go to Step 4
Go to
applicable OTC
System OK
Engine
6-1141
DTC P1518 Throttle Actuator Control (TAC) Module Serial Data Circuit
~
~o-;:;N-;-D - - - - - - - -
I C1=BLU
I C2=CLEAR
I
I
I
v~-~:~~1-~-
TAC
Serial
Data
L -
~ Powertrain
TAC
Serial
Data
-14-
I
I
Control
Module
(PCM)
A
! Hot In RUN Or START I
r---------,E
.
I
I ~Qlne
I
I
I
Power.
-<1
Distribution
Schematics
in Wiring
Systems
G10
ELEC
Wiring
THROT I Harness
CONT I Junction
Minifuse Bl
1 OC k 2
10 A
L---------..1
PNK 339
IHot At AH Times I
'" I
I Je
'Ja
L
- - - - - - - ., Engine
TCS BATT
I Wiring
I Harness
I Junction
20 A
"' Block 1
ORN
1540
ORN/BLK 1061
16 ____ _1
...
Power
Distribution
Schematics
In Wiring
Systems
ORN 1540
7
--------------3
,---T-AC
_____
TA_C_ _ _ _ _ _ _ _ _ _ _ _ _
lg-nit-io-n-------,8..;..a_tte-ry----, Throttle
Serial
Data
Serial
Data
Positive
Voltage
TAC
Ground
Positive
Voltage
Actuator
Control
(TAC)
Module
J,,
TAC
Ground
-------l
1
17
5
BLK/ BLK/WH.T 451
Fuel
WHT 451
- __.,. Pump
BLK/WHT 451
Relay
------
BLK/ BLK/WHT 451

WHT 451
BLK/ ~------<11
WHT
~------
Ground
Distribution
Schematics
In Wiring
Systems
548609
Circui1t Description
The TAC module and the PCM communicate via a
dedica1ed serial data circuit. This serial data circuit is
separate from any other serial data circuit on the
vehicle. Accurate transmitting and receiving of serial
data requires not only good circuit integrity but
also adequate system voltage. This diagnostic
monitors the accuracy of the serial data transmitted
between the TAC module and the PCM. If the
PCM/TAC module detects a loss of data or invalid
data, this OTC sets.


Invalid or missing serial data messages are detected
for a predetermined amount of time.

" The PCM will illuminate the MIL during the
TRACTION OFF lamp.
Records data.

malfunction.
., The OTC can be cleared by using a scan tool.
6-1142
Engine
Diagnostic Aids
Damaged harness.

Systems.
Important: DTC P1518 sets if the battery voltage is

low or the PCM is replaced/reflashed. If the customers
concern is slow cranking or no crank because
battery voltage is low, ignore DTC P1518. Clear any
DTCs from memory that may have set from the
low battery voltage condition.
The following could cause an intermittent condition:
Systems.

Test Description
diagnostic table.
DTC P1518 Throttle Actuator Control (TAC) Module Serial Data Circuit
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

Important: If OTC P1120, P1220, P1221, P1515 or P1516

are set, refer to the appropriate OTC first for further
diagnosis.

3. With the ignition OFF, measure the voltage of the
TAC module ignition feed circuit using a DMM that is
Does voltage at or near the specified value?
ov

2. Measure the voltage from the TAC module ignition
feed circuit using a DMM that is connected to a good
ground.
B+
Test the TAC module ground circuits using a test lamp

Does the test lamp illuminate when probing both circuits?
'
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 10
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 13
Go to Step 14
Go to Step 7
Go to Step 8
Test for voltage between both TAC module serial data

circuits and a good ground using a DMM.
2-5 V
Does the voltage measure more than the specified range?
2-5 V
Go to Step 11
Does the voltage measure less than the specified range?
2-5 V
Go to Step 9
Engine
6-1143
DTC P1518 Throttle Actuator Control (TAC) Module Serial Data Circuit (cont'd)
Step
Action
10
11
Repair the short to battery voltage in the ignition feed

Test for a short to voltage on the TAC module serial data

Wiring Systems.
Repair the open or short to ground in the ignition feed

12 . circuit. Refer to Wiring Repairs in Wiring Systems.
Repair the open in the TAC module ground circuit. Refer
13
Values
Test for an open or short to ground in the serial data

Wiring Systems.
Go to Step 16
Go to Step 17
Go to Step 18
Go to Step 18

16

17

18

conditions.
Does the DTC reset?
19
not diagnosed?
Go to Step 18
Go to Step 18
Inspect for a faulty serial data connections at the TAC

module. Refer to Testing for Intermittent and Poor
15
No
Go to Step 18
14
Yes
Go to Step 18
Go to Step 15
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 2
Go to Step 19
Go to
applicable DTC
System OK
6-1144
Engine
DTC P1519 Throttle Actuator Control {TAC) Module Internal Circuit

Circuit Description
The TP sensor 1 signal is fed into a multiplier (5X) to

produce a high resolution calculated TP sensor
voltage. This higher resolution TP sensor voltage is
used for actuator control in low throttle angle
conditions.

OTCs P0606, P 1517, P1518 are not set.

The high resolution TP sensor is out of range.

Frame data.

malfunction.
Diagnostic Aids
Test Description
diagnostic table.
OTC P1519 Throttle Actuator Control (TAC) Module Internal Circuit

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3

Important: If any other DTCs are set, refer to those

DTCs first.
Operate within Fail Records conditions.


conditions.
Does the DTC reset?
not diagnosed?
Go to Step 4
Go to Step 2
Go to Step 5
Go to
applicable DTC
System OK
Engine
6-1145
DTC P1523 Throttle Closed Position Performance

') Circuit Description
During Battery Saver Mode the TAC module

determines if the throttle plate is returning to the
correct de-energized position. If this fault is detected
the TAC module sends a message to the PCM across
serial data and this DTC is set.

malfunction.
Diagnostic Aids
"
If you do not find any trouble, inspect for mechanical

problems or binding that may be temperature
related. Components may not move freely in extreme
heat or cold due to the presence of contaminants
or ice formation.
The following could cause an intermittent condition:

The ignition is ON and the engine is OFF.
The ignition voltage is more than 8.5 volts.
Battery Saver Mode is active.

The TAC module detects that the commanded and
actual throttle positions are not within a calibrated
range of each other.
.Test Description

Frame data.

diagnostic table.
DTC P1523 Throttle Closed Position Performance

Values
Action
Step
Yes

Go to Step 2
2

1.
2.
3.
4.
Turn OFF the ignition for 15 seconds.

Allow the pedal to rest at idle stop for 20 seconds.
With a scari tool, observe the indicated Throttle
Position parameter.
Does the scan tool indicate throttle position within the
specified range?
Remove the throttle body!TAC assembly. Refer to Throttle

Did you find any obstructions preventing the throttle blade
from returning to the default position?
Remove the obstruction.

Replace the throttle body!TAC assembly. Refer to Throttle


conditions.
Does the DTC reset?
not diagnosed?
No
Go to A
Powertrain On
Board
Diagnostic (OBD) .
System Check
Diagnose these
DTCs first
Go to Step 3
Go to Step6
Go to Step 4
Go to Step 5
Go to Step 6
10.8-23.2 %
..
Go to Step 7
Go to Step 7
Go to Step 2
Go to Step 8
Go to
applicable OTC
System OK
6-1146
Engine
DTC P1546 Air Conditioning (A/C) Clutch Relay Control Circuit
I I
lHot In Run, Bulb Test And Start l

.- Po\;;;r- -
I
I
I
Power
Distribution
Schematics
In Wiring
Systems
G7
NC-CRUISE
MlnlFuse
15 A
Distributi?n
Sche~at1cs
In Wiring
Systems
899
ITiil
...- - - - -
A/C
Compressor B
Clutch Diode
1 Amp
899
DKGRN 59
8~i;essor
.-,,-Gr-ou-nd.,.._.-,
Distribution
Schematics
In Wiring
Systems
Engine Wiring
!Harness
I Junction Block 2
I
--------,
[If]~
f
~
~
"
1
:
Relay
PNK 139 PNK 139

.- - - - - - - - - - - , Engine Wiring
I
. DB
010
. AIC
I Harness
1
1
1
1 Junction Block 2
. Clutch
:
L----------.1
PNK 139
- - - - -
DKGR~ 59
~ - - __c~r-0~ ;R~/1v:s9~ -- ~ ~
WHT
DK GRN 59
DK GRN/WHT 459
BLK 450
BLK
39 C2
.- - - .,.. - - - - - - - ., Powertrain
I A/C
CONN ID
I Control
I Relay \
C1=BLU
I Module
: .Control!
C2=CLEAR
: (PCM) J>
1'
450
/
/
..... -
- -
.J
548617
Circuit Description
Output driver modules (OOMs) are used by the PCM
functions. Each OOM is capable of controlling up to
quad driver modules (QOMs) used in prior model
years, OOMs have the capability of diagnosing each
output circuit which controls the A/C compressor
control relay.

The ignition is ON.

the output circuit which controls the A/C
compressor control relay.
30 seconds.

Frame data.

malfunction.
Engine
.)
6-1147
Diagnostic Aids
Test Description

diagnostic table.

O Poor terminal connection.
Systems.
Damaged harness.
Systems.
when 1he DTC was ra:st set.

scan tool.

3. Tests for voltage at the coil feed side of the relay.
4. Verifies that the PCM is providing ground to
the relay.
5. Tests if ground is constantly being applied to

the relay.
When the.PCM is replaced, the new PCM must be
programmed.
6.;1148
Engine. Controls - 3.8L
Engine
OTC P1546 Air Conditioning (A/C) Clutch Relay Control Circuit

Step
Action
Did you perform the Powertrain On~Board

.Diagnostic (OBD) System Check?
1
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Goto
Diagnostic Aids
Go to Step 3
Go to Step4
Go to Step 10
Go to. Step 8
Go to Step 5
Go to Step 7 .
Go to Step 6
Go to .Step 13
Go to Step9
..
1. Turn ON the ignition, with. the engine OFF.

2. With a scan tool, command the A/C relay ON
and OFF.
Does the relay turn ON and OFF with each command?

2. Disconnect' the relay.
4. Probe the coil feed circuit of the relay using a test

relay and the coil feed circuit ofthe relay.
and OFF.
command?

command?
Test the control circuit of the relay for a short to voltage or

an open. Refer to Wiring Repairs in Wiring Systems.
Inspect for faulty connections at the relay. Refer to Testing


10
'
Test the control circuit of the relay for a short to ground.

Repair the feed circuit of the relay. Refer to Wiring Repairs

in Wiring Systems.
Go to Step 13
Go to Step9
Go to Step 13
Go to Step .11
Go to Step 13
Go to Step 12
Go to Step 13
Go to Cruise
Control
Diagnosis in
Cruise Control
Systems
11
Replace the relay.

12

13

Does the OTC reset?
Go to Step 13
Go to Step 13
Go to Step2
System OK
Engine
6-1149
OTC P1571 Traction Control Torque Request Circuit
'" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Powertrain
I CONN ID
I C1=BLU
..
I C2-CLEAR
I
L
12V.
Tachometer
Output
_[
Desired
Torque
Input
.
. .
I Module
(PCM)
Logic
-------------------J
>
------------9IC2
71I_C1
~
TAN/BLK 464
WHT r,21
TAN/BLK r464
ORN/BLK 463
. ORN/BL" 463
l ______________
~ l ______________ 1
-Jr-----~,;,;
?? --" C1
-T;h;;-m;,r-1- Input
- -
Torque
Output
Delivered
Torque
Input
-=-
-r.
- -;- - ~
I
I
IC On
t ro I .
~----
WHT 121
11
I
..
Torque
-'r
O u t p u t ~ PWM
Delivered
PWM .
ar--
-------
. -'r
PWM
-=-
Logic
L-------------------------------
~~~k~(f~iction
I
.
A
1 ontro
I C.
Module
~ (EBTCM)
P1'
~
370828
Circuit Description
Diagnostic Aids
The PCM supplies 5 volts on the desired torque circuit

to the electronic brake and traction .control
module (EBTCM). The EBTCM toggles this 5 volt
signal to a ground in order to produce a duty cycle
signal. The signal is proportional to the amount
of engine output torque reduction requested by the
EBTCM. The EBTCM supplies this signal when
it detects a wheel slip. In order to reduce engine output
torque, the PCM reduces the amount of spark
advance and in some cases, the PCM disables a
num~er of fuel injectors. This diagnostic test checks
for a desired torque signal failure. If the PCM does not
receive the desired torque signal, this DTC sets.
Important: Do not perform this diagnostic procedure if

the c.ustomers concern is not related to the ABS
and/or the Traction Contro_l systems.
The following may cause an intermittent:

The traction control has not failed.
20seconds.

The .desired torque signal is not received by the PCM
for 3 seconds.

Frame data.
Conditions. for Clearing the MIUDTC

malfunction.

improperly formed or damaged terminals; and
tension. Refer to Testing tor Intermittent and Poor
Systems.
Damaged harne_ss_.
on the ,scanJool while moving connectors
arid wiring harnesses .related to the .sensor. A
change in the display may in_dicate the location of
the fault. Refer to .W.iring Repairs in Wiring
Systems.
.
Inspect thE3 PCM and the engine grounds for
clean an.d secure connections.
.
,.,
'
6-1150
Engine
Test Description
diagnostic table.
2. This step determines if the EBTCM is receiving
the 5.0 volts from the PCM. Use the connector
test kit adaptor when probing the EBTCM
connector.
3. If no DTCs are set, inspect connections at

the EBTCM.
11. This OTC will not report a pass. The scan tool
status for this DTC will never report a pass.
The scan tool will only display when the diagnostic
fails. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.
DTC P1571 Traction Control Torque Request Circuit

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step.3
Go to Step 4
GotoABS .
Brakes or Body
and Accessories
for further
dia.gnosis
Go to
Diagnostic Aids
Go to Step 7
Go to Step 5
Go to Step 8
Go to Step6
Go to Step 11
Go toStep 9

Important: Perform this diagnostic procedure only if the

customers concern is related to the ABS and/or the
Traction Control systems. Refer to Self-Diagnostics in ABS
Brakes.

5.0 V
4. Probe the desired torque circuit using a DMM. that is

Does the voltage measure at or near the $pecified value?
Important: Verify communication between the. scan tool

and the EBTCM before you continue with this table. If you
can not establish communications, refer to
Self-Diagnostics in ABS Brakes.
Are any ABS/TCS DTCs or BCM DTCs set?
Did the voltage measure more than the specified value?
5.2V
Probe the desired torque circuit using a test lamp that is

connected to B+.
Test for an open in the desired torque circuit. Refer to

Did you find and correct the .condition?
Repair the short to B+ on the Desired Torque circuit. Refer

Repair the short to ground on the Desired Torque circuit.
Go to Step 11
Go to Step.11
Go to Step 11
10


Go to Step 10
-
Go to Step 11

11
12

conditions.
Does the OTC reset?
..
not diagnosed?
Go to Step 2
Go to Step 12
Go to
applicable OTC
System OK
Engine
6-1151
DTC P1574 Stoplamp Switch Circuit

)
IHot At All TimesI

-----,,;p
'"Power _____
Distribution
STOP/HAZARDI Fuse
Schematics
Fuse 1
I Block
in Wiring
20 A
I._~s!;_m!,_ _ _ _ _ _ _ _ _ ..I
I
I
ORN 140
A C1
Stop
Lamp
Switch
(Normally
Exterior
Lights
Schematics
In Wiring
Systems
______ _.+
BIC1
LTBLU
20
open)
LTBLU 20
LTBLU
20
LT BLU 20
6 ,, Ci
LTBLU
20
'" -St.;-p,a1-,
I
I
1
1._
Electronic
I Brake
Switch
Signal
Control
1 Module Jt.
1 (EBCM)~
_______ .
_
-
9
'" - Brai; - , Throttle
I
I
Switch
Actuator
:
Signal
: Control (TAC)Jt.
._ ____ .. Module
~
548635
Circuit Description
Diagnostic Aids
The stop lamp switch (TAC brake switch) is a normally

open switch. When the switch is closed, the TAC
module senses ignition voltage on the signal circuit. If
the PCM senses a high rate of deceleration without
a input from this switch this OTC will set.
In order to adjust the stop lamp switch perform the

following:
1. With the brake pedal depressed, insert the brake
lamp switch into the retainer until the switch body
seats in the retainer. You can hear clicks as
you push the threaded portion of the switch
through the retainer.
2. Slowly pull the brake pedal fully rearward against
the stop until you can no longer hear the clicks.

The engine speed is more than 1000 RPM.
The wheel speed must be more than 20 MPH in
order to enable the diagnostic. The diagnostic
will disable when the wheel speed is less
than 5 MPH.

The vehicle speed decreases 0.5 MPH in
transition.
. The condition is present for 20 accel/decel cycles.

Frame data.

malfunction.
)

I
Systems.
" Damaged harness.
change in the display may indicate the location bf
Systems.
If the OTC is determined.to be intermittent, reviewing
when the DTC was last set
6-1152
Engine

OTC P1574 Stoplamp Switch Circuit
Step
Action
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 8
Go to
Diagnostic Aids
Go to Step 4
Go to Step 20
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 11
Go to Step 15
Go to Step 12
Go to Step 16
Go to Step 13
Go to Step 20
Go to Step 10

With a scan tool, observe the TAC brake switch

parameter.
Depress the brake pedal approximately half-way.

Does the scan tool indicate Applied?
Test the adjustment of the brake switch. Refer to

Diagnostic Aids.
Inspect the condition of the fuse.

Is the fuse OK?
1. Disconnect the brake switch.

3. Probe the brake switch feed circuit using a test lamp
1. With a scan tool, observe the TAC brake switch

parameter.
2. Connect a fused jumper between the feed and signal
circuits.
Does the parameter indicate Applied when the jumper is
installed?
1. With a scan tool, observe the TAC brake switch

parameter.
Does the parameter indicate Released when the switch is
disconnected?
Test the feed circuit for a short to ground. Refer to Circuit



in Wiring Systems.
Test the signal circuit for an open between .the switch and
the EBTCM. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
13

2. Probe the signal circuit using a test lamp that is
14
Repair the short to voltage on the signal circuit. Refer to

Inspect for poor connections at brake switch. Refer to

10
11
12
15
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 19
Go to Step 14
Go to Step 17
Go to Step 20
Go to Step 20
(
Go to Step 16
Engine
6".1153
DTC P1574 Stoplamp Switch Circuit (cont'd)

Step
16
Action
Replace the brake switch. Refer to Stop/amp Switch
Replacement in Hydraulic Brakes.
Values
-
18

19

Pedal Replacement (TAC Module and Bracket Assembly)
20

conditions.
Does the OTC reset?
21
not diagnosed?
No
-
Go to Step 20
Test the signal circuit for an open or high resistance

between the TAC module and the EBTCM. Refer to Circuit
17
Yes
Go to Step 20
Go to Step 18
Go to Step 20
Go to Step 19
Go to Step 20
Go to Step 2
Go to Step 21
Go to
applicable DTC
System OK
6;.1154
Engine
DTC P1586 Cruise Control Brake Switch 2 Circuit
'" --t
!Hot In RUN And START!
J7
1- _
ENG - , Engine Wiring

SEN
I Harness
Minifuse I Junction Block 1
J6__2D_!,._
..1
PNK 539
C C2
m~~~e
I
rSJ
,A
!Loe
pp~r~~
li::Jswitch
30 C1
" - - - - - - -Brake
- - - - ., Powertrain
I
I
CONN ID
C1 = BLU
C2=CLEAR
Switch.
Signal
I Control
I Module
I
(PCM) j.4
I~
L-----------..1
548669
Circuit Description
Diagnostic Aids
The brake switch indicates brake pedal status to the

powertrain control module (PCM). The brake switch is
a normally-closed switch that supplies battery
voltage to the PCM. Applying the brake pedal opens
the switch, interrupting voltage to the PCM. This
DTC is for manual transmission vehicles only, this
switch is used for TCC operation on automatic
transmission vehicles.

Ask about the customers driving habits. Ask about
unusual driving conditions (e.g. stop and go,
expressway, etc.).
Inspect the brake switch for proper mounting and
operation.
" Inspect for ABS DTCs. A faulty ABS condi1ion
may contribute to setting this OTC.

component. Ensure that the gaskets are instaUed
Systems.
Damaged harness.
Systems.
If the DTC is determined to be intermittent, reviewing (

1 secound.
The wheel speed is more than 20 mph in order to
enable the diagnostic. The diagnostic disables
when the wheel speed is less than 5 mph.

The vehicle speed decreases 1 MPH in
transition.
The condition is present for 1O accel/decel cycles.

Frame data.

malfunction.
Engine
Engine Controls -.3.8L
6-1155
DTC P1586 Cruise Control Brake Switch 2 Circuit

)
Action
Step

2
3
With a scan tool, observe the brake switch parameter.

Depress the brake pedal approximately half-way.
Does the scan tool indicate brake switch as Applied?
Test the adjustment of the brake switch. Refer to Stop/amp
Switch Adjustment in Hydraulic Brakes.
Values
Is the fuse open?

3. Probe the feed circuit using a test lamp that is
No
Go to Step 2
Go to A
Powettrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 5
Go to
Diagnostic Aids
Go to Step 4
Go to Step 17
Go to Step 8
Go to Step 9
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 13
Go to Step 14
Go to Step 17
Go to Step 12
..

Inspect the condition of the fuse.
Yes

1. With a scan tool, observe the brake switch

parameter.
2. Install a fused jumper between the feed and signal
circuit.
Does the parameter switch to Released?
1. With a scan tool, observe the brake switch

parameter.
Does the parameter switch to Applied?
Test the feed and signal circuits for a short to ground.

Systems.

10

in Wiring Systems.
11
Test for an open in the signal circuit. Refer to Circuit

Go to Step 17
12
Inspect for poor connections at the brake switch. Refer to

Replace the brake switch. Refer to Stop/amp Switch
Replacement in Hydraulic Brakes.
Repair the short to voltage in the signal circuit. Refer to
15
Go to Step 17
Go to Step 13
-
Go to Step 17
-

Go to Step 15
14
Go to Step 17
13
Go to Step 17
Go to Step 16
Go to Step 17
Go to Step 16
6-1156
Engine
DTC P1586 Cruise Control Brake Switch 2 Circuit (cont'd)

Step
16
17
Action
Values

With a scan tool, observe the brake switch parameter.

Does the parameter indicate Released and switch to
Applied when the brake pedal is depressed?
Yes
No
Go to Step 17
System OK
Go to Step 2
Engine
6-1157
DTC P1626 Theft Deterrent Fuel Enable Signal lost

'"r;tt- - ., Body
I
I
Deterrent
Control
Module
~ s~n~ _ ~ {BCM)
Fuel Enable
D8IC3 ~
>
DK BLU 229
.
DK BLUI229
70 Ci
,. - - - - - - - - Fu;i - - - - - - - - ., Powertrain
I
I
I
fEnable
Control
PCM
I
Control
I Module
I I (PCM)
II
~-------~----------J~
I
sv
1c1 = BLU
C2=CLEAR
"'
Jiii'
226770
Circuit Description
The body control module (BCM) produces the Theft
Deterrent Fuel Enable signal when ignition is ON and
the proper key resistor pellet is sensed. The PCM
monitors the Fuel Enable signal during crank. If
the proper signal is present on the Theft Deterrent
Fuel Enable circuit, the PCM enables fuel delivery to
allow the engine to start. If the PCM detects that
the fuel enable signal is not present or incorrect while
the engine is running, DTC P1626 will be set.
DTC P1626 can cause a no-start condition or normal
operation depending on when the loss of the fuel
enable signal was detected. The engine will continue
to start and run if the condition that set DTC P1626
occurred after the BCM sensed the proper key resistor
pellet and signaled the PCM to continue fuel delivery.
The engine will start and immediately stall if the
condi1ion that set DTC P1626 occurred before the
BCM sensed the proper key resistor pellet. With this
condi1ion present, the PCM will inhibit fuel delivery and
the BCM will disable the starter. If the problem
affects inputs to the BCM, the starter motor may be
disabled. If this condition is present, refer to Vehicle
Theft Deterrent System for further diagnosis.


The PCM detects an incorrect signal on the Theft
Deterrent Fuel Enable Circuit.

Frame data.

malfunction.
Diagnostic Aids
Systems.
Damaged harness.
Systems.
6-1158
Engine
Test Description
diagnostic table.

DTC P1626 Theft Deterrent Fuel Enable Signal Lost

Step
Action
Diagnostic (OBD) System Check performed?
Values
Go to Step 3
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Diagnostic
in Theft
Deterrent
Go to Step 4
Go to Step 6
Yes
Go to Step 2
10
11
Important: Before continuing, ensure that the vehicle

battery is fully charged.
Does the engine crank?
1.
2.
3.
4.

Disconnect the body control module (BCM).
.Measure the voltage on the vehicle theft deterrent
fuel enable circui.t using a DMM that is connected to
a good ground.
2. Reconnect the BCM.
4. Backprobe the BCM connector to measure frequency
between the vehicle theft deterrent fuel enable circuit
using a .DMM that. is connected to a good ground.
Does the frequency measure within the specified range?
2. Attempt to start the vehicle.
Does the vehicle start and continue running?
Test the vehicle theft deterrent fuel enable circuit for an
open, short to grou11d, or short to voltage. Refer to Circuit
Inspect the theft deterrent fuel enable circuit for a poor
an.d Poor Connections and Connector Repairs in Wiring
Systems.
Inspect for poor connections at the BCM. Refer to Testing
Replace the PCM. Refer to PCM Replacement/
Programming.
Replace the BCM. Refer to Body Control Module
Replacement in Body Control System.
2. With a scan tool;observe the VTD Fuel Disable
parameter while cranking the engine.
Does the scan tool indicate Active?
5V
40-60 Hz
Go to Step 5
Go to Step 8
Go to
Diagnostic Aids
Go to Step 7
Go to Step 11
Go to Step 7
, Go to Step 11
Go to Step 9.
Go to Step 11
Go to.Step 10
Go to Step
11
Go to Step 11
Go to Step 2
System OK
Engine
6-1159
DTC P1629 Theft Deterrent Fuel Enable Signal Not Received

~Theft- ..... ~ Body
Deterrent
Control
I Fuel Enable I Module

~s~n~ _ ~ (BCM)
LJil
D8IC3 ~
);
DK BLU 229
DK BLUI229
70 C1
,. - - - - - - - - Fu; - - - - - - - - .,
I
I
I
I
fEnable
Control
I
5V
Powertrain
I
Control
I Module
I I (PCM)
PCM
IC1=BLU
I I
C2=CLEARI I
A
JlfK'
L------------------~~
226770
Circuit Description
Diagnostic Aids
The body control module (BCM) produces the Theft

Deterrent Fuel Enable signal when ignition is ON and
the proper key resistor pellet is sensed. The PCM
monitors the Fuel Enable signal during crank. If
the proper signal is present on the Theft Deterrent
Fuel Enable circuit, the PCM enables fuel delivery and
starter operation to allow the engine to start. If the
PCM detects that the fuel enable signal is not present
or incorrect while an attempt is made to start the
engine, DTC P1629 will be set. The engine will not
start and the starter motor will be disabled. This
conditions will occur if the problem also affects inputs
to the BCM. Refer to Vehicle Theft Deterrent
System for further diagnosis.

OTC P1626 is not present.
An attempt is made to start the engine.

The PCM detects an incorrect signal on the Theft
Deterrent Fuel Enable Circuit.

. The PCM will not illuminate the malfunction
Frame data.

malfunction.

component. Ensure .that the gaskets are installed
terminals,. improper mating, broken locks,
Systems.
Damaged harness.
lnspectthe wiring harness for damage. If the
.
Systems.
Test Description
diagnostic table.

6-1160
Engine
DTC P1629 Theft Deterrent Fuel Enable Signal Not Received

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to A
Diagnostic
in Theft
Deterrent
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 8
Go to
Diagnostic Aids
Go to Step .7

Diagnostic (OBD) System Check performed?
1
Important: Before continuing, ensure that the vehicle

battery is fully charged.
Does the engine crank?

2. Disconnect the body control module (BCM).
4. Measure the voltage on the vehicle theft deterrent
fuel enable circuit using a DMM that is connected to
a good ground.
5V

4. Backprobe the BCM connector to measure frequency
between the vehicle theft deterrent fuel enable circuit
Does the frequency.measure within the specified range?
40-60 Hz

5
2. Attempt to start .the vehicle.

Does the vehicle start and continue running?
Inspect the theft deterrent fuel enable c.ircuit for a poor

connection at the PCM, Refer to Testing for Intermittent
and .Poor Connections and Connector Repairs in Wiring
Systems.
10
11
Go
Go to Step 11
Go to Step 9
Go to Step 11.
Go to Step 10
'


2. With a scan tool, observe the VTD Fuel Disable
parameter while cranking the engine.
Does the scan tool inaicate Active?
to Step
Go to Step 11
Inspect for poor connections at the BCM. Refer to Testing

Replace the BCM. Refer to Body Control Module

Replacement in Body Control System.
Test the vehicle theft deterrent fuel enable circuit for an

open, short to ground, or short to voltage. Refer to Circuit
Goto Step 11
Go to Step 11
.
-
Go to Step 2
System OK
Engine
6-1161
DTC P1635 5 Volt Reference 1 Circuit
.. - - - - - - - - - - - - - - - - - - sv- ., Powertrain
1
I
I
L,
.
EGA
Valve
Control
5 volt
Reference
LT BLU 697
Module (PCM)
A.
JIJfl'
c; ~
- - - - - - - - - - - - - - - ~ - - - ~ - - - 33
I'control
GRY 598
fei~:r;
_J_-_--"'-----"1. . .I
I.____.]...-_-_-_-_-_-_-_-
B
BLK 552
GAY 435
LTGRN 432
BRN 1456
32
.. -
I
I
I
Control
Ground
28
C1
EGR
- EGA
Plntle
Position
Signal
C2
ORN/BLK 469
13 C1
31
-
- EGA -
Pintle
Position
Ground
CONN ID
Cl '.:.BLU
C2-CLEAA
- MAP
Sensor
Ground
25 C2
-
MAP -
Sensor
Signal
...
I
I
Powertrain
Con t ro I
Module (PCM)
,6
1..-------------------------------------J~
~
370117
Circuit Description
The PCM uses this 5 Volt Reference circuit as a
sensor feed to the following sensors:
The MAP sensor
The EGR valve pintle position sensor
The PCM monitors the voltage on this 5 Volt
Reference circuit. If the voltage is out of tolerance, the
PCM will set DTC P1635.


The PCM detects a voltage out of tolerance
condition on this 5 Volt Reference circuit.
" The above condition is present for more than
10 seconds.

which the diagnostic test has been run and failed ...
Records data.

malfunction.
6-1162
Diagnostic Aids

lnspectthe harness connectors for backed out
tension. Refer to Testing for Intermittent andPoor
Systems.
Engine
Damaged harness.
Systems.
clean and secure.connections.
when. the OTC was last set.
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 14
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 7
Go to
Diagnostic Aids
Go to Step B
Go to Step 9
Go to Step 10
Go to Step 14
Go to Step 11
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 13

Visually/physically inspect the PCM and engine grounds.

Ensure the grounds are clean and secure.
1. Disconnect all of the following components:

EGR
MAP
Fuel sender connector
A/C pressure sensor
2. Measure the voltage on the 5 volt reference circuit at
the EGR connector using a DMM that is connected to
ground.
5V
1. Leave the DMM connected to the EGR 5 volt

reference circuit.
2. Reconnect each component one at a time.
Does the measured voltage remain at or near the specified
value when each component is connected?
5V
1. Heconnect the. EGR.

2. Disconnect the MAP.
the MAP sensor connector.
5V
)
6
Is the voltage below the specified value?
Test the signal circuit of the effected component for a

short to B+. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the signal circuit of the EGR for a short to B+. Refer
Test the 5 volt reference circuit for a short to ground. Refer

Did you firid and correct the condition?
10

Systems.
11
Replace the effected component.

12
Replace the EGR. Refer to EGR Valve Replacement.

13

14

Does the DTC reset?
15
not diagnosed?
4.8V
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 2
Go to Step 15
Go to
applicable OTC
System OK
6-1164
Engine
I
I~
~c
~T,igerant
B'
Pressure
Sensor
[S]
N
GRY 720
RED/BLK 380
LT BLU/ 1688
BLK
FTP
Sensor
i~ -
LT BLLJ/ 1688
BLK
Fuel Tank
Unit and
TFT Sensor
GAY 720
27 '" ______ _?~ '" _ i3.? , C2
- NC - - - Sensor
Signal
;v; - - - - Senoor - - - - - - ~ Powertrain

Referenc1
B
SV
Ground
Control
CONN ID
C1=BLU
I Module
C2=CLEAR
~-------------------~J
(PCM)~~
369065
Circuit Description
Diagnostic Aids
The PCM uses this 5 volt reference circuit as a sensor

feed for the A/C refrigerant pressure sensor and the
fuel tank pressure sensor. The PCM monitors the
voltage on this 5 Volt Reference circuit. If the voltage
is out of tolerance, the PCM will set DTC P1639.
Conditions for Running. the DTC


The PCM detects a voltage out of tolerance
condition on this 5 Volt Reference circuit.
Above condition for more than 1O seconds.

The PCMwill illuminate the malfunction indicator
Records data.

malfunction.

the cpnnector gaskets when diagnosing or replacing a
Poor terminal .connection.
tensior:i. Refer to Testing for Intermittent.and Poor
Systems.
Damaged harness.
Inspect the wiring harne.ss for damage. If the
the fault. Refer to Wiring Repairs in Wiring.
Systems.
If the DTC is determined to be intermittent; reviewing
Engine

Step
Action
Values
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 14
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 7
Go to
Diagnostic Aids
Go to Step 9
Go to Step B
Go to Step 10
Go to Step 14
Go to Step 11
Go to Step 14
, Go to Step 12
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 13
'
,>2
8
,.
10
11
12
Visually/physically inspect the PCM and engine grounds.

Ensure the grounds are clean and secure.
1. Disconnect all of the following components:
EGR
MAP
Fuel sender connector
A/C pressure sensor
2. Measure. the voltage on the 5 volt reference circuit at
the A/C pressure sensor connector using a DMM that
is connected to ground.
Does .the voltage measure at or near the specified value?
1. Leave the DMM connected to the A/C pressure
sensor 5 volt reference circuit.
2. Reconnect each component one at a time.
Does the measured voltage remain at or near the specified
value when each component is connected?
1. Reconnect the A/C pressure sensor.
2. Disconnect the MAP.
the MAP sensor connector..
Does the voltage.measure at or.near the specified value?
Is the voltage below the specified value?
Test the signal circuit of the effected component for a
short to B+: Refer to Circuit Testing and Wiring Repairs in ,
Wiring Systems.
Test the signal Circuit of the A/C pressure sensor for a
short t6 B+. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the 5 volt reference circuit for a short to ground. Refer
Did you find and corre.ct the condition?
, Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Replace the effected component.
Replace the A/C pressure sensor.
Did you completeJhe repair?
Replacement/Programming,
5V
5V
5V
4.8V
,'
13
14
15

DoesJl'le OTC.reset?
not diagnosed?
Go to Step 14
Go to Step 14
Go to Step 14
-
Go to Step 2
Go to
applicable OTC
Go to Step 15
System OK
6-1166
Engine
Engine Controls .. 3.8L
DTC P1689 Traction Control Delivered Torque Output Circuit
~--------------------------------~-,p
v
owert.
ram
I
12
I I CONN ID II T.ach.ometer
I
C1=BLU
ii
~ 1C2=CLEAR -
Outp t
-
u -
.-
-l
Delivered~
Torque
. _ PWM _-: - Output-~:::- -
.-
-l
PWM -
_ Input
Control
IM
d I
TAN/BLK 464
l12V D .
Tachometer
Input
1
e1vere
Torque
O U
- Logic
81
91C2
w:: t--------rAN1BL:r-------ORN/B:1::
WHT 121
~ (P~M)
----A
Desired
Torque
.
Output
_r
-
PWM
I
I
ElectrO(fnlC .
Brake
C
I ract1.on
Ontro
-=~
.. _______________________________
.. ~~~~t
(
)
Logic
fM:"1
LliJ
71IC1
ORN/BLK 463
-"'------------------"'----
~I
Desired
Torque
Input
j6
~
370828
Circuit Description
The electronic brake and traction control
module (EBTCM) controls the PWM signal on the
Desired Torque circuit while monitoring the wheel
speed sensors to detect slippage. The PCM monitors
the PWM signal and reduces engine torque as
needed by retarding ignition timing, decreasing boost
duty cycle, increasing air/fuel ratio, or, in severe
cases, shutting OFF up to three fuel injectors. The
PCM sends a PWM signal to the electronic brake and
traction control module (EBTCM) on the delivered
torque circuit informing the EBTCM of response made
to the desired torque signal. A problem with the
delivered torque circuit should cause OTC P1689 and
ABS/TCS OTC 76 to set and traction control to be
disabled. Refer to ABS/TCS for further information.

The ignition is ON.

the output circuit which controls the traction
control delivered torque output.
The above conditions present for at least
30 seconds.

Frame data.

malfunction.
Diagnostic Aids
Systems.
Damaged harness.
Systems.
Engine
Test Description
Also tests for a component that is going open

while being operated, resulting in a measured
current of O milliamps.

diagnostic table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Tests for a shorted component or a short to B+ on
the control circuit. Either condition would result in
a measured current of over 500 milliamps.
6-1167
4. Tests for a short to voltage on the control circuit.

DTC P1689 Traction Control Delivered Torque Output Circuit

Step
Action
Values
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 6
Go to Step 11
Go to Step 4
Go to Step 10
Go to Step 5

Disconnect the PCM.
Measure the voltage on the delivered torque control
circuit using a O.MM that is connected to a good
ground.
B+
1. Measure the current on the delivered torque cbntrol

circuit using a DMM.
2. Observe the current for at least 2 minutes.
Does the current remain within the specified range?
0.001-0.5 Amp
(1-500 mA)
1.
2.
3.
4.
Yes

4. Turn QN the ignition.

5. Measure the voltage on the delivered torque control
circuit using a DMM that is connected to a good
ground.
Repair short. to voltage in the delivered torque control
ov
'
Go to Step 16

2. Inspect the ignition feed fuse for the EBTCM.
Is the fuse open?
1. Repair short to ground Jn ignition feed circuit for the

EBTCM. RefEJr to Wiring Repairs in Wiring Systems.
2. Replace the fuse,
1. Disco11nect the EBTCM ..

2. Turn. ON the ignition.
3. Measure the voltage on the ignition feed circuit for
the EBTCM using a DMM that is connected to a good
ground.
Does the voltage measur.e near the specified value?
B+
Test the delivered torque control circuit for an open or a

short to ground. Refer to Circuit Testing and Wiring
Go to Step 7
Go to Step 8
Go to Step 16
Go to Step 9
Go to Step. 13
Go to Step 16
Go to Step 10
6-1168
Engine

DTC P1689 Traction Control Delivered Torque Output Circuit (cont'd)
Step
Action
Values

The delivered torque control circuit for a poor
connection at the PCM.
The delivered torque c.ontrol circuit for a faulty
connection at the EBTCM,
The EBTCM ignition feed circuit for a poor
connection at the EBTCM.
2. Refer to Testing for Intermittent and Poor
Systems.
Did you .find and correct the condition?

Reconnect the PCM.
Disconnect the EBTCM.
Connect a test lamp between the delivered torque
control circuit and the ignition feed circuit.
6. With a scan tool, command the delivered torque
output ON and OFF.
Does the test lamp blink ON and OFF?
12
Inspect the delivered torque control circuit for a poor

Systems.
13
Repair open in ignition feed circuit to the EBTCM. Refer to

Replace the EBTCM. Refer to Electronic Brake Control

Module (EBCM) Replacement in ABSfTCS.


conditions.
Does the DTC reset?
10
11
14
15
16
1.
2.
3.
4.
5.
Symptoms
Important Preliminary Checks Before Starting
Perform the A Powertrain On Board Diagnostic (080)
System Check before using the. Symptom tables,
and verify all of the following are true:
The PCM and MIL (Service Engine Soon) are
There are no DTCs stored.
Ensure that the engine coolant temperature is not
above 130C (266F). This condition causes the
PCM to operate in Engine Coolant Over
Temperature-Fuel Disabled Mode. While in
Engine Coolant Over Temperature-Fuel Disabled
Yes
No
Go to Step 16
Go to Step 14
Go to
Diagnostic Aids
Go to Step 12
Go to Step 16
Go to Step 15
Go to Step 16
-
Go to Step 16
Go to Step 16
Go to Step 2
System OK
Mode, the PCM turns the Juel off to four cylinders

at a time in order to keep engine temperatures
from reaching damaging levels. The system
perceives Engine Coolant Over Temperature as a
lack of power, miss, or rough idle. If the vehicle
is operating in Engine Coolant Over
Temperature-Fuel Disabled Mode, refer to
Engine/Engine Cooling for diagnosis.
The scan tool data is within the normal operating
range, refer to Scan Tool Data List.
Verify the customer complaint, and locate the
correct symptom in the table of contents. Inspect
the items indicated under that symptom.
Engine
Visual/Physical Check
Several of the symptom procedures ask for a Careful
Visual/Physical inspection. This step is extremely
important :_ it can lead to correcting a problem without
further testing and can save valuable time. This
inspection checks for the following:
PCM grounds are clean, tight, and in their proper
location.
Vacuum hoses are not split, kinked, and proper
connections are present, as shown on the
Vehicle Emission Control Information label. Inspect
thomughly for any type of leak or restriction
Mass air flow (MAF) sensor is installed correctly.
The arrows on the plastic portion of the sensor
must point toward the engine
Air intake ducts are not collapsed or damaged.
No Air leaks at throttle body mounting area, Mass
Air Flow (MAF) sensor, and the intake manifold
sealing surfaces.
Ignition wires are not cracked, hardened or carbon
tracking.
Ignition wires are routed correctly.
Engine wiring is not damaged.
Terminals have proper connections.
Intermittent
Important: Inspect for improper installation of electrical
components if an intermittent condition exists.
Inspect for aftermarket theft deterrent devices, lights
and cel.lular phones. Ensure that no aftermarket
equipment is connectecl to the Class 2 circuit. If you
can not locate an intermittent condition, a cellular
phone signal communication may cause the condition.
Important: The problem may or may not turn ON
the Malfunction Indicator Lamp (MIL} or store a DTC.
DO NOT use the Diagnostic Trouble Code (DTC)
tables for intermittent problems. The fault must
be present in order to locate the problem.
Faulty electrical connections or wiring cause most
intermittent problems. Perform a careful visual/physical
inspection for the following conditions:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
An improperly formed or damaged terminal.
Reform or replace connector terminals in the
problem circuit in order to insure proper contact
tension.
Poor terminal to wire connection requires removing
the terminal from the connector body iri order
to check.
6-1169
Road test the vehicle with a digital multimeter

connected to the suspected circuit. An abnormal
voltage when the malfunction occurs is a good
indication that there is a malfunction in the circuit
being monitored.
Use a scan tool in order to help detect intermittent
conditions. The GM Techline equipment (Scan Tool}
has several features that you can use to locate
an intermittent condition. Use the following features to
find intermittent faults:
You can trigger the Snapshot feature in order to
capture and store engine parameters within the
scan tool when the malfunction occurs. You
can then review this stored information in order to
see what caused the malfunction.
Using a Scan Tools Freeze Frame buffer or
Failure Records buffer can also aid in locating an
intermittent condition. Review and capture the
information in the Freeze Frame and/or Failure
record associated with the intermittent DTC being
diagnosed. Drive the vehicle in the conditions
that were present when the DTC originally set.
Important: If the intermittent condition exists as a

start and then stall, check for DTCs relating to the theft
deterrent system. Inspect for improper installation of
electrical options such as lights, cellular phones etc.
Any of the following may cause an intermittent
Malfunction Indicator Lamp (MIL) with no stored DTC:
The ignition coils shorted to a ground, arcing at
the ignition wires or the spark plugs.
The PCM grounds, refer to PCM wiring diagrams.
The ignition control (IC) wires for being routed
to close to the secondary ignition wires, coils,
or the generator - Ensure that all of the circuits
from the PCM to the ignition coils have good
connections.
An open diode across the A/C compressor clutch
and other open diodes.
Use the following tables when diagnosing a symptom
complaint:
Hard Start
Surges/Chugg/es
Lack of Power, Sluggishness, or Sponginess
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses
Poor Fuel Economy
Rough, Unstable, or Incorrect Idle and Stalling
Dieseling, Run-On
Backfire
6-1170
.Engine
Hard Start
Checks
Action
DEFINITION: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary ,
Refer to the Symptoms.

Search for bulletins.
Sensor/System
Test engine coolant tamperature (ECT) sensor for being shifted in value. Install
a scan tool and compare the displayed engine coolant tamperature with intake
air temperature .on a cold engine. Test the resistance of the ECT sensor if
engine coolant temperature is not within 3C (5F) of intake air temperatwe.
Refer to Temperature vs Resistance. If the ECT sensor resistance is not within
the specification, refer to OTC P0117 Engine Coolant Temperature (ECT)
Sensor Circuit Low Voltage or OTC P0118 Engine Coolant Temperature (ECT)
Sensor Circuit High Voltage.
Inspect the throttle body inlet screen for foreign objects or damage that may
affect the MAF sensor airflow sample. Refer to Throttle Body Air Inlet Screen
Replacement.
EGR system. Inspect for the following conditions:
- EGR pipes and adapter for vacuum leaks.
- Remove the EGR valve and inspect for a stuck open pintle. Refer to EGR
Valve Replacement.
Fuel System
Test the fuel pump relay circuit for proper operation.

Refer to Fuel Pump Electrical Circuit Diagnosis.
Test for incorrect fuel pressure.
R.~fer to Fuel System Pressure Test

Test the fuel injectors.
- Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C
(50-95 Degrees F).
- Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C
(50-95 Degrees F).
Test for fuel contamination. Refer.to Alcohol/Contaminants-in-Fuel Diagnosis.
Engine
Engine Controls - 3.SL 6-1171

Hard Start (cont'd)
Ctiecks
Ignition System
Action
Test for proper ignition voltage output using the following steps:
- Clip the J 26792 spark tester to engine ground.
- Connect one erid of a spark plug wire to the spark tester, leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower, connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the spark tester, a spark should be
observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coils, inspect for the following conditions:
- Coils - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
Coil Secondary Resistance
5000 - 8000 ohms (5K - 8K ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched'. incorrect routing, or a resistance value more than the
specified value.
Spark Plug Wire Resistance
3280-4921 ohms/meter(1000-1500 ohms/ft)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
- Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and inspect for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Engine Mechanical
Excessive oil in combustion chamber-Leaking valve seals.

Low cylinder compression.
For incorrect basic engine parts. Inspect the following:
- Cylinder heads
- Camshaft and valve train components
- Pistons, etc.
Refer to Base Engine Misfire Diagnosis in Engine Mechanical.
6-1172

.
Checks
Engine
Surges/Chuggles
..
Action
DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
Preliminary
. Refer to the Symptoms.

Be sure driver understands transmission torque converter clutch, and A/C
compressor operation as explained in the owners manual. Inform customer how
TCC and the A/C clutch operates.
Sensor/System
Test the heated oxygen sensors. The heated oxygen sensors should respond
quickly to different throttle positions. If not, inspect the H02S for silicon or other
contaminants from fuel or use of incorrect RTV sealant. The sensors may have
a white powdery coating. Silicon contamination causes a high but false H02S
signal voltage (rich exhaust indication). The PCM will reduce the amount of luel
delivered to. the engine, causing a severe driveability problem. Refer to heated
oxygen sensors in Information Sensors/Switches Description.
Test the MAF sensor and inspect the related wiring.
Test the EGR valve for a stuck open pintle.
Fuel System
Test the fuel pressure.

Refer to Fuel System Pressure Test and Fuel Pump Electrical Circuit Diagnosis.
Test for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Ensure each injector harness is connected to the correct injector/cylinder. Refer
to Engine Controls Schematics.
Test items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range). Refer to Diagnostic Aids for OTC P0172 Fuel
Trim System Rich Bank 1.
Test items that can cause an engine to run lean (long term fuel trim is
significantly in the positive.range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.
Engine
Engine Controls- 3.SL
6-1173
Surges/Chuggles (cont'd)
Checks-
Action
-Ignition System
Testfor proper ignition voltage output using the following steps:

- - Connect one end of a spark plug wire to the spark tester, leave the other end
observed.
If adequate spark is not present at the coils, test for the following conditions:
..:. Coils - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
5000 - 8000 ohms (5K - BK ohms)
boot damage, pinched, incorrect routing, or a resistance value more than the
specified value.
Spark Plug Wires Resistance
3280-4921 ohms/meter(1000-1500 ohms/ft).
- Fouled plugs
-Cracks
-Wear
- Incorrect gap
Additional Tests
Test TCC operation. Refer to A Diagnostic Starting Point in 4L60-E Automatic

Transmission.
Inspect the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the muffler for heat distress or possible internal failure.
- Test for possible plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check.
s. 1174

,,
Engine
lack of Power, Sluggishness, or Sponginess
Checks
Action
',
DEFINITION: Engine delivers less than expected power. Little or no increase in speed when the accelerator pedal is pushed
down part way.
Preliminary Checks
.

Search for bulletins .
Fuel System
Test the following items:

Fuel pressure.
- Refer to Fuel System Pressure Test and Fuel Pump Electrical Circuit
Diagnosis.
- Fuel injectors.
(50-95 Degrees F).
- Refer to Fuel Jnj Coil Test - ECT Outside 10-35 Degrees C
(50-95 Degrees F).
- Contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
- Test items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range). Refer to Diagnostic Aids for OTC P0172
Fuel Trim System Rich Bank 1.
.,... Testitems that can cause an engine to run lean (long term fuel trim is
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171
Fue1 Trim System Lean Bank 1.
Sensor/System
Using a scan tool, monitor KS system for excessive spark retard activity. Refer
to Knock Sensor (KS) System Description.
If knock retard is above 10~ 12 degrees, disconnect the knock sensor and ground
the sensor harness connector. Monitor the knock retard on the scan tool, there
should be no knock retard present. If knock retard is still present, the PCM is
malfunctioning. Replace the PCM. Refer to PCM Replacement/Programming.
Test the EGR valve for a stuck open pintle. Refer to EGR Valve Replacement.
Inspect for a restricted intake duct or a dirty air cleaner element. Refer to Air
Engioe
6-1175
Lack of Power, Sluggishness, or Sponginess (cont'd)

Checks
Ignition System
Action
- Connect one end of a spark plug wire to the spark tester, leave the other end
of the spark plug wire to the coil. being tested.
observed.
'
Coils - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
5000 - 8000 ohms (5K - 8K ohms)
Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug boot
damage, pinched, incorrect routing, or a resistance value more than the
specified value.
3280-4921 ohms/meter(.1000-1500 ohms/ft).
locate an intermittent problem. Ignition components will arc to ground 'Nhe.n a
Malfunctioning ignition control module.
Ignition System Wiring - Loose ignition module feed or ground connection, or
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
Engine Mechanical

- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Tests
Testthe exhaust system for a possible restriction.

Inspect the exhaust system for damaged or collapsed pipes.
Inspect the muffler for heat distress or possible internal failure.
Test for a plugged three-way catalytic converter. Refer to Restricted Exhaust
System Check.
Test for proper TCC operation. Refer to A Diagnostic Starting Point in 4L60E
Automatic Transmission.
6.;1176
Engine
Checks
Action
DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening.
Preliminary Checks

Fuel System
Ignition System
Inspect the spark plugs for proper application.

Refer to Spark Plug Usage in Engine Electrical.
Engine Cooling System
Engine Mechanical
Test for incorrect fuel pressure.

Test items that can cause an engine to run lean (long term fuel trim significantly
in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel Trim System
Lean Bank 1.
Inspect for obvious overheating problems:

Low engine coolant.
Restricted air flow to radiator, or restricted water flow through radiator.
Electric cooling fans operation. Refer to Electric Cooling Fan Diagnosis
(Description).
Correct coolant solution should be a 50/50 mix of GM approved antifreeze
coolant and water.
Combustion cha_mbers for excessive carbon buildup. Clean using Top engine
cleaner. Follow instructions on can.
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Tests
Test for proper EGR system operation. Refer to OTC P0401 Exhaust Gas
Recirculation (EGR) Flow Insufficient.
Test the transaxle range switch input with the vehicle in drive and the gear
selector in drive or overdrive.
Test TCC operation. A malfunctioning TCC can cause the engine to spark
knock. Refer to A Diagnostic Starting Point in 4L60E Automatic Transmission:
If scan tool readings are normal and there are no engine mechanical problems,
fill the fuel tank with a known quality gasoline that has a minimum octane
reading of 87 and re-evaluate vehicle performance.

Checks
Action
DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually
more pronounced when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe
enough.
Preliminary

Sensor/System
Test the heated oxygen sensors. The heated oxygen sensors should respond
quickly to different throttle positions. If not, inspect the H02S for silicon or other
contaminants from fuel or use of incorrect RTV sealant. The sensors may have
a white powdery coating. Silicon contamination causes a high but false H02S
signal voltage (rich exhaust indication). The PCM will reduce the amount of fuel
delivered to the engine, causing a severe driveability problem. Refer to heated
oxygen sensors in Information Sensors/Switches Description.
Test the TP sensors and inspect the related wiring.
Test the MAF sensor and inspect the related wiring.
Test the EGR valve for a sticking pintle. Refer to EGR Valve Replacement.
Engine
6-1177
Hesitation, Sag, Stumble (cont'd)

Action
Checks
Fuel System

Test the injectors.

Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C (50~95 Degrees F).
Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C (50-95 Degrees F).
Test items which can cause an engine to run rich (long term fuel trim is
Trim System Rich Bank 1,
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.
Ignition System
observed.
If spark is not present at the coils, test for the following conditions:
specified range.
5000 - 8000 ohms (5K - 8K ohms)
specified value.
3280-4921 ohm/meter(1000-1500 ohm/ft).
Important: Spraying the secondary ignition wires with a light mist .of water may help
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
6-1178
Engine

Cuts Out, Misses
Checks
Action
DEFINITION: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases:
Preliminary

Fuel System
Test system fuel pressure.


Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C (50-95 Degrees F).
Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C (50-95 Degrees F).
Test items which can cause an engine to run rich (long term fuel trim
test items that can cause an engine to run lean (long term fuel trim significantly
in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel Trim System
Lean Bank 1.
Inspect for fuel i.n the fuel pressure regulator vacuum hose. If fuel is present,
replace the fuel pressure regulator. Refer to Fuel Pressure Regulator
Replacement.
Sensor/System
Inspect for conditions which cause an incorrect idle speed.

- Throttle body tampering, excessive deposits, or damage.
- Restricted air intake duct or dirty air cleaner element. Refer to Air Cleaner
Element Replacement.
- Large vacuum leak.
Test the Electronic Throttle Control and inspect the related circuit wiring.
Test the EGR system:
- The EGR pipes and adapter for vacuum leaks.
- Remove the EGR valve and inspect for a sticking pintle. Refer to EGR Valve
Replacement.
Inspect the PCV valve for proper installation.
- Refer to Crankcase Ventilation System Inspection.
- Test the transaxle range switch input with the vehicle in drive and the gear
- Inspect for the following conditions:
- Bent harmonic balancer interrupter rings.
- Damaged crankshaft position sensor.
Engine
Engine Controls- 3.8l 6-1179

Cuts Out, Misses (cont'd)
Checks
Ignition System
Action
observed.
specified range.
5000 - 8000 ohms (5K - 8K ohms)
specified value.
3280-4921 ohms/meter(1000-1500 ohm/ft)
- Malfunctioning ignition control module
Remove spark plugs and test for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
test for the following intermittent ignition system conditions:
- Intermittent CKP Sync or CKP 18X Signal.
- Intermittent ignition feed circuit or sensor ground circuit to the crankshaft
position sensor or the camshaft position sensor.
- Intermittent 3X reference signal.
- Intermittent camshaft position signal
6;.1180
Engine
Cuts Out, Misses (cont'd)
Checks
Engine Mechanical
Action
'"' '"'..
Test the following:

- Engine compression
_, Sticking or leaking valves
- Worn camshaft lobes
...:..Valve timing
Bent push rods
Worn rocker arms
Broken valve springs
Excessive oil in combustion chamber-Leaking valve seals
Low cylinder compression

- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Tests
Test the exhaust system for a possible restriction.

- Inspect exhaust system for damaged or collapsed pipes.
- Inspect mufflers for heat distress or possible internal failure.
- For possible plugged Three-Way catalytic converter. Refer to Restricted
An engine miss condition can be caused by Electromagnetic Interference (EMI)
on the reference circuit. EMI can usually be detected by monitoring engine RPM
with a scan tool. A sudden increase or decrease in RPM with little change in
actual engine RPM change indicates that EMI is present. Inspect the routing of
secondary ignition wires. Also, inspect the ignition coils for cracks, carbon
tracking, or signs of arcing.
Inspect for intake and exhaust manifold passages for casting flash.
Inspect for loose, worn, or broken motor mounts.
Poor Fuel Economy

Checks
Action
DEFINITION: Fuel economy; as measured by an actual road test is noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.
Preliminary

Check owners driving habits.
'- Is A/C ON full time (Defroster mode ON)?
- Are tires at.correct pressure?
'-- Are excessively heavy loads being carried?
- Is acceleration too much, too often?
Fuel System
Test for incorrect fuel pressure. Refer to Fuel System Pressure Test.
(50-95 Degrees F).
(50-95 Degrees F).
Ensure each injector harness is connected to the correct injector/cylinder. Refer
Inspect for fuel in the pressure regulator vacuum hose.
Sensor/System
Inspect the intake system and crankcase for air leaks.

Test for proper calibration of speedometer. Connect a J 33431-C signal
generator to VSS electrical connector. Ignition ON, tester ON and monitor the
speedometer.
'
Engine
6;,.1181
Poor Fuel Economy (cont'd)
Checks
Ignition System
Engine Mechanical
Additional Tests
Action
- Clip the. J 26792 spark tester to engine ground.
observed.
specified range.
5000 .: 8000 ohms (5K - 8K ohms)
boot damage, pinched, incorrect routing, or a resistance more than the
specified value.
Spark Plu~ Wires Resistance
3280-4921 ohms/meter(1000-1500 ohm/ft).
- Fouled plugs
..
- Cracks
-Wear
- Incorrect gap
Test engine coolant level for a low condition.
O Test for incorrect or malfunctioning engine thermostat. Refer to Engine
Overheating in Engine Cooling.
Test for the following:
.
- Sticking or leaking valves
-: Worn camshaft lobes
- Valve timing
- Bent push rods
- Worn rocker arms
- Broken valve springs
- Excessive oil in combustion chamber-Leaking valve seals
For incorrect basic engine parts. Inspect for the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Test TCC operation. Refer to A Diagnostic Starting Point in 4L60E Automatic
Transmission.
6-1182
Engine Controls
3.8L
Engine
Poor Fuel Fill Quality
Problem
Causes
DEFINITION: Difficulty when refueling the vehicle.

Difficult to fill
The check valve is stuck closed.

The fill limiter vent valve is stuck closed.
The EVAP canister is restricted.
The EVAP vent valve is stuck closed.
Restricted EVAP pipes.
High Reid vapor pressure.
High fuel temperature.
The fuel filler hose/pipe is pinched, kinked, or blocked.
Ignition switch ON.
Over fill
The pressure relief valve in the fill limiter vent valve is stuck open.
The pressure relief valve in the fill limiter vent valve is leaking.
The fill limiter vent valve is stuck open.
The fill limiter vent valve is leaking.
Pre-mature shut-off of the fuel

dispensing nozzle
Fuel Spit Back

The EVAP vent valve is stuck closed.

Ignition switch ON.
The check valve is stuck open.

O The check valve is stuck closed.
The check valve is leaking.
Liquid fuel in EV AP canister

Liquid fuel leak
Fuel Odor
The
The
The
The
'"
pressure relief valve in the fill limiter vent valve is stuck open.
pressure relief valve in the fill limiter vent valve is leaking.
fuel filler hose is loose or torn.
fill limiter vent vaive is stuck open.
The EVAP canister is saturated.
Engine
6-1183
Rough, Unstable, or Incorrect Idle .and Stalling

Checks
Action
DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Preliminary Checks

Search for bulletins:
Fuel System

- Refer to Fuel System Pressure Test.
(50-95 Degrees F).
(50-95 Degrees F).
test for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
ln~pect for fuel in the pressure regulator vacuum hose.
O Ensure each injector harness is connected to the correct injector/cylinder. Refer
Test items whjch can cause an engine to run rich (long term fuel trim is
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank. 1.
Sensor/System
Inspect for conditions which cause an incorrect idle speed.

- Throttle body tampering, excessive deposits, or damage.
- Restricted air intake duct or dirty air cleaner element. Refer to Air Cleaner
Element Replacement.
- Large vacuum leak.
Inspect the crankcase ventilation valve for proper installation. Refer to
Crankcase Ventilation System Inspection.
Test the ETC and inspect related wiring.
Test the EGR system for proper operation. Refer to OTC P0401 Exhaust Gas
Recirculation (EGR) Flow Insufficient.
Test the transaxle range switch input with the vehicle in drive and the gear
6-1184
Engine
Rough, Unstable, or Incorrect Idle and Stalling (cont'd)

Checks
Ignition System
Action
observed.
Coils - Cracks, carbon tracking/arcing, or a resistance value outside the

specified range.
5000 - 8000.ohms (5K - 8K ohms)
Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
specified value.
3280-4921 ohms/meter(1000-1500 ohms/ft).
Malfunctioning ignition control module.
Ignition System Wiring - Loose ignition module feed or ground connection, or
Remove spark plugs and test for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
Engine Mechanical
Test the following:

- Sticking or leaking valves
- Worn camshaft lobes
- Valve timing
- Bent push rods
- Worn rocker arms
- Broken valve springs
- Excessive oil in combustion chamber-Leaking valve seals
- Camshaft
- Cylinder heads
- Pistons, etc.
Engine
6-1185

Action
.Checks

- for possible plugged Three-Way catalytic converter. Refer to Restricted
Inspect for loose; worn, or broken motor mounts.
O An engine miss condition can be caused by Electromagnetic Interference (EMI)
on the rnference circuit. EMI can usually be detected by monitoring engine RPM
with a scan tool. A sudden increase or decrease in RPM with little change in
actual engine RPM indicates that EMI is present. Inspect for incorrect routing of
secondary ignition wires. Also inspect the ignition coils for cracks, carbon
tracking, or signs of arcing.
Inspect for intake and exhaust manifold passages for casting flash.
Additional Tests
Dieseling, Run-On
Action
Checks
DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smooth, inspect the
igni1ion switch and adjustment.
Preliminary Checks
. Refer to the Symptoms.

Fuel System
Test the Fuel injectors.

Refer to Fuel In} Coil Test - ECT Between 10-35 Degrees C (50-95 Degrees F).
Additional Tests:
Test for short between B+ and any of the ignition feed circuit. Refer to Circuit
Testing.
Refer to Fuel In} Coil Test - ECT Outside 10-35 Degrees C (50-95 Degrees F).
Backfire
Actions
Checks
DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making loud popping noise.
Preliminary Checks

Sensor/System
Inspect for the following intermittent ignition system conditions:

- Intermittent CKP Sync or CKP 18X signal
- Intermittent ignition feed circuit or sensor ground circuit to the crankshaft
position sensor or the camshaft position sensor.
- Intermittent 3X reference signal
- Intermittent camshaft position signal
Inspect the throttle body inlet screen for foreign objects or damage that can
affect the MAF sensor airflow sample.
Fuel System
Test for incorrect fuel pressure. Refer to Fuel System Pressure Test.
Ensure each injector harness connector is connected to the correct injector.
'
6-1186
Engine
Backfire (cont'd)
Checks
Ignition System
Actions
observed.
specified range,

5000 - 8000 ohms (5K - 8K ohms)
- Spark plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
specified value.

3280-4921 ohm/meter(1000-1500 ohms/ft).
Important: Spraying the. secondary ignition wires with a light mist of water may help
Engine Mechanical
Additional Tests

- Ignition system wiring - Loose ignition module feed or ground connection, or
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
O If spark plugs are gas or oil fouled, the cause of the fouling must be determined
Test for the following:
O
Engine compression
Sticking or leaking valves
Worn camshaft lobes
Valve timing
Bent push rods
Worn rocker arms
Broken valve springs
Excessive oil in combustion chamber-Leaking valve seals
O
Low cylinder compression
~ For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Inspect the intake and exhaust manifolds for casting flash.
O Test TCC operation. Refer to A Diagnostic Starting Point in 4L60E Automatic
Transmission.
Engine
6;.1187
Restricted Exhaust System Check

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Dia.gnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
System OK
Go to Step 5
Go to Step 6

1. Remove a pre-catalyst H02S. Refer to Heated

Oxygen Sensor (H02S) Repfacement.
In
place of the H02S, install a J 35314-A/BT-8515/
2.
BT-8515A exhaust back pressure tester.
4. With the transmission in Park or Neutral and the
engine idling at normal operating temperature,
observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?
1. Leave the transmission in Park or Neutral.

2. With the exhaust back pressure tester in place of the
pre-catalyst H02S, increase engine speed to
2000 rpm.
3. Observe the exhaust system back pressure reading
on the gage.
20.7 kPa (3 psi)
1. Reinstall the pre-catalyst H02S.

2. Remove the post-catalyst H02S.
3. In place of the H02S, install J 35314-A/BT-8515/
BT-851 SA exhaust back pressure tester.
4. Engine at normal operating temperature.
6. Increase engine speed to 2000 rpm.
on the gage.
20. 7 kPa (3 psi)
Locate and repair the restriction in the exhaust system

past the three way catalytic converter. Possible faults
include the following:
Collapsed pipe
Heat distress
Internal muffler failure
Replace the three way catalytic Converter. Refer to

Catalytic Converter Replacement (3.8 L) in Engine
Exhaust.
8.6 kPa
(1.25 psi)
Go to Step 7
Go to Step 7
1. Remove a pre-catalyst H02S.

2. In place of the H02S, install J 35314-A/BT-8515/
BT-8515A exhaust back pressure tester.
4. Engine idling at normal operating temperature.
on the gage.
8.6 kPa
(1.25 psi)

2. With exhaust each pressure tester in place of the
pre-catalyst H02S, increase engine speed to
2000 rpm.
on the gage.
20.7 kPa (3 psi)
Go to Step 4
Go to Step 8
Go to Step 5
System OK
6;.1188
Powertrain Control Module Diagnosis

The approved procedure for diagnosing all powertrain
control system malfunctions is included in the
Strategy Based Diagnosis. The preliminary checks
and the .Powertrain On-Board Diagnostic System
Check mustbe performed to successfully diagnose
and repair the powertrain systems.
To read and clear diagnostic trouble codes, use a
scan tool.
Important: Use a scan tool to clear diagnostic trouble

codes from the PCM memory. Diagnostic trouble
codes can also be cleared by turning OFF the ignition
and disconnecting the battery power from the PCM
for 30 seconds, but this method will also cause
all diagnostic information in the PCM memory to be
cleared and all the diagnostic tests will have to
be re-run.
Since the PCM can have a failure which may affect
only one circuit, following the approved diagnostic
procedures will determine which circuit has a problem
and where it is. If a diagnostic table indicates that
the PCM connections or PCM is the cause of a
problem and the PCM is replaced, but does not correct
the problem, one of the following conditions may exist:
Engine
" The EEPROM program is not correct for the
application.
Incorrect components may cause a malfunction
and may or may not set a OTC.
The problem is intermittent. This means that 1he
problem is not present at the time the system is
being checked. In this case, refer to the Symptoms
portion of the manual and make a careful visual
and physical inspection of all suspected
components and wiring associated with the
affected system.
" Shorted solenoid, relay coil, or harness. Solenoids
and relays are turned ON and OFF by the PCM
using internal electronic switches called drivers.
Each driver is part of a group of seven called
output driver modules. A shorted solenoid, relay
coil, or harness will not damage the PCM but .
will cause the solenoid or relay to be inoperative.
The J 34636 tester, or equivalent, provides a
fast, accurate means of checking for a shorted coil
or a short to battery voltage.
(.
.
There is a problem with the PCM connections.

The diagnostic table will indicate that the PCM
connections or PCM is the problem. The terminals
may have to be removed from the PCM
connector in order to check them properly.
Engine
6-1189
PCM Controlled A/C Circuit Diagnosis

.. Po:er- -
Distribution
Schematics
in Wiring
Systems
'"'" -
A/C- CRUISE
Mini Fuse
15 A
!Loe
,Engine Wiring
I
Fuse
I
Block I
L----------.1
PNK 139
Power
Distribution
Schematics
In Wiring
Systems
PNK 139
- - - - - - - - ,Engine Wiring
010
I Harness
~~~pressor I Junction Block 2
[g]
I
I
1,
I
~ - - _c1~1-D~ ~R~14~9- - - - ~
DKGRN 59
DKGRN 59
DKGRN 59
[ID
A/C
Compressor Bv
Clutch Diode
1 Amp
899
.-------,1
1l~
_,
DK GRN/WHT 459
Clutch
Sensor
BLK 450 T
I
BLK
450
)
/
/
DEF
I
I
I
- - HTR
VENT
._ _ _ _ _ _ _ _ _ _ _ J
j, _Pressure
A/C
Refrigerant
~~~presser
Ground
Distribution
Schematics
In Wiring
Systems
BRN 241
C C2
I OFF
I
I
I
899
.4'~
.I
HVAC ,. - - - - - - - - - - .,
1
Control
/
I
I
Assembly 1
WHT
BRN
241
I
I
Clutch
Relay
I
I
20 A
HVAC I
Fuses I
F2
E
BRN 241
Power
Distribution
Schematics
In Wiring
Systems
PNK 139
,. - - oa
Distribution
~chE:l!lat1cs
1nWmng
Systems
L------
+---------',
I
- -,
r------lP I Power
I Harness
I Junction Block 2
A C2
DK
GRN/WHT 762
Fuel
Tank
-<II Unit and
TFT Sensor
RED/BLK 380
DK
GRN/WHT 762
LT BLU/ 1688
GRY 720
BLK
39
_____2_7_
A/C
I Relay
I Control ~
Sensor.
Signal
~
I
- - '~-!
"l A/C -1--
5 ; 01;
-1--Sen;, - - - - - - - - NC - -i-
34
35
Reference
El
Ground
__________________ 22 C2
CONN ID
c1 = BLU
Request
Signal
C2=CLEAR
5V
~ Powertrain
I
L---------------------------~J
Control
Module
(PCM)
A.
pa
~
548658
Circuit Description
When an A/C mode is selected, the HVAC control
head supplies a battery positive voltage signal to the
PCM A/C request input. The A/C compressor
clutch relay is controlled by the PCM. The PCM
provides a ground path for the A/C relay coil. When
the A/C compressor relay is engaged battery positive
voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested unless one or more of the following
, conditions are present:
Throttle angle is more than 90 percent.
A/C head pressure is more than 414 psi
(4.27 volts) or less than 34 psi (0.35 volt) (a:s
determined by the A/C refrigerant pressure
sensor).
Ignition voltage is below 10.5 volts.

ECT is more than 125C (257F).
IAT is less than 5C (41F).
Ahy of the conditions described.above will inhibit A/C
compressor relay operation.
Diagnostic Aids
Inspect for conditions that will disable A/C operation:
Throttle angle more than 90 percent.
A/C head pressure more than 414 psi (4.27 volts)
or less than 34 psi (0.35 volt) (as determined by
the A/C refrigerant pressure sensor).
Ignition voltage less than 10.5 volts.
Engine speed more than 5440 RPM.
ECT more than 125C (257F).
IAT less than 5C (41F).
6-1190
Engine Controls - 3.8L .
Test Description
diagnostic table:
2. Stored diagnostic trouble codes may disable the
A/C compressor. This diagnostic table may
lead to improper diagnosis and replacement of ..
good parts if diagnostic trouble codes are present.
3. The A/C. compressor clutch should engage if the
appropriate conditions have been met.
4. The A/C compressor clutch should not be engaged
with the engine running if an A/C mode is not
selected at the control head.
6. Tests for an A/C request signal from the control
head to the PCM.
Engine
13. Determines whether the A/C relay or the circuitry
is at fault.
21. Determines if the PCM is tuming the A/C relay

ON due to a false A/C request.
22. Isolates the probiem to the A/C control head or

the PCM.
.
27. Determines if the A/C relay is malfunctioning or
the A/C relay control circuit is grounded all
the time.
35. This vehicle is. equipped with a PCM which utilizes
Memory (EEPROM). When the PCM is replaced, l
the new PCM must be programmed,
12. Tests the ignition positive voltage circuit to the

A/C relay.
PCM Controlled A/C Circuit Diagnosis
Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powerfrain On
Board
.
Diagnostic (OBD)'
System Check
Go to
applicable DTCs
Go to Step 3

Are any powertrain DTCs stored?
Important: Before continuing with diagnosis, the following

conditions must be met:
Intake air temperature more than 9C (48F).
Engine coolant temperature less than 119C (246F).
1. With the A/C OFF, start and idle the engine.
2. Observe the A/C compressor.
Is the A/C compressor clutch engaged?
1. Run the engine at 1000-1500 RPM.

2. Select an A/C mode on HVAC control head.
With an A/C mode still selected, observe A/C Request

parameter on the scan tool.
Does A/C Request display Yes?
1.
2.
3.
4.
Turri OFF the ignition.

Disconnect the PCM.
With an A/C mode still selected, measure voltage on
the A/C request circuit at the PCM harness connector
Is the voltage near the specified value?
Test the A/C request circuit for the followin9 conditions:
Open.
Shorted to ground.
Poor connection at the A/C control head or A/C
programmer (as applicabler Refer to Circuit Testing
and Wiring Repairs or Testing for Intermittent and
Poor Connections and Connector Repairs in Wiring
Systems.
(
'
Go to Step 21
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5 ..
Go to Step,9.
Go to Step 6
Go to Step 8
Go to Step 7
B+
Go to Step 37
Go to A
Diagnostic
System Check
in HVAC
Engine
6-1191
PCM Controlled A/C Circuit Diagnosis (cont'd)

Step
Action
Values
Inspect the A/C request circuit for a poor connection at the

With a scan tool, observe the A/C refrigerant pressure

parameter.
Does the scan tool indicate A/C pressure within the
specified range?
234-2854 kPa
(34-414 psi)
11

2. Disconnect the PCM and the A/C refrigerant pressure
sensor.
3. Measure the resistance of the' following circuits
between the PCM and the A/C refrigerant pressure
sensor:
The A/C refrigerant pressure sensor signal circuit
The 5 volt reference B circuit
The sensor ground circuit
4. If any resistance is higher than the specified value,
locate and repair cause of high resistance in circuit
as necessary. Refer to Wiring Repairs in Wiring
Systems.
5ohms
12
1. Disconnect the A/C relay.

3. Probe both ignition positive voltage circuits at the A/C
relay harness connector using a test lamp that is
Does the test lamp illuminate when probing both circuits?
13
Connect a fused jumper between the ignition positive

voltage circuit and A/C compressor clutch feed circuit at
the A/C relay connector.
Go to Step 37
Go to Step 35
Go to Step 12
Go to Step 10
Go To Step 11
Go to Refrigerant
Recovery 'and
Recharging
in HVAC
Go to Step 37
Go to Step 18
Go to Step 13
Go To Step 31
Go to Step 14
Go to Step 15
Go to Step 37
Go to Step 32
Go to Step 16
Go to Step 17
Go to Step 37
Go to Step 33
Go to Step 37
Go to Step 34
Does the A/C compressor clutch engage?

Inspect for poor connections at A/C relay. Refer to Testing
15
1. Disconnect the A/C compressor clutch (leave the

ignition positive voltage circuit and A/C compressor
clutch feed circuit jumpered at the A/C relay
connector).
2. Connect a test lamp between A/C compressor clutch
feed circuit and the compressor ground circuit.
16
Inspect for poor connections at the A/C compressor clutch.

Connector Repairs.
17
Test for an open or short to ground in the A/C compressor

clutch feed circuit. Refer to Circuit Testing and Wiring
14
No
0.35-4.27 V
1. Connect a J 39500 refrigerant recovery, recycling,

and recharging station to monitor high side refrigerant
pressure. Refer to Heater, Ventilation and Air
Conditioning.
2. Observe high side refrigerant pressure on the gauge.
Is pressure within the specified values?
10
Yes
6-1192
Er1gi11e

Step
Action
1. Leave the PCM and the A/C refrigerant pressure

sensor disconnected.
18
Values
Yes
No
Go to Step 19
Gerta Step 20
<

3. Measure the voltage on the A/C refrigerant pressure
signal circuit using a DMM that is connected to a
good ground.
OV

O
The 5 volt reference B circuit for a poor connection

at the PCM.
The 5 volt reference B circuit for a poor connection

at the A/C refrigerant pressure sensor.
The A/C refriger~nt pressure signal circuit for a
poor connection at the PCM.
19
The A/C refrigerant pressure signal circuit for a

poor connection at the A/C refrigerant pressure
sensor.
,,
The sensor ground circuit for a poor connection at

the A/C refrigerant pressure sensor.
2. Repair as necessary. Refer to Testing for Intermittent
and Poor Connections and Connector Repairs in
Wiring Systems.
20
Repair short to voltage in the A/C refrigerant pressure

Go to Step 36
Go to Step 37
,,
Go to Step 37
21
2. A/C OFF.
3. With a scan tool, observe A/C Request parameter.
Go To Step 22 .
Does the scan tool indicate Yes?

22
4. A/C OFF.
5. Measure the voltage between the A/C request circuit
at the PCM harness connector using a DMM that is
23
To
Step 24
.,
B+

Test the A/C request circuit for a short to B+. Refer to
Go
to Step 35
Go To Step 23
Go
Go to Step 37
Go to A
Diagnostic
Bystem Check
in HVAC
Go to Step 29
Go to 9tep 25
Go to Step 27
Go to Step 26
1. Disconnect the A/C relay.

24
2. Start the vehicle.

25
Probe the A/C compressor clutch control circuit at the A/C

relay harness connector using a test lamp that 'is

26
Replace the A/C relay.

Go.to Step 37
Engine

Step
27
Action
3. Probe the A/C relay control circuit at the PCM
connector with a test lamp that is connected to B+.
Values
29
30
31
32
Repair short to ground in the A/C compressor clutch relay

control circuit. Refer to Wiring Repairs in Wiring Systems.

2. Disconnect the A/C compressor clutch.
Repair short to voltage in the A/C compressor clutch feed

Repair open or short to ground in the ignition positive

voltage circuit to the A/C compressor relay. Refer to Wiring
Replace the A/C compressor relay.

Go to Step 30
Go to Step 37
Go to Step 37
34
Repair open in the A/C compressor clutch ground circuit.


36
Replace the A/C refrigerant pressure sensor.

37
Important: Before continuing with diagnosis, the following

conditions must be met
Intake air temperature more than 9C (48F).
Engine coolant temperature less than 119C {246F).
1. With the A/C OFF, start and idle the engine.
1. Run the engine at 1000-1500 rpm.

2. Select an A/C mode on the HVAC control head.
3. Observe A/C compressor.
38
Go to Step 35
Go To Step 33
33
35
Go to Step 28
Go to Step 37
Repair the A/C compressor clutch. Refer to Compressor

Clutch Plate and Hub Assembly Removal (VS Conventional Mount) in HVAC.
No

28
Yes
Go to Step 37
Go to Step 37
Go to Step 37
Go to Step 37
Go to Step 37
Go to Step 21
Go to Step 38
System OK
Go to Step 5
6-1194
Engine
MAP Sensor Circuit Diagnosis
J
______
'" - - - - - - - - - - ., Powertrain
I Control
sv
I
I
:
..
EGR
Valve
s Volt
Reference A
1 Module
(PCM)
----'I
33 C2
GRY 598
GRY
598
(
M
Li
J.
M
I ~I
C
GRY 598
Manifold
Absolute
Pressure
(MAP) Sensor Al
ORN/BLK 469
LT GRN 432
13AC1
I" - . -
CONN ID
c1~BLU
C2 = CLEAR
.1
25 C2
-
MAP
Sensor
Ground
MA.P
Sensor
Signal
Powertrain
Con t ro I
I
Module ,6
I (PCM) ~
I
!.--------------~------'
368338
Circuit Description
Diagnostic Aids

varies from below 2.0 volts at idle (high vacuum) to
above 4.0 volts with the key on, engine not running, or
engine running at wide open throttl~ (low vacuum).
The MAP sensor is used to determine manifold
pressure changes while the linear EGR flow test
diagnostic is being run to determine engine vacuum
level for other diagnostics and to determine barometric
pressure (BARO). The PCM monitors the MAP
signals for voltages outside the normal range of the
MAP sensor. If the PCM detects a MAP signal voltage
that is excessively high, OTC P0108 Manifold
Absolute Pressure (MAP) Sensor Circuit High Voltage
will be set. If the PCM detects a MAP signal voltage
that is excessively low, OTC P0107 Manifold Absolute
Pressure (MAP) Sensor Circuit Low Voltage will
be set.
The PCM also uses the MAP sensor for throttle
position sensor performance. If the PCM detects a TP
in an out of range condition, when the MAP reading
is above or below a calibrated amount then
OTC P1514 Throttle Body Performance will be set.

suriaces before servicing a component. Inspect
Systems.
Damaged harness.
change in the display may indicate.the location of
Systems.
Engine
6-1195
MAP Sensor Circuit Diagnosis

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 14
Go to Step 3
Go to Step 4
Go to Step 12
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 9
Go to Step 14
Go to Step 9
Did you perform the Powertrain On-Board Diagnostic

System Check?
-

MAP sensor seal missing or damaged.
Vacuum hoses disconnected, damaged, incorrectly
routed.
2
Intake manifold vacuum leaks.

Vacuum leaks at throttle body.
Vacuum leaks at EGR valve flange and pipes.

Positive crankcase ventilation valve faulty, missing, or
incorrectly installed. Refer to Crankcase Ventilation
System Inspection.
2. With a scan tool. observe the MAP voltage

parameter.
o.ov

specified value?
1. Connect a test lamp between battery positive voltage

and the MAP sensor signal circuit.
4
2. Observe the MAP voltage parameter on the

scan tool.
4.95V

specified value?
1. Jumper the 5 volt reference A circuit and the MAP
signal circuit together.

5
2. Observe the MAP voltage parameter on the

scan tool.
specified value?
1. Test the sensor ground circuit for high resistance, an

open or poor connection at the PCM. Refer to Circuit
Testing or Testing for Intermittent and Poor
2. Repair as necessary. Refer to Wiring Repairs and
4.95V

1. Test the 5 volt reference A circuit for high resistance,
an open or poor connection at the PCM. Refer to

Circuit Testing or Testing for Intermittent and Poor

1. Test the MAP signal circuit for high resistance, an

open or poor connection at the PCM. Refer to Circuit
Testing or Testing for Intermittent and Poor
6-1196
Engine

MAP Sensor Circuit Diagnosis (cont'd)
Step
Action
Values
Yes
No
1. Test the MAP sensor signal circuit for a poor

9

2: Repair as necessary. Refer to Connector Repairs in
Wiring Systems.
1,
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 11
1. Test for a poor connection at the MAP sensor. Refer

10
to Testing for Intermittent and Poor Connections in

Wiring Systems.
2. Repair as necessary. Refer to Connector Repairs in
Wiring Systems.

Replacement.
12
Test the MAP signal circuit for a short to voltage or a short

to the 5 volt reference A circuit. Refer to Circuit Testing
13

14
With a scan tool, observe the MAP parameter while

increasing engine RPM.
Does the MAP value change?
11
Go to Step 14
Go to Step 14
Go to Step 13
Go to Step 14.
System OK
Oo to Step 2
Engine
6-1197
Electric Cooling Fan Diagnosis (Description)
.. !-
Hot At All Times
!Hot At All Times l
I
Power
Distribution
Schematics
in Wiring
Systems
COOL FAN
Maxi Fuse
40 A
Power
Distribution
Schematics
In Wiring
Systems
,Engine Wiring
I Harness
I
.
Junction Block 1
COOLING
FAN
MiniFuse
10 A
-------------
____ J
ORN 1640
RED 402
.-~--cr-~-,-...,...;..~~~~-:-:--:-1'-~-:-:-~~~;:::::::::====:=;--,
Power
Distribution
Schematics
lnWlring
Engine
Wiring
1
RED 402
systems
Harness
ORN 1640
Junction
WHT 504
ORN 1640
ORN 1640
RED 402
Block 1
'" - - - - - - . - - - - - - - - - - - - - - - - - -.- - - .,
,,.. -
-~
.----~1'-----------..--41------~
Powertrain
Control
Module
(PCM) ~
>
[~J~J Ji ~:\Jff:, 111--d 1~~' up-~i ~::,

00
'. ~
Y;Lr::
rt-
L-T-BLcB_U1r.0-9- - - -
,Engine
I Coolant
I Temperature
..,(ECT) Sensor
_c~
-B~
~4
-~~ ;O~ ---~ Right
Engine
c001ng
1
Fan
DKBLU 473
A
BLK 150
GRY 532
DK GRNi335
DK BLU 473
BLK
15 0
1
_ ~ ..:.-..:-:...-:.-.:.-..:f ....:-:...-:.-.:.-..:-..:~-:.-.:.-..:-..:~-:.-.:.-..:-..::..:-~ C1
ECT
Sensor
Ground
cooling
Fan Relay 1
.f Control
jl
WHT 504
B
~ Engine
Left
DKGRN 335
I
I
'.:o - - - - -
___J
Cooll
Fan
DK BLU 473
DK BLU 473
_____
ng
BRN 718
/
CONN ID
C1 = BLU .
C2 = CLEAR
Coclin; Fan Relay

2 and 3
j l Control
L __________ __________________ ____
BLK 150'- - - :
,
Powertrain
I Control
I Module
J,
~ (PCM)~
Ground
Distribution
Schematics
~y~~~~~
548579
Circuit Description:
The cooling fans are controlled by the PCM based on
various inputs. Ignition voltage is supplied to all
three cooling fan relay coils. The PCM controls cooling

fan relay # 1 by providing the ground path. The
PCM controls cooling fan relays # 2 and # 3 together
by providing a ground path. The left and right
cooling fans are connected in series. This will enable
both fans on low speed when the fan #1 relay is
energized. When all three fan relays are energized,
both fans will operate at high speed. The high speed is
possible because the fan relays are wired in a
parallel circuit. When the PCM detects that certain
DTCs are set, the PCM will enable the cooling fans.
The PCM will enable the engine cooling fans when

certain Diagnostic Trouble Codes are set. The
PCM will also enable the cooling fans after the ignition
is turned off. When engine coolant temperature
exceeds 140C (284F) and the ignition is turned off,
the cooling fans will be enabled on low speed.
6-1198
Engine
Diagnostic Aids
If the owner complained of an overheating problem,
determine if the complaint was due to an actual boil
over, or the warning indicator light illuminated, or the
engine coolant temperature gauge indicated
overheating. The gauge accuracy can also be checked
by comparing the Engine Coolant Temperature (ECT}
sensor reading using a scan tool and comparing its
reading with the gauge reading. If the engine is actually
overheating and the gauge indicated overheating, but
the cooling fan is not coming ON, the Engine Coolant

Temperature (ECT) sensor has probably shifted out of
calibration and should be replaced.
If the engine is overheating and the cooling fans are
ON, the cooling system should be checked, refer
to Engine Overheating.
The PCM will command low speed fans ON at 108C

(226F) and OFF at 103C (217F) and, high speed
fans ON at 113C (235F) and OFF at 108C (226F}.
Electric Cooling Fan Diagnosis (Functional Check)

Test Description
The numbers below refer to numbers on the
diagnostic table.
3. Allow engine coolant temperature to cool below

100C (212F} before proceeding with diagnosis.
2. The PCM will enable the engine cooling fans

when certain Diagnostic Trouble Codes are
set. Go to applicable DTC Table first before
Electric Cooling Fan Functional Check

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to applicable
OTC Table
Go to Step 3
Go to Step 4
Go to Electric
Cooling Fan
Diagnosis
(Table 1)
Go to Step 5
Go to Electric
Cooling Fan
Diagnosis
(Table 2)
Go to Step 6
Go to Electric
Cooling Fan
Diagnosis
(Table 3)
Go to Step 8
Go to Step 7
.System OK
Go to A
Diagnostic
Starting Point
Go to A
Diagnostic
Starting Point
in HVAC.
Go to Step 9

1
Are any DTCs set?

1. Engine coolant temperature must be below the
specified value for all the fan diagnoses.
2. Turn ON the Ignition, with the engine and A/C OFF.
Are the cooling fans OFF?
With a scan tool, command the Low Speed Fans ON.

Are both cooling fans ON?
With a scan tool, command the High Speed Fans ON.

Do both cooling fans switch to high speed?
100C (212F)
1. With a scan tool, exit outputs.

2. Idle the engine leaving the A/C OFF.
Are the cooling fans ON?
Turn ON the A/C.

Does the scan tool indicate A/C request as YES?

Replace the PCM.
System OK
Engine
6-1199
Electric Cooling Fan Diagnosis (Table 1)

Electric Cooling Fan Table #1
Action
Step
Value(s)
Yes
No
Go to Step 2
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Step 8
Go to Step 3
Go to Step 4
Go to Step 10
Go to Step 11
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 7
Go to Step 13
Go to Step 14
Go to Step 16
Go to Step 9
Go to Step 13
Go to Step 14
Go to Step 16
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Step 15
Did you perform the Cooling Fan Functional Check?

1
Disconnect fan relay #1

Are both fans OFF?
Disconnect fan relay #3

Are both fans OFF?
1. Disconnect the left fan.

2. Probe terminal B of the left fan connector using a
J 34142-8 Test Lamp that is connected to a good
ground.
Probe terminal A of the left fan connector using a test

Probe the cooling fan relay 2 and 3 control circuit (473) at

the cooling fan relay #3 connector location (C10) using a
test lamp that is connected to B+.

2. Leave the test lamp installed.
Is the test lamp still illuminated?
Probe the cooling fan relay 1 control circuit (335) at the

cooling fan relay #1 connector location (81) using the test
lamp that is connected to B+.
i. Turn OFF the ignition.

9
10
2. Leave the test lamp installed.

Is the test lamp still illuminated?
Repair the RH fan feed circuit (504) for a short to voltage.
11
Repair the LH fan feed circuit (409) for a short to voltage.

12
Repair the short to voltage in the relay #3 switch feed

circuit (532). Refer to Wiring Repairs in Wiring Systems.
13
Replace the cooling fan relay #1.

Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
6-1200
Engine

Electric Cooling Fan Table #1 (cont'd)
Step
Action
14
Repair the relay 2 and 3 control circuit (473) or the relay 1

control circuit (335) for a short to ground. Refer to Wiring
15
16
Yes
Value(s)
Replace the cooling fan relay #2.


Replace the PCM.
No
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)

Step
Action
Yes
No
Go to Step 2
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Step 3
Go to Step 4
Value(s)
..

1
Did either fan turn ON when the Low Speed Fans were
commanded ON?
1. Disconnect fan relay #3.

Did the Left fan turn OFF?

2. Probe the relay 1 control circuit (335) at the relay #1
connector location (81) using a J 34142-B Test Lamp
that is connected to 8+.
3. With a scan tool, command the Low Speed Fans ON.
Probe both feed circuits (1640 and 402) at the relay #1

connector locations (83 and C3) using a test lamp that is
Does test lanip illuminate for both circuits?
Important: Leave jumper in place for remainder of

this table.
Connect a fused jumper wire between the switch feed
circuit (402) and the LH fan feed circuit (409) at the
relay #1 connector locations (83 and C1 ).
Do both fans turn ON?
1. Disconnect the left fan.

2. Probe fan harness connector terminal 8 with a test
lamp that is connected to a good ground,
Connect a second fused jumper wire between the fan

harness connector terminals.
Is the right fan ON?
(
Go to Step 25
Go to Step 20
Go to Step 5
Go to Step. 12
Go to Step 6
Go to Step 21
Go to Step 22
Go to Step .7
.,.
'
Go to Step 8
Go to Step 23
Go to Step 15
Go to Step 9
Engine
6-1201

Action
Step
Value(s)
Yes
No
Go to Step 10
Go to Step 24
Go to Step 25
Go to Step 11
1. Reconnect the left fan.

3. Probe the switch feed circuit (532) at the fan relay #3

connector location (CS) using a test lamp that is
10
Using the second jumper wire, jumper the switch ignition

feed circuit (532) and the RH fan feed circuit (504)
together at relay #3 connector locations (89 and CS).
Do the fans come ON?

1. Reconnect fan relay #3.
'
2. Disconnect the right fan.

11
3. Probe fan harness connector terminal B with a test

Go to Step 15
Go to Step 17
Is the test lamp illuminated?
Go to Step 19
Go to Step 20
Inspect the PCM connections. Repair faulty connections as

Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Step 26
Is the left fan ON?

1. Test lamp still connected.
12
13

4. Probe the cooling fan #1 relay control circuit at the
PCM connector, with a fused jumper wire that is
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Repair the relay 1 control circuit (335) for an open or

shorted to B+. Refer to Wiring Repairs in Wiring Systems.
14
15
Inspect the fan motor ground circuit for a open or the fan
motor connections and repair as necessary. Refer to
Connector Repairs or Wiring Repairs in Wiring Systems.
16
17
Repair the RH fan feed circuit (504) for an open. Refer to

Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Replace the fan which was not operating.

18
19
Replace fan relay #2.

Go to Step 16
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Replace the fan motor.

6-1202
Engine

Step
20
21
22
Action
Repair the relay #3 switch feed circuit (532) for a short to
1. Test for the following:

- Open on the feed circuit
- Short to ground on the feed circuit
- Either fan motor shorted to ground
2. Repair as necessary. Refer to Circuit Testing and
Wiring Repairs in Wiring Systems or Cooling Fan
Motor Replacement - Electric in Engine Cooling.
23
Repair the LH fan feed circuit (409) for a open. Refer to

24
Repair the relay #3 switch feed circuit (532) for a open.

25
26


Replace the PCM.
Value(s)
Yes
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
No
(
Go to Step 25
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to l=lectric
Cooling Fan
Piagnosis
(Functional
Check)
Go to Step 8
Go to Step 3
Go to Step 9
Go to Step 4
1. With a scan tool, command the Low Speed Cooling

Fans ON.
2
2. Command the High Speed Cooling Fans ON while

observing the fans.
Did both fans operate with no change?
Did the left fan stop operating?
Engine
6-1203

Step
Action

2. Probe the relay 2 and 3 control circuit (473) at
relay #2 connector location (84) using a J 34142-8
Test Lamp that is connected to B+.
3. Command the High Speed Cooling Fans ON using a
scan tool.
Does the test lamp illuminate after several seconds?
Probe the coil feed circuit (1640) at relay #2 connector

location (C6) using a test lamp that is connected to a good
ground.
Probe the switch feed circuit (402) at the relay #2

connector location (C4) using a test lamp that is connected
to a good ground.
Does the test lamp iHuminate?
Jumper the switch ignition feed circuit (402) and the

RH fan feed circuit (504) together at the relay #2
connector locations (C4 and 86).
Is the right fan ON?
1.
2.
3.
4.
10
11
12
13

Disconnect the PCM.
Disconnect fan relay #1.
Jumper the switch feed circuit (402) and the LH fan
feed circuit (409) together at the relay #1 connector
locations (83 and C1 ).
5. Turn the ignition ON.
6. Probe the PCM harness connector for the cooling fan
relay #2 and #3 control with a test lamp that is
Do the fans switch from low to high speed?
Value(s)
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 13
Go to Step 7
Go to Step 14
Go to Step 15
Go to Step 16
Go to Step 22
Go to Step 17
Go to Step 10
Go to Step 18
Go to Step 11
Go to Step 19
Go to Step 20
Go to Step 21
Probe the ground circuit (150) at the relay #3 connector

location (B10) using a test lamp that is connected to B+.
Probe the coil feed circuit (1640) at the relay #3 connector

location (BS) using a test lamp that is connected to a good
ground.
Repair the open in the relay #2 coil feed circuit (1640).

No

2. Probe the relay 2 and 3 control circuit (473) at the
relay #3 connector location (C10) using a test lamp
3. Command the High Speed Cooling Fans ON using a
scan tool.
Repair the relay 2 and 3 control circuit (473) for an open

between fan relay #2 and the splice. Refer to Wiring
Yes
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
6-1204
Engine

Step
14
15
Action
Repair the open in the relay #2 switch feed circuit (402).

Replace the fan relay #2.

16
Repair the open in the RH fan feed circuit (504) between

fan relay #2 and the splice. Refer to Wiring Repairs in
Wiring Systems.
17
Repair the fan 2 and 3 relay control circuit (473) for an

open or for a short to B+. Refer to Wiring Repairs in
Wiring Systems.
18
Repair the open in the fan 2 and 3 relay control

circuit (473) between fan relay #3 and the splice. Refer to
19
20
21
22
23
Repair the open in the ground circuit (150). Refer to Wiring

Replace the fan relay #3.

Repair the open in relay #3 coil feed circuit (1640). Refer

1. Inspect the PCM connections. Refer to Testing for

2. Repair faulty connections as necessary. Refer to
Replace the PCM.
Value(s)
Yes
No
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Electric
Cooling Fan
Diagnosis
(Functional
Check)
Go to Step 23
Engine
6-1205
Cruise Control Diagnosis

!Hot In RUN And STARit
[l]
! Hot In ON And START!
'" - - .. -ENG .. ., Engine Wiring
Cruise
I
J7
SEN I Harness
Clutch
I
J6
~~nltuse I Junction Block 2
--- Switch
1. _ _ _ _ _ _ J
BRN
(Manual
Trans Only)
PNK 539
C C2
WHJ 379
11
[l]
[ZJ
Brake
Switch
PP~r~:O
'"
PNK 139
Cruise
Brake
Switch
BR:186
30 C1
24 C2
'" - ir'a~ - - - - - .,.... - - - - -c;;;is; ., Powertrain
I
Switch
CONN ID
Conlrol I Control
I
Signal
c1 =BLU
Release I Module
I
C2=CLEAR
Signal I {PCM)
I
I
I
I
A.
- - - -P;;e7" - , Engine Wiring

Distribution I Harness
Schematics I Junction Block 2
I
NC Cruise inWirlng
Systems I
Minifuse
15A
L!.w
. -------J
PNK
r------
Headlamp And
- - - - - ., Cruise Turn Signal
.
I Conlrot
I switch Control Switch
10F~
OFF .... _.. ______ _ I
1
I
I
I
I
I..
(M;l
ON
---~
______
_ "iii-icoAsiR/A :
pP
1.----------------J~
GRY
DKBLU
BLK
----1---1
I
DKBLU 84
.
GRY/BLK 87
20 ______ l;I ______2_1
GRY 397
Cruise
Cruise
Throttle Actuator A.
Set/Coast
Resume/Accel Control {TAC) P'
4
,....__ _ _ _ _ _ _ _Signal
________
_ _ _ _ _ _- J
Signal
Module
.~
Cruise On/Off
Signal
548587
Circuit Description
The Cruise Control System is a speed control system
that maintains a desired vehicle speed under
normal driving conditions. The cruise control system
has the capability of the following:
Cruise
Coast
Resume speed
Accelerate
Raise (Tap-up) the vehicle speed by
1.6 km/h (1 mph)
Lower (Tap-down) the vehicle speed by
1.6 km/h (1 mph)
The PCM controls the cruise system. When the cruise
control switch is in the ON position and you push
the cruise SET/COAST switch, the PCM maintains the
current vehicle speed. If the engine load varies, the
PCM commands the throttle blade to the appropriate
position in order to maintain the desired vehicle speed.
The cruise control system consists of the following
components:
Throttle actuator control (TAC) module
Throttle body/TAC assembly
Cruise control actuator lever
Conditions for Enabling the Cruise System

The cruise switch is in the ON position.
The ignition voltage is between 9 and 16 volts.
Ignition voltage is present to the cruise
actuator lever.
The vehicle speed is more than 39 km/h (24 mph).
The engine speed is between 550 and 5900 RPM.
O The clutch or brake pedal is not depressed.
The transmission is in a forward gear other
than first.
The vehicle is not in a traction control event.
The engine is not in Engine Coolant Over

Temperature-Fuel Disabled mode.
5 seconds.
6-1206
Engine
Conditions for Disabling the Cruise System
Diagnostic Aids
The cruise switch is turned to the OFF position.

. " Ignition voltage is interrupted to the cruise
actuator leyer.
The .vehicle speed is less than 39 km/h (24 mph).
The clutch or brake pedal is depressed.
The engine is in Engine Coolant Over
Temperature-Fuel Disabled mode.
The transmission is placed into neutral.
A problem with the clutch or brake pedal switches
or circuits that the PCM module interprets as the
pedal is applied.
Use the scan tool in order to monitor the Cruise

Disengage History. This parameter lists the last
8 cruise disengage events. Refer to Cruise Disengage
History table for a description of each condition.
The cruise control system disables for the current

ignition cycle if an intermittent condition. exists
and DTC P0567 or DTC P0568 sets.
Cruise Control Disengage Definitions

Scan Tool Display
Definition
ALDL
The PCM detects the scan tool has sent a inhibit message
via serial data.
Bad Memory
The cruise system has detected a RAM corruption.
Brake
The PCM detects one of the brake switches active (TCC

Brake Switch/Cruise Control Brake Switch or Stop Lamp
Switch).
Pedal Initialize
The PCM does not detect the brake switch active during an
ignition cycle. (Auto Trans only)
Cancel
The PCM detects the cruise cancel switch has been

depressed.
Clutch Switch
The PCM detects the clutch has been depressed.
Coast Disengage
The PCM senses the vehicle speed is greater than 8 km/h

(5 mph) below the set speed or the coast button is
depressed for longer than 3 seconds.
Coast Speed Low
The Set/Coast switch is pushed and held until vehicle speed

drops below 32 km/h (20 mph). Vehicle speed below 32 km/h
(20 mph) will disable the cruise system.
Eng Run Time
The PCM has detected the engine has not been running for
longer than 5 seconds.
Eng Speed
The PCM has detected the engi~e speed is not between 5!50
and 5900 RPM.
TAC Inhibit
The PCM has detected that an Electronic Throttle Control

fault is active.
OTC Set
The PCM has detected DTCs P0500, P0502, P0503, P0560,

P0567, P0568, P0571, P0704, P0719, P0724, P0751,
P0753, P0756, P0758, P0785 or P1574 are present.
Acee! Rate
The vehicle acceleration is greater than the expected

acceleration rate which is calculated by the PCM.
Decel Rate
The vehicle deceleration is greater than the expected

deceleration rate which is calculated by the PCM.
High Speed
The PCM detects that the vehicle speed is greater than

225 km/h (140 mph).
Illegal CC Mode
The PCM will not allow cruise with the current position of the
cruise switches.
INJ Disable
The PCM detect the Fuel Disable Mode is active.
Low Speed
The PCM detects that the vehicle speed is less than 39 km/h
(24 mph) when cruise enable is attempted.
Man Neutral CC
The PCM has detected the transmission is in neutral.
MPH Limited
The PCM has detected that high speed fuel cutoff has been
reached.
Cruise Off
The PCM does not detect that the cruise enable switch is
active.
Engine
6-1207
Cruise Control Disengage Definitions (cont'd)

Definition
Scan Tool Display
Over Set Speed
The TAC module detects that the vehicle speed is greater

than the cruise memory speed by more than a
predetermined amount or, the vehicle speed is greater than
a predetermined value during a transient maneuver, such as,
Resume, Accel, Tap-up or Tap-downs etc.
SIC On-Speed High
This parameter is displayed when the Set/Coast switch is

applied (tap down vehicle speed) and the vehicle speed is
greater than the cruise memory speed by more than a
predetermined value. For example, if the cruise control
system is set to maintain a vehicle speed of 48 km/h
(30 mph) then the vehicle is accelerated to 80 km/h (50 mph)
and you depress the Set/Coast again, the S/C On-Speed
High message appears in the Cruise Control Disengage
History.
Simul SC/RA Sw
The PCM detects the Set/Coast and Resume/Acee! switches

are active at the same time.
Traction Loss
The PCM module detects the vehicle is in a Traction

Control event.
Under Set Speed
The PCM detects that the vehicle speed is less than the
cruise memory speed by more than a predetermined amount
or, the vehicle speed is less than a predetermined value
during a transient maneuver, such as, Resume, Accel,
Tap-up or Tap-downs etc.
First Gear
When the PCM detects the vehicle is in first gear.
Pedal Greater CC
The PCM senses the accelerator pedal is at a greater value

than the commanded cruise position for more than 1 minute.
Ignition Volts
The PCM detect voltage out of the range of 9 to 16 volts.
Trans
The PCM detect the transmission is not in forward gear

higher than 1st gear (auto trans) or the clutch is depressed
(manual trans).
Wheel Speed Low
The PCM has detected the driven (rear) wheels are at a

greater speed than the front wheels.
Wheel Speed High
The PCM has detected the driven (rear) wheels are at a

lower speed than the front wheels.
MPH Governor
The PCM detects the vehicle has reached

190 km/h (118 mph).
RPM Governor
The PCM detects the engine has reached 5900 RPM.
Cruise Control System Check

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 5
Go to Step 3
Go to Step 4
Go to
applicable OTC

-
Is the NC CRUISE fuse open?

2. With a scan tool, observe the brake, cruise release
and TAC brake switch parameters.
3. Apply the brake.
Does the scan tool indicate RELEASED and switch to
APPLIED when the brake pedal is depressed?
6-1208
Engine
Cruise Control System Check (cont'd)

Step
Action
Values
Yes
No
Go to Step 6
Go to
applicable OTC
Go to Step 19
Go to Step 21
Go to Step 7
Go to Step 9
Important: This step is for manual transmission vehicles

only. If the vehicle has an automatic transmission, refer to
step 6.
With a scan tool, observe the clutch anticipate switch and

the cruise release switch parameters while depressing the
clutch pedal.
Does the scan tool indicate RELEASED and switch to
APPLIED when the clutch pedal is depressed?
1. Disconnect the 11 pin connector at the base of the

steering column.
2. Probe the following circuits at the female end of the
connector using a .test lamp that is connected to B+.
Switch feed (M)

Cruise On/Off signal (L)
Set/Coast signal (K)

Resume/Acee! signal (J)
Does the test lamp illuminate when touched to any of the
circuits?
6
2. With a scan tool, observe the cruise switch

parameter.
3. Turn the cruise switch ON and OFF.
Does the scan tool indicate OFF and switch to ON when

the switch is turned ON?
1. With a scan tool, observe the cruise set/coast
parameter.
2. Push the cruise set/coast switch in.
Does the scan tool indicate ON when the switch was

pushed in?
Go to Step 8
Go to Step 12
Go to
Diagnostic Aids
Go to Step 14
Go to Step 10
Go to Step 16
Go to Step 21
Go to Step 11
System OK
Go to Step 24
Go to Step 20
Go to Step 13
System OK
Go to Step 23
1. With a scan tool, observe the cruise resume/accel

parameter.
2. Push the cruise resume/accel switch in.
Does the scan tool indicate ON when the switch is

pushed in?
Does. the cruise switch parameter indicate ON at all times?
1. With a scan tool, observe the cruise switch

parameter.
10
2. Disconnect the cruise switch.
Does the parameter switch to OFF when the switch is

dicconnected?
11
T.est the cruise On/Off signal circuit for a short to voltage.

Systems.

steering column.
12
2. With a scan tool, observe the Set/Coast parameter.

3. Probe the Set/Coast signal circuit (K) at the female
end of the connector using a test lamp that is
connected to B+
Does the scan tool indicate ON when the test lamp is

touched to the circuit?
13
Test for an open in the Set/Coast signal circuit. Refer to

Engine
6-1209
Cruise Control System Check (cont'd)

Step
Action
Values
14

steering column.
2. With a scan tool, observe the Resume/Accel
parameter.
3. Probe the Resume/Accel signal circuit (J) at the
female end of the connector using a test lamp that is
connected to B+
15
Test for an open in the Resume/Accel signal circuit. Refer

16

steering column.
3. Probe the switch feed (M) at the female end of the
connector using a test lamp that is connected to
ground.
17
1. With a scan tool, observe the Cruise Switch

parameter.
2. Probe the Cruise On/Off signal circuit (L) at the
female end of the connector using a test lamp that is
connected to B+
18
Test for an open in the Cruise On/Off signal circuit. Refer

.
19
Test for a short to ground in the circuit which illuminated

the test lamp. Refer to. Circuit Testing and Wiring Repairs
in Wiring Systems.
20
Inspect for poor connections at the 11 pin connector. Refer

to Testing for Intermittent and Poor Connections and
21
1. Test the Steering column harness for opens, shorts

or poor connections. Refer to Testing for Intermittent
and Poor Connections and Connector Repairs or
2. If no problem is found replace the cruise switch.
Refer to Multifunction Turn Signal Lever Replacement
- On Vehicle in Steering Column.
22
Repair the open in the switch feed. Refer to Circuit Testing

--

23
24
Replace the TAG .module., Refer to Accelerator Controls

Yes
No
Go to Step 20
Go to Step 16
System OK
Go to Step 23
Go to Step 17
Go to Step 22
Go to Step 20
Go to Step .18
System OK
Go to Step 23
System OK
Go to Step 24
System OK
Go to Step 21
System OK
-
System OK
System OK
Go to Step 24
System OK
6-1210
Engine Controls
3.8l
Engine
Engine Oil level Sensor/Switch Diagnosis
.-------~
I
I
Ground
Distribution
Schematics
In Wiring
Systems
IL0 c
[SJ
N
3 BLK 451
0.35 BLK/WHT 451

A
Engine
Oil
Level
Switch
0.35 BRN 1174
BI
. t
58
C2
,. - - - - - - Oil - - - - - - , Powertrain
i
I
Level
Signal
CONN ID
C1=BLU
C2=CLEAR
12v
Control
I Module
I (PCM) .._
I
,,.
L--------------J
~
548666
Circuit Description
The engine oil level switch is a simple float switch that
is grounded when the engine oil level is OK. The
PCM tests the engine oil level switch circuit at startup.
Before testing the state of the engine oil level
switch, the PCM performs a test routine based on time
and engine coolant temperature to ensure that the
engine oil has drained back into the sump. To test for
low oil level at startup, one of the following conditions
must be present:
If the engine coolant temperature was between
15C (59F) and 130C (266F) at the last key
OFF, the engine coolant temperature at key ON
must be at least 12C (22F) cooler than the
engine coolant temperature at the last key OFF.
If the engine coolant temperature was higher than
100c (212F) at the last key OFF, the time
between last key OFF and the present key ON
must be sufficient to allow the oil to drain back to
the sump. The PCM will remain powered up
for 10 seconds to ensure that the oil has drained
back to the sump. If the key is turned back
ON while the PCM is still powered up, the oil level
will not be tested.
The low oil level lamp will be illuminated for
approximately 7 minutes when the PCM tests for low
oil level and the engine oil level switch indicates
that a low oil level condition exists (Engine Oil Level
switch circuit not grounded). When the ignition is
first turned ON, the PCM commands the low oil level
lamp ON for a brief period of time to test the bulb.
Diagnostic Aids
For diagnosis of the instrument panel, perform the
System Check in the Instrument Cluster section
of Electrical Diagnosis.

A switch stuck closed will indicate oil level parameter
OK at all times even in a Low oil condition.
Engine oil level switch circuit: If the problem with the
low oil level lamp can not be isolated using the Engine
Oil Level Switch Diagnostic table, use the PCM
Controlled Lamps Diagnostic table.

Inspect the hamess connectors for backed out
Systems.
Damaged harness.
Systems.
Inspect the PCM and the engine grounds tor
Engine
6-1211
Oil Level Circuit Diagnosis

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 7
Go to Step 11
Go to Step 5
Go to Step 9
Go to Step 6
Go to Step B
Go to Step 10
System OK
Go to Step 14
System OK
Go to Step 14

Important: This table assumes that the oil level is at the

proper level or the oil level was low and the Low Oil Level
message never was displayed. Check for BCM DTCs.
With a scan tool, observe the Oil Level parameter.
Does the scan tool indicate OK?
1. With a scan tool, observe the oil level parameter.

3
2. Disconnect the oil level switch.
Does the scan tool indicate LOW when the switch is

disconnected?
1. Disconnect the oil level switch.
2. With a scan tool, observe the oil level parameter.
4
3. Install a fused jumper between the signal and ground

circuits.
Does the scan tool indicate OK when the jumper is

installed?
1. Disconnect the jumper from the ground circuit.
5
2. Connect the jumper to a good ground.
Does the scan tool indicate OK when the jumper is

installed?
6
Probe the signal circuit using a test lamp that is connected

to a good ground.
Test for a short to ground on the signal circuit. Refer to
Test for a short to voltage on the signat circuit. Refer to

Repair the open in the ground circuit. Refer to Wiring

10
Test for an open in the signal circuit. Refer to Circuit

System OK
Did you find.and correct the condition?
11
Inspect for poor connections at the switch. Refer to

Replace the oil level switch.
1. Inspect the PCM for poor connections. Refer to
Testing for Intermittent and Poor Connections in
Wiring Systems.
13
2. Repair as necessary. Refer to Connector Repairs in

Wiring Systems.
System.OK
Go to Step 13
System OK
Go to Step 12

12
System OK
System OK
Go to Step 14

14

System OK
6-1212
Engine Controls -3.8l
Engine
(
21433
Circuit Description
When the ignition is turned ON, the powertrain control
module (PCM) will turn ON the .in-tank fuel pump. The
in-tank fuel pump will remain ON as long as the engine
is cranking or running and the PCM is receiving
reference pulses. If there are no reference pulses, the
PCM will turn the in-tank.fuel pump OFF 2 seconds
after the ignition switch is turned ON or 2 seconds after
the engine stops running. The in-tank fuel pump is an
electric pump within an integral reservoir (4). The
in-tank fuel pump supplies fuel through the fuel
feed pipe (1 ), and in-line fuel filter (2) to the fuel rail
assembly (8). The fuel pump is designed to provide fuel
at a pressure above the pressure needed by the fuel
injectors (9). A fuel pressure regulator (7), attached to
the fuel rail, keeps the fuel available to the fuel injectors
at a regulated pressure. Unused fuel is returned to the
fuel tank by a separate fuel return pipe (5). The fuel
pump flex pipe (3) functions as a conduit for
transporting pressurized fuel from the fuel pump to the
above cover fuel feed pipe. The fuel pump flex pipe also
eliminates fuel pump generated pressure pulse noise,
and eliminates clamps formerly needed for rubber
hoses or nylon pipes. The fuel pressure gauge
J 34730-1A (10). The fuel pipe return and feed hose
assemblies are the pinch points used during the fuel
system pressure test (6).
. Test Description
diagnostic table.
2. With the ignition ON and the fuel pump running,

the fuel pressure indicated by the fuel pressure
gage should be 333-376 kPa (48-55 psi). This
pressure is controlled by the amount of pressure
the spring inside the fuel pressure regulator
can provide.
3. A fuel system that drops more than 5 psi in
1O minutes has. a leak in one or more areas:
5. Fuel pressure that drops-off during acceleration,
cruise or hard cornering may cause a lean
condition. A lean condition can cause a loss of
power, surging, or misfire. A lean condition can be
diagnosed using a scan tool. lfan extremely
lean condition occurs, the oxygen sensorss will
stop toggling. The oxygen sensor output voltages
will drop below 500 mV. Also, the fuel injector
width will increase.
Engine
8. When the engine is at idle, the manifold pressure

is low (high vacuum). This low pressure (high
vacuum) is applied to the fuel pressure regulator
diaphragm. The low pressure (high vacuum)
will offset the pressure being applied to the fuel
pressure regulator diaphragm by the spring inside
the fuel pressure regulator. When this happens,
the result is lower fuel pressure. The fuel pressure
at idle will vary slightly as the barometric
pressure changes, but the fuel pressure at idle
should always be less than the fuel pressure noted
in step 2 with the Engine OFF.
12. A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition
may cause a OTC P0132 or a OTC P0172 to set.
Oriveability conditions associated with rich
conditions can include hard starting (followed by
black smoke) and a strong sulfur smell in the
exhaust.
13. This test determines if the high fuel pressure is
due to a restricted fuel return pipe or if the
high fuel pressure is due to a faulty fuel pressure
regulator.
6-1213
15. A lean condition may result from the fuel pressure

being below 333 kPa (48 psi). A lean condition
may cause a OTC P0131 or a OTC P0171 to set.
Oriveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.
16. Restricting the fuel return pipe with the fuel pipe
shut-off adapter causes the fuel pressure to
rise above the regulated fuel pressure. Using a
scan tool to pressurize the system, the fuel
pressure should rise above 376 kPa (55 psi) as
the valve on the fuel pipe shut-off adapter
connected to the fuel return pipe becomes partially
closed.
22. Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking.
If checking the spark plug associated with a
particular fuel injector for fouling or saturation does
not determine that a particular fuel injector is
leaking, use the following procedure.

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 12
Go to Step 10
Go to Step 4
Go to Step 19
Go to Step 5
Go to Step 6
Go to Step B
Did you preform the Powertrain On-Board


personal injury. The towel will absorb any fuel leakage
Relief Procedure.
2. Turn OFF the air conditioning system.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel level.
4. With the fuel pump running, measure the fuel
pressure indicated on the fuel pressure gauge.
specified value?
333-376 kPa
(48-55 psi)
The fuel pressure may vary slightly when the fuel pump
stops running, the fuel pressure should stabilize and
remain constant.lmportantNote the fuel pressure after the
fuel pump stops running.
Does the fuel pressure drop more than the specified value
in 10 minutes?
34 kPa (5 psi)
With the fuel pressure gauge, relieve the fuel pressure to

the specified higher value.
Does the fuel pressure drop more than the specified lower
value within 10 minutes?
69 kPa (10 psi)

14 kPa (2 psi)
Is the fuel pressure suspected of dropping-off during

acceleration, cruise, or hard cornering?
6-1214
Engine

Fuel System Pressure Test (cont'd)
Step
Action
Values
. Visually and physically inspect the following items for a

restriction:
. The in-line fuel filter. Refer to In-Line Fuel Filter
Replacement.
The fuel feed pipe. Refer to Fuel Hose/Pipes
Replacement (Chassis) or Fuel Hose/Pipes
Replacement (Engine Compartment).
1. Remove the modular sender assembly. Refer to Fuel

Sender Assembly Replacement.
2. Visually and physically inspect the following items:
The fuel pump strainer for a restriction, correct
position, and installation on the fuel sender
assembly
The fuel pump flex pipe for leaks.
Verify the fuel pump is the correct fuel pump for
this vehicle.
1. Turn OFF the ignition, for 10 seconds.

achieve the highest possible fuel level.
4. Let the engine run to a normal operating temperature.
Does the fuel pressure measurement drop less than the
specified value?
21-69 kPa
(3-10 psi)
1. Disconnect the fuel pressure regulator vacuum hose.

2. With the engine idling, apply 12-14 inches of vacuum
to the fuel pressure regulator.
Does the fuel pressure measurement drop within the
specified value?
21-69 kPa
(3-10 psi)
10

Relief Procedure.
2. Disconnect the fuel feed pipe and the fuel return pipe
from the fuel rail. Refer to Quick Connect Fitting(s)
Service (Metal Collar).
3. Install the J 37287 fuel pipe shut-off adapters
between the fuel feed pipe and the fuel return pipe
and the fuel rail.
4. With the J 37287 fuel pipe shut-off adapters, open
the valve.
6. With a scan tool pressurize the fuel system.
Relief Procedure.
8. With a scan tool, command the fuel pump ON.
9. Wait for the fuel pressure to build.
Notice: Do not allow the fuel pressure to exceed
450 kPa (65 psi). Fuel pressure in excess of
450 kPa (65 psi) may damage the Fuel Pressure
Regulator.
10. With the fuel pipe shut-off adapter, close the fuel
feed valve.
Does the fuel pressure remain constant?
Yes
No
Go to Step 24
Go to Step 7
Go to Step 24
Go to Step 19
Go to Symptoms
Go to Step 9
Go to Step 20
Go to Step 21
(
Go to Step 19
Go to Step 11
Engine
6-1215
Fuel System Pressure Test (cont'd)
Step
Action
Values.
Yes
No
Go to Step 21
Go to Step 22
Go to Step 13
Go to Step 15
Go to Step 23
Go to Step 14
Go to Step 24
Go to Step 21
Go to Step 16
Go to Step 17
Go to Step 21
Go to Step 7
Go to Step 24
Go to Step 18
1. With the fuel pipe shut-off adapter, open the fuel

feed valve.
11
2. With a scan tool, pressurize the fuel system.

4. With the fuel pipe shut-off adapter, close the fuel
return valve.
12
Does the fuel pressure measure above the

specified value?
13

Relief Procedure.
2. Disconnect the fuel pipe shut-off adaptor, from the
fuel rail return pipe. Refer to Quick Connect Fitting(s)
Service (Metal Collar).
3. Attach a length of flexible fuel hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Turn OFF.the ignition, for 10 seconds.
7. Measure the fuel pressure with the fuel pump
running.
specified value?
14
15
Visually and physically inspect the fuel rail outlet

passages for a restriction.
Does the fuel pressure measure above the
specified value?
376 kPa (55 psi)
333-376 kPa
(48-55 psi)
O kPa (0 psi)

Relief Procedure.
2. Disconnect the fuel return pipe from the fuel rail.
16
Ref~r to Quick Connect Fitting(s) Service (Metal

Collar).
3. Install the J 37287 fuel pipe shut-off adapter between
the fuel return pipe and the fuel rail.
4. With the fuel pipe shut-off adapter, open the valve.
6. With a scan tool, pressurize the fuel system.
7. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
8. With the fuel pressure gauge, Bleed off the air.
450 kPa (65 psi) may damage the Fuel Pressure
Regulator.
333-37'6 kPa
(48-55 psi)
9. With the fuel pipe shut-off valve, slowly close the fuel
return valve.
Does the fuel pressure rise above the specified value?
17
Perform Fuel pump relay circuit diagnostic. Refer to Fuel

Pump Electrical Circuit Diagnosis.
6-1216
Engine
Fuel System Pressure rest (cont'd)

Step
18
19
20
21
22
23
..
Action
Values
Visually and physically inspect the following items:

The in-line fuel filter for obstructions. Refer to In-Line
Fuel Filter Replacement.
The fuel feed pipe for a restriction. Refer to Fuel
Hose/Pipes Replacement (Chassis).
The fuel pump strainer for obstructions. Refer to Fuel
Pump Strainer Replacement.
The fuel pump flex pipe for leaks. Refer to Fuel
Replace the modular fuel sender assembly. Refer to

Fuel Sender Assembly Replacement.
Locate and repair the loss of vacuum to the fuel

pressure regulator.
Replace the fuel pressure regulator. Refer to Fuel

Locate and replace any leaking fuel injectors. Refer to

Fuel Injector Replacement.
Locate and correct the restriction in the fuel return pipe.

Yes
No
Go to Step 24
Go to Step 19
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24

Relief Procedure.
24
25
2. Turn OFF the air conditioning system.

achieve the highest possible fuel level
4. With the fuel pump running, measure the fuel
pressure.
specified value?
Important: The fuel pressure may vary slightly when the
fuel pump stops running, the fuel pressure should stabilize
and remain constant. when the fuel pump stops running,
measure the pressure.
in 10 minutes?
333-376 kPa
(48-55 psi)
Go to Step 25
Go to Step 11
Go to Step 10
System OK
34 kPa (5 psi)
Engine
6-1217
e-
FUEL INJECTOR
TESTER+
READY TO TEST
Ii
O
TEST IN PROGRESS
LOW VEHICLE BATTERY
AMPERAGE SUPPLY SELECTOR SWITCH

Coil Test
4amp
2.Samp
o.samp
Balance Test
4amp
0.5-2.5
amp
B+
PUSH TO START TEST
J 39021
17713
Legend
(2) Second Reading
(1) First Reading
Injector Balance Test Example
Cylinder
1st Reading
330 kPa (48 psi)
2nd Reading
330 kPa (48 psi) 330 kPa (48 psi) 330. kPa (48 psi) 330 kPa (48 psi) 330 kPa (48 psi)
165 kPa (24 psi)
124 kPa (18 psi) 152 kPa (22 psi) 186 kPa (27 psi) 165 kPa (24 psi) 165 kPa (24 psi)
Amount of Drop 165 kPa (24 psi)
206 kPa (30 psi) 179 kPa (26 psi) .145.kF'a (21 psi) 165 kPa (24 psi) 165 kPa (24 psi)
Average Range:
162-183 kP
a (23.5-26.5 psi)
Faulty injector too much

fuel drop
Injector OK
Injector OK
Test Description
diagnostic table
Caution: Wrap a shop towel around the fuel

pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
4. The engine coolant temperature must be below
the operating temperature in order to avoid
irregular fuel pressure readings due to Hot Soak
fuel boiling.
Faulty injector too.little

fuet drop
Injector.OK
Injector OK
5. The fuel pressure should be within the specified

range. If the fuel pressure is not within the
specified range.
6. The fuel pressure should reach a steady value. If
the fuel pressure does not reach a steady value.
7. If the pressure drop value for each fuel injector is
within 10 kPa (1.5 psi) of the average pressure
drop value, the fuel injectors are flowing properly.
Calculate the pressure drop value for each fuel
injector by subtracting the second pressure
reading from the first pressure reading. Refer to
the Injector Balance Test Example.
6-1218
Engine

Step
Action
Values
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
Go to Step 4
Go to Step 5

Did you perform the Fuel Injector Coil Test Procedure?
Is the engine coolant temperature above the

specified .value?
94C (201F)
Allow the engine to cool below the specified value.

Is the engine coolant temperature below the
specified value?
94C (201F)

1. Install the fuel pressure gauge.
2. Energize the fuel pump using the scan tool.
4. Bleed the air out of the fuel pressure gauge.
5. Using a scan tool pressurize the fuel system.
2 seconds. Repeat Step 5 as necessary in order to
achieve the highest possible fuel pressure.
7. Observe the reading on the fuel pressure gauge.
Is the fuel pressure within the specified limits?
333-376 kPa
(48-55 psi)
Turn the fuel pump OFF.

Go to Step 5
Go to Step 6
Go to Fuel
System
Pressure Test
Go to Step 7
Go to Fuel
System
Pressure Test
Engine
6-1219
Fuel Injector Balance Test (cont'd)

Step
Action
Values
Yes
No
Go to Step 8
Go to Symptoms
Go to Symptoms
1. Connect the J 39021 fuel injector tester to a fuel

injector.
"
2. Set the amperage supply selector switch on the fuel
injector tester to the Balance Test 0.5-2.5 amp
position.
3. Turn. the fuel pump ON then OFF in. order to
pressurize the fuel system.
4. Record the fuel. pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes. This
is the 1st pressure reading.
5. Energize the fuel injector by depressing the Push to

Start Test button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge needle
has stopped moving. This is the 2nd pressure
reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the 2nd pressure reading from the
1st pressure reading for one fuel injector. The result
is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values. This is
the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that is
either higher than the average pressure drop or lower than
the average pressure drop by the specified value?
Notice: Do Not repeat any portion of this test before

running the engine in order to prevent the engine from
flooding.
Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 7.
Does any fuel injector still have a pressure drop value that
is. either higher than the average pressure drop or lower
than the average pressure drop by the specified value?
Replace the faulty fuel injectors. Refer to Fuel Injector

Replacement.
...
1O kPa (1.5 psi)
10 kPa (1.5 psi)
Go to Step
System OK
6-1220
Engine
Fuel Injector Balance Test with Tech 2

Circuit Description
The scan tool first energizes the fuel pump and then
the injectors for a precise amount of time allowing
a measured amount of fuel into the manifold.
This causes a drop in system fuel pressure that can
be recorded and used to compare each injector.
Test Description
The numbers below refer to the step numbers in the
diagnostic table.

fuel boiling.
4. Tests the fuel system for the ability to reach a

specified fuel pressure range.
5. Tests the fuel system for the abilty to maintain a

specified fuel pressure range.
within 1O kPa (1.5 psi) of the average pressure
reading from the first pressure reading.

Step
Action
Values
Yes

Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Between
1Os35Degrees c
(50-95 Degrees F)
or Fuel lnj Coil
Test- ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Did you perform the Fuel Injection coil test.
Important: Do not preform this test if the engine coolant

temperature is above 94C (201 F).
Install a scan tool.
Does the scan tool indicate that the ECT parameter is less
than the specified value?
No
94C (201F)
Go to Step 4
Engine
6-1221
Fuel Injector Balance Test with Tech 2 (cont'd)

Step
7
8
Action
2. Connect the J 34730-tA fuel pressure gauge to the
fuel pressure test port.
4. With a scan tool, Command the fuel pump ON.
2 seconds. Repeat as necessary in order to achieve the
highest possible fuel pressure.
7. Command the fuel pump ON.
8. Observe the reading on the fuel pressure gauge while
the fuel pump is running.
specified Value?
After the fuel pump stops, the fuel pressure may vary
slightly, then should hold steady.
Does the fuel pressure remain constant within the
specified value?
3. With a scan tool, select Fuel injector Balance within
the Special Functions menu.
4. Select an injector to be tested.
5. Press Enter. This will prime the fuel pump.
7. Energize the fuel injector by depressing the Pulse
Injector button on the scan tool. This will energize the
injector and decrease the fuel pressure.
8. Record the fuel pressure indicated .by the fuel
reading.
9. Press Enter again to bring you back to the Select
Injector screen.
10. Repeat for each fuel injector.
Replace the faulty fuel injectors. Refer to Fuel Injector
Replacement.
Is the replacement complete?
Does any driveabilty condition still exist?
Values
Yes
No
Go to Step 5
Go to Fuel
System
Diagnosis
Go to Step 6
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Symptoms
333-380 kPa
(48-55 psi)
333-380 kPa
(48-55 psi)
10 kPa (1.5 psi)
Go to Step 8
Go to applicable
diagnostic
System OK
6-1222
Engine
F=uel lnj Coil Test - ECT Between 10-35 Degrees C (50-95 Degrees F)
J 39200DMM
LOW VEHICLE BATTERY

READY TO TEST
TEST IN PROGRESS
CJCJCICJ
ii Cl Cl CJ
FUEL INJECTOR
- TESTER +
mvo.,...
6'
$
O
V-DC
V-AC
mA
A

Coi,ITest
Balance Test
4amp
2.Samp
4amp
00
0.5-2.5
o.sa,mp
amp
PUSH TO START TEST
B+
J 39021
(
17707
Test Description
The below refer to the step numbers in the
diagnostic table.

2. The engine coolant temperature affects the ability
of the fuel injector tester to detect a faulty fuel
injector. If the engine coolant temperature is NOT
Between 10C-35C (50F-95F).
3. The first second of the voltage displayed by the
DMM may be inaccurate due to the initial
current surge. Therefore, record the lowest voltage
displayed by the DMM after the first second of
the test. The voltage displayed by the DMM should
be within the specified range (refer to the
Example). The voltage displayed by the DMM

may increase throughout the test as the fuel
injector windings warm and the resistance of the
fuel injector windings changes. An erratic
voltage reading (large fluctuations in voltage that
do not stabilize) indicates an intermittent
connection within the fuel injector.
Resistance
Ohms
11.4-12.6
Fuel injector
number
1
2
3
Voltage Specification at 10C-35C

(50F-95F)
5.7-6.6
Voltage Reading
6.3
5.9
6.2
6.1
Pass/Fail
5
6
4.8
6.0
p
p
p
p
Engine
6~1223
Fuel lnj Coil Test - ECT Between 10-35 Degrees C (50-95 Degrees F)
Step
Action
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go to Step 4
Go to Fuel
Injector
Balance Test

-
1. Connect the scan tool.

2. Check the engine coolant temperature.
Is the engine coolant temperature between the specified
limits?
10C-35C
(50F-95F)
1. Turn the ignition OFF.

Notice: In order to prevent flooding of a single cylinder and
possible engine damage, relieve the fuel pressure before
performing the fuel injector coil test procedure.
Relief Procedure.
Access
the fuel injector electrical connectors as
3.
required.
4. Connect the J 39021 fuel injector tester. to B+ and
ground.
injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the DMM to the fuel injector
tester. Refer to the illustration.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel
injector tester.
Observe
the voltage reading on the DMM.
10.
Important: The voltage reading may rise during the test.
11. Record the lowest voltage observed after the
first second of the test.
12. Repeat the procedure for the remaining fuel injectors.
Did any fuel injector have an erratic voltage reading or a
voltage reading outside of the specified limits?
5.7-6.6 volts
Replace the fuel injectors. Refer to Fuel Injector

Replacement.
Go to Fuel
Injector
Balance Test
..
6-1224
Engine
Fuel lnj Coil Test - ECT Outside 10-35 Degrees C (50-95 Degrees F)
J 39200 DMM
LOW VEHICLE BATTERY
READY TO TEST
TEST IN PROGRESS
CJ CJ CJ CJ
CJCJCJ
FUEL INJECTOR
- TESTER +
mvo,....
V-DC
mA
A
V-AC
AMPERAGE SUPPLY $ELECTOR $WITCH
Coil Test
4amp
2.Samp
O.Samp
Balance Test
4amp
0.5-2.5
00
amp
PUSH TO START TEST
B+
J 39021
(
17707
Test Description
diagnostic table.

. 2. The engine coolant temperature affects the ability
?f. the fuel injector tester to detect a faulty fuel
Outside 10C-35C (50F-95F}, go to Fuel
Injector Coil Test Procedure - engine coolant
tamperature Between 10C- 35C (50F-95F).
c~rrent surge. Therefore, record the lowest voltage
!he test. The voltage displayed by the DMM may
increase throughout the test as the fuel injector
windings warm and the resistance of the fuel
injector windings changes. An erratic voltage
reading (large fluctuations in voltage that do not
stabilize) indicates an intermittent connection
within the fuel injector. From the voltages

recorded, identify the highest voltage, excluding
any voltages above 9.5 volts. Subtract each
voltage that is not above 9.5 volts from the highest
voltage. Record each subtracted value (refer to
the. Example}. The .subtracted value for any
fuel injector must not exceed 0.6 volt. A fuel
injector with a subtracted value that is more than
0.7 volt is faulty. Replace the fuel ii;ijector. A
fuel injector with a recorded voltage above
9.5 volts is also faulty. Replace the fuel injector.
Highest Voltage Reading

7.1 Volts
Injector
Number
Voltage
1
9.8
2
6.6
3
6.9
4
5.8
5
7.0
6
7.1
Acceptable Subtracted
Value Above/Below
10C-35C
(50F-95F)
0.6 V
Subtracted
Value
PassfFail
-
0.5
0.2
1.3
0.1
0.0
p
p
F
p
p
Engine
Step
Action

Is the engine coolant temperature outside the specified
limits?

Relief Procedure.
3. Access the fuel injector electrical connectors as
required.
4. Connect the J 39021 fuel injector tester to B+ and
ground.
6. Connect the leads from the DMM to the fuel injector
tester. Refer to the illustration.
injector tester.
10. Observe the voltage reading on the DMM.
12. Repeat the procedure for the remaining fuel injectors.
13. Identify the highest voltage reading recorded other
than those above 9.5 volts.
14. Subtract any other voltage reading recorded from the
highest voltage reading recorded.
15. Repeat step 14 for all the remaining fuel injectors.
Is any value that resulted from subtraction more than the
specified value?
Replace any fuel injector that had any of the following:

A subtracted value exceeding 0.6 volts.
An initial reading above 9.5 volts.
An erratic reading.
Refer to Fuel Injector Replacement
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
50-95 Degrees F).
10C-35C
(50F-95F)
0.6 volts
Go.to Step 4
Go to Fuel
Injector
Balance Test
Go to Fuel
Injector
Balance Test
6-1226
Engine
Engine Controls - 3;8L
Fuel Tank Leak Check

Caution: Place a dry chemical (Class B) fire
4. Carefully loosen the stopper in order to release

the pressure.
extinguisher near the area before pertorming a

Fuel Tank Leak Check. Before removmg the
fuel tank for a suspected leak, make sure that the
fuel pipes or the tubes are not leaking onto t~e
tank. Once .removed, make sure that the fuel ts not
leaking around the fuel sender 0-ring. Failure to
follow these precautions may result in personal
injury.
6. Put the cylinder on a level surface for

approximately 5 minutes in order to allow
adequate liquid separation.
Important: This. check requires a fuel sender

assembly, a fuel filler cap, and a fuel sender gasket to
be installed in the fuel tank.
1. Relieve fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
2. Remove the fuel tank. Refer to Fuel Tank
3. Cap the fuel feed pipe, the fuel return pipe, and
the EV AP pipe on the fuel sender assembly.
4. Install a piece of fuel line on vent pipe.
5. Submerge the fuel tank in water or apply a soap
solution to the outside of the fuel tank.
6. Apply 31-38 kPa (4112-5112 psi) air pr~ssur~ to the
piece of hose on the fuel tank vent p1~e. ~ir
bubbles appearing from the fuel tank indicate
a leak.
7. Replace the fuel tank if it is leaking. Refer to Fuel
Tank Pressure Sensor Replacement.
Alcohol concentrations greater than 10 percent in fuel
can be detrimental to fuel system components and
may cause driveability problems such as hesitation,
lack of power, stall, no start, etc.
The problems may be due to fu~I system_ cor~osion
and subsequent fuel filter plugging, detenorat1on
of rubber components, and/or air-fuel mixture leaning.
Various types and concentrations of alcohol are
used in commercial fuel. Some alcohol is more
detrimental to fuel system components than others. If
an excessive amount of alcohol in the fuel is
suspected as the cause of a driveability condition, the
following procedure may be used to detect the
presence of alcohol in the fuel.
Testing Procedure
The fuel sample should be drawn from the bottom of
the tank so that any water present in the tank will
be detected. The sample should be bright and clear. If
the sample appears cloudy, or contaminated with
water (as indicated by a water layer at the bottom of
the sample), this procedure should not be used,
and the fuel system should be cleaned.
1. Using a 100 ml specified cylinder with 1 ml
graduation marks, fill the cylinder with fuel to
the 90 ml mark.
2. Add 1O ml of water in order to bring the total fluid
volume to 100 ml and install a stopper.
3. Shake the cylinder vigorously for
10 to 15 seconds.
5. Re-install the stopper and shake the cylinder

vigorously again for 10 to 15 seconds.
If alcohol is present in the fuel, the volume of the

lower layer (which would now contain both alco~ol and
water) will be greater than 10 ml. For example, 1f
the volume of the lower layer is increased to 15 ml,
this indicates at least 5 percent alcohol in the fuel. The
actual amount of alcohol may be somewhat greater
because this procedure does not extract all of the
alcohol from the fuel.
Fuel Quality Diagnosis

Fuel quality may cause driveability problems such as
hesitation, lack of power, stall, no start, etc.
Certain driveability problems can be related to fuel
quality. Fuel testing is limited. Therefore, all other.
system checks must be performed (e.g. P~w~rtrain
System, Fuel System, Ignition System, Em1ss1on
System) before fuel quality is diagnosed. If these
checks fail to solve the problem, gain information from
the customer about when the condition occurs,
when and where the fuel was purchased, and which
octane level was used. Ask the customer to change
fuel brands. If the symptom persists, perform the Fuel
System Diagnosis Alcohol in Fuel test. If this is not
conclusive, drain the tank and refill with a known good
quality fuel.
Due to increasing awareness towards vehicle

emissions (Evaporative and Exhaust) and their impact
on the environment, federal regulations are limiting
certain characteristics of fuel. These limitations
are causing driveability problems that ar~ extre~ely
difficult to diagnose. In order to make a d1agnos1s,
a basic understanding of fuel and its effects on
the vehicles fuel system must be gained.
Octane
Octane is a measure of a fuel's ability to resist spark
knock. Spark knock occurs in the combustion
chamber just after the spark plug fires, when the
air/fuel mixture in the cylinder does not completely
burn. The remaining mixture spontaneously combusts
due to temperature and pressure. This secondary
explosion causes a vibration that is heard as a knock
.
(ping). Fuel with a high octane numb~r has_ a
greater resistance to spark knock. This vehicle requires
87 octane (VIN K) and 91 (VIN 1) (supercharged)
octane ([R+M]/2 method) in order to ensure proper
performance of the fuel control system. Using fuel with
an octane rating lower can create spark knock,
which would cause the PCM to retard ignition timing to
eliminate the knock. In a case such as this, poor
engine performance and reduced fuel e?onomy could
result. Also, in severe knock cases, engine damage
may occur.
Engine
6-1227
Volatility
Fuel System Deposits
Volatility is a fuels ability to change from a liquid state

to a vapor state. Since liquid gasoline will not burn,
it must vaporize before entering the combustion
chamber. The rate at which gasoline vaporizes
determines the amount of evaporative emissions
released from the fuel system, and therefore has made
volatility an environmental concern. The federal
government has lowered the maximum allowable
volatility, but certain driveability conditions have
resulted.
Volatility can be determined through three different
tests: the Vapor-Liquid Ratio, the Distillation Curve,
and the Reid Vapor Pressure Test (RVP). The
Vapor-Liquid Ratio test determines what temperatures
must exist to create a vapor-liquid ratio of 20. The
distillation curve is a graph showing the relationship
between temperature and the percentage of fuel
evaporated. The. fuel components that boil at relatively
low temperatures (below about 90F) are known as
light ends and those that boil at about 300F are
known as heavy ends. The light ends are important for
cold starting and cold weather driveability. Heavy
ends provide engine power and are important for hot
weather driveability. It is the proper mixture of
these components that provide proper operation
across a wide range of temperatures. However, the
distillation curve of a gasoline usually requires
laboratory testing. The Reid Vapor Pressure (RVP)
test measures the pressure (psi) vaporized fuel exerts
within a sealed container when heated to 100F.
Volatility increases proportional to RVP. While RVP
can easily be measured in the field, it may be
misleading because it is possible for two fuels with the
same RVP to have different distillation curves, and
therefore, different driveability characteristics.
As stated, improper volatility can create several
driveability problems. Low volatility can cause poor
cold starts, slow warm ups, and poor overall cold
weather performance. It may also cause deposits in
the crankcase, combustion chambers and spark plugs.
Volatility that is too high could cause high evaporative
emissions and purge canister overload, vapor lock,
and hot weather driveability conditions. Since volatility
is dependent on temperature, different fuels are
used during certain seasons of the year, thus creating
problems during sudden temperature changes.
Fuel system deposits can cause various driveability

problems. Deposits usually occur during hot soaks
after key OFF. Poor fuel quality or driving patterns
such as short trips followed by long cool down periods
can cause injector deposits. This occurs when the
fuel remaining in the injector tip evaporates and leaves
deposits. Leaking injectors can increase injector
deposits. Deposits on fuel injectors affect their spray
pattern, which in turn could cause reduced power,
unstable idle, hard starts and poor fuel economy.
Intake valve deposits can also be related to fuel
quality. While most fuels contain deposit inhibitors,
some do not and the effectiveness of deposit inhibitors
varies by manufacturer. If intake val.ve deposits
occur, fuel may be suspected. These deposits can
cause symptoms such as excessive exhaust
emissions, power loss and poor fuel economy.
Sulfur Content
The sulfur content in fuel is also regulated to a certain
standard. Premium grades of fuel generally have a
lower sulfur content than the less expensive blends. A
high sulfur content can promote the formation of
acidic compounds that could deteriorate engine oil and
increase engine wear. It could also produce excessive
exhaust emissions or a rotten egg smell from the
exhaust system.
6--1228
Engine
EVAP Control System Diagnosis

Refer. to EVAP System Overview.
System
Description
.
..
The EVAP canister purge valve allows manifold
vacuum to purge the canister. The powertrain control
module (PCM) supplies a ground to energize the
purge valve (purge ON). The EVAP purge valve control
is pulse width modulated (PWM) or Turned ON and
OFF several times a second. The duty cycle
(pulse width) is determined by engine operating

conditions including load, throttle position, coolant
temperature and ambient temperature. The duty cycle
is calculated by the PCM a:nd the output is
commanded when the appropriate conditions have
been met.
The EVAP Vent valve is used to seal the EVAP
system during diagnostic tests. The fuel tank pressure
sensor is used to monitor vacuum in the system
during the diagnostic tests.
A stuck .closed EV AP canister purge valve, Stuck
open EVAP vent valve, disconnected or damaged
EVAP Purge line or vent hose, leaking fuel cap, or fill
neck should set a OTC P0440. A small leak in the
EVAPsystem should set a OTC P0442 An EVAP vent
valve stuck closed, a restricted vent hose, or a
blocked EV AP canister should set a OTC P0446. A
continuous purge condition with no purge commanded
by the PCM (EV AP purge valve stuck open or
leaking) should set a OTC P1441. Refer to the OTC
tables for further diagnostic procedures regarding
the EVAP system.
Diagnostic Aids
Check for the following conditions:
Cracked or punctured EV AP canister
Damaged or disconnected source vacuum line,
EV AP purge line, vent hose or fuel tank
vapor line.
" Poor connection at the PCM
.. Damaged harness. Inspect the wiring harness to
the EVAP vent valve, the EVAP purge valve,
and the fuel tank pressure sensor for an
intermittent open or short circuit.
Kinked, pinched or plugged vacuum source,
EVAP purge, or fuel tank vapor line. Verify that the
lines are not restricted.
" Use the following procedure to check for a carbon
release condition that could plug the system.
2. Remove the EV AP canister purge valve. Refer
to EVAP Canister Purge Valve Replacement.
3. Lightly tap the canister purge valve on a clean
either of the vacuum ports.
4. If no car.ban release is evident, reinstall the

components and continue with the OTC P0440
diagnostic table. If carbon is being released
from either component, continue with this
service procedure.
off on the J 41413 EVAP purge/pressure
diagnostic station.
nitrogen cylinder to the J 41413 EVAP
purge/pressure diagnostic station at the
pressure regulator by unscrewing the knurled
nut on the regulator. No tools are required
to remove the black hose from the regulator.
one end over the open threaded fitting of the
EVAP purge/pressure diagnostic station
pressure regulator.
9. Connect the. remaining end to the purge valve

end of the EVAP purge line at the vehicle and
turn on the.main nitrogen cylinder valve.
Continue to blow any debris from the purge
line for 15 seconds.
10. Return the J 41413 EVAP pressure/purge
reinstalling the black hose that was
disconnected in step 7.
11. Replace the following components:
The EVAP canister purge valve. Refer to
EVAP. Canister Purge Valve
Replacement.
.. The EVAP canister. Refer to EVAP

Test Description
diagnostic table:
1. The Powertrain On-Board Diagnostic (OBD)
and Failure Records Data on the scan tool
if applicable .
2. If a vent valve or EV AP purge valve electrical
malfunction is present, the purge system will
malfunction that caused the DTC to set will very
likely correct the condition.

high condition. The fuel tank pressure must
purge valve. The fuel fill cap will not relieve the
fuel tank pressure due to a check valve in the filler
neck. The check valve seals when pressure is
applied to prevent vapors from escaping through
the filler neck. The scan tool should read
within 1.0 inch H20 of the specified value.
4. Inspects for a large leak in the EVAP system.
Engine

at 5 volts. the scan tool can only read a max
pressure of 6.0 inches of H20 (0 volts). However
\lalue should be within 0.5 of the specified value.
6-1229
6. Inspects for a stuck closed EVAP vent valve. The

value should decrease to within 1.0 in Hg of the
specified value.
canister purge valve. The scan tool should read
8. Ensures that sufficient source vacuum is present
at the EVAP canister purge valve/solenoid.
14. Inspects for a small leak in the EVAP system.
EVAP Control System Diagnosis

Step
Action
Values
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
applicable DTC
Go to Step 3
Go to Step 4
Go to Step 9
Go to Step 5
Go to
DTCP0440
Evaporative
Emission (EVAP)
System
Go to Step 6
Go to Step 11

\)

conditions:
" Loose or missing fuel fill cap.

2. Disconnect the canister purge line from the EVAP
parameter.
specified value?
O in H20

EVAP pressure and vacuum (inches of H20) Gauges on
the J41413 EVAP pressure/seal diagnostic station.
disconnected,
3. Install the J 41415-40 fuel tank cap adapter to the
fuel fill neck and fuel fill cap.
4. Connect the EV AP station to the fuel tank cap
adaptor.
6. With a scan tool, capture Fail Record data for
DTC P0440 and clear DTCs.
specified value.
system to the specified value by slowly turning the
pressure with the gauge on the EVAP station with the
5 in. H20
1. With the EVAP station, maintain the fuel tank

pressure at the specified value. Monitor the pressure
with the gauge on the cart with the rotary switch in
the OFF/HOLD position.
parameter.
specified value?
5 in H20
6-1230
Engine

EVAP Control System Diagnosis (cont'd)
Step
Action
With a scan tool, command the vent valve OFF (open) to
relieve the pressure.
Does the pressure decrease to near the specified value
within 2 minutes with the rotary switch in the OFF/HOLD
position?
Values
O in. Hg
'1. With a scan tool, increase purge to '100 percent.

2. Run the engine from '1200-'1500 RPM and observe
vacuum level.
Does the vacuum level measure above the
specified value?
'15 in. Hg
'1. Turn OFF the ignition.

or EVAP canister.
4. With a scan tool, observe Fuel Tank Pressure
Parameter.
specified value?
O in H20
'10
Check for a kinked or restricted canister purge line

canister.
O in. H20
'1'1
Visually/Physically inspect for the following conditions:

O Restricted fuel tank vapor line.
RestrJcted EVAP purge line.
'12
Check for no source vacuum to the EVAP purge valve.

'13
Important: Check for carbon release into the EVAP

system. Refer to Diagnostic Aids.
Locate and repair cause of no source vacuum to the
EVAP purge valve.
14

disconnected.
3. With scan tool, select the Seal option to seal the
EVAP system.
specified value.
first specified {higher) value by slowly turning the
Does the EVAP pressure decrease to less than the
second specified {lower) value within 2 minutes with the
No
Go to Step 7
Go to
DTCP0446
Evaporative
Emission (EVAP)
Vent System
Performance
Go to Step B
Go to Step 12
Go to Step 14
Go to Step 13
Go to Step 10
Go to
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage
5 in. H20
'1. Connect the inch Hg vacuum hose on the EV AP

station to the canister side of the purge valve.
3. With a scan tool, selectthe Seal option to seal the
EVAP system.
5. Run the engine from '1200-'1500 RPM and observe
vacuum level.
Does the vacuum level measure above the
specified value?
Yes
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 14
Go to
DTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage
-
Go to Step 12
'15 in H20
'10 in H20
Go to
DTCP0442
Evaporative
Emission (EVAP)
System Small
Leak Detected
(
System OK
Engine
6-1231

Procedures
The System Status table shows the DTCs that must

run in order for the System Status to indicate a system
test has been Completed.
System Status For Satisfying the Federal

Inspection/Maintenance (1/M) Regulations
System Status
The scan tool System Info menu includes the System

Status selection.
Several states require that the vehicle pass on-board
(OBD II system) tests for the major diagnostics
prior to having a vehicle 1/M emission inspection. Some
areas may require that the vehicle pass the OBD II
system tests and the 1/M emission inspection in order
to renew license plates.
Using a scan tool, the technician can observe the
System Status (Complete or Not Complete) in order to
verify that the vehicle meets the criteria which
complies with the local area requirements. Using the
System Status display, monitor any of the following
systems or a combination of the systems (depending
on vehicle make and model) for 1/M Readiness:
~
Catalyst
Heated oxygen sensor (H02S)

" Heated oxygen sensor (H02S) heater
System Status
DTCs Used to Set System

Status
Catalyst
P0420
H02S
P0133, P0153, P1133,

P1134, P1153, and P1154
H02S Heater
P0135, P0147, and P0155
EGR System
P0401
EVAP System
P0440, P0442, P0446,

P1441, or the Service
Bay Test
AIR System
Scan Tool Tests

The scan tool for some systems depending upon the
vehicle make and model include the Service Bay
Tests. Use the Service Bay Tests in order to
test certain systems and reset the System Status to
Complete. The EVAP Service Bay Test is included for
this vehicle. Refer to Service Bay Test for important
preliminary instructions.
Exhaust gas recirculation (EGR)
Service Bay Test
Evaporative emission (EV AP)
The Service Bay Test is included on the scan tool for

some systems, depending upon the vehicle make
and model. The EVAP Service Bay Test is used to test
the EVAP system and indicate the failed DTC codes
or to state that the EVAP system passed. The
EVAP Service Bay Test may be used to test the
EV AP system after repairs are completed. This test
takes some time to run.
Secondary Air Injection .System (AIR)

Important: The System Status display indi.cates only if
the PCM has completed the required tests (DTCs).
The System Status display does not necessarily mean
that the test has passed. If a failure indication is
present for a DTC associated with one of the above
systems, that test has failed. Diagnosis and repair are
necessary in order to meet the 1/M requirement.
Verify that the vehicle passes all of the diagnostic tests
associated with the displayed System Status prior to
returning the vehicle to the customer.
Following a DTC Info Clear, battery disconnect, or a
control module replacement, all of the System
Status information will be set to Not Complete.
Refer to the diagnostic support information associated
with each DTC in order to obtain the Conditions for
Running the DTC. The vehicle operating conditions
that the system must meet in order for a DTC to
run are the Conditions for Running the DTC.
Important: Ensure that the vehicle meets the following

requirements before performing the EVAP Service
Bay Test. Failure to meet the necessary requirements
may cause inaccurate test results.
The EVAP Service Bay Test can be performed when
the vehicle meets the following conditions:
The Powertrain On-Board Diagnostic (OBD)
System Check has been performed, ensuring that
no DTC has set.
O The battery voltage is 5-18 volts.
., The fuel level is 15-85 percent of capacity, or
approximately 1/4-3/4 full.
The ignition is on and the engine coolant
temperature (ECT) is 5C - 70C (40F - 158F) .
.. The IM Ready Flag must not be on.
The startup intake air temperature (IAT) is
4C - 30C (30F - 86F).
The vehicle speed is less than 3 mph.
" The throttle angle is less than 2 percent.
" The BARO is more than 75 kPa.
Follow the instructions on the scan tool after ensuring
the above conditions have been met.
If any of the above conditions are not met upon
activating the Service Bay Test, exit and run the test
when the above conditions have been achieved.
6-1232
Engine
Repair Instructions
PCM Replacement/Programming
Notice: In order to prevent possible electrostatic

discharge damage to the PCM, do not touch
the connector pins or soldered components on the
circuit board.
Service of the PCM should normally consist of either
replacement of the PCM or EEPROM programming.
If the diagnostic procedures call for PCM Replacement,
check the PCM first to see if it is the correct part. If
the PCM is faulty, remove it and install the new
service PCM.
The new service PCM will not be programmed. You
must program the new PCM. DTC P0602 indicates the
EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent possible electrostatic
discharge damage to the PCM, do not touch
the connector pins or soldered components on the
circuit board.
21745
Notice: Turn the ignition OFF when installing or

removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.) in order
to prevent internal PCM damage.
Important: When replacing the production PCM with a
service PCM (controller), it is important to transfer.
the broadcast code and production PCM number to the
service PCM label. Do not record on PCM cover.
This will allow positive identification of PCM parts
throughout the service life of the vehicle.

Removal Procedure
1.
2.
3.
4.
Disconnect the negative battery cable.

Remove the PCM from the mounting hardware.
Disconnect the harness connectors from the PCM.
Remove the PCM from the engine compartment.
Engine
Engine Controls- 3.8l
6-1233
1.
2.
3.
4.
Connect the harness connectors to the PCM.

Position and install the PCM into the vehicle.
Connect the negative battery cable.
If you are installing a new PCM, program the new
PCM EEPROM.
21745
EEPROM Programming
1. Set-up - Ensure that the following conditions have
been met:
The battery is fully charged.
The ignition is ON.
The connection at the DLC is secure.
2. Program the PCM using the latest software
matching the vehicle. Refer to up-to-date Techline
equipment users instructions.
3. If the PCM fails to program, proceed as follows:
Ensure that all PCM connections are OK.
~ Check the Techline equipment for the latest
software version.
Attempt to program the PCM. If the PCM still
cannot be programmed properly, replace the
PCM. You must program the
replacement PCM.
Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and th.e engine run for
one minute.
3. Use the scan tool in order to scan for the DTCs.
6-1234
CKP System Variation Learn Procedure

The crankshaft position system variation compensating
values are stored in the PCM non-volatile memory
after a learn procedure has been performed. If
the actual. crankshaft position system variation does
not match the crankshaft position system variation
compensating values. stored in the PCM, DTC P0300
may set, refer to Diagnostic Aids for DTC P0300.
The Crankshaft Position System Variation Learn
Procedure should be performed if any of the following
conditions are true:
DTC P1336 is set.
The PCM has been replaced.
The engine has been replaced.
The crankshaft has been replaced.
The crankshaft harmonic balancer has been
replaced.
" The crankshaft position sensor has been replaced.
Caution: Set the vehicle parking brake and

block the drive wheels when performing the
Crankshaft Position System Variation Learning
Procedure in order to prevent personal injury.
Release the throttle immediately when the engine
starts to decelerate. Once the learn procedure
is completed, the PCM will return the engine
control to the operator and the engine will respond
to the throttle position.
Important: Begin the crankshaft position system
variation learn procedure with the ignition OFF. Do not
turn ON the ignition or start the vehicle unless
instructed to do so by the scan tool.
learn function will be inhibited if any powertrain DTCs
other than DTC P1336 are set before or during the
crankshaft position system variation learn procedure.
Clear DTCs before attempting to perform the
crankshaft position system variation learn procedure. If
any DTCs reset, the DTCs must be diagnosed and
repaired before the crankshaft position system
variation learn procedure can be successfully
completed.
The crankshaft position system variation learn function
will be inhibited if the PCM detects a malfunction
involving the camshaft position signal circuit,
the 3X reference circuit, or the 18X reference circuit.
If the scan tool indicates that a problem with
the camshaft position signal exists, refer to
OTC P0341 Camshaft Position (CMP) Sensor
Performance.
e If the scan tool indicates that a problem with the
3X crank signal exists, refer to OTC P1374
Crankshaft Position (CKP) High to Low Resolution
Frequency Correlation.
If the scan tool indicates that a problem with the
18X crank signal exists, refer to OTC P0336
Crankshaft Position (CKP) Sensor Circuit.
Engine
learn function will not be enabled until engine coolant
temperature is more thanJ0C (158F).
Selecting the crankshaft position system variation

learn procedure on the scan tool will command
the PCM to enable CKP system variation learn fuel
cutoff and allow the crankshaft position system
compensating values to be stored in the PCM. The
PCM must detect an engine speed of 5150 RPM (CKP
system variation learn fuel cutoff) during the
crankshaft position system variation learn procedure to
store the crankshaft position system compensating
values and complete the procedure.
1. Set the parking brake.
2. Block the drive wheels.
3. Close the hood.
4. Start the engine and allow engine coolant
temperature to reach at least 70C (158F).
6. .Select and enable the crankshaft position variation
learn procedure with the scan tool.
7. Start the vehicle
8. Ensure that the transaxle is in Park.
9. Apply the service brake pedal firmly and hold.
10. Increase accelerator pedal position until CKP
system variation learn fuel cutoff is reached.
CKP system variation learn fuel cutoff is reached
at.5150 RPM. Immediately release the
aq;elerator p~dal when fuel cutoff is reached.
11. The crankshaft position system variation

compensating values are learned when RPM
decreases back to idle. If the procedure
terminates, refer to Important above for
instructions.
12. Opserve DTC status for DTC P1336.

13. If the scan tool indicates that DTC P1336 ran and
passed, the crankshaft position system variation
learn procedure is complete. If the scan tool
indicates DTC Pf336 failed or not run, check for
other DTCs. If no DTCs other than P1336 are
set, repeat the crankshaft position system variation
learn procedure as necessary.
Engine
6-1235
ECT Sensor Replacement

Removal Procedure
Engine Coolant Temperature sensor. Damage to the
engine co9lan.t temperature sensor will affect
proper operation of the fuel injection system.
1. Drain the radiator coolant. Refer to Draining and
2. Disconnect the ECT sensor electrical connector.
3. Using a 19 mm deep well socket, remove the
sensor.
21671
1. Coat engine coolant temperature sensor threads
INith sealer P/N 1052080 or equivalent.
Notices.
2. Hand start the ECT sensor into the engine.
Tighten
Tighten the ECT sensor to 12.5 Nm (9.2 lb ft}.
4. Refill radiator with coolant. Refer to Draining and
5. Start the engine and inspect for a coolant leak.
21671
6-1236
Engine
MAF Sensor Replacement
Removal Procedure
1. Disconnect the MAF sensor electrical connector.
2. Remove the MAF sensor fasteners.
3. Remove th.e MAF sensor from the throttle body.
15006
1. Carefully position the MAF sensor to the
throttle body;
Notices.
2. Install the MAF sensor fasteners.
Tighten
Tighten the MAF sensor fasteners to
3 Nm (27 lb in).
15006
Engine
6-1237
MAP Sensor Replacement

)
Removal Procedure
1. Disconnect the MAP sensor electrical connector.
2. Carefully open the MAP sensor retaining tabs
just enough to remove the MAP sensor from
the vacuum source.
3. Pull the MAP sensor straight out of vacuum
source.
1. Ensure that the seal is correctly installed on MAP
sensor and that the seal is not damaged.
2. Install the MAP sensor to the vacuum source.
Ensure the retaining tabs engage.
____________________
...._
_.
21663
6-1238
Engine

Replacement
Bank 1 H02S 1 and Bank 2 H02S 1
Notice: The Heated Oxygen Sensorseach usea

permanently attached pigtail a.nd connector. This pigtail
should not be removed from the heated oxygen
sensor. Damage or removal of the pigtail or connector
could affect proper operation of the heated oxygen
sensor.
Removal Procedure
28514
Important: Take care when handling the heated

oxygen sensor. The in-line electrical connector and
louvered end must be kept tree of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor/catalyst monitor. A dropped sensor is a
bad sensor.
The heated oxygen sensor may be difficult to remove
when the engine temperature is below 48C (120F).
Excessive force may damage threads in the exhaust
manifold or exhaust pipe.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Disconnect the H02S electrical connector.
3. Carefully back out the heated oxygen sensor.
187262
Engine
6-1239
Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti seize
compound applied before reinstallation.
1. Coat threads of heated oxygen sensor/catalyst
monitor with anti-seize compound P/N 5613695,
or equivalent if necessary.
0

Notices.
2. Hand start the heated oxygen sensor.
Tighten
Tighten the heated oxygen sensor to
42 N-m (31 lb tt).
3. Connect the H02S electrical connector.
187262
Bank 1 H02S 2
Notice: The Heated Oxygen Sensors each use a
permanently attached pigtail and connector. This pigtail
should not be removed from the heated oxygen
sensor. Damage or removal of the pigtail or connector
could affect proper operation of the heated oxygen
sensor.
Removal Procedure
lmpo,rtant: Take care when handling the heated
oxygen sensor. The in-line electrical connector and
louvered end must be kept free of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor/catalyst monitor. A dropped sensor is a
bad sensor.
The heated oxygen sensor may be difficult to remove
when engine temperature is below 48C (120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle in General Information.
196425
6-1240
Engine Controls .., 3.SL
Engine
reinstalled, the threads must have anti-seize
1. Coat threads of heated oxygen sensor/catalyst

monitor With anti-seize compound P/N 5613695,
or equivalent if necessary.

Notices.
2. Hand start the heated oxygen sensor.

Tighten
196434

42 Nm (31 lb ft).
IAT Sensor Replacement

The IAT sensor is mounted in the air intake resonator.
Removal Procedure
1. Disconnect the IAT sensor electrical connector.
2. Carefully remove the IAT sensor (snaps into

place).
21677
Engine
6-1241
1. Install the IAT Sensor into the air intake resonator
(snaps into place).
21677

(TAC Module and Bracket Assembly)
Removal Procedure
1. Remove the exterior retaining bolt and discard.
403996
2. Remove the left instrument panel insulator. Refer

to Closeout/Insulator Panel Replacement - Left in
Instrument Panel, Gages and Console.
296111
6-1242
Engine
3. Disconnect the harness from the TAC module.
403994
4. Remove the interior retaining bolt and nut.

5. Remove the pedal/TAC module assembly from
the vehicle.
403993
1. Install the pedal/TAC module assembly to the
vehicle.

Notices.
2. Install the interior retaining bolt and nut.
Tighten
Tighten the bolt to 25 N-m(19 lb ft) and tighten the
nut to 20 N-m(15 lb ft).
403993
Engine
6-1243
3. Connect the harness to the TAC module.
403994
4. Install the left instrument panel insulator. Refer to

Closeout/Insulator Panel Replacement - Left in
Instrument Panel, Gages and Console.
296111
5. Install the new exterior retaining bolt.

Tighten
Tighten the bolt to 8 N-m(1 O lb ft).
403996
6-1244
Engine

(Bracket and Rod Assembly)
Removal Procedure
1. Remove the TAC module and bracket assembly

from the vehicle. Refer to Accelerator Controls
Pedal Replacement (TAC Module and Bracket
Assembly).
2. Disconnect the plastic link (3) from the TAC
module arm and discard.
3. Remove the bolts (2) retaining the TAC
module (1) to the bracket (4).
4. Remove the TAC module (1) from the bracke1 (4).
579466
2
Important: When the Bracket and Pedal assembly is

replaced, the APP Min Reset must be preformed
using the scan tool output function.
1. Install the bracket (4) to the TAC module (1 ).
and Notices.
2. Install the bolts (2) that retain the TAC module (1)
to the bracket (4).
Tighten
Tighten the bolts to 6 N-m(53 lb in).
579466
Important: This link (3) must not be damaged at

installation.
3. Connect the plastic link (3) to the TAC
module arm.
4. Install the TAC module (1) and bracket
assembly (4) to the vehicle. Refer to Accelerator
Controls Pedal Replacement (TAC Module
and Bracket Assembly).
5. Perform the APP Min Reset using the scan tool.
Engine
Engine Controls-. 3J3L
6-1245

(Pad, Spring and Pin)
Removal Procedure
1. Remove the TAC module and bracket assembly
from the vehicle. Refer to Accelerator Controls
Pedal Replacement (TAC Module and Bracket
Assembly).
2. Disconnect the pad spring (5) from the rod.
3. Remove the pin (7) from the pad (6) and rod.
4. Remove the pad (6) and pad spring (5) from
the rod.
579466
1.
2.
3.
4.
Install the pad (6) and pad spring (5) to the rod.
Install the pin (7) to the pad (6) and rod.
Connect the pad spring (5) to the rod.
Install the TAC module and bracket assembly to
the vehicle. Refer to Accelerator Controls Pedal
Replacement (TAC Module and Bracket
Assembly).
579466
Throttle Body Assembly Replacement

Removal Procedure
Notice: Do Not use solvent of any type when cleaning
the gasket surfaces on the intake manifold and the
throttle body assembly, as damage to the gasket
surfaces and throttle body assembly may result.
Use care in cleaning the gasket surfaces on the intake
manifold and the throttle body assembly, as sharp
tools may damage the gasket surfaces.
1. Drain the radiator coolant. Refer to Draining and
2. Remove the air intake duct form the throttle body.
3. Disconnect the MAF sensor electrical connector.
4. Disconnect the throttle body/TAC electrical
connector.
5. Remove the throttle body/TAC retaining bolt
and nuts.
6-1246
Engine
6. Remove the throttle body/TAC assembly from the

intake.
7. Remove and discard the gasket.
1. Install the new gasket to the intake.
2. Install the throttle body/TAC assembly to the
Intake.

Notices.
3. Reinstall the retaining bolt and nuts
Tighten
4.
5.
6.
7.
Tighten the throttle body retaining bolt and nut to

1O Nm (89 lb in).
Reconnect the throttle body/TAC electrical
connector.
Reconnect the MAF electrical connector
Reinstall the air intake duct to the throttle
body/TAC assembly.
Refill the radiator in order to replace the lost
coolant. Refer to Draining and Filling Cooling
System (3.8 L) in Engine Cooling.

Replacement
Removal Procedure
1. Remove the air intake tube.
2. Remove the snap ring (3).

3. Remove the throttle body air inlet screen (2) from
the throttle body (1 ).
180140
Engine
1. Install the throttle body air inlet screen (2) to the
throttle body (i ).
2. Install the snap ring (3).
3. Install the air intake tube.
180140
Fuel Pressure Relief Procedure

Relief Procedure
Tools Required
J 34730-tA Fuel Pressure Gauge
1. Disconnect the negative battery terminal. Refer to
2. Loosen the fuel filler cap to relieve tank vapor
pressure.
3. Connect fuel pressure gauge J 34730-tA to the
fuel pressure connection. Wrap a shop towel
around the fuel pressure connection while
connecting the fuel pressure gauge in order to
avoid spillage.
4. Install the bleed hose into an approved container
and open the valve to bleed the system pressure.
The fuel connections are now safe for servicing.
5. Drain any fuel remaining in the fuel pressure
gauge into an approved container.
180378
6-1248
Engine
(Metal Collar)
Removal Procedure
Tools Required
J 37088-A Fuel Line Quick-Connect Separator
Caution: Wear safety glasses when using
compressed air, as flying dirt particles may cause
eye injury.
Caution: Relieve the fuel system pressure before
servicing fuel system components in order to
reduce the risk of fire and personal injury.
1211s
After relieving the system pressure, a small

amount of fuel may be released when servicing
the fuel lines or connections. In order to reduce the
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that
may leak out. Place the towel in an approved
container when the disconnection is complete7
Notice: Before attempting any On-Vehicle Service,
place a dry chemical (Class B) fire extinguisher
near work area.
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Important: Always maintain cleanliness when

servicing fuel system components.
2. Grasp both sides of the fitting. Twist the female
connector 114 turn in each direction to loosen any
dirt within the fitting.
3. Blow dirt out of the fitting using compressed air.
\ I
\L
c: )@
.....
'
'
12776
Engine
6-1249
4. Choose the correct tool from J 37088-A Tool Set

for the size of the titting. Insert the tool into the
female connector, then push inward to release the
locking tabs.
12780
5. Pull the connection apart.

Notice: If it is necessary to remove rust or burrs from
a fuel pipe, use emery cloth in a radial motion with
the fuel pipe end in order to prevent damage to
the 0-ring sealing surface.
6. Using a clean shop towel, wipe off the male
pipe end.
7. Inspect both ends of the fitting for dirt and burrs.
Clean or replace the components as required.
12782
Caution: In order to reduce the risk of fire and
personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine
oil to the male pipe ends.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male
pipe end.
12784
6-1250
Engine
2. Push both sides of the fitting together to. cause

the retaining tabs to snap into place.
12786
3. Once installed, pull on both sides of the fitting to

make sure the connection is secure.
4. Tighten the fuel filler cap.
5. Reconnect the negative Battery Cable. Refer to
Procedure in engine electrical.
6. Inspect for leaks.
6. 1. Turn ON the ignition for 2 seconds.
6.2. Turn OFF the ignition for 10 seconds.
6.3. Turn ON the ignition.
6.4. Check for fuel leaks.
12787

(Plastic Collar)
Removal Procedure
chance of personal injury, cover th.e regulator
container when the disconnection is complete.
eye injury.
157703
Engine
6-1251
Notice: Before attempting any On-Vehicle Service,

place a dry chemical (Class B) fire extinguisher
near work area.
and passages.

Relieve the fuel system pressure. Refer to Fuel
1. Grasp both sides of the quick-connect fitting.
Twist quick-connect fitting 1/4 turn in each
direction to loosen any dirt within fitting.
2. Repeat for other fuel pipe fitting.
3. Blow out dirt from quick-connect fittings at both
ends, using compressed air.
....
''
~==m~k:::
155410
4. Squeeze plastic tabs of male end connector.
12777
6-1252
Engine
5. Pull connection apart.
Repeat for the other fitting.
6. Wipe off the male pipe end using a clean
shop towel.
7. Clean or replace components/assemblies as
required.
12778
1. Apply a few drops of clean oil to the male
pipe end.
155425
2. Push both sides of the quick-connect fitting

together in order to cause the retaining
tabs/fingers to make sure snap into place.
155771
Engine
6-1253
3. Pull on both sides of the quick connect fitting in

order to make sure the connection is secure.
5. Reconnect negative battery cable. Refer to
6. Inspect for fuel leaks.
6.1. Turn ON the ignition for 2 seconds.
6.4. Check for leaks.
155399
In-Line Fuel Filter Replacement

Removal Procedure
and passages.

Important:
" There is no service interval for fuel filter
replacement. Only replace a restricted fuel filter.
" Inspect the fuel tank internally and clean the fuel
tank if you find a restricted fuel filter.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Raise the vehicle. Go to Lifting and Jacking the
Vehicle in General Information.
3. Clean all the fuel filter connections and the
surrounding areas before disconnecting the
fuel pipes in order to avoid possible c.ontamination
of the fuel system.
4. Disconnect the quick-connect fitting at the fuel
filter inlet (3). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
5. Disconnect the threaded fitting (1) from the fuel
filter outlet.
6. Slide the fuel filter (2) from the bracket (4).
7. Inspect the fuel pipe 0-ring for cuts, nicks,
swelling, or distortion. Replace the 0-ring if
necessary.
12603
61254
Engine

Notice: Always re-attach the fuel lines and fuel filter
with all original type fasteners and hardware.
Do not repair sections of fuel pipes.
Important: If fuel line bundle attaching hardware is

damaged or broken replace it.
1. Slide the fuel filter (2) into the bracket (4).
2. Reconnect the threaded fitting (1) to the fuel filter
outlet.
'

Notices.
3.
12603
4.
5.
6.
7.
Tighten
Tighten the fuel filter fitting to 30 N-m (22 lb ft).
Reconnect the quick-connect fitting to the fuel
Lower the vehicle.
Tighten the fuel filler cap.
Reconnect the negative battery cable. Refer to
Inspect for leaks.
Fuel Tank: Draining Procedure

Tools Required
J 42960-1 Fuel Drain Hose
J 42960-2 Fuel Flapper Door Holder
Remove the fuel filler cap.
Install the J 42960-2 fuel flapper door holder into
the fuel fill pipe in order to hold the door open.
3. Insert the J 42960-1 fuel drain hose into the fuel
tank until the hose reaches the bottom of the
fuel tank,
4. Use an air operated pump device in order to drain
as much fuel through the fuel fill pipe as possible.
"
1.
2.
387061
Engine
Engine Controls -
a~aL
6-1255
Fuel Tank Replacement

Removal Procedure
Tools Required
J34730-1A Fuel Pressure Gauge

J 39765 Fuel Sender Lock Nut Wrench
J42960-1 Fuel Tank Drain Hose
Caution: Refer to the Battery Disconnect Caution

1. Disconnect the negative battery cable.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Raise the vehicle. Refer to Lifting and Jacking the
5. Remove the fuel fill pipe shield.
6. Remove the fuel tank fill pipe support bracket bolt.
7. Remove the exhaust system from the catalytic
converter back. Refer to Muffler Replacement in
Engine Exhaust.
8. Remove the exhaust pipe heat shield and the
exhaust muffler heat shield. Refer to Exhaust
Pipe and Muffler Heat Shields Replacement
in Engine Exhaust.
21288
327608
9. Clean all fuel pipe connections and surrounding

areas before disconnecting the fuel pipes in order
to avoid possible contamination of the fuel
system.
10. Disconnect the fuel return pipe (2) at the rear
quick-connect fitting.
11. Disconnect the EVAP purge pipe (1) at the rear
356450
6-1256
Engine>Controls - 3J3L
Engine
12. Disconnect the fuel feed pipe at the fuel filter inlet.
13. Cap the fuel pipes in order to prevent possible
fuel system contamination.
- ----.:::.
----. . . h
. (/Jj O----
~ . . . ...
..
Y7
327204
14. Remove the rear pipe clip.
355809
15. Remove the fuel tank.

16. Place the fuel tank in .a suitable work area. .. .
327609
Engine
Engine Controls - 3.8L .6-1257
17. Disconnect the hose from the EVAP canister vent

solenoid.
18. Remove the EVAP canister vent solenoid from the
fuel tank bracket.
376991
19. Disconnect the fill limiter verit valve pipe from the
EVAP canister.
20. Carefully bend the fuel tank bracket in order to
remove the EV AP canister.
376984
21. Disconnect the fuel feed pipe '(4}, the fuel return
pipe (2), and the EVAP pipe (3) from the fuel
sender.
22. Disconnect the EVAP pipe from the fill limiter vent
valve pipe (10).
23. Remove the fuel and EV AP pipes from the
fuel tank.
24. Disconnect the fuel sender electrical
connectors (1 ).
25. Remove the fuel sender electrical harness (8)
from the fuel tank.
376978
6.-1258
Engine
26. Remove the fuel sender assembly from the fuel
tank. Refer to Fuel Sender Assembly
Replacement.
376982
27. Remove the fuel fill hose to fuel. tank clamp (1).
28. Remove the fuel fill pipe and hose from the
fuel tank.
376980
Installation Procedu.re
1. Install the fuel fill pipe and hose to the fuel tank.
Notice: Refer to the Fastener Notice in Cautions

and Notices.
Tighten
Tighten the fuel fill hose clamp (1) to
2.5 Nm (22 lb in).
376980
Engine
6-1259
2. Install the fuel sender assembly to the fuel tank.

Refer to Fuel Sender Assembly Replacement.
3. Perform the fuel tank leak check. Refer to Fuel
Tank Leak Check.
376982
4 ... Install the fuel sender electrical harness (8) to the

fuel tar:ik.
5. Connect the fuel sender electrical connectors (1 ).
6. Install the fuel feed pipe (4) and the fuel return
pipe (2) to the fuel sender and the fuel tank clips.
7. Connect the EVAP pipe (3) to the fuel sender.
8. Connect the, EV AP pipe to the fill limiter vent valve
pipe (10).
376978

install .the EVAP canister.
10. Connect the fill limiter vent valve pipe to the
EVAP canister.
376984
6-1260
Engine
11. Install the EVAP canister vent solenoid.to the fuel
tank bracket.
12. Connect the hose to the EVAP canister vent
solenoid.
376991
13. With the aid of an assistant, position and support .

the fuel tank.
14. Position the fu~I tank straps up.
15. Install the fuel tank strap attaching bolts.
Tighten
Tighten the fuel tank strap attaching bolts to
33 N-m (24 lb ft).
16. ;Connect the fuel sender and th.e fuel pressure

seinsqr electrical connectors ai the pass through
connector.
(
327144
Engine
6~1261
17. Remove the caps from the fuel pipes.

18. Connect the fuel feed pipe at the fuel filter inlet.
327204
19. Connect the EVAP purge pipe (1) at the rear

20. Connect the fuel return pipe (2) at the rear
356450
21. Install the fuel and EVAP pipes into the pipe clip,
22. Align the fuel and EVAP pipes into
23. Install the pipe clip bolt.
afh:1t position.
Tighten
Tighten the pipe clip bo.lt to 5 ..5 Nm (49 lb in).
355809
6-1262
Engine
24. Install the fuel tank fill pipe support bracket bolt.
Tighten
Tighten the fuel tank fill pipe support bracket bolt
to 1O N-m (89 lb in).
25. Install the exhaust system heat shields and
attaching screws. Refer to Exhaust Pipe and
Muffler Heat Shields Replacement in Engine
Exhaust.
26. Install the exhaust system. Refer to Muffler
Replacement in Engine Exhaust.
327608
27.
28.
29.
30.
31.
32.
Install the fuel filler pipe shield.

Lower the vehicle.
Refill the fuel tank.
Install the fuel filler cap.
Inspect for leaks.
32.2. Turn OFF the ignition for 1O seconds.
21288
Fuel Tank Pressure Sensor Replacement

Removal Procedure
2. Drain fuel tank. Refer to Fuel Tank Draining
Procedure.
Replacement.
5. Remove the electrical connector from the fuel
tank pressure sensor.
6. Remove the fuel tank pressure sensor (10) from
the modular fuel sender.
370970
Engine
6-1263
1. Install the new fuel tank pressure sensor (10) to
the modular fuel sender.
2. Connect the electrical connector to the fuel tank
pressure sensor.
3. Reinstall the fuel tank. Refer to Fuel Tank
Replacement.
4. Refill the fuel tank.
5. Reconnect the negative battery cable. Refer to
6. Inspect for fuel leaks.
6.3. Tum ON the ignition.

370970
Fill limiter Vent Valve Replacement

Removal Procedure
amount of fuel may be.released when servicing
Caution: Gasoline or gasoline vapors are highly
flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or
diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical
(Class B) fire extinguisher nearby.
Caution: Always wear safety goggles when
working with fuel in order to protect the eyes from
fuel splash.
and passages.
Important: Always replace the fuel limiter vent valve
0-ring when reinstalling the fuel limiter vent valve.

1. Relieve the fuel system fuel pressure. Refer to
Replacement.
4. Remove the fuel limiter vent valve snap ring.
155562
6-1264
Engine
5. Remove the fuel limiter vent valve.
6. Remove the fuel limiter vent valve 0-ring.
7. Clean the fuel limiter vent valve 0-ring sealing
surfaces.
8. Inspect the fuel limiter vent valve 0-ring sealing
surfaces.
9. Inspect the fuel limiter vent valve for cracks or
damage.
10. If the fuel limiter vent valve is cracked or damaged
replace it.
Important: Be sure that the fuel limiter vent valve
retaining snap ring is fully seated within the tab slots
on the fuel tank.
1. Position the new fuel limiter vent valve 0-ring on
the fuel tank.
2. Install the fuel limiter vent valve.
3. Reinstall the fuel limiter vent valve snap ring.
Replacement.
7. Inspect for leaks;
7.1. Inspect turn the ignition to the ON position

for two seconds.
7.2. Turn OFF the ignition for ten seconds.
7.3. Turn ON the ignition again.
7.4. Visually inspect the fuel system for
fuel leaks.
155562
Engine
6-1265
Filler Tube Replacement

Removal Procedure
1. Remove the fuel filler cap.
2. Remove the left rear wheelhouse panel.
3. Disconnect the fuel fill hose (3) and the vent
hose (4) from the fuel tank fill and vent pipe (1 ).
4. Remove the fuel fill hose (3) and the vent
hose (4) from the fuel tank.
5. Cap the open ends of the fuel tank.
43532
6. Disconnect the fuel system ground strap.
43530
7. Remove the fuel tank fill and vent pipe from the
fuel filler pocket.
71231
6~1266
Engine
1. Install the fuel tank fill and vent pipe to the fuel
filler pocket.
Notice: Refer to the Fastener Notice in Cautions and

Notices.
Tighten
Tighten the fuel tank fill and vent pipe bolts to
2.5 N-m (22 lb in).
71231
2. Connect the fuel fill pipe ground strap.

Tighten
Tighten the fuel fill pipe ground strap bolt to
8 N-m (71 lb in).
43530
3. Uncap the openings on the fuel tank.

4. Connect the fuel fill hose (3) and the vent hose to
the fuel tank.
5. Connect the fuel fill hose (3) and the vent
hose (4) to the fuel tank fill and vent pipe (1 ).
Tighten
Tighten the fuel fill hose clamps and the vent
hose clamps to 4 N-m (35 lb in).
6. Install the left rear wheelhouse panel.
7. Install the fuel filler cap.
(
43532
Engine
6-1267
Fuel Sender Assembly Replacement

Removal Procedure
personal injury that may result from a fuel
leak, always replace the fuel sender gasket when
reinstalling the fuel sender assembly.
Notice: Do Not handle the fuel sender assembly by
the fuel pipes. The amount of leverage generated
by handling the fuel pipes could damage the joints.

and passages.
376982

Procedure.
Replacement.
5. Remove the fuel sender assembly retaining
nuts (1 ), the retaining ring (2), the fuel sender
assembly (3), and the gasket (4). Discard
the gasket.
Caution: Drain the fuel from the fuel sender

assembly into an approved container in order to
Never store the fuel in an open container.
6. Clean the gasket sealing surfaces.
1. Position the new gasket on the fuel tank.
Important: The fuel pump strainer must be in a
horizontal position when the fuel sender is installed in
the tank. When installing the fuel sender assembly,
assure that the fuel pump strainer does not block full
travel of the float arm.
2. Carefully fold the strainer to allow it to fit through
the opening in the fuel tank. Make sure the
strainer unfolds once it is placed in the tank.
3. Install the fuel sender assembly into the fuel tank.
4. Install the fuel sender retaining ring (2).

Notices.
5. Reinstall the fuel sender assembly retaining
nuts (1 ).
Tighten
Tighten the fuel sender assembly retaining nuts
alternately and evenly to 6.5 N-m (58 lb in).
Replacement.
7. Add fuel.
376982
6-1268
Engine Controls.- 3.8L
Engine
8. Reinstall the fuel filler cap.
1OA. Check for fuel leaks.
Fuel Tank Pump Module Replacement

Removal Procedure
Tools Required
J 42960-1 Fuel Tank Drain Hose
Procedure.
3. Remove the fuel tank: Refer to Fuel Tank
Replacement.
(
327609
4. Remove the fuel sender assembly. Refer to Fuel

376982
Engine
5. Note the position of the fuel strainer (4) on the
fuel pump.
6. Support the fuel sender assembly with one hand
and grasp the strainer (4) with the other hand.
7. Pull the strainer off the pump. Discard the strainer
after inspection.
8. Inspect the strainer. Replac-e a contaminated
strainer and clean the fuel tank.
9. Disconnect the fuel pump electrical connector (7).
10. Remove the fuel level sensor electrical connector
retaining clip (9).
11. Disconnect the fuel level sensor electrical
connector (8) from under the fuel sender cover.
12. Remove the fuel level sensor retaining clip (6).
13. Squeeze the locking tangs and remove the
fuel level sensor (5).
14. Remove the fuel pressure sensor (1 ).
6-1269
370970
1.
2.
3.
4.
Install the fuel pressure sensor (1 ).

Install the fuel level sensor (5).
Install the fuel level sensor retaining clip (6).
Connect the fuel level sensor electrical
connector (8).
5. Connect the fuel level sensor electrical connector
retaining clip (9).
6. Connect the fuel pump electrical connector (7).
Important: Always install a new fuel strainer

when replacing the fuel tank fuel pump module.
7. Install a new fuel strainer (4) in the same position
as noted during disassembly. Push the strainer on
the bottom of the fuel sender until the strainer
is fully seated.
370970
8. Install the fuel sender assembly. Refer to Fuel

376982
6-1270
Engine
9. Install t.he fuel tank, Refer to Fuel Tank
Replacement.
10; Refill.the fuel tank.
13, 1. Turn ON the ignition for 2 seconds.
14. Perform the idle learn procedure. Refer .to PCM
327609
Fuel Pump Strainer Replacement

Removal Procedure
1. Relieve fuel system pressure. Refer to .Fuel
4. Note the position of the strainer (5) for aid in
installation.
370970
5. Support the reservoir with one hand and grasp the

strainer with the other hand.
6. Use a screwdriver to pry the strainer ferrule off
the reservoir.
7. Discard the strainer.
54511
Engine
6-1271
1. Install the new strainer (5) to the reservoir.
2. Support the reservoir with one hand and grasp the
strainer with the other hand twisting the strainer
into position.
Lifting and Jacking the Vehicle in Engine
Electrical.
6. Inspect for fuel leaks:
370970
Fuel level Sensor Replacement

Removal Procedure
1. Relieve fuel system pressure. Refer to Fuel
4. Remove the fuel level sensor (8) from the
modular fuel sender.
370970
1. Install the fuel level sensor (8) to modular fuel
sender.
5. Inspect for fuel leaks:
5.1. Turn ON the ignition for 2 seconds
fuel leaks.
370970
6-1272
Engine
Fuel Hose/Pipes Replacement (Chassis)
Removal Procedure
172963
Tools i:;tequired
Procedure.
4. Clean all the fuel and EVAP pipe connections and
the surrounding areas before disconnecting the
pipes .in order to avoid possible contamination of
the fuel system.
5. Disconnect the engine compartment fuel feed
pipe (2) from the chassis fuel feed pipe (3).
Refer to Quick Connect Fitting(s) Service
(Metal Collar).
6. Disconnect the engine compartment EV AP
pipe (5) from the c.hassis EVAP pipe (4). Refer to
Quick Connect Fitting(s) Service (Plastic
Collar).
7. Raise the vehicle.
8. Remove the rear fuel pipe shield attaching
nuts (3) and bolt (6).
9. Remove the rear fuel pipe shield (4).
10. Remove the front fuel pipe shield attaching
nuts (1 ).
11. Remove the front fuel pipe shield (2).
7~
173551
Engine
6-1273
12. Disconnect the fuel feed pipe (1) from the outlet
side of the fuel filter (2). Discard the 0-ring.
12603

quick connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).
15. Remove the fuel pipe attaching hardware and the
fuel pipes. Note the position of the fuel pipes for
installation.
16. Inspect the pipes for bends, kinks, and cracks.
Repair or replace the pipes as required.
183854
Repair Procedure
When repairing the fuel or EVAP pipes with hoses,
always replace them with original equipment or parts
meeting GM specifications. Use only reinforced
fuel resistant hose which is identified with the word
Fluoroelastomer or GM 6163-M on the hose.
The inside hose diameter must match the outside pipe
diameter.
Do Not use rubber hose within 100 mm (4 in) of any
part of the exhaust system or within 254 mm (10 in) of
the catalytic converter.
A minimum of 13 mm (1/2 in) clearance must be
maintained around sharp edges such as flanges, pinch
welds, etc., in order to prevent contact and chafing.
A minimum of 19 mm (% in) clearance must be
maintained around all moving parts.
s.:1274
Engine
Cut the ends of the pipe remaining on the car square
with a tube cutter. Using the first step of a double
flaring tool, form a bead on the end of both pipe
sections. If the pipe is too corroded to withstand the
beading operation without damage, the pipe should be
replaced. If a new section of pipe is used, form a
bead on both ends of the pipe also.
Use screw type hose clamps. Slide the clamps onto
the pipe and push the hose 51 mm (2 in) onto
each portion of the fuel pipe.
If more than a 6 in length of pipe is removed, use a
combination of steel pipe and hose so that the
total hose lengths, including the 100 mm (4 in)
additional length will not be more than 254 mm (10 in)
long. Follow the same routing as the original pipe.
113403
...--------------------,
Important:
When replacing the fuel or EV AP pipes, always
replace them with original equipment or parts
that meet the GM specifications for those parts.
The replacement pipes must have the same
type of fittings as the original pipes in orde.r to
ensure the integrity of the connection.
Do Not use copper or aluminum tubing to replace
steel tubing. Only tubing meeting the 124-M
specification or its equivalent is capable of meeting
all pressure, corrosion and vibration characteristics
necessary to ensure the durability standard
required.
1. Position the fuel and EVAP pipes to the frame rail.
Notice: Refer to the Fastener Notice in Cautions
and Notices.
2. Loosely install the number 1 position pipe
clip stud .
clip stud.
173409
Engine
6-1275

clip stud.
Tighten
Tighten the 3 studs to 5 Nm (44 lb in).
173412
s.
Align the fuel and EVAP pipes to the number 5

and number 6 position.
6. Install the front pipe clip bolts.
Tighten
Tighten the front pipe clip bolts to
4.5 Nm (40 lb in).
173417
7. Align the fuel and EVAP pipes to the number 4

position clamp.
8. Install the pipe clamp stud.
Tighten
Tighten the pipe clamp stud to 5 Nm (44 lb in).
173416
6..;1276
Engine
9. Connect the fuel.return pipe (4) atthe rear quick
connect fitting. Refer to Quick Connect Fitting(s)
183854
11. Connect the fuel feed pipe (t) to the fuel filter (2).
Tighten
Tighten the fuel feed pipe fitting to
30 Nm (22 lb ft).
(
'
12603
12. Install the fuel and EVAP pipes into the rear
pipe clip.
13. Align the fuel and EVAP pipes in a flat position.
14. Install the rear pipe clip bolt.
Tighten
Tighten the rear pipe clip bolt to 5.5 Nm (49 lb in).
(
175268
Engine
6-1277
15. Position the front fuel pipe shield (2) to the 3 fuel
pipe clip studs and the brake pipe clip stud (7).
16. Install the pipe shield nuts (1).
Tighten
Tighten the pipe shield nuts to 5 Nm (44 lb in).
17. Position the rear fuel pipe shield (4) to th~ fuel
pipe stud and the fuel pipe clip stud (5).
18. Loosely install the pipe shield nuts (3).

19. Install the pipe shield bolt (6).
Tighten
19.1. Tighten the pipe shield bolt to
5 Nm (44 lb in).
19.2. Tighten the pipe shield nuts to
5 Nm (44 lb in).
7t::J
173551
21. Connect the engine compartment EVAP pipe (5)

to the chassis EVAP pipe (4). Refer to Quick
Connect Fitting(s) Service (Plastic Collw).
22. Connect the engine compartment fuel feed
pipe (2) to the chassis fuel feed pipe (3). Refer to
Quick Connect Fitting(s) Service (Metal Collar).
25. Connect the negative battery cable.


26.4. Inspect for fuel leaks.
172963
Engine
6.;1278 Engine Controls - 3.8L

(Engine Compartment)
Removal Procedure
215517
Caution: In order to Reduce the Risk of Fire and

Personal Injury:
If nylon fuel pipes are.nicked, scratched or
damaged during installation, Do Not atte111pt to
repair the sections of the nylon fuel pipes.
Replace thE:m.
'
,. When installing new fuel pipes, Do Not
hammer directly on. the fuel h~mess body clip~
as it may damage the nylon pipes reslting
in a possible fuel leak.
Always cover nylon vapor pipes with a wet

towel before using a torch n~ar them..Also,.
never expose the vehicle to temperatures
higher than 115C (239F) for more than
one hour, or more than 90C (194F) for any
extended period.
.. . Before connectingfuf;:I pipe fittings, always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel te.ak.
(During normal operation/the O~rings ..
located in the female connector will swelland
may prevent proper reconnection if not
lubricated.)
Notice: Do not attempt to straighten any kinked nylon
fuel lines. Replace any kinked nylon fuel feed or
return pipes in order to prevent damage to the vehicle.
Notice: Replace the EV AP pipes. and hoses with

the original equipment or parts that meet the
GM specifications for those parts ..The replacement
EV AP pipe must have the same type of iittings as the
original pipe in order to ensure the integrity of the
connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified .with the
word Fluoroelastomer or GM 6163-M on the.hose. The
inside hose diameter must match the outside pipe
diameter. Do not use rubber hose with.in 100 mm (4 in)
of any part of the exhaust system or within 254 mm
(1 O in) of the catalytic converter:

and passages.

Procedure.
3. Clean all the engine compartment connecting fuel
pipe connections and the surrounding areas
before disconnecting in order to avoid possible
contamination of the fuel system.
Engine
6-1279
4. Disconnect the fuel teed pipe (1) at the engine.

Refer to Quick Connect Fitting(s) Service (Metal
Collar).
5. Disconnect the fuel return pipe (2) at the engine.
6. Disconnect the EVAP pipe (6) at the engine.
8. Disconnect the EVAP pipe (5) at the chassis fuel
and EVAP pipes.
9. Disconnect the fuel teed pipe (4) at the chassis
fuel and EVAP pipes.
10. Disconnect the fuel return pipe (3) at the chassis
fuel and EVAP pipes.
11. Remove the fuel feed, return, and EVAP pipes.
Important:
Always re-attach the fuel lines and fuel filter with
all original type fasteners and hardware.
If fuel line bundle attaching hardware is damaged
or broken replace it.
1. Install the fuel teed, return, and EVAP pipes.
2. Connect the fuel feed pipe (4) at the chassis fuel
and EVAP pipes.
3. Connect the fuel return pipe (3) at the chassis fuel
and EVAP pipes.
4. Connect the EVAP pipe (5) at the chassis fuel
and EV AP pipes.
6. Connect the fuel feed pipe (1) to the engine.
7. Connect the fuel return pipe (2) to the engine.
8. Connect the EVAP pipe (6) to the engine.
12.4. Check tor fuel leaks.
215517
6-1280
Fuel System Cleaning

Important:
Only use oil free compressed air to blow out the
fuel pipes.
Inspect the fuel tank internally and clean the fuel
tank if you find a plugged fuel filter.
Procedure.
Replacement.
5. Inspect the fuel pump strainer: Replace a
contaminated strainer and inspect the fuel pump.
6. Inspect the fuel pump inlet for dirt and debris.
Replace the fuel pump if you find dirt or debris
in the fuel pump inlet.
Engine.
Important: When flushing the. fuel tank, handle the
fuel and water mixture as a hazardous material.
Handle the fuel and water mixture in accordance with.
all applicable local, state, and federal laws and
regulations.
.
7. Flush the fuel tank with hot water.
8. Pour the water out of the fuel sender assembly
opening. Rock the tank to be sure that removal
of the water from the tank is complete.
10. Install the fuel tank. Refer to Fuel Tank
Replace~ent..
12. lnst~II the fuel filler cap.
14.1. Turn. ON the ignition for 2 seconds.
Engine
6-128.1
Fuel Rail Assembly Replacement

Removal Procedure
Tools Required

and passages.
1. Bleed fuel pressure from the fuel system. Refer to
2. Glean the fuel rail assembly and connections.

3. Remove the fuel feed and fuel return pipes from
the fuel rail tubes. Refer to Quick Connect
Fitting(s) Service (Metal Collar).
4. Remove the fuel injector coil wires.

5. Remove the vacuum line from the vacuum source
6. Remove the MAP sensor electrical connector.
7. Remove the vacuum line to the vacuum switch
from the fuel pipe bundle.
8. Remove the vacuum source from the intake
manifold.
9. Remove the fuel injector electrical connectors.
10. Remove the fuel injector harness fasteners.
11. Remove the fuel rail hold-down bolts.
12. Remove the fuel rail with equal force on both
sides of the fuel rail.
13. Remove the front fuel injector retaining clips on
each side of the fuel rail.
14. Remove the front fuel injector on each side of the
fuel rail. The fuel rail will now clear the intake
manifold.
12815
leak, 11lways install the fuel injector 0-rings in the
proper position. If the upper and lower 0-rings
are different colors (black .and brown), be sure to
instalTJhe black 0-ring.in the upper position
and the brown 0-ring. in the lower position on the
fuel injector. The 0-rings are the same size but
are made of different materials.
12815
64282
Engine
Engine Controls - 3.BL
Notice:
Use care when servicing the fuel system
components, especially the fuel injector electrical
connectors, the fuel injector tips, the injector
0-rings. Plug the inl.et and the outlet ports of the
fuel rail in order to prevent contamination.
Do not use the compressed air to clean the fuel
rail assembly as this may damage the fuel rail
components.
Do not immerse the fuel rail assembly in a solvent
bath in order to prevent damage to the fuel rail
assembly.
1. The 0-rings must be replaced on all components
that are replaced.
2. Lightly oil the fuel injector 0-rings with clean
engine oil.
3. Place the fuel rail assembly (WITHOUT the front
fuel injectors on each side of the fuel rail) on the
intake manifold.
4. Reinstall the front fuel injector on each side of the
fuel rail.
5. Reinstall the fuel injector retaining clips on the
front fuel injector on each side of the fuel rail.
6. Seat the fuel injectors by HAND.

Notices.
Tighten
7.
8.
9.
1O.
11.
12.
13.
14.
15.
16.
Tighten the fuel rail holdsdown bolts to

10 N-m (89 lb in).
Reconnect the fuel injector harness fasteners.
Reconnect the fuel injector electrical connectors.
Reinstall the vacuum source to the intake
manifold.
Reinstall the vacuum line to the vacuum switch
from the fuel pipe bundle.
Reinstall the vacuum line from the vacuum source
Reconnect th.e fuel feed and fuel return pipes by
pushing the pipes onto the fuel rail t.ubes,
Reconnect the MAP sensor electrical connector.
Reconnect the fuel injector coil wires.
Reconnect the negative battery cable. Refer to
Inspect for leaks.

16. . 1. Turn ON the ignition for 2 seconds.
16.2. Turn OFF the ignition for .1 O seconds.
Engine
6-1283
Fuel Pressure Regulator Replacement

Removal Procedure
and passages.
Relief Procedure.
2. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement.
3. Clean any dirt from the fuel pressure regulator
retaining ring.
4. Remove the snap ring (i ).
5. Using a shop towel to catch any spilled fuel, lift
and twist the fuel pressure regulator in order to
remove the fuel pressure regulator (2) from
the fuel pressure regulator housing.
6. Remove the pressure regulator small 0-ring (6).
7. Remove the pressure regulator filter screen (5).
8. Remove the pressure regulator large 0-ring (4).
9. Remove the pressure regulator 0-ring back up (3).
10. Cover the fuel pressure regulator housing in
order to prevent contamination from entering
the fuel system.
12686
Notice:
O
Do not use compressed air in order to test or
clean a fuel pressure regulator as damage to the
fuel pressure regulator may result.
e Clean the fuel pressure regulator filter screen with
'gasoline if necessary.
O Do not immerse the fuel pressure regulator in a
solvent bath in order to prevent damage to the
fuel pressure regulator.
1. Install new 0-rings on the fuel pressure regulator.
Lubricate the 0-rings lightly with clean engine oil.
2. Install pressure regulator 0-ring back up (3).
3. Install pressure regulator large 0-ring (4).
4. Install pressure regulator filter screen (5).
5. Install pressure regulator small 0-ring (6).
6. Install the fuel pressure regulator (2) in the fuel
pressure regulator housing.
7. Install the snap ring (1).
8. Install the fuel rail.
9. Reconnect the negati\le battery cable. Refer to
12686
Engine
6-1284
Fuel Injector Replacement
Removal Procedure
and passages.
Notice: Use care in removing the fuel injectors in
order to prevent damage to the fuel injector electrical
connector pins or the fuel injector nozzles. Do not
immerse the fuel injector in any type of cleaner. The
fuel injector is an electrical component and may
be damaged by this cleaning method.
12687
Important: The fuel injector is serviced as a complete

assembly only. If the fuel injectors are found to be
leaking, the engine oil may be contaminated with fuel.
Always maintain cleanliness when servicing fuel
system components.
Relief Procedure.
2. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement.
3. Remove the fuel injector retaining clip (2).
4. Remove the fuel injector (3).
5. Remove the fuel injector upper 0-ring (1 ).
6. Remove the fuel injector lower 0-ring (5).
7. Remove the fuel injector 0-ring back up (4).
Important: Each fuel injector is calibrated for a

specific flow rate. Be sure to use the correct part
number when ordering replacement fuel injectors.
When replacing the fuel injector 0-rings, be sure to

install the brown 0-ring in the lower position.
12687
The fuel injector lower 0-ring uses a nylon collar,

called the 0-ring backup, to properly position
the 0-ring on the fuel injector. Be sure to reinstall the
0-ring backup, or the sealing 0-ring may move on
the fuel injector when installing the fuel rail. If
the sealing 0-ring is not seated properly, a vacuum
leak is possible and driveability complaints may occur.
1. Coat all new 0-rings with clean engine oil
before installing.
2. Install the fuel injector 0-ring back up (4).
3. Install the fuel injector lower 0-ring (5).
4. Install the fuel injector upper 0-ring (1 ).
5. Install the fuel injector (3).
6. Install the fuel injector retaining clip (2).
fuel leaks.
Engine
6-1285
Fuel Pump Relay Replacement

Removal Procedure
1. Remove the cover from the relay center (2).
2. Remove the fuel pump relay by pulling upward.
255043
1. Push the relay into the relay center socket.
2. Install the cover on the relay center (2).
255043
EVAP Canister Purge Valve Replacement

Removal Procedure
2. Remove the electrical connector and hose from
the EV AP canister purge valve.
3. Remove the hold down bolt from the EV AP
4. Remove the EV AP canister purge valve.
1. Install the EVAP canister purge valve to the
intake.
Notices.
2. Reinstall the hold down bolt through the EVAP
3. Connect the electrical connector and hose to the
EVAP canister purge valve.
6-1286
Engine

EVAP Vent Valve Replacement
i
Removal Procedure
Tools Required
3ss522

Procedure.
Replacement.
5. Disconnect the EV AP canister vent valve electrical
connector (2).
6. Slide the vent hose clamp (1) back.
7. Disconnect the vent hose from the EVAP
vent valve.
8. Remove the EVAP canister vent valve from the
EVAP canister vent valve bracket.
376991
Engine
6-1287
1. Install the EV AP canister vent valve to the EVAP
canister vent valve bracket.
376991
2. Connect the vent hose to the EVAP canister

vent valve.
3 .. Slide the vent hose clamp (1) back into position.
4. Connect the EV AP canister vent valve electrical
connector (2).
Replacement.
9.1. Turn ON the ignition ON for 2 seconds.
385622
6.;1288
Engine
EVAP System Hoses/Pipes Replacement.

Removal Procedure
74274
Notice: Do Not attempt to repair the EVAP pipes or

the connecting hoses. Replace the damaged
EVAP pipes or the connecting hoses are damaged. If
the nylon EVAP pipe becomes kinked and cannot
be straightened, it must be replaced.
Notice: Replace the EVAP pipes and hoses with the
original equipment or parts that meet the GM
specifications for those parts. The replacement EVAP
pipe must have the same type of fittings as the
original pipe in order to ensure the integrity of the
connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified with the
word Fluoroelastomer or GM 6163-M on the hose. The
inside hose diameter must match the outside pipe
diameter. Do not use rubber hose within 100 mm (4 in)
of any part of the exhaust system or within 254 mm
(1 O in) of the catalytic converter.
2. Remove the hardware retaining the EVAP pipes.
Note the location of the attaching hardware for
installation.
3. Disconnect the EVAP pipes at the EVAP canister.
4. Disconnect the EVAP pipes at the fueltank
5. Remove the EVAP pipes.
Important: Route the replacement EVAP pipe in the
same manner as the original EVAP pipe was routed.
1. Reinstall the EV AP pipes into the vehicle.
2. Connect the EV AP pipes onto the fuel tank.
3. Connect the EV AP pipes onto the EVAP canister.
Notice: Properly secure the EVAP pipe in order to
prevent chafing of the pipe.
4. Install the hardware retaining the EVAP pipe.
74274
Engine
6-1289
EVAP Canister Replacement

Removal Procedure
Tools Required
" J34730-1A Fuel Pressure Gauge

Procedure.
Replacement.
5. Disconnect the fill limiter vent valve pipe (6) from
the EV AP canister.
6. Disconnect the EVAP purge pipe (7) from the
EV AP canister.
7. Disconnect the vent hose (5) from the EVAP
canister.
8. Carefully bend the bracket in order to remove the
EV AP canister from the bracket.
376978
376984
6-1290
Engine

1. Install the EVAP canister to the bracket.
376984
2. Connectthe vent hose (5) to the. EVAP canister.

3. Connect the EVAP purge pipe (7) to the EVAP
canister.
4. Connect the fill limiter vent valve pipe (6) to the
EVAP canister.
Replacement.

7
376978
EVAP System Cleaning

6
Inspection Procedure
Tools Required
J 41413 EVAP Pressure/Purge Diagnostic Station
Whenever the OTC diagnostics lead to a no trouble

found or a purge solenoid replacement, proceed
with the following charcoal canister diagnostics.
Notice: Use the EVAP Pressure/Purge Diagnostic

Station J 41413 in order to provide a clean, dry,
low pressure gas source. Do not substitute any other
pressurized gas source. Damage may result to the
EVAP system.
The J 41413 EVAP pressure/purge diagnostic stw:ion
is required to provide a clean, dry, low pressure
gas source. Do not substitute any other pressurized
gas source or damage to the EV AP system may result.
20803
Engine
6-1291
2. Remove the EV AP canister purge solenoid from

the vehicle.
3. Lightly tap the EVAP canister purge solenoid on a
clean work area.
4. Look for carbon particles existing from either of
the vacuum ports.
components. Continue with the published
service manual DTC procedures.
6. If carbon is being released from either component,
continue with this service procedure.
8. Turn off the main cylinder valve (1) on the J 41413
EVAP pressure/purge diagnostic station.
9. Disconnect the black hose (4) that connects the
nitrogen cylinder to the cart at the pressure
regulator (5).
10. Using a section of the vacuum hose, connect
one end onto the open fitting of the pressure
regulator (5).
11. Connect the other end of the vacuum line side of
the EV AP purge line at the vehicle.
12. Turn on the main nitrogen cylinder valve (1).
13. Continue to blow any debris from the purge line
for 15 seconds.
14. Return the J 41413 to its original condition by
re-installing the black hose (4) disconnected in
step 9.
15. Replace the EV AP purge solenoid and the
charcoal canister with the new components.
16. Proceed with the published service manual
diagnostics for the manifold vacuum
vehicles (4.3L).
Ported Applications with EVAP Vacuum Switch

1. Connect a scan tool and display the data
parameter EV AP vacuum switch.
2. Start the engine and allow the engine to reach the
operating temperature.
3. Open the throttle until the engine speed reaches
2000 RPM.
4. If the EV AP vacuum switch changes its state, go
to step 6.
5. If the EVAP vacuum switch does not change
state, repair the low source vacuum condition
by performing a complete throttle body service
including a cleaning of the purge ports. Go
to step 1.
6. If .the EV AP vacuum switch does change state,
" proceed with the published service manual
diagnostics.
20803
6-1292
Engine
Ported Applications with EVAP Service Port

1.. Connect the EVAP diagnostic cart J 41413 to the
vehicle EVAP service port. Turn the four position
switch to Purge.
2. Start the engine. Allow the engine to reach the
operating temperature.
3. Open,the throttle until the engine speed reaches

2000 RPM.
4. Note the H20 vacuum gauge on the EVAP. cart.
The vacuum should read more than
15 inches H20.
5. If the vacuum is less than 15 inches H20, perform
a complete throttle body service including a
cleaning of the purge ports as outlined in the
service manual. Go to step 1.
6. If the vacuum is more than 15 inches H20,
continue with the published service manual
diagnostics.
20803
Ignition Control Module Replacement

Removal Procedure
1..Disconnect the 14~way connector at ignition
control module.
2. Disconnect .the spark plug wires from the
ignition coils.
3. Remove the 6 screws securing coil assemblies to
ignition control module.
4. Disconnect the ignition coils from ignition control
module.
5. Remove the ignition control module retaining bolt
and nuts.
6. Remove the ignition control module from the
vehicle.
187266
1. Position the ignition control module onto the
bracket.
Notices.
2. Install the ignition control module. retaining .bol.t
and nuts.
Tighten
Tighten fasteners to 8 N-m(70 lb in).
3. Positio.n the ignition coils onto the ignition control
module.
4. Hand start 6 screws through the ignition coils and
module to the bracket.
Tighten
Tighten screws to 4-5 N-m(40 lb in).
5. Connect the spark plug wires to the ignition coils.
6. Connect the 14-way connector to the ignition
control module.
12299
Engine
6-1293
Ignition Coil(s) Replacement

Removal Procedure
1. Disconnect the spark plug wires from the coil

assemblies.
2. Remove 6 screws (1) securing the coil assemblies

to the ignition control module.
3. Remove the coils (2) from the ignition control.
module (3).
12299
1. Attach the coils to the ignition control module.

and Notices.
2. Install 6 ignition coil attaching screws

Tighten
Tighten the screws to 4-5 Nm (40 lb. in.).
3. Connect the spark plug wires.
187266

Replacement
Removal Procedure
Tools Required
J 38197 Balancer Remover
2. Remove the serpentine belts from crankshaft
pulley.
3. Using 28 mm socket, remove the crankshaft
harmonic balancer retaining bolt.
4. Remove the crankshaft harmonic balancer using
J 38197 balancer remover.
5. Remove the crankshaft position sensor shield. Do
Not use a pry bar.
6. Disconnect the sensor electrical connector.
7. Remove the sensor from the block face.
187269
6-1294
Engine
1. Position the crankshaft position sensor onto the
engine block face.

Notices.
2. Install the bolts to hold the sensor to the engine
block face.
3.
4.
5.
6.
187288
7.
8.
Tighten
Tighten bolts to 20-40 N-m (14-28 lb ft).
Position and install the crankshaft position sensor
shield.
Connect the electrical connector.
Position the balancer onto the crankshaft.
Apply thread sealer GM-1052080 or equivalent to
threads of crankshaft balancer bolt.
Tighten
Tighten bolt to
150 N-m +76 degrees(110 lb ft +76 degrees).
Install the serpentine accessory drive belt.

Replacement
Removal Procedure
1 . Disconnect the negative battery cable.
2. Disconnect the electrical connector.from camshaft
position sensor.
3. Remove the camshaft position sensor
retaining screw.
4. Remove the camshaft position sensor.
187294
Engine
6-1295
1. Position the camshaft position sensor.

Notices.
2. Hand start the camshaft position sensor
retaining bolt.
Tighten
Tighten the retaining bolt to 5 Nm (44 lb in).
3. Connect the electrical connector.
187294
Knock Sensor (KS) Replacement

Removal Procedure
1. Drain the cooling system.
2. Disconnect the wiring harness connector from the
3. Remove the knock sensor from engine block.
21707
Important: Do Not apply thread sealant to sensor
threads. Sensor is coated at the factory and applying
addi1ional sealant will affect the sensors ability to
detect detonation.

Notices.
1. Hand start the knock sensor into the engine block.
righten
Tighten the knock sensor to 19 N-m (14 lb ft).
2. Connect the wiring harness connector to the
3. Fill the cooling system.
21707
6-1296
Engine Controls
Engine
3.8l
EGR Valve Replacement
Removal Procedure
1. Disconnect the electrical connector at the

EGA valve.
2. Remove the 2 base to flange nuts.
3. Remove the linear EGA valve assembly.
187211
Notices.
1. Position the linear EGA valve assembly and hand
start the two nuts holding the EGA Valve to the
adapter.
Tighten
Tighten the nuts to 29 Nm (21 lb ft).
'---------------~--~-------~
187211
Engine
6-1297
Clutch Anticipate Switch Replacement

Removal Procedure
The clutch anticipate switch is located on the
brake/clutch pedal bracket.
1. Remove the left side hush panel.
2. Disconnect the electrical connectors.
3. Grasp and pull the clutch anticipate switch straight
out of the retainer.
21679
1. Position the clutch anticipate switch into the
Brake/Clutch Pedal Bracket.
Hold the clutch pedal depressed while installing
the switch.
The switch should bottom in the retainer. Note
that audible clicks can be heard as the switch
is pressed into the retainer.
2. Slowly pull the clutch pedal rearward against the
pedal stop.
3. Release the clutch pedal and pull back on it again
to ensure proper switch adjustment.
4. Con_nect the electrical connector.
5. Install the left side hush panel.
21679
6-1298
Engine
Crankcase Ventilation System Inspection
Removal Procedure
1. While holding down the PCV valve cover, remove
the two (2) cover retaining bolts.
2. Remove the PCV valve cover.
3. Remove the PCV valve, spring, and 0-ring.
21764
1. Install the PCV valve, spring, and 0-ring.
Notices.
2. Position the PCV valve cover (use a new gasket if
necessary) and hand start the two (2) cover
retaining bolts.
Tighten
Tighten the 2 cover retaining bolts to
12 N-m (106 lb in).
21764
Air Cleaner Element Replacement

Removal Procedure
Notice: If the mass air flow (MAF) sensor is installed
backwards, the system will go rich. An arrow cast
into the plastic portion of the sensor indicates proper
air flow direction. The arrow must point toward the
engine.
1. Release the fasteners located at the front of the
air cleaner duct assembly.
2. Remove the air cleaner element from the air
cleaner duct assembly.
229388
Engine
6-1299
\
Notice: Verify that the radiator air deflector is in

position before installing an air cleaner assembly.
Improper installation may allow water intrusion which
could damage the engine.
1. Install a new air cleaner element into the air
cleaner assembly.
2. Position and lock the fasteners located at the front
of the air cleaner duct assembly.
229388
Air Cleaner Intake Duct Replacement

Removal Procedure
engine.
1. Release the fasteners located at the front of the
air cleaner duct/resonator assembly.
2. Release. the button fasteners located at the rear
of the air cleaner duct assembly.
3. Loosen the hose clamp from the air intake duct at
the air cleaner duct assembly.
4. Loosen the hose clamp from the air intake duct at
the throttle body assembly
5. Remove the air intake duct from the air cleaner
duct/resonator assembly.
229388
Notice: Verify that the radiator air deflector is in
position before installing an air cleaner assembly.
Improper installation may allow water intrusion which
could damage the engine.
1. Position the air intake duct at the front of the air
cleaner assembly.
2. Position the air intake duct onto the front of the
throttle body unit.
3. Securely fasten the hose clamp at the air cleaner
. assembly.
4; Securely fasten the hose clamp at the throttle
body assembly
5. Position the air cleaner assembly onto the radiator
support.
6. Install the button fasteners located at the rear of
the air cleaner assembly.
229388
6-1300
Engine

18X Reference PCM Input
Powertrain Control Module Description
From the ignition control module, the PCM uses this

signal to calculate engine RPM and crankshaft position
at engine speeds below 1200 RPM. The PCM also
uses the pulses on this circuit to initiate injector pulses.
If the PCM receives no pulses on this circuit,
DTC P0336 will set and the PCM will use the
3X reference signal circuit at all times for fuel and
ignition control. The engine will continue to start and
run using the 3X reference signal only.

The A/C refrigerant pressure sensor signal indicates
high side refrigerant pressure to the PCM. The
PCM uses this information to adjust the idle air control
valve to compensate for the higher engine loads
present with high A/C refrigerant pressures and 10
control the cooling fans. A fault in the A/C refrigerant
pressure sensor signal will cause DTC P0530
to set.
A/C Request PCM Input

187237
The Powertrain Control Module (PCM) is the control

center of the vehicle. It controls the following items:
Fuel metering system.
Transaxle/transmission shifting.
Ignition timing.
" On-board diagnostics for powertrain functions.
It constantly monitors the information from various
sensors, and controls the systems that affect vehicle
performance. The PCM also performs the diagnostic
function of the system. It can recognize operational
problems, alert the driver through the MIL, and store
diagnostic trouble codes which identify the problem
areas to aid the technician in making repairs.
The type of PCM used is a PCM 32U. The knock
sensor system is no longer a separate component. The
PCM contains integrated knock sensor (KS) diagnostic
circuitry. For further information, refer to Knock
Sensor (KS) System Description.
Information Sensors/Switches Description

3X Reference PCM Input
From the ignition control module, the PCM uses this
signal to calculate engine RPM and crankshaft position
at engine speeds above 1200 RPM. The PCM also
uses the pulses on this circuit to initiate injector pulses.
If the PCM receives no pulses on this circuit,
DTC P1374 will set and the PCM will use the
18X reference signal circuit for fuel and ignition control.
The engine will continue to start and run using the
18X reference signal only.
The A/C request signal indicates to the PCM that A/C

mode is selected at the A/C control head. The
PCM uses this information to adjust the idle speed
before turning ON the A/C clutch. If this signal is not
available to the PCM, the A/C compressor will be
inoperative.
The crankshaft position sensor provides a sigr:,al used

by the ignition control module to calculate ignition
sequence. The ignition control module also uses the
crankshaft position sensor signals to initiate 18X
and 3X reference pulses which the PCM uses
as reference to calculate RPM and crankshaft position.
Camshaft Position (CMP) Sensor and CAM

Signal
The camshaft position sensor sends a cam signal to
the PCM which uses it as a sync pulse to trigger
the injectors in proper sequence. The CAM signal is
passed through the ignition control module. It is filtered
and buffered by the ignition control module, but the
signal is not processed in any other way. The
PCM uses the CAM signal to indicate the position of
the #1 piston during its power stroke. This allows
the PCM to calculate true Sequential Fuel
Injection (SFI) mode of operation. If the PCM detects
an incorrect CAM signal while the engine is running,
DTC P0341 will set.
If the CAM signal is lost while the engine is running,
the fuel injection system will shift to a calculated
sequential fuel injection mode based on the last fuel
injection pulse, and the engine will continue to run. The
engine can be restarted and will run in the calculated
sequential mode as long as the fault is present
with a 1 in 6 chance of injector sequence being correct.
Engine
Clutch Anticipate Switch (Manual Transaxle)

The Clutch Anticipate Switch input allows the
PCM!fAC to adjust the idle when the manual
transmission clutch is being disengaged. The PCM
monitors the Clutch Anticipate Switch input; if a
low voltage is monitored, the PCM considers the
Clutch Anticipate Switch closed to ground (clutch pedal
released). When the ground at the Clutch Anticipate
Switch input is interrupted (clutch pedal applied),
the PCM will immediately decrease idles. This is done
to avoid a possible RPM flare caused by the sudden
change in engine load.
Electronic Brake Control Module (EBCM) PCM Serial Data (CKT 800)
The PCM uses the UART seria.l data line (CKT 800) to
communicate with variou.s other components and
systems within the vehicle. The PCM receives rough
road information from the EBCM on the serial data
circuit The PCM uses the rough road information to
enhance the misfire diagnostic by detecting crankshaft
speed variations caused by driving on rough road
surfaces. This allows false misfire information to be
rejected. The EBTCM I EBCM calculates rough
road information by monitoring the ABS wheel speed
sensors. If a malfunction occurs which does not
allow the EBTCM I EBCM to transmit correct rough
road information to the PCM while a misfire OTC
is requesting the MIL, OTC P1380 will set. If a loss of
communications occurs which causes the PCM to
not receive rough road information while a misfire OTC
is requesting the MIL, OTC P1381 will set.
6-1301
high when the engine is cold, and low when the

engine is hot. By measuring the voltage, the PCM
calculates the engine coolant temperature. The scan
tool displays engine coolant temperature in degrees.
After engine startup, the temperature should rise
steadily to about 90C (194F) then stabilize when
thermostat opens. If the engine has not been run for
several hours (overnight), the engine coolant
temperature and intake air temperature displays
should be close to each other.
Engine coolant temperature affects most systems the
PCM controls. A hard fault in the engine coolant
sensor circuit should set OTC P0117 or OTC P0118;
an intermittent fault should set a OTC P1114 or P1115.
This section also contains a specification table to
check for sensor resistance values relative to

temperature.
EGR Pintle Position Sensor

commands from the PCM and to detect a fault if the
pintle position sensor and control circuits are open
or shorted. If the PCM detects a pintle position signal
voltage outside the normal range of the pintle
position sensor, or a signal voltage that is not within a
tolerance considered acceptable for proper EGR
system operation, the PCM will set OTC P1404. Refer
to EGR System Description for a complete description
of the EGR system.
Heated Oxygen Sensors
14490
42212
The engine coolant temperature sensor is a thermistor

(a resistor which chang~s value based on temperature)
mounted in the engine coolant stream. Low coolant
temperature produces a high resistance
(100,000 ohms at -40C/-40F) while high temperature
causes low resistance (70 ohms at 130C/266F).
The PCM supplies a 5 volt signal to the engine coolant
temperature sensor through a resistor in the PCM
and measures the voltage. The voltage will be
The fuel control Heated Oxygen Sensors (Bank 1

H02S 1 and Bank 2 H02S 1) are mounted in
the exhaust manifolds where they can monitor the
oxygen content of the exhaust gas stream. The oxygen
present in the exhaust gas reacts with the sensor to
produce a voltage output. This voltage should
constantly fluctuate from approximately 1OOmV (high
oxygen content - lean mixture) to 900mV (low
oxygen content - rich mixture). The heated oxygen
sensor voltage can be monitored with a scan tool.
6-1302
By monitoring the voltage output of the oxygen

sensor, the PCM can calculate what fuel mixture
command to send the injectors (lean mixture-low
H02S voltage= rich command, rich mixture-high
H02S voltage= lean command).
An open Bank 1 H02S 1 circuit should set a
OTC P0134; an open in Bank 2 H02S 1. circuit should
set a OTC P0154. With an open H02S signal, the .
scan tool will display a constant vqltage between
400 - 500mV. A constant voltage below 300mV in the
Bank 1 H02S i sensor circuit (circuit grounded)
should set OTC P0131. A constant voltage below
300mV in the Bank 2 H02S 1 sensor circuit (circuit
grounded) should set OTC P0151. A constant voltage
above 800mV in the Bank 1 H02S 1 circuit should
set OTC P0132, while a constant voltage above
800mV in the Bank 2 H02S 1 circuit should set
OTC P0152. A fault in the Bank 1 H02S 1 heater
circuit should cause OTC P0135 to set. A fault in the
Bank 2 H02S 1 heater circuit should cause
OTC P0155 to set. The PCM can also detect H02S
response problems. If the response time of an H02S is
determined to be too slow, the PCM will store a
OTC that indicates degraded H02S performance.
to monitor this process using the Bank 1 H02S 2.
The Bank 1 H02S 1 or Bank 2 H02S 1 produces an
output signal which indicates the amount of oxygen
present .in the exhaust gas entering the three-way
catalytic converter. The Bank 1 H02S 2 sensor
produces an output signal which indicates the oxygen
storage capacity of the catalyst; this in turn indicates
the catalyst's ability to convert exhaust gases
efficiently. If the catalyst is operating efficiently, the
Bank 1 H02S 1 and the Bank 2 sensor 1 signals will
be far more active than that produced by the
Bank 1 H02S 2 sensor.
Although the Bank 1 H02S 2 sensors' main function is
catalyst monitoring, they also plays a limited role in
fuel control. If the sensor output indicates a voltage
either above or below the 450 millivolt bias voltage for
an extended period of time, the PCM will make a
slight adjustment to fuel trim to ensure that fuel
delivery is correctfor catalyst monitoring.
A problem with the Bank 1 H02S 2 signal circuit
should set OTC P0137, P0138 or P0140 depending on
the specific condition. A fault in the heated oxygen
sensor heater element or its ignition feed or ground will
result in slower oxygen sensor response. This may
cause erroneous catalyst monitor diagnostic results. A
fault in the Bank 1 H02S 2 heater circuit should
cause OTC P0141 to set.
Engine
Intake Air Temperature Sensor
21677
The Intake Air Temperature (IAT) sensor is a

thermi.stor which changes .value based on the
temperature of air entering the engine. Low
temperature produces a high resistance
(100,000 ohms at -40C/,4QF), while high temperature
causes low resistance (70 ohms at 130C/266F).
The PCM supplies a 5 volt signal to the sensor through

a resistor in the PCM and measures the voltage.
The voltage .will be high when the incoming air is cold,
and low when the.air is hot. By measuring the
voltage, the PCM calculates the incoming air
temperature.
The IAT sensor signal is used to adjust spark timing
according to incoming air density. The scan tool
displays temperature of the air entering the engine,
which should read close to ambient air temperature
when engine is cold, and rise as underhood
temperature increases. If the engine has not been run
.for several hours (overnight) the IAT sensor
temperature and engine coolant temperature should
read close to each other. A failure in the IAT
sensor circuit should set OTC P0112 or OTC P0113.
(.
Reference low
This is a ground circuit for the digital RPM counter
inside the PCM, but the wire is connected to engine
ground only through the ignition control module.
Although this circuit is electrically connected to the
PCM, it is not connected to ground at the PCM. The
PCM compares voltage pulses on the 18X and
3X reference input circuits to any on this circuit,
ignoring pulses that appear on both. If the circuit is
open, or connected to ground at the PCM, it may
cause poor engine performance and possibly a MIL
with no OTC set.
Engine
Knock Sensors
The knock sensors detect abnormal vibration (spark
knocking) in the engine. The sensors are mounted in
the engine block near the cylinders. The knock sensors
produce an AC voltage signal under all engine
operating conditions. The PCM adjusts the Ignition
Control (IC) spark timing based on the amplitude and
frequency of the KS signal being received.
The PCM contains integrated Knock Sensor (KS)
diagnostic circuitry. The PCM uses the circuitry
to diagnose the KS sensors and related wiring. The
PCM calculates an average voltage of each knock
sensor's signals and takes instantaneous signal
voltage readings. The PCM uses the instantaneous
signal voltage readings to determine the state of
the knock sensor circuitry. If the knock sensor system
is operating normally, the PCM should monitor
calculated average voltage. If the PCM malfunctions in
a manner which will not allow proper diagnosis of
the KS circuit OTC P0325 will set. DTCs P0327 and
P0332 are designed to diagnose the knock sensors,
and related wiring, so problems encountered with
the KS system should set a DTC.
For further information, refer to Knock Sensor (KS)
System Description.
6-1303
operating condition of the engine, to control fuel

delivery. A large quantity of air indicates acceleration,
while a small quantity indicates deceleration or idle.
The scan tool displays the MAF value in grams
per second (gm/s). At idle, MAF should read between
4 gm/s -7 gm/son a fully warmed up engine. Values
should change rather quickly on acceleration, but
values should remain fairly stable at any given RPM.
A MAF sensor malfunction or MAF signal circuit
problem should set OTC P0101, OTC P0102, or
DTC P0103.
Manifold Absolute Pressure Sensor
Mass Air Flow Sensor
21663
The Manifold Absolute Pressure (MAP) sensor

varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the linear EGR flow test diagnostic is
being run, to determine engine vacuum level for other
diagnostics and to determine barometric
pressure (BARO).
15006
The Mass Air Flow (MAF) sensor measures the

amount of air which passes through the throttle body.
The PCM uses this information to determine the
6-1304
If the PCM detects a voltage that is lower than the

possible range of the MAP sensor, OTC P0107 will be
set. A signal voltage higher than the possible range
of the sensor will set OTC P0108. An intermittent
low or high voltage will set OTC P1107 or P1.106
respectively. The PCM can also detect a shifted MAP
sensor. The PCM compares the MAP sensor signal
to a calculated MAP based on throttle position
and various engine load factors If the PCM detects a
MAP signal that varies excessively abov.e or below
the calculated value, OTC P0106 will set.
TCC Brake Switch

The TCC brake switch signal indicates when the brake
pedal is applied. The TCC brake switch information
is used by the PCM mainly to control the transmission
torque converter clutch. This switch is used as a
redundant input to the PCM on vehicles equipped with :
manual transmissions and if faulty, could cause a
OTC P1586 to set.
Transmission Temperature Sensor

The transmission fluid temperature sensor is a
thermistor which changes value based on the
temperature of the transmission fluid. A high
transmission fluid temperature may cause the vehicle
to operate in Hot Mode. While in Hot Mode, shift
points may be altered, 4th gear disabled, and TCC
forced ON in 2nd gear.
A failure in the TFT sensor or associated wiring
should cause OTC P0712 or P0713 to set. In this case,
engine coolant temperature will be substituted for
the TFT sensor value, and the transmission will
operate normally.
PCM Controlled Warning lamps

Description
MIL Operation
The Malfunction Indicator Lamp (MIL) is located on the
instrument panel (CHECK ENGINE) or (SERVICE
ENGINE SOON). The MIL performs the following
functions:
" It informs the driver that a problem has occurred
and that the vehicle should be taken for service
as soon as possible.
" As a bulb check and system check, the MIL will
illuminate with the ignition switch ON and the
engine not running. when the engine is started, the
MIL will turn OFF. If the MIL remains ON, the
self-diagnostic system has detected a problem. If
the problem goes away, the MIL will turn OFF
in most cases, but a diagnostic trouble code will
remain stored.
" If the MIL is illuminated, then the engine stalls, the
MIL will remain Illuminated so long as the ignition
switch is ON.
Now, if the MIL is not illuminated and the engine
stalls, the MIL will not illuminate until the ignition
switch is cycled OFF, then ON.
0
Engine
Perform the Powertrain On-Board Diagnostic System

Check first, when the following conditions are
present:
When the MIL does not turn ON when the ignition
switch is turned to the RUN position
When the MIL remains ON while the engine is
running
When you suspect a driveability problem
low Oil level lamp

The PCM commands the Low Oil L:.evel Lamp ON if
the engine oil level sensor ind.icates that a low oil level
condition exists. The PCM determines whether or
not to test for low oil level based onthe difference
between engine coolant temperature at the last
shutdown and engine coolant temperature at startup.
This is to ensure that the oil has drained back into
the oil pan before testing.
The engine oil I.eve! switch is a simple float switch that
is grounded when the engine oil level is OK .. When
the ignition is first turned ON, .the PCM commands the
Low Oil Level lamp ON for a brief period of time to
test the bulb (approximately 3 seconds). The PC.M also
checks the engine oil level switch cir.cuit at startup.
If the engine has been running, the PCM performs a
test routine based on .engine coolant tell)perature
to ensure that the engine oil drained back into
the sump before checking the state of the engine oil
level switch. If the engine coolant temperature is
between 15C (59F) and 130C (266F), the PCM
compares the engine coolant temperature at the
last key OFF to the engine. coolant temperature at the
current key ON. If the difference between the
recorded temperature values is at least 12c (54'F),
the PCM will test the engine oil level.
Generator Lamp
The PCM commands the generator lamp ON under
When the engine speed is greater than 1200 rpm
and system voltage falls below 10 volts for
longer than 1O seconds. The PCM commands the
generator lamp OFF when system voltage rises
to above 12 volts.
.
When the generator control circuit (L terminal)
remains low for longer than 10 seconds.
Second Gear Lamp (4L60E Transaxle 011iy)

The PCM supplies 12 volts to the second gear
start switch through a pull-up resistor. The
second gear start switch is a normally open switch.
The PCM senses a high input voltage, commands
normal transaxle shifting, and the secbnd gear start
lamp is not illuminated. When the second gear
start switch is closed, the input voltage to the PCM is
pulled low: The PCM turns the second gear lamp
ON and commands the to vehicle begin in second gear
(the following gears shift in normal sequence).
Engine
')

Description
Operation
)
.
The air conditioning system uses a compressor with

variable displacement. This compressor is referred
to as the V-5 type compressor. The V-5 compressor
meet.s A/C requirements without cycling. The A/C
compressor operation is controlled by the Powertrain
Control Module (PCM) for the following reasons:
.. Improved idle quality during compressor
clutch engagement.
Improved wide open throttle performance (WOT).
" Protects the A/C compressor from operation
with incorrect refrigerant pressures.
The A/C clutch electrical system consists of the
The A/C control head and/or the A/C programmer.
The A/C refrigerant pressure sensor.
The A/C compressor clutch.
The A/C compressor clutch relay.
The PCM.
When an A/C mode is selected at the A/C control
head, the A/C programmer provides a 12 volt signal to
the A/C request circuit. The PCM monitors the A/C
request circuit and controls the A/C compressor relay
based on the A/C request signal. This allows the
PCM to increase the engine idle speed just prior to
A/C clutch engagement for better idle quality. In
addition, the PCM will command the cooling fans ON
during A/C operation. The PCM also monitors the
A/C refrigerant pressure sensor circuit. If the A/C
refrigerant pressure is too high or low, the PCM will
disable the A/C compressor relay.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C ha.s been
requested unless one or more of the following
conditions are present:
Throttle angle is more than 90%.
AJC head pressure is more than 414 psi
(4.27 volts) or less than 34 psi (0.35 volt) as
determined by the A/C refrigerant pressure sensor.
Ignition voltage is less than 10.5 volts.
Engine speed is more than 5400 RPM for any
amount of time.
Engine speed is more than 4500 RPM for longer
than 5 seconds.
ECT is more than 125C (257F).
IAT is less than 5C (41F).
Any of the conditions described above will inhibit A/C
compressor relay operation.
Diagnosis
OTC P0530, P0560 or P1639 can affect A/C operation.

Refer to the OTC tables if any DTCs are set.
The A/C Clutch Control Circuit Diagnosis table should
be used for diagnosing the electrical portion of the
A/C compressor clutch circuit if a OTC is not set. To
diagnose the refrigerant portion of the HVAC

system, refer to the Heater, Ventilation, and Air
Conditioning (HVAC) section. A scan tool will be used
in diagnosing the system. The scan tool has the
ability to display the A/C request and refrigerant
pressure inputs to the PCM. The scan tool can display
when the PCM has commanded the A/C clutch ON.
The scan tool also has the ability to override the
A/C request signal and energize the A/C control relay.
Engine Cooling Fan Description Electric

Operation
The Powertrain Control Module. (PCM) controls the
operation of the cooling fans. This is accomplished by
providing a ground path for the cooling fan relay
coils within the PCM. The relay contacts will close and
complete the circuit between the fusible link at the
battery junction block and the fan motors. Whenever
there is a fan ON request both fans will be running.
Power for the fan motors is supplied through a fusible
link at the battery junction block. Battery positive
voltage is applied to the cooling fan relay contacts and
coils. The cooling fan relays are energized when
current flows through the relay coils to ground at the
PCM. The cooling fan relay #1 control circuit is
used for low speed cooling fan operation. The cooling
fan relay #1 control circuit and the cooling fan
relay #2 and #3 control circuit are both grounded for
high speed fan operation. The cooling fan relay control
circuits are monitored by the PCM. Before using the
Electric Cooling Fans diagnostic tables be sure to
perform the Powertrain On-Board Diagnostic System
Check. If diagnostic trouble codes P0480 or P0481
are present, use the appropriate OTC diagnostic tables
prior to performing Electric Cooling Fans diagnostics.
Important: When certain Diagnostic Trouble
Codes (DTCs) are present, the PCM may command
the cooling fans to run all the time. It is important
to perform the Powertrain On-Board Diagnostic System
check prior to diagnosing the engine cooling fans.
The PCM will complete the ground path for cooling fan
relay #1 under any of the following conditions:
When engine coolant temperature exceeds
105C (221 F).
When A/C is requested and ambient temperature
is more than 10C (50F).
When A/C refrigerant pressure is more than
190psi (2volts).
For high speed cooling fans operation, the PCM will
delay control of the cooling fan #2 and #3 relays
for 6 seconds. The 6 second delay ensures that the
cooling fan electrical load will not exceed the capacity
of the system. The PCM will complete the ground
paths for cooling fan relays #1, #2, and #3 under any
of the following conditions:
O
When engine coolant temperature exceeds

113C (235F).
" When A/C refrigerant pressure is more than

275 psi (2.9 volts).
6-1306
Engine
Diagnosis
If a problem that involves the low speed cooling fan
relay control circuit (cooling fan relay #1 control) exists,
DTC P0480 should set. If the problem affects the
high speed cooling fan relay control circuit (cooling fan
relay #2 and #3 control), OTC P0481 should set. A
problem with the ECT sensor should set OTC P0117,
P0118, P1114, or P1115. Any of these DTCs will
affect cooling fan operation and should be diagnosed
before using the Electric Cooling Fan Diagnosis
table. The Electric Cooling Fan Diagnosis table should
be used to diagnose the PCM controlled cooling
fans only if no DTC is set.
PCM Controlled Generator Description

The generator provides voltage to operate the vehicles
electrical system and to charge the vehicles battery.
A magnetic field is created when current flows through
the rotor.
This field rotates as the rotor is driven by the engine,
creating an AC voltage in the stator windings. The
AC voltage is converted to DC voltage by the rectifier
bridge and is supplied to the electrical system at
the battery terminal.
The operation of the charging system is monitored by
the PCM. The PCM monitors the charging system
loads and adjusts the idle speed accordingly. The PCM
also sends information to the Instrument Panel
Cluster (IPC) when the charging system is inoperative
and tells the IPC to illuminate the volts telltale lamp.
The PCM supplies 5 V through the L circuit to the
generator. If the generator becomes inoperative, the
PCM can detect the fault through the L circuit and tell
the IPC to illuminate the volts telltale lamp.
The PCM also monitors the duty cycle of the generator
through the L circuit. As the generator load increases,
the PCM will adjust the idle speed accordingly. If
the IPC does not see any activity from the PCM the
IPC will illuminate the volts telltale lamp.
If the Voltage telltale is on and the (L) terminal voltage
is low while the PCM is commanding the generator
on for more than 30 seconds OR
If the Voltage telltale is on and the PWM is less than
5% while engine RPM is less than 2500 for more
than 30 seconds OTC P0620 will set.
If the Voltage telltale is on but no DTCs are set, use
the PCM Controlled Generator Diagnosis to diagnose
the problem.
Generator Assembly
The generator assembly is mounted to the front of the
engine on the passenger side of the vehicle. The
CS-type generator uses an internal regulator which
features built-in fault detection. The generator used on
this vehicle, is not to be disassembled for service.
Fuel Supply Component Description

System Overview
The fuel tank stores the fuel supply. An electric fuel
pump, located in the fuel tank within the modular fuel
sender assembly, pumps fuel through an in-line
fuel filter to the fuel rail assembly. The pump provides

fuel pressure greater than is needed by the injectors.
The fuel pressure regulator keeps fuel available to the
injectors at a regulated pressure. A separate fuel
pipe is used to return fuel to the fuel tank.
Fuel Tank Vent Valve

The fuel tank vent valve is located in the rear of the
vehicle near the fuel tank. The fuel tank vent valve is a
pressure/vacuum relief valve. When the fuel tank
pressure exceeds a specified pressure, the valve
opens allowing the tank pressure to bleed off. When
the fuel tank is in a vacuum condition, the vent
valve opens when the vacuum is within a specified
range allowing fresh air to be pulled in.
Fuel Tank
The fuel tank stores the fuelsupply. The fuel tank is
located in the rear of the vehicle. The fuel tank is held
in place by two metal straps that attach to the frame.
The fuel tank is made. of steel and is coated internally
with a special corrosion inhibitor.
Fuel Tank Filler Pipe

The fuel tank filler pipe has a built-in restrictor and
deflector, .in order to prevent refueling with leaded fuel.
Fuel Filler Cap
173450
Notic~: If a fuel tank filler cap requires replacement,

use only a fuel tank filler cap with the same features.
Failure to use the correct fuel tank. filler cap can
result in a serious malfunction of the fuel and EVAP
system.
The fuel tank filler neck is equipped with a tethered
fuel filler cap. The cap requires a quarter of a
turn to remove it. A built in torque-limiting device
prevents over tightening. In order to install the cap,
turn the cap clockwise until you hear three audible
clicks. This signals that the correct torque has been
reached and the cap is fully seated. A fuel filler
cap that is not fully seated may cause a malfunction in
the emission system.
Engine Controls -
Engine
a~aL
6-1307
Fuel Pump
Modular Fuel Sender Assembly
50611
The Modular Fuel Sender Assembly consists of the

following major components: fuel sender strainer, fuel
pump strainer, roll-over valve, fuel level sensor,
and Juel tank pressure sensor.
Fuel level Sensor
49371
The fuel pump is mounted in the fuel reservoir within

the modular fuel sender. The fuel pump is an
electric high pressure gerotor pump. The fuel is
pumped to the fuel rail at a specified flow and
pressure. Excess fuel returns to the fuel tank by a
return pipe. The fuel pump delivers a constant flow 6f
fuel to the engine even during low fuel conditions
and aggressive vehicle maneuvers. The electric fuel
pump operation is controlled by the Powe.rtrain Control
Module (PCM) through a fuel pump relay. The fuel
pump flex pipe acts to dampen the fuel pulses
and noise generated by the fuel pump. The fuel pump
is serviced as part of the Modular Fuel Sender.
Fuel Pressure Regulator Assembly

The fuel pressure regulator attaches to the fuel rail on
the fuel return side. The fuel pressure is a diaphragm
operated relief valve and is referenced to manifold
vacuum. If the fuel pressure is too low, poor
performance could result. If the pressure is to high,
excessive odor and a Diagnostic Trouble Code (DTC)
may result.
50562
The Fuel Level Sensor consists of the following

components: float, the wire float arm, and the ceramic
resistor card. The Fuel Level Sensor is mounted on
the Modular Fuel Sender Assembly and is used as an
input to the PCM. The PCM uses this information
as a fuel level input for Various diagnostics. In addition
the PCM transmits the fuel level over the Class II
communication circuit to the IP cluster. This
information is used for the IP Fuel Gauge, and low
Fuel Warning indicator if applicable.
s..1308
Engine
Fuel Pump Strainer
fuel filter has a quick-connect inlet fitting and a

threaded outlet fitting. The threaded fitting is sealed
with an 0-ring. There is no service interval for fuel filter
replacement. Replace a restricted fuel. filter.
Fuel Feed and Fuel Return Pipes

The fuel feed and fuel return pipes carry fuel from the
modular fuel sender assembly to the fuel injection
system and back to the modular fuel sender assembly.
Fuel Tank Vapor Pressure Sensor
50673
The fuel pump strainer attaches to the lower end of

the modular fuel. sender assembly. The fuel pump
strainer. is made .of woven plastic. The. functions of the
fuel pump strain.e.r is to filter contamir:iants and to
wick fuel. The .life of the fuel pump strainer is generally
c~msidered to be that of the fuel pump, is self-cleaning
and normally requires no maintenance. Fuel
stoppage at this point .indicates that the fuel tank
contains an abnormal amount of sediment or water, in
which case the tank should be thoroughly cleaned
and replace the plugged fuel pump strainer with
a new one.
In-Pipe Fuel Filter

2
12628
The fuel feed pipe has a steel fuel filter installed

ahead of the fuel injection system. The paper filter
element (2) traps particles in the fuel that may damage
the injection system. The filter housing (1) is made
to withstand maximum fuel system pressure, exposure
to fuel additives, and changes in temperature. The
18839
The fuel tank pressure sensor is used to detect small

.leaks in the evaporative emission system. The fuel
tank pressure sensor is a three wire strain gauge
sensor much like that of the common GM MAP sensor.
However, this sensor has very different electrical
characteristics due to its pressure differential design.
The sensor measures the difference between the
air pressure (or vacuum) in the fuel tank and
the outside air pressure. The sensor mounts at the top
of the fuel tank. A three wire electrical harness
connects it to the Powertrain Control Module (PCM).
The PCM supplies a five volt reference voltage
and ground to the sensor. The sensor will return a
voltage between 0.1 and 4.9 volts. When the air
pressure in the fuel tank is equal to the outside air
pressure, such aswhen.the fuel fill cap is removed, the
output voltage of the sensor will be 1.3 to 1.7 volts.
Engine
Fuel Feed and Return Pipes
)
The fuel feed pipe carries fuel from the fuel tank to the
fuel rail assembly. The fuel return pipe carries ful3I
from the fuel rail assembly back to the fuel tank. The
fuel feed and return pipes consist of three sections:
The rear fuel pipe assemblies are located from
the top of the fuel tank to the chassis fuel
pipes. The rear fuel pipes are constructed of nylon.
The chassis fuel pipes are located under the
vehicle and connect the rear fuel pipes to
the engine compartment connecting fuel pipes.
These pipes are constructed of steel.
The engine compartment connecting fuel pipes
connect the chassis pipes to the engine fuel
rail. These fuel pipes are constructed of nylon.
5;..1309
Nylon fuel pipes are somewhat flexible and can be

formed around gradual turns .under the vehicle.
However, if nylon fuel pipes are forced into sharp
bends, the pipes will kink and restrict the fuel
flow. Also, once exposed to fuel, nylon pipes may
become stiffer and are more likely to kink if b~nt too
far. Take .special care when working on a vehicle with
nylon tu.el pipe!3.
Quick-Connect Fittings
Quick-connect fittings provide a simplifi.ed means of
instaHing and connecting fuel system components'. The
fittings consist of a unique female connector and a
compatible male pipe end. 0-rings,located inside the
female connector, provide the fuel seal. Integral
locking tabs or fingers hold the fittings together.
Nylon Fuel Pipes
Fuel Pipe 0-Rings

Personal Injury:
If nylon fuel pipes are nicked, scratched or
damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes;
Replace them.
When installing new fuel pipes, Do.Not
hammer directly on the fuel hames$ body clips
as it may damage the nylon pipes resulting
in ;{possible fuel leak.
towel before using a torch near them. Also,
higher than 1.15C (239F) for more than ..
eKtended period.
Before connecting fuel pipe fittings, always
reconnection and prevent a possible fuel leak.
(During normal operation, the O~rings
located in the female connector will swell and
lubricated.)
Nylon fuel pipes are designed to perform the same job
as the steel or flexible fuel pipes or hose.s that they
replace. Nylon pipes are constructed to withstand
:maximum fuel system pressure, exposure to
fuel additives, and changes in temperature. There are
three sizes of nylon fuel pipes used: 3/8 in ID for
.the fuel feed, 5/16 in ID for the fuel return, and 1/2 in
ID for the vent.
The fuel feed and return pipes are. assembled as a
harness. Retaining clips hold the pipes together
and provide a means for attaching the pipes to.the
vehicle. Heat resistant rubber hose arid/or corrugated
plastic cohduit. protect the sections of the pipes
that are exposed to chafing, high temperature or
vibration:
An 0-ring seals the threaded connection at the fuel

filter. Fuel system 0-ring seals are made of special
material. Service the 0-ring seals with.the correct
service part.
Fuel Metering Modes of Operation

Purpose
The basic function of the air/fuel metering system is to
control air/fuel delivery to the engine. The best
air/fuel mixture to minimize exhauste111issions is
14.7 to 1, which allows the catalytic converter
to operate most efficiently. Fuel is delivered to the
engine by individual fuel injectors mounted in
the intake manifold near each intake valve.
The main control sensor is the Heated Oxygen Sensor
(H02S), located in the exhaust manifold. The H02S
telis the Powerfrain Control Module (PCM) how
much oxygen is in the exhaust gas and the PCM
changes the air/fuel ratio to the engine by controlling
the fuel injector on time. Because of the constant
measuring and adjusting of the air/fuel ratio, the fuel
injection system is called a Closed Loop system.
Modes of Operation
The PCM monitors voltages from several sensors to
determine the engine's fuel needs; Fuel is delivered
under one of several conditions called modes. All
modes are controlled by the PCM and are
described below.
Starting Mode
When the ignition is first turned ON the PCM energizes
the fuel pump relay for two seconds, allowing the
fuel pump to build up pressure. The PCM then. checks
the Engine Coolant Temperature (ECT) sensor and
the Throttle Position (TP) sensor. During cranking, the
PCM checks the crankshaft position signal in order
to determine the proper air/fuel ratio for starting.
The PCM controls the amount of fuel delivered in the
starting mode by changing how long the fuel
injectors are energized. This is done by pulsing th.e
fuel injectors for very short times.
6-1310
Engine
Run Mode
Catalytic Converter Protection Mode
The run mode has two conditions called Open Loop

and Closed Loop.
When the engine is first started and engine speed is
above 725 RPM, the system is in Open Loop
operation. In Open Loop the PCM ignores the signal
from the Heated Oxygen Sensor (H02S), and
calculates the air/fuel ratio based on inputs from the
TP, ECT, and MAF sensors.
The system remains in Open Loop until the following
conditions are met:
The H02S has a varying voltage output showing
that it is hotenough to operate properly (this
depends on temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since
starting the engine.
The specific values for the above conditions vary with
different engines. When these conditions are met,
the system enters Closed Loop operation. In Closed
Loop the PCM changes fuel injector on-time based on
the signal from the H02S. This allows the air/fuel
ratio to stay very close to 14.7:1.
The PCM constantly monitors engine operation and

estimates conditions that could result i.n high ca1alytic
converter temperatures. If the PCM determines the
catalytic converter may overheat, it causes the system
to return to Open Loop operation and enriches the
fuel mixture.
Acceleration Mode
The PCM provides extra fuel when it detects a rapid
increase in throttle position and air flow.
Deceleration Mode
The PCM reduces the amount of fuel injected when it
detects a decrease in throttle position and air flow.
When deceleration is very fast, the PCM may cut off
fuel completely for short periods.
Battery Voltage.Corrction Mode

When battery voltage is low, the PCM will compensate
for the weak spark in the following ways:
Increasing the amount of fuel delivered.
Increasing the idle RPM.
Increasing ignition dwell time.

Description
Basic System Operation
The fuel metering system starts with the fuel in the
fuel tank. An electric fuel pump, located in the fuel tank
with the gauge sending unit, pumps fuel to the fuel
rail through an in-pipe fuel filter. The fuel pump
is designed to provide fuel at a pressure above the
pressure needed by the fuel injectors. A fuel pressure
regulator in the fuel rail keeps fuel available to the
fuel injectors at a constant pressure. Unused fuel is
returned to the fuel tank by a separate pipe. For further
information on the fuel tank, in-pipe filter, and fuel
pipes, refer to Fuel Supply Component Description.
Throttle Body Unit

The throttle body has a throttle plate to control the
amount of air delivered to the engine. The MAF sensor
is mounted on the throttle body.
Fuel Rail
4
Fuel Cut Off Mode

The PCM has the ability to shut OFF the fuel injectors
completely or selectively when certain conditions
are met. This fuel shut off mode allows the powertrain
to protect itself from damage and also improve its
driveability.
The PCM will disable the injectors under the following
conditions.
Ignition OFF (prevents engine run-on).
Ignition ON but no ignition reference signal
(prevents flooding or backfiring) .
. High engine speed (above red line).
High vehicle speed (above rated tire speed).
Extended high speed closed throttle coastdown
(reduce emissions and increases engine braking).
Fuel RPM cut off ranges:

Important: These RPM cut off ranges may vary
according to PCM calibration, axle ratio, tire size, and
tire rating.
Park and Neutral - 4000 RPM
Reverse - 4000 RPM
Drive - 5950 RPM
2
12819
The fuel rail (1) is mounted to the top of the engine and
distributes fuel to the individual fuel injectors (3). Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
pipes. The fuel then goes through the fuel rail to the fuel
pressure regulator (2). The fuel pressure regulator
maintains a constant fuel pressure at the fuel injectors.
Remaining fuel is then returned to the fuel tank. Fuel
pressure can be observed using a fuel pressure gauge
at the fuel pressure gauge connection (4).
Engine
Fuel Injector
6-1311
fuel pressure across the injectors at all times. The

pressure regulator compensates for engine load
by increasing fuel pressure as engine vacuum drops ..
The cartridge regulator is serviced as a separate
component. When servicing the fuel pressure
regulator, irn~ure that the 0-ring backup (3), large
0-ring (4), filter screen (5), and small 0-ring (7) are
properly placed on the pressure regulator.
If the fuel pressure is too low, poor performance and a
OTC P0171, could result. If the pressure is too high,
excessive odor.and a OTC P0172, may result. Refer to
Fuel System Pressure Testfor information on
diagnosing fuel pressure conditions.
(3X) Reference PCM Input (CKT 430)
1
2
13651
The Sequential Multiport Fuel. Injection (SFI) fuel

injector is a solenoid op~rated device controlled by the
PCM. The PCM energizes the solenoid which opens
a valve to allow fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess
.
fuel not used by the injectors passes through the fuel
pressure regulator before being returned to the
fuel tank.
A fuel injector which is stuck partly open will cause a
loss of fuel pressure after engine shut down,
causing long crank times to be noticed on some
engines.
From the electronic ignition module, t.he PCM uses

this signal to calculate engine speed and crankshaft
position. The PCM compares pulses on this circuit
to reference low CKT 453. The PCM also uses
.
the pulses on this circuit to initiate fuel injector pulses.
If the PCM receives rio pulses on this circuit, no
fuel injection pulses will occur and the engine will
not run.
CAM Signal (CKT 630) .

The PCM uses this signal to. determine the position of
the #1 piston during its power stroke, allowing the
PCM to calculate true Sequential Multiport Fuel
Injection (SFI). A loss of this signal will set a
OTC P0341. If the CAM signal is lost while the engine
is running, the fuel injection system will shift to a
calculated sequential fuel injection based on the last
fuel injection pulse and the engine will continue to run.
The engine can be restarted and will run in the
calculated sequential mode as long as the fault is
present with a 1 in 6 chance .of being correct. Refer to
OTC P0341 Camshaft Position (CMP) Sensor
Pet1ormance.
Fuel Pump Electrical Circuit
Wheri the key is first turned ON the PCM energizes

the fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within
two seconds, the PCM shuts the fuel pump OFF and
waits until the engine is cranked. When the engine
is cranked and the RPM signal has been detected by
the PCM, the PCM supplies 12 volts to the fuel
pump relay in order to energize the electric. in-tank
fuel pump.
An inoperative fuel pump relay can result in a no start
condition.
An inoperative fuel pump would cause a no start
condition. A fuel pump which does not provide enough
pressure cari result in poor performance.
12249
The cartridge type fuel pressure regulator (1) is a

diaphragm~operated relief valve (6) with fuel pump
pressure on one side, and regulator spring (2)
pressure, and intake manifold vacuum on the other
side. The regulator's function is to maintain a constant
6-1312
Short Term Fuel Trim Description

The short term fuel.trim is a PCM erasable memory
register. The neutral value for the short term fuel trim is
0%. Any deviation from 0% indicates the short term
fuel trim is changing the injector pulse width. The
amount of pulse width change depends on how far the
short term fuel trim value is from 0%. Ttie short
term fuel trim is rich when the scan tool indicates 99% .. The short fuel trim is lean when the scan
tool indicates 99%. The short term fuel trim changes
the pulse width by varying the Closed Loop factor
of the base pulse width equation. As the PCM monitors
the oxygen sensors input, it is constantly varying the
short term fuel trir:n value. The value is updated
very quickly, therefore, the short term fuel trim only
corrects for short term mixture trends. The correction
of long term mixture trends is the function of long
term fuel trim.
When the PCM determines that the Short Term Fuel

Trim is out of the operating range, the following
OTCs will set:
O OTC P0171 Bank 1 Lean.
OTC P0172 Bank 1 Rich.
OTC P0174 Bank 2 Lean.
Long Term Fuel Trim Description

The long term fuel trim is a matrix of cells arranged by
RPM and MAP. Each cell of the long term fuel trim
is a register like the short term fuel trim. As the engine
operating conditions change, the PCM will switch
from cell to cell to determine what long term fuel trim
factor to use in the base pulse width equation.
While in any given cell, the PCM also monitors the
short term fuel trim. If the short term fuel trim is
far enough from 0%, the PCM will change the long
term fuel trim value. Once the long term fuel trim value
is changed, it should force the short term fuel trim
back toward 0%. If the mixture is still not correct (as
judged by the H02S), the short term fuel trim will
continue to have a large deviation from the ideal 0%.
In this case, the long term fuel trim value will
continue to change until the short term fuel trim
becomes balanced. Both the short term fuel trim and
long term fuel trim have limits which vary by
calibration. If the mixture is off enough so that long
term fuel trim reaches the limit of its control and
still cannot correct the condition, the short term fuel
trim would also go to its limit of control in the
same direction. If the mixture is still not corrected by
both short term fuel trim and long term fuel trim at their
extreme values, a Fuel Trim Diagnostic Trouble
Code (OTC) will likely result. When the PCM
determines that the Long Term Fuel Trim is out of the
operating range, the following OTCs will set:
O
Under the conditions of power enrichment, the PCM
sets the short term fuel trim to 0% and freezes it there
until power enrichment is no longer in effect. This is
Engine
done so the Closed Loop factor and the long term fuel
trim will not try to correct tor the commanded
richness of power enrichment.

Description
Enhanced EVAP System Operation
The basic Evaporative Emission (EVAP) Control
system used on all vehicles is the charcoal canister
storage method. This method transfers fuel vapor from
the fuel tank to an activated carbon (charcoal)
storage device (canister) to hold the vapors when the
vehicle is not operating. When the engine is running,
the fuel vapor is purged from the carbon element
by intake air flow and consumed in the normal
combustion process.
The EVAP purge valve allows manifold vacuum to
purge the canister. The Powertrain Control
Module (PCM) supplies a ground to energize the
EVAP purge valve (purge ON). The EVAP purge valve
control is Pulse Width Modulated (PWM) or turned
ON and OFF several times a second. The PCM
controlled PWM output is commanded when the
appropriate conditions have been met
Engine coolant temperature above 50C (77F).
" After the. engine has been running about 3 minutes
on a cold start or 30 seconds on a warm start.
The vehicle is operating in closed loop fuel control.
Canister purge PWM duty cycle varies according
to operating conditions determined by mass air flow,
fuel trim, and intake air temperature. Canister
purge will be disabled if TP angle increases to above
55%. Canister purge will be re-enabled when TP
angle decreases below 53%.
The evaporative leak detection diagnostic strategy is
based on applying vacuum to the EVAP system
and monitoring vacuum decay. The fuel level sensor
input to the PCM is used to determine if the fuel
level in the tank is correct to run the EVAP diagnostic
tests. To ensure sufficient volume in the tank to
begin the various diagnostic tests, the fuel level must
be between 15% and 85%. The PCM monitors
system vacuum level via the fuel tank pressure
sensor input.
Diagnosis
The evaporative leak detecUon diagnostic strategy is
and monitoring vacuum decay. Before the EVAP
system diagnostic tests are run the following conditions
must be present:
No VSS, TP, H02S, Misfire, IAT, MAP, Fuel Trim,
Injector circuit, EGR Pintle Position, ECT, or MAF
sensor OTCs set.
Engine coolant temperature is between 4C and
30C (40F and 86F).
Intake air temperature is between 4C and
30C (40F and 86F).
Fuel tank level is between 15% and 85%.
BARO is above 75 kPa.
Engine
The EVAP system diagnostic tests Will be run following

a cold start; as indicated by the ECT and IAT
sensors. The fuel level sensor input to the PCM is
used to determine if the fuel level in the tank is
appropriate to run the EVAP diagnostic tests;To.
ensure sufficient volume in the tank to begin the
various diagnostic tests, the fuel level must be
between. 15% and 85%. The PCM monitors vacuum
level via the fuel tank pressure sensor input. At
an appropriate time; the EVAP purge valve. and the
EVAP canister vent valve are turned ON, allowing
engine va.cuumto draw a slight vacuum on the entire
evaporative emission system. After the.desired
vacuum level has .been achieved, the EVAP purge
valve is turned OFF, sealing thesystem. A leak
is detected by monitoring for a decrease in.vacuum.
level over a given time period. A.small leak in the
system will cause DTC P0442 to be set. If the.desired
vacuum .level cannot be achieved in the test
described above, a large leak or a malfunctioning
EVAP purge valve is indicated. This can be caused by
Disconnected or malfunctioning fuel tan.k pressu~e
sensor.
Missing, incorrect, or malfunctioning fuel cap.
Disconnected, damaged, pinched, or blocked
EVAP purge line.
Disconnected or damaged EVAP venthose.
Disconnected, damaged, pinched, or blocked fuel
tank vapor line.

Disconnected or malfunctioning EVAP canister
\lent valve.
Disconnected or malfunctioning EVAP canister
vent valve.
Open ignition feed .circuit to the EV AP canister
vent or EVAP purge valve.
Damaged EVAP canister.

Any of the above conditions can set DTC P0440.
A restricted or blocked EVAP canister vent path
is detected by drawing vacuum into the EVAP system,
turning OFFthe EVAP canister vent valve and the.
EVAP purge valve (EV AP canister vent valve Open,
EVAP canister purge 0% ) and monitoring the fue.1 tank
pressure sensor input. With the EVAP canister vent
valve open, any vacuum in the system should
decrease quickly unless the. vent path .is blocked. A
blockage can be caused by the following conditions:
Malfunctioning EVAP canister vent valve (stuck
closed).
Plugged, kinked, or pinched vent hose.
Shorted EV AP canister vent valve control circuit
Plugged evaporative. canister.
If any of the above conditions are present, DTC P0446
will set.
6-1313
The system checks for conditions that cause the

EV AP system to purge continuously by commanding
the EVAP canister vent valve ON and the EV AP purge
valve OFF (EVAP canister vent valve Closed, EVAP
canister purge 0%). If fuel tank vacuum level
decreases during the test, a continuous purge flow
condition is indicated. This can be caused by the
EVAP purge valve leaking.
EV AP purge and engine vacuum source lines
switched at the EVAP purge valve.
EVAP purge valve control circuit grounded.
If any of these conditions are present, DTC P1441 will
set. Refer to the DTC tables for further diagnostic
procedures regarding the EV AP system.
Evaporative Emissions System

Purge/Pressure Diagnostic Station J 41413
20803
Legend
(1) Main Valve
(2) Evaporative Emission System Purge/Presure
Diagnostic Station J 41413
(3) f\Jitrogen Cylinder
(4) Black Connecting Hose
(5) Threaded Fitting
(6) Gauge Set
The EV AP system purge/pressure diagnostic station is
used to clear carbon released into the EV AP system
by the canister. Carbon released into the EVAP system
may cause EVAP system components to be
inoperative. If diagnosis indicates that an EV AP
system component needs to be replaced, .the system
should be checked for released carbon. A released
carbon condition must be corrected before replacing
any EV AP system component. Procedures for
checking the EV AP system for released carbon and
for correcting a released carbon condition are in
the Diagnostic Aidsfor the applicable DTC tables.
6-1314
Engine
Electronic Ignition (El) System Description

air/fuel mixture. at the correct time. To provide optimum
advance of the ignition system. Electronic ignition has
the following advantages over a mechanical
distributor system:
No moving parts.
Less maintenance.
" Remote mounting capability.
No mechanical load on the engine.
More coil cool down time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation
time. Increased available ignition coil
saturation time.
the ignition coils - more than 40 kilovolts (40,000 volts)

at any engine RPM. The voltage required by each
spark plug is determined by the polarity and the
cylinder pressure. The cylinder on the compression
stroke requires more voltage to fire the spark plug than
the cylinder on the exhaust stroke,

It is possible for one spark plug to fire even though a
plug wire from the same coil may be disconnected
from its companion plug. The disconnected plug wire
acts as one plate of a capacitor, with the engine
being the other plate. These two capacitor.plates are
charged as a spark jumps across the gap of the
connected spark plug. The plates are then discharged
as the secondary energy is dissipated in an oscillating
current across the gap of the spark plug that is still
connected. Secondary voltage requirements are very
high with an open spark plug or spark plug wire;
The ignition coil has enough reseNe energy to fire the
plug that is still connected at idle, butthe coil may
not fire the spark plug under high engine load. A more
noticeable misfire may be evident under load; both
spark plugs may then be misfiring.
Operation
System Components
Purpose
The electronic ignition system does not use the

conventional distributor and coil. The ignition system
consists of three ignition coils, an ignition control
module, a dual Hail-effect crankshaft position sensor,
an engine crankshaft balancer with interrupter
rings attached to the rear, related connecting wires,
and the Ignition Control (IC) and fuel metering portion
of the PCM.
Conventional ignition coils have one end of the
secondary winding connected to the engine ground. In
this ignition system, neither end of the secondary
winding is grounded. Instead, each end of a coil's
secondary winding is attached to a spark plug. Each
cylinder is paired with the cylinder that is opposite
it (1/4, 2/5, 3/6). These two plugs are on companion
cylinders, i.e., on top dead center at the same
time. When the coil discharges, both plugs fire at the
same time to complete the series circuit. The
cylinder on compression .is said to be the event
cylinder and the one on exhaust is the waste cylinder.
The cylinder on the exhaust stroke requires very
little of the available energy to fire the spark plug. The
remaining energy will be used as required by the
cylinder on the compression stroke. The same process
is repeated when the cylinders reverse roles. Thi?
method of ignition is called a waste spark ignition
system.
Since the polarity of the ignition coil primary and
secondary windings is fixed, one spark plug always
fires with normal polarity and its companion plug fires
with reverse polarity. This differs from a conventional
ignition system that fires all the plugs with the
same polarity. Because the ignition coil requires
approximately 30/o more voltage to fire a spark plug
with reverse polarity; the ignition coil design is
improved, with saturation time and primary current
flow increased. This redesign of the system allows
higher secondary voltage to be available from
12303
Crankshaft Position Sensor and Crankshaft

Balancer Interrupter Rings
The dual crankshaft position sensor. is secured in.an
alumi.num mounting bracket and bolted to the front left
side of the engine timing chain cover, partially
behind .the crankshaft balancer. A 4-wire harness
connector plugs into the sensor, connecting it to the
ignition control module. The dual crankshaft position
sensor contains two Hall-effect switches with
one shared magnet mounted between them. The
magnet and each Hall-effect switch are separated by
an air gap. A Hall 0 effect switch reacts like a solid
state switch, grounding a low current signal voltage
when a magnetic field is present. When the magnetic
field is shielded from the switch by a piece of steel
placed in the air gap between the magnet and
the switch, the signal voltage is not grounded.
Engine
6-1315
If the piece of steel (called an interrupter) is repeatedly

moved in and out of the air gap, the signal voltage
will appear to go ON - OFF - ON - OFF - ON - OFF. In
the case of the electronic ignition system, the piece
of steel is two concentric interrupter rings mounted to
the rear of the crankshaft balancer.
12305
12358
legend
(1) Crankshaft Balancer
(2) Interrupter Rings
Each interrupter ring has blades and windows that
either block the magnetic field or allow it to close
one. of the Hall effect switches. The. outer Hall effect
switch produces a signal called the CkP 1SX because
the outer interrupter ring has 18 evenly spaced
blades and windows. The CKP 1SX portion of the
crankshaft position sensor produces 18 ON OFF pulses per crankshaft revolution. The Hall-effect
switch closest to the crankshaft, the CKP. Sync
portion of the sensor, produces a signal that
approximates the inside interrupter ring. The inside
interrupter ring has 3 unevenly spaced blades
and windows of different widths. The CKP Sync portion
of the crankshaft position sensor produces 3 different
length ON - OFF pulses per crankshaft revolution.
When a CKP Sync interrupter ring window is between
the magnet and inner switch, the magnetic field will
cause the CKP Sync Hall effect switch to ground
the CKP Sync signal voltage supplied from the ignition
controlmodule. The CKP 18X interrupter ring and
Hall-effect switch react similarly. The ignitioncoritrol
module. interprets the CKP 18X and CKP Sync
ON - OFF signals as an indicatio11. of crankshaft
position, and the ignition control.module must have
both signals to fire the correct ignition coil. The ignition
control modul.e determines crankshaft position for
correct ignition coil sequencing by counting how many
CKP 18X signal transitions occur, i.e.; ON - OFF or
OFF - ON, during a CKP Sync pulse.
The camshaft position sensor is located on the timing

cover behind the water pump near the. camshaft
sprocket. As the camshaft sprocket turns, a magnet in
it activates the Hall effect switch in the camshaft
position sensor. When the Hall-effect switch is
activated, it grounds the signal line to the ICM, pulling
the camshaft position sensor signal circuit's applied
voltage low. This is interpreted as a CMP Sensor
signal. The CMP Sensor signal is created as piston #1
is approximately 25 degrees aft.er top dead center
on the power stroke.
12299
Legend
(1) Screws
(2) Ignition Coil
(3) Ignition Control Module
6-1316
Engine
Ignition Coils
Powertrain Control Module (PCM)
Three twin-tower ignition coils are individually mounted

to the ignition c.ontrol module. Each coil provides
spark for two plugs simultaneously (waste spark
distribution). Each coil is serviced separately.
Two terminals connect each coil pack to the module.
Each coil is provided a fused ignition feed. The
other terminal at each coil is individually connected to
the module, which will energize one coil at a time
by completing and interrupting the primary circuit
ground path to each coil at the proper time.
Ignition Control Module (ICM)

The ignition control module performs the following
functions:
It powers the dual crankshaft position sensor
internal circuits.
It supplies the voltage signals that each respective
Hall effect switch pulses to ground to generate
the CKP Sync and CKP 18X signal pulses.
It determines the correct ignition coil firing
sequence, based on how many CKP 18X signal
transitions occur during a CKP Sync pulse.
This coil sequencing occurs at start-up. After the
engine is running, the module remembers the
sequence, and continues triggering the ignition
coils in proper sequence.
It determines whether or not the crankshaft is
rotating in the proper direction, and cuts off
fuel delivery and spark to prevent backfiring if
reverse rotation is detected.
It sends the 3X reference and 18X reference
signals to the PCM. The PCM determines engine
RPM from these signal. These signals used by
the PCM to determine crankshaft speed for
Ignition Control (IC) spark advance calculations.
The falling edge of each 3X reference and
18X reference signal pulse occurs at a specific
time in relation to top dead center of any cylinder
stroke. The 3X reference signal sent to the
PCM by the ignition control module is an ON OFF pulse occurring 3 times per crankshaft
revolution. This is neither the CKP Sync pulse nor
the 18X crankshaft position sensor pulse, but
both of these are required before the ignition
control module will generate the 3X reference
signal. The ignition control module generates the
3X reference signal by an internal divide-by-6
circuit. This divider circuit divides the CKP
18X signal pulses by 6. The divider circuit is
enabled, or ready to begin dividing, only after it
receives a crankshaft position sensor CKP
Sync pulse. After beginning, the divider circuit
does not need the Sync pulses to continue
operating. If either the CKP 18X or CKP Sync
pulses are missing at start-up, the ignition control
module will not generate 3X reference or
18X reference signal pulses and no fuel injector
pulses will occur.
159242
The PCM is responsible for maintaining proper spark

and fuel injection timing for all driving conditions.
Ignition Control (IC) spark timing is the PCM method
of controlling spark advance and ignition dwell. To
provide optimum driveability and emissions, the PCM
monitors input signals from the following components
in calculating Ignition Control (IC) spark timing:
"
"
..
Ignition Control module (ICM).

Engine Coolant Temperature (ECT) sensor.
Intake Air Temperature (IAT) sensor.
Mass Air Flow (MAF) sensor.
Trans Range or PNP inputs from Trans Range
switch or Park/Neutral Position switch.
Throttle Position (TP) sensors.

.. Vehicle Speed Sensor (VSS) I Trans Output
Speed Sensor (TOSS).
The ignition system uses many of the same ignition
module-to-PCM circuits as did previous Delco
engine management systems using distributor type
ignition. The following describes the PCM to ignition
control module circuits:
3X reference PCM input
From the ignition control module, the PCM uses
this signal to calculate engine RPM and crankshaft
position. The PCM compares pulses on this
circuit to any that are on the Reference Low
circuit, ignoring any pulses that appear on both.
The PCM also uses the pulses on this circuit
to initiate injector pulses.
18X reference PCM input - The 18X reference
signal is used to accurately control spark timing at
low RPM and allow IC operation during crank.
Below 1200 RPM, the PCM is monitoring
the 18X reference signal and using it as the
reference for ignition timing advance. When engine
speed exceeds 1200 RPM, the PCM begins
using the, 3X reference signal to control spark
timing.
Engine
',
Camshaft Position PCM input

The PCM uses this signal to determine the
position of the cylinder #1 piston during its power
stroke. This signal is used by the PCM to
calculate true Sequential Fuel Injection (SFI)
mode of operation. The PCM compares the
number of CAM pulses to the number of 18X and
3X reference pulses; If the number of 18X and
3X reference pulses occurring between CAM
pulses is incorrect, or if no CAM pulses are
received while the engine is running, the PCM will
set OTC P0341 . If the cam signal is lost while
the engine is running the fuel injection system will
shift to a calculated sequential fuel injection
mode based on the last cam pulse, and the engine
will continue to run. The engine can be re-started
and will run in the calculated sequential mode
as long as the condition is present with a
1 in 6 chance of being correct.
Reference low PCM input
This is a ground circuit for the digital RPM
counter inside the PCM, but the wire is connected
to engine ground only through the ignition
control module. Although this circuit is electrically
connected to the PCM, it is not connected to
ground at the PCM. The PCM compares voltage
pulses on the 3X or 18X reference input to
those on this circuit, ignoring pulses that appear
Oh both.
Bypass signal PCM output
The ignition control module maintains a fixed
spark timing while the engine is cranking (Bypass
Mode). Once the PCM receives 3X reference
pulses, the PCM commands the ignition module
to allow the PCM to control the spark advance
(IC Mode). The ignition control module determines
correct operating mode based on the voltage
level that the PCM sends to the ignition control
module on the bypass circuit. The PCM provides
5 volts on the bypass circuit if the PCM is
going to control spark timing (IC Mode).
Ignition Control (IC) PCM output
The IC output circuitry of the PCM sends out
timing pulses to the ignition control module. When
in the Bypass Mode, the ignition control module
grounds these pulses. When in the IC Mode,
the ignition control module uses the timing pulses
for coil dwell and spark timing. Proper sequencing
of the 3 ignition coils, i.e.; which coil to fire, is
always the job of the ignition control module.
Modes of Operation
The ignition system uses the same four ignition
module-to-PCM circuits as did previous Delco engine
management systems using distributor-type ignition.
Ignition Control (IC) spark timing is the PCM's method
of controlling spark advance and ignition dwell
when the ignition system is operating in the IC Mode.
There are two modes of ignition system operation:
Bypass Mode.
IC Mode.
6-1317
In Bypass Mode, the ignition system operates

independently of the PCM, at a fixed spark timing. The
PCM switches to IC Mode (PCM controlled spark
advance) as soon as the engine begins cranking. After
the switch is made to IC Mode, it will stay in effect
until one of the following conditions occur:
The engine is turned off.
The engine quits running.
The IC output circt.Jitry in the PCM generates IC output
pulses anytime crankshaft reference signal input
pulses are being received. When the ignition system is
operating in the Bypass Mode (no voltage on the
bypass control circuit), the ignition control module
grounds the IC pulses coming from the PCM.
The ignition control module will remove the ground
from the IC circuit only after switching to the IC Mode.
The PCM commands switching to IC Mode by
applying 5 volts on the bypass circuit to the ignition
control module. The PCM monitors the IC and Bypass
circuits for electrical malfunctions affecting proper
ignition system operation. If a malfunction occurs,
diagnosis is included in OTC P1351, P1352, P1361
and P1362 diagnostic tables. If diagnostic trouble
codes are encountered, go to the OTC tables
for diagnosis.
In the IC Mode, the ignition spark timing and ignition
dwell time is fully controlled by the PCM. IC spark
advance and ignition dwell is calculated by the PCM
using the following inputs:
Engine speed (18X reference or 3X reference).
Crankshaft position (18X reference or
3X reference and Camshaft position PCM input
signal).
Engine Coolant Temperature (ECT sensor).
Throttle Position (TP sensors).
Knock Signal (Knock sensor).
Park/Neutral Position (PRNDL input).
Vehicle Speed (Vehicle Speed Sensor).
PCM and ignition system supply voltage.
The following describes the PCM to ignition control
module circuits:
3X reference PCM input - From the ignition
control module, the PCM uses this signal to
calculate engine RPM and crankshaft position.
The PCM compares pulses on this circuit to any
that are on the Reference Low circuit, ignoring
a:ny pulses that appear on both. The PCM
also uses the pulses on this circuit to initiate
injector pulses. If the PCM receives no pulses on
this circuit, the PCM will use the 18X reference
pulses to calculate RPM and crankshaft position.
The engine will continue to run and start
normally, but OTC P137 4 will be set.
6-1318
Engine
18X reference PCM input - The 18X reference

signal is used to accurately control spark timing at
low RPM and allow IC operation during crank.
Below 1200 RPM, the PCM is monitoring the
18X reference signal and using it as the reference
for ignition timing advance. When engine speed
exceeds 1200 RPM, the PCM begins using the,
3X reference signal to control spark timing. If the
18X reference signal is not .received by the PCM
while the engine is running, a OTC P0336 will be
set and 3X reference will be used fo control spark
advance under 1200 RPM, and Bypass Mode will
be in effect at under 400 RPM. The engine will
continue to run and start normally.
Reference low PCM input - This is a ground circuit.
for the digital RPM counter inside the PCM, but the
wire is connected to engine ground only through
the ignition co.ntrol module. Although this circuit is
electrically connected to the PCM, it is not
connected to ground at the PCM. The PCM
compares voltage pulses on the 3X or
i 8X reference input to those on this circuit, ignoring
pulses that appear on both. If the circuit is open, or
connected to ground at the PCM, it may cause poor
engine performance and possibly a MIL (Service
Engine Soon) with no OTC.
Bypass signal PCM output -The ignition control
module maintains a fixed spark timing while the
engine cranking (Bypass mode). Once the PCM
receives 3X reference pulses, the PCM commands
the ignition module to allow the PCM to control the
spark advance (IC Mode). The ignition control
module determines correct operating mode based
on the voltage level that the PCM sends to the
ignition control module on the bypass circuit. The
PCM provides 5 volts. on the bypass circuit if the
PCM is going to control spark timing (IC Mode).
" Ignition Control (IC) PCM output - The IC output
circuitry of the PCM sends out timing pulses to the
ignition control module on this circuit. When in the
Bypass Mode, the ignition control module grounds
these pulses. When in the IC Mode, these pulses
are sent to the ignition control module to control coil
dwell and spark timing, Proper sequencing of the 3
ignition coils, i.e., which coil to fire, is always the job
of the ignition control mod.ule.
Knock Sensor (KS) PCM input -The PCM contains
integrated knock sensor (KS) diagnostic circuitry.
The KS system is comprised of A knock sensor,
PCM, and related wiring. The PCM monitors the
knock sensor signal to detect engine detonation
(spark knock). When the spark knock occurs, the
PCM retards the spark timing (IC) to reduce
detonation. Retarded timing can also be a result of
excessive valve lifter, pushrod or other mechanical
engine or transaxle noise.
Camshaft Position PCM input (CAM signal) - The

PCM uses this signal to determine the positipn of
the cylinder #1 piston during its intake stroke.
This signal is used by the PCM to calculate true
Sequential Fuel Injection (SFI) mode of operation.
The PCM compares the number of CAM pulses
to the number of 18X and 3X reference pulses. If
the cam signal is lost while the engine is
running the fuel injection system will shift to a
calculated sequential fuel injection mode based on
the. last cam pulse, and the engine will continue
to run. The engine can be re-started and will
run in the calculated sequential mode as long as
the fault is present with a 1 in 6 chance of
being correct.
Knock Sensor (KS) System Description

Purpose
Varying octane levels in today's gasoline may cause
detonation in some engines. Detonation is caused
by an uncontrolled explosion (burn) in the combustion
chamber. This uncontrolled explosion could produce
a flamE:l front opposite that of the normal flame
front produced by the spark plug. The rattling sound
normally associated with detonation is the result
of two or more opposing pressures (flame fronts)
colliding within the combustion chamber. Though light
detonation is sometimes considered normal, heavy
detonation could result in engine damage. To control
spark knock, a Knock Sensor (KS) system is used.
This system is designed to retard spark timing
when spark knock is detected in the engine. The KS
system allows the engine to use maximum spark
advance. for optimal driveability and fuel economy.
Operation
The PCM contains integrated Knock Sen.sor (KS)
Diagnostic Circuitry. Input signals from the knock
sensors are used to detect engine detonation, allowing
the PCM to retard Ignition Control (IC) spark timing
based on the amplitude and frequency of the KS signal
being received. The knock sensors produce an AC
signal under all engine operating conditions. The PCM
calculates an average voltage of each knock
sensor's signal and takes instantaneous signal voltage
calculated average voltage (as shown in the normal
knock sensor figure). If the PCM detects a knock
sensor signal voltage within the calculated average
voltage range, OTC P0327 or P0332 will set (as shown
in. the abnormal knock sensor figure).
Engine
6~1319
Abnormal Knock Sensor Signal
Normal Knock Sensor Signal
4
4
245253
Legend
Legend
(1)
(2)
(3)
(4)
245257
Upper
Knock
Knock
Lower
Fail Region
Sensor CalcLtlated Average
Sensor Signal (Normal)
Fail Region
(1)
(2)
(3)
(4)
Upper
Knock
Knock
Lower
Fail Region
Sensor Calculated Average
Sensor Signal (Failed)
Fail Region
Diagnosis
If the PCM malfunctions in a manner which will not
allow proper diagnosis of the knock sensor system,
OTC P0325 will set.
OTCs P0327 and P0332 are designed to diagnose the
knock sensors, and related wiring. Problems
encountered with the KS system should set a OTC.
However, if the customer's complaint is detonation/
spark knock, use the tables for OTC P0327 or P0332
to diagnose the condition.
6-1320
Engine

Operation
EGR System Description

Linear EGR Valve
~---3
l.!!,;!!...._ _ _
11696
14441
Purpose
The Exhaust Gas Recirculation (EGR) system is used
to lower Oxides of Nitrogen (NOx) emission levels
caused by high combustion temperature. It does this
by decreasing combustion temperature.
The main element of the system is the linear EGR
valve. The EGR valve feeds small amounts of exhaust
gas back into the combustion chamber. With the
fuel/air mixture diluted by the exhaust gases,
combustion temperatures are reduced.
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Cap-Sensor
Sensor-EGR Pintle Position
Pole Piece-Primary
Bobbin and Coil Assembly
Sleeve-Armature
Valve-Pintle
Armature and Base Assembly
The linear EGR valve is designed to accurately supply

EGR to an engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust
to the intake manifold through an orifice with a PCM
controlled pintle. During operation, the PCM controls
pintle position by monitoring the pintle position
feedback signal. The feedback signal can be monitored
with a scan tool as ACTUAL EGR POS. ACTUAL
EGR POS should always be near the commanded
EGR position (DESIRED EGR POS). The PCM uses
information from the following sensors to control
the pintle position:
Engine Coolant Temperature (ECT) sensor.
o Throttle Position (TP) sensor.
Mass Air Flow (MAF).
The linear EGR valve is usually activated under the
e Warm engine operation
.. Above idle speed
Engine
Diagnosis
The TAC system components include but is not limited

to the following:
" The Accelerator Pedal Position (APP) sensor
The Throttle Body
" The Throttle Actuator Control (TAC) module
The Powertrain. Control Module (PCM)
Each of these components interface together to
ensure accurate calculations and control of the throttle
position.
Accelerator Pedal Position (APP) Sensor

The APP sensor is mounted on the accelerator pedal
assembly. The APP is actually three individual
accelerator pedal position sensors within one housing.
There are three separate signal, ground and
reference circuits. The APP sensor voltage increases
as the accelerator pedal is depressed.
'--2
11699
Legend
(1)
(2)
(3)
(4)
)
Linear EGR Valve

Exhaust Gas
To Cylinders
Pintle
Too much EGR flow at idle, cruise, or cold operation

may cause any of the following conditions to occur:
Engine stalls after cold start.
Engine stalls during closed throttle conditions.
Vehicle surges during cruise.
Rough idle.
OTC P0300 (misfire detected).
Too little or no EGR flow may allow combustion
temperatures to get too high. This could cause the
following symptoms:
Spark knock (detonation).
Engine overheating.
Emission test failure.
OTC P0401.
Poor fuel economy.
EGR flow diagnosis is included in the OTC P0401
diagnostic table. Pintle position error diagnosis
is covered in OTC P1406. If EGR diagnostic trouble
codes P0401 and/or P1406 are encountered, go to the
OTC tables for diagnosis.
Throttle Actuator Control System

Description
6.;1321
Throttle Actuator Control (TAC) Overview

The Throttle Actuator Control (TAC) system uses
vehicle electronics and components to calculate and
control the position of the throttle blade. This
eliminates the need for a mechanical cable attachment
from the accelerator pedal to the throttle body. This
system also performs the cruise control functions
as well.
Throttle BodyfTAC Assembly

The throttle body for the TAC system is similar to a
conventional throttle body with several exceptions.
One exception being the use of a motor to control the
throttle position instead of a mechanical cable.
Another exception is the new design Throttle
Position (TP) sensor. The TP sensor mounts on the
side of the throttle body. The TP sensor is actually two
individual TP sensors within one housing.
Two separate signal, ground and reference circuits are
used to connect the TP sensors and the TAC
module. The TP sensor signal voltage increases as
the throttle opens.
Throttle Actuator Control (TAC) Module
The TAC module is the 'Control Center' for the
electronic throttle system. The Module is also located
on the accelerator pedal assembly. The.TAC
module and the PCM communicate via a dedicated
redundant serial data circuit. The TAC module and the
PCM monitor the commanded throttle position and
compare it to the actual throttle position. This is
accomplished by monitoring the APP and the TP
sensor. These two values must be within a calibrated
value of each other. The TAC module also monitors
each individual circuit of the TP sensor and the APP to
verify proper operation.
Battery Saver Mode
When the PCM detects the ignition ON for 10 seconds
without the engine running it sends a message to
the TAC Module. At this time the TAC module
will allow the throttle blade to return to it's default
position. This removes the draw that is present while
holding the throttle blade at it calculated idle
position.
Crankcase Ventilation System Description

Purpose
A crankcase ventilation system is used to consume
crankcase vapors in the combustion process instead of

venting them to atmosphere. Fresh air from the
throttle body is supplied to the crankcase, mixed with
blow-by gases and then passed through a crankcase
ventilation valve into the intake manifold.
6-1322
Engine

Air Intake System Description ..
Operation
The air induction system provides contaminant and

sound filtration of the outside air as it is drawn into the
engine. A remotely mounted air cleaner reduces
induction noise while preventing contaminants in 1he
air from entering the engine. The filtered air is
routed into an intermediate air duct assembly. The air
then enters the engine by flowing through the
throttle body, into the intake manifold, through the
cylinder head intake ports, and into the cylinders.

, Tool Number/Description
Illustration
J 34730-405
Injector Test Light
13561
The primary control is througt., the crankcase

ventilation valve which meters the flow at a rate
depending on inlet vacuum. To maintain idle quality,
the crankcase ventilation valve restricts the flow when
inlet vacuum is high.
385603
J 39200
Digital Multi-meter
J 34730-E
Fuel Pressure Gauge Kit
21764
5377
If abnormal operating conditions arise, the system is

designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent into the
throttle body to be consumed by normal combustion.
. ]26792
'Spark Tester
5381
Engine
Illustration
Illustration
6:.1323
J 34142-B
J 35689-A
Metri-Pack Terminal Kit
Test Light
5395
5382
J 28742-A
Weather Pack
Terminal Remover
J 23738-A
Vacuum Pump
5396
5386
J 39194-B
Oxygen Sensor Wrench
J 37027-A
IAC Motor Analyzer
5399
5388
J 34730-1A
J 35616-A
Fuel Pressure Gauge
Connector Test Adapter Kit
8917
J .35314-A
Exhaust Back .Pressure
Tester
Tech 2 Kit 7000081
50062
13544
6~1324
Engine. Controls - 3.8L

Illustration.'
Engine
Illustration
(
J 33431-B
Signal Generator and
Instrument Panel Tester
.. J 37088-A
Fuel
Line Quick Connect

Separator
12366
J 37287
Inlet ahd Return Fuel Line
.Shut-off Adapters
J 39363
Supercharger Actuator
Adjuster
547097
13541
J.39021
Fuel Injector Coil/Balance
Tester
J41413
Pressure/Purge Diagrlostic
Station
J 39021-380
Fuel Injector Test Harness
J 41416
Ultrasonic Leak Detector
385606
Engine
5;.1325

)
Specifications
oc
OF
OHMS
Temperature vs Resistance Values (Approximate)

100
212
177
90
194
241
80
176
332
70
158
467
60
140
667
50
122
973
45
113
1188
40
104
1459
35
95
1802
30
86
25
77
2238
2796
20
68
3520
15
59
4450
10
50
5670
41
7280
32
9420
....:5
23
12300
-10
14
16180
-15
21450
-20
-4
28680
-'-30
-22
52700
-AO
-40
100700

Specifications
Application
AIR Check Valves

AIR Pipe To Exhaust Manifold Bolts
Metric
English
23Nm
17 lb ft
20Nm
15 lb ft
AIR Pump to Bracket
9N-m
801bin
AIR Right Side Pipe Bracket-to-Cylinder Head Bolt
25N-m
18 lb ft
AIR ShutOff Valve Bracket-to-Cylinder Head Bolt
20N-m
14 lb ft
AIR Shut Off Valve Retaining Nut
12 Nm
8 lb ft
Camshaft Position (CMP) Sensor Bolt
25Nm
18 lb ft
Crankshaft Position (CKP) Sensor Bolt
25Nm
18 lb ft
EGR Valve to Mounting Flange, First Step
10N-m
89 lb ft
EGR Valve to Mounting Flange, Second Step
25N-m
18 lb ft
17 Nm
13 lb ft
Fuel Fill Hose Clamps
2.5N-m
221bin
Fuel Filter Fitting
30Nm
22 lb ft
Fuel Pipe Front Clip Bolts
4.5Nm
401bin
Fuel Pipe Rear Clip Bolt
5.5N-m
491bin
Fuel Pipe Shield Bolt
5N-m
441bin
Fuel Pipe Shield Nuts
5N-m
44 lb in
6.;1326
Engine

Specifications
Metric
English
Fuel Pipe Shield Studs
5N-m
441bin
Fuel Rail Attaching Bolts
10Nm
891bin
Application
Fuel Tank Fill Pipe Shield Bolt
2.5N-m
22 lb ft
Fuel Tank Fill Pipe Support Bracket Bolt
10N-m
891bin
Fuel Tank Strap Bolts
33N-m
24 lb ft
41 Nm
30 lb ft
Idle Air Control (IAC) Valve Attaching Screws
3N-m
27 lb ft
Knock Sensor (KS)
15 Nm
11 lb ft
Powertrain Control Module (PCM) Connector End Bolts
8N-m
701bin
PCV Hose Assembly Mounting Cable Nut
12 N-m
1061bin
Throttle Body Attaching Bolts
12N-m
106 lbin
Throttle Position (TP) Sensor Attaching Screws
2N-m
18 lb in
Fuel System Specifications

If you have the 3800 V6 engine (VIN Code K), us_e
regular unleaded gasoline rated at 87 octane or higher.
If you have the 5.7L VB engine (VIN Code G), use
premium unleaded gasoline rated at 91 octane
or higher for best performance. You may use middle
grade or regular unleaded gasolines, but your
vehicle may not accelerate as well.
It is recommended that the gasoline meet specification
which have been developed by the American
Automobile Manufactures Association (AAMA) and
endorsed by the Canadian Motor Vehicle
Manufacturers Association for better vehicle
performance and engine protection. Gasolines
meeting the AAMA specification could provide
improved driveability and emission control system
performance compared to other gasolines. For. more
information, write to: American Automobile
Manufacturer's Association, 7430 Second Ave,
Suite 300; Detroit Ml 48202.
Be sure the posted octane for premium is at least 91
(at least 89 for middle grade and 87 for regular). If
the octane is less than 87, you may get a heavy
knocking noise when you drive. If it's bad enough, it
can damage your engine.
If you're using fuel rated at the recommended octane
or higher and you hear heavy knocking, your
engine needs service. But don't worry if you hear a
little pinging noise when you're accelerating or driving

up a hill. That's normal, and you don't have to buy
a higher octane fuel to get rid of pinging. It's the heavy,
constant knock that means you have a problem.
Notice: Your vehicle was not designed for fuel that
contains methanol. Do not use methanol fuel
which can corrode metal parts in your fuel system and
also darnage plastic and rubber parts. This kind of
damage would not be covered under your warranty.
If your vehicle is certified to meet to meet California
Emission Standards (indicated on the under hood
emission control label), it is designed to operate on
fuels that meet California specifications. If such
fuels are not available in states adopting California
emissions standards, your vehicle will operate
satisfactorily on fuels meeting federal specifications,
but emission control system performance may be
affected. The malfunction indicator lamp on your
instrument panel may turn on and/or your vehicle may
fail a smog-check test. If this occurs, return to your
authoriz$d deal.er for diagnosis to determine the cause
of failure. In the event it is determined that the
cause of the condition is the type of .fuels used, repairs
may not be covered by your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane.~enhancing additive
called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask your service station operator
whether or not the fuel contains MMT.
Engine Controls - 5.7L 6".1327
Engine
Application
3.430
Accelerator Pedal
3.451
3.402
3.410
2.383
2.383
3.682
1.516
3.130
3.140
3.145
3.140.
Air Cleaner Assembly

Air Filter
Engine Oil Level Senso.r
EVAP Canister
EVAP Fuel Tank Pressure Sensor
EVAP Hoses and Pipes
EVAP Purge Solenoid
EVAP Vent Valve
Fuel Hoses and Pipes
Fuel Injectors
Fuel Pump
Fuel Pump Relay
Fuel Rail Assembly
Fuel Sender
'
Fuel Tank
Fuel Tank Straps
GM .SPO Group Number
Accelerator Control Cable

Idle Air Control (IAC) Valve
Ignition Coil/Module
lnline Fuel Filter
Intake Air Duct
Knock Sensors
Positive Crankcase Vent Valve.
Secondary AIR hoses/pipes and check valves
Secondary AIR Pump
Secondary AIR Relay
Secondary AIR Solenoid
Secondary AIR Shut Off Valve
Throttle Body Assembly
..
Throttle Position (TP) Sensor

Vehicle Speed (VSS) Sensor
3.140
3.670
3.163
3.300
3.900
3.900
3.330
3.107
3.001
3.022
3.682
3.338
2.170
3.890
.. 3.417
3.682
2.383
3.682
3.682
1.745
3.670
3.670-3:675
3.q60
3:682
3.670.
3.670
3.335
3.339
3.682
6-1328
Engine
Engine Controls_- 5.7L

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
To HVAC
To Power Brake Booster
EVAP System Test Port
To EVAP Canister
EVAP Canister Purge Solenoid
Throttle Body
Positive Crankcase Ventilation (PCV) Valve
Crankcase Ventilation Hose
Crankcase Ventilation Hose
344981
Engine Controls Schematic Icons

Icon
Icon Definition
Refer to ESD Notice in Cautions and Notices.
19384
Refer to OBD II Symbol Description Notice in Cautions and Notices.
19385
Engine Controls Schematics (Power and Ground)
I Hot In RUN, BULB TEST And START j
iHot At All Times I

'"1 P-;;-w;D~bution- Schematics In
I Wiring Systems
L-------
- - - - ., Engine
PCM BAT
I Wiring
MlniFuse I Harness
1oA
I Junction
I
I
----J~~1
L -
H7
Ha
PCM IGN
MlnlFuse
1s A
-
I fh
~ - - - M~c;0 ; -
Power Distribution., Engine

Schematics In
I Wiring
Wiring Systems I Harness
r -
::s
I Junction
Block 2
L-
AB
0.50RN 340
0.5 PNK/BLK
439
C101
I>
::I
~ Instrument
Cluster
(I)
Indicator
;+' Lamp (MIL)
(SERVICE
I ~" ~
ENGINE SOON) I ~
I
I
(C
------.1
0.35 BRN/WHT 419
0.50RN 340
$106---------.
0.5 PNK 439
0.50RN 340
0.50RN 340
0.35 BRN/WHT 419
57
r - - - - - - I
I
ea11';;'ry- -
20
46 C2
19 C1
- - - - - ~ 11';ry- - - - - - - 79 .io';;" - - - - - - - - - - - - - - - - - - - - Mil - -
Positive
Voltage
Positive
Voltage
Positive
Voltage
Control
I
~ _ _ _ _ _ _ _ _ _ _ _ _ Ground _ _ _ _ _ _ Ground _ _ _ _ _ _ Ground _ _ _ _ Ground _ _ _ _ _ _ _
------------40
C2
---------40
C1
"7>c~ - ., Powertrain
I Control
I Module
C1 = BLU
C2=RED
~~
>
. __________ ~
::s
::s
(I)
(C
0.8 BLK 451
0.8 BLK 451
Ground Distribution
/
Schematics Iii
11>---J
Wiring Systems
0.8 BLK 451
0.8 BLK 451
0
0
::s
S110
'0"'
ur
CJ1
3BLK 451
=...i
O')
I
-=- G110
..a.
(,.)
487998
c.o
a,
Engine Controls Schematics (Data link Connector)
.,,!.
I
I
Power Distribution
Schematics in
Wiring Systems
03
C3
I
I
CIG/ACCY
Fuse 11
25A
.,
IP
J
__________ .
r -
I Fuse
I
I
I Block
I
1
,.
.. _________ ----.!
C4
PCM
C1=BLU
7V
C2=RED
Serial Data
(Class II)
C1
0.35 DK GRN 1049
+- - - - - - -
-a Powertrain
I
I
I
Contro
I Module
(PCM)
1
A
58
1 ORN 540
Power Distribution
Schematics in
Wiring Systems
8240
[Hot At All Timesl
r -
!Loe I
rSJ
c
~
~
P110
m
::I
(Cl
::I
(I)
:::s
" 'I
en
(11
K C230
1 ORN 540
(.,)
(,.)
0.35 DK GR; 1049

r - - -
P110
- -: - -
"'
C220
Splice
Pack
SP200
0.8 BLK/WHT 451
0.8 BLK/WHT 451

$11
Data Link
Connector
I Schematics ._ - . I
I inWiring
I
I.. _
Systems
_ _ _ _ _ _ JI
Ground Distribution
Schematics in
Wiring Systems
!>--------
0.35 PPL 1132

$215
.,._ - - ~;
0.5
BLK/
I
WHT 451
1
I
3BLK
$216---6-5_0_ _ _ 8217
3 BLK 451
3 BLK 650
0.8 BLK 650

4
G110
G200
16
Data Link
Connector
(PLC)
:::s
-
:::,
487999
(I)
__
Engine Controls Schematics (Ignition Modules/Coils, Bank 1)
::::,
!L c I
I Hot wnn lgnmon Relay energized I

~ Pow";r - ~~-- - - - "'Engine Wiring
Distribution
I Schematics
I In Wiring
JS.
JS
INJ 1
: Harness
MinlFuse
Block 2
15 A
I
---------J
...
_systems
0.8 PNKIWHT 639
1.
Ignition
Control
1
Ignition
Control
3
26 ' - - - - - - - - - - - - - - -
Power
Distribution
Schematics
In Wiring
Systems
.- - - - - - - - - - - - - - -
IJ
0.8 PNK 639
Junction
... - - - - - - - - - - - - - - - - - - - - - - - - - I
I
A, C100
Reference
Low
69 , --- - --- -- -- -- --. . - - -60
Ignition
Control
5
- - - - - - - -
68"' - - - - - - - - - - - - - 27
0.8
DKGRN 2125
+ ~s102
0.8 PPL 2121
0.5 PNK 639
0.8 LT BLU 2123
TC2
n~
>
_ _ ., ~"~
,..___ _..;.._ _~
0.8 BAN 2129
J
(I)
[S]c
1"'1 Powertra,
IC1=BLU I I Control
C2=REDI I Module
Ignition
,
1(PCM)
Control
_
-
.-PCM
cc
0.8 RED 2127
H, ------- -----~~ _ --------------~,,--------------------~-- ----------~ ~--- .- ___________________ B,,C106
S122./,--------"'l'---------.Jl'-----------.ll'---~
""'-~----------'I'--------,
D'
Ignition
Feed
r
[]
Ignition Reference Ignition

Control Low
Coil/
Signal
Module
____, 1
Ground
..._,..__
A
Spark
Plug
.--------...,,/ 8123
Bi
..-lg-nlt-lo-n--lg_n_iti_on--R-ef-er-en_ce....,,
Feed
Control
Signal
rn~
Low
1.----:-~-ou_n_d_ _ ___,
8126
B
Ignition
Coil/
Module
D,
C,
.-R-e-fe-re_n_ce-lg_n_iti_o-n--lg...
ni-tio_n__,
Low
Feed
rn~
Control
Signal
1----:--o_un_d_ _ ___,
Ignition
Coil/
Module
D'
Reference
Low
rn~r.:
Ignition
Feed
C,
Ignition
Control
Signal
1.----:-r-ou_n_d_ _ _....,
Ignition
Coil/
Module
::::,
cc
-::::,
(I)
0
::::,
' "'(
A C106
en
Ground
,i
0.8 BLK 550

o. 8 BLK
Distribution
8100 - - - - - - - - - - - Schematics
550
In Wiring
3 BLK 550
.kG112
(11
:....
Systems
3BLK
450
r-
0,
.....
I
488001
w
w
.....
Engine Controls Schematics (Ignition Modules/Coils, Bank 2)
0,
I
...I,
IHot With Ignition Relay Energized I

~
Po;;r - - -
01str1butlon
1 Schematics
I In Wiring
- - - - "Engine Wiring
J11
J10
INJ .2
,,.. : Harness
MiniFuse""' Block 2
15 A
I
~ ~s~'n_: - - - - - - - ~
Power
0.8PNK 839
Distribution
Schematics
In Wiring
Systems
Junction
~- - - - - - - - - - - - - - - - - - - - - - - - -
0.8 PNK 839

A , C101
'
Ignition
Control
6;'
lgnit.lon
Control
-----.----------2i
----------------
- - - - - - - - - - - - - - - - -, - PCM-
1g;:=~~ 1: Module
:
1
I
I~ ~~~:~ral l~cl
!Loe
.
Reference,L _ '::
_L~~-61
Ignition
Control
n~
r-o--.-8-----2i' -------------;e,C2
[B
J~
-o 8109
LT BLU/WHT 2126
0.8 RED/WHT 2122
I\)
:::,
cc
:::,
CD
:::,
" "I
0
U)
(11
:....
r-
0.8 DK GRN/WHT 2124
0.5 PNK 839
CA>
1 (PCM)
1 ,6
lg. nltion
Control
(A)
0.8 PPL/WHT 2128

G C107
0.8 BRN/WHT 2130
E
--------
-------------- ,----------------- ~------------
,----------- ,--------------------------
8124:(-------------~~---------------'~------------------~,......----,
D
Ignition
Feed
rn~;k
c
Ignition
Control
Signal
D,
Reference
Low
r----:-r_ou_n_d_ _ ___.
Ignition
Coil/
Module
~----------...// 8125
C,
B}
,-1-gn-lt-lo-n--lg-n-iti-on--R-ef-er-en_c_,,e Ignition
Feed
Control Low
Coil/
Signal
Module
r----:-r-ou_nd
_____
rn~.:k
'"R-e-fe-re-n-ce-1-gn-itl-.o-n--,g-ni-tio_n_,, Ignition
Low
Feed
Control
Coil/
Signal
Module
L----:-r-ou_n_d_ _ ___.
rn ~~
Reference Ignition
Low
Feed
c
Ignition
Control
Signal
Ground
.________A
__________.
rn~i:k
Ignition
Coil/
Module
8
8127
I"-......_______________-,---------------------------~
A
C107
'
0.8 BLK 550

0. 8 BLK
8100e----------550
3 BLK 550
3BLK
<3112
Ground
Distribution
Schematics
In Wiring
Systems
450
:::,
cc
488oos
CD
'~--/
Engine Controls Schematics (Camshaft Position Sensor, Crankshaft Position Sensor, and Knock Sensors)
r -
-: -
.,
Crankshaft
Position
(CKP)
Sensor
Electronic
I ~;:; I Brake Control

I Input
I Module (EBCM)
~
L.---J
11
!Loe I
Camshaft
Position
(CMP)
Sensor
Hall Sensor
Trigger Circuit
Amplifier And
Voltage Reg
Electronics
A
G
C105
C1)
[B
0.35
0.35 DK BLU/WHT 1869
LT GRN 1867
Gnd
0.35
YELi 1868
0.35 WHT 121
:::s
~
~
0.35 WHT 121

w/Tractlon
Control
::I
(Q
BLK
0.35 PNK/BLK 632
0.35 RED 631
0.35 BRN/WHT 633
.
I
I
10
C2
Engine
Speed
Output
21
12
CKP Sensor
Signal Input
2
Reference
Low
-------r.-----------.- - - - - - - - - - - - - - - - ,
73 C1
61
Reference
Low
I
:
I
I
c.MP Sensor
Signal Input
39
C2
12V
Powertram
IC
Ignition
I
Feed
:~~
I
PCM
C1=BLU
C2=RED
L. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
KS
KS
I
Signal
Signal
I
Front _ _ _ _ _ _ _ Rear _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J
0.35 51
ontrol
Module
~a.
::I
(Q
r---------
::I
~ ~~-1-11c1
DK BLU 496
C1)
LT BLU 1876
::I
" "I
Ar-------------~1
rn
-:::-
Front
Knock
Sensor
(KS)
rn
...
'iii
u,
:....
r
Rear
Knock
Sensor
(KS)
en
I
"="
..I,
488005
w
CA>
w
Engine Controls Schematics (BCM and Fuel Pump)
0)
......
I
IL0 c
!Esc!
1.----~-------.1
1 ORN 1340
...
~
~
~
---- __ .,
____
::::,
(Q
::::,
C1)
::::,
" 'I
in
0,
r-
AB
88
w
w
.r::i,
1 GRY 120
0.35 BLK/WHT 451
i=o
C200A
AB
..Theft- - " Body
I
I
Deterrent
Control
I
Fuel Enable : Module
~s~n~
DB
/.
1 GRY
- ., (BCM)
C101
20
0.35 BLK/WHT 451
C3
Fuel Pump
0.35 DK BLU 229
$110
0.35 DK GRN/WHT 465
----,
l
C230
Ground
Distribution
Schematics
D C101
In Wiring
P110
Systems
0.35 DK BLU 229
0.35 DK GRN/WHT 465
9 C2
30
,. -
I
I
I
- Theft Deterrent
Fuel
Enable
~---
3 BLK 451
PCM
C1=BLU
02 =RED
- Fuel
Pump
Relay
Control
Powertrain
I Control
- .,
I Module
I {PCM)
-----------------------------~~~
G110
=s
(Q
::::,
488006
C1)
Engine Controls Schematics (Fuel Tank Unit)
::,
!L c I
5244
Fuel
Pump
Relay
.--~~~~~ID-~~~~~~~~~~~~~~
0.35 GAY 720
0.35 GRY 720
[S]c
F3
G3
C405B
Fr-~~~~~-~,~~~
:05A
[B
1 GAY 120
83
1 GA~r1~~- - - - - - - - - - - -
,..----------I
I
I
I
I
...
Fuel
Pump
----I
[E
C
~~~ ~~~130
. - - - - - .,Fuel
I
FuelTank
Tank
I
Pressure
Unit
I
I
I
Sensor
..
,_C..... - - - - - - - - A- _,_ - - - - - - - -- - ...I
1 BLK 150
C
. .
..
0.35GAY 720
0.5 DK GAN 890

0.5 GAY/BLK 416
HC405A
1B: 10~------:~ ~;1=-~::
58
~:1~i~ D~~:;I: ----------~
:::J
C230
CQ
:::J
P110
46
54 C2
Ci
: ~u:11-v- -- -5: -u; ---~~~

G305
I
I
Feed
0
::,
0.35 GAY 720
0.35 GRY 474
Level
I
nput
(I)
0.35 DK GRN 890
0.35 PPL 1589
Ground
Distribution
Schematics
In Wiring
Systems
s
(I)
0.5 BLK/WHT 651
ca
1--~=--- -r- --:
64 C2
23
C1 = BLU
C2=RED
G
d
roun
'ii'
c.n
'1
C1
6M~~d:~Irain
F~el-
Pressure
" "I
O U
I""'
I (PCM) A
I
lfl!!i>
.. __________________ .:_ ___ . . ; ______-___ ..
O')
I
......
(;.)
(;.)
488008
c.n
!Loe I
en
.....I
w
w
en
[SJc
cc
Engine Controls Schematics (Fuel Injectors)
!Hot With Ignition Relay Energized I

'" - - - - - - - I Power Distribution
I Schematics In
I Wiring Systems
I
....
J11
J
10
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Engine
I
Wiring
INJ 2
Mini Fuse
15 A
J9
JS
I Harness
I Junction
I Block 2
INJ 1
Mini Fuse
15 A
________ -----------------------------------~
B
C101
0.5 PNK 839
: rFUel
I :~jector
....
B
....
Power Distribution
Schematics In
Wiring Systems
0.5PNK
839
0.5 PNK 839
C100
0.8 PNK 639
0.8 PNK 839

Power Distribution
Schematics In
Wiring Systems
0.5 PNK 839
0.5 PNK 839
0.5,PNK 639
0.5PNK
639
0.5 PNK 639
0.5 PNK 639
.. - "'Fuel
0.5 LT
GRN/BLK 1745
~jector
~jector
~jector
0.5
YEL/BLK 846
0.5LT
BLU/BLK 844
....
B
~jector
....
....
B
....
0.5 BLK 1744
....
B
....
0.5
BLKJWHT 845
0.5
PNK/BLK 1746
0.5DK
BLU/WHT 878
::,
CD
(')
0
::,
-..:
en
U'1
:._.
0.5 PNK 639
: JI 'F:Uel !]11 i\"~ctor lrFu,;

lrFuOI
llj
Ij
lrFUel
Ij
T]11~~
A
~
~
0.8 PNK/WHT 639
0.8 PNK 839
m
::,
uel
:]I 'F:~jector
....
B
....
0.5
RED/BLK 877
44
37
77
36
3
76
43 C1
4
.. - - - - - - - - - - - -1- - - - - - - - - - - - - - - - - - - - - -- - - - - - - - ----------- - - - - - - ------------ - - - - - - - - - - ., Powertram
I
:
I
:
-i=
Fuel
Injector 2
Driver
-l
=
Fuel
Injector 4
Driver
---1=
Fuel
Injector 6
Driver
1=
Fuel
Injector 8
Driver
---1=
Fuel
Injector 1
Driver
--1=
Fuel
Injector 3
driver
-l=
Fuel
Injector 5
Driver
I Control
---1=
Fuel
Injector 7
Driver
:Module
(PCM)
PCM
C1=BLU
C2=RED
I ,/.
: ~
1...-------------------------------~~-----------------------------~
:::s
cc
::,
488010
(I)
Engine Controls Schematics (Engine Sensors)
.-----I Power
I
I
I...
Distribution J7
Schematics,
lnWiring
J6
Systems
____ _
~p-
I Sensor
~ ~g~I-
5V
_ R,:te:n: _
31 C2
0.35 YEL 492
0.8 PNK 539

B C105
5V
_ _ _ _ _ _ _ _ _ _ _ !e~e.!:,ce_
Sensor
_ _ _ _ _ _ S~n~ _
48
C1
251C2
Power
Distribution
Schematics
In Wiring:'
Systems
Antilock
Brakes
Schematics
0.35 GAY 416
Ignition
Power
Mass Air
MAF
Sensor
Signal
Flow (MAF)
rn
A
Sensor
Intake
In Brakes
Air
Temperature
(IAT)
Sensor
0.35PPL 719
0.35 PPL
8128
- , 719
Ground
0.35
OAN/BLK 407
32 C2
~
3 BLK 451
I
I
I
G110
MAP -
54 C1
-
Sensor
Signal
cc
:l
(D
rsJ
c
~
~
,6.,
!. !. ~~
.__. 1~:_-_-_-_-_-:_-_
.
..
C
0.35 BLK
452
Anti lock
Brakes
Schematics
In Brakes
:l
cc
0.35
DK BLU 417
0.35 PPL 719
57
1-----1- -
24 C2
---------------'
Sensor
Ground
:l
(I)
0.35 BLK 452
I.~ - - - - - - - -1.- -~
MAP
Sensor
:Ground
(fP)
B
0.35 BlK 452
0.35
DK BLU 417
0.35 DK BLU
5118
417
S119
0.35 LT GRN 432
5110
0.35 GAY 596
Manifold
'
Ground
Distribution
-<Ill Schematics
In Wiring
Systems
(PCM)
!Loe I
A/C
Refrigerant
Pressure
Sensor
Absolute
...____________. Pressure
(MAP)
8
A
Sensor
0.35 BLK/WHT 451
0.35 GAY
8116
596
I' r:f'
I
_ _____
8 ~C1
0.35 GAY 596
0.35 TAN 472
0.8 PNKf539
8104
- - __.
0.8 PNK 539
~:~frin
r:A~ -Jsv- -J-5V ------,:-J-5V -----------~~:o~I5V ------:
- - - - .,Engine
ENG SEN I Wiring
MiniFuse I Harness
20
A
: Junction
____ ... Block 2
:l
TP
Sensor
Signal
60 C1
' ""I
'
Sensor
Ground
~
:l
PCM -
c1 = BLU
02
_RED
-
~ Powertram
Control
I Module
I (PCM)
in
c.n
:....i
r-
I~
~----------------------------------------------..1~
en
I
..I,
(,.)
(,.)
488011
.......
Engine Controls Schematics (Oxygen Sensors)
O')
.....
I
IHot With lgn 1 Energized I

'" - - - - - - -
IL 0 c
- - - - , Engine
ENG SEN I Wiring
Fuse 10
I Harness
20
A
: Junction
_ ___ ., Block 2
I :~:~~::~on
I Wiring Systems
,. _ _ _ _ _ _ _
0.8 PNK 539
B
C105
0.8 PNK 539
Power Distribution
Schematics In
Wiring Systems
'"
,.
Bank #1
Left Front
69
-----
H02S
Low
PPL/WHT
1665
0.8
PNK 539
TAN/WHT 1653
0.8
BLK 450
H02S
High
H02S
Low
H02S
Low
H02S
High
0.8
0.8
0.8
PNK 539
TAN/WHT 1669
Bank1
Left Front
Heated Oxygen
Sensor (H02S) 1
PPL/WHT
Bank1
Left Rear
Heated Oxygen
Sensor (H02S) 2
0.8
BLK 450
0.8
TAN 1667
1668
[B
::s
ui'
I
c.n
~
- , Powertrain
I
I Control
I Module
H02S
.,I (PCM)
High
Bank #2
Right Rear
H02S
Low
Bank2
Right Front
Heated Oxygen
Sensor (H02S) 1
C1
0.8
PPL 1666
0.8
0.8
0.8
PCM
C1 = BLU
C2-RED
-
-29 - - - - - - - - - - - - - - 68 - - - - - -28 - - - - - - - -26 - - - - - -66 - - - - - - - - - - - - - - - - - - 25 - - - - - -65
0.8
- -
Bank #2
Right Front
_____________________________________ ------- _______

H02S
High
::s
c.c
::s
(D
Bank #1
Left Rear
~c
~
S104
I
I
w
w
co
PNK 539
D
0.8
BLK 450
TAN 1671
0.8
0.8
PPL 1670 PNK 539
Bank2
Right Rear
Heated Oxygen
Sensor (H02S) 2
c
0.8
BLK 450
Ground Distribu1ion
Schematics In
Wiring Systems
;;
c.c
488014
(D
-__-/
m
::,
Engine Controls Schematics (AIR Pump and IAC)
IL 0 c
1 ORN 1440
3 ORN 1440
3 ORN 1440
r -
Fa - - - - es
Pump
Relay
Wiring
I Harness
I Junction
I Block2
F8
:1.---
___ .,
0.35 BRN 436
C105
Secondary
A.ir Injection
[ ] (AIR) Bypass
Valve
B
ea
0.35 PNK/BLK 429
3RED 78
A
Secondary
Air
I
I
I
"
0;35 LT
BLU/BLK 1748
0.35 LT
BLU/WHT 1747
A"
0.35 LT
GRN/WHT 1749
0.35 LT
GRN/BLK 444
C101
t~-----
---T
:~lenoid
Relay
Control
78
:;pass
"---T Valve
Control
A
High
, ______ ??J
Low
:1 B
Low
76
:1 B
High
PCM
::,
cc
rt.
I C~~:oratn
I Module
I (PCM)
C1 =BLU I
::,
C'D
0
::,
J.
- ,:
ii'
Ground Distribution
---cl Schematics In
Wiring Syste111s
3 BLK 150
CD
[B
~-----------------------------------~~~~~
3 BLK 150
_
Coil
4 - -- - ---- - - - - __ ?9 '----------------~ c2
r--------------------------------------,p
1
1
~~I
~~I
0.35 B:
Injection
(AIR)
Pump
8113
J .
J
1OR:11440
- - - ,I Engine
--------AIR
85
II
Coil
A
::I
~c
~
Idle Air
Control
(IAC)
Valve
Stepper
Motor
(Q
c.n
:..,.
r
'f
r,-----.J
0)
G106
I
...I,
CA)
488016
(.0
en
I
Engine Ctlntrols Schematics (BCM, Cruise Control Module, EBCM, IPC, Radio, and VSS)
r;i
~
1
I
res - ~ Elec.tronic
Brake
Spark
Retard
Control
.. !il!1a1_ ...I Module J;

19
C1 (EBCM) ~
I Export I
IChevrolet !
r- I
I
r" ,cruise
I vss I Control J;
I input I Module~
.I
L, -
L, -
16
,Radio
I
I
r- - , Instrument
I vss I Cluster
11nput I J;
.I
I. -
cs
88
.I
4,.~
r- I
I
L, -
C6
, Body
I Control
I Module J;
..1 (BCM) ~
CS
P100
0.35 GRY/BLK 1687
K C101
0.35 DK GRN/WHT
0.35
DKGRN/ 817
WHT
0.35 DK GRN/WHT 817
0.35. DK GRN/WHT 817
IL 0 c
loEsc!
~
~
~
0.35 DK GRN/WHT 817
.;.a.
(,,)
.i::.
0
m
::::,
ca
::::,
CD
::::,
' "'I
in
(11
:...
....
S242
0.35 DK GRN/WHT 817
C220
~I
-------A
'
Vehicle Speed
- ~ - Sensor (VSS)
P110
B
0.35 DK GRN/WHT 817
0.35 PPL/WHT 821
0.35
LTGRN/ 822
BLK
0.35 GRY/BLK 1687

53
r -
I
I
I
TCS Spark Retard

Signal
C2
50
vss - - - - Output
.- -
PCM
C1=BLU
C2=RED
21
20 C2
vss - - . - vss . - - - , Powertra1n
High
Low
I Control .A
I Module fl/I#
I (PCM) ~
L----------------------------------..1
m
::::s
ca
::::s
488019
CD
Engine Co.ntrols Schematics (EGR and EVAP) ..
!L0c I
l Hot With lgn 1 Relay Energized I

" - - - - - I Power Distribution
Schematics In
: Wiring Systems
- -
1.. _ _ _ _ _ _ _ _
- - - - "Engine
I
ENG CTRL I Wiring
MlniFuse Harness
1
1s A
Junction
_ ___ ..,I Block 2
Power
Distribution
In Wiring
Systems
,.
B
Evaporative
Emission
[ ] (EVAP)
Canister
B
Purge
Valve
I.
Valve
Vei;it
Valve
0.35
BAN 1456
0.35BLK 407
0.35
B C405D
0.35
RED 1676
GAY 416
B2IC405B
0.5 WHT 1310
C
(EGA)
0.35 WHT 1310
0.35 DK GRN/WHT . 4.28
0;35GRY 435
C230
:::s
cc
0.5 WHT 1310
(I)
P110
r- ----~a:.: )------~~~fie:i;- -----~~:o~ l

i
34
I
I
I
I
I
Purge
Valve
Control
~
PCM
C1 = BLU
C2 = RED
45 C2
Vent
Valve
Control
~
(I)
ExtiaUSt Gas
Rec.irculation
II
[ ] Emission
Evapor.a.tive
(EVAP)
Canister
. B
5'
~c
~
~
~
P100
0.5 PNK 239
8182 ___o_._5_P_N_K_ _11111--~
239
0.5PNK 239
02 C200B
C200D
G C100
0.5 PNK 239
0.5 PNK 239
A2 C405B
0.5 PNK'
8107
AI C405D
239
0.SPN: 239
0.35 PN: 239
IAutomatic I
:::s
cc
41
-t]5V
- -
Ground -
C1
- - - - - _,_ - - - - -41-
C2
~~~
Ground

5V
Reference
-..
-f- -;-J-1;--- -i --:
55
47
0
0.
:::s
~
EGA PinUe
Position
Signal
EGA Valve
Control
" 'I
in
~~~:~rain
Module
I (PCM)
I A..
?1
.......
r
.....
I ~
en
I
~----------------------------------------------------"'
..a.
c,.)
.i::,.
488020
..a.
En,gine Controls Schematics (Cruise Control Module, ECT Sensor, Engine Oil Level Switch and Generator)
!Loe I
[SJ
[I]
Engine Coolant
Temperature (ECT)
Sensor
'" - , Generator
I Tum I
On
l 1nput I
.. -
.I
A
0.35 BLK 407
0.35 RED 225
~
~
~ - - - - -112v - - - -
A
Engine
Oil
Level
Switch
0.35 BLKIWHT 451

.,..... __
8110
I
I
I
I
~~~el
Switch
:::s
ca
:::s
(D
:::s
" "I
'en
r
-r----------
80
llv ---
C1
15
ECT
Sensor
Ground .,,.
PCM
C1 =BLU
I
C2=RED
L.;,;.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
I
Input
ECT
Sensor
Signal
.i::,;
:......
0.35 BRN 1174

74
c.n
0.35 YEL 410
70
0,
Cruise
Control
Inhibit
_!ll!!!,la!_
C2
Generator - - - ~ Powertrain
Terminal
Control
I Module
L Output
I (PCM)
I
Cruise
I J,,
Control
I~
Enable
I
____ ~IQ_!!.al_ _ _ _ _.
37 [ - - -
-~-~~
~:!1:2
0.35 DK GRN 83
3 BLK 451
.,,. G110
0.35 DK GR:
F C105
F--~.~~:1
85
Cruise
-,--Control
Cruise
Module
-=- Engaged
__
1g_n__________1g_n_________ ,~~
488021
:::s
ca
:::s
(D
',.,,._...-/'
Engine Contr()ls Schem~tics (Cr:uise Control Clutch Switch and Manual Transmi!;sion)
----.,
1t--
D
r -
I
I
I
Clutch
An~lclpate
SWitch
Cruise
I Control
I (Clutch)
I Switch
r----l
Power
I
I
I...
Distribution
Schematics
lnWlring
Systems
____ _
.. -- - -..!
c
:i
!Loe I
- - - - ., Engine
ENG SEN I Wiring
MiniFuse . I Harness
20
A
._
: Junction
_..;.. __ .:.Block2
0.8 PNK 539
[B
B C105
0.8 PNK 539

A
-------------~
C270
0.35 BLK/WHT,, 451

r -
. -
0.35 GRY 48
$215
0.8 BLK/WHT 451
Power
Distribution
Schematics
In Wiring
Systems
8104
+- - - - - - - - - - - - - -...
0.8 PNK 539
:
8
C220
0.8 PNK 539
[E
.. ~.{ - ;:: - - - - - - - - - A - - - - .,I Manual

I
. E
s
C'D
[SJc
0.35 GAY 48
0.35 BLK/WHT 451 -
ca
~
II
Reverse
Inhibit
Sol~noid
Skip
Shift
Solenoid
Tran~mission
.. _ ----------- ----..!
0.8 BLK/WHT 451
- - - - - . - - --- - -
P110
..
0.35 LT GAN 1652
0.35GAY 587
:i
ca
Ground
Distribution
Schematics ..._ _ _ _ _
In Wiring
Systems
:i
CD
0.35 GAY 48
110
::::,
3 BLK 451
~
G110
32 C1
I
I
-c;ch - - - - - - - - - - - - - - - - - - - Switch
Signal
-=-
' "'I
Solenoid Control
-=-
79 C1
-;v;rs:"rn';;';b;;" - - - - -,-s;;i;- - - 1
---1
---1
44 C2
C1=BLU
~Powetrain
Control
I
, Module
I (PCM)
C2=RED
Solenoid control
PCM
-=-
u;
I
CTI
:....
1.-------------------------------------------.1~
0,
.....
I
488023
w
.,:.i.
w
0)
Engine Controls Schematics (Automatic Transmission and Stop Lamp Switch)
IHot With lgn 1 Relay Energized i

r -
ENG SEN
MlnlFuse
20 A
JS
I. -
Distribution
Schematics
In Wiring
-
Systems - -
Distribution
Schematics
In Wiring
- - - -
- - -
- -
- - -
GS
- - - - ENG CTRL
MlnlFuse
15 A
- -
G9
_systems - - -
!Loe
- - -
"I
- - - -
0.5 PNK 239

0.8 PNK 539
--~
8104
Power
Distribution
Schematics
In Wiring
Systems
.. - -
I~::i::;tt
o. 5 839
RED
7- ---"'
C2
: t--
1.
DIC2
Stop
:~~~h
.1
(Open with
C220
l:
II
- -
:::::s
(I)
:I
"0"'
'iii'
(11
239
0.5 RED 839
Torque
DillA] Torque
Converter
.converter
Clutch
Clutch Pulse
Solenoid
Width
- -
- -
- -
- -
- "'Automatic
Transmission
BI
0.5 RED 839
i;t~~i:SOL)
Valve
Solenoid
(3 -2 SS)
Valve
AI
Assembly
II
II
Solenoid
(2-3 SS)
Valve
BI
Solenoid
(1-2 SS)
Valve
81
-O~T~Nu 4:-----------s
___ ~-~w:T 68:--------__ :5.:e~13 :2~--------A- 1~ __ _
:~L:.G~
- - - - - - - -
C1
o.5
0.5
TAN/BLK 422
10
TCC/CrulseBrake _ _ _ _ _ _ _ _ _ _ _ _ _ _
Switch
Input
PCM
0.5 RED 839
Dills 3-2Shift DillA 2-3Shift DillA 1-2Shift
0.58
~~~SOL)
BLK 422
T
08
_ P~
~
cc
0.5PNK
0.5 PNK 239

E C1
- - - - - o.5 RED 839
0.5 RED 839
~ _____
~:~r:~s~d~I
0.8 PPL 420
- - - -
:::::s
C220
0.8 PNK 539

r
.i::,.
.i::,.
:.....
r
$107
P110
C100
0.5 PNK 239
0.8PNK 539
~
~
~
Power
Distribution
Schematics
In Wiring
Systems
239
E;J
- .. Block2
0.5PNK
8182
C105
Engine
I Wiring
I Harness
I Junction
0.5 PNK 239
0.8 PNK 539

B
IHot With lgn 1 Relay Energized I
- - - - - - - Po~r- - - - - - - - - - - - - - - - P-;w;;;: - - - - J7
.....
42
___
0.5 WHT
-o~~
~R; : :
79
687
c,
LT GRN 1222
~~us;
TCCSOL - - TCCPWMSOL---3-2SS - - - Valve

Valve
Valve Assembly
Control
Control
Control
1~3 ____
C2
2:...3ss----1-2ss
Valve
Valve
Control
Control
~Powertram
Control
I Module
:. ___________________________________________________
g:~~~
.:
(PCM)
J.
~
::;J
cc
:I
488026
(I)
.. Engine Controls Schematics (Automatic Transmission and Park/Neutral Position Switch)
r--------------------------------,p~~~
Control
1
I
I
I
,.
Transmission
Range A
Input __
63
Transmission
Transmission
Range B
Range C
. _ _ _ _ Input :-_ ':" _-::. _-:. :-_ Input _ _ _ _ _ _ _
C2
17
0.5 PNK 1224
0.5 DK BLU 1225
N
I"
0.5P~Kr224 -
18
. 1 -~
0.50~Nr226 -
C2
0.5Bfl1227 -
r--.,---------....,....------,,,--------.,.,---,
REV
03
Switch
--- Switch
LO
Switch
02
--- Switch
04
Switch
Automatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch
Transmission
Fluid
Temperature
(TFT)
Sensor
rm
~
I 0.5
I ORN/ 434
Pressure
Control Solenoid
Ic:==J= I
I
I
BLK
(PC SOL.) Valve
:::s
(I)
B
.- - / - - - - .,Park/
I
I Neutral
IP
1 I Position
2 /' I Switch
I ~
R ,
11
Automatic
Transmission
Ci
[SJc
~
~
0.5 ORN/BLK 434

0.5 ORN/BLK
8234
434
0.5 YEL/BLK 1227
_____________ ~
IL 0 c
Auto Trans
Shift Lock
Control
Schematics in
Automatic
Transmission
(PCM)
TFT
Module
I
Sensor
~
1
Signal __
51
0.5 RED 1226
__________ ~
0.5DKB~UF!25 -
C1
1
I
::I
(.Q
I._
-,
N@ D.-"
- .. ..,... .a
I
I
_______ ...
A
0.35
BLK/WHT 451
0.5 LT BLU 1229
0.5 PPL 1228
8215
0.8 BLK/WHT 451
E C220
o.s G:v 452
---------------------------------------------..1
C
D
0.8 BLK/WHT 451
C1
C220
,..
I
Ground Distribution
Schematics In
Wiring Systems
::I
--------
0.5
0.5 BLK 407
(C
PiiO
:I
______ J
Cl)
RED/BLK 1228
0.5 LT BLU/WHT 1229
0.5
ORN/BLK 434
::I
-c
53 C1
I" -
I
I
I
Sensor Ground
8
-
--------
PC SOL. - Valve Low
C2
- PC SOL. Valve High
34
-
en
C1
PNP - Switch
Signal
- - PCM
c1= BLU
C2=RED
.. Powertra1n
C1I
I Control
I Module (PCM)
I
:...i
....
1.--------------------------------..1~~
en
.....
I
Cio)
.,::,.
488028
UI
Engine Controls Schematics (A/C Compressor Control)
0,
I Hot In RUN Or START I

~
I
I
I
Power
Distribution
Schematics
In Wiring
Systems
-P:ie;-D;rlbutl; ~ E~Qine
Schematics In
Wmng
I
CRUISE Wiring Systems
Harness
MiniFuse
I Junction
15A
I
NC
G6
~
~
~
c
.. _ _
_ ________ ., Block 2
0.5 PNK 139
..,.. ___ .s"""1_;;,6s"'---_~

0.5 PNK 139 0.5 PNK 139
'" - 01; - - - - os
- - - , Engine
I Wiring
- - - - - - - NC
85
!Loe
- G7 - - -
COMP I Harness
Relay I Junction
:Block2
I
86
......
IN
.i:::,.
en
::::s
(.Q
::::s
(I)
::::s
"'II
ui
U1
~ - _cs_I_ 0.5
- - ~oi_ - - - ~
DKGRN 59
0.35 DK GRN/WHT 459
Br--- -- _q
1
C 00 0.5 DK GRN
S105
----~;~:-r- --------------f
59
0.35 DK GRN/WHT 459
0.5 DK GRN 59
43
~ =~~~
I C2=RED
Relay
\
Control1---
:
I
I
0.35 DK
GR:~~~*6~-------~-~~ -~~~!~~~1~:o
FI
P110
C230
0.35 DK GRN/WHT 762

A c2
~
;- ~HVAC
.. ___ .. Control
I
Request
$114
0.5 DKGRN 59
18 C2
NC Refrigerant
P~essure Sensor
Signal
A/C
Request
0.5 DKGRN
59
0.35
Sensor
Ground
G~~1~;4
B
<]
57
rI
Pressure
Sensor
0.35 PPL
719
8128
:
I
~M)
i .ocmpressor
[].
Intake
Air
J~~perature
0.5 BLK 450
- .,
Sensor
$108
A/C
Diode
Clutch
B
0.5 BLK 450
$115 - - - - - - - '
0.35 PPL 719
~7r,igerant
~~::~rain
I Module
I (PC
Clutch
Status
NC Refrigerant
Pressure Sensor
5V Reference
IT
~sv
~c- - - - - - - - - ~
__.,.
Ground
Distribution
Schematics
In Wiring
Systems
3BLK 450
gJ
G112
(.Q
::::s
488031
(I)
EngineControls Schematics (Cooling Fans)
...
-I
Hot At All Times
-------- ;;;w; - - - - - - - -
L1
COOL FAN
MaxiFuse
.40 A
K1
Distribution
Sch~~atics
In Wmng
Systems
J7
COOL
- - .,lw
Engine
FAN
MiniFuse
10 A
J6
mng
1Harness
Junction
L:iJ
b--------~-------------------..1~0~1
I
Power
Distribution
Schematics
In Wiring
Systems
0.35 ORN 1640
3 RED 3 RED 402

402
8169
3 RED 402
8179
0.35 ORN 1640
3WHT 504
3 RED 402
0.35 ORN 1640

0.35 ORN 1640
- - - - -
oo
~
.--....------..,,..-, Engine
I\1---Q 1::~:
Engine
Cooling
Fan
Relay #1
~.:. -trn:B~.1409 - - - - - - - - - c,
~ . Left
Engine
M
Cooling
42
3WHT 504
g-~5BLU 473
Ci
}~
33
~~~l~~ay1
. -
L -
PCM
150
C2
~:!~~lay -
; -
- -
6~~i~ram
I Module (PCM)
I ~
..I
3BLK 150
3 BLK
,!.
:J
CD
.f 2 and 3
Control
C1=BLU
C2=RED
(,Q
Fan
0.35 DK BLU 473
..,___ _ _ _ _ _ _ __.
:J
Cooling
C100
I ....f Control
I
_;
~Rig
~
Engine
3 GRY 532
0.35 DK GRN 335
iw
I mng
C100
Engine
iiS51:6~6~ :,~ - - - - - - - - - - -._-__-_-_-.......J'f'-____

- 3_-w_-_H_;__~67 -
'10
Fan
- ---=\ ~: i ~~Tn
0.35 DK BLU 473
0.35 DK GRN 335
- - - - ., Engine
Ground
Distribution
Schematics II>- in Wiring
Systems
:J
8113
..,
0
..,
fl)
3BLK 150
c.n
:...i
1 BLK
150
I"""
....
I
G106
(,.)
.i:::,.
488034
......
6-1348
Engine
Component locator
Engine Controls Components

Name
Location
A/C Clutch Diode
Sealed in a harness, approximately 17 cm

(6.8 in) from the A/C compressor clutch
connector

A/C Refrigerant
Pressure Sensor
Locator View
Connector End View

-
In the front of the engine, on the lower

right side

Engine Controls
Connector End Views
Above the right front wheelhouse, attached

to the refrigerant line

in HV AC with A/C Manual
Engine Controls
Connector End Views
Automatic Transmission Behind the engine
ABS Component Views in lnline Harness Connector
End View in Automatic
Transmission
Body Control
Module (BCM)

blower motor
Body Control Module

Component Views in
Body Control Module

Camshaft
Position (CMP) Sensor
Mounted in the top rear center of the

engine
Engine Controls
Component Views
Engine Controls
Connector End Views
Crankshaft
Position (CKP) Sensor
In the lower front of the engine
Engine Controls
Component Views
Engine Controls
Connector End Views
Cruise Control (Clutch)

Switch
Mounted in the clutch pedal bracket
Mounted to the left frame rail, forward of

the wheelhouse
Cruise Control
Component Views in
Cruise Control

End Views in Cruise
Control
Under the IP, right of the steering column
Data Link
Communications
Component Views in
Data Link
Communications
Data Link
Communications
Data Link
Communications

ABS Connector End

Views in Antilock Brake
System
Engine Controls
Component Views
Engine Controls
Connector End Views
Behind the radiator
Cooling System
Component Views in
Engine Cooling
Cooling System
Engine Cooling
On the lower right side of the engine, in

the oil pan
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Connector End Views

Junction Block 1

compartment
Power and Grounding

Component Views in
Wiring Systems

Junction Block 2

compartment
Power and Grounding

Component Views in
Wiring Systems
Data Link
Connector (DLC)
Electronic Brake Control Mounted with brake pressure modulator

Module (EBCM)
valve on the top of the left front frame rail
Engine Coolant
Temperature (ECT)
Sensor
Engine Cooling Fans
On the lower left side of the engine, above

the generator
Evaporative
Emission (EV AP)
Canister Purge
Solenoid Valve
On the left side of the engine, mounted to

the intake manifold
Evaporative
Emission (EVAP)
Canister Vent
Solenoid Valve
On the top right side of the engine, part of

the EV AP canister
Engine Controls
Component Views

End Views in Cruise
Control
Engine Controls
Connector End Views
(
Engine Controls
Component Views
Engine Controls
Connector End Views
Engine
6-1349

Name
location
Exhaust Gas
On the left rear of the engine, mounted to
Recirculation (EGR) Valve the intake manifold
Locator View
Connector End. View
Engine Controls
Component Views
Engine Controls
Connector End Views
Fuel Injectors
Mounted on the intake manifold, part of

the fuel rail
Engine Controls
Component Views
Engine Controls
Connectdr End Views
Fuel Tank Unit
Under the rear of the vehicle
Engine Controls
Component Views
Engine Controls
Connector End Views
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Electrica.l
Engine Electrical
Generator
On the front left side of the engine

Mounted in the left exhaust manifold
Bank 1, Sensor 1
Engine Controls
Component Views

At the rear of the left catalytic converter
Bank 1, Sensor 2
Engine Controls
Component Views
Engine Controls
Connector End Views

Mounted in the right exhaust manifold
Bank 2, Sensor 1
Engine Controls
Component Views
Engine Controls
Connector End Views

At the rear of the right catalytic converter
Bank 2, Sensor 2
Engine Controls
Component Views
Engine Controls
Connector End Views
HVAC Control
In the center of the IP, above the radio

HVAC Connector End

Views in HV AC with A/C
Manual
Idle Air
Control (IAC) Valve
On the right front of the engine, on the

throttle body
Engine Controls
Component Views
Engine Controls
Connector End Views
Ignition Coils/Modules
(Bank 1)
On the valve cover at the top of each

engine cylinder, on the left side of the
engine
Engine Controls
Component Views
Ignition Coils/Modules
(Bank 2)
On the valve cover at the top of each

engine cylinder,. on the right side of the
engine
Engine Controls
Component Views
Instrument Cluster
On the left side of the IP
Intake Air
Temperature (IAT)
Sensor

intake manifold
IP Fuse Block
On the left end of the IP carrier
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Instrument Panel,
Gauges, and Console
Instrument Panel,
Gauges and Console
Engine Controls
Component Views
Engine Controls
Connector End Views
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Knock Sensor, Front
On the center of the engine below the

intake manifold
Engine Controls
Component Views
Engine Controls
Connector End Views
Knock Sensor, Rear
On the center of the engine below the

intake manifold
Engine Controls
Component Views
Engine Controls
Connector End Views
Manifold Absolute
Mounted to the right side of the intake
Pressure (MAP) Sensor manifold
Engine Controls
Component Views
Engine Controls
Connector End Views
Manual Transmission
Behind the engine
Mass Air Flow (MAF)

Sensor

intake manifold
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Component Views
Engine Controls
Connector End Views
6-1350
Engine

Name
Location
Switch
Powertrain Control
Module.(PCM)
I

In the center of the IP, below the HVAC
control
Radio
Secondary Air
Injection (AIR) Pump
Connector End View
Shift Lock Control
Component Views in
Engine Controls
Connector End Views
Engine Controls
Component Views
PCM Connector
End Views
Entertainment
Component Views in
Entertainment
Entertainment Connector
End Views in
Entertainment
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
. Gauges and Console
Reverse Inhibit Solenoid On the rear left side of the transmission
Secondary Ai.r Injection

Bypass, Valve
Locator View
(
.
Mounted to the right front frame rail
Engine Controls
Connector End Views
On the front left frame rail, in the engine

compartment
Engine Controls
Connector End Views
On the center left side of the transmission
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Mounted on the brake pedal bracket
Cruise Control
Component .Views in
Cruise Control
Lighting Systems
Lighting Systems
Engine Controls
Component Views
Engine Controls
Connector End Views
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Connector End Views
On the rear left side of the transmission
Instrument Panel,
Gauges, and Console
Component Views in
Instrument Panel,
Gauges and Console
Engine Controls
Connector End Views
Splice Pack SP200
Under the left side of the IP, near the DLC
Lighting Systems
Component Views in
Lighting Systems
Data Link
Communications
Data Link
Communications
C100 (10 cavities)

wheelhouse

Wiring Systems

End Views in Wiring
Systems
C101 (10 cavities)

engine compartment, above .the right
wheelhouse

Wiring Systems

End Views in Wiring
Systems
C105 (8 cavities)

wheelhouse
Harness Routing Views. in

Wiring Systems

End Views in Wiring
Systems
C106 (7 cavities)
Engine to the engine jumper harness
C107 (7 cavities)
Engine to the engine jumper harness
Skip Shift Solenoid
Stop Lamp/TCC Switch

(Automatic)
Throttle Position (TP)
Sensor
(Automatic)
Vehicle SpEleq Sensor
C200A (17 cavities)
C2008 (18 cavities)
Mounted to the front of the throttle body
On the rear right side of the transmission

I
Forward lamp toJP harness, between the


End Views in Wiring
Wiring Systems
Systems


End Views in Wiring
Wiring Systems
Systems
Engine
6-1351

Name
Locator View
Connector End View


Wiring Systems

End Views in Wiring
Systems
C220 (10 cavities)
IP to engine harness, under the right .side


Wiring Systems

End Views in Wiring
Systems
C230 (10 cavities)


Wiring Systems

End Views in Wiring
Systems
C270 (2 cavities)
IP harness of the cruise control harness,

near the brake/clutch pedal bracket

Wiring Systems

End Views in Wiring
Systems

End Views in Wiring
Systems

Wiring Systems

End Views in Wiring
Systems

End Views in Wiring
Systems
C2000 (48 cavities)
C405A (7 cavities)
Location
Fuel tank harness to the IP. harness pass

C405B (16 cavities)
IP harness pass through connector,

forward of the rear axle
C4050 (4 cavities)

G106

support

Wiring Systems
G110

cylinder head

Wiring Systems
G112

cylinder head

Wiring Systems
G200
Near the left A-pillar, bolted to the IP

mounting stud behind the kick panel

Wiring Systems
G305
Bolted to the left rocker panel at the floor

pan bar

Wiring Systems
P100
Left side in the dash panel, engine to the


Wiring Systems
P110
Right side in the dash panel, engine to the


Wiring Systems
S100 (Automatic
Transmission)
8100 (Manual
Transmission)
In the engine harness, approximately

12 cm (4.7 in) from the automatic
transmission breakout
..
(2 in) from the vehicle speed sensor
breakout
8102

engine oil pressure sensor breakout
8104
in the engine harness, approximately

14 cm (5.5 in) from the powertrain control
module (PCM) breakout
8105
In the engine harness at the A/C

refrigerant pressure sensor breakout
8106
In the engine harness, main branch

8107

.-
S108 (Automatic
Transmission)

automatic transmission breakout
6,.;t352
Engine

Name
8108 (Manual
Transmission)
Locator View
Location
Connector End View

vehicle speed sensor breakout
8109

(3.2 in) from the fuel injector 4 breakout .
8110

8113
In the forward lamp harness approximately

7 cm (2.8 in) from the electronic throttle
module breakout
8114

17 cm (6.7 in) back from the A/C
compressor clutch breakout
8115

20 cm (7.9 in) back from the A/C
compressor clutch breakout
8H6'

(3.5 in) from the manifold absolute
pressure (MAP) sensor breakout
8118

15 cm (6 in) from the manifold absolute
8119 (Automatic
Transmission)

automatic transmission breakout
8119 (Manual
Transmission)

approximately 9 cm .(3.5 in) from the
vehic.le speed sensor breakout
'
'
"'
'
(
-
8122
In the engine jumper harness
8123
-.
8124
8125
8126
8127
8128

(1.8 in) from the manifold absolute
8165

8166

breakout
8167

electronic brake control module (EBCM)
breakout
8169
1.n the forward lamp harness,

8177

'
'
'
(
-
Engine
Engine Controls- 5.7L 6-1353

Name
Location
8179

25 cm (9.8 in) from the engine wiring
8182

8215

8216
In the. IP harness, main branch,

approximately 1O cm (4 in) from the
instrument cluster breakout
8217

approximately 18 cm (6.8 in) from the body
8234 (Automatic)
. In the IP harness, main branch,

approximately 5 cm (2 in) from the body
Locator View
Connector End View
'
'
8240
In the. IP harness, main branch,

8242

(1.6 in) from the data link connector (DLC) ..
breakout
8244 (Convertible)
In the IP harness, approximately 46 crri

(18 in) from C405
8244 (Coupe)

(15.8 in) back from C405
6-1354
Engine Controls;.. 5.7L
Engine
Engine Controls ComponehtViews

Full Engine View LH Side
7
426407
Legend
(1) EVAP Canister Purge Solenoid
(2)
(3)
(4)
(5)
(6)
(7)
Fuel Pulse Dampener

Fuel Rail With Injectors
PCV Crossover Hose
Left Bank Ignition Coils/Modules
Left Bank H02S Sensor 1 Mounting Flange
(8)
(9)
(10)
(11)
(12)
(13)
Fuel Pressure Gauge Test Connector

Idle Air Control (IAC)
Throttle Body
Right Bank Ignition Coils/Modules
Engine
Engine .Controls.- 5.7L 6.1.355

Idle Air Control (IAC) Motor, Throttle Position (TP) Sensor, Generator
1
)
218886
Legend
(1) Idle Air Control (IAC) Motor
(2) Throttle Position (TP) Sensor
(3) Generator
(4) ThrottleBody
6-1356
Engine
Engine Controls - 5. 7L
Mass Air Flow Sensor and Intake Air Temperature' Sensor
(
218744
Legend
(1) Mass Air Flow (MAF) Sensor
(2) Intake Air Temperature (IAT) Sensor
(3) Air Cleaner Housing
Engine
Engine Controls ,5.7L 6-1357
Manifold Absolute Pressure (MAP) Sensor, Camshaft Position (CMP) Sensor, Oil Pressure Switch
)
247435
Legend
(1) Manifold Absolute Pressure (MAP) sensor
(2) Camshaft Position (CMP) sensor
(3) Oil Pressure switch

(4) Connector to Knock sensor jumper harness
6-1358
Engine

Knock Sensors
(
198593
Legend
(1) Front Knock Sensor
(2) Rear Knock. Sensor
Engine
6-1359
AIR System
1
605146
Legend
(1)
(2)
(3)
(4)
AIR Shut Off Valve

Air supply hose from AIR Pump
AIR Solenoid Valve
Left Bank AIR Tube and Check Valve
(5) Air inlet hose to AIR pump

(7) Right Bank AIR Tube and Check Valve
6-1360
Engine
AIR Pump location
(
218771
Engine
6-1361
Air Cleaner Housing and Resonator
247788
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Air cleaner housing top cover

Seal
Air intake duct to resonator
Clamp
Air intake duct to top cover retainer
Intake Air Temperature (IAT) sensor
Clamp
Air intake resonator
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Air intake duct to throttle body

Mass Airflow (MAF) sensor
Isolator
Air cleaner housing lower assembly
Front retaining clips
Air filter element frame
Air filter element
6-1362- E11gine Control~ -
5. 7L
Engine
Air Cleaner location
(
218754
legend
Engine

Crankshaft Position Sensor Location
222858
Legend
(1) CKP Mounting Bolt
(2) CKP Mounting Location
(3) Crankshaft Position Sensor (CKP)
6-1364
Engine
H02S Location
(
218748
Legend
(1) H02S Bank 2 Sensor 1


Engine
6-1365
PCM. Location
421858
6-1366
Engine
Fuel Tank Assembly with EVAP Canister
(
421732
Legend
(1)
(2)
(3)
(4)
Fuel Sender Assembly

Hose (EVAP Canister to Vent Solenoid)
EVAP Vent Valve
Fuel Tank Harness
(5)
(6)
(7)
(8)
EVAP Canister
Fuel Tank
Overpressure Relief Valve
Engine
~ngine Controls"- 5.7L
6-1367
Fuse Blocks #1 and #2
245570
Legend
(1) Fuse Block #1
(2) Fuse Block ~2
6-1368
Engine
PCM Connector End Views

PCM Connector C1 (BLU)
r-,
r.
r,
[g}
60
~o 41'@@@@@@@@@@@@@@@@@@@@
@@@@@@@@@@@@@@@@@@@@.
D
1
20
r-,
61
80
@@@@@@@@@@@@@@@@@@@@
ID @@@@@@@@@@@@@@@@@@@@ C
21
40
1r
23346
Connector Part
Information
Pin
Wire Color
1
BLK
2
LTGRN
PNK/BLK
3
4
LT GRN/BLK
5-7
8
GRA
9~10
11
12
13-16
17
18
19
20
21
22
23
24
25
26
27
28
LT BLU
DK BLU/WHT
TAN/WHT
1669
H02S Signal Low Bank 1 Sensor 2
29
TAN/WHT
1653
30-31
32
33
34
35
DKBLU
RED
PNK
ORN
YEUBLK
GRA
TAN
TAN
-
GRY
PPL
ORN/BLK
-
48
420
434
-
TCC Brake Switch

PNP Switch Signal
Not Used
Injector 1 Control
BLK
1744
37
YEUBLK
846
Injector 6 Control
Not Used
Not Used
Clutch Pedal Position Switch Signal
36
38-39
PCM Connector C1 Assembly 12191489

TPA (BLU) 12176408
Connector Cover 12191108
.Function
Circuit No.
451
PCM Ground
1867
Crankshaft Position Sensor B+ Supply
1746
Injector 3 Control
1745
Injector 2 Control
Not Used
TP Sensor 5V Reference
596
Not Used
1876
Knock Sensor Signal Rear
Crankshaft Position Sensor Signal
1869
Not Used
1225
Transmission Range Signal B
1226
Transmission Range Signal C
439
Ignition Positive Voltage
340
Battery Positive Voltage
1868
Crankshaft Position Sensor Reference Low
Not Used
720
Fuel Tank Pressure Sensor/Fuel Tank Sender Ground
Not Used
1671
1667
Not Used
40
BLK
451
41
BLK
407
PCM Ground
EGR Pintle Position Sensor Ground
42
43
DKGRN
RED/BLK
335
877
Injector 7 Control
Engine Cooling Fan Relay 1 Control
Engine
6-1369
PCM Connector C1 (BLU) (cont'd)
r-.
.--,
r,
41
60
@@@@@@@@@@@@@@@@@@@@
, :::i @@@@@@@@@@@@@@@@@@@@
1
.
20
'
Ig}
ao
I ,.., I
~
la
cr
61
60
@@@@@@@@.@@@@@@@@@@@@
@@@@@@@@@@@@@@@@@@@@
21
40
23346
Connector Part
Information
Wire Color
Pin
LT BLU/BLK
44
GRA
45
GRA
46
GRA
47
GRA
48
49-50
DKBLU
51
52
BLK
53
ORN/BLK
54
BAN
55
56
ORN
57
DKGRN
58
59
BLK
60
61
PNK/BLK
62-64
PPL
65
PPL
66
67
PPUWHT
68
69
PPUWHT
BAN
70
71-72
BRN/WHT
73
YEL
74
75
BLKIWHT
76
77
DKBLU/WHT
78
GRA orWHT
79
BLK
80

TPA (BLU) 12176408
Function
Circuit No.
Injector 4 Control
844
A/C Refrigerant Pressure Sensor 5V Reference
474
Fuel Tank Pressure Sensor 5V Reference
474
EGA Pintle Position Sensor 5V Reference
416
MAP Sensor 5V Reference
416
Not Used
Knock Sensor Signal Front
496
Not Used
Transmission Temperature Sensor Ground
407
MAP Sensor Ground
407
EGR Pintle Position Sensor Signal
1456
Not Used
Battery Positive Voltage
340
Serial Data
1049
Not Used
TP Sensor Ground
452
Camshaft Position Sensor Reference Low
632
Not Used
H02S Signal High Bank 2 Sensor 2
1670
1666
Not Used
1668
1665
1174
Low Oil Level Switch
Not Used
Camshaft Position (CMP) Sensor Signal
633
Engine Coolant Temperature (ECT) Sensor Signal
410
Not Used
Injector 5 Control.
845
Injector 8 c.ontrol
878
Not Used
Skip Shift Solenoid Control (MIT) or 3-2 Shift Solenoid Control (A/T)
587 or 687
Engine Coolant Temperature (ECT) Sensor Ground
407
6-1370. Engine Controls - 5.7L
Engine
PCM Connector C2 (RED)
(
I
r-,
I ,-,
t
;
41
.
.
60
@@@@@@@@@@@@)@@@@@@@@
:J @@@@@@@@@@@@@@@@@@@@ D
'-..:
r,
[O}
0.
20
r,
61
BO
@@@@@@@@@@@@@@@@@@@@.
tJ @@@@@@@@@@@@@@@@@@@@ C
21
40
Connector Part
Information
Pin
Wire Color
1
BLK
2
BRN
3
4
PPL
5
6
RED/BLK
RED
7
8
LT BLU/WHT
9
DK GRN/WHT
10
23346
>
11-12
13
14
15
16
17
18
19
20
21
22-23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
WHT
WHT
RED/BLK
RED
DKGRN/WHT
DKGRN
LT GRN/BLK
PPLlWHT
DKBLU
TAN
PPL
RED
LT BLU/WHT
DKGRN/WHT
DKBLU
YEL
LTGRN
DKBLU
DKGRN/WHT
BRN
DKGRN

TPA (RED) 12176410
Circuit No.
451
PCM Ground
418
TCC Control Solenoid
421
1228
1676
1229
465
121
85
380
225
762
59
822
821
417
472
2121
2127
2126
2124
229
492
432
473
428
436
83
RED
631
Function
Not Used
...
AIR Solenoid Relay Control
Not Used
Transmission Fluid Pressure Control Solenoid High
EGR Control
Transmission Fluid Pressure Control Solenoid Low
Fuel Pump Relay Control
Engine Speed (Tach) Output Signal
Not Used
:
Cruise Control Enable Signal
A/C Refrigerant Pressure Sensor Signal ..
Alternator L Terminal
Not Used
A/C Request Signal
A/C Status Signal
Not Used
Vehicle Speed Sensor.(VSS) Reference Low
Vehicle Speed Sensor (VSS) Signal
Not Used
..
TP Sensor Signal
IAT Sensor Signal
Ignition Control 1
Ignition Control 7
Ignition Control 6
Ignition Control 4
VTD Fuel Enable Signal
MAF Sensor Signal
MAP Sensor Signal
Engine Cooling Fan Relay 2 and 3 Control
EVAP Canister Purge Valve Control
Not Used
AIR Pump Relay Control
Cruise Control Inhibit
Not Used
Camshaft Position Sensor B+ Supply
Engine
6-1371
PCM Connector C2 (RED) (cont'd)
I II
F
41
. . .
.
.
. .
60
@@@@@@@@@@()@@@@@@@@@
~ :::J @@@@@@@@@@@@@@@@@@@@ D
,
1
20
I9l
~r,
'
I .., I
.-, I
..
61
.
.
.
80
@@@@@@@@@@@@@@@@@@@@..
:J @@@@@@@@@@@@@@@@@@@@ C
21
40
'E
23346
Connector Part
Information.
Pin
Wire Color
Circuit No.
40
41
42
43
44
45
46
47
BLK
451
435
422
459
1652
1310
419
1223
1222
48

TPA (RED) 12176410
49
50
51
52
53
54
55-56
57
58-59
60
61
62
63
64
65
66
67
68
69
70-75
76
77
78
79
80
GRA
TAN/BLK
DKGRN/WHT
LTGRN
WHT
BRN/WHT
YEUBLK
LTGRN
DKGRN/WHT
YEUBLK
GRA/BLK
PPL
-
PPL
BRN
BRN/WHT
-
PNK
DKGRN
PPUWHT
RED/WHT
DKGRN
LT BLU
-
LT GRN/WHT
LT GRN/BLK
LT BLU/BLK
LT BLU/WHT
817
.. 1227
1687
1589
719
2129
2130
1224
890
2128
2122
2125
2123
1749
444
1748
1747
-
Function
PCM Ground
EGR Position Sensor Ground
TCC Enable Circuit
A/C Clutch Relay Control
Reverse Inhibit Solenoid Control
EVAP Canister Vent Valve Control
Malfunction Indicator Lamp (MIL} Control
Transmission Shift Solenoid B
Transmission Shift Solenoid A
Not Used
Vehicle Speed Output Circuit
Transmission Temperature Sensor Signal
Not Used
Spark Retard Signal
Fuel Level Sensor Signal
Not Used
IAT Sensor Ground
Not Used
Ignition Control Reference Low Bank 1
Ignition Control Reference Low Bank 2
Not Used
Transmission Range Signal A
Fuel Tank Pressure Sensor Signal
Not Used
Ignition Control 8
Ignition Control 2
Ignition Control 5
Ignition Control 3
Not Used
IAC Coil B High
IAC Coil B Low
IAC Coil A Low
IAC Coil A High
Not Used
6-1372
Engine
Engine Controls Connector End Views
62453
62440
Connector Part
Information
1216-2017
2 Way F Metri-Pack
Pin
150 Series (GRY)
Pin
Wire Color
Circuit
, No.
DKGRN
59

Control
450
A/C Compressor.Clutch
Ground
BLK
Connector Part
Information
Function
Wire Color
1205-9595
3 Way F Metri-Pack
150 Series (BLK)
Circuit
No.
BRN/WHT
633
PNK/BLK
RED
632
631
Function
Camshaft Position (CMP)
Sensor Signal Input
Reference Low
Ignition Feed
62453
258299
Connector Part
Information
1211-0192
Connector Part
Information
3 Way F Metri-Pack .
150 Series Pull To Seat (BLK)
Pin
Wire Color
Circuit
No.
PPL
719
Function
Sensor Grour:id
GRY
474

Sensor 5.0V Reference
RED/BLK
380

Sensor Signal
1205-9595
3 Way Metri-Pack
.1 !iO Series (BLK)
Circuit
No.
Pin
Wire Color
DK BLU/
WHT
1869
YEUBLK
LTGRN
1868
1867
Function
Crankshaft Position (CKP)
Sensor Signal Input
Reference .Low
Ignition F.eed
Engine
Engine Controls. - 5~7L
6-1373
Engine Oil Pressure Sensor
I~
.........
516595
518983
Connector Part
Information
1216-2195
2 Way F Metri-Pack
150.2 Series Sealed
P2S (BLK)
Pin
Pin
Wire Color
Circuit
No.
BLK
407
Sensor Ground
410
Engine Coolant
Temperature
Sensor (ECT) Signal
YEL
Connector Part
Information
Function
Wire Color
1206-5299
4 Way F Metri-Pack
150 Series. Sealed (BLK)
Circuit
No.
Function
TAN
31
Oil Pressure Sensor.

Output
BLK/WHT
451
Ground
C-D
Not Used
Evaporative Emission (EVAP) Canister
Purge Valve
35437
35437
Connector Part
Information
Pin
Wire Color
1205-2641
2 Way F Metri-Pack
Circuit
No.
Function
BRN
1174
Oil Level Switch Input
BLK/WHT
451
Ground
Connector Part
Information
.1205~2643
2 Way Metri-Pack 150 Series
Sealed (RED)
Pin
Wire Color
Circuit
No.
PNK
239
Fused Ignition Feed
DKGRN/
WHT
428
EVAP Canister Purge

Valve Control
Function
6;.1374
Engine

Fuel Injector #1
Evaporative Emission (EVAP) Canister
Vent Valve
(
(
154327
35437
Connector Part
Information
1205-2643
2 Way F Metri-Pack
Pin
Wire Color
Circuit
No.
PNK
239
WHT
1310
1212-9140
Connector Part
Information
2 Way F Metri~Pack
280.1 Series Pull To
Seat(BLK)
Pin
Wire Color
Circuit
No.
Fused Ignition Feed
PNK
639
Fused lgnitiori Feed
EVAP Canister Vent

Valve Control
BLK
1744
Fuel Injector #1 Control
Function
Function
Fuel Injector #2
~0000
154327
258663
Connector Part
Information
Pin
A
Wire.Color
GAY
1218-6056
5. Way F Metri-Pack
150 Series Pull to Seat (BLK)
Circuit
No.
1212-9140
Connector Part
Information
435
BLK
407
Exhaust Gas
Recirculation (EGA)
Sensor Ground
BAN
1456
Exhaust Gas
Recirculation (EGR) Pintle
Position
GRY
416
Exhaust Gas
Recirculation (EGA) 5V
Reference
RED
1676
Exhaust Gas
Recirculation (EGA) Valve
Control

Seat (BLK)
Pin
Wire Color
Circuit
No.
PNK
839
Fused Ignition Feed
LT GAN/
BLK
1745
Function
Exhaust Gas
Recirculation (EGA) Valve
Ground
2 Way F Metri-Pack
Function
Engine Cont.-ols .. 5.7L 5..1375
Engine
Fuel Injector #5
Fuel: Injector #3
154327
Connector Part
Information
Pin
Wire Color
1212-9140
1212-9140
2 Way F MetriaPack
Seat(BLK)
Circuit
No.
154327
Connector Part
Information
Function.
Pin
Wire Color
2 Way F Metri-Pack
280.t .Series Pull To
Seat (BLK)
Circuit
No.
Function
PNK
639
Fused Ignition Feed
639
Fused Ignition Feed
PNK/BLK
1746
845
Fuel Injector #4
Fuel Injector #6
154327
Connector Part
Information
Wire Color
Circuit
No.
PNK
839
LT BLU/
BLK
Pin
1212-9140
2 Way F Metri-Pack
280, 1 Series Pull To
Seat (BLK)
844
Function
Fused Ignition Feed
154327
Connector Part
Information
1212-9140
2 Way F Metri-Pack
Seat (BLK)
Wire Color
Circuit
No.
PNK
. 839
YEUBLK
846
Pin
Functic:>n
Fused .lgnitipn Feed
Fuel lnjectqr #:6. Control
6-1376
Engine

Fuel Injector #7
Fuel Level Sensor/Fuel Pump
(
-
,,
...
@J IIf
@] I]]
::::, 00
\..\;.
-,i
t:I
r
518981
154327
Connector Part
Information
1212-9140
2 Way F Metri-Pack
.Seat (BLK)
Connector Part
Information
Pin
Wire Color
Circuit
No.
PPL
30
Wire Color
Circuit
No.
PNK
639
Fused Ignition Feed
GRY
RED/BLK
877
BLK
BLK/WHT
Pin
1216-0482
4 Way F Metri-Pack
150 Series Seald (BLK)
Furiction
..
Function
Fuel Levellnput
120
Fuel Pump Control
150
Fuel Pump Ground
651
Fuel Level Sensor Ground
Fuel Injector #8
154327
Connector Part
Information
Pin
Wire Color
1212-9140
2 Way F Metri-Pack
Seat (BLK)
Circuit
No.
Function
258675
Connector Part
Information
1205-9595
3 Way F Metri-Pack
150 Series (BLK)
Pin
Wire Color
Circuit
No.
ORN/BLK
469
Fuel Sensor Ground
Function
PNK
839
Fused Ignition Feed
DK BLU/
WHT
878
Fuel Injector #.8 Control
DKGRN
890
Fuel Tank Pressure

Signal
GRY/BLK
416
5V Sensor Feed
Engine
Heated Oxygen Sensor (H02S), Bank 1,

Sensor 2, Left Rear
6-1377'
Heated Oxygen Sensor (H02S), Bank2,

Sensor 2, Right Rear
280761
Connector Part
Information
Pin
Wire Color
1216-0825
4 Way Metri-Pack
150 Series (BLK)
Circuit
No.
280761
Connector Part
Information
~
Function
Pin
Wire Color
TAN/V\iHT
1669
LR Heated Oxygen
Sensor (H02S) - Low
PPLMiHT
1668
LR Heated Oxygen
BLK
BLK
PNK
450
539
Ground
Fused Ignition Feed
PNK
1216-0825
.4 Way M Metri-Pack
i
150 Series Series (BLK)
Circuit
No.
Function
RR
Heated Oxygen
Sensor (H02S) - Low
TAN
1671
PPL
1670 RR Heated Oxygen
Heated Oxygen Sensor (H02S), Bank 2,

Sensor 1, Right Front
450
539
Ground
Fused Ignition Feed
.289328
280761
Connector Part
Information
Pin
Wire Color
.1216-0825
4 Way M Metri-Pack
Circuit
No.
Function
Connector Part
Information
1216-2190
4 Way F Metri-Pack
150.2.Series Pull to
Seat (BLK)
Circuit
No.
Pin
Wire Color
LT GRN/
BLK
444

Valve Coil B Signal - Low
Function
TAN
1667
RF Heated Oxygen
Sensor (H02S) - Low
PPL
1666
RF Heated Oxygen
LT GRN/
WHT
1749

Valve Coil B Signal - High
BLK
Ground
PNK
LT BLU/
BLK
1748
450
539

Valve Coil A Signal - Low
LT BLU/
WHT
1747

Valve Coil A Signal - High
Fused Ignition Feed
6-1378
Engine
68719
Connector Part
Information
Pin
A
Wire Color
PPL
TAN
" 1216-2199
2 Way F Metri Pack
150.2 Series Pull to
Seat (GRY)
68740
Connector Part
Information
1212-9946
3 Way F Metri Pack
150 Series (GRY)
Pin
Wire Color
Circuit
No.
ORN/BLK
407
719
Intake.Air
Ground
Manifold Absolute
.Pressure (MAP) Sensor
Ground
LT GRN
432
472
Intake Air
Signal
Manifold Absolute
Signal
416
Manifold Absolute
Pressure (MAP).
Sensor 5.0V Reference
Circuit
No.
Function
GRY
Knock Sensors (KS)
Function
.Mass Air Flo.w (MAF) Sensor
35437
Connector Part
Information
Pin
Wire Color
1205-2641
0 2 Way F Metri-Pack
Circuit
No.
Function
DKBLU
496
Knock Sensor (KS)

Signal - Front
LT BLU
1876
Knock Sensor (KS)

Signal - Rear
62453
Connector Part
Information
1205-9595
3 Way F Metri-Pack
150 Series (BLK)
Pin
Wire Color
Circuit
.No.
YEL
492
Mass Air Flow (MAF)

Sensor Signal
BLK/WHT
451
Ground
PNK
539
Fused Ignition Feed
Function
Engine
6-1379
Secondary Air Injection (AIR) Pump
Park/Neutral Position Switch
68730
392014
Connector Part
Information
Pin
A
Wire Color
BLK/WHT
1201-5307
e 6 Way F Metri-Pack (BLK)
Circuit
No.
451
Connector Part
Information
Function
Pin
Ground
Wire Color
1211-0293
3 Way F Metri-Pack
150 Series (BLK)
Circuit
No.
Function
ORN/BLK
434
PCM Park/Neutral
Position Signal
RED
78
Secondary Air Injection

Pump Motor. Feed.
BRN
141
Fused Ignition Feed
PNK/BLK
429

Solenoid - Feed
LTGRN
24
Back Up Lamps Feed
150
Ground
PPUWHT
1035
Fused Ignition Feed
BLK
E
F
DKGRN
1433
Starter Enable
Secondary Air Injection (AIR) Bleed Valve

Solenoid
258299
0
35437
Connector Part
Information
Pin
Wire Color
1205-2643
2 Way F Metri-Pack .
Circuit
No.
Function
PNK/BLK
429

Bleed Valve
Solenoid - Feed
BLK
150
Ground
Connector Part
Information
Pin
Wire Color
1211-0192
3 Way F Metri-Pack
150 Series Pull To Seat (BLK)
Circuit
No.
Function
Sensor 5V Reference
GRY
596
BLK
452
Sensor Ground
417

Sensor Signal
DKBLU
6-1380
Engine
Engine Controls~ 5.7l

Procedures
Vehicle Speed Sensor (VSS)
A Diagnostic Starting Point
68719
Connector Part
Information
Pin
Wire Color
1216-2195
2 Way F Metri-Pack
150.2 Series Pull to
Seat {BLK)
Circuit
No.
Begin the system diagnosis with the A Powertrain On

Board Diagnostic (080) System Check.. The
Powertrain OBD System Check will provide the
following information:
The identification of the control modulE:i(s) which
command the system.
e The ability of the control module(s) to
communicate through the serial data circuit.
The identification of any stored diagnostic trouble
codes (DTCs) and their status.
The use of the Powertrain OBD System Check will
identify the correct procedure for diagnosing the
system and where the procedure is located.
Function
LT GRN/
BLK.
822
Vehicle Speed
Sensor (VSS)
Signal - Low
PPUWHT
821
Vehicle Speed
Sensor (VSS)
Signal - High
Engine
6-1381
A Powertrain On Board Diagnostic .(OBD) System Check

Description
The Powertrain OBD System Check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction. The
Powertrain OBD System Check is the starting point for
any driveability concern diagnosis: The Powertrain
OBD System Check directs the service technician to
the next logical step in diagnosing a concern.
Understanding and using the table correctly will reduce
the diagnostic time and prevent the replacement of
good parts.
Do not perform this check if no driveability concern
exists. A driveability condition includes all PCM
controlled systems and components.
For automatic transmission DTCs, refer to Diagnostic
Trouble Code (OTC) List/Type in Automatic
Transmission. The DTCs associated with the automatic
transmission are:
DTCs P0502 and P0503.
Any 700 (except OTC P0704) and 1800 series
DTCs (i.e. OTC P07XX and P1 BXX).
For Domestic and Export OTC Types, refer to
Diagnostic Trouble Code (OTC) List/Type.
This vehicle is equipped with a Powertrain Control
Module (PCM) utilizing an Electrically Erasable
Program the new PCM when diagnostics call for
replacement of the PCM. When the PCM is replaced,
the following must be performed.
The PCM must be programmed. Refer to PCM
The CKP System Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
The Idle Learn Procedure. Refer to PCM Idle
Learn Procedure.
The Engine Oil Life Monitor reset procedure.
Refer to Engine Oil Life Monitor Reset Procedure.
When the PCM power is interrupted or the PCM
is reprogrammed, the PCM Idle Learn Procedure must
be performed.
Diagnostic Aids
If an intermittent condition exists, inspect the PCM
wiring harnesses for improper installation of
electrical components. Inspect for aftermarket theft
deterrent devices, lights, and cellular phones.
Ensure that no aftermarket equipment is
connected to the Class 2 circuit. A cellular phone
signal communication may cause an intermittent
condition.
- Poor connections; Refer to Testing tor
Intermittent and Poor Connections in Wiring
Systems.
- Corrosion.
- Mis-routed harness.
- Rubbed through wire insulation.
- Broken wire inside the insulation.
If multiple DTCs are set, inspect the IGN relay for

proper operation. The following components are
powered by the IGN relay:
- Injectors/Ignition coils
- A/C system
- Transmission
- EVAP solenoid and EVAP Vent Valve
- MAF sensor
- Heated Oxygen Sensors
For an intermittent, refer to Symptoms.
Test Description
diagnostic table.
1, Use a properly functioning scan tool with the
diagnostic tables in this section. DO NOT use the
Clear Info function unless instructed by a
diagnostic procedure.
3. An Ignition 1 voltage that is too low may cause
A no start
e Stalling
" High idle
An inoperative scan tool
5. This step determines if a OTC is set for the
Vehicle Theft Deterrent (VTD) system. A VTD OTC
set causes a no start condition.
6. If multiple DTCs are stored, diagnose in the
following order of priority:
1. PCM failure DTCs (P0601, P0602, P0604)
2. System Voltage DTCs
3. Component level DTCs (Sensors, Solenoids,
Relays etc.). Multiple DTCs within this
category should be diagnosed in numerical
order starting with the lowest numbered OTC.
4. System level DTCs (Misfire, Fuel Trim, etc.)
For Automatic Transmission DTCs, refer to Diagnostic
Trouble Code (OTC) List/Type in Automatic
Transmission.
It is beneficial to review the Freeze Frame Data and/or
Fail Records. Use the odometer information and the
fail counter in order to determine how frequently
and how recently the OTC set. This information and
the other operating conditions when the OTC set may
help diagnose an intermittent condition. Capturing
the stored info preserves data that the PCM will lose
when instructed to Clear Info at the end of a
diagnostic table, or if you disconnect the PCM or
replace the PCM during a diagnostic procedure. The
scan tool stores the data in the scan tool's memory.
Review the captured info at the end of the diagnostic
procedure in order to catch the next OTC in the
event there are multiple DTCs stored. Follow the order
of priority as listed above.
6-1382
Engine
7. Compare actual control system data with the

values in the Engine Scan Tool Data List to
determine if any parameter is not within limits.
Keep in mind that a base engine condition
(i.e. advanced cam timing) may substantially alter
sensor values. If the actual data does not

correspond with the values in the Engine Scan
Tool Data List, refer to the appropriate
system/component diagnostic aids or test
descriptions.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to .Scan Tool
Does Not Power
Up in Data Link
Communications
Go to Step 3
Go to Scan Tool
Does Not
Communicate
w/Class 2 Data
Line in Data Link
Communications
Go to Step 4
Go to
DTCP0562
System
Voltage. Low
Gci to StepB
Go to Step 5
Go to
OTC P1626 Theft
Detetrerit Fuel
Enable
Signal Lost
Go to Engine
Cranks but Does
Not Run
Go to the
applicable
OTC table
Go to Step 7
Go to Symptoms
Go to Diagnostic
Aids and Test
Descriptions
Important:
Search for applicable service bulletins before
proceeding with diagnosis.
0
Do not turn the ignition OFF when performing this

diagnostic table.
Ensure the battery is fully charged before proceeding

with this diagnostic.
1. Connect a scan tool to the Data Urik
Connector (DLC).
2. Turn ON the ignition leaving the engine OFF.
Does the scan tool power-up?
Important: Save or capture the Freeze Frame and/or

Failure Records information if the PCM displays data.
Does the scan tool display PCM data?
Important: If the starter does not engage, refer to A

Diagnostic Starting Point - Engine Electrical in Engine
3
Electrical.
B+
Monitor the Ignition 1 voltage using a scan tool while

cranking the engine, or while the engine is operating.
Is the Ignition 1 voltage near the specified voltage?
Is OTC Pi 626 stored?
Monitor the OTC information using a scan tool.
Are any DTCs displayed?
Compare the scan tool data with the values shown in the
Scan Tool Data List.
:'-
Are the values normal or within typical ranges?
Engine
6-1383
Scan Tool Data list

The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool.
The list is arranged in alphabetical order. A given
parameter may appear in any one of the data lists, and
in some cases may appear more than once, or in
more than one data list in order to group certain related
parameters together.
Use the Engine Scan Tool Data List only after the
following is determined:
Powertrain On-Board Diagnostic System Check is
completed.
No Diagnostic Trouble Codes (DTCs).
On-board diagnostics are functioning properly.
Scan tool values from a properly running engine may
be used for comparison with the engine. you are
diagnosing. The Engine Scan Tool Data List
represents values that .would be seen on a normally
running engine.
Important: A scan tool that displays faulty data should

not be used. The scan tool concern should be
reported to the manufacturer. Use of a faulty scan tool
can result in misdiagnosis and unnecessary parts
replacement.
Only the parameters listed below are referenced in
this service manual for use in diagnosis. If all values
are within the typical range described below, refer
to Symptoms tor diagnosis.
The column labeled Data List indicates where a
parameter can be located on the scan tool. Refer.to
the scan tool operating manual for the exact locations
of the data lists. The following is a description of
each term listed:
All: The Parameter is in all data lists indicated below.
EE: Enhanced EV AP Data
FF/FR: Freeze Frame/Failure Records
FT: Fuel Trim Data List
MF: Misfire Data List
Scan Tool Data List

Data List
Parameter Range/Units
Typical Data Values
Scan Tool Parameter
Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed loop/Accessories Off
Eng 2
0-5 Volts
Varies
kPa/psi
Eng 2
Varies
Eng 1, 2, EE, MF
On/Off
Off
A/C Relay Command
Yes/No
No
Eng 1, 2, EE, MF
A/C Request
Eng 1, 2, EE, MF
On/Off
Off
A/C Status
Eng 1
0-100%
0%
Actual EGR Position
Eng 1, 2, FT
On/Off
Off
AIR Pump Relay
Eng 1, 2, FT
On/Off
Off
AIR Solenoid
Air Fuel Ratio
FF, FR
Ratio
14.7:1
65-104 kPa/3.5-4.9 Volts
Eng 1, FT, FF, FR
kPa/Volts
BARO
(Varies w/Altitude)
Eng 1
Eng 1
Counts
Counts
Varies
Varies
Eng1, 2, MF
Eng1, 2, EE
Depressed/Released
Varies
Cold Startup
Yes/No
Varies
Commanded EGR
Eng 1
0-5 Volts
Less than 1.3 volts
Cruise Requested
Eng1, 2
No
Cruise Control Inhibit
Eng1, 2
Yes/No
Yes/No
CAM Signal Input High to Low

CAM Signal Input Low to High
Clutch Pedal Position Switch
Current Gear
Yes
Eng 2, FF, FR
Transmission Gear
Position
Cycles of Misfire Data
MF
0-100 Counts
Varies
Cylinder Mode Misfire Index
MF
Counts
DTC Set This Ignition
Eng 1, 2, EE, FT
Yes/No
Varies
No
Desired IAC Airflow
Eng 1
0-64 g/s
Varies
Desired EGR Position
Eng1
0-100%
0%
Desired Idle Speed
Eng 1, FF, FR
RPM
PCM Controlled
ECT
Eng 1, 2, EE, FT, MF,

FF, FR
Eng 1
-39 to 140C
(-38 to 284F)
0-5.0 Volts
85 to 113C
(185 to 235F)
Less than 1.3 volts
Eng 1
0-5.0 Volts
Less than 1.3 Volts
EGR Closed Pintle Position

EGR Pintle Position
6-1384
Engi,ne
Scan Tool Parameter

Data List
Typical Data Values
Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off
1-4%@ Idle
0-100%
Engine Load
MF, FF, FR
5-9% .@ 2500 RPM
Eng 1, 2, EE, FF, FR
Hrs, Min, Sec
Varies
Engine Run Time
.
0-10,000
RPM
Engine Speed
All
Varies
0.,--25%
EVAP Canister Purge
Eng 1, 2, EE, FT, FR
0-100%
EVAP Canister Vent Valve
Eng 1, 2, EE, FT
Not VentingNenting
Venting
FR
Counts
Fail Counter
Varies ..
Failures Since First Fail
FR
Counts
Varies
Depends on engine
coolant temperature and
On/Off
FC Relay 1
Eng 1, 2, EE
A/C Pressure
Depends on engine
FC Relay 2 and 3
Eng 1, 2, EE
On/Off
coolant temperature and
A/C. Prel3sure
Enabled/Disabled
Varies
FT Diag. Inhibit
FT
Eng 2, EE
Fuel Gauge Control
0-100%
Varies
Fuel Level Sensor
Eng 2, EE
5-0 Volts
Fuel Tank Level Remaining

Fuel Tank Level Remaining
Eng 2, EE, FT
0-16.6 gal./0-62.8 L
0.7-2.5 Volis
Varies
Eng 2, EE, FT
0-100%
Varies
Fuel Tank Pressure
Eng 1, 2, EE
-32.7 to 14.0 mm/Hg

(-17.5 to 7.5 in/H20)
Varies
Fuel Tank Pressure
Eng 2, EE
Eng 2, EE, FT
0-5.0 Volts
Varies
16.6 gal./62.8 L
16.6 gal./62.8 L
Fuel Trim Cell
Eng 1, FT
0-23
16, 17,20
Fuel Trim Learn
Eng 1, 2, EE, FT
Enabled/Disabled
Enabled (may Toggle)
Generator L Terminal
Eng 2,
Active/Inactive
Eng 1, FT
Eng 1, FT
Millivolts
Millivolts
10--:1,000 mV and Varying

10-1,000 mV and Varying
Eng 1, FT
Millivolts
10'-1 ;000 mV and Varying
Eng 1, FT
Millivolts
10.;.1,000 mV and Varying
IAC Position
Eng 1
Varies
IAT
Eng 1, 2, EE, FT
Counts
-39 to 140C
(-38 to 284F)
Fuel Tank Rated Capacity
. >
..
Active
Varies
IC Circuit Cylinder 1-8
MF
Ok/Fault
Ignition 1
0-25 Volts
lnj. PWM Average Bank 1
Eng 2, EE
Eng 2, EE, FT, FF, FR
Milliseconds
lnj. PWM Average Bank 2
Eng 2, EE, FT, FF, FR
Milliseconds
Knock Retard
Eng 1, EE, FT
0.0-16
oo
Long Term FT 1 Average
FT
Percentage
Near 0%
Long Term FT 2 Average
FT
Percentage
Near0%
Long Term FT Bank 1
Eng 1, 2, EE, FT,

FF, FR
Percentage
Near 0%
Long Term FT Bank 2
Eng 1, 2, EE, FT,

FF, FR
Percentage
Near 0%
Loop Status
Eng 1, 2, EE, FT MF,

FF, FR
Open/Closed
Closed
Low Oil Lamp
Eng 2
On/Off
Off
Low Oil Level
Eng 2
Yes/No
No
Ok
11.5-14.5 Volts
1-4
1-4
MAF

FF, FR
Grams Per
Seconds (g/s)
5-9 g/s@ Idle (depends

on altitude)
20-26 g/s @ 2,500 RPM
(depends on altitude)
MAF Frequency
Eng 2
0-31,999 Hz
Varies
...
Engine
6-1385.
Scan Tool Parameter
Data List
Typical Data Values
Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off
20-48 kPa/1.0-2.0 Volts
Eng 1, 2, EE, FT,
MAP
kPa/Volts
FF,FR
(varies w/altitude)
Eng 1, 2, EE
Off/On
MIL
Off
Eng 2
km/Miles
Mileage Since OTC Cleared
Varies
FF,FR
km/Miles
Varies
Mileage Since First Failure
FR
km/Miles
Varies
Mileage $ince Last Failure
Mileage Since MIL Request
FF
km/Miles
Varies
MF
0-200 Counts
0
Misfire Current #1-#8
MF
0-65,535 Counts
Misfire History #1-#8
0
Prim. Cyl# 0-8
00000000 Prim.
MF
Misfiring Cylinder
Sec. Cyl# 0-8
00000000 Sec.
Misfire Revolution Status
MF
Reject/Accept
Varies
Counts
Varies
Not Run Counter
. FR
PCM Reset
Eng 1, 2, MF
Yes/No
No
Park/Neutral
Eng 2
Park/Neutral
PNP (A/T only)
R-0321
FR
Counts
Varies
Pass Counter
Reverse Inhibit (MIT only)
Eng 1, 2
Yes/No
No
Revolutions With Misfire
MF
Counts
0
SHRT FT Average 1
FT
Percentage
Near 0%
FT
Percentage
SHRT FT Average 2
Near 0%
Eng 1, 2, EE, FT,
Percentage
Neiar 0%
FF, FR
Eng 1, 2, EE, FT,
Percentage
Near 0%
Short rerm FT.Bank 2
FF, FR.
Skip Shift Lamp (MIT only)
Eng 1., 2
On/Off
Off
Eng 1, 2
Enabled/Disabled
Skip Shift Solenoid (MIT only)
Disabled
Eng 1, 2, EE, FT, MF
Degrees
Varies
Spark
co/FO
Eng 1, FF, FR, EE
Varies
Start Up ECT
Eng 1, 2, FF, FR
Applied/Released
TCC Brake Switch
Released
Eng 1, 2, MF, FF, FR
Enabled/Disabled
TCC Duty Cycle
Disabled
Eng 1, 2, MF, FF, FR
Enabled/Disabled
TCC Enable Sol.
Disabled
Counts
MF
Total Misfire Current Count
.. 0
MF
0-65,535
Tolal Misfire Failures Since First Fail
0
MF
0-65,535
Total Misfire Passes Since First Fail
0
TP Sensor
Eng 2
0-5.0 Volts
.4-.9 Volts
0-100%
TP Angle
0%
. FF, FR
)
Traction Control
Transmission OSS
TransmissionRange
Eng 1, 2, FF, FR
FF,FR
Eng 1, 2,.FF, FH
Vehicle Speed
Eng 1, 2, EE, FT,

FF, FR
VTD Fuel Disable

Warm-Ups w/o Emission Faults
Warm~Ups w/o Non-Emission Faults
Eng 2, FF, FR
Eng 2
Eng 2
Active/Inactive
RPM
0-4
km/h
mph
Active/Inactive
0-255 Counts
0-255 Counts
Inactive
Varies
"'w.
1
0
Inactive
Varies
Varies
6-1386
Scan Tool Data Definitions

The Engine Scan Tool Data Definitioi:,s contains a
brief description of all engine related parameters
available on the scan tool. The list is in alphabetical
order. A given parameter may appear in any one of the
data lists. In some cases, the parameter may appear
more than once or in more than one data list in
order to group certain related parameters together.
A/C High Side Pressure: The scan tool displays
15-452 psi/103:-3116 kPa/0-5.0 Volts. This parameter
represents the A/C refrigerant pressure sensor
signal. The amount of pressure indicates the amount
of load that the A/C compressor places on the
engine. The PCM uses this information in order to
adjust idle and in order to control the cooling fans.
A/C Relay Command: The scan tool displays On or
Off. The A/C Relay Command parameter represents
the PCM commanded state of the A/C clutch relay
control circuit. When the scan tool displays ON,
the A/C clutch should be engaged.
A/C Request: The scan tool displays Yes or No.
The A/C Request displays the state of the A/C request
input circuit from the HVAC controls. The PCM uses
the A/C request signal in order to determine whether
the A/C compressor operation is being requested.
A/C Status: The scan tool displays On or Off. The
scan tool displays ON when the PCM detects a voltage
at the A/C status circuit.
Actual EGR Position: The scan tool displays
percentage. This parameter indicates the position of
the EGR pintle position in percentage. A fully
closed EGR displays 0%. A fully open EGR
displays 100%.
AIR System: The scan tool displays On or Off. The
scan tool displays ON when the PCM enables the
entire AIR system. The scan tool displays OFF when
the PCM disables the entire AIR system.
AIR Pump Relay: The scan tool displays On or Off.
The scan tool displays ON when the PCM grounds
the AIR pump relay control circuit. The scan tool
displays OFF when the PCM disables the ground
circuit.
AIR Solenoid Valve: The scan tool displays On or
Off. The scan tool displays ON when the PCM
grounds the AIR solenoid valve control circuit. The
scan tool displays OFF when the PCM disables
the ground circuit.
Air Fuel Ratio: The scan tool display indicates the
Air to Fuel Ratio. The Air Fuel ratio is determined
from the Heated Oxygen sensor output. The PCM uses
the fuel trim to adjust fueling to attempt to maintain
an Air Fuel Ratio of 14.7:1.
BARO: The scan tool displays a range of
10-105 kPa/0.00-5.0 Volts. The Barometric Pressure
reading is determined from the MAP sensor signal.
The PCM monitors the MAP signal during key up and
Wide-Open Throttle (WOT) conditions. The Barometric
Pressure compensates for altitude differences.
Engine
CAM Signal Input High to Low: The scan tool
displays 0-65,535 counts. The counts incrementas
the PCM detects the Camshaft sensor signal voltage
going from high to low.
(
.
CAM Signal Input Low to High: The scan tool

displays 0-65,535 counts. The counts increment as
the PCM detects the Camshaft sensor signal voltage
going from low to high.
Clutch Pedal Position Switch (MIT only): . The
scan tool displays depressed or released. This
parameter displays the position of the clutch pedal.
Cold Start Up: The scan tool displays Yes or No. A
cold start up is when the engine coolant temperature
rises above a predetermined temperature during
an ignition cycle. The next ignition cycle the engine
coolanttemperature should be .below a pr'3determined
temperature. Also the engine coolant temperature
and the Intake Air temperature are less than
50 degrees C (122 degrees F) and are within
3 degrees C (5 degrees F) of each other. at start up.
When the above is true the scan tool displays Yes.
Commanded EGR: The scan tool displays
0-5.0 Volts. This parameter is the EGR pintle position
commanded by the PCM.
Current Gear: The scan tool displays 0-4. The scan
tool displays which gear the transmission is in. An
illegal transmission position displays 9.
Cycles of Misfire Data: The scan tool displays a
range of 0-100. The PCM Counts the number of
misfire tests during 200 revolutions.
(.
Cylinder Mode Misfire Index: The scan tool

displays a range of 0-65,535. This parameter displays.
the amount of crankshaft decelerations. When an
engine is operating without a misfire, the scan
tool displays less than 1,000 counts. When an engine
misfire occurs, the counter displays more than
1,000 counts.
DTC Set This Ignition: The scan tool displays Yes
or No. This parameter indicates if a Diagnostic
Trouble Code (DTC) set during the current
ignition cycle.
Desired IAC Airflow: The scantool displays a
range of 0-64 Grams Per Second (g/s). This
parameter displays the calculated airflow in the IAC
passage.
Desired EGR Position: The scantool displays
0-5.0 Volts. This parameter displays the desired
position of the EGR pintle as requested by the PCM.
This parameter should be very close to Actual
EGR position.
Desired Idle Speed: The scan tool displays .a range
of 0-3, 187 RPM. The PCM commands the desired
idle speed. The PCM compensates for various engine
loads based on engine coolant temperature in order
to keep the engine at the desired speed.
Engine
\)
ECT: The scan tool displays a range of -39C to

140C (-38F to 284F). The Engine Coolant
Temperature (ECT) sensor is mounted in the cylinder
head of the left bank. The PCM applies 5.0 Volts
to the ECT sensor circuit. The sensor is a thermistor.
which changes internal resistance as temperature
changes. When the sensor is cold (internal resistance
high), the PCM monitors a high signal voltage and
interprets the voltage as a cold engine. As the sensor
warms (internal resistance decreases), the voltage
signal decreases and the PCM interprets the
lower voltage as a warm engine.
EGR Closed Pintle Position: The scan tool
displays o.::..5.0 Volts. This display represents the
voltage that the PCM uses to determine w~ether or .
not the EGR valve is closed. The voltage displayed will
be the closed position of the EGR pintle learned by
the PCM.
EGR Pintle Position: The scan tool displays
0-5.0 Volts. This.parameter displays the actual .EGR
pintle position in voltage.
Engine Load: The scan tool displays a range of
0%-100%. The PCM calculates the Engine load from
engine speed and MAF sensor readings. The
Engine Load increases with an increase in RPM or

airflow.
Engine Run Time: The scan tool displays Hours,.
Minutes, Seconds. This displays the amount of engine
run time for the currentignition cycle. When you
cycle the ignition off, the timer will reset to zero.
Engine Speed: The scan tool displaysa range of
0-10,000. RPM. The PCM computes Engine speed
from the ignition refe.rence pulses. The Engine speed
should remain close to desired idle under various
engine loads with the engine idling.
EVAP Canister' Purge: The scan tool displays a
range of 0%-100%. The PCM commands the
PWM duty cycle of the EV AP Purge Solenoid valve.
0% displayed indic::ates no purge; 100% displayed
indicates full purge.

EVAP Canister Vent Valve: The scan tool displays
venting or not venting. The scan tool displays
venting when the PCM commands the EVAP system .
to purge. The scan tool will show not venting when
the valve is closed.
.
.
Fail Counter: This scan tool displays the.amount of
times a OTC fails'. This parameter is located in the
Failure Records Hst.
Failures Since First Fail: The scan tool displays the
number of times a OTC failed since the first failure.
FC Relay 1: The scan tool displays On or Off. The
scan tool displays ON when the PCM commands
a coolant fan relay ON. Both. fans are enabled on low
speed when the PCM commands the fan one relay
control ON.
FC Relay 2 and 3: The scan tool displays On or Off.
The scan tool displays ON when the PCM commands
a coolant fan relay ON. Both cooling fans are
enabled on high speed when the PCM commands
both fan control circuits ON.
6-1387
FT Diag. Inhibit: The scan tool displays Enabled or

. .
Disabled. The scan tool displays Disabled when
the PCM determines that certain parameters prohibit
the Fuel Trim diagnostic from running. The scan
tool displays Enabled when the PCM determines that
the Fuel Trim diagnostic is allowed to run.
Fuel Gauge Control: The scan tool displays
0-100%. This parameter indicates the fuel level that
the PCM is commanding the fuel gauge to. The
scan tool displays in percentage the fuel level in the
fuel tank.
Fuel level Sensor: The scan tool displays
5.0-0 Volts. The PCM supplies a 5.0 Volt signal circuit
to the fuel level sensor. The float inside the fuel
tank controls a variable resistor which varies the
resistance based on fuel level. The scan tool displays
below 1.0 Volt for an empty tank, and close to
2.5 Volts for a full tank.
Fuel Tank Level Remaining: The scan tool displays
o:..:62.6 L (0-16.8 gal). The scan tool displays in
Liters or Gallons the amount of fuel remaining in the
fuel tank.
Fuel Tank level Remaining: The scan tool displays
0-100%. The scan tool displays in percentage the
amount of fuel remaining in the fuel tank:
Fuel Tank Pressure: The scan tool displays in
-32.7 to 13.96 mm/Hg or-17.4 to 7.5 (in/H20). This
parameter indicates the pressureNacuum inside of the
fuel tank. A negative value indicates a vacuum. A
positive value indicates a pressure.
Fuel Tank Pressure: The scan tool displays
0-5.0 Volts. The scan tool displays in voltage the
pressure inside of the fuel tank.
Fuel Tank Rated Capacity: The scan tool displays .
62.6 L (16.8 gal). The scan tool displays the .capacity
of the fuel tank in Liters or Gallons.
Fuel Trim Cell: The scan tool displays a range of
O to 23. The PCM determines from the MAP and RPM
inputs wh.ich fuel trim cell to operate the eng!ne in.
The fuel trim cell displayed on the scan tool 1s the cell
that the engine is operating under.
Fuel Trim learn: The scan tool displays Enabled or
Disabled. When conditions are appropriate for
enabling long term fuel trim corrections, the scan tool
displays Enabled. This indicates that the long term
fuel trim is responding to the short term fuel trim. If the
scan tool displays Disabled, then long term fuel trim
will not respond to changes in short term fueltrim.
H02S Bank 1 and Bank 2 Sensor 1: The scan tool
displays a range of 0-1,000 mV. The H02S Bank 1
and Bank 2 Sensor 1 parameter represents the
fuel control exhaust oxygen sensor output voltage.
The voltage fluctuates constantly within a range
between 1O mV (lean exhaust) and 1,000 mV (rich
exhaust) while operating in Closed Loop.
6-1388
H02S Bank 1 and Bank 2 Sensor 2: The scan tool

displays a range of 0-1,000 mV. The H02S Bn1
and Bn2 Sensor 2 parameter represents the exhaust
oxygen sensor outputvoltage. The voltage fluctuates
constantly within. a range between 1O mV (lean
exhaust) and 1,000 mV (rich exhaust) while operating
in Closed Loop.
IAC Position: The scan tool displays counts from
O to 1,024. The counts represent the commanded IAC
position by the PCM. The scan tool displays
O counts for a fully seated IAC pintle. The counts
increase as the idle increases. The counts vary
depending on the load placed on .the engine at idle.
IAT: The scan tool displays a range of -39C
to 140C (~38F to 284F). The PCM converts the
resistance of the intake air temperature sensor
to degrees. The PCM uses the Intake Air
Temperature (IAT) in order to adjust fuel delivery and
spark timing according to incoming air density.
IC Circuit Cylinder 1-8: The scan tool displays OK
or Fault. If there is a problem with an ignition control
circuit, the scan tool displays Fault. The scan tool
displays OK under the normal operating conditions.
Ignition 1: The scan tool displays 0-25.5 Volts. The
Ignition 1 represents the system voltage measured
by the PCM at the ignition feed circuit.
lnj. PWM Average Bank 1 and Bank 2: The scan
tool displays a range of 0-:-1,000 m/sec. The
Injector average indicates the amount of time the PCM
commands each injector ON during each engine
cycle. A longer injector pulse width causes more fuel
to be delivered. The Injector Pulse Width increases
with an increased engine load.
Knock Retard: The scan tool displays a range of
0.0 degrees-16 degrees. Knock Retard indicates
the amount of spark the PCM removes from the IC
spark advance in response to the signal from the
knock sensors.
Long Term FT Average Bank 1 and Bank 2: The
scan tool displays Percentage. This parameter
indicates the average of all long term fuel trim cells.
The short term fuel trim cells are rated (Weighted) for
the amount of which they are used. For example,
an idle cell is rated higher than a wide open cell. If a
fueling malfunction occurs in the idle cell and the
wide open cell, the average would be more affected
by the idle cell than the wide open cell. A negative
value significantly below O percent indicates that the
fuel system is rich and fuel delivery is being reduced
(decreased injector pulse width), A positive value
significantly more than O percent indicates that a lean
condition exists and the PCM compensates by
adding fuel (increased injector pulse width). When the
average of the cells reach a predetermined high or
low, a fuel trim DTC sets.
Long Term FT Bank 1 and Bank 2: The scan tool
displays Percentage. The PCM derives the Long
Term Fuel Trim from the Short Term Fuel Trim value.
The Long Term Fuel Trim represents a long-term
correction of fuel delivery. A value of O percent
indicates that fuel delivery requires no compensation
Engine
in order to maintain the PCM commanded air/fuel
ratio. A negative value significantly below O percent
indicates that the fuel system is rich and the PCM
is reducing the fuel delivery (decreased injector pulse
width). A positive value significantly greater than
O Percent indicates that a lean condition exists and
the PCM compensates by adding fuel (increased
injector pulse width). Fuel trim values at maximum
authority indicates an excessively rich or lean system.
Loop Status: The scan tool displays Open or
Closed. Closed Loop indicates that the PCM is
controlling fuel delivery according to oxygen sensor
voltage. In Open Loop, the PCM ignores the oxygen
sensor voltage and bases the amount of fuel to
be delivered on TP sensor, engine coolant, and MAF
sensor inputs only.
Low Oil Lamp: The scan tool displays On or Off.
The scan tool displays On when the PCM detects that
there is a low oil level condition. The Low Oil Lamp
is then commanded on by the PCM.
Low Oil Level: The scan tool displays Yes or No.
This parameter indicates when t.he engine oil level
is low. The scan toot. displays YES when. the
PCM detects the engine oil level is. low.
MAF: The scan tool displays a range of 0.0-655 g/s.
The MAF (Mass Air Flow) is the MAF Input Frequency
converted to grams of air per second. This indicates
the amount of air entering .the engine.
MAF Frequency: The scan tool displays a range of
0-31,999 Hz. The PCM converts .current draw
needed by the MAF (to keep the hot wires at a
constant temperature) into a frequency signaL The
scan tool displays this frequency in Hertz signal.
MAP: The scan tool displays a range of
10-105 kPa/0.00-5.0 Volts. The Manifold Absolute
Pressure (MAP) sensor measures the change in
the intake manifold pressure from engine load, and
speed changes. As the intake manifold pressure
increases, the intake vacuum decrease$ resulting in a
higher MAP sensor voltage and kPa reading. The
PCM uses the MAP sensor signal for the following: (1)
Updating the BARO reading; (2) Enabling factor for
several of the diagnostics,
MIL: The .scan tool displays On or Off. The scan tool
indicates if the PCM has commanded the Malfunction
Indicator Light (MIL) On.
Mileage Since DTC Cleared: The scan tool displays
Kilometers or Miles. This parameter indicates the
mileage accumulated since an emission Diagnostic
Trouble Code cleared. The PCM stores this mileage in
the Freeze Frame and Failure records buffers.
Mileage Since First Failure: The scan tool. displays
Kilomet.ers or Miles. This parameter (ndicates the.
mileage accu.mulated since an emission Diagnostic
Trouble Code first failed. The PCM stores this mileage
in the Freeze Frame and Failure records buffers.
Mileage Since Last. Failure: The scan tool displays
Kilometers or Miles. This parameter indicates the.
mileage accumulated since an emission Diagnostic
Trouble Code last failed. The PCM. stores this mileage
in the Freeze Frame and Failure records buffers.
Engine
Mileage Since MIL Request: The scan tool displays
Kilometers or Miles. This parameter indicates the
mileage accumulated since the PCM requested the
MIL to illuminate. The PCM stores this mileage in the
Freeze Frame and Failure records buffers.
Misfire Current #1 - #8: . The scan tool displays a
range of 0-200 Counts. The Misfire Current counters
increment at a rate according to the number of
possible misfires the PCM detects on each cylinder
during the last 2oocylinder firing events.
Misfire History #1 - #8: The scan tool displays a
range of 0-65,535 Counts. The Misfire History
counters display the total level of misfire that has been
detected on each cylinder. The Misfire History
counters will not update or show any activity until a
misfire DTC (P0300) has become active. The
Misfire History counters will update every 200 cylinder
firing events.
Misfiring Cylinder: The scan tool displays
Prim. Cyl # 0-8 and Sec, Cyl # 0-8. When a multiple
misfire occurs, the scan tool displays the cylinder
with the most significant misfire under Prim. Cyl. The
scan tool displays the least significant misfire under
Sec. Cyl.
Misfire Revolution Status: The scan tool displays
Reject/Accept. This parameter indicates the misfire
diagnostic is inhibited. The scan tool displays Reject
when the conditions for running the OTC are not
in range.
Not Run Counter: The scan tool displays counts
from Oto 65;535. The scan tool displays the number of
times a. OTC diagnostic has not reached it's
predetermined criteria in order to run since it's
first failure.
PCM Reset: The scan tool displays Yes or No. This
parameter indicates when the internal. PCM resets.
The scan tool displays YES when an. internal
PCM reset occurred. The scan tool displays NO under
the normal operating conditions.
PNP: The scan tool displays PARK/NEUTRAL or
R-0321. When the transmission is in park or neutral
the scan tool displays PARK/NEUTRAL. When
you place the gear selector into reverse or any forward
gear position, the scan tool displays R-0321.
Pass Counter: The scan tool displays the number
of times a DTC has passed.
Reverse Inhibit (MIT only): The scan tool displays
Yes or No. The PCM grounds the control circuit
when the conditions are met for enabling the Reverse
Inhibit solenoid. The scan tool displays Yes when
the PCM grounds the control circuit.
Revolutions with Misfire: The scan tool displays
the number of engine revolutions the engine is
misfiring.
SHRT FT Average 1 and 2: The scan tool displays

Percentage. This parameter indicates the average
of the short term fuel trim cells. The short term fuel trim
cells are rated (Weighted) for the amount of which
they are used. For example, the PCM rates an idle cell
higher than a wide open cell. If a fueling malfunction
6-1389
is occurs in the idle cell and the wide open cell, the
idle ce!.1 would affect more than then the wide
open celL A negative value significantly below
O percent indicates that the fuel system is rich and the
PCM is reducing the fuel delivery (decreased injector
pulse width). A positive value significantly more
than O percent indicates that a lean condition exists
and the PCM is compensating by adding h.1el
(increased injector pulse width). When the average of
the cells reach a predetermined high or low, a fuel
trim OTC sets.
Short Term FT Bank 1 and Bank 2: The scan tool

displays Percentage. The Short Term FuerTrim
represents a short-term correction to fuel delivery by
the PCM in response to the amount of time the
fuel control oxygen sensor voltage spends above or
below the 450 mV threshold. If the oxygen sensor
voltage mainly remains less than 450 mV, indicating a
lean air/fuel mixture, short term fuel trim increases
into the positive range above O percent. The
PCM adds fuel. If the oxygen sensor voltage stays
mainly above the threshold, the short. term fuel
trim decreases below O percent into the negative
range. The PCM reduces the fuel delivery in order to
compensate for the indicated rich condition. Under
certain conditions such as an extend.ad idle and a high
ambient temperature, the canister purge may cause
the Sh.ort Term Fuel Trim to read in the negative range
during normal operation. The Fuel trim values at
maximum authority may indicate an excessively rich .or
lean system.
Skip Shift Lamp (MIT only): The scan tool displays
On or Off. The PCM .sends a message to the IPC
(via class 2) to enable the Skip Shift Lamp when the
Skip Shift Solenoid is enabled. Thescan tool displays
On when .the Skip Shift Lamp is On.
Skip Shift Solenoid (MIT): The scan tool displays
Enabled or Disabled. The PCM grounds the control
circuit when the c.onditions are met for enabling
the Skip Shift solenoid. The scan tool displays Enabled
when the PCM grounds the control circuit.
Spark: The scan tool displays a range of
-64 degrees to 64 degrees. The scan tool displays the
amount of degrees the PCM commands the spark

advance on the IC circuit. The PCM computes
the desired spark advance using the following:
(1) Engine coolanrtemperature; (2) Engine
speed (RPM); (3) Load; (4) Vehicle speed. The PCM
adjusts the timing;
Start Up ECT: The scan tool displays a range of
-39C to 140C (-38F to 284F). The scan tool
displays the Engine Coolant Temperature at the time
the engine was started. The PCM uses Start Up
ECT for certain DTCs.
TCC Brake Switch: The scan tool displays Applied
or Released .. This parameter indicates the state of
the TCC brake switch circuit input. The scan tool
displays Applied when you apply the vehicle brakes.
The torque converter clutch disengages. The scan tool
displays Released when you release the vehicle
brakes. This allows the torque converter clutch to
engage.
6-1390
TCC Duty Cycle: The scan tool displays Disabled or

Enabled. This parameter is the commanded state of
the TCC PWM solenoid. The scan tool displays
Enabled when the commanded state of the solenoid is
ON. The scan tool displays Disabled when the
solenoid is not on.
TCC Enable Sol.: The scan tool displays Enabled or
Disabled. The scan tool displays Enabled when the
electrical system supplies a voltage to the TCC Enable
solenoid.
Total Misfire Current Count: The scan tool
displays a range of 0-200. The Total Misfire Current
Count displays the total number of cylinder firing
.
events that the PCM detected as being misfires during
the last 200 crankshaft revolution sample period.
Total Misfire Failures Since First Fail: The scan

tool displays a range of 0-65,535. The Total
Misfire Failures Since First Fail displays the total
number of cylinder firing events that the PCM detected
as being misfires since the first failure.
Total Misfire Passes Since First Fail: The scan
tool displays a range of 0-65,535. The Total Misfire
Passes Since First Fail displays the total number
of cylinder firing events that the PCM detected
as being good since the first fail.
TP Angle: The scan tool displays 0-100 percent.
The scan tool displays the amount of throttle opening
in percentage. The scan tool displays about
O percent at closed throttle. The scan tool displays
about 100 percent at wide open throttle.
TP Sensor: The .scan tool displays 0-5 Volts. The
scan tool displays the amount of throttle opening
in voltage. When the throttle is at a closed throttle the
voltage is between 0.4-0.9 Volts. When the throttle
is at wide open throttle the voltage is above 4.0 Volts.
Traction Control: The scan tool displays Active
or Inactive (If so equipped). The scan tool displays
active if the PCM receives a signal from the Electronic
Brake and Traction Control Module (EBTCM)
requesting torque reduction during a traction control
maneuver. The scan tool displays Inactive under
Transmission OSS: The scan tool displays
transmission output speed. This parameter indicates
the rotational speed of the transmission output
shaft expressed as revolutions per minute.
Transmission Range: The scan tool displays the
transmission gear position.
Vehicle Speed: The scan tool displays km/h and
mph. The vehicle speed sensor signal is converted into
km/h and mph for display on the scan tool.
Engine
VTD Fuel Disabled: . The scan tool displays
Active/Inactive. The PCM receives a 40-60 Hertz
signal from the Body Control Module (BCM) when the
proper starting procedure occurs. When the PCM
receives this 40-60 Hertz signal the fuel system
is enabled and the engine starts. The scan tool
displays Active once the hertz signal is received by
the PCM. If an improper starting procedure occurs, the
BCM will not send the 40-60 Hertz signal to the
PCM and the PCM disables the fuel system. The scan
tool displays Inactive. .
Warm-Ups w/o Emis.sion Faults: The scan tool

displays a range of 0-255. This parameter counts the
number of warrn up cycles without an emission
fault present. The counter increments to 255 and roll
back to O unless a fault.occurs. If a fault occurs,
.
the counter reverts back to O until the fault is corrected.
Clearing the information with a scan tool or a loss of
power to the PCM also resets the counter to 0.
Warm-Ups w/o Non-Emission Faults: The scan
tool displays a range of .0-255. This parameter counts
the number of warm up cycles without a non-emission
fault present. The counter increments to 255 apd
roll back to O unless a fault occurs. If a fault occurs, .
the counter reverts back to O until the fault is corrected.
Clearing information with a scan tool or a loss of
power to the PCM also resets the counter to 0.
Diagnostic Trouble Code (OTC) Type

Definitions
Diagnostic Trouble Codes (DTCs) are categorized .into
emissions and non-emissions related types. When
a DTC is set, the MIL and Failure data are utilized by
the control modules diagnostic executive according
to the DTC type. Each DTC is set based upon
the individual DTCs running and setting criteria. It is
important to read the Action Taken When the
DTC Sets and Conditions for Clearing the MIUDTC in
the supporting text for taking appropriate action to
each DTC.
Emissions Related DTCs

Type A .
The following actions occur at the time of the
first failure:
Turns
the MIL
Stores DTC in memory
Stores Freeze Frame/Failure records data
Some Type A DTCs will not perform the above actions
when the DTC first detects afailure. Two consecutive
failures are required. This allows systems, such as
EVAP, to accurately identify what failure exists before
setting a DTC and requesting MIL illumination.
on
Engine
Engine Controls -5.7L
6-1391
Type B
Diagnostic Trouble Code (DTC) List/Type
The following actions occur at one of the

following times:
The service information contained in this manual refers

to the Federal calibration package. The export
change is NOT reflected in the service information on
the DTC's diagnostic support information page or
in the Repair Instructions. The .OTC Type table
information refers to domestic and Export calibration
packages. Export vehicles may have differences
in OTC types that will affect Malfunction Indicator
Lamp (MIL) operation. Certain OTCs have been
changed from type A to type C or, in some cases,
type X. When a type A diagnostic fails, a DTC is set
immediately and the Malfunction Indicator Lamp (MIL)
is illuminated. When a type B OTC diagnostic fails,
the Malfunction Indicator Lamp (MIL) will illuminate if
the fault is present after two consecutive ignition
cycles. A type C OTC will set after one failure and be
stored in history but will not illuminate the Malfunction
Indicator Lamp (MIL). Type X OTCs have been
turned off (the diagnostic does not run, no codes are
stored, and the Malfunction Indicator Lamp (MIL)
will not illuminate.
If a system is malfunctioning and the associated OTC
has been disabled (Type X), it may be beneficial to
use the diagnostic table as aguide to aid in diagnosis.
Many of the OTC tables include a functional check
of the system that may pinpoint a problem. However,
it is important to remember that the OTC tables
are specifically. designed for use only when a OTC is
set. Therefore, a thorough understanding of the
normal operation of .the system being diagnosed is
necessary and use of the tables for this purpose is at
the discretion of the technician.
First failure:
- Stores the OTC in memory as Failed
Last Test
- Stores Failure Records data
Second consecutive drive cycle with a failure:
- Turns on the MIL
- Stores the OTC in memory as a history OTC
- Stores Freeze Frame data
Second non-consecutive drive cycle with a failure:
- Stores the OTC in memory as Failed
Last Test
Non-Emissions Related DTCs

Type C
The following actions occur at the time of a failure:

Does not turn on the MIL
Stores the OTC in memory as a history OTC
Stores Failure Records data
Some Type C DTCs may also cause an auxiliary
service lamp to be illuminated, and/or display a
message to the vehicle operator.
TypeX
No actions occur. These DTCs are coded into the

control modules software, but will not run because
one of the following reasons:
Associated hardware is not installed with the
vehicles emission package
The diagnostic is not required for the vehicles
emission package
Important: An export vehicle may have unrequired

emissions components removed.
5..1392
Engine

Diagnostic Trouble Code (DTC).Type Table
Domestic
Export Unleaded
Fuel
RPO K29,
and VE1
Export Leade.d
Fuel
RPO NM8
OTC P0101 Mass Air Flow (MAF) Sensor Performance
OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
DTC Description
OTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
OTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit

Low Voltage
OTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit

High Voltage
'
OTC P0112 Intake Air Temperature (IA T) Sensor Circuit Low

Voltage
OTC P0113 Intake Air Temperature (/AT) Sensor Circuit High

Voltage
OTC P0117 Engine Coolant Temperature (ECT)Sensor Circuit

Low Voltage
OTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit

High Voltage
OTC P0121 TP Sensor Circuit Insufficient Activity
OTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage
Die P0123 Throttle Position (TP) Sensor Circuit High Voltage
OTC P0125 Engine Coolant Temperature (ECT) Excessive Timff_

to Closed Loop Fuel Control
..
OTC P0154 H02S Circuit Insufficient Activity Bank 2 Sensor 1
OTC P0157 H02S Circuit Low Voltage Bank 2 Sensor 2
OTC P0171 Fuel Trim System Lean Bank 1
OTC P0172 Fuel Trim System Rich Bank 1
OTC P0174 Fuel Trim System Lean Bank 2
OTC P0175 Fuel Trim System Rich Bank 2
OTC P0200 Injector Control Circuit
OTC P0218 Transmission Fluid Overtemperature (5.7L)
c
c
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
c
c
OTC P0230 Fuel Pump Relay Control Circuit
B
(No MIL)
B
(No MIL)
..
B.
OTC P0133 H02S Slow Response Bank 1 Sensor 1
OTC P0137 H02S Circuit Low Voltage Bank 1 Sensor2 ..
OTC P0153 H02S Slow Response Bank 2 Sensor 1
OTC P0300 Engine Misfire Detected

OTC P0325 Knock Sensor Module Performance
.
'
Engine
6-1393
Diagnostic Trouble Code (DTC) Type Table (cont'd)

)
DTC Description
Domestic
Export Unleaded
Fuel
RPO K29,
and VE1
Export Leaded
Fuel
RPO NM8
OTC P0327 Knock Sensor (KS) 1 Circuit
OTC P0332 Knock Sensor (KS) 2 Circuit
c
c
c
c
OTC P0335 Crankshaft Position (CKP) Sensor Circuit
OTC P0336 Crankshaft Position (CKP) Sensor Performance
OTC P0341 Camshaft Position (CMP) Sensor Performance
OTC P0342 Camshaft Position (CMP) Sensor Circuit Low

Voltage
OTC P0343 Camshaft Position (CMP) Sensor Circuit High

Voltage
OTC P0351 Ignition Coil 1 Control Circuit
OTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient
OTC P0404 Exhaust Gas Recirculation (EGR) Open Position

Performance
OTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor

Circuit Low Voltage
OTC P04.10 Secondary Air lnjection(AIR) System
B
B
c
c
OTC P0412 Secondary Air Injection (AIR) Solenoid Control

Circuit
OTC P0418 Secondary Air Injection (AIR) Pump Relay Control
Circuit
x
x
x
OTC P0440 Evaporative Emission (EVAP) System
OTC P0442 Evaporative Emission (EVAP) System Small Leak

Detected
c
c
c
c
c
OTC P0443 Evaporative Emission (EVAP) Purge Solenoid

Control Circuit
OTC P0446 Evaporative Emission (EVAP) Vent System

Performance
OTC P0449 Evaporative Emission (EVAP) Vent Solenoid Control

Circuit
OTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage
OTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage
OTC P0461 Fuel Level Sensor Performance

OTC P0463 Fuel Level Sensor Circuit High Voltage
c
c
c
OTC P0420 Catalyst System Low Efficiency Bank 1
OTC P0430 Catalyst System Low Efficiency Bank 2
OTC P0480 Cooling Fan Relay 1 Control Circuit
OTC P0481 Cooling Fan Relay 2 and 3 Control Circuit
c
c
c
c
c
c
c
c
OTC P0500 Vehicle Speed Sensor (VSS) Circuit

c
x
OTC P0502 Vehicle Speed Sens.or (VSS) Circuit Low Input (5.7L)
OTC P0462 Fuel Level Sensor Circuit Low Voltage
x
x
c
c
c
C
..
6-1394
Engine

Diagnostic Trouble Code (DTC) Type Table (cont'd)
Domestic
Export Unleaded
Fuel
RPO K29,
and.VE1
Export Leaded
Fuel
RPO NM8
B
B
B
B
B
B
OTC P0563 System Voltage High
c
c
c
c
c
c
OTC P0601Control Module Read Only Memory (ROM)
A.
OTC P0602 Control Module Not Programmed
DTC Description
OTC P0503 Vehicle Speed Sensor (VSS) Circuit Intermittent
(5.7L) (Automatic Transmission)
OTC P0506 Idle Speed Low
. OTC P0507 Idle Speed High
OTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor
Circuit
OTC P0562 System Voltage Low
c
c
c
..
OTC P0604 Control Module Random Access Memory (RAM)
OTC P0608 Vehicle Speed Output Circuit
OTC P0645 Air Conditioning (A/C) Clutch Relay Control Circuit
c
c
OTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit
(No MIL)
(No MIL)
(No MIL)
c
c
c
x
c
c

OTC P0711 TFT Sensor Circuit Range/Performance (5.7L)
c
c
.C
... .c
OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit

Low Input (5. 7L)
OTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit

High Input (5. 7L)
c
c
c
c
c
c
OTC P0742 TCC System Stuck On (5.7L)
B
B
B
B
OTC P0748 Pressure Control Solenoid Circuit Electrical (5.7L)
OTC P0751 1-2 Shift Solenoid Valve Performance (5.7L)
'
OTC P0753 1-2 Shift Solenoid Circuit Electrical (5.7L)
OTC P0756 2-3 Shift Solenoid Valve Performance (5. 7L)
OTC P0758 2-3 Shift Solenoid Circuit Electrical (5. 7L)
OTC P0785 3-2 Shift Solenoid Circuit Electrical (5. 7L)
OTC P0801 Reverse Inhibit Solenoid Control Circuit

c
c
c
c
c
c
c
c
c
c
c
x
OTC P0803 Skip Shift Solenoid C.ontrol Circ.uit

OTC P1111 Intake Air Temperature (!AT) Sensor Circuit

OTC Pt 112 Intake Air Temperature (/AT) Sensor Circuit

OTC P0719 Brake Switch Circuit Low Input (5. 7L)

OTC P0724 Brake Switch Circuit High Input (5.7L)
OTC P0740 TCC Enable Solenoid Circuit Electrical (5.7L)


'.
OTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High

Voltage
OTC P1122 Throttle Position (TP) Sensor Circuit Intermittent Low

Voltage
c
c
c
x
Engine
6-1395
Diagnostic Trouble Code (OTC) Type Table (cont'd)

Export Unleaded
Fuel
Domestic
RPO K29,
and VE1
Export Leaded
Fuel
RPO NMB
8
8
8
c
c
c
x
x
x
OTC P1258 Engine Coolant Overtemperature - Protection Mode

Active
OTC Pt 336 Crankshaft Position (CKP) System Variation Not

Learned
c
c
x
x
x
x
8
8
x
x
x
x
DTC Description
OTC P1134 H02S Transition Time Ratio Bank 1 Sensor 1
OTCP1380 Misfire Detected - Rough Road Data Not Available

OTC P1381 Misfire Detected - No Communication with Brake
Control.Module
OTCP1404 Exhaust Gas Recirculation(EGR) Closed Position
Performance
OTC Pt 441 Evaporative Emission (EVAP) System Flow During

Non-Purge
c
c
c
OTC Pt 539 Air Conditioning (AIC) Clutch Feedback Circuit High

Voltage
OTC P1546 Air Conditioning (AIC) Clutch Feedback Circuit Low

Voltage
c
c
DTCP1415 Secondary Air Injection (AIR) System Bank 1

OTC P1416 Secondary Air Injection (AIR) System Bank 2
OTC P1626 Theft Deterrent Fuel Enable Signal Lost
c
c
OTC Pt 635 5 Volt Reference 1 Circuit
OTC P1637 Generator L-Terminal Circuit
DTCP1639 5.Volt Reference 2 Circuit
8
8
8
8
8
8
8
8
OTC P1810 TFP Valve Position Switch Circuit (5.7L)

OTC Pt 860 TCC PWM Solenoid Circuit Electrical (5. 7L)
OTC Pt 870 Transmission Component Slipping (5. 7L)
c
c
c
6-1396
Engine

Description
The Engine Cranks but Does Not Run diagnostic table
assumes that battery condition and engine cranking
speed are OK. If the battery condition and the cranking
speed are not OK, refer to Engine Cranks/Cranks
Slowly, but Does Not Start in Engine Electrical
for diagnosis. Make sure that there is adequate fuel in
the tank.
Diagnostic Aids
- Poor connections-refer to Testing for
Systems.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Check the duct work between the Mass Air
Flow (MAF) sensor and the throttle body for
air leaks.
A malfunctioning MAF sensor may cause a no
start or a stall after start. If you suspect this,
disconnect the MAF sensor. The PCM will default
to the speed density (MAP, IAT, RPM) in order
to calculate the load and the air flow. If this
corrects the condition and the connections are
OK, replace the MAF sensor. Refer to MAF
Sensor Replacement for procedures.
If certain components are disconnected at the
same time, the engine may not start and NO
DTCs set.
.. For an intermittent, refer to Symptoms.
Test Description
diagnostic table.
2. Certain DTCs only set while cranking the engine.
This step verifies if a component is causing the
no start condition.
4. This step is testing for a grounded ignition feed
circuit for.the crankshaft position sensor and
the camshaft position sensor. When the ignition
feed circuit is shorted, a no start occurs and
no DTCs are set. The ignition feed circuits are
connected internally within the PCM. The
PCM cannot detect that the engine is cranking
with a grounded ignition feed circuit If no engine
speed is displayed on the scan tool, inspect
the ignition feed circuit for a short to ground.
The scan tool may reset if the battery is at a low
state of charge. The battery may need to be
charged to perform this step.
5. This step verifies the IGN relay for proper
operation. The IGN relay supplies voltage to the
injectors and the ignition coils. When the IGN relay
is not operating properly, a no start condition
occurs. If the test lamp does not illuminate, th.is
indicates the IGN relay is not suppling a voltage to
the fuses.
6. The Crankshaft Position sensor is located near
the starter.
7. The Camshaft Position sensor is located at the
rear of the engine behind the intake manifold.
8. The ignition feed circuit for the Camshaft and.
Crankshaft Positior:i sensors is internally
connected within the PCM. A short. to ground on
either circuit causes a no start condition.
10. The fuel cap may need to be removed to hear if
the fuel pump is operating.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to the
applicable
OTC table
Go to Step 3
Go to
OTC P1626 Theft
Deterrent Fuel
Enable
Signal Lost
Go to Step 4
Go to Step 5
Go to Step 6

1
Important: Refer to applicable DTC table if any of the

following DTCs are set: P0230, P0335, P0336, P0601,
P0602, P0604.
Crank the engine for the specified amount of time.
Does the scan tool display any DTCs that failed this
ignition?
Monitor the VTD Fuel Enabled status using a scan tool.
Does the scan tool display Active?
Monitor the engine speed while cranking the engine.

Is engine RPM indicated on the scan tool?
15 seconds
Engine
6-1397

Step
Action
Value(s)

2. Probe both sides of the fuses (located in the
Underhood Electrical Center 2) listed below using the
J 34142-8 test lamp connected to ground.
INJR1
INJR2
ENG CTRL
ENG SEN
A/C CRUISE
Does the test lamp illuminate on both sides of all
the fuses?
1. Disconnect the Crankshaft Position (CKP) sensor

electrical connector. Refer to Crankshaft
2. Measure the voltage at the ignition feed circuit at the
CKP electrical connector using the DMM.
Does the DMM display near the specified value?
B+
1. Disconnect the Camshaft Position (CMP) sensor

electrical connector. Refer to Camshaft
2. Measure the voltage at the ignition feed circuit at the
CMP electrical connector using the DMM.
Does the DMM display near the specified value?
B+
Yes
No
Go to Step 9
Go to Ignition
Relay Diagnosis
Go to Step 13
Go to Step 7
Go to Step 14
Go to Step 8
Go to Step 16
Go to Step 15
Go to Step 10
Go to
OTC P0118
Engine Coolant
Temperature
(ECT) Sensor
Circuit High
Voltage
Go to Step 11
Go to Fuel Pump
Electrical Circuit
Diagnosis
Go to Step 12
Go to Fuel
System
Diagnosis
1. Test the Camshaft and Crankshaft Position sensor
ignition feed circuits for a short to ground. Refer to

Testing for Short to Ground in Wiring Systems.
2. If you find a grounded circuit repair the circuit as
necessary. Refer to Wiring Repairs in Wiring
Systems.
Monitor the engine coolant temperature using the

scan tool.
Is the engine coolant temperature on the scan tool close to
the actual engine temperature?
10
Enable the fuel pump using the scan tool.

Does the fuel pump operate?
11

2. Install a fuel pressure gauge. Refer to Fuel System
Diagnosis.
3. Turn ON tl:,e ignition leaving the engine OFF.
4. Observe the fuel pressure.
Is the fuel pressure within the specified range when the
fuel pump is operating?
380420 kPa (5561 psi)
6-1398
Engine

Step
Action
12
Perform the following additional inspections:

Inspect the duct work between the Mass Air
Flow (MAF) sensor and the throttle body for air .leaks.
Inspect that the throttle angle is at 0% at a closed
throttle. If the throttle angle is not at 0%, refer to
OTC P0122 Throttle Position (TP) Sensor Circuit Low
Voltage and OTC P0123 Throttle Position (TP) Sensor
A malfunctioning MAF sensor may cause a no start or
a stall after a start. If you suspect this, disconnect the
MAF sensor. The PCM will default to the speed
density (MAP, IAT, RPM) in order to calculate the
engine load and the intake air flow. If disconnecting
the MAF sensor corrects the condition and the
connections are OK, replace the MAF sensor. Refer to
MAF Sensor Replacement.
Inspect the spark plugs for being gas fouled. Refer to
Spark Plug Visual Diagnosis in Engine Electrical. If the
spark plugs are gas fouled, determine what caused
the rich condition.
Inspect for an engine mechanical failure that causes
an engine not to start (i.e. timing chain, low
compression).
Compare MAP/BARO parameters to another vehicle.
The parameter values should be close to each other.
Replace the CKP sensor. Refer to Crankshaft


Important: Program the replacement PCM. Refer to PCM

Replace the PCM.
1. Select the Diagnostic Trouble Codes (DTC) option

and the Clear DTC Information option using the
scan tool.
2. Attempt to start the engine.
Does the engine start and continue. to run?
17

2. Monitor the Diagnostic Trouble Code (DTC) option
using the scan tool.
Are any DTCs displayed?
18
Select the Capture Info option and the Review Info option
Are any DTCs displayed that you have not diagnosed?
13
14
15
16
Value(s)
Yes
No
Go to Step 16
Go to Hard Start
for diagnosis
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 17
Go to.Step 2
Go to the
applicable
DTC table
Go to Step 18
Go to the
applicable
DTC table
System OK
Engine
6-1399
lgnjtion Relay Diagnosis

Power
Distribution
Cell10
!Loe
RED 2
RED 2
Starter and
Charging
Cell30
B C2
'" - - - ; -- - - - ., Ignition
I
I Switch .
Llli
~B.::rt .:
: AL::k 8 ..
oit'
L----
Run Test I
---.J
C C2
PNK 3
PNK
~ - - - - - - - - - - ~- - - - - - - - l ! J >
3
PNK 3
PNK 3
'" -
c"; - - - - - - - - - - - - - - "'" - - Ignition

Relay
:~~ ~0~9 -
~ Underhood
I Fuse Block
H7
H6
'. -
Power
Distribution
Cell 10
PCM IGN
Mini Fuse
15 A
H9
HS
ABS IGN
Mini Fuse
10 A
Assembly 2
I'
I
I
-1----------------"
PCM
PNK 1039
PNK 1039
- -.- -
- - - Underhood ~ Fuse Block

--------------------------.---------,
Assembly 2 I1 G9
ENG CTRL
G7
A/C CRUISE G11
J7
ENG SEN
J9
INJ 1
J11
I GS
Mini Fuse
15 A
G6
Mini Fuse
15 A
Not
Used
J6
Mini Fuse
20 A
JS
L-
EVAP Canister Purge Solenoid,

Vent' Solenoid and Transmission
Mini Fuse
15 A
-
NC Clutch
Relay
MAF Sensor, H02S, Reverse

Inhibit Solenoid and
Skip Shift Solenoid
Bank 1 Injectors and

Ignition Coil/Modules
J10
-
- - - ..,
INJ 2
Mini Fuse
15 A
-,- -
...I
Bank 2 Injectors and

Ignition Coil/Modules
372882
Circuit Description
The IGN relay powers the following components:
Injectors/Ignition coils
Transmission
A/C system
EVAP solenoid and EVAP Vent Valve
MAF sensor
Heated Oxygen Sensors
Diagnostic Aids
- Poor connections; Refer to Testing for
Systems.
- Corrosion
Mis-routed harness.
Rubbed through wire insulation.
- Broken wire inside the insulation.
For an intermittent, .refer to Symptoms.
6-1400
Engine
9. Inspect the fuses for the IGN relay for being open.
If a fuse. is open, inspect the circuits for a .short to
(
ground.
Test Description
diagnostic table.
4. This step tests the ignition relay ground circuit
5. This step isolates the circuit from the IGN relay.
All of the circuits at the relay are good if the
test lamp illuminates.
11. Remove the underhood electrical center and

inspect the circuits that are supplied a voltage by
the IG.N relay.
8. Inspect the fuses for the IGN relay for being open.
If a fuse is open inspect the circuits for a short to
ground.
Ignition Relay Diagnosis

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 8

Important: For terminal identification, refer to Electrical

Center Identification Views in Wiring Systems.
2. Remove the underhood electrical center 2 cover.
3. Remove the IGN relay.

4. Probe the IGN relay B+ feed circuit (switch side of
relay) at the underhood electrical center 2 with the

J 34142-8 test lamp connected to battery ground.

2. Probe the IGN relay ignition feed circuit (coil side of
relay) at th.e underhood electrical center 2 with the
J 34142-8 test lamp connected to battery ground.
2. Measure the resistance of the IGN relay ground
circuit at the underhood electrical center 2 using the
DMM connected to the battery ground.
Is the resistance less than the specified value?
(
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 10
o-2n

2. Jumper the IGN relay B+ teed circuit and the IGN
relay load circuit together at the underhood electrical
center 2 using a fused jumper wire. Refer to Using
Fused Jumper Wires in Wiring Systems.
3. Probe the fuses for the following components with the
J 34142-8 test lamp connected to a ground.
ENG CTRL
A/C CRUISE
INJR1
INJR2
ENG SEN
1. Inspect the IGN relay for poor connections at the

underhood electrical center. Refer to Testing for
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
I.
Go to Step 6
Go to Step 11
(
System OK
Go to Step 7
Engine
6-1401
Ignition Relay Diagnosis (cont'd)

Action
Step
Replace the IGN relay.

Repair the open B+ supply to the IGN relay. Refer to
Value(s)
-
System OK
No
System OK

Repair the ignition feed circuit to the IGN relay. Refer to
10
Repair the open or the high resistance. int.he ground circuit

for the IGN relay. Refer to Wiring Repairs in Wiring
Systems.
11
Repair the IGN relay load circuit. Refer to Wiring Repairs

in Wiring Systems.
Yes
System OK
System OK
-
System OK
6-1402
Engine
! Hot At All Times!
P-;;;N; - - -
I Distribution
GRY 1120
GR:I120
.. -
- - - - ., Fuel
I
Fuel
Pump
Tank
Unit
L-
BLK
.I
1150
Cell 10
H9
- - - -
~Underhood
FUEL PUMP I Fuse Block
MiniFuse Assembly 1
ITT
LlLI
Im----- ____ .,
I
H8
20A
ORN 1340
:-1- A,O1- ---;; l~u: ~ ~~~=r~~~~

i C:(--y_=j
Assembly2
~~~ --:K G-R::H:14~-;
BLK/WHT 451
BLK/WHT 451
DK GRN/WHT 465
lll
slc2
BLK 1050
Ground
Distribution
Cell14
r--------------,
v
Powertrain
I
I
I
I
CONN ID
C1 =BLU
C2=RED
Fuel
Pump
Relay
Control
-,
Ground
Distribution
Cell14
....
Control
I Module
I (PCM)
I
BLK 451
L-------------~ ~
(
372984
Circuit Description
Diagnostic Aids
When the ignition switch is ON, the PCM activates the

in-tank fuel pump. The fuel pump remains ON as
long as the PCM receives reference pulses from the
ignition system. If there are no reference pulses,
the PCM turns the fuel pump OFF after about
2-3 seconds. The pump delivers fuel to the fuel rail
~nd injectors. The fuel pressure regulator, located
in the fuel tank, maintains the system pressure at 380410 kPa (55-60 psi). Excess fuel returns to the fuel
tank. When the engine is stopped, a scan tool in
the output controls function can turn ON the fuel pump.
Improper fuel system pressure results in one or
many of the following symptoms:
Cranks but will not run
Cuts out, may feel like an ignition problem
Poor fuel economy
Loss of power
Hesitation
DTCs
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that 1he
gaskets are installed correctly. The gaskets
prevent contaminant intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
J 35616-A connector test adapter kit. Using this kit
prevents any damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
For an intermittent, refer to Intermittent Conditions.
Test Description
diagnostic table.
2. Command both the ON and OFF states. Repeat
3. This step determines if the condition is localed on
the coil side or the switch side of the circuit.
4. Verifies that the powertrain control module is
providing voltage to the fuel pump relay.
5. Tests for an open in the ground circuit to the fuel
pump relay.
Engine
6. This step determines if a voltage is constantly
being applied to the fuel pump relay.
12. This step determines if the condition is between

the fuel pump relay and the body pass. through
connector.
15. This step tests if the relay is causing the condition.
Use a fused jumper wire with a 20 Amp fuse.
16. This step determines if the condition is between
the fuel pump relay and the body pass through
connector.
6-1403
17. This step verifies if the fuel pump ground circuit is

causing the condition. Inspect all connections for
corrosion or poor connections.
18. A condition with the fuel pump jumper harness
may cause the pump to be inoperative. Inspect
the fuel pump jumper harness carefully.
20. This step determines if the condition with the
circuit is intermittent. If the fuse does not
open, inspect the supply voltage circuit between
the fuse and the fuel pump for an intermittent
condition.

Step
Action
Yes
No
Go to Step 2
Go to A Powertrain
On Board
Diagnostic (OBD)
System Check
Go to Intermittent
Conditions
Go to Step 3
Go to Step 9
Go to Step 4

Disconnect the fuel pump relay.
Probe the control circuit of the fuel pump relay with a test lamp
5. With a scan tool, command the fuel pump relay ON and OFF.
Does the test lamp turn ON and OFF? .
Go to Step 5
Go to Step 6
1. Connect a test lamp between the control circuit of the fuel

pump relay and the ground circuit of thefuel pump relay.
Does the test lamp turn ON and OFF?
Go to Step21
Go to Step24
Does the test lamp remain illuminated with each command?
Go to Step 7
Go to Step 8
1. Dlsconnect the PCM. Refer to PCM

Replacement/Programming:
2. Test the control circuit of the fuel pump relay for a short to
voltage. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Did you find and correct the condition? "
Go to Step29
Go to Step 28
1. Disconnect the PCM. Refer toPCM

2. Test the control circuit of the fuel pump relay for a short to
ground or an open. Ref~r to Cirpuit Testingrand Circuit Testing
in Wiring Systems.
Go to Step 29
Go to Step 22
Turn ON the ignition, with the. engine OFF.

Does the fuel pump operate continuously?
Go to Step 10
Go to Step 11
10

2. Disconnect the fuel pump relay.
3. Turn ON the ignition; with theengine OFF.
Does the fuel pump operate continuously?
Go to Step23
Go to Step 27
1i
Is the fuel pump fuse open?
Go to Step 12
Go to Step 14
Did you perform the Diagnostic System Check-Engine Controls?

1

Does the fuel pump turn ON and OFF?
With a scan tool, command the fuel pump relay ON and .OFF.
Do you hear a click when you command the fuel pump relay ON
and OFF?
1.
2.
3.
4.
6-1404
Engine

Step
Action
Yes
No
12
Disconnect the fuel pump jumper harness from the body pass
tnrough connector. Refer to Outside Left Rear of the Floor Pan,
Forward of the Rear Axle in Wiring Systems.
Test the supply voltage circuit of the fuel pump for a grounded
circuit between the. fuel pump relay and the body pass through
connector. Refer to Circuit Testing and Wiring Repairs in Wiring
Systems.
Replace the fuel pump fuse if necessary.
Go to Step29
Go to Step 13
13
1. Lower the fuel tank. Refer to Fuel Tank Replacement.

2. Test or inspect the fuel pump jumper harness for the following:
Damage to the harness.
e A grounded circuit. Refer to Circuit Testing and Wiring
Go to Step29
Go to Step20

Disconnect the fuel pump relay.
Probe the battery voltage circuit of the fuel pump relay switch
with a test lamp that is connected to a good ground.
Go to Step 15
Go to Step25
Connect a 20 amp fused jumper wire between the battery voltage

circuit of the fuel pump relay switch and the supply voltage circuit of
the fuel pump.
Does the fuel pump operate?
Go to Step21
Go to Step 16
1. Disconnect the fuel pump jumper harness from the body pass
through connector. Refer to Outside Left Rear ofthe Floor
Pan, Forward of the Rear Axle in Wiring Systems.
2. Test the supply voltage circuit of the fuel pump for an open or
high resistance between the fuel pump relay and the body
pass through connector. Refer to Circuit Testing and Wiring
Go to Step29
Go to Step 17
Test the ground circuit of the fuel pump for an open or high
resistance between the body pass through connector and ground.
Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
Go to Step29
Go to Step 18
Inspect for poor connections at the fuel pump jumper harness to the
body pass through connector. Refer to Testing for Intermittent and
Poor Connections and Connector Repairs in Wiring Systems.
Go to Step29
Go to Step 19
1. Lower the fuel tank. Refer to Fuel Tank Replacement

2. Test or inspect the fuel pump jumper harness for the following:
e A open circuit. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
O Poor connection at the fuel pump connector. Refer to
Go to Step29
Go to Step26
14
15
16
.
1.
2.
3.
4.
Important: Visually/physically inspect the ground circuit for being

tight, corrosion on terminals, or damage to the wiring harness.
17
18
19
Engine
6-1405

Step
Yes
No
Is the fuel pump fuse open?
Go to Step26
Go to Intermittent
Conditions
Inspect for poor connections at the fuel pump relay. Refer to Testing
for Intermittent and Poor Connections and Connector Repairs in
Wiring Systems.
Go to Step29
Go to Step27
22
Inspect for poor connections at the harness connector of the PCM.

Go to Step29
Go. to Step 28
23
Repair the supply voltage circuit of the fuel pump for a short to
\
Go to Step29
Repair the open fuel pump relay ground circuit. Refer to Wiring
Go to Step29
Repair the battery voltage circuit of the fuel pump relay switch.
Go to Step29
20
21
24
25
Action
1. Install all disconnected components.

2. Install a new fuel pump fuse.
3. With a scan tool, turn ON the fuel pump.
Important: Inspect for poor connections at the fuel pump, within the
fuel tank, before replacing the fuel pump.
1. Replace the fuel pump. Refer to Fuel Tank Pump Module
Replacement.
2. Replace the fuel pump fuse if necessary.
Go to Step29
27
Replace the fuel pump relay.

Did you complete the replacement? .
Go to Step29
28
Replace the PCM. Refer to PCM Replacement/Programming.

Go to Step29
29

. 26
System OK
Go to Step2
6-1406
Engine
Engine Controls - 5]l
(
218096
Legend
(1) J 37287 Fuel Line Shut-off Adapters
(2) Rear Fuel Return Pipe
(3) T-connector
(4) Fuel Return Pipe

(5) Fuel Feed Pipe
(6) J 34730-1A Fuel Pressure Gauge
Circuit Description
Test Description
When you turn ON the ignition switch, the Powertrain

Control Module (PCM) turns ON the in-tank fuel
pump. The in-tank fuel pump remains ON as long as
the engine is cranking or running and the PCM
receives reference pulses. If there are no reference
pulses, the PCM turns the in-tank fuel pump OFF
2 seconds after the ignition switch is turned ON
or 2 seconds after the engine stops running.

diagnostic table.
The electric fuel pump attaches to the fuel sender

assembly inside the fuel tank. The in-tank fuel pump
supplies fuel through an in-pipe fuel filter to the fuel rail
assembly. The fuel pump provides fuel at a pressure
above the pressure needed by the fuel injectors.
The fuel pressure regulator keeps the fuel available to
the fuel injectors at a regulated pressure. The fuel
pressure regulator attaches to the fuel sender
assembly return pipe. Unused fuel returns to the fuel
tank by a separate fuel return pipe. The fuel return
pipe attaches to a T-connector in the fuel feed pipe on
the outlet side of the fuel filter.
2. When the ignition switch is ON and the fuel pump

is running, the fuel pressure indicated by the fuel
pressure gauge should read 380-410 kPa
(55-60 psi). The spring pressure inside the fuel
pressure regulator controls the fuel pressure.
3. A fuel system that drops more than 34 kPa (5 psi)
in 10 minutes has a leak in one or more of the
following areas:
.. The fuel pipes.
The fuel pump check valve.
., The fuel pump flex pipe.
0 The valve or valve seat within the fuel pressure
regulator.
.. The fuel injector(s).
4. A fuel system that drops more than 14 kPa (2 psi)
in 10 minutes after being relieved to
69 kPa (10 psi) indicates a leaking fuel pump
check valve.
Engine
5. Fuel pressure that drops-off during acceleration,
cruise, or hard cornering may cause a lean
condition. A lean condition can cause a loss of
power, surging, or misfire. You can diagnose
a lean condition using a scan tool. If an extremely
lean condition occurs, the heated oxygen
sensors(s) will stop toggling. The heated oxygen
sensor output voltage(s) will drop below
300 mV. The fuel injector pulse width will increase.
Important: Make sure the fuel system is not operating
in the Fuel Cut-Off Mode. This can cause false
indications by the scan tool.
10. A rich condition may result from the fuel pressure
being above 41 O kPa (60 psi). A rich condition
may cause DTC P0132, DTC P0152, DTC P0172
or DTC P0175 to set. Driveability conditions
associated with rich conditions can include hard
starting followed by black smoke and a strong
sulfur smell in the exhaust.
11. This test determines if the high fuel pressure is
due to a restricted fuel return pipe or if the
high fuel pressure is due to a faulty fuel pressure
regulator.
12. A lean condition may result from the fuel pressure
being below 380 kPa (55 psi). A lean condition
may cause DTC P0131, DTC P0151, DTC P0171
or DTC P0174 to set Driveability conditions
associated with lean conditions can include hard
starting (when the engine is cold), hesitation,
poor driveability, lack of power, surging, and
misfiring.
6;..1407

500 kPa (72 psi) may damage the fuel pressure
regulator.
13. Restricting the fuel return pipe with the J 37287
fuel pipe shut-off adapter causes the fuel
pressure to rise above the regulated fuel pressure.
Using a scan tool to pressurize the fuel system,
the fuel pressure should rise above
41 O kPa (60 psi) as the valve on the fuel pipe
shut-off adapter connected to the fuel return pipe
becomes partially closed.
18. Check the spark plug associated with a particular
fuel injector for fouling.or saturation in order to
determine if that particular fuel injector is leaking.
If checking the spark plug associated with a
particular fuel injector for fouling or saturation does
not determine that a particular fuel injector is
leaking, use the following procedure:
1. Remove the fuel rail, but leave the fuel pipe
connected to the fuel rail. Refer to Fuel Rail
2. Lift the fuel rail just enough to leave the fuel

injector nozzles i.n the fuel injector ports.

personal injury that may result from fuel spraying
on the engine, verify that the fuel rail is positioned
over the fuel injector ports. Also verify that the
fuel injector retaining clips are intact.
3. Pressurize the fuel system by using the scan
tool fuel pump enable.
4. Visually and physically inspect the fuel injector
nozzles for leaks.
6-1408
Engine
Step
Action
Value(s)
Yes
Did you perform the Powertrain On-Board Diagnostic (OBD)

System Check?

2. Turn the air conditioning system OFF.
3. Install the J 34730-1A fuel pressure gauge (6).
4. Place the bleed hose ofthe fuel pressure gauge into
7. Turn the ignition OFF for 10 seconds.
achieve the highest possible fuel pressure.
9. Observe the fuel pressure with the fuel pump running.
380-410 kPa
(55-60 psi)
Important: The fuel pressure .may vary slightly when the

fuel pump stops running. After the fuel pump stops running
the fuel pressure should stabilize arid remain constant.
in 1O minutes?
34 kPa (5 psi)
Relieve the fuel pressure to the first specified value.

Does the fuel pressure drop more than the second specified
value in 10 minutes?
69 kPa (10 psi)

14 kPa (2 psi)
Do you suspect the fuel pressure of dropping-off during

acceleration, cruise, or hard cornering?
Visually and physically inspect the following items for a

restriction:
The fuel filter.
The fuel feed pipe (5).
Did you find a restriction?

2. Visually and physically inspect the following items:
The fuel pump strainer for a restriction
The fuel pump flex pipe for leaks
The fuel pressure regulator for leaks
The fuel pressure regulator fuel return pipe for leaks
Verify the fuel pump is the correct fuel pump for this
vehicle
Did you find a problem in any of these areas?
Go to Step 2
Go to A
Powertrain On
. Board
Diagnostic (080)
System Check
Go to Step 3
Goto Step 10
Go to Step 8
Go to Step 4
Go to Step 17
Go to Step 5
Go to Step 6
Go1o
Symptoms
Go to Step 21
Go to Step 7
Go to Step 21
Go to Step 17
No
Engine
6-1409
Fuel System Diagnosis (cont'd)
10
11
Value(s)
Action
Step
1. Relieve the fuel pressure. Refer to the Fuel Pressure

Relief Procedure.
2. Disconnect the fuel feed pipe (5) from the fuel rail.
3. Install the J 37287 fuel pipe shut-off adapter (1)
between the fuel feed pipe and the fuel rail.
4. Open the valve on the fuel feed pipe shut-off adapter.
5. Pressurize the fuel system using a scan tool.
6. Pl.ace the bleed hose of the fuel pressure gauge (6)
into an approved gasoline container.
9. Close the valve in the fuel feed pipe shut-off adapter.
Important: This step requires the aid of an assistant.
1. Open the valve in the fuel feed pipe shut-off
adapter (1 ).
Relief Procedure.
4. Disconnect the steel fuel return pipe (4) at the nylon
rear return pipe (2).
5. Drain any remaining fuel from the pipes into an
between the steel fuel return pipe and the rear nylon
return pipe.
9. Close the valve in the fuel pipe shut-off adapter that is
connected to the fuel return pipe (4).
Is the.fuel pressure above the specified limit?
Relief Procedure.
2. Disconnect the steel fuel return pipe (4) at the nylon
3. Drain any remaining fuel from the fuel pipes into an
4. Attach a length of flexible fuel hose to the steel fuel
return pipe attached to the T-connector (3).
5. Place the open end of the flexible fuel hose into an
6. Turn ON the fuel pump using a scan tool.
7. Observe the fuel flow with the fuel pump running.
Is there fuel flow?
12
Is the fuel pressure above the specified value?
Yes
No
Go to Step 9
Go to Step 18
Go to Step 16
Go to Step 17
Go to Step 11
Go to Step 12
Go to Step20
Go to step 19
Go to Step 13
Go to Step 14
..
410 kPa (60 psi)
O kPa (0 psi)
6-1410
Engine
Fuel System Diagnosis (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 16
Go to Step 7
Go to Step 15
Go to Fuel
Pump Electrical
Circuit
Diagnosis
Important: This step requires the aid of an assistant.

Relief Procedure.

3. Disconnect the steel fuel return pipe (4) from the nylon
4. Drain any remaining fuel from the fuel pipes into an
between the steel fuel return pipe and the nylon rear
fuel return pipe.
13
410 kPa (60 psi)
6. Open the valve on the fuel pipe shut-off adapter.

8. Place the bleed hose of the fuel pressure gauge (6)
into an approved gasoline container.
500 kPa (72 psi) may damage the fuel pressure regulator.
10. Slowly close the valve in the fuel pipe shut-off adapter
that is connected to the fuel return pipe.
Does the fuel pressure rise above the specified value?
Turn ON the fuel pump using a scan tool.
14
Does the fuel pump run?
Visually and physically inspect the following items:
The fuel filter for obstructions.

15
O
The fuel feed pipe (5) for a restriction.
The fuel pump strainer for obstructions.
The fuel pump flex pipe for leaks.

Did you find a problem in any of these areas?
16
17
Go to Step 21
Replace the fuel pressure regulator. Refer to Fuel Pressure

Regulator Replacement.
Replace the fuel pump. Refer to Fuel Tank Pump Module
Replacement.
19
Locate and replace any leaking fuel injector(s).

Locate and correct the restriction in the steel fuel return
pipe (4) or the T-connector (3).
System OK
:
Visually and physically inspect the nylon rear fuel return

pipe (2) for a restriction.
System OK
-
Repair the problem as necessary.

System OK
System OK
-
Did you find a restriction?

21

20
18
Go to Step 17
Go to Step 21
System OK
Go to Step 16.
Engine
6-1411

F -
C105
O.SPNKf 539
$104
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0.8 PNK 539
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I
I MAF
I S~nsor
I Signal
Distribution
Schematics
In Wiring
Systems
Powertrain
Control
I Module
I {PCM)
"I
o.asv!~p~
______________________
Power
.._ Ground
3 BLK 451
PCM
C1 =BLU
C2=RED
...-----,
. . ___ ------..! ""
Power
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0.35 BLK/W.
:Ti451
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__
Sensor
~
__,
Signal
Mass Air
Flow (MAF)
Sensor
Ground
Distribution
- i Schematics
hi Wiring
Systems
.,,. G110
582405
Circuit Description
The Mass Air Flow (MAF) sensor measures the.
amount of air ingested by the engine. The direct
measurement of the air entering the engine is more
accurate than calculating the airflow from the MAP, the
IAT and the engine speed (speed/density). The
MAF sensor has a battery feed, ground, a.nd a signal
) circuit.
The MAF sensor used on this engine is a hot wire
type. This engine uses the MAF sensor to measure air
flow rate. The MAF output frequency is a function of
the po\fler required to keep the air flow sensing
elements (hot wires) at a fixed temperature above the
ambient temperature. Air flowing through the sensor
cools the sensing elements. The amount of cooling is
proportional to the amount of air flow. The MAF.
sensor requires a greater amount of current in order to
maintain the hot wires at a constant temperature as
the air flow increases. The MAF sensor converts
the changes in current draw to a frequency signal read
by the PCM. The PCM calculates the air flow (grams
per second) based on this signal.
The PCM monitors the MAF sensor frequency. The
PCM can determine if the sensor is stuck low,
stuck high, not providing the airflow value expected for
a given operating condition, or that the signal
appears to be stuck based on a lack of signal variation
expected during the normal operation. This diagnostic
tests the range/performance of the MAF sensor.
The MAF system performance or rationality diagnostic
uses the MAP, the IAT, and the engine speed to
calculate an expected airflow rate. The PCM then
compares the rate to the actual measured airflow from
the MAF sensor. The PCM only compares the
) actual MAF value and the calculated value during
conditions where the values are likely to match. This
DTC sets if the actual MAF reading is not within a
predetermined range of the calculated reading.

DTCs POi 02, POi 03, POi 07, P0108, POi 21,
POi 22, P0123 not set.
" The TP sensor angle is less than 50 percent
and the engine vacuum (BARO-MAP) is greater
than 65 kPa.
The system voltage is.more than 11 volts but less
than 18 volts.
" The EGR pintle position is less than 90 percent
" The change in TP sensor is less than 3 percent.
All above conditions stable for 2.0 seconds.

The MAF frequency is 50 percent different from
the speed density calculation.
All conditions met for 5.0 seconds.

The PCM illuminates the malfunction indicator
lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails.
" The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure Records.
6-1412

The PCM turns the malfunction indicator
lamp (MIL) OFF after 3 consecutive ignition cycles
that the diagnostic runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History O.TC clears after 40 consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.
Diagnostic Aids
Important:
diagnosing/replacing the PCM. Ensure that the
in Wiring Systems for procedures.
Any un-metered air may cause this OTC to set.
- An engine vacuum leak
- The PCV system for vacuum leaks
- An incorrect PCV valve
- The engine oil dip stick not fully seated
Engine
Test Description
diagnostic table.
2. The MAF system performance or rationality

diagnostic uses the MAP sensor signal along with
other inputs in order to calculate an expected
airflow rate. The PCM then compares the
expected flow rate to the actual measured airflow
from the MAF sensor. The first few steps of
this table verifies the MAP sensor is working
properly. Correct any MAP sensor OTCs first.
3. The MAP sensor is difficult to remove. Twist the
MAP sensor forward and pull up. This forward
motion clears the retaining clip.
5. This step monitors a smooth transition to the
original scan tool value.
and/or a fail. Operate the vehicle within th.e same
isolates when the OTC failed.
7. Any un-metered air causes this OTC to set.
Inspect the PCV system for vacuum leaks. Also
inspect the dip stick for being pulled out.
Inspect the oil fill cap for being loose:
8. This step verifies the signal circuit from the MAF
sensor electrical connector to the PCM.
9.. This step verifies whether a ground and B+ circuit
is available.
10. This step tests the signal circuit for an open.
11. This step tests the signal circuit for a short to B+.
Engine
6-1413

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
DTC P0107
Manifold Absolute
Pressure (MAP)
Sensor Circuit
Low Voltage or
DTC P0108
Manifold Absolute
Pressure (MAP)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 4
Go to Step 19
Go to Step 5
Go to Step 19
Go to Step 6
Go to Step 19
Go to Step 7
Go to
Diagnostic Aids

1
If any MAP sensor DTCs are set, refer to the applicable

DTC before proceeding.
1. Idle the engine.
2. Monitor the MAP sensor voltage parameter using a
scan tool.
Is the MAP sensor voltage outside of the specified range?

2. Remove the MAP sensor from the intake manifold
leaving the electrical harness connected. Refer to
MAP Sensor Replacement.
3. Connect a hand operated vacuum pump to the MAP
sensor.
5. Observe or record the MAP sensor display while
slowly applying vacuum up to 20 inches Hg as
indicated on the pump gauge. Each 1 inch of vacuum
applied should result in a 3 to 4 kPa drop in the MAP
sensor value on the scan tool and the value should
change smoothly with each increase in vacuum.
Did the MAP sensor value change smoothly through the
entire range of the test without any erratic readings?
Apply 20 inches Hg vacuum to the MAP sensor.
Is the MAP sensor reading on the scan tool the same or
less than the specified value?
0.8-4V
34 kPa
Disconnect the vacuum source from the MAP sensor.

Does the MAP sensor reading return to the original value
that was observed in step 3?

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
4. Re-install the MAP sensor and any disconnected
components.
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
7. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
ignition?
6-1414
Engine

Action
Step
Value(s)
No
Yes

O
Objects blocking the MAF sensor inlet screen
Intake manifold vacuum leaks
Vacuum leaks at the throttle body
Crankcase ventilation valve faulty, missing, or

incorrectly installed
2. If you find a condition, repair as necessary.
Go to Step 21
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 13
Go to Step 12
Go to Step 14
Go to Step 11
Go to Step 20
Go to Step 17
Go to Step 15
Go to Step 16
Go to Step 21
Go to Step 18

2. Disconnect the MAF sensor connector.

4. Measur.e the voltage between the MAF sensor signal
circuit and the battery ground using the DMM.
5V
Connect a J 34142-8 test lamp between the MAF sensor

ignition feed and the ground circuit at the MAF sensor
harness connector.
10
Is the voltage less than the specified value?
4.5V
11
2. Disconnect the PCM connector C2 located on the

opposite side of the manufacturer's logo. Refer to
4. Measure the voltage between the MAF sensor signal
circuit and ground.
OV

12
Connect a J 34142-8 test lamp between the MAF sensor

ignition feed circuit and the battery ground.

1. Inspect for a poor connection at the MAF sensor.
Refer to Testing for Intermittent and Poor
13
2. If you find a poor connection, replace the faulty

terminal(s). Refer to Repairing Connector Terminals
in Wiring Systems.
Did you find a poor connection?

1. Inspect the MAF sensor signal circuit between the
PCM and the MAF sensor for the following:
An open circuit
A short to ground
14
A short to the MAF sensor ground circuit.
2. Repair the circuit if the MAF sensor signal circuit is

open or shorted. Refer to Wiring Repairs in Wiring
Systems.
15
Locate and repair the open in the ground circuit to the

MAF sensor. Refer to Wiring Repairs in Wiring Systems.
Go to Step 21
Locate and repair the open in the ignition feed circuit to

the MAF sensor. Refer to Wiring Repairs in Wiring
Systems.
Go to Step 21
16
Go to Step 20
Go to Step 21
Engine
6-1415

Action
Step
17
18
19
20
Value(s)
Locate and repair the short to voltage in the MAF sensor


Replacement.

Replacement.

Replace the PCM.

Yes
No
Go to Step 21
Go to Step 21
Go to Step 21
Go to Step 21
21
1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific OTC option, then enter the DTC number
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
22
diagnosed?
Go to Step 22
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1416
Engine
DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency.
,. - - - sv - - - - - ..
I
I MAF
: ~~r;:r . .
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In Wiring
Systems
______________
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Control
I Module
C2=RED
Powertrain
PCM
C1 =BLU
(PCM)
_,
v!A~1~22 .
Ji,
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Ignition
MAF
Mass Air
Power
Sensor Flow (MAF)
,___.,;a,G""'ro_un_d_ _ _ _ _ _ _ _
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0.35 BLK/WH.T
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= G110
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Ground
Distribution
Schematics
~y:;:~
582405
Circuit Description
IAT, and the engine speed (speed/density). The
MAF sensor has a battery feed, a ground, and a signal
circuit.
type. This engine uses the MAF sensor in order
to measure air flow rate. The MAF output frequency is
a function of the power required to keep the air flow
sensing elements (hot wires) at a fixed temperature
above the ambient temperature. Air flowing through the
sensor cools the sensing elements. The amount of
cooling is proportional to the amount of air flow. The
MAF sensor requires a greater amount of current
in order to maintain the hot wires at a constant
temperature as the air flow increases. The MAF sensor
converts the changes in current draw to a frequency
signal read by the PCM. The PCM calculates the
air flow (grams per second/hertz) based on this signal.
PCM determines if the sensor is stuck low, stuck high,
not providing the airflow value expected for a given
operating condition, or that the signal appears to
be stuck based on a lack of signal variation expected
during the normal operation. This diagnostic tests
for too low of an airflow rate. This DTC sets when the
PCM detects that the MAF sensor frequency is
below a predetermined value.

The engine is operating longer than 0.5 seconds.
The engine speed is more than 30Q RPM.
The system voltage is at least 8.0 volts.
Conditions for Settia,g the DTC

The MAF frequency is less than iO Hz.
All conditions met for 1 second

The PCM records the operating conditions at the
Failure Records.

A last test failed (current DTC) clears when the
A History DTC clears after 40 consecutive
Use a scan tool in order to clear the MIUDTC.
Engine
Diagnostic Aids
Important:
in Wiring Systems.
Any un-metered air may cause this DTC to set.
- An engine vacuum leak
- The PCV system for vacuum leaks
- An incorrect PCV valve
- The engine oil dip stick not fully seated
- The engine oil fill cap loose or missing
Test D~scription
diagnostic table.
2. Monitoring the MAF sensor frequency will
determine if the fault is present or the malfunction
is intermittent.
6-1417

isolates when the DTC failed.
4. This step tests whether the MAF sensor ignition
feed circuit is shorted to a ground. If the fuse is
open, repair the circuit as necessary and replace
the fuse.
5. This step tests whether the 5.0 volts is available
to the MAF sensor signal circuit.
6. This step tests if the signal circuit is shorted to
another 5.0 volt reference circuit. If another
DTC sets, repair the circuits that are shorted
together. If no DTCs set it may be necessary to
road test the vehicle.
10. Inspect the fuse 19 for being open. If the fuse is
open, inspect the MAF sensor ignition feed
circuit for a short to ground.
11. This step verifies whether B+ is available to the
MAF sensor.
Step
Action
Value(s)
Yes
No
Gd to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids

1

2. Idle the engine.
3. Monitor the MAF sensor frequency display on the
Engine 2 Data List of the scan tool.
Is the MAF sensor frequency below the specified value?
data for this OTC and observe the parameters.
the OTC.
6. Select the Diagnostic Trouble Code (OTC} option, the
Specific OTC option, then enter the OTC number
ignition?
10 Hz
6-1418
Engine

OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency (cont'd)
Step
Action
Is the ENG.SEN fuse open?
Value(s)
Yes
No
Go to Step 19
Go to Step 5
Go to Step 6
Go.to Step 7
Go to Step 20
Go to Step 11
Go to Step 14
Go to Step 8
Go to Step 15
Go to Step 9
Go to Step 10
Go to Step 16
Go to Step 17
Go to Step 22
Go to Step 13
Go to Step 12
Go to Step 18
Go to Step 19
Go to Step 24
Go to Step 21

2. Disconnect the MAF sensor connector.

4. Measure the voltage between the MAF sensor signal
circuit and the battery ground using the DMM. Refer
to Measuring Voltage in Wiring Systems.
5V

2. Jumper the MAF sensor signal circuit to battery
ground using a fused jumper. wire. Refer to Using
Do any additional DTCs set?

2. Disconnect the PCM. Refer to PCM
4. Measure the voltage at the MAF sensor signal circuit
at the PCM harness connector using a DMM. Refer
to Probing Electrical Connectors in Wiring Systems.
Does theDMM display a voltage?
1. Turri OFF the ignition.

2. Test for continuity of the MAF sensor signal circuit
using a DMM. Refer to Testing for Continuity in
Wiring Systems.
Does the DMM display OL?
Test for continuity of the MAF sensor signal circuit to

battery ground using a DMM. Refer.to Testing for
Continuity in Wiring Systems.
Test for continuity at the PCM harness between the MAF

sensor signal circuit and all other circuits at both PCM
connectors using a DMM. Refer to Testing for Continuity in
Wiring Systems.
Connect the J 34142-8 test lamp between the MAF sensor

ignition feed circuit and the ground circuit at the MAF
sensor harness connector.
Connect the J 34142-8 test lamp between the MAF sensor

ignition feed circuit and the battery ground.
10
11
12
1. Inspect for a poor connection at the MAF sensor
13
14
15
harness terminals. Refer to Testing for Intermittent

and Poor Connections in Wiring Systems.
Wiring Systems.
Did you find a poor connection?
Repair the short to voltage in the MAF sensor signal

Repair the open in the MAF sensor signal circuit. Refer to

Go to Step 24
Go to Step 24
Engine

OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency (cont'd)
Step
Action
Value(s)
Repair the short to ground in the MAF sensor signal


Repair the MAF sensor ground circuit for an open. Refer

19
1. Repair the open or grounded ignition feed circuit to

the MAF sensor. Refer to Wiring Repairs in Wiring
Systems.
20
Repair the circuits that are shorted together between the

MAF sensor signal circuit and the circuit for which the OTC
set. Refer to Wiring Repairs in Wiring Systems

Replacement.
22
1. Inspect for a poor connection at the PCM. Refer to

Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
23

Replace the PCM.
24

the Clear OTC Information option using the scan tool.
the Specific OTC option, then enter the OTC number
applicable .
diagnosed?
16
17
18
21
..
25
Yes
No
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 24
Go to Step 23
Go to Step 24
GO to Step 25
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1420
Engine
,.. -.- - ;:; - - - - - - .,Powertrain

I
I
J.
PCM
Control
I MAF
C1=BLU
I Module
I S. ~nsor
C2=RED
I (PC.M)
B
C105
O.SPNKf 539
$104 - - -+
0.8 PNK 539
I Signal
- - - - - 1.--""".
Power
Distribution
Schematics
In Wiring.
Systems
______ ....
035Y:j:
....-,g-n-illo_n_ _ _ _ _ _ _ _ _M_A_F_
Power
Sensor
..__ _
Gr_ou_n_d_ _ _ _ _ _ _ _s_ig_n_al__,
~
Mass Air
Flow (MAF)
Sensor
Ground
Distribution
---<Ill Schematics
In Wiring
451
Systems
0.35 BLKIW:Ti451
8110
3 BLK
.,,.. G110
582405
Circuit Description
IAT, and the engine speed (speed/density). The
MAF sensor has a battery feed, a ground, and a signal
circuit.
type. This engine uses the MAF sensor in order
to measure air flow rate. The MAF output frequency is
a function of the power required to keep the air flow
sensing elements (hot wires) at a fixed temperature
above the ambient temperature. Air flowing through the
sensor cools the sensing elements. The amount of
cooling is proportional to the amount of air flow. The
MAF sensor requires a greater amount of current
in order to maintain the hot wires at a constant
temperature as the air flow increases. The MAF sensor
converts the changes in current draw to a frequency
signal read by the PCM. The PCM calculates the
air flow (grams per second/hertz) based on this signal.
PCM determines if the sensor is stuck low, stuck high,
not providing the airflow value expected for a given
operating condition, or that the signal appears to
be stuck based on a lack of signal variation expected
during the normal operation. This diagnostic tests
for too high of an airflow rate. This OTC sets when the
PCM detects that the MAF sensor frequency is
above a predetermined value.
Conditions for R1..mning the DTC

The engine is operating longer than 0.5 seconds.
.. The engine speed is more than 300 RPM.
The system voltage is more than 8.0 volts.
Conditions for Setting the. DTC

The MAF frequency is more than 14,000 Hz.
All conditions met for less than 1 second.

conditions to the.Freeze Frame and updates the
Failure Records.
O

.. A last test failed (current OTC) clears when the
" A History OTC clears after 40 consecutive
Engine
\)
6-1421
Diagnostic Aids
Test Description
Important:
prevent contaminant i.ntrusion into the PCM.
in Wiring Systems.
Water entering the air intake system that reaches
the MAF sensor could cause this DTC to set.
The water rapidly cools the hot wires in the sensor,
causing a false indication of excessive airflow.
Inspect the following areas for evidence (witness
mp.rks) of water intrusion:
- AIR system
- Intake air system

diagnostic table.
2. Monitoring the MAF sensor frequency determines
if the fault is present or the malfunction is
intermittent. A poor connection at the MAF sensor
or at the fuse causes this DTC to. set.
3. Using the Freeze Frame.and/or Failure Records
4. This step tests for electro-magnetic interference
on the MAF sensor signal circuit. There should
be no signal indicated on the scan tool with
the sensor disconnected.
Action
Step

1
1. Idle the engine.

2. Monitor the MAF sensor display on the Engine 2 Data
List of the scan tool.
Is the MAF sensor frequency above the specified value?

the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
ignition?
1.
2.
3.
4.
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 7
Go to Step 5
14,000 Hz

Disconnect the MAF sensor connector.
Idle the engine.

Monitor the MAF sensor frequency using the
scan tool.
Does scan tool indicate a MAF sensor frequency?
6-1422
Engine
DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency (cont'd)
Step
Action
1. Inspect for a poor connection at the MAF sensor

harness terminals. Refer to Testing for Intermittent
2. If you find a poor connection repair the condition as
Wiring Systems.

Replacement.
1. Inspect the MAF sensor harness for incorrect routing

at the following locations:
Near secondary ignition wires or components.
Other high .current components. Such as
solenoids, relays, and motors.
2. Correct the harness routing if you find incorrect
routing.
1. Inspect for poor connections at the PCM. Refer to

Wiring Systems.
Wiring Systems.

Replace the PCM.

applicable.
diagnosed?
10
11
Value(s)
Yes
No
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 10
Go to Step 11
Go to Step 2
Go to the
applicable
OTC table.
System OK
Engine
6-1423
DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit low Voltage
"' - - - -sv - - .,1 Powertrain

I
I MAP
sv
I Reference
L---
48
Control
Module
I PCM
I
I(
--...!
c1
>
0.35 GRY 416
U:il
C"'
I ~ .. 1=:ut~
.
~ . Pressure
0.35 LT G'-R-~--14-3-2.-----A--I....
~~~:tr
0.35
ORN/BLK 407
32 C2
54 C1
"' - - , - - - .,I Powe.

rtrain.
. ~ - - -1_- - - PCM
_
Control
1MAP
Sensor
I Ground
MAP
c1 =BLU
I Module ~
Sensor
C2=RED
-=-
~----------------~J
Ground
(PCM) ~~
.
I
582413
Circuit Description
The Manifold Absolute Pressure (MAP) sensor is

mounted to the rear of the intake manifold. The MAP
sensor measures. the pressure changes within the
intake manifold which is an indication of the engine
load. The MAP sensor has a 5.0 volt reference,
a ground, and a signal circuit.
The MAP sensor contains a diaphragm which changes
the resistance based on pressure. When the manifold
pressure is low (high vacuum) the sensor output
voltage is low. When the manifold pressure is high
(low vacuum) the sensor output voltage is high.
The MAP sensor voltage (depending on altitude) can
range from 1.0-1.5 Volts at idle (high vacuum) to
4.0-4.9 volts at wide open throttle (low vacuum).
When the PCM senses a signal voltage lower than the
normal operating range of the sensor, this OTC sets.

No TP sensor OTCs set.
The engine is operating.
The TP sensor angle is O percent when engine
speed is less than 1200 RPM.
Or
The TP sensor angle is less than 20 percent
when engine speed is more than 1200 RPM.

The MAP sensor voltage is less than 0.10 volt.
All conditions met for more than 2 seconds.

Failure Records.

A History OTC clears after 40 consecutive
6-1424
Engine
Diagnostic Aids
3. This step determines if the malfunction is present.
Important:
in Wiring Systems.
The PCM 5.0 volt reference circuits are internally
connected within the PCM. If all the MAP sensor
circuits are OK, inspect the following
componenVcircuits for malfunctions:
- Throttle Position sensor
- EGR Valve

ignition cycles the diagnostic _report_e~ a pass
Test Description
diagnostic table.
2. If OTC P1635 sets at the same time, this indicates
that the 5 voltage reference circuit is either
shorted to a ground or shorted to a voltage. The
5 volt reference circuit is internally connected
within the PCM. The Throttle Position sensor or
the EGR valve may be causing this OTC to
set. Refer to OTC P1635 for further diagnosis.
5. If the scan tool displays 5. volts, the MAP sensor

signal, 5 volt reference circuit, and the PCM
are OK.
The MAP sensor is difficult to remove. Twist the
motion disengages the retaining clip.
6. If the scan tool displays 5 volts, the MAP sensor
signal circuit and the PCM are OK.
7. Disconnecting the PCM allows using the DMM in
order to test the continuity of the circuits. This
aids in locating an open or a shorted circuit.
motion disengages the retaining clip.
Engine
6-1425
DTC P0.107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
Step
Action

1

2. Idle the engine.
3. Monitor the OTC Information option using the
scan tool.
Did OTC P1635 fail this ignition cycle?
Monitor the MAP sensor voltage on Engine 1 Data List on
the scan tool.
Is the MAP sensor voltage below the specified value?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
DTCP1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go toStep 11
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 13
Go to Step 8
0.10V

5. Operate the vehicle within the conditions requiredfor
4
the DTC.
... Does the scan tool indicate that this diagnostic failed this
ignition?

Refer to MAP Sensor Replacement.
2. Jumper the 5 volt reference circuit and the MAP
sensor signal circuit together at the MAP sensor
harness connector.
3. Observe the MAP sensor voltage display on the
scan tool.
Is the MAP sensor voltage near the specified value?
5V
1. Connect a J 34142-8 test lamp between B+ and the

MAP sensor signal circuit at the MAP sensor harness
connector.
2. Observe the MAP sensor voltage display on the
scan tool.
Is the MAP sensor voltage near the specified value?
5V
same side as the manufacturer's logo. Refer to PCM

3. Test the MAP sensor 5 volt reference circuit for an
open or short to a ground. Refer to Circuit Testing in
Wiring Systems.
4. If you find the 5 volt reference circuit is open or
shorted to a ground, repair the circuit as necessary.
6-1426
Engine
DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage (cont'd)
Step
Action
1. Inspect the 5 volt reference circuit for a poor

Wiring Systems.

3. Test the MAP sensor signal circuit for the following:
Open circuit
Short to a ground
Short to sensor ground circuit
4. If you find the MAP sensor signal circuit is open or
shorted to a ground, repair the circuit as necessary.
10

Wiring Systems.
Wiring Systems.
11

Replacement.
12

Replace the PCM.
13

Value(s)
14
No
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 12
Go to Step 13
Go to Step 13

applicable.
diagnosed?
Yes
Go to Step 14
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1427
"- - - -sv - - .,1Powertrain

I
I MAP
I sv
~ ~~n:e_
48
_ _
C1
Control
I Module
I PCM
~ ( Ji )
~
0.35 GRY 416
L2.w
C "'
I ~!
Manifold
Absolute
Pressure
--A.--I~ t~:br
o.35 LT G,_R_~.,.,.14_3_2_
0.35
ORN/BLK 407
32 C2
54 C1
" MAP , - - - - - 1- - - - - - ,... - .,.I Pow.ertra.in
I
Sensor
I
Ground
I
I
-=-
MAP
Sensor
Ground
PCM
c1=BLU
C2=RED
Control
Module Ji
I (PCM).~
I
I
~-----------------J
M2413
Circuit Description
The Manifold Absolute Pressure (MAP) sensor is
mounted to the rear of the intake manifold. The MAP
sensor measures the pressure changes within the
intake manifold which is an indication of the engine
load. The MAP sensor has a 5.0 volt reference,
The MAP sensor contains a diaphragm which changes
the resistance based on pressure. When the manifold
pressure is low (high vacuum) the sensor output
voltage is low. When the manifold pressure is high
(low vacuum) the sensor output voltage is high.
The MAP sensor voltage (depending on altitude) can
range from 1.0-1.5 Volts at idle (high vacuum) to
4.0-4.9 volts at wide open throttle (low vacuum).
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
DTC sets.

No TP sensor DTCs set.
The TP sensor angle is less than 5 percent when
the engine speed is no more than 1,000 RPM.
OR
The TP sensor angle is less than 18 percent when
engine speed is more than 1,000 RPM.

The MAP sensor voltage is more than 4.3 volts.

Failure Records.

6-1428
Engine
Diagnostic Aids
Important:
J 35616-A connector test adapter kit. Using t.his kit
in Wiring Systems.
connected within the PCM. If all the MAP sensor
circuits are OK, inspect the following
component/circuits for malfunctions:
Throttle Position Sensor
EGR Valve

Test Description
5. This step verifies whether the signal circuit is

shorted to a voltage.
6. This step verifies whether a ground circuit is
available at the MAP sensor.
motion clears the retaining clip. Remove the MAP
sensor and verify if vacuum is available to the
sensor. Also, inspect the MAP sensor seal
for nicks and cuts.

diagnostic table.
2. If OTC P1635 and P1639 set at the same time,
this indicates that the 5 voltage reference
circuit is shorted voltage. The 5 volt reference
circuit is internally connected within the PCM. The
EGR or TP sensor circuits may be causing this
OTC to set. Refer to OTC P1635 for further
diagnosis.
Engine
6-1429
Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to Step 16
Go to Step 12
Go to Step 9
Go to Step 15
Go to Step 13
Go to Step 14

1
2. Idle the engine.

2
3. Monitor the DTC Information option using the

scan tool.
Did OTC P1635 and P1639 fail this ignition cycle?
Important: If the engine idle is rough, unstable or

incorrect, repair the idle condition before using this table;
refer to Symptoms.
Monitor the MAP sensor voltage on the Engine 1 Data List
on the scan tool.
Is the MAP sensor voltage above the specified value?
4.3V

the OTC.
Specific OTC option, then enter the DTC number
ignition?
Refer to MAP Sensor Replacement.
2. Observe the MAP sensor voltage displayed on the
scan tool.
1V
Is the MAP sensor voltage below the specified value?
Probe the sensor ground circuit with the J 34142-8 test

lamp connected to B+. Refer to Probing Electrical
Connectors in Wiring Systems.
1. Test the MAP sensor signal circuit for a short to

voltage or a short to the 5 volt reference circuit.
2. Repair the MAP sensor signal circuit if the circuit is
shorted. Refer to Wiring Repairs in Wiring Systems.
Is the MAP sensor signal circuit shorted?
Measure the voltage at the 5 volt reference circuit to the

battery ground using the DMM.
5V
Inspect for a plugged or leaking vacuum supply to the

MAP sensor.
Is the vacuum supply OK?
6-1430
Engine
DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage (cont'd)
Step
,-.
Action
Value(s)
10
.1. Disconnect the PCM connector C1 located on the

same side of the manufacturer's logo. Refer to PCM
2. Test for continuity of the MAP sensor ground circuit.
Refer to Testing for Continuity in Wiring Systems.
3. Repair the open or the poor connection if the MAP
sensor ground circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
20
11
1. Inspect for a poor PCM connection. Refer to Testing

for Intermittent and Poor Connections in Wiring
Systems.
2. If you find a poor connection repair as necessary.
Systems.
12

Replace the PCM.
13

Replacement.
14
Repair the faulty vacuum supply.

15
Repair the 5 volt reference circuit for a short to voltage.

16

2. Idle the engine at the normal operating temperature:
the Specific DTC option, then enter the DTC number
the DTC as specified in the supporting text, if
applicable.
17
diagnosed?
Yes
No
Go to Step 16
Go to Step 11
Go to Step 16
Go to Step 12
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 17
Go to Step 2
Go to the
applicable
.DTC table
System OK
Engine
6-1431
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit low Voltage
r -
I IAT
I sensor
J
-
sv - .,1Powertrain
~ ~n~ 25
C2
Control
I Module
I (PCM)
rn
~ Jt-
0.35TAN 472
Intake
Air
Temperature
(IAT)
Sensor
0.35 PPL 719

A/C
0.35 PPL
81281------11> Refrigerant
719
Pressure
Sensor
0.35 PPL 719
57 C:2
r
1
I..
-1- - - - - - - ., Control
Powertrain
Sensor
PCM
c21:BLU
C_
-RED
_Ground
_____
_ _ _ JI
Module ...
~
{PCM)
582415
Circuit Description
The Intake Air Temperature (IAT) sensor contains a
semiconductor device which changes the resistance
based on the temperature (a thermistor). The IAT
sensor is located in the air intake passage of
the engine air induction system. The IAT sensor has a
signal circuit and a ground circuit. The PCM applies
5.0 volts on the signal circuit to the sensor. The
PCM monitors the changes in this voltage caused by
changes in the resistance of the sensor in order to
determine intake air temperature.
When the intake air is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is
only pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high
signal voltage (low temperature). When the intake air
is warm, the sensor resistance is low. The signal
voltage is pulled down a greater amount; therefore,
the PCM senses a low signal voltage (high
temperature).

DTCs P0101, P0102, P0103, P0117, P0118,
P0125, P0500, P0502, P0503 not set
The engine run time is more than 30 seconds.
The vehicle speed at least 40 km/h (25 mph).

The Intake Air Temperature is more than
139C (282F).
.. All conditions met for 5.0 seconds.

Failure Records.

5;.1432
Engine
Diagnostic Aids
Test Description
Important:
O Remove any debris from the PCM connector
.. For any test that requires probing the PCM or
in Wiring Systems.
If the engine has sat overnight, the engine coolant
temperature and the intake air temperature values
should display within a few degrees of each other. If
the temperatures are not within 3C (5F), refer to

diagnostic table.
Temperature vs Resistance.
If you determine that the DTC occurs intermittently,
performing the P1112 diagnostic table may isolate the
cause of the fault.
2. This verifies if the condition is present.

4. An IAT below -30C (-22F) indicates the PCM
an the IAT wiring are OK.
order: to test continuity of the circuits. This aids
in locating an open or a shorted circuit.
Engine
6-1433
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
Step
Action
Value(s)
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
Go to Step 8
Go to Step 7

2
3. Monitor the IAT display on the Engine 1 Data List of

the scan tool.
Is the IAT above the specified value?
possible. Special operating conditions \hat you need
the DTC.
Does the scan tool indicate that this diagn9stic failed this
ignition?
2. Observe the IAT display on the scan tool.
Is the IAT at the specified value?
3. Test the IAT signal circuit for a short to a ground.
4; If you find the IAT sensor signal circuit is grounded,
repair the circuit as necessary. Refer to Wiring
Is the IAT signal circuit grounded?
Replacement.
Replace the PCM.
applicable.
diagnosed?
139C (282F)
-39C (-38F)
Go to Step 8
Go to Step 8
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1434
Engine
'" - - - - - , Powertrain
I
Jsv
Control
I IAT
I Module
I s~nsor
. I (PCM)
~~"~-
25
rn
-~ ~
C2 ~
0.35TAN 472
Intake
Uil
Air
Temperature
(IAT)
Sensor
0.35 PPL 719

0.35 PPL
8128
719
0.35 PPL 719
NC
Refrigerant
f'!ressure
Sensor
57 C2
'" - 1" - - - - - - - , Powertrain
I
I
.t
PCM
Control
Sensor
C1=BLU
.1Module.~
C2=RED
..I ..;Ground
________
"'I (PCM) ~
582415
Circuit Description
semiconductor device which changes the resistance
based on the temperature (a thermistor). The IAT
sensor is located in the air intake passage of
the engine air induction system. The IAT sensor has a
signal circuit and a ground circuit. The PCM applies
5.0 volts on the signal circuit to the sensor. The
PCM monitors the changes in this voltage caused by
determine intake air temperature.
resistance is high. The PCMs signal voltage is
only pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high
signal voltage (low temperature). When the intake air
is warm, the sensor resistance is low. The signal
voltage is pulled down a greater amount; therefore,
the PCM senses a low signal voltage (high
temperature).
DTC sets.

.. DTC(s) P0101, P0102, P0103, P0117, P0118,
P0125, P0500, P0502, P0503 not set.
e The engine coolant temperature is more than
0C (32F).
" The vehicle speed is less than 11 km/h (7 mph).
" The mass air flow is less than 15 g/s.
Conditions for Setting the .DTC .

. The Intake Air Temperature is .less than
-35C (-31 F).

" The PCM illuminates the malfunction indicator
Failure Records.

" A History DTC clears after 40 consecutive
Engine
6-1435
Diagnostic Aids
Test Description
Important:
in Wiring Systems.

diagnostic table.
If you determine that the OTC occurs intermittently,
cause of the fault.

3. If DTCs P1635 and P1639 set at the same time,
this indicates that the signal circuit is shorted to
a voltage.
will isolate when the OTC failed.
5. An intake air temperature above 139C (282F)
indicates the PCM and IAT sensor wiring
is OK.
6. An .intake air temperature above 139C (282F)
indicates the PCM and IAT sensor signal circuit
is OK.
order to test continuity of the circuits. This aids
order to test for a short to voltage.
6-1436
Engine
OTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
Step
Action
Value(s)
Yes

1
C3o to Step 2

3. Monitor the IAT sensor display on the Engine 1 Data
Is the IAT sensor at the specified value?
Are DTCs P1635 and P1639 also set?
1. Turn ON tt)e ignition leaving the engine OFF.

3. Turn OFF the ignition for i 5 seconds.
the DTC.
ignition?
No
Goto.A
Powert,-ain On
Board
. Diagnostic (OBD)
System Check
-39C (-38~F)
Go
to Step 3
Go to Step 4
Go to Step 14
C3o to Step 5
Go to Step 5
Go to
Diagnostic Aids
Go to Step B
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 11
Go to Step 16
Go to Step 14
Go to Step 9

2. Jumper the IAT sensor harness terminals together
using a fused jumper wire. Refer to Using Fused
Jumper Wires in Wiring Systems.
3. Observe the IAT parameter on the scan tool.
140C (284F)
Jumper the IAT sensor signal circuit to a known good

ground.
140C (284 F)

opposite side of the manufacturers logo. Refer to
3. Test the IAT sensor signal circuit for an open. Refer
to Testing for Continuity in Wiring Systems.
Is the IAT sensor signal circuit open?

2. Remove the jumper harness from the IAT sensor
harness connector.
3. Disconnect the PCM connectors. Refer to PCM
5. Probe the IAT signal circuit at the PCM harness
connector using the DMM connected to ground. Refer
Does the DMM display a voltage?
Engine
Engine Controls -5.7l 6-1437

DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage (cont'd)
Step
Action
Test continuity from the IAT signal circuit to all other PCM
circuits at the PCM harness connectors using the DMM.
Example: probe one lead to the IAT sensor signal circuit
(at the PCM harness connector) and probe the other lead
to each terminal at the PCM harness connectors. Refer to
Testing for Continuity in Wiring Systems.
Does the DMM display continuity within the specified
range from the IAT sensor signal circuit to any other PCM
circuit?
Value(s)
Yes
No
Go to Step 15
Go to Step 12
Go to Step 13
Go to Step 16
0-2Q

10
11
12
13
14
15
2. Disconnect the PCM connector C2. Refer to PCM

3. Inspect the IAT sensor ground circuitfor an open.
Is the IAT sensor ground circuit open?
Repair the IAT sensor signal circuit. Refer to Wiring


Replacement.
Repair the IAT sensor ground circuit. Refer to Wiring

Repairs in Wiring Systems:
Repair the IAT sensor signal circuit for a short to voltage.

',
Repair the short between the IAT sensor signal circuit and
the PCM circuit that had continuity. Refer to Wiring
"'
Go to Step 18
Go to Step 18
-
Go to Step 18
Go to Step 18
'
Go to Step 18

16
17

Wiring Systems.
2. If you find a poor connection, repair the conditions as
Systems.

Replace the PCM.
Go to Step 18
Go to Step 17
Go to Step 18
1. Select the Diagnosti9 Trouble Code (DTC) option and
18
19
the Clear DTC Information optjon using the scan tool.

applicable.
diagnosed?
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
6;.1438
Engine
OTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit low Voltage
0.35 YEL 410
rn
Engine Coolant
Temperature (ECT)
Sensor
.
0.35 BLK 407 .
;---1 r:;-~l--~c:74
I .
I ECT
I Sensor
I Signal
80
C1
Sensor
Ground ~
C1=BLU
C2=RED
~6~~:~rain
I Module
I (PCM)
I 41.
I
Iii'
L----------------J~
585397
Circuit Description
The Engine Coolant Temperature (ECT) sensor
contains a semiconductor device which changes the
resistance based on the temperature (a thermistor).
The ECT sensor is mounted in the left bank cylinder
head near the front of the engine. The ECT sensor has
a signal circuit and a ground circuit. The PCM
applies a voltage (about 5.0 volts) on the signal circuit
to the sensor. The PCM monitors the changes in
.this voltage caused by changes in the resistance of
the sensor in order to determine the coolant
temperature.
When the coolant is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is only
pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high signal
voltage (low temperature). When the coolant is
warm, the sensor resistance is low. The signal voltage
is pulled down a greater amount; therefore the PCM
senses a low signal voltage (high temperature).
At normal operating temperature, the scan tool should
display an ECT value of 1.5-2.0 volts.
The engine coolant temperature information is
sent to the instrument panel cluster via the
class 2 circuit.

OR
The engine run time is less than 10 seconds, when
the IAT is less than 50C (122F).

139C (282F).
All conditions met for 20 seconds.

cycle that the diagnostic runs and fails .
Failure Records.

Engine Controls - s~7L
Engine
6"'.1439
Diagnostic Aids
Test Description
Important:

diagnostic ta,ble.
3. Using the Freeze Frame and/or Failure. Records
4. An engine coolant temperature below -30C
(-22F) indicates the PCM and the ECT sensor
wiring are OK.
5. Disconnecting the PCM allows using the OMM in
7. Inspect for proper terminal tension/connec.tions at
the PCM harness before replacing the PCM.

in Wiring Systems.
If you do determine that the OTC occurs intermittently,
performing the P1114 diagnostic table may isolate
the cause of the fault.
DTC P0117 Engine Coolant Temperature (ECT).Sensor Circuit l?W Voltage

Step
Action
Important: If the engine is overheating, correct the

overheating condition before proceeding with this table. An
over heat condition causes this DTC to set.
3. Monitor the ECT sensor display on the Engine 1 Data
Is the ECT sensor above the specified value?
Value(s)
.Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
139C (282F)


the DTC.
ignition?
6-1440
Step
Engine
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage (cont'd)
Action
Value(s)
Yes
No
2. Observe the ECT sensor display on the scan tool.
-30C (-,--22F)
Is the ECT sensor below the specified value?
Go to Step 6
Go to Step 5
Go to Step 8
Go to Step 7

3. Test the ECT sensor signal circuit for a short to a

ground.
4. If you find the ECT sensor signal circuit is grounded,

repair the circuit as necessary. Refer to Wiring
Did you find the ECT sensor signal circuit grounded?

Replacement.

Replace the PCM.
Go to Step 8
'
Go to Step 8



applicable.
diagnosed?
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1441
[1]
0.35 YEL 410
Engine Coolant
Temperature (ECT)
Sensor
0.35 BLK 407

74
'(' .;. - - sv- - - - -
.
I
I
I ECT
I Sensor
I Signal
t T
.lJ
-1-----.,
80
ECT
Sensor
C1
PCM
C1=BLU
Powertrain
I Control
I Module
(PCM)
"""' I'
I
A..
L----------------J~
585397
Circuit Description
contains a semiconductor device which changes the
resistance based on the temperature (a thermistor).
The ECT sensor is mounted in the. left bank cylinder
head near the front of the engine. The ECTsensor has
a signal circuit and a ground circuit. The PCM
applies a voltage (about 5.0 volts) on the signal circuit
to the sensor. The PCM monitors the cha.nges in
this voltage caused by changes in the resistance of
the sensor in order to determine the coolant
temperature.
When the coolant is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is only
pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high signal
voltage (low temperature). When the coolant is
warm, the sensor resistance is low. The signal voltage
is pulled down a greater amount; therefore, the
PCM senses a low signal voltage (high temperature).
At normal operating temperature, the scan tool
should display an ECT value of 1 .5-2.0 volts.
OTC sets.
The engine coolant temperature information is sent to
the instrument panel cluster via the class 2 circuit.

OR
The engine run time is less than 60 seconds when the
IAT is more than 0C (32F).

The engine coolant temperature is less than
-39C (-38F).
..

Failure Records.

s~t442
Engine Controls. - 5.7L
Engine
Diagnostic Aids
Test Description
Important:

diagnostic table.

in Wiring Systems.
temperature and intake air temperature values should
display within a few degrees of each other. If the
temperatures are not within 3C (5F), refer to
cause of the fault.

3. If OTC P1635 and P1639 set at the same time,
this indicates that the signal circuit is shorted
to a voltage.
5. An engine coolant temperature above
139C (282F) indicates the PCM and ECT sensor
wiring is OK.
6. An engine coolant temperature above
139C (282F) indicates the PCM and ECT sensor
signal circuit is OK.
order to test for a short to voltage.
Engine
6-1443
Step
Action
Value(s)
Yes
No
Go to Step 2
Goto A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step .14
Go to Step 5

-

3. Monitor the ECT sensor display on the Engine 1 Data
Is the ECT sensor at the specified value?
-39C (-38F)
Are DTCs P1635 and P1639. also set?

. 5. Operate the vehicle within the conditions required for
the OTC.
ignition?
'

2. Jumper the ECT sensor harness terminals together.
3. Observe the ECT parameter on the scan tool.
140C (284F)
Jumper the ECT sensor signal circuit to a known good

ground.
140C (284F)

3. Test the ECT sensor signal circuit for an open.
Is the ECT sensor signal circuit open?

2. Remove the jumper harness from the ECT sensor
harness connector.
3. Disconnect the PCM. Refer to PCM
5. Probe the ECT signal circuit at the PCM harness
connector using the DMM connected to ground. Refer
Does the DMM display a voltage?
Go to Step 5
Go to
Diagnostic Aids
Go to Step 8
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 11
Go to Step 16
Go to Step 14
Go to Step 9
Engine
6-1444 Engine Controls - 5.7L
DTCP0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage (cont'd)
Step
Action
Value(s)
Test for continuity from the ECT signal circuit to all other
PCM circuits at the PCM harness connectors using the
DMM. Example: probe one lead to the ECT sensor signal
circuit (at the PCM harness connector) and probe the
other lead to each terminal at the PCM harness
connectors . .Refer to Testing for Continuity in Wiring
Systems.
Does the DMM display continuity within the specified
range from the ECT sensor signal circuit to any other PCM
circuit?
0-2Q
10

3. Inspect the ECT sensor ground circuit for an open.
Is the ECT sensor ground circuit open?
Repair the ECT sensor signal circuit. Refer to Wiring


Replacement.
lnepair the ECT sensor ground circuit. Refer to Wiring

Repair the ECT sensor signal circuit for a short to voltage.

15
Repair the short between the ECT sensor signal circuit

and the PCM circuit that had continuity. Refer to Wiring
16
1. Inspect the PCM harness connector for poor

connections. Refer to Testing for Intermittent and
2. If you find a poor connection, repair the conditions as
Systems.

Replace the PCM.
18

applicable.
19
diagnosed?
11
12
13
14
17
Yes
No
Go to Step 15
Go to Step 12
Go to Step 13
Go to Step 16
Go to Step 18
-
Go to Step 18
-
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 19
Go to Step 2
Go to the
applicable
OTC table
System OK
-,-
Engine
6-1445
DTC P0121 TP Sensor Circuit Insufficient Activity

r- - - - :;- - - - - - - ., Powertrain
5
I Control
: I
TP Sensor
I 5V
I Reference
i . . - ...... _
....
I l II
I Module
:{PCM)
_______ .. Jti.
Ci
8116
~
~
Sensor
0.35 BLK 452
0.35 GRY 596

0.35 GRY
596
Throttle
Position {TP)
Antilock
Brakes
Schematics
In Brakes
0.35 GRY 596
0.35 DK BLU 417

0.35DKBLU
8118
417
8119
0.35 DK BLU 417
0.35 BLK
24 C2
60
I"
1
I
I
-T;
-1------
Antilock
- - - Brakes
Schematics
0.35 BLK
In Brakes
452
4 52
C1
-1'- - - - - - - - .. Powertrain
_..
PCM
icontro I A
~
C1-BLU
Sensor
c2:RED
I Module lflll'
Sensor
Signal
Ground
I {PCM) ~
L---~--------------J
582456
Circuit Description
The Throttle Position (TP) sensor is a potentiometer.
The TP sensor is mounted to the left side of the throttle
body. The TP sensor provides a voltage signal that
changes relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
The TP sensor signal voltage should be near 0.6 volt
at idle. The TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
This diagnostic compares actual throttle position from
the TP sensor to a predicted throttle position value.
The predicted throttle position is calculated from
engine speed and other inputs. If the PCM detects the
predicted throttle position is below the actual TP
sensor value, this OTC sets.

No MAP sensor or TP sensor OTCs set.
0C (32F).
The IAC is between O and 255 counts.
" The MAP is less than 55 kPa.
OR
The MAP is more than 65 kPa.
MAP steady.
Conditions for Settirng the DTC

The predicted throttle angle does not match the
actual throttle angle.
.. All conditions present for 20 seconds:

.. The PCM records the operating conditions at the
Failure Records.
Conditions for Clearing the MILJDTC

.. A History OTC clears after 40 consecutive
" Use a scan tool in order to clear the MIUOTC.
6-1446
Diagnostic Aids
Important:
in Wiring Systems.
connected within the PCM. If all the TP sensor circuits
are OK, inspect the MAP sensor and EGR valve for
malfunctions.
If it is determined that the OTC occurs intermittently,
performing the OTC P1121 diagnostic table may
isolate the cause of the fault.
Test Description
diagnostic table.
Engine
3. The MAP value should change with the engine
speed. If a MAP sensor voltage changes,
there is no malfunction with the MAP sensor.
4. This step tests for an intermittent connection at

the sensor.
motion clears the retaining clip.
8. If the TP sensor voltage changes, there is no
malfunction with the TP sensor wiring or the PCM.
9. Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicated the OTC, the information
and/or a fail. Operate vehicle within the same
11. This tests the 5 volt reference circuit, signal
circuit, and the PCM. If the scan tool displayed
5 volts, the TP sensor circuits are OK.

that the 5 volt reference circuit is either shorted to
a ground or shorted to a voltage. The 5 volt
reference circuit is internally connected within
the PCM.
DTC P0121 TP Sensor Circuit Insufficient Activity

Action
Step
Value(s)
Yes
No
Go to Step 2
Go fo A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to the
applicable
DTC table
Go to Step 3
Go to Step B
Go to Step 4
Go to Step 16
Go to Step 5

1. Install the scan tool.
2. Idle the engine.

2

scan tool.
Did Pi 404 or Pi 635 or any MAP sensor DTCs also set?

2. Monitor the MAP sensor voltage.
3. Increase the engine speed to the specified value.
Does the MAP sensor voltage change when the engine
speed changed?
2. Move the MAP sensor electrical connector, the
harness and the PCM connectors (by hand only)
while observing the scan tool display.
Is the MAP value affected by moving the harness or
connectors?
2000 RPM
Engine
6-1447
DTC P0121 TP Sensor Circuit Insufficient Activity (cont'd)

Step
Action
Value(s)
1. Remove the MAP sensor from the intake manifold but

leave the electrical harness connected. Refer to MAP
Sensor Replacement.
2. Connect a hand operated vacuum pump to the MAP
sensor.
3. Observe and/or record the MAP display while slowly
applying vacuum up to 20 inches Hg as indicated on
the pump gauge. Each 1 inch of vacuum applied
should result in a 3 to 4 kPa drop in the MAP sensor
value on the scan tool a.nd the value should change
smoothly with each increase in vacuum.
Did the MAP value change smoothly through the entire
range of the test without any erratic readings?
Apply 20 inches Hg vacuum to the MAP sensor.

Is the MAP sensor reading the same or less than the
specified value?
Yes
No
Go.to Step 6
Go to Step 17
Go to Step 7
Go to Step 17
Go to Step 8
Go to Step 17
Go to Step 9
Go to Step 10
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 13
Go to Step 12
Go to Step 14
34 kPa
Disconnect the vacuum source from the MAP sensor.

Does the MAP sensor reading return to the original value
that you observed in step 5?
10
11
12
2. Monitor the TP sensor voltage while moving the

accelerator pedal from a closed throttle to a wide
open throttle.
Does the TP sensor voltage go from below the specified
value to above the specified value?
data for this DTC and record the parameters.
4. Re-install the MAP sensor and any other
disconnected components.
recorded in Freeze Frame/Failure Records as
the DTC.
which was set using the scan tool.
ignition?
1. Disconnect the TP sensor.
2. Observe the TP sensor display on the scan tool.
Is the TP sensor voltage near the specified value?
Below 1.0V to
above 4.0V
.,
o.ov
Jumper the TP sensor 5 volt reference circuit to the TP

sensor signal circuit using a fused jumper wire. Refer to
Using Fused Jumper Wires in Wiring Systems.
Is the TP sensor voltage near the specified value?
5V
Replace the TP sensor. Refer to TP Sensor Replacement.

Go to Step 18
6-1448
Engine
DTC P0121 TP Sensor'Circuit Insufficient Activity (cont'd)

Step
Action
Value(s)
Yes
14
Test for the following conditions:

TP signal circuit or 5 volt reference circuit for a
poor connection. Refer to Testing for Intermittent
TP signal circuit or 5 volt reference circuit for high
resistance between the PCM and the TP sensor.
If you find a condition, repair as necessary. Refer to
15

Replace the PCM.
16
Locate and repair the affected circui.ts..

17
Replace the MAP Sensor. Refer to MAP Sensor

Replacement.
18

3. Select the Diagnostic Trouble Code {DTC) option and
applicable.
19
Select the Capture Info option and the Review Info using
the scan tool.
diagnosed?
13
No

TP signal circuit for a short to voltage.
TP sensor ground circuit for high resistance
between the PCM and the TP sensor.
TP sensor ground circuit for a poor connection.
2. If you find a condition repair as necessary. Refer to
Go to Step 18
Go to Step 15
Go to Step 18
Go to Step 15
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1449
OTC ?0122 Throttle Position (TP) Sensor Circuit low Voltage

r -
I
I
Isv .
TP Sensor
.~ ;f'.:e~e-
- - -
Powertrain
I Control
I
Module
- .,
r-----i I;~~ftf~~
~ _ _ _ _ _ _ J(P~M)
C1.
l
C
D.35 GRY 596
8116
0.35GRY
596
Anti lock
Brakes
Schematics
In Brakes
0.35GRY 596
Sensor',';
B
0.35 BLK 452
0.35 DK BLU 417

D.35 DK BLU
8118
417
8119
0.35 DK BLU 417
0.35 BLK
24 C2
60
-T; -,-- - .......... -
I
I
L -
_ .
-
-- -
Antilock
-- -
452
C1
-.r
-
Brakes
Schematics
In Brakes
0.35 BLK
452.
"." -
=
Sensor
Ground.
sensor
Signal
-
(TP)
-P;M- - - ~ Powe.rt.rain
c1-BLU
Control
A.
I Module P
I {PCM) ~
c2:RED
-
..!
582456
Circuit Description
The TP sensor Signal voltage should be near 0.6 volt
normal operating range of the sensor, this DTC sets.

The ignition switch is in the ON position or the engine
is operating.

The TP sensor signal voltage is less than 0.2 volt.
The above conditions are present for 10 seconds.

Failure Records.

.. A last test failed (current DTC) clears when the
Diagnostic Aids
Important:
in Wiring Systems.
malfunctions.
If it is determined that the DTC occurs intermittently,
performing the DTC P1122 diagnostic table may
6-1450
Test Description
diagnostic table.
ground or shorted to a voltage ..The 5 volt
the PCM.
3. This step verifies that a malfunction is present.
you cannot duplicate the OTC, the information
~ecords data can help determine how many miles
Engine
5. This determines if the short is caused from the
Accelerator and Servo Control Module (ASM).
After repairs are made, reconnect the Accelerator
and Servo Control. Module (ASM) and clear
any DTCs that set when the Accelerator and
Servo Control Module (ASM) was disconnected.
6. If the scan tool indicates 5 volts, indicates the TP

sensor circuits and PCM are OK.
8. Disconnecting the PCM will allow using the DMM
to test continuity of the circuits. This will aid in
locating an open or shorted circuit.
10. Disconnecting the PCM will allow using the DMM
to test continuity of the circuits. This will aid in
locating an open or shorted circuit.
Engine
6-1451
DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage

.Action
Step.
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
. System Check
Go to
DTCP16395
Volt Reference 2
Circuit
Go toStep 3
Go to Step5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to A
Diagnostic
System
Check - ABS in
Antilock Brake
System.
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 10

-

2. Idle the engine.
2
3. Mon.itor the Diagnostic Trouble Code (OTC)

Information using the scan tool.
Did DTC,P1639 fail this ignition?
1. Turn ON.the ignition leaving the engine OFF.

2. With the throttle closed, monitor the TP sensor
display on the scan tool.
Is the TP sensor voltage below the specified value?
0.2V

data for this OTC and record the parameters.
the OTC.
ignition?
Important: After you complete this diagnosis reconnect

the Accelerator and Servo Control Module (ASM). Also,
clear any ASM DTCs that may have set when the ASM
was disconnected.
2. Disconnect the ASM. Refer to Accelerator and Servo
Control Module (ASM) Replacement in Antilock Brake
System.
Is the TP sensor voltage still below the specified value?
0.2V
1. Disconnect the TP sensor electrical connector.

2. Jumper the 5 volt reference circuit and the TP signal
circuit together at the TP sensor harness connector.
3. Observe the TP sensor voltage display on the
scan tool.
Is the TP sensor voltage above the specified value?
4.7V
1. Connect the test lamp J 34142-8 between B+ and the

TP sensor signal circuit at the TP sensor harness
connector.
scan tool.
4.7V
6-1452
Step
Engine Controls .. 5.7l
Engine
DTC P0122 Throttle Position (TP) Sensor Circuit low Voltage {cont'd)
Value(s)
Action
Yes
3. .Test the 5volt reference circuit for an open or short
to ground.
4. If the 5 volt reference circuit is open or shorted to
ground, repair the circuit as necessary. Refer to
Wiring.Repairs in Wiring Systems.
1. Test the 5 volt reference circuit for a poor connection
at the PCM. Refer to Testing for Intermittent and Poor
2. If you find a poor connection repair the terminal as
Wiring Systems ..
Go to Step 14
Go to Step 9
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 11
10

opposite side of the manufacturer's logo.
3. Test the signal circuit for an open, short to ground, or
for a short to the sensor ground circuit.
4. If you find the sensor signal circuit is open or shorted
to ground, repair the circuit as necessary. Refer to
11
1. Test the sensor signal circuit for a poor connection at

Wiring Systems.
12

13

Replace the PCM.

the Clear DTClnformation option using the scan tool.
applicable.
the scan tool.
diagnosed?
15
14
No
Go to Step 14
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 15
Go .to Step 2
Go to the
applicable
DTC table
System OK
--~--~--. -M~----- '---
Engine
Engine Controls 5.7L
6-1453
DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage
I
~ ;f~e~e- --.. ---.. 1
,. - - - - - - - - - - - , Powertrain
sv
I Control
I
I
Tl'"=
Module
C1
B
0.35 BLK 452
0.35GRY 596
$116
0.35GRY
596
Anti lock
Brakes
Schematics
In Brakes
0.;35 GRY 596
. JIE:;rrPl
(P~M)
0.35 DK BLU 417

Antilock
0.35 DKBLU
Brakes
$118
417
Schematics
0.35 BLK
8119
In Brakes
452
0.35 DKBLU 417
0.35 BLK 452
24 C2
60 C1
~
-P;;-M- - - ~ Powertrain
Sensor
~
c1-BLU
Control A
I Signal
Sensor
c2:RED
I Module JP
I
_
Ground
I (PCM) _M
-r; -,-- - - - - -.f - -
L, -
-- -
582456
Circuit Description
The TP sensor Signal voltage should be near 0.6 volt
OTC sets.
Conditions for Running The DTC

The ignition switch is in the ON position or the engine
is operating.
Conditions for Setting The DTC

The TP sensor signal voltage is more than
4.75 volts.
Condition present for 10 seconds.

Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
malfunctions.
If it is determined that the OTC occurs intermittently,
performing the DTC P1121 diagnostic table may
6-1.454
Engine
Test Description
diagnostic table.
2. If DTCs P1635 sets at the same time, this
indicates that the 5 volt reference circuit is shorted
to a voltage. The 5 volt reference circuit is
internally connected within the PCM.
3. This step verifies if the fault is present..
you cannot duplicate theDTC, the information
~nd/or a fail. Operate Vehicle within the same

lreeze frame conditions (RPM, load, vehicle
5. Vehicles equipped with Accelerator and Servo

Control Module (ASM) will have to disconnect
the Accelerator qnd Servo Control Module (ASM).
This will determine if the short is caused from
the Accelerator and Servo Control Module (ASM).
After repairs are made, reconnect Accelerator
and Servo Contwl Module (ASM) and clear
the OTCs that set when the Accelerator and Servo
Control Module (ASM) was disconnected.
i.
This tests whether the ground circuit is available

to the TP sensor. Inspect for poor electrical
connections at the TP sensor.
Engine
6-1455
DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage

Step
Action

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (DTC)
Did DTC P1635 fail this ignition?
2. With the throttle closed, observe the TP sensor
voltage and percentage display on the scan tool.
Is the TP sensor voltage or the Throttle Angle above the
specified values?
data for this DTC and record the parameters.
the DTC.
ignition?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P16355
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to A
Diagnostic
System
Check - ABS in
Antilock Brake
System.
Go to Step 7
Go to Step 10
Go to Step B
Go to Step 11
Go to Step 14
Go to Step 9
4.7V, 0%
Important: After you complete this diagnosis reconnect

the Accelerator and Servo Control Module (ASM). Also,
clear any ASM DTCs that may have set when the ASM
was disconnected.
2. Disconnect the Accelerator and Servo Control
Module (ASM). Refer to Accelerator and Servo
Control Module (ASM) Replacement in Antilock Brake
System.
4.7V

scan tool.
Is the TP sensor voltage below the specified value?
0.20V
Probe the sensor ground circuit at the TP sensor harness

connector with the J 34142-8 test lamp connected to B+.
Measure the voltage at the 5 volt reference circuit to

ground using the DMM.
Is the voltage more than the specified value?
5V

Go to Step 15
6-1456
Engine
DTC P0123Throttle Position (TP)SensonCircuit High Voltage (cont'd)

Step
Action
10

3. Test for a short to voltage on the TP sensor signal
circuit; also test for a shorted circuit between the TP
sensor signal circuit and the Accelerator and Servo
Control Module (ASM).
4. If you find the TP sensor signal circuit shorted, repair
the circuit as necessary. Refer to Wiring Repairs in
Wiring Systems.
11
12
Value(s)
1. Test for an open TP sensor ground circuit. Refer to

2. If you find the TP sensor ground circuit open, repair
the circuit as necessary. Refer to Wiring Repairs in
Wiring Systems.
3. Inspect for a poor connection at the PCM. Referto
Wiring Systems.
4. If you find a poor connection, repair the terminal as
Connections in Wiring. Systems.
..
Go to Step 15
Go to Step 12
Go to Step 15
Go to Step 13
.'
15

4 .. Operate the vehicle within the Conditions for Running
applicable.
Does the scan tool indicate th.at this test ran and passed?
16
the scan tool.
diagnosed?
----~~-
Go to Step 13

14
Go to Step 15
..
"'
No

Replace the PCM.
13
Yes
Go to Step 15
-
Go to Step 1.5
Go to Step 16
Go to Step 2
Goto the
applicable
DTC table
System OK
Engine
6-1457
OTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed

Loop Fuel Control
rn
---yr---1-----,
Engine Coolant
Temperature (ECT)
Sensor
0.35 YEL 410
uJ
0.35 BLK 407
74
ECT
I Sensor
I Signal
80
ECT
Sensor
Ground -=-
C1
PCM
C1=BLU
C2=RED
Powertrain
Control
I Module
I (PCM)
I
I
I
A
P
L----------------J~
585397
Circuit Description
The PCM monitors the ECT sensor in order to
determine how long it takes the engine to reach the
coolant temperature required for Closed Loop
operation. OTC P0125 sets if the PCM determines that
the engine does not reach Closed Loop temperature
in a specified amount of time. This test will not
run if either the intake air or engine coolant
temperature is too low at start-up.

OTCs P0112, P0113, P0117, P0118 not set
.The engine coolant temperature is between -36C
(-33F) and 40C (104F) at engine start-up.
The intake air temperature is mar e
than -7C (19F).
The vehicle speed is more than 1.6 km/h (1 mph).

The closed loop coolant temperature of 34C (93F) is
not reached within a predetermined time. The
maximum allowable time depends on the start-up
coolant temperature and the amount of airflow into the
engine. The range for the time is from 2 minutes
and 20 seconds to 22 minutes and 30 seconds.

The PCM il.luminates the malfunction indicator
Failure Records.

6-1458
Engine
Diagnostic Aids
Important:
" Remove any debris from the PCM connector
in Wiring Systems.
1.f the engine has sat overnight, the engine coolant
performing the P1114 or P1115 diagnostics table may
An engine coolant temperature exceeding 34C
(93F), indicates that the engine is capable of reaching
the proper temperature, but not necessarily in the
correct amount of time. Repeat this diagnostic table on
a cold engine, and measure the time required to
reach the temperature threshold. When starting a cold

engine, measure the amount of time it takes the
engine to reach the specified temperature. The engine
should reach the specified temperature within
5 minutes or less. If the engine does not reach the
specified temperature within 5 minutes, inspect for the
following:
" Coolant level: refer to Loss of Coolant in Engine
Cooling .
Thermostat operation: refer to Thermostat
Diagnosis in Engine Cooling.
Are fans on at all times? Refer to Electric Cooling
Fan Diagnosis.
., Refer to Engine Fails To Reach Normal Operating
Temperature in Engine Cooling.
For an intermittent condition, refer to Symptoms.
Test Description
diagnostic table.
2. An ECT failure could cause a OTC P0125 to set,
so correct any ECT OTCs that are set.
6. If it is obvious that the engine is not reaching full
operating temperature, for example the radiator
hoses never get very warm, or there is a concern
of little or no heat from the heater, you can

skip th.is step.
DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed loop Fuel Control
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

Are any engine coolant temperature DTCs set?
1. Install a sca:n tool.

Does scan tool indicate the ECT sensor is less than the
specified value?
Jumper the terminals of the ECT sensor harness
connector together using a jumper wire.
Does the scan tool indicate the ECT is greater than the
specified value?
Go to the
applicable
DTC table
.
Go to Step 3
Go to Step 4
Go to
OTC P0117
Engine Coolant
Temperature
(ECT) Sensor
Circuit Low
Voltage
Go to Step 5
Go to
OTC P0118
Engine Coolant
Temperature
(ECT) Sensor
Circuit High
Voltage
-35C (-31 F)
139C (282F)
Engine
6-1459
DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed loop Fuel Control
(cont'd)
Step
Action
1. Reconnect the ECT sensor.
2. Idle the engine.
3. Observe the ECT sensor display on the Engine 1
Data List of the scan tool.
Important: Allow the engine to warm up if it has not
already reached the. specified temperature. 5 minutes is
the maximum amount of time it should take to reach this
temperature from a cold start. Less time is required if the
engine is already warm.
Does the scan tool indicate the engine coolant
temperature reached the specified value?
Value(s)
Test the engine cooling system for the following:

Thermostat operation: refer to Thermostat Diagnosis in
Engine Cooling.
Coolant level: refer to Loss of Coolant in Engine
Cooling.
Coolant to water ratio: refer to Coolant Concentration
Testing in Engine Cooling.
Cooling fan operation etc.: refer to Electric Cooling
Fan Diagnosis.
Refer to Engine Fails To Reach Normal Operating
Temperature in Engine Cooling.

Replacement.

4. Operate the vehicle within the Co.nditions for Running
applicable.
Does the scan tool indicate that this test failed?
10
diagnosed?
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
34C (93F)
Measure the resistance of the ECT sensor using a DMM.

Refer to Temperature vs Resistance.
Is the ECT resistance close to the value indicated in the
Temperature vs Resistance Table?
Yes
Go to Step 9
-
Go to Step 9
Go to Step 2
Go to Step 10
Go to the
applicable
OTC table
System OK
6-1460
Engine
(
~
Fuse Block
Details
Cell 11
.----------------- -
--- ---.. - ;;k;; - ... - - - - - - - , Powertrain II
I
Left Front
L---"--------.
I H02S
H02S
High
0.8
PNK 539
... -
CONN ID
C1=BLU
C2=RED
Low
...-:. .:-... :-""-: -
69ro8
... -
I Control
I Module
I (PCM)
..ll
291C1
TAN/Wi; 1653
J,.
0.8
ENG SEN
Fuse 10
20 A
Winng
Harness
1
Junction
I
.. - - - - - - - - - - - - .a Block
'[S]
1\1
0.8 PNK 539

B
I
I
I
I
I
I
I
0.8 PNK 539
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
Bank #1
left Front
Heated Oxygen
Sensor (H02S) #1
J7
.
J6
0.8
PPL/WHT 1665
Pow";r - - - -- - - - - - ... ~ E~9.ine
I Distribution
Schematics
I
in Wiring
I Systems
T
I
I
I
I
I
I
BLKl450
~--------------0.8 BLK1=4~,-~
=====-
~~......,.Gr-ou-nd.,..--,
Distribution
Cell 14
582459
Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
below a predetermined voltage. If the PCM detects the
voltage is below a predetermined voltage, this
DTC sets.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The AIR, EGR, and the catalyst diagnostics are

not active.
" The fuel system is operating in Closed .Loop.
" The fuel trim lea.rn is enabled.
., The TP sensor angle is between 2-70 percent.

The H02S signal voltage remains below 200 mV.
The conditions are present for 33 seconds.

Failure Records.
Engine

Diagnostic: Aids
Important:
gaskets are instaned correctly. The gaskets
in Wiring Systems.
The PCM sets this OTC when the vehicle runs out
of fuel.
Heated Oxygen Sensor (H02S) wire: Sensor
pigtail may be in contact with the exhaust manifold
or the exhaust system.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provide
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to Heated Oxygen Sensor (H02S) Wiring Repairs
in Wiring Systems.
Inspect for an intermittent ground in the signal
wire between the connector and the sensor.
Lean injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test with
Tech 2 or Fuel Injector Balance Test with
Special Tool.
6-1461
Fuel contamination: Water near the in-tank fuel

pump inlet can be delivered to the injectors. Refer
to Alcohol/Contaminants-in-Fuel Diagnosis. The
water causes a lean exhaust and can set a DTC.
Fuel pressure: System will be lean if fuel pressure
is low. Refer to Fuel System Diagnosis.
Exhaust leaks: An exhaust leak near the H02S can
cause a lean condition. Refer to Exhaust Leakage
in Engine Exhaust.
.. Vacuum or crankcase leaks can cause a lean
condition.
If the above are OK, the H02S may be at fault.
Test Description
diagnostic table.
2. If the H02S voltage is fixed well below 200 mV,
this indicates a short to battery ground or
chassis ground. If the voltage is fixed near or
above 200 mV, this indicates a short to a PCM
ground.
The engine must be at the normal operating
temperature before performing this test.
If you can not duplicate the OTC, the information
Counter can also aid in determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that the PCM
recorded. This isolates when the OTC failed.
4. A sensor that is disconnected should indicate a
bias voltage. If the voltage is low inspect the
signal circuit for a short to ground.
5. Disconnecting the PCM allows using a DMM in
order to test continuity of the circuits. This
aids in locating an open or shorted circuit.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3

1
Important: Inspect the H02S for being secure before

proceeding with this DTC. A sensor that is loose could
cause this OTC to set.
3. Operate the vehicle within parameters specified under
Conditions for Running the DTC in the
supporting text.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Is the H02S voltage less than the specified value?
200 mV
6-1462
Engine
OTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1 (cont'd)

Step
Action
4. Idle the engine.
the OTC.
Specific OTC option, and then enter the OTC number
ignition?
2. Jumper the H02S low circuit (PCM side} to a known
good ground.
3. Monitor the H02S voltage using the scan tool.
Is the H02S voltage within the specified range?
Important: Disconnecting the PCM may eliminate the
short to ground if the signal circuit is shorted to another C1
circuit.
3. Test the H02S high signal circuit for a short to
ground or a short to the sensor ground circuit. Refer
to Testing for Short to Ground in Wiring Systems.
Is the H02S signal circuit shorted?
Wiring Systems.
Replace the PCM.
applicable.
diagnosed?
Value(s)
Yes
No
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5
350-550 mV
(
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
Go to Step 9
Go to Step2
Go to the
applicable
OTC table
System OK
Engine Controls:.. 5.7l
Engine
6-1463
~ Pow";r - - - - - - - - - fuse Block

Details
Celf 11
.....
I Distribution
~che~atics
1
.....
,n w,nng
,--------------- - '" -
~a;k;;- Left Front
I
I
I H02S
High
0.8
H02S
Low
- - -
- - - ., Powertrain
CONN ID I Control
C1;BLU
I Module
C2;RED I (PCM)
--= .:-_ :--":.' - - - - - - - 69ro 8 291C1

~
.I
I. -
PNK 539
-- -
B . TANM/H: 1653
0.8
PPL/WHT
ENG SEN
Fuse 10
20 A
I Systems
.. -:- - - - - - - - - - - -
I
I
I
I
I
I
I
I
I
~ E~Qine
I
Wmng
Harness
Junction
I
.a Block 2
1
0.8 PNK 539

B
0.8PNK 539
1665
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
Bank #1
Left Front
Heated Oxygen
T
I
I
I
I
I
I
Sensor (H02S) #1
J7
0.8
BLK450
0.8 BLKf~4~,-~
=====-~-<II
Ground
Distribution
"-"""Ce=ll-'-'14.....__.
582459
Circuit Description
sensor varies the voltage over a rangefrom about

The PCM monitors and stores. the heated oxygen
determines if majority of the samples are out ofthe
operating range.
above a predetermined voltage. If the PCM detects the
voltage is above a predetermined voltage, this
DTC sets.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
.. The AIR, EGR, and catalyst diagnostics are not
active.
0 The ignition voltage is more than 9.0 volts.
The fuel system is operating in Closed Loop.
The fuel trim learn is enabled.
O The TP sensor angle is between 2-70 percent.
0

" The H02S signal voltage remains above 775 mV.
" The .conditions are present for 33 seconds.
Engine

Leaking injector: Refer to the Fuel System

Diagnosis.
Evaporative emissions (EVAP) canister purge.
Inspect for fuel saturation. If full of fuel, inspect the
canister control and hoses. Refer to EVAP
Control System Operation Description.
MAF sensor: Disconnect the MAF sensor and see
if the rich condition is corrected. If so, inspect for
proper installation. If installed OK, replace the
MAF sensor. If the MAF sensor is installed
backwards, the system goes rich. The plastic
portion of the sensor has arrows cast into
it indicating proper air flow direction. The arrows
must point towards the engine.
for proper operation. The H02S wires provides
in Wiring Syst~ms.
TP sensor: An intermittent TP sensor output
causes the system to go rich, due to a false
indication of the engine accelerating.
Test Description
6-1464

Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
Inspect the H02S electrical connections for evidence
of water intrusion. Water present in the connector
causes the B+ supply to the heater to bleed over to the
signal circuit.
Fuel pressure: The system goes rich if the
pressure is too high. The PCM compensates for
some increase. However, if the fuel pressure is too
high, a DTC may set. Refer to Fuel System
Diagnosis.
" Rich injector(s): Perform the Injector Balance
Special Tool.

diagnostic table.
2. This step tests for a rich condition.

data may aid in locating an intermittent condi.tion.
If you can not duplicate the DTC, the information
included in the Freeze Frame and/or Failu.re
Counter can also aid in determining how
vehicle speed, temperature etc.) that the PCM
recorded. This isolates when the DTC failed.
4. If the voltage remains high, this indicates the

signal circuit is shorted to a voltage. If the voltage
goes low, this indicates a rich conditio.n.
5. This step isolates the condition. If the voltage
remains high, this indicates t.he signal circul is. not
shorted to the heater feed circuit.
8. Test for a short between the H02S signal circuit
and any other wires powered by this fuse that
run together inside the same harness.
Engine
Engine Controls ~.5.7L
6-1465

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powerlrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 8
Go to Step 9
Did you pertorm the Powertrain On-Board

1

3. Operate the engine above 1200 RPM for two minutes.
Data List using a scan tool.
Is the H02S voltage greater than the specified value?
4. Idle the engine.
..
the OTC.
Specific OTC option, and then enter the OTC number
ignition?
2. Monitor the H02S voltage.
775mV
775mV
Remove the H02S heater fuse while monitoring the H02S

voltage.
Does the voltage drop to within the specified range when
the power to the heater is disconnected?
350-550 mV
1. Reinstall the fuse.

3. Jumper the H02S low circuit (PCM side) to a known
good ground.
Does the scan tool indicate the H02S voltage within the
specified range?
350-550 mV

short to voltage if the signal circuit is shorted to another
C1 circuit.
5. Test for a voltage on the H02S sensor signal circuit
at the PCM harness connector using the OMM.
Is a voltage present?
Repair the short to voltage in the H02S signal circuit.

Go to Step 11
6;.1466
Engine

OTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1 (cont'd)
Value(s)
Step
Action

Replace the PCM.
10

Sensor (H02S) Replacement Bank 1 Sensor 1.
11
12
Yes
No
(
Go to Step 11
Go to Step 11

2. Idle the engine at the normal operating temperature;
applicable.
Select the Capture Info option and the Revi,ew Info option
diagnosed?
Go to Step 12
Go to Step2
Go to the
applicable
DTCtable
System OK
Engine
6-1467
Hot With Ignition

Rela Ener ized
Fuse Block
Details
Cell 11
<II---
'
_ _________..,.. - - - - - - - -
..--_;_
_;_
' '
'
Low
_-:..:-_:-_-:--------J
Htgh
11. . .
69ro8
B
29IC1
TAN/WH: 1653
J6
_______ -
-. -
...
Wmng
Harness
Junction
Block 2
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
Bank #1
Left Front
Heated Oxygen
Sensor (H02S) #1
ENG SEN
Fuse 10
20 A
0.8
PPL/WHT 1665
~ E~Qine
J7
0.8 PNK 539

I
B
I
I
I
0.8 PNK 539
I
I'-------~
I
I
I
" - ..Bank#1
- - - - - - - - - - -. ,I Powertrain
.
I
. Left Front
CONN ID
Control
I
C1=BLU
I Module
I H02S
H02S
C2=RED I (PCM)
.
0.8
PNK 539
~ Pow';r - - .. - - - - - - I Distribution
Schematics
I
in Wiring
I Systems
T
I
I
I
I
I
I
0.8
BLK450
o.. 8 BLKt-=-4.~,-~
=====-
~--<111.__..Gr=-ou
.....
nd,....__.
Distribution
Cell 14
582459
Circuit Description
The engine air flow is between 20 g/s and 50 g/s.
The PCM continuously monitors the Heated Oxygen

Sensor (H028) activity for 100 seconds. During
the monitor period the PCM counts the number of
times that the H028 responds from rich to lean and
from lean to rich and adds the amount of time it took to
complete all transitions. With this information, the
PCM can determine the average time for all transitions.
If the average response time is too slow, a OTC
will set.
The PCM determines the lean to rich transition when
the H028 voltage changes from less than 300 mV
to greater than 600 mV. The PCM determines the rich
to lean transition when the H028 voltage changes
from more than 600 mV to less than 300 mV. An H02S
that responds too slowly is most likely defective.
Replace the H028.
The EVAP canister purge duty cycle is more

than O percent.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258,
not set.
O The engine coolant temperature is more than
50C (122F).
o The ignition voltage is more than 9.0 volts.
O The fuel system is operating in Closed Loop.
The engine speed between 1,000 RPM and
2,300 RPM.

O
The lean to rich response (below 300 mV to

above 600 mV) average time is more than
250 milliseconds.
The rich to lean response (above 600 mV to

below 300 mV) average time is more than
250 milliseconds.
The above conditions are met for 60 seconds.

Failure Records.
6-1468

" The PCM turns the malfunction indicator
that the diagnostic runs and .does not fail.
" A last test failed (current DTC) clears when the
A History DTC .clears after 40 consecutive
Diagnostic Aids
Important:
" For any test that requires probing the PCM or
in Wiring Systems.
This diagnostic only runs once per ignition cycle.
A malfunction in the H02S heater circuits causes a
DTC to set. Inspect the H02S heater circuits for
an intermittent open or for a poor connection.
A malfunction in the H02S heater circuits causes a
an intermittent open or for a poor connection.
Engine
An oxygen supply inside the H02S is necessary for
proper operation. The H02S wires provides the supply
of oxygen. Inspect the H02S wires and connections
for breaks or contamination. Refer to Heated Oxygen
Sensor (H02S) Wiring Repairs in Wiring Systems.
Test Description
diagnostic table.
2. This step determines if the fault is present. This
test may take 5 minutes for the diagnostic
to run.
3; When DTCs P0133 and P0153 are set at the
same time, it is a good indication that a fuel
contamination condition is present.
4. An exhaust leak 6-12 inches away from the
H02S can cause a DTC to set.
5. This step verifies whether a good ground circuit is
available.
6. This step verifies the integrity of the signal circuit
to the PCM.
to the PCM.
8. Certain RTV silicone gasket materials give off
vapors that can contaminate the H02S. There
is also a possibility of silicone contamination
cause.d by silicone in the fuel. If the sensors
appear to be contaminated by silicone and all the
silicone sealant is a non silicone base, advise
the customer to try a different fuel company.
A missing fuel filler restrictor indicates the
customer may have used leaded fuel.
Engine
6-1469

Action
Step

1
Value(s)
Did DTC P0153 also fail this ignition?
1. Inspect the exhaust system for a leak. Refer to

Exhaust System Inspection in Engine Exhaust. After
you inspecfthe exhaust system, return ,to this
diagnostic.
2. If you find an exhaust leak, repair the exhaust leak as
necessary.
Did you isolate an exhaust leak?
1. Visually/physically inspect the following items:

Ensure that the H02S is securely installed..
Inspect for corrosion on the terminals.
Inspect the terminal tension at the H02S and at
the PCM.
Inspect for damaged wiring.
2. If you find a condition repair as necessary.

good ground.
3. Monitor the H02S voltage on the Engine 1 Data List
Does the scan tool indicate a voltage within the
specified range?
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 8
Go to Step4
Go to Step 14
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
Important: If any DTCs are set (except P0153), refer to

those DTCs before proceeding with this diagnostic table.
3. Operate the vehicle within the parameters specified
under Conditions for Running the DTC in the
supporting text.
4. Monitor the DTC Information option using the
scan tool.
Yes
350-550 mV
'"
1. Jumper the H02S high and low (PCM side) signal

circuits to a battery ground.
2, Monitor the H02S voltage using the scan tool.
Does the scan tool indicate a voltage below the
specified value?
200 mV
""
Important: Determine and correct the cause of the

contamination before replacing a sensor. Inspect for the
Fuel contamination
Use of improper RTV sealant
Engine oil/coolant consumption
Replace the affected Heated Oxygen sensor. Refer to
Heated Oxygen Sensor (H02S) Replacement Bank 1
Sensor 1 and/or Heated Oxygen Sensor (H02S)
Replacement Bank 2 Sensor 1.
Go to Step 14
6-1470
Engine
OTC P0133 H02S Slow Response Bank 1 Sensor 1 (cont'd)

Value(s)
Step
Action
9,
1. Remove the jumper wire from the H02S low circuit.

2. Measure the voltage from the H02S low signal circuit
to a battery ground using the DMM.
Does the OMM indicate a voltage near the
specified. value?
5V
Repair the high signal circuit for a short to ground or for a

shorted to voltage. Refer to Wiring Repairs in Wiring
Systems.
Repair the open H02S low circuit or repair the faulty PCM
connections. Refer to Wiring Repairs in Wiring Systems.
12
Repair the H02S high signal circuit for an open or repair

the faulty PCM connections. Refer to Wiring Repairs in
Wiring Systems.
13
Replace the H02S. Refer to Heated Oxygen ' '


applicable.
diagnosed?
10
11
14
15
Yes
No
(
Go to Step 12
Go to Step 11
Go to Step 14
Go to Step 14
Go to Step 14
, Go to Step 14
(
Go to Step 15
Go to Step 2
Go to the
applicable
OTC table
SystemOK.
Engine

Hot Wrth Ignition
Rela Ener ized
~
<II- -
---.
.... ....
.... ....
....
.-------------_.,.. - - - - - - - -I
;a;k;; - - - - - - - - - ., Powertrain
r -
Left Front
CONN ID
C1=BLU
C2=RED
I H~2S
H02S
Low
I Control
I Module
I (PCM)
0.8 539 69roa

L-------------.1
~
___ 29IC1
~
0.8
High
PNK
TAN/W~ 1653
PPLIWHT 1665
Bank #1
Left Front
Heated Oxygen
Sensor (H02S) #1
0.8
Pow-;;r - - - - - - - .. - -
I Distribution
Schematics
I
In Wiring
I Systems
BLK450
J7
J6
ENG SEN
Fuse 10
20 A
~ E~~ine
I
1
Wmng
Harness
Junction
.. - - - - - - - - - - - - .. Block 2
I
I
I
I .___ _ _ _ __,
0.8 PNK 539
I
I
I
t
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
T
I
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0.8 BLKt.,,.~~~;;;;;:
r
-..
~--gfstn-ou-.~~--o-n...
Cell14
582459
Circuit Description
about 1O mV when the exhaust is lean.
operating range.
The PCM monitors the H02S voltage and detects if
the voltage goes out of the bias range. If the PCM
does not detect the voltage went out of the bias range,
this DTC sets.
Conditions for Running .the DTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P012~
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The AIR, EGR, and the Catalyst diagnostics are
not active.

The H02S signal voltage is steady between
350 mV and 550 mV.
6-1472
Engine

., The PCM illuminates the malfunction indicator
!amp (MIL) on the se.cond consecutive ignition
. time the diagnostic fails. The first time the
diagnosticfails, the PCM stores this information in
Failure Records.

" Use a scan tool in order to clear the MIUDTC.
e
Diagnostic Aids
Important:
.. Remove any debris from the PCM connector
e For any test that requires probing the PCM or
in Wiring Systems.
Test Description
The numbers below .refer to the step numbers on the
diagnostic table.
2. The engine must be at the normal operating

Counter can also be used to determine how many
ignition cycles the diagnostic: reported a pass
speed, temperature etc.) that the PCM recorded.
This isolates when the DTC failed.
4. If the scan tool indicates the H02S voltage goes
below 200 mV, this indicates the H02S circuits

and PCM are OK.
5. This step verifies whether the signal circuit from

the PCM is OK.
6. This step verifies whether the low signal circuit
from the PCM is OK. A voltage indicates the
PCM and wiring are OK.
Engine
6-1473

Step
Action
Did you perfdrm the Powertrain On-Board

cause this DTC to set.
3. Operate the engine above 1200 RPM for two minutes.
Does the scan tool indicate the H02S voltage varying
outside the specified range?
4. Idle the engine.
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, w.here
applicable, are listed in Conditions for Running
the DTC.
ignition?
Value(s)

Does the DMM. indicate near the specified value?
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Goto
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 10
350-550 mV

Is the H02S voltage below the specified value?
Yes
200mV
5 Volts
..

3. Test the continuity of the H02S high circuit. Refer to
4. Repair the open circuit if no continuity is indicated on
the DMM. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the H02S high circuit condition?
6-1474
Engine

Value(s)
Step
Action

3'. Test the continuity of th.e H02S low circuit. Refer to
4. Repair the open or the poor connection if no
continuity is indicated on the DMM. Refer to Wiring
1. Inspect the H02S circuits for a poor connection at the

H02S harness connector.
Did you find and. repair the condition?

10

Systems.
11

Replace the PCM.
12

applicable.
13
diagnosed?
Yes
No
..
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 12
Go to Step 11
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1475

Hot With Ignition
Rela Ener ized
Fuse Block
Details
Cell11
-<!-- -
'
' '
'
,--------------- -
- - - - - -I
.. - ;a-;;-k;;; .. - - - - - - - - ., Powertrain
I
Left Front
CONN ID
C1=BLU
C2=RED
I H02S
High
0.8
PNK 539
H02S
Low
I Control
I Module
I (PCM)
,. __-:.:-_:-~'".:'--------.! J.
69ro 8
B
29IC1
TAN/WH: 1653
Bank#1
left Front
Heated Oxygen
Sensor (H02S) #1
~ E~Qine
I
I
1. -
I
I
I
I
I
I
I
I
J7
ENG SEN
Fuse 10
20 A
J6
-
I
-
...
Wmng
Harness
Junction
l--1i1
Block 2
0.8 PNK 539
B
0.8 PNK 539
0.8
PPL/WHT 1665
~ Pow";r - - - - - ....... - I Distribution

I Schematics
in Wiring
I Systems
0.8
BLK450
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
T
I
I
I
I
I
I
~ =====_~~
0.8 BLK~=4~,-
,.....,,,.Gr-ou-nd.,...-..,
Distribution
Cell 14
582459
Circuit Description
The PCM supplies a bias voltage (approximately
450 mV) on the Heated Oxygen Sensor (H02S) signal
high and low circuits. When you turn the ignition to
the ON position, battery voltage is supplied to
the H02S heater. As the heater reaches the operating
temperature, the H02S voltage responds by
changing from a bias voltage range to the normal
operation. Typically, as the H02S reaches the
operating temperature, the H02S voltage goes from a
bias voltage to a voltage below 300 mV. Depending
on the exhaust gas content, it is possible for the H02S
voltage to go. above 450 mV.
The PCM runs the heater test only on a cold start
(depends on the cumulative air flow) and only once an
ignition cycle. When you start the engine the PCM
monitors the H02S voltage. When the H02S voltage
goes above or below the bias range threshold, the
PCM determines how much time it took. If the
PCM detects that the process took too much time for
the H02S to enter into normal operating range,
this DTC sets. The time the process takes the H02S
to reach operating temperature. is based on the
) amouni of air that flows into the engine.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
" The intake air temperature and the engine coolant
temperature are less than 50C (122F) and are
within 8C (14.5F) of each other at engine
start-up.
The ignition voltage is between 10.0 volts and
18.0 volts.
not active.

The H02S voltage remains between 300 mV and
700 mV for a predetermined amount of time (depends
on engine coolant temperature and air flow).
6-1476

.. The PCM illuminates the malfunction indicator
Failure Records.

.. The PCM turns the malfunction indicator
" A last test failed (current OTC) clears when the
Diagnostic Aids
Important:
in Wiring Systems.
Engine
The heater diagnostic only runs on a cold start and
runs once per ignition cycle .
Test Description
diagnostic table.
2. Allow the engine to cool before performing 1his
test. If the sensor is at the operating temperature
the H02S voltage will stay high or low. If the
H02S voltage stays between 300-700 mV
indicates the H02S heater is inoperative.
3. If more than one H02S OTC is set, this is a good
indication that the H02S fuse is open. Test all
the related circuits going to all the heated rn<ygen
sensors for a short to ground. If all the wiring
is OK, it may be necessary to disconnect each
H02S one at a time to locate a shorted sensor.
4. This step verifies whether a B+ supply is a1Jailable
at the sensor.
5. This step verifies whether a ground is available at
the sensor.
6. This step verifies whether the H02S heater
element is internally open.
7. Inspect the ignition feed circuits at the Underhood

Electrical Center for poor connections.
8. Test the ground circuits for an open if more then
one heater OTC sets.
DTC POi 35 H02S Heater Performance Bank 1 Sensor i

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 11
Go to Step 4

Important: Allow the engine to cool for about one half

hour before proceeding with this table.
2

300-700 mV
Data List of the scan tool.Does the H02S voltage go from a bias voltage to above or
below the specified range?
3
Inspect the H02S fuse for an open.

Is the H02S fuse open?
Engine
6-1477

Step
Action
Value{s)

3. Probe the ignition feed circuit at the H02S electrical
connector (PCM side) using a J 34142-8 test lamp
connected to ground (a known good ground. Do not
use the H02S heater ground or the H02S low
circuits).
Connect the J 34142-8 test lamp between the H02S

ignition feed and the H02S heater ground.
Measure the resistance between the H02S ignition feed

and the H02S heater ground at the H02S pigtail using
aDMM.
Is the H02S resistance within the specified range?
Repair the open in the H02S ignition feed circuit to the

H02S. Refer to Wiring Repairs in Wiring Systems.
Repair the open in the H02S heater ground circuit. Refer

10
1. Inspect for a poor connection at the H02S. Refer to

Wiring Systems.
Systems.
Yes
No
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
3.5-14.0Q
Go to Step 12
-
Go to Step 12
Go to Step 12
Go to Step 10
Go to Step 12
11
1. Locate and repair the short to ground in the H02S

ignition feed circuit.
2. Replace the faulty fuse. Refer to Wiring Repairs in
Wiring Systems.
12

applicable.
Does the scan tool indicate that this. test ran and passed?
13
diagnosed?
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1478
Engine

Fuse Block
Details
Cell 11
..__
__
Hot With Ignition

Rela Ener ized
'
- - - - - - - - - - - - , Engine
- - - - - , Ir Power
I w . ,
,--~~~~~~~~~~~~~~--'9-,
r - - - - - - - - - - - - - I CONN ID
I C1=BLU
I C2=RED
H02S
H02S
~:;~:~r
High
I. -
Low
.,
I
I
I
Powertrain
Control
Module
(PCM)
~.~ ~p=i~-11~: =--:;-;!;1.1 ~

B
TAN/WH: 1669
1.
J7
Schematics
J6
in Wiring
ENG SEN
Fuse 10
20 A
mng
I Harness
I Junction
~s~m.:. _- - - - - - - - .a Block 2
I
I
I
'f
0.8 PNK 539
Bank 1 H02S #1
Bank 2 H02S #1
Bank 2 H02S #2
0.8
0.8 PN: 539
I
I
I
I
I
Distribution
c
0.8 BLK 450
I
I
I
I
I
I
I
I
Bank#1
Left Rear
Heated Oxygen
Sensor (H02S)#2
0.8 PNK 539
_____ J
'
BLK 450' ' - ______

-
-41
- -41
Ground
Distribution
Cell 14
(
582463
Circuit Description
Conditions for, Running the DTC

1 000 mV when the exhaust is rich, down through
sensor (H02S} voltage information. The PCM
operating range.
voltageis below a predetermined voltage, this
DTC sets;
Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
" The fuel system is operating in Closed Loop,
The AIR, EGR, and, the Catalyst diagnostiqs are
not active.
The TP sensor angle is between 2-70 percent.
OR
Criteria 2
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The ignition voltage ,is more than 9.0 volts.
not active.
The Power Enrichment mode is enabled for more
than 1.0 second.
Engine
Criteria 1
The Criteria 1 conditions are present for
80 seconds.
OR
Criteria 2
10 seconds during the Power Enrichment mode.

lamp (MIL} on the second consecutive ignition
a1 the time of the failure. The PCM writes the
Failure Records.

lamp (MIL} OFF after 3 consecutive ignition cycles
Diagnostic Aids
Important:
J35616-A connector test adapter kit. Using this kit
in Wiring Systems.
The PCM sets this OTC when the vehicle runs out
of fuel.
Heated Oxygen Sensor (H02S} wire: Sensor
for proper operation. The H02S wires provides
in Wiring Systems.
6-1479

0

Special Tool.
" Fuel contamination: Water near the in-tank fuel

pump inlet can be delivered to the injectors.
The water causes a lean exhaust and can set
a DTC.
" Fuel pressure: System will be lean if fuel pressure
e
Exhaust leaks: An exhaust leak near the H02S

can cause a lean condition. Refer to Exhaust
Leakage in Engine Exhaust.
Vacuum or crankcase leaks can cause a lean

condition.
Test Description
diagnostic table.
ground. When the H02S voltage is fixed near
200 mV, indicates the DTC set when the
fuel system was in a Power Enrichment mode of
operation. This OTC sets if the H02S voltage
is less than 420 mV during a Power Enrichment
mode of operation.

data may aid in locating an intermittent.condition.
4. Lower the exhaust system to gain sufficient
access to the H02S and/or the H02S connector if
necessary. Disconnecting the H02S should
cause the H02S voltage to display a bias voltage.
A voltage staying near 0.0 volts indicates the
low circuit is open, or the high circuit is open or
grounded.
order in order to test continuity of the circuits.
This aids in locating an open or shorted circuit.
6-1480
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2.
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3


proceeding with this OTC. A sensor that is loose could
2. Idle the engine at t.he normal oper~ting temperature.
supporting text.
Is the H02S voltage fixed below the specified value?
80mV

4. Idle the engine.

met before the PCM will run this diagnostic, where
the DTC.
ignition?
good ground.
Does the scan tool indicate the H02S voltage is within the
specified range?
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5
Go.to Step 6
Go to Step 7
350-550 mV

circuit.
3. Test the H02S signal circuit for a short to ground or
a short to the sensor ground circuit. Refer to Testing
for Short to Ground in Wiring Systems.

Wiring Systems.

Replace the PCM.
Go to Step 8
(
-
Go to Step 8
Engine
6-1481
DTC P0137 H02S Circuit Low Voltage Bank 1 Sensor 2 (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK


8
the Specific DTC option, then enter the OTC number

4. Operate the vehicle within the Condition.s for Running
applicable.
diagnosed?
6-1482
Engine
Engine Controls;.. 5.7L

Fuse Block
Details
Cell 11
I" -
I
I
I
CONN ID
C1=BLU
C2=RED
;.,;;-#
'
~ - - - ~ I"
' '
1
-,
Powertrain
I Control
I Module
I (PCM)
.,
Left Rear
~[1~::-_:;a-]~1.. '~
H02S
High
_-_-o_,: ~P:~~
.__Lo
.
0.8 PNK 539
D
..a---
H02S
Low
0.8
TAN/WHT 1669
B
I
I
Pow-;. - - - - - - - - - - ., Engine
I
I
I
Distribution
Schematics
in Wiring
L.
~s~m.:, -
J7
J6
-
I VViring
I Harness
I Junction
.1 Block 2
I
I
I
I
0.8 PNK 539
I
I
"
Bank 1 H02S #1
Bank 2 H02S #1
Bank 2 H02S #2
ENG SEN
Fuse 10
20 A
T
0.8 PNK 539
c
0.8 BLK 450
Bank #1
Left Rear
Heated Oxygen
Sensor (H02S)#2
_____ J
.....
.....
BLK 450 '- _ - - - - -
-cq
----------cf!
Ground
Distribution
Cell 14
582463
Circuit Description
operating range.
DTC sets.

Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P012~
P0200, P0335, P0336, P0351-P0358, P1258
not set.

not active.
OR
Criteria 2
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
not active.
" The Deceleration Fuel Cut-off mode is enabled for
3 seconds to 1O seconds.

Criteria 1
The H02S signal voltage remains above 930 mV.
" The Criteria 1 conditions are present for
40 seconds.
OR
Criteria 2
5 seconds during the Deceleration Fuel
Cut-off mode.
Engine
. cycle that the diagnostic runs and fails.
Failure Records.

0
Diagnostic Aids
Important:
in Wiring Systems.
signal circuit.
~ Fuel pressure: The system goes rich if the
Diagnosis.
Rich injector(s): Perform the Injector Balance
Special Tool.
Diagnosis.
6-1483

Control System Operation Description .
portion of the sensor has arrows cast .into
in Wiring Systems:
Test Description
diagnostic table.
2. This OTC also sets during a deceleration fuel
cut-off. Inspect items which could cause a
rich exhaust during a deceleration (leaking
injectors, stuck injectors etc.). Refer to. Conditions
for Setting the OTC.

data may aid in locating an intermittentcondition.
If you cannot duplicated the DTC, the information
included in the Freeze Frame arid/or Failure
since the DTC set. The Fail Courter and Pass
speed, temperature etc.)that you observed. This
will isolate when the DTC failed.

goes low, this indicates a rich condition.
remains high, this indicates the signal circuit is not
run together inside the harness.
6-1484
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System C/1eck
Go to Step 4
Go to Step 3

1
Important: Monitor the front H02S voltage before

proceeding with this DTC. If the front H02S voltage is
fixed below 300 inV, refer to OTC P0131 H02S Circuit
Low Voltage Bank 1 Sensor 1.
2. Idle the engine until the normal operating temperature
is reached.
3. Raise the engine speed to 1200 RPM.
the DTC.
930mV

Specific DTC option, and then enter the DTC number
ignition?

350-550 mV

voltage.
350-550 mV

good ground.
specified range?
350-550 mV
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 8
Engine
6-1485
DTC P0138 H02S Circuit High Voltage Bank 1 Sensor 2 (cont'd)

Step
Action
Value(s)

C1 circuit.
at the PCM harness connector using the OMM.

10
11
12

Replace the PCM.

Yes
No
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 11


the Clear OTC Information option using the scan tooL
applicable.
Does the sc.an tool display any DTC.s th.at you have not
diagnosed?
Go to Step 11
Go to Step 12
Go to Step 2
Go to. the
applicable
OTC table
System OK
6-1486
Engine
....------, .. Pow';r - - - - - - - - - - , Engine
' '
.. -
I
I
I
CONN ID
C1=BLU
C2=RED
~.:
- B-;;n;;-# 1
Left Rear
~p=~~
H02S
Low
-,
Powertrain
I Control
I Module
I (PCM)
-[: :-_:;8-l~;
H02S
High
TAN/WHAT 1669
I
I
I
I
I
Distribution
Schematics
in Wiring
~5:.~ - - - - - - - - -
J7
J6
ENG SEN
Fuse 10
20 A
I Wiring
I Harness
I Junction
J Block 2
I
I
OB
0.8 PN K 539
0
ot With Ignition
Rela Ener ized
Fuse Block
Details
Cell 11
0.8 PNK 539
~
Bank 1 Ho2s#1
Bank 2 H02S #1
Bank 2 H02S #2
T
0.8 PNK 539
c
0.8 BLK 450
Bank #1
Left Rear
Heated Oxygen
Sensor (H02S)#2
_____ J
'
----------4
BLK 450' ' - _ - - - - - __.,.
Ground
Distribution
Cell 14
(
582463
Circuit Description

operating range.
this OTC sets.
The H02S signal voltage is steady between 409 mV

and 489 mV for 2.5 minutes.

OTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
not active.

The PCM records the operating conditions a1 the
Failure Records.

Engine
6-1487
Diagnostic Aids
Test Description
Important:
the .PCM connector gaskets .when
in Wiring Systems.

diagnostic table.
This isolates when the OTC failed.
and PCM are OK.
the PCM is OK.
6-1488
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4


3. Operate the engine above 1200 RPM for 2 minutes.
. 350-550 mV


4. Idle the engine.
the DTC.
ignition?

200 mV

Does the DMM indicate near the specified value?
5 Volts

3. Test the continuity of the H02S high circuit. Refer to
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 10
Engine
6-1489

Step
Action
1. Turn OFF the ignition:

3. Test the continuity of the H02S low circuit. Refer to

Wiring Systems.
Systems.

10

Wiring Systems.
Systems.
11

Replace the PCM.
Value(s)
Yes
No
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 9
-
Go to Step 12
Go to Step 12
Go to Step 11
Go to Step 12
t. Select t,he Diagnostic Trouble Code (DTC) option and
12
13
\\

2. ldle,the engine at the normal operating temperature.
the Specific DTC option, then ,enter the DTC number
4. Operate ,the vehicle within the Conditions for Running
applicable.
diagnosed?
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1490
Engine
Fuse Block
Details
Cell 11
r - - - - - - - - I CONN ID
I C1=BLU
I C2=RED
HO. 28
-0.~
Left Rear
I Control
I Module
I (PCM)
0.8 PN: 539
H02S
Low
1
J
0.8
TAN/WH: 1669
Pow-;r - - - - - - - - - - , Engine
Distribution
Schematics
in Wiring
, Systems
-,
:p:i~-11::=--:;-;]; ~
High
I,, -
;n;;-#,- - - ., Powertrain
.-------, r
I
I
I
I
I
I
I
I
I
I
I
1.. -
J7
JS
-
I Wiring
I Harness
I Junction
ENG SEN
Fuse 10
20 A
-
IM:"""l
Ll:!J
Block 2
0.8 PNK 539
Bank 1 H02S #1
Bank 2 H02S #1'
Bank 2 H02S #2
T
0.8 PNK 539
c
0.8 BLK 450
Bank #1
Left Rear
Heated Oxygen
Sensor (H02S)#2
_____ J
'
BLK 450' ' - _ - - - - - --..
---------~
Ground
Distribution
Cell 14
(
582463
Circuit Description
450 mV) on the Heated Oxygen Sensor (H02S) signal ,
high and low circuits. When the ignition is turned to
the ON position, battery voltage is supplied to the
H02S heater. As the heater reaches operating
temperature, the H02S voltage responds by changing
from a bias voltage range to normal operation.
Typically, as the H02S reaches operating temperature,
the H02S voltage goes from a bias voltage to a
voltage below 300 mV. Depending bn the exhaust gas
content, it is possible for the H02S voltage to go
above 450 mV.
The PCM will run the heater test only on a cold start
(depends on cumulative air flow) and only once
an ignition cycle. When the engine is started the PCM
will monitor the H02S voltage. When the H02S
voltage goes above or below the bias range threshold,
the PCM will determine how much time it took. If
the PCM detects that it took too much time for the
H02S to enter into normal operating range, this OTC
sets. The time it takes the H02S to reach the
operating temperature is based on the amount of air
that flows into the engine.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The intake air temperature and engine coolant
temperature are less than 50C (122F) and
are. within 8C (14.5F) of each other at engine
start-up.
" The ignition voltage is. between 10.0 volts and
18.0 volts.
not active.

Engine
Engine Controls - 5..7L

Failure Records.

warm-up cycles, if this or any other .emission
Diagnostic Aids
Important:
J 35616-A connector test adapter kit. Using this. kit
in Wiring Systems.
6-1491

runs once per ignition cycle.
Test Description
diagnostic table.
2. Allow the engine to cool, before proceeding with
this diagnostic table. The H02S may be at the
operating temperature and no drop or rise in the
H02S voltage would occur. If the H02S voltage
stays between 300-700 mV indicates the
H02S heater is inoperative.
3. If more then one H02S heater OTC is set, this is
good indication that the H02.S fuse is open.
Test all the related circuits going to all of the
heated oxygen sensors for a short to ground. If all
wiring is OK, it may be necessary to disconnect
each H02S one at a time to locate a shorted
sensor.
4. This step verifies whether B+ supply is available
at the sensor.
the sensor.
element is internally open.

Step
Action
Important: If the engine has just been operating, allow the

engine to cool for about one half hour before proceeding.
1: Turn OFFthe ignition.
Does the H02S voltage go from a bias voltage to above or
Inspect the fuse for the H02S ignition feed circuit.
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 11
Go to Step 4
300-700 mV
6-1492
Engine Controls
Engine
5.7L

Step
Action
Value(s)

connector (PCM side} using a J 34142-8 test lamp
connected to a known good ground. Do Not use the
H02S heater ground or the H02S low circuit.


the DMM.
Is the H02S resistance within the. specified range?

H02S. Refer to Heated Oxygen Sensor (H02S) Wiring

to Heated Oxygen Sensor (H02S) Wiring Repairs in
Wiring Systems.

Wiring Systems.
Systems.

11
Locate and repair the short to ground in the H02S ignition

feed circuit and replace the fuse. Refer to Wiring Repairs
in Wiring Systems.
12

applicable.
diagnosed?
10
13
Yes
No
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
3.5-14.0Q
Go to Step 12
Go to Step 12
(
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1493
!Hot With lgn Relay Energized

'" Po;er- -
I
I
I
Distribution
J7
Schematics in
Wiring Systems J6
ENG SEN
Fuse Io
20 A
Engine Wiring
I Harness Junction
I Block 2
LI.I
&.------ -----.!
0.8 PNK 539
B
0.8 PNK 539
,.... /
Fuse Block
Details
Cell11
-Ii>-
,,-
,.. - - - - - l ! I I - - - - - - - - - - - - - - - - - - - - - - .
I
I
I
'" -
I
I
I ~~s
..
-B;;k-; -
C1=BLU
C2=RED
~~~s
Powertrain
I Control
I Module ~
I (PCM) ~
CONN ID
Right Front
&.--------------.!
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
26r--;.~ -p~~11~~6
1667
0.8 TAN
0.8 PNK 539
D
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
0.8 BLK 450
L -
------------'
' ' - ______

BLK 450'
-<11
----------<II
Ground
Distribution
Cell14
582470
Circuit Description
operating range.
DTC sets.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.

O The fuel system is operating in Closed Loop.
not active.


Failure Records.
6-1494
Engine

Diagnostic Aids
Important:
in Wiring Systems.
The PCM sets this DTC when the vehicle runs out
of fuel.
in Wiring Systems.
Special Tool.
Fuel contamination: Water near the in-tank fuel

a DTC.
" Exhaust leaks: An exhaust leak near the H02S
Vacuum or crankcase leaks can cause a lean
condition.
Test Description
diagnostic table.
ground.
Counter can also be used to determine how many'
.
4. A sensor that is disconnected should indicate a
bias voltage. If the voltage is low inspect the
signal circuit for a short to ground.


Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check


2: Idle the engine at the normal operating temperature.
under Conditions for Running the OTC in the
supporting text.
200 mV
(
Go to Step 4
Go to Step 3
Engine
6-1495

Step
Action
4. Idle the engine.
the OTC.
Does the scan tool indicate that this diagnostic fajled this
ignition?
good ground.
3. Monitor the H02S voltage using the .scan tool.
specified range?
circuit.
Wiring Systems.
Replace the PCM.
applicable.
diagnosed?
Value(s)
Yes
No
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 7
350-550 mV
Go to Step 10
Go to Step 10
Go to Step 9
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1496
Engine
DTC P0152 H02S Circuit High Voltage Bank 2 Sensor1
IHot With lgn Relay Energized
I Schematics in
ENG SEN
Fuse 10
Engine Wiring
I Harness Junction
I Block 2
I Wiring Systems J6
20 A
r Po;er- -
Distribution
J7
!.------
l..JiJ
-----.1
0.8 PNK 539
.,.. -
B
0.8 PNK 539
I
I
I
llll----------,-------,------.
r - I
Fuse Block
Details
Cell11
-~
r -
-B;k-; "". 2
Right Front
H02S
Low
- -
Powertrain
I Control
I Module "'
I (PC.M) .1,._4.
- .,
CONN ID
C1=BLU
C2=RED
H02S
High
1.--------------J
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
26,--~.~ -p~t11~~6
11667
0.8 TAN
0.8 PNK 539
D
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
0.8 BLK 450
L -
111------------'
'
BLK 450' ' - ______

-
Ground
Distribution
Cell 14
(
582470
Circuit Description
operating range.
voltage is above a predetermined voltage, a DTC
will set.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
not active.

Engine
the Failure Records. If the diag,nostic reports a
Failure Records.

6-1497

Diagnosis.
Control System. Operation Description.
in Wiring Systems.
.. TP sensor: An intermittent TP sensor output
Diagnostic Aids
Test Description
Important:
in Wiring Systems.
signal circuit.
high, a OTC may set. Refer to Fuel System
Diagnosis.
Special Tool.

diagnostic table.
2, The engine must be at the normal operating

since the OTC.set. The Fail Counter and Pass
4; If the voltage remains high, this indicates the
remains high, this indicates the signal circuit is not
run together inside the same harness.
6-1498
Engine
DTC P0152 H02S Circuit High Voltage Bank: 2 Sensor 1

Step
Action

1
Value(s)
Yes
..

4. Idle the engine.
the DTC.
ignition?

Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
(3o

No
tci Step 2
775mV
Go to Step 4
Go to Step 3
Go to Step 4
Goto
Diagnostic Aids
Go to Step 5
Go to
Diagnostic Aids
775mV

voltage.
the power to the. heater is disconnected?
350-550 mV

good ground.
specified range?
350-550 mV
Important: Disconnecting the PCM may eliminate

the short to voltage if the signal circuit is shorted to
another C1 circuit.
at the PCM harness connector using the DMM.

I'
Go to Step 6
Go to Step 7
Go to Step 10
Go to StepB
Go to Step B
Go to Step 9
-
Go to Step 11
Engine
6-1499

Action
Step
10
11

Replace the PCM.

Value(s)
12
No
Go to Step 11
-
Go to Step 11

applicable.
diagnosed?
Yes
Go to Step 12
Go to Step 2
Go to the
applicable
DTC table
System OK
6~1500
Engine
Hot With lgn Relay Energized

r-l Power
Distribution
J7 ENG SEN
I Schematics in
Fuse 10
I.. Wiring Systems J6 20A
., Engine Wiring
I Harness Junction
s1ock 2
___________ ...I
Ll:!I
0.8 PNK 539
.,.... -
B
0.8 PNK 539
I
I
I
_.,.
r -
Fuse Block
Details
Cell11
-ell---------,.,------------,
r - I
-B;;k-; - 2
Right Front
- ..... -
.,.. -
CONN ID
C1=BLU
C2=RED .
Powertrain
I Control
, I Module ~
...I (PCM) ~
.,
.. ______________
~~~s
I ~~s
26r- -~.~-p~t11~~6
11667
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
0.8 TAN
A
0.8 PNK 539
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
0.8 BLK 450
L -
R----------~
' ' ' - ______
BLK 450
Ground
-
---------~
Distribution
Cell14
(
582470
Circuit Description
Sensor (H02S) activity for 100 seconds. During
times that the H02S responds from rich to lean and
complete all transitions. With this information, the
PCM can determine the average time for all transitions.
If the average response time is too slow, a OTC
will set.
The PCM determines the lean to rich transition when
the H02S voltage changes from less than 300 mV
to greater than 600 mV. The PCM determines the rich
to lean transition when the H02S voltage changes
from more than 600 mV to less than 300 mV. An H02S
that responds too slowly is most likely defective.
Replace the H02S.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The engine coolant temperature is greater than
50C (122F).
not active.
The engine speed is between 1,000 RPM
and 2,300 RPM.
.. The engine air flow is between 20 g/s and 50 g/s.
" The EVAP canister purge duty cycle is more
than O percent.
Engine
The lean to rich response (below 300 mV to

above 600 mV) average time is more than
250 milliseconds.
The. rich to lean response (above 600 mV to
below 300 mV) average time is more than
250 milliseconds.
The above conditions are met for 60 seconds.

diagnostic tails, the PCM stores this information in
Failure Records.

Diagnostic Aids
Important:
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals. Refer to Using Connector
Test Adapters in Wiring Systems.
6-1501
A malfunction in the H02S heater circuits cause a

intElrmittent opens/connections. Refer to Testing for
to Heated Oxygen Sensor (H02S) Wiring Repairs in
Wiring Systems.
Test Description
diagnostic table.
2.' This step determines if the fault is present. This
to run.
3. When DTCs P0133 and P0153 are set at the
5. This step verifies whether a good ground circuit is
available.
to the PCM.
to the PCM.
caused by silicone in the fuel. If the sensors
6-1502
Step
Engine

Action
Value(s)
Yes

supporting text.
scan tool.
Did OTC P0153 fail this ignition?
Did OTC P0133 also fail this ignition?
1. Inspect the exhaust system for a leak. Refer to

Exhaust System Inspection in Engine Exhaust. After
you inspect the exhaust system, return to this
diagnostic.
necessary.

Ensure that the H02S is securely installed.
Inspect the terminal tension at the H02S and at
the PCM.
2. If you find a condition repair as necessary.
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to StepB
Go to Step 4
Go to Step 14
Go to Step 5

good ground.
specified range?
specified value?
Fuel contamination
No
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
350-550 mV
200mV
(
Go to Step 14
Engine
6-1503

Action
Step
Value(s)
Yes
No
Go to Step 12
Go to Step 11

9

5V
Does the DMM indicate a voltage near the

specified value?
10
Repair the high signal circuit for a short to ground or for a

shorted to voltage. Refer to Wiring Repairs in Wiring
Systems.
11
12

Go to Step 14
13
Go to Step 14

the faulty PCM connections. Refer to Wiring Repairs in
Wiring Systems.
Go to Step 14

connections. Refer to. Wiring Repairs in Wiring Systems.
'
Go to Step 14

14

the DTC as specified i.n the supporting text, if
applicable.
15
diagnosed?
Go to Step 15
Go to Step 2
Go to the
applicable
DTC table
.System OK
Engine
!Hot With lgn Relay Energized
.---'
Power
Distribution
J7
I Schematics in
I
L, -
ENG SEN
Fuse 10
Wiring Systems J6
-
20A
-
-- -
, Engine Wiring
I Harness Junction
'Block2
_
...
0.8PNK 539
.,... -
B
0.8 PNK 539
Fuse Block
Details
Ceil11
-~
'
'" - - -~k-;2- - - - - - - - - , Powertrain
I
I
I
I
I ~~S
Right Front
~~~s
I Control
I Module ~
I (PCM)~
CONN ID
C1=BLU
C2=RED
'---------------.!
26r--~-~ -p!t11~~6
1667
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
'
0.8 TAN
I
I
I
I
I
I .
I
I
I
L -
0.8 PNK 539
D
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
0.8 BLK 450
-
----------'
- - - - - - - - - -<l
Ground
Distribution
Ceil 14
(
582470
Circuit Description
operating range.
a DTC will set.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258,
not set.
The AIR, EGR, and the Catalyst system
diagnostics are not active.

350 mV and 550 mV.
All conditions present for 60 seconds.
Engine
" The. PCM records the operating conditions at the
Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
6-1505

proper operation. The H02S wires provide the supply
Sensor (H02S} Wiring Repairs in Wiring Systems.
Test Description
diagnostic table.
and PCM are OK.
the PCM is OK.
7. Disconnecting the PCM allows using a DMM to
test the. continuity of the circuits. This aids in
!oca~ing ar;1 open or shorted, circuit.
6-1506
Engine

Step
Action
Important: Verify that the H02S is secure before


4. Idle the engine.
the OTC.
ignition?
Value(s)
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
350-550 mV

200 mV

to a battery ground using the DMM J 39200.
5 Volts

3. Test the continuity of the H02S high circuit using the
DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.
Yes
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 10
Engine
6-1507

Step
Action

3. Test the continuity of the H02S low circuit using the
DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.
Did you find and correct the H02S low circuit condition?

H02S harness connector. Refer to Testing for
Wiring Systems.
Did you repair the condition?


Wiring Systems for procedure.
Did you repair the condition?
10
Value(s)
Yes
No
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 9
-
Go to Step 12
Go to Step 12
Go to Step 11

11
12
13
Replace the PCM.
1. Select. the Diagnostic Trouble Code (OTC) option and

applicable.
Seiectthe Capture Info option and the Review Info option
diagnosed?
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
..
6-1508
Engine
Engine Controls - 5~7l
.---
I Power
Distribution
I
J7
Schematics in
Wiring Systems J6
ENG SEN
Fuse 10
20A
, Engine Wiring
I Harness Junction
I Block 2
. . ______ -----..11I
0.8 PNK 539

B
0.8 PNK 539
,,... -
Fuse Block
Details
-II-
Cell11
,- - - - - -111------------------~
I
I
I
.- -
I
I
-B;k-; - 2
Right Front
~:s
~~~s
CONN ID
C1=BLU
C2=RED
Powertrain
I Control
I Module Ji.
I (PCM) ~
1.--------------.J
26 -pt~11~~6
0.8
11667 . 0.8 539
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
TAN
r--~-~
PNK
D
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
oo----------~
" ' - ______ --4 Ground
BLK 450"
0.8 BLK 450
L -
-<II
Distribution
Cell 14
(
582470
Circuit Description
voltage to go above 450 mV.
The PCM runs the heater. test only on a cold start
PCM detects that the process took too much time for
this OTC sets. The time the process takes the H02S
to reach operating temperature is based on the
amount of air that flows into the engine.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The intake air temperature and the engine coolant
within 8C. (14.5F) of each other at engine
start-up.
.. The ignition voltage is between 10.0 volts and
18.0 volts.
" The AIR, EGR, and the Catalyst diagnostics are
not active.
O

Engine

The PCM illuminates the malfunction. indicator
" The PCM rec.ords the operating conditions at the
Failure Records.

.. A History OTC dears after 40 consecut.ive
Diagnostic Aids
Important:
the .PCM connector gaskets when
in Wiring Systems.
6-1509

proper operation. The H02S wires provide the supply
of oxygen. Inspect the H02S wires .and connections
Sensor (H02S} Wiring Repairs in Wiring Systems.
.Test Description
diagnostic table.
2. The engine must be allowed to cool. The H02S
may be at operating temperature and no drop
or rise in H02S voltage will occur. If the H0.28
voltage stays between 300-700 mV indicates the
H02S heater is inoperative.
3. An open H02S fuse causes multiple H02S OTCs

to set. Test all the related circuits going to all of
the heated c;,xygen senso~s for a short to ground. If,
all of the wiring is OK, it may be necessary to
disconnect each H02S one at a time to locate a
shorted sensor.
4. This step verifies whether the B+ supply is
available at the sensor.

the sensor.
element is internally ;open.
Fuse. Block for poor connections.


Step
Action
Value(s}
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 11
Go to Step 4

-
Important: Allow engine to cool for about one half hour

before proceeding.
Daia List of the scan tool.
Inspect the fuse for H02S ignition feed.
300-700 mV
6-1510
Engine

Step
Action
Value(s)
1. Raise the vehicle. Refer to. Lifting and Jacking the

Vehicle in General lnforrnation.
connector (PCM side) using the J 34142-8 test lamp
connected to a known good ground. Do not use the


the DMM.
Is the H02S resistance within the specified range?


Wiring Systems.
Systems.
10

Sensor (H02S} Replacement Bank 2 Sensor 1.
11
Locate and repair the short to ground in the H02S ignition

feed circuit and replace the faulty fuse. Refer to Wiring
12

2. Idle the engine at the normai operating temperature.
applicable.
13
diagnosed?
No
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
3.5-14.0Q
Repair the open H02S ignition feed circuit to the H02S.

Yes
Go to Step 12
Go to Step 12
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-151 l
DTC P0157 H02S Circuit low Voltage Bank: 2 Sensor 2
IHot With lgn Relay Energized I

.. Power
- -
Distribution
I Schematics
I in Wiring
Fuse Block
- - - - - - - .,I Engine Wiring

J7
ENG SEN
Harness
1Junction
Fuse 10
J6 20 A
I Block 2
Systems
Details
Cell 11
r- - -
L------------.1
0.8 PNK 539
Ir - - - - - - ;n;#;- 11
11
11
B
0.8 PNK 539
CONN ID
Right Rear
C1=BLU
C2=RED
: L -
H02S
Low
H02S
High
,Powertrain
I Control
'Module
I (PCM)
;5-r-= ::_ :-_:-6-;1~; ~
0.8
0.8
TAN 1671 PPL 1670 0.8
PNK 539
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #1
Bank#2
Right Rear
Heated Oxygen
Sensor (H02S)#2
'f
I
I
I
I
I
I
I
L
c
0.8 BLK 450
-&---------~
' :-,.,
0.8 BLK 450 ' - ______ _,. Ground
-
-oll
Distribution
Cell14
)
582472
Circuit Description
operating range.
OTC sets.

Criteria 1
OTCs P0101, P0102, P0103, P0112, P01 i 3,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The AIR, EGR, and Catalyst diagnostics are not

active.
" The TP sensor angle is between 2-70 percent
s
OR
Criteria 2
O
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, POi25,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
" The AIR, EGR, and Catalyst diagnostics are not
active.
" The Power Enrichment mode is enabled for more
than 1 second.

Criteria 1
" The H02S signal voltage remains below 80 mV.
80 seconds.
OR
Criteria 2
10 seconds during the Power Enrichment mode.
Engine

Special Tool.
" Fuel contamination: Water near the in-tank fuel
a OTC.
" Exhaust leaks: An exhaust leak near the H02S
" Vacuum or crankcase leaks can cause a lean
condition.
6-1512

Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
The PCM sets this DTC when the vehicle runs out
of fuel.
or exhaust system.
for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to Heated Oxygen
Inspect for an intermittent ground in the signal wire
between the connector and the sensor.
Test Description
diagnostic table.
ground. When the H02S voltage is fixed near
200 mV, indicates the DTC set when the
fuel system was in a Power Enrichment mode of
operation.
Idle the engine at the normal operating

data may aid in locating an intermittent .condition.
necessary. Grounding the low side circuit of the
H02S causes the H02S voltage to display a bias
voltage. If the voltage stays near 0.0 volts, this
indicates the low circuit is open, or the high circuit
is open or grounded.
in locating an open or shorted circt,1it.
Engine
Step

Value(s)
Action
Yes

applicable.
6-1513
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 7
80mV

)
4

recorded in Freeze Frame and/or Failure Records as
the OTC.
ignition?

good ground.
Is the H02S voltage within the specified range?
350-550 mV

grounded circuit if the signal circuit is shorted to another
C1 circuit.
same side as the manufacturers logo. Refer to PCM

Wiring Systems.

Replace the PCM.
Go to Step 8
Go to Step 8
6-1514
Engine

Step
Action
Value(s)
Yes
No
1. Select the Diagnostic Trouble Cod~ (OTC) option and

applicable.
diagnosed?
(
-
Go to Step 9
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
5..1515
IHot With lgn Relay Energized]

'" Power
- - - - - - - - - - - - .,I Engine Wiring
Distribution
Schematics
in Wiring
I Systems
I
I
J7
JS
ENG SEN
Fuse 10
20 A
....-- -
Harness
1Junction
I Block 2
Fuse Block
Details
Cell 11
r- - -
L------------..1
I'" - - - - - - ;n;#; - - .,Powertrain
0.8 PNK 539

B
11
II
11
CONN ID
Right Rear.
C1=BLU
C2=RED H02S
H02S
Low
High
I Control
I Module
I (PCM)
:--~fr: :~; :1
0.8 PNK 539
~~70~
.
v1
PNK 539
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #1
Bank#2
Right Rear
"
Heated Oxygen
Sensor (H02S)#2
I
I
I
I
I
I
I
L
c
0.8 BLK 450
-
-------------'
'
:-,,.
0.8 BLK 450 ' - ______ -<4

- - - - - - - - - -4
Grou
Distribution
Cell 14
)
582472
Circuit Description
operating range.
DTC sets.

Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,

P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.

not active.
O The TP sensor angle is between 2-70 percent.
OR
Criteria 2
., DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
" The AIR, EGR, and the Catalyst diagnostics are
not active.
O The Deceleration Fuel Cut-off mode is enabled for
3 seconds to 10 seconds.

Criteria 1
40 seconds.
OR
Criteria 2
5 seconds during Deceleration Fuel Cut-off mode.
6.;1516

conditions to the Freeze.Frame and updates the
Failure Records.
Engine
O

Diagnostic Aids
Important:
prevents any damage to the harness conriector
in Wiring Systems.

of water intrusion ..Water present in the connector
signal circuit.
. pressure is too high. The PCM compensates for
Diagnosis.
Test. Refer to Fuel Injector Balance Test with Tech
2 or Fuel Injector Balance Test with Special Tool.
Diagnosis.
For

Control System Operation Description.
in Wiring Systems.
an intermittent condition, refer to Symptoms.
Test Description
diagnostic table.
2. This DTC also sets during a deceleration fuel
cut-off. Inspect items which could cause a
~i~h exhaust du~i~g a deceleration (leaking
inJectors, stuck mJectors etc.). Refer to Conditions
for Setting the DTC.
Idle the engine at the normal operating
~ecords data can help deter.mine how many miles
s1.nce the DTC set. The Fail Counter and Pass
Counter can al$O. help determine how many
remains high, this indi.cates .the signal circuit is not
8. Review the system mechanization. Test for a
short between the H02S signal circuit and
any other wires powered by this fuse that run
together inside the harness.
Engine
6-1517

Step
Action

1
Value(s)

the OTC.
the Specific OTC option; then enter the OTC number
ignition?
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Important: Monitor the front H02S voltage before

proceeding with this OTC. If the front H02S voltage is
fixed below 300 mV, refer to OTC P0151 H02S Circuit
Low Voltage Bank 2 Sensor 1.
3. Increase the engine speed to 1200 RPM.
4. Monitor the H02S voltage display on the Engine .1
Yes
930mV
..
Go to Step 4
Goto
Diagnostic Aids
Go to Step 5
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 8
930mV
Remove the H02S heater fuse while monitoring the

H02S voltage.
350-550 mV

good ground.
specified range?
350-550 mV
6-1518
Engine

Value(s)
Step
Action

C1 circuit.
at the PCM harness connector using the DMM.

10
11
12

Replace the PCM.
Yes
No
Go to Step 8
Go to Step 9
-
Go to Step 11
Go to Step 11
Go to Step 11

4. Operate the vehicle within the conditions for Running
applicable.
diagnosed?
Go to Step 12
Go .to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1519
!Hot With lgn Relay Energized i

'"Pow-; - - - - - - - - - - "' Engine Wiring
I Distribution
I Schematics
J7
I in Wiring
J6
ENG SEN
Fuse 10
,,, ,,,
I Harness
1Junction
I Block 2
20 A
-~
Fuse Block
Details
Cell 11
r- - -
____________ ..
I._ Systems
...---
1.- - - - - - 11 CONN ID
11 c1=BLU
11 C2=RED H02S
Low
0.8 PNK 539

B
0.8 PNK 539
;n;#; - Right Rear

.
H02S.
High
,Powertrain
I Control
I Module
I (PCM)
:;,-;1~; ~
-r-= .:-_
: ... - - - ; 5
=-I
0.8
0.8
TAN
1671
PPL
1670 0,8
I
_1_
PNK 539
T
A
B
D
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #1
Bank#2.
Right Rear
Heated Oxygen
Sensor (H028)#2
"'
I
I
I
I
I
I
I.....
___________
0.8 BLK 450
- -
'
___,
:-,...
0.8 BLK 450 '-_~_-.,-_-<II
- - -
---
.___,.
Ground
Distribution
Cell 14
582472
Circuit Description
operating range.
this OTC sets.

DTCs P0101, P0102,.P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, POt25,
P0200, P0335, P0336, P0351~P0358, P1258,
not set.
" The fuel system is operating in Closed Loop.
System voltage is greater than 9.0 volts.
not active.

409 mV and 489 mV.
.. All conditions present for 2 minutes and
30 seconds.
6-1520
Engine

Failure Records.

Diagnostic Aids
Important:
J 356.16-A connector test adapter kit. Using this kit
in Wiring Systems.
proper operation. This supply of oxygen is provided
through the H02S wires. All H02S wires and
connections should be inspected for breaks or
contamination. Refer to Heated Oxygen
Test Description
diagnostic table.

data may aid in locating an intermittent condi1ion.
and PCM are OK.
the PCM is OK.
Engine
6-1521

Step
Action.


4. Idle the engine.
the DTC.
ignition?
Value(s)
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Steps
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 10
350-550 mV

200mV

5 Volts

3. Test the continuity of the H02S high circuit using the
DMM. Refer to Testing for Continuity in Wiring
Systems.
Yes
6-1522
Engine

Step
Action
Value(s)

Wiring Systems.
Systems.
Replace the H02S. Refer to Heated Oxygen Sensor

(H02S) Replacement Bank 2 Sensor 2.
10

Wiring Systems.
Systems.
11
lmpo11ant: Program the replacement PCM. Refer to PCM

Replace the PCM.
12

applicable.
13
diagnosed?
Yes
No

3. Test the continuity of the H02S low circuit using the
DMM. Refer to Testing for Continuity in Wiring
Systems.
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 12
Go to Step 11
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1523
IHot With lgn Relay Energized I

~
Pow';r - - - - - - - - - - "' Engine Wiring
Distribution
I Schematics
I in Wiring
I Systems
J7
J6
ENG SEN
Fuse 10
20 A
.,,. ....--- -
Harness
1Junction
Fuse Block
Details
Cell 11
r - - - - f - - - - - - - - - - - -...
I Block 2
L------------.1
1r - - - - - - ;n;#;- 11 CONN ID
Right Rear
II C1 =BLU
.
11 C2=RED H02S
H02S
0.8 PNK 539

B
,Powertrain
I Control
I Module
I (PCM)
:--~fr: ~ir1~:o~
Low
0.8 PNK 539
High
PNK 539
1_
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #1
Bank#2
Right Rear
I
I
I
I
I
I
I
Heated Oxygen
Sensor (H02S)#2
c
0.8 BLK 450
-
-ft-----------'
'
:-..
0.8 BLK 450 ' - ______ -<II

- - - - - - - - - -<II
Ground
Distribution
Cell14
582472
Circuit Description
voltage to go above 450 mV.
The PCM runs the heater test only on a cold start
PCM detects that the process took too much time tor
this OTC sets. The time the process takes the H02S
to reach operating temperature is based on the
amount of air that flows into the engine.
Conditions fc:>r Running the DTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118,P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
" The intake air temperature and the engine coolant
within 8C (14.5F) of each other at engine
start-up.
18.0 volts.
not active.

6-1524
Engine

Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
An oxygen supply inside the H028 is necessary for

proper operation. The H028 wires provide the supply
Sensor (H02S) Wiring Repairs in Wiring System.
For an intermittent condition, refer to Symptoms,
Test Description
diagnostic table.
2. The engine must be allowed to cool, as the H028
may be at operating temperature and no drop or
rise in H028 voltage would occur. If the H028
voltage stays between 300-700 mV indicates the
H028 heater is inoperative.
3. If more than one H028 heater OTC is set, this is
a good indication that the H02S fuse is open.
Test all the related circuits going to all of the
heated oxygen sensors for a short to ground. If all
wiring is OK, it may be necessary to disconnect
each H02S one at a time to locate a shorted
sensor.
necessary. This step verifies whether the B+
supply is available at the sensor.
the sensor.
6. This step tests whether the H02S heater element
is internally open.


Step
Action
Value(s)
No
'

1
Yes
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Important: If you have been operating the engine, allow

the engine to cool for about one half hour before
proceeding.
2

300-700 mV

below the specified values?
Go to
Diagnostic Aids
Go to Step 3
Engine
6-1525

Step
Value(s)

connector (PCM side) using the J 34142-B test lamp
connected to a known good ground. Do not use the
Connect the J 34142-B test lamp between the H02S


the DMM.
Is the H02S resistance within the specified values?
3.5...;.14.0Q

H02S. Refer to Wiring Repairs in Wiring Systems.


Wiring Systems.
Systems.

11
1. Repair the short to ground in the H02S ignition feed

circuit.
2. Replace the faulty fuse. Refer to Wiring Repairs in
Wiring Systems.
12

applicable.
diagnosed?
Action
Inspect the fuse for the H02S ignition feed.

10
No
Go to Step 11
Go to Step 4
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 12
-
Go to Step 12
Go to Step 12
Go to Step 10
Go to Step 12
""
13
Yes
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1526
Engine

Circuit Description
The PCM controls a Closed Loop air/fuel metering
system in order to provide the best possible
combination of driveability, fuel economy, and emission
control. The PCM monitors the heated oxygen
sensor signal voltage and adjusts the fuel delivery
based on the signal voltage while in Closed Loop. A
change made to the fuel delivery changes the
Long and Short Term Fuel Trim values. The Short
Term Fuel Trim values change rapidly in response to
the H02S signal voltages. These changes fine
tune the engine fueling. The Long Term Fuel Trim
values change in response to trends in Short
Term Fuel Trim. The Long Term Fuel Trim makes
coarse adjustments to fueling in order to re-center and
restore control to Short Term Fuel Trim. You can
use a scan tool in order to monitor the Short and Long
Term Fuel Trim. The ideal fuel trim values are
around O percent. A positive Fuel Trim value indicates
that the PCM is adding fuel in order to compensate
for a lean condition. A negative Fuel Trim value
indicates that the PCM is reducing the amount of fuel
in order to compensate for a rich condition. If the
PCM detects an excessively Rich or Lean condition,
the PCM sets a OTC. The long term fuel trim
diagnostic parameter is an average of several of the
long term speed load learn cells which the PCM
selects based on the engine speed and the
engine load.

OTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0200, P0300, P0335, P0336,
P0351-P0358, P0405, P0410, P0412, P0418,
P0443, P0500, P0502, P0503, P1258, P1404,
P1415, P1416 not set.
The engine coolant temperature is between
50C (122F) and 115C (239F).
The barometric pressure is more than 74 kPa.
.. The mass air flow is between 5.0 g/s and 90 g/s'.
" The manifold absolute pressure is between
26 kPa and 90 kPa.
The intake air temperature is between
-20C (-4F) and 90C (194F).
" The engine speed is between 400 RPM and
3,000 RPM.
The TP sensor angle is less than 90 percent.
The vehicle speed is less than 137 km/h (85 mph).
" The fuel level is more than 10 percent.

The average Long Term Fuel Trim cell values are
above a predetermined threshold.
All the above conditions are present for 6 seconds.

The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic fails under the same conditions (load,
RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed.
The first time the diagnostic fails, the PCM
records the operating conditions in Failure
Records.
The second consecutive ignition cycle that this
diagnostic fails [under the same conditions
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test. ran and failed], the PCM
stores this information in Freeze Frame. The
PCM copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then overwrites the Freeze
Frame. The only exception to this is if a Misfire
OTC was already recorded in F.reeze Frame.
In this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records.
Conditions for Clearing the. Mll/DTC

The PCM turns the MIL OFF after
three consecutive ignition cycles that the
diagnosUc runs and does not fail within the same
conditions that the OTC last failed.
Important: If the last failure was during a non-typical
driving condition, the MIL may remain ON longer
than the three ignition cycles. Review the Freeze
Frame/Failure Records for the last failure conditions.
A History OTC clears after forty consecutive
r.elated diagnostic does not report any failures.
A last test failed (Current OTC) clears when the
Engine
6~1527
Diagnostic Aids
Test Description
Important:
This OTC sets if the engine runs out of fuel.
A fuel delivery malfunction causes this DTC to set.
Thoroughly inspect all items that cause a lean
condition.
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
help determine how many miles since the DTC
set. The Fail Counter and Pass Counter can also help
determine how many ignition cycles the diagnostic
The numbers below refer to the step numbers .on the

diagnostic table.
4. If DTC 174 is also set indicates both banks of the
would cause both banks to operate lean,
5. A vacuum leak causes DTGs P0171 and P0174 to
that it is tight. Inspect that the engine oil dip stick
is fully seated.

Step
Action

refer to those DTCs before proceeding with this diagnostic.
4. Monitor .the LT FT Bn 1 display on the Fuel Trim Data
List using the scan tool.
Is the LT FT less than the specified value indicated?

the DTC.
ignition?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
24% LT
6-1528
Engine
DTC P0171 Fuel Trim System Lean Bank 1 (cont'd)

Step
4
Action
connections. Refer to Emission Hose Routing
Diagram.
Crankcase ventilation valve and/or system for
leaks. Refer to Crankcase Ventilation System
Description.
~ Contaminated fuel. Refer to
PCM and sensor grounds are clean, tight and in
the proper locations.
Air induction system after MAF sensor for
vacuum leaks.
Engine mechanical failure. Refer to Engine
Mechanical.
2. If you find a condition repair the condition as
necessary.
Did. you find any problems in any of the above areas?
Bank 1 exha.ust leaks, missing or loose exhaust
hardware.
Bank 1 H02S 1 is. installed securely and the electrical
connector not contacting exhaust system or
ignition wires.
Engine mechanical failure. Refer to Engine
Mechanical.
Vacuum leaks that will only affect bank 1, such as the
intake manifold, the injector O rings, etc.
1, Select the Diagnostic Trouble Code (DTC) option and
3. Se.1.ect the Djagnostic Trouble Code (DTC) option and
applicable.
diagnosed?
Value(s)
Yes
Go to Step 5
No
Go to Step 6
Go to Step 7
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Fuel
System
Diagnosis
Go to Step 8
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1529
DTC P0172 Fuel Trim System Rich Bank: 1

Circuit Description

Term Fuel Trimvalues change rapidly in response to
use a scan tool in order to monitor the Short and. Long
around O percent. A positive Fuel Trim value. indicates
indicates that the PCM is reducing the amount of. fuel
the PCM sets a DTC. The long term fuel trim
engine load.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0200, P0300, P0335, P0336,
P035i-P0358, P0405, P0410, P0412, P0418,
P0443, P0500, P0502, P0503, P1258, P1404,
P1415, P14i6 not set.
The engine coolant temperature is between 50C
(122F) and 115C (239F).
" The barometric pressure is more than 74 kPa.
" The mass air flow is between 5.0 g/s and 90 g/s.
O The manifold absolute pressure is between
26 kPa and 90 kPa.
-20C (-4F) and 90C (194F).
O The engine speed is between 400 RPM and
3,000 RPM.

below a predetermined threshold.
" All the above conditions are present for
40 seconds.

.. The PCM illuminates the Malfunction Indicator
Records.
ignition cycle that the test ran and failed], the PCM
Frame. The only exception to.this is if a Misfire
DTC was already recorded in Freeze Frame.

diagnostic runs and does not fail within the sarne
conditions that the DTC last failed.
.. A History DTC clears after forty consecutive
A last test failed (Current DTC) clears when the
s~t530 Engine Controls - 5.7L
Engine
Diagnostic Aids
Test Description
Important:

diagnostic table.
4. If OTC 175 is also set, then both banks are
banks to operate rich,
the PCVvalve from the intake manifold and plug
fresh air pipe from the rocker cover and plug with
fuel in the oil.

For any test that. requires probing the PCM or
component har.ness connectors, use t.he
J 356.16-A connector test adapter kit. Using this kit
cannot duplicate the OTC, the information included in
help determine how many miles since the OTC
(.
.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4


4. Monitor the LT FT Bn 1 display on the Fuel Trim Data
Is the LT FT more than the specified value indicated?
Example: More than would equal -12, -11 etc.
-13% LT



3

the DTC.
ignition?
(
Go to Step 4
Go to
Diagnostic Aids
Engine
6-1531
DTC P0172 Fuel Trim System Rich Bank 1 (cont'd)

Action
Step
Value(s)
-
Yes
No
Go to Step 5
Go to Step 6


5


necessary. Refer to Engine Oil and Oil Filter Change
in Engine Mechanical 5. 7L.
Go to Fuel
Go to Step 7
System
Diagnosis
Go to Step 9
Go to Step 8
Important: When the fuel system test is .finished, return to

this table.
Inspect the Bank 1 injectors for leaking, refer to Fuel
System Diagnosis.
7

. Replace the faulty H02S. Refer to Heated Oxygen
Sensor (H02S) Replacement Bank 1 Sensor 1 or Heated
Oxygen Sensor (H02S) Replacement Bank 1 Sensor 2.
Go to Step 9
Go to Step 9

1. Select the Diagnostic Trou.ble Code (DTC) option and
3. Select the Diagnostic Trouble. Code (DTC) option and


applicable.
10
Does the scan tool display any DTCs th.at you have not
diagnosed?
Go to Step 10
Go to Step 2
Go to the
applicable
DTCtable
System OK
6-1532
Engine

Circuit Description
indicates that the PCM is reducing the amount of fuel
diagnostic parameter is an average of several ofthe
engine load.

" DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0200, P0300, P0335, P0336,
P0351-P0358, P0405, P0410, P0412, P0418,
P0443, P0500, P0502, P0503, P1258, P1404,
P1415, P1416 not set.
(122F) and 115C (239F).
" The barometric pressure is more than 74 kPa.
.. The mass air flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between
26 kPa and 90 kPa.
.. The intake air temperature is between
-20C (-4F) and 90C (194F).
" The engine speed is between 400 RPM and
3,000 RPM .
.. The TP sensor angle is less than 90 percent.
" The fuel level is more than 10 percent.

above a predetermined threshold.
All the above conditions are present for 6 seconds.

Records.
PCM copies any data previously stored in .Freeze
Frame and copies the data into.the Failure

diagnostic runs and does not fail within the same
Important: If. the last .failure was during a non-typical
A History OTC clears after forty consecutive
Engine
6-1533
Diagnostic Aids
Test Description
Important:
Remove any .debris from the PCM connector
prevents any.damage to the harness connector
This OTC sets if the engine runs out of fuel.
A fuel delivery malfunction causes this OTC to set.
Thoroughly inspect all items that cause a lean
condition.

diagnostic table.
2. This test determines whether the fault is present.
3. Using the Freeze Frame and/or Failure. Records
data may aid in locating an .intermittent condition.
since the OTC set.The Fail Counter and Pass
freeze frame conditions. (RPM, load, vehicle
speed, temperature .etc.) that you observed. This
4. If OTC 171 is also set indicates both banks of the
engine are operating lean, Inspect items that
5. A vacuum leak will cause OTCs P0171 and
P0174 to set at the same time. Inspect all areas
of the engine for a vacuum leak. Also inspect PCV
Make sure the engine oil fill cap is in place
and that it .is tight. Inspect that the engine oil dip
stick is fully seated.

Step
Action
Value(s)
Yes

1
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4

Is the LT FT less than the specified value indicated?
No
24% LT
.
Engine
6-1534 Engine Controls - 5.7l

DTC P0174 Fuel Trim System Lean Bank 2 (cont'd)
Step
Action
Va!ue(s)
Yes
No


where applicable are listed in Conditions. for Running
the OTC.
ignition?

Vacuum hoses for splits, kinks and proper
connections. Refer .to Emission Hose Routing
Diagram.
Refer to Crankcase Ventilation System Description.
Contaminated fuel. Refer to Fuel System Diagnosis.
The PCM and sensor grounds are clean, tight and in
proper locations.
Air induction system after MAF sensor for
vacuum leaks.
Engine mechanical failure.

Bank 2 exhaust leaks, missing or loose exhaust
hardware.
. Bank 2 H02S #1 is installed securely and electrical
connector not contacting exhaust system or
ignition wires.
Engine mechanical failure.
Vacuum leaks that will only affect bank 1 such as the
intake manifold, the injector 0-rings, etc.

-:

applicable.
diagnosed?
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
(
Go to Step 7
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Fuel
System
Diagnosis
Go to Step 8
Go to Step 9
Go to the
applicable
DTC table
Go to Step 2
(
System OK
Engine
6-1535

1
Circuit Description
system in order to provide the .best possible
for a lea.n condition. A negative Fuel Trim value
indicates .that the PCM is reducing the amount of fuel
engine load.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0200, P0300, P0335, P0336,
P0351-P0358, P0405, P0410, P0412, P0418,
P0443, P0500, P0502, P0503, P1258, P1404,
P1415, P1416 not set.
(122F) and 115C (239F).
The mass air flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between
26 kPa and 90 kPa.
-20C (-4F) and 90C (194F).
The engine speed is between 400 RPM
and 3,000 RPM.

below a predetermined threshold.
Al.I the above conditions are present for
40 seconds.

The firsttime the diagnostic fails, the PCM
Records.


than the three ignition .cycles. Review the Freeze
A History DTC clears after forty consecutive
6'."1536
Engine
Diagnostic Aids
Test Description
Important:

diagnostic table.
2. This test determines whether the fault is present.
since the OTC set. The Fail. Counter and Pass
4. If OTC 172 is also set, then both banks are
5; Excessive fuel in the oil will cause DTCs P0172
fresh air pipe from the rockercover and plug with
fuel in the oil.

.
the PCM connector gaskets .when
.
This will isolatewhen the DTC failed.

Step
Action

Is the LT FT more than the specified values indicated?
Example; More than would equal -12, -11 etc.
Value(s)
. (
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
-i3% LT
Engine
6-1537
DTC P0175 Fuel Trim System Rich Bank 2 (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6

.
3

4 . Start the engine.
to .meet before the PCM will run this diagnostic,
the OTC.

Do.es the scan tool indicate that this diagnostic failed this
ignition?

The MAF sensor for being installed in the proper

direction and for foreign objects blocking the inlet
screen. Refer to M.A.F Sensor Replacement.
G

necessary. Refer to Engine Oil and Oil Filter Change
in Engine Mechanical-5.?L.
Go to Fuel
Important: When the fuel system test is finished, return to

this table.
6
Inspect the Bank 2 injectors for leaking, refer to Fuel
Go to Step 7
System
Diagnosis
Go to Step 9
Go to Step 8
System Diagnosis.
7

Sensor (H02S) Replacement Bank 2 Sensor 1 or Heated
Oxygen Sensor (H02S) Replacement Bank 2 Sensor 2.
Go to Step 9
Go to Step 9

2. Idle the engine at the normal operatirig temperature.

9


applicable.
10
diagnosed?
Go to Step 10
Go to Step 2
Go to the
applicable
OTC table
System OK
6,;;1538
Engine
DTC P0200 Injector Control Circuit

Refer to Engine Controls Schematics, Fuel Injectors
for complete circuit details.
Circuit Description
The PCM enables an injector on the intake stroke of
each cylinder. Individual cylinder fuel control is referred
to as Sequential Multi-port Fuel Injection (SFI).
Ignition voltage is supplied directly to the fuel injectors.
The PCM controls each injector by grounding the
control circuit via an internal switch called a driver. The
primary function of the driver is to supply the ground
for the component being controlled. Each driver
or control circuit is equipped with a fault line which is
monitored by the PCM. When the PCM is
commanding an injector ON, the voltage of the control
circuit should be low. When the PCM is commanding
the injector OFF, the voltage potential of the control
circuit should be high. If the PCM detects the injector
control circuit voltage other than what is expected,
the PCM sets a DTC.

" The engine speed is more than 400 RPM.
" The ignition voltage is more than 6.0 volts but less
than 18.0 volts.

The PCM detects the wrong voltage potential on any
injector driver circuit for 5 seconds.

Failure Records.

.. A History DTC clears after 40 consecutive
"' Use a scan tool in order to clear the MIUDTC.
Diagnostic Aids
Important:
diagnosing/replacing the PCM. Ensure that 1he
in Wiring Systems.
A misfire may not be apparent at idle. The misfire may
only occur above idle under a load. Road test the
vehicle and monitor the misfire current counters.
Observe, if more than one cylinder is mis-firing, the
scan tool may only display one cylinder mis-firing. This
will not be apparent until the repair is completed.
Also, if an injector fuse is open for one side of
the engine, the scan tool may only display
2 or 3 cylinders mis-firing.
When the injector driver is disabled, an engine misfire
will be apparent and a misfire DTC sets.
Test Description

diagnostic table.
2. This step determines if a malfunction is present.
The Misfire Current Counters will not increment
if certain DTCs set at the same time or after
DTC P0300. sets. Refer to conditions for running
OTC P0300 for applicable DTC list.
If more than one cylinder is misfiring, the Misfire
Current Counters may increment for only
one cylinder. Example: Cylinders 1 and 8 are both
misfiring, yet only cylinder 8 increments on the
Misfire Current Counter.
If one injector fuse open, only two or three Misfire
current counters may increment for the
corresponding side of the engine.
3. There are two ways to isolate a malfunctioning
injector circuit:
DTC P0300 indicates a misfire is present. So
use the Misfire Current Counters to locate
the cylinder that is misfiring.
If no misfire DTC is present, Start and idle the
engine while monitoring Misfire Current
Counters. If a misfire is present, the Misfire
Current Counters will increase for a cylinder
that has a misfire.
Engine
4. The injector fuses also feed the ignition
coil/modules. Thoroughly inspect the circuits going
to the ignition coil/modules for a short to ground.
A shorted ignition coil/module may also cause
a fuse to open.
7. Inspect the injector connections before replacing
the injector. A faulty connection causes an
inoperative injector.
6-1539
11. Disconnecting the PCM allows testing the

continuity of the circuits with the DMM. This aids
in locating an open or shorted circuit. Tests
for an ignition feed circuit that is shorted to ground.
13. Tests for an ignition feed circuit that is shorted to
ground.
14. The injector fuses also feed the ignition
coil/modules. Thoroughly inspect the circuits going
to the ignition coil/modules for a short to ground.
A shorted ignition coil/module may also cause
a fuse to open.
6-1540
Engine

DTC P0200 Injector Control Circuit
Step
Action
Value(s)
Yes
No
Go to Step 2
Go toA
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 18
Go to
Diagnostic Aids
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 10

t. Install the scan tool.

2
3. Monitor all the Misfire Current Counters on the Misfire

Data List (There are a total of 8 counters.
One counter per cylinder) with a scan tool.
Are any of the Misfire Current Counters incrementing?
Monitor the Misfire History Counters on the Misfire Data

List (There are a total of 8 counters. One counter per
cylinder) with a scan tool.
Do any of the Misfire History Counters indicate a number
other than 0.0 counts?
Are the injector fuses OK?

2. Disconnect the injector(s) harness that the Misfire
Current Counter is incrementing for.
4. Probe the injector harness ignition feed circuit with
the test lamp J 34142-8 connected to ground. Refer

2. Connect the injector test lamp J 34730-2C to the
isolated injector harness.
Does the injector test lamp blink?
1. Inspect the injector harness terminals for poor

Wiring Systems.

2. Disconnect the four injector harness connectors
related to the fuse that was open.
3. Probe the injector ignition feed circuits of one of the
injector harnesses that are disconnected with the test
lamp J 34142-8 connected to B+. Refer to Probing
Electrical Connectors in Wiring Systems.
Important: Return to this Diagnostic after performing the

Fuel Injector Coil Test.
Perform the Fuel Injector Coil Test. Refer to Fuel lnj Coil
Test - ECT Between 10-35 Degrees C (50-95 Degrees F).
Did the Fuel Injector Coil Test isolate an injector
condition?
Repair the injector ignition feed circuit to the isolated

injector.Refer to Wiring Repairs in Wiring Systems.
10
(
Go to Step 7
Go to Step 11
Go to Step 19
Go to Step 9
Go to Step 13
Go to Step 9
Go to Step 15
Go to Step 14
Go to Step 19
Engine
6-1541
DTC P0200 Injector Control Circuit (cont'd)

Step
11
12
13
14
15
16
17
18
19
)
20
Action
short to ground, or short to voltage if the injector circuit is
shorted to another PCM circuit.
3. Test the injector control circuit for an open, short to
ground or a short to voltage. Refer to Circuit Testing
in Wiring Systems.
Is the injector control circuit open or shorted?
Repair the injector control circuit for an open, short to
ground, or a short to voltage. Refer to Wiring Repairs in
Wiring Systems.
1. Repair the grounded ignition feed circuit to the
injectors. Refer to Wiring Repairs in Wiring Systems.
2. Replace the open fuse.
Repair the intermittent short to ground in the injector
ignition feed circuit. Refer to Wiring Repairs in Wiring
Systems.
Replace the faulty injector(s) that was isolated. Refer to
Fuel Injector Replacement.
Wiring Systems.
Wiring Systems.
Replace the PCM.
1. Inspect the appropriate injector circuit for the
following:
Poor connections at the injector and the PCM
terminal.
Intermittent shorts to ground.
e Intermittent opens. Refer to Testing for Intermittent
2. If a condition is found, repair as necessary. Refer to
the Clear OTC Information option with the scan tool.
with the scan tool.
applicable.
with the scan tool.
diagnosed?
Value(s)
Yes
No
Go to Step 12
Go to Step 16
Go to Step 19
Go to Step 19
Go to Step 19
Go to Step 19
Go to Step 19
Go to Step 17
Go to Step 19
Go to Step 19
Go to Symptoms
Go to Step 20
Go to Step 2
Go to the
applicable
OTC table
System OK
6.;;1542
Engine
(
~
u
GRY 1120
GR:1120
.- -
- - - - ., Fuel
Fuel
I Tank
Pump
: Unit
I
I
L-
BLK
----.J
1150
ORN 1340
.- - - - - - - - - -
- - ., Underhood
d1--01=~!~~:~~~~
A10
iI
810
~~~ --:K G-R::H:14~5-;
BLK/WHT 451
BLK/WHT 451
- -
DK GRN/WHT 455
BLK 1050
r -
Ground
Distribution
Cell14
I
I
elc2
-
CONN"
C1 = BLU
;::::,
Relay
C2=RED
Control
I
.4.
1rTv- - - .I,
12
Powertrain
Ground
Distribution
Cell14
Control
I Module
----
I (PCM)
I>
BLK 451
L-------------~~
(
372984
Circuit Description
When you turn the ignition switch to the on position,
the PCM activates the in-tank fuel pump. The fuel
pump remains on as long as the PCM receives
reference pulses from the electronic ignition system. If
there are no reference pulses, the PCM turns the
fuel pump off after about 2-3 seconds. The PCM
controls the fuel pump relay by applying B+ to the
primary function of the driver is to supply a voltage
to the fuel pump relay. The driver has a fault line which
the PCM monitors. When the PCM commands the
fuel pump on, the voltage of the control circuit should
be high (near battery voltage). When the PCM
commands the control circuit to the fuel pump OFF,
the voltage potential of the circuit should be low (near
O volts). This DTC sets when the PCM detects the
fuel pump control circuit is shorted to ground.

18.0 volts.

cycle, the PCM rec.ords the operating conditions
Failure Records.


The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All the above conditions present for a minimum of
2.5 seconds.
Engine
6-1543
Diagnostic Aids
Test Description
Important:
in Wiring Systems.

diagnostic table.
Command both the ON and the OFF states.
Repeat the commands as necessary.
4. This step tests the ground circuit for the fuel
pump relay.
5. This step verifies tha.t the PCM is providing B+ to

the fuel pump relay.
6. This step tests if B+ is constantly being applied to
the fuel pump relay.

Step
Action
Value(s)
Yes.
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
. Go to Step 4
Goto Step 4
Go to
Intermittent
Conditions
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 14
Go to Step 10

1

and OFF.
Does the fuel pump relay turn ON and OFF with each
command?
data for this DTC.
3

4. Operate the vehicle within the same Conditions for
running the DTC as specified in the supporting text or
as close to the Freeze Frame and/or Failure Records
data that you observed.
Does the DTC reset?

2. Disconnect the fuel pump relay from the underhood
electrical center.

4. Probe the coil side ground circuit of the fuel pump
relay with a test lamp that is connected to B+.

fuel pump relay and the coil side ground circuit of the
fuel pump relay.

and OFF.

command?

command?
1. Test the control circuit of the fuel pump relay for an
open, or short to ground. Refer to Circuit Testing in
Wiring Systems.
6-1544
Engine
DTC P0230 Fuel Pump Relay Control Circuit (cont'd)

Step
Action
1. Test the control circuit of the fuel pump relay for a
short to voltage. Refer to Circuit Testing in Wiring
Value(s)
No
Systems.
Yes
1. Inspect for poor connections at the fuel pump relay.

2. If you find a condition, repair as necessary. Refer to
Repairing Connector Terminals in Wiring Systems.
Go to Step 14
Go to Step 13
Go to Step 14
Go to.Step. 12
. Go to Step .14
Go to Step 13

Wiring Systems.
10
11

Repair the relay coil side ground circuit for an open. Refer

12
13
Replace the fuel pump relay.


Replace the PCM.
Go to Step 14
Go to Step 14
Go to Step 14
14

the DTC as specified in the supporting text.
Does the OTC reset?
15
With a scan tool, review the Stored Information

(capture info).
diagnosed?
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code {OTC)
List/Type
System OK
Engine
6-1545

Circuit Description
The Crankshaft Position sensor is mounted through

the side of the engine block at the rear of Bank 2
behind the starter assembly. The Crankshaft Position
sensor works in conjunction with a 24X reluctor
wheel on the crankshaft. The reluctor wheel is inside
the engine immediately in front of the rear main
bearing. The PCM provides a i 2 volt power supply to
the CKP sensor as well as a ground and a signal
circuit.
A misfire causes a change in crankshaft speed. The
PCM 1imes the interval b.etween each pulse and
compares each new time interval with the previous
one in order to determine when an excessive change
in crankshaft speed has occurred. You can expect
a certain amount of acceleration/deceleration between
each iiring stroke, but if the crankshaft speed
changes are greater than an expected amount, the
PCM interprets this as a misfire.
The PCM uses the Crankshaft Position sensor for
both spark and fueling. As the crankshaft rotates, the
reluctor wheel teeth interrupt a magnetic field
produced by a magnet within the sensor. The sensors
internal circuitry detects this and produces a signal
which the PCM reads. The PCM uses this 24X signal
in combination with the Camshaft Position sensor
1X signal in order to accurately determine crankshaft
position. The PCM also calculates a 4X signal
from this information. The PCM uses the 4X signal for
internal calculations. The 4X signal also provides a
tach signal for any .device which requires one.
Observe that as long as the PCM receives the
Crankshaft Position sensor 24X signal, the engine will
start. The PCM can determine top dead center for
all cylinders by using the Crankshaft Position sensor
24X signal alone. The Camshaft Position sensor
1X signal is used by the PCM to determine if
the cylinder at top dead center is on the firing stroke,
or the exhaust stroke. The system attempts
synchronization and looks for an increase in engine
speed indicating the engine started. If the PCM
does not detect an increase in engine speed, the PCM
assumes it incorrectly synchronized to the exhaust
stroke and re-syncs to the opposite cam position.
A slightly longer cranking time may be a symptom of
this condition.

" DTCs P0101, P0102, P0103, P01 i 7, POi 18,
P0121, P0122, P0123, P0125, P0335, P0336,
P0341, P0342, P0343, P0500, P0502, P0503,
Pi 258 not set.
The engine speed is between 450 RPM and
3,001 RPM.
18.0 volts.
" The engine coolant temperature is between
-7C (19F) and 130C (266F).
Fuel level is more than 10 percent.
.. The TP sensor angle is steady within 1 percent.
The ABS and Traction Control systems are not

active.
" The transmission is not changing gears.
.. The AIR diagnostic test is not in progress.
The A/C clutch is not changing states.
.. The PCM is not in fuel shut-off or decel fuel
cut-off mode.
.. The ABS signals not exceeding rough road
thresholds.

.. The PCM determines that an emission type
Misfire is present.
" The PCM determines that a catalyst damaging
Misfire is present.

Lamp (MIL) under the following conditions:
Records.
The PCM determines the percent of misfire over a
1,000 revolution period is high enough to cause
excessive tail pipe emissions. The PCM
illuminates the Malfunction Indicator lamp the next
consecutive ignition cycle that the diagnostic
runs and fails, if the diagnostic fails under
the same conditions (load, RPM, temperature,
etc.) as the previous ignition cycle that the test ran
and failed.
Or
" The PCM flashes the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails a
catalyst damaging misfire.

" The PCM turns the MIL OFF after
" A History DTC clears after forty consecutive
Use a scan tool in order to clear the MIUDTC .
6-1546
Engine
Diagnostic Aids
Test Description
Important:
in Wiring Systems.
The following may cause a misfire:
Running the vehicle out of fuel causes sufficient
misfire to set OTC P0300. A vehicle that is out
of fuel may have OTC P0461 also set.
A restricted fuel filter can cause sufficient misfire
to set OTC P0300. Refer to Fuel System

diagnostic table.
2. A misfire may not be apparent at idle. The misfire
may only occur above idle or under a load. Road
test the vehicle and monitor the Misfire Current
Counters.
Diagnosis.
A misfire may not be apparent at idle. The misfire

may only occur above idle under a load. Road
test the vehicle and monitor the misfire current
counters.
Observe, if more than one cylinder is mis-firing,
the scan tool may only display one cylinder
mis-firing. This will not be apparent until the repair
is completed. Also, if an ignition coil/module
ground circuit is open for one side of the engine,
the scan tool may only display 2 or 3 cylinders
mis-firing. Inspect the ground circuit for the ignition
coil/modules on the cylinder bank of the engine
that has more then one cylinder mis-firing.
Excessive vibration from sources other than the
engine could cause a misfire OTC. The following
are possible sources of vibration:
- Variable thickness brake rotor
- Drive shaft not balanced
- Certain rough road conditions
The Misfire Current Counters will not increment if

certain DTCs set at the same time or after
DTCP0300 sets, Refer to conditions for running
DTC P0300 for applicable OTC list.
If more than one cylinder is misfiring, the Misfire
Current Counters may increment for only
one cylinder. Example: Cylinders 1 and 8 are both
misfiring, yet only cylinder 8 increments on the
Misfire Current Counter.
If one injector fuse open, only two or three Misfire
Current Counters may increment for the
corresponding side of the engine.
Wetting down.the secondary ignition system with
water from a spray bottle may help locate
damaged or deteriorated components. Look/listen
for arcing or misfiring as you apply the water.
If the Misfire Current Counters are incrementing
and there is no apparent misfire, an erratic
CKP sensor signal .could be the cause. Perform
the diagnostic table for OTC P0335 first if this
condition is suspected.
If a misfire is present and you suspect a fuel
control condition, force the fuel system into Open
Loop using the scan tool and allow the engine
to run for a few minutes. If this eliminates
the misfire, referto any fuel control related DTCs
which are set. If no other DTCs are set, refer
to the Engine Scan Tool Data List.
4. The cylinder with the more significant misfire may

cause another cylinders counter to increment
only by a small amount.
10. If the engine misfire moves with the spark plug,
this is good indication that you should. replace
the spark plug.
12. If you cannot locate a fuel system condition, refer
to Engine Mechanical-5.7L. An engine mechanical
condition can cause a spark plug to gas foul.
Inspect for loose rockers, collapsed lifters or worn
camshaft lobes.
17. If the customers concern is the MIL is flashing,
this indicates that a Catalyst Misfire has
occurred. Drive the vehicle in the conditions to run
the catalyst diagnostic.
Engine Controls- 5.7L 6-1547
Engine
DTC P0300 Engine Misfire Detected.
Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step5

Important:
You must perform the CKP System Variation Learn

Procedure before proceeding with this diagnostic
table. Refer to CKP System Variation Learn
Procedure.
Ensure that the ABS and Traction Control systems are
functioning properly before proceeding with this
diagnostic.
If any DTCs are set, refer to those DTCs before
proceeding with this diagnostic.
Monitor all the Misfire Current Counters on the misfire data
list (There are a total of 8 counters, one counter per
cylinder) using the scan tool.
Are any of the Misfire Current Counters incrementing?


3

the OTC.
6. Select the Diagnostic Trouble Code (OTC) option.
ignition?
Is only one Misfire Counter incrementing?
6-1548
Engine

Step
Action
Value(s)
',
Yes
No
Go to Step 17
Go to Step 6
Accessory drive belt and pulleys for damage or

misalignment. Refer to Symptoms - Drive Belt in
Engine Mechanical 5.7L.
Vacuum hoses for splits, kinks and proper
connections. Refer to Emission Hose Routing
Diagram.
Throttle body and intake manifold for
vacuum leaks
Crankcase ventilation valve and/or system for
vacuum leaks. Refer to Crankcase Ventilation
System Description.
PCM grounds for being clean and secure. Refer to

Ground Distribution Schematics in Wiring
Systems.
Verify that all injector harness connectors. are
connected to the proper injector/cylinder.
Inspect the injector and Ignition Control fuses for
being open. If you find an open fuse, locate and
repair the shorted circuit. Refer to Wiring Repairs
in Wiring Systems.
Test for low fuel pressure or restricted fuel flow.
Refer to Fuel System Diagnosis.
Inspect for a restricted exhaust. Refer to
Restricted Exhaust in Engine Exhaust.
Fuel contamination. Refer to
Alcohol/Contaminants-in-Fue_l Diagnosis.
I>
, I
,.
Did any of the above tests isolate a condition requiring a , r,

repair?
i
2. Disconnect the injector that corresponds to the Misfire

6
Current Counter(s) that was incrementing.

3. Connect the J 34730.-2C. injector test lamp to the
injector .electrical connector.
4. Idle the engine.
Is the injector test lamp flashing?
Go to Step 7
Goto
DTCP0200
Injector Control
Circuit
Go to Step 9
Go to Step 8
Go to Electronic
Ignition (El)
System
Diagnosis
Go to Step 16
2. Reconnect the injector harness electrical connector.

3. Disconnect the ignition wire(s) from the spark plug
7
that corresponds to the Misfire Current Counter(s)

that was incrementing.
4. Install J 26792 spark tester to ground.
Does the spark jump the tester gap and is the spark
consistent?
1. Remove the ignition wire for the cylinder that is

misfiring.
8
2. Measure the resistance of the ignition wire using

the DMM.
7000
Is the ignition wire resistance less than the specified

resistance?
1. Remove the spark plug(s) from the cylinder that

9
indicated a misfire. Refer to Spark Plug Replacement

2. Visually inspect the spark plug(s). Refer to Spark

Plug Visual Diagnosis in Engine Electrical.
Does the spark plug appear to be OK?
Go to Step 10
Go to Step 11
Engine
6-1549

Step
Action
Value(s)
10
lmportal'!t: If the Injector Coil Test Procedure does not

isolate the condition, refer to Base. Engine Misfire
Diagnosis in. Engine Mechanical-5.7L
1. Swap the suspected spark plug with another cylinder
that is operating properly.
2. Operate the Vehicle under the same conditions that
the. misfire oc.curred.
Did the misfire move with the spark plug?
Are the spark plugs oil or coolant fouled.
11
12
Important: If the Fuel System is OK, refer to Base Engine

Misfire Diagnosis in Engine Mechanical-5.7L.
Are the spark plugs gas fouled?

Important: If the Injector Coil Test Procedure does not
isolate the condition, refer to Base Engine Misfire
Diagnosis in Engine Mechanical-:-5.7L.
13
Do the spark plugs show any signs of being cracked,
worn, or improperly gapped? ..
14
15
Replace the faulty spark plug(s). Refer to Spark Plug

Replacement inEngine ElectricaL
Replace the faulty ignition wire(s). Refer to Spark Plug

Wire Harness Replacement (5. 7 L) in Engine Electrical.
Go to Step 15
Gb to Fuellnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
Go to Base
Engine Misfire
Diagnosis in
Engine
Mechanical-5. 7L
Go to Step 12
Go to Fuel
System
Diagnosis
.Go to Step 13
Go to Step 14
Go to Fuel lnj
Coil Test O ECT
Between
10-35 Degrees C
(50-95 Degrees F)
..
Go to Step 1. 7
Go to Step 17
Go to Step 17
Was the customers concern that the MIL was flashing?
17
No
1. Replace or re-gap spark plugs.

2. lfimproper gap is found, be sure to re-gap spark
plugs using a wire type gauge.
16
Yes
Goto
DTCP0420
Catalyst System
Low Efficiency
Bank 1 or
DTCP0430
Catalyst System
Low Efficiency
Bank2
Go to Step 18
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK

18
19
3. Select the Diagnostic Trouble Code (DTC) option.

applicable.
diagnosed?
6".1550
Engine
DTC P0325 Knock Sensor Module Performance

Circuit Description
The KS system monitors both knock sensors in order
to determine if pre-detonation is present. If the KS
system determines that excessive knock
(pre-detonation) is present, the PCM retards the spark
timing based on the signals from the KS system.
When knock is present, the KS system voltage input
signal to the PCM goes low. The PCM then retards
timing until no knock is present. When the KS system
is malfunctioning, the KS circuit voltage going to
the PCM goes low. The PCM interprets this low signal
as spark knock.

The engine speed is between 1,650 RPM and
3,000 RPM.
60C (135F).
The throttle angle is more than 0.5 percent.

A malfunction with the KS system or circuits within
the PCM are faulty.
All above conditions present for 3.0 seconds.

Failure Records.

O A History DTC clears after 40 consecutive
Diagnostic Aids
Important:
" Remove any debri$ from the PCM connector
in Wiring Systems.
If the diagnostic test does not run; review the
Conditions for Running the DTC.
Test Description
diagnostic table.
2. This DTC indicates an internal PCM fault.
Engine
6-1551
DTC P0325 Knock Sensor Module Performance

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

Replace the PCM.

the Clear OTC option using the scan tobl.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
diagnosed?
Go to Step 3
Go to Step 4
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1552
Engine
DTC P0327 Knock Sensor (KS) 1 Circuit

I" -
I
PCM
I Ci=BLU
I c2=RED
KS
Signal
I._ _ _ _ _ _ Front _ _ _ .
"Powertrain
I Control
I
I Module
I (PCM)
KS
Signal
..
Rear _ _ _ .,1 ~
_ _
51
11 C1
0.35
DKBLU 496
0.35
LT BLU 1876
J----------]
A
~:
~
k
rn~~:
k
rn
Sensor
(KS)
Sensor
(KS)
Circuit Description
The Knock Sensor (KS) system detects engine
pre-detonation. The PCM retards the spark timing
based on the signals from the knock sensors.
The knock sensors produce an AC voltage when
specific frequencies are detected. The knock sensor
voltages are an input to the PCM. The amount of
AC voltage produced is proportional to the intensity of
the knock.
An operating engine produces a normal amount of
engine mechanical vibration (noise). The knock
sensors produce an AC voltage signal from this noise.
When an engine operates, the PCM learns the
minimum and maximum frequency of the noise the
engine produces. When the PCM determines that this
frequency is less than or greater than the expected
amount, a knock sensor OTC will set.

3,000 RPM.
" The engine coolant temperature is more than
60C (i 35F).
The throttle angle is greater than 0.5 percent.

The PCM determines that this frequency is less than
or more than the expected amount for less than
3 seconds.

582322

Failure Records.

O


e
Diagnostic Aids
Important:
in Wiring Systems.
Inspect the knock sensor for proper installation. A
knock sensor that is loose or over torqued may cause
the OTC P0327 to set.
Engine
Test Description
)
the connections at the PCM. Refer to the wiring

schematic for the correct connector and terminal.
Then inspect the connections at the appropriate
knock sensor. Failure Records data does not
include the parameter KS Activity, however other
parameters may aid in locating the conditions
under which an intermittent occurred.

diagnostic table.
2. Thi.s verifies the malfunction is present. The scan
tool will display DTC Ran=Yes and Pass=lnt if
. knock sensors should be verified to be in the
correct, inspect the KS system wiring connections.
When testing the KS system connections, start
loca_ted behind the intake manifold. Then inspect
6,-1553
3. This test isolates the Knock Sensor from the rest

of the circuit.
4. Tap on the engine block near the appropriate
knock sensor. Do not tap on plastic engine
components.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go toStep 6
Go to Step 5
Go to Step 7


engine mechanical co.ndition before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis in Engine
Mechanical.
1. Turn ON the ig~ition leaving the engine OFF.

the DTC.
information using a scan tool.
ignition?
1. Disconnect the knock sensor electrical connector
located behind the intake manifold.
2. Measure the resistance .between the appropriate
knock. sensor signal circuit (sensor side of harness)
and the battery ground using the DMM.
Is the resistance of the knock sensor within the
specified range?
1. Connect the DMM between the appropriate knock
sensor signal circuit (sensor side of harness) and the
engine block.
Important: Do riot tap on plastic engine components.
3. Tap on the engine near the appropriate knock sensor
while observing the signal indicated on the DMM.
Is any signal indicated on the DMM while tapping on the
engine near the appropriate Knock Sensor?
93-107KQ
6-1554
Engine

OTC P0327 Knock Sensor (KS) 1 Circuit (cont'd)
Value(s)
Step
Action

2. Test the KS signal circuit between the PCM and the
knock sensor connector for the following:
An open
A short to voltage
A short to ground
Systems.
1. Remove the intake manifold. Refer to Intake Manifold

Replacement in Engine Mechanical-5.7L.
2. Test for an open or a short to ground in the signal
circuit between the knock sensor jumper harness
connector, located at the back of the intake manifold,
and the knock sensor connector. Refer to Circuit
Replace the appropriate Knock Sensor. Refer to Knock

Sensor (KS) Replacement.
10
11

Replace the PCM.

No
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 7
Go to Step 10

Wiring Systems.
Systems.
Yes
(
-
Go to Step 10
Go to Step 9
Go to Step 10

applicable.
Seiect the Capture Info option and the Review Info option
diagnosed?
Go to Step 11
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1555

- - - - - - - - - - - - - - - - - - , Powertrain
I c 1:;~
: Control
I C2=RED
I Module
I
KS
KS
I (PCM)
~
Signal
Signal
I
I
.. _ _ _ _ _ Front _-:.:-:.:-_":""_"':'_-:_Rear _ _ _ .a
51
J;
11 C1
0.35
DKBLU 496
0.35
LT BLU 1876
B
J-- --------J
[lJ
~~~nik
Sensor
(KS)
[I]
~~~~k
Sensor
(KS)
582322
Circuit Description
The Knock Sensor (KS) system detects engine
pre-detonation. The PCM retards the spark timing
based on the signals from the knock sensors.
The knock sensors produce an AC voltage when
specific frequencies are detected. The knock sensor
voltages are an input to the PCM. The amount of
AC voltage produced is proportional to the intensity of
the knock.
An operating engine produces a normal amount of
engine mechanical vibration (noise). The knock
sensors produce an AC voltage signal from this noise.
When an engine operates, the PCM learns the
minimum and maximum frequency of the noise the
engine produces. When the PCM determines that this
frequency is less than or greater than the expected
amount, a knock sensor OTC will set.

3,000 RPM.
60C (135F).
.. The throttle angle is more than 0.5 percent.

The PCM determines that this frequency is less than
or more than the expected amount for less than
3 seconds.

1ime the diagnostic fails. The first time the

Failure Records.

Diagnostic Aids
Important:
e

in Wiring Systems.
.. Inspect the knock sensor for proper installation. A

knock sensor that is loose or over torqued may
cause the OTC P0332 to set.
6-1556
Engine
Test Description
the connections at the PCM. Refer to the wiring

schematic for the correct connector and terminal.
Then inspect the connections at the appropriate
knock sensor. Failure Records data does not
include the parameter KS Activity, however other
parameters may aid in locating the conditions
under which an intermittent occurred.

diagnostic table.
tool will display OTC Ran=Yes and Pass=lnt if
correct, inspect the KS system wiring connections.
When testing the KS system connections, start
located behind the intake manifold. Then inspect
3. This test isolates the Knock Sensor from the rest

of the circuit.
4. Tap on the engine block near the appropriate
knock sensor. Do not tap on plastic engine
components.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check


engine mechanical condition before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis in Engine
Mechanical.
the DTC.
information using a scan tool.
ignition?
1. Disconnect the knock sensor electrical connector
located behind the intake manifold.
2. Measure the resistance between the appropriate
knock.sensor signal circuit (sensor side of harness)
and the battery ground using the DMM.
Is the resistance of the knock sensor within the
specified range?
1. Connect the DMM between the appropriate knock
sensor signal circuit (sensor side of harness) and the
engine block.
Important: Do not tap on plastic engine components.
3. Tap on the engine near the appropriate knock sensor
while observing the signal indicated on the DMM.
Is any signal indicated on the DMM while tapping on the
engine near the appropriate Knock Sensor?
(
-
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 7
93-107KQ
Engine
6-1557
DTC P0332 Knock Sensor (KS) 2 Circuit (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 7

same side .as the manufacturer's logo. Refer to PCM
2. Test the KS signal circuit between the PCM and the
knock sensor connector for the following:
5
An open
A short to voltage
A short to ground

Systems.

Replacement in Engine Mechanical-5.?L.
2. Test for an open or a short to ground in the signal
circuit between the knock sensor jumper harness
connector, located at the back of the intake manifold,
and the knock sensor connector. Refer to Circuit
Replace the appropriate Knock Sensor. Refer to Knock

Sensor (KS) Replacement.

Wiring Systems.
Systems.

Replace the PCM.

Go to Step 10
Go to Step 10
Go to Step 9
Go to Step 10


10
11

applicable.
using the. scan tool.
diagnosed?
Go to Step 11
. Go to Step 2
Go to the
applicable
OTC table
System OK
6-1558
Engine
ICamshaft
Solid State
Position
Crankshaft
c (CMP)
B
A
Position
Sensor
(CKP)
c'
0.35
B
A
Sensor
0.35
0.35
BRN/WHT 633
DKBLU/ 1869
LTGRN 1867
WHT
0.35 PNK/BLK 632
0.35 RED 631
0.35
YELi 1868
BLK
Solid State
12 '- ___ .?~ . .__ _____ g,

~ -CKPSen7orI
1
Signal Input
- - 1
Le erence
ow
_____________ ~1_ ~ . ______ ??!

-
-1
Ignition
Feed
I CONN IOI
IC1=BLU
I
I~~
-1;
C1
;e;e:e- CMPS-;;n;;r- Low

Signal Input
[SJ
iA
39 , C2
-
-.- -
Ignition
Feed
12V
!Loe
~ Powertrain
I
Control
Module
(PCM)
I
I
I>
1,M
~-------------------------------------J
582388
Circuit Description
The Crankshaft Position Sensor CKP is mounted in
the right rear of the engine block behind the starter.
The CKP sensor works in conjunction with a
24X reluctor wheel mounted on the rear of the
crankshaft. The CKP sensor has a B+ power supply,
As the crankshaft rotates, the reluctor wheel teeth
interrupt a magnetic field produced by a magnet within
the sensor. The sensor's internal circuitry detects
this and produces a signal which the PCM reads. The
PCM uses this signal to accurately measure
crankshaft velocity which is a variable used in order to
detect misfire, and control spark and fueling.

DTCs P0101, P0102, P0103, P0341, P0342,
P0343 are not set.
The CMP sensor is transitioning.
The MAF is more than 3 g/s.
The ignition switch in the crank mode.

The PCM determines no signal from the CKP sensor
for less than 8 seconds.

Failure Records.

diagnostic runs and does. not fail.
Diagnostic Aids
Important:
in Wiring Systems.
The following conditions may cause this DTC .to set:
O Poor connections/terminal tension at the sensor.
Refer to Testing tor Intermittent and Poor
Crankshaft reluctor wheel damage or improper
installation.
The sensor coming in contact with the
reluctor wheel.
., The engine running out of fuel.
Excess crankshaft end play causes the CKP sensor
reluctor wheel to move out of alignment with the CKP
sensor. This could result in any one of the following:
O A no start
" A start and stall
" Erratic performance
Engine
Test Description
diagnostic table.
6. This step simulates a CKP sensor signal to the
PCM. If the PCM receives the signal, the fuel
pump will operate for about two seconds. If
the fuel pump operates, the condition is either
terminal contact at the CKP sensor, the CKP
sensor or, the CKP sensor reluctor wheel.
7. This test determines if the CKP sensor signal
circuit or if the PCM is faulty.
11. The CKP System Variation Learn Procedure must
be performed anytime the relationship between
the CKP sensor and the CKP reluctor wheel
is changed.
6a1559
12. To inspect the reluctor wheel, remove the starter

and rotate the crankshaft while viewing the
reluctor wheelthrough the CKP sensor hole. If
you cannot determine if the reluctor wheel
is damaged, the oil pan may have to be removed.
14. The CKP System Variation Learn Procedure must
be performed anytime the relationship between
the CKP sensor and the CKP reluctor wheel
is changed.
15. Before replacing the PCM, inspect the PCM
harness connections.
16. The repair is not complete if the scan tool

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 9

-

data for this DTC and record or document the
parameters.

the OTC.
6. Select the Specific DTC option under the Diagnostic
Trouble Code (DTC) option using a scan tool.
ignition?
Caution: Before proceeding, remove the fuses for the

ignition coil and fuel injector feed circuits in order to
prevent personal injury from engine rotation, sparks,
and excessive engine fueling.

2. Lift the vehicle. Refer to Lifting and Jacking the
3. Disconnect the Crankshaft Position (CKP) sensor.
4. Measure the voltage from the CKP ignition feed
circuit using the DMM J 39200.
Does the DMM display the specified value?
Measure the voltage between the CKP sensor ignition
feed circuit and the CKP sensor ground circuit using the
DMM J39200.
B+
B+
6-1560
Engine

Step
Action
Value(s)
Momentarily connect the test lamp J 34142-8 between the

CKP sensor signal circuit and the CKP sensor ignition feed
circuit.
Does the fuel pump operate when ignition voltage was
applied to the CKP sensor signal circuit?
Important: Use the connector test adapter kit J 35616-A

when probing the PCM connectors. Refer to Using
Connector Test Adapters in Wiring Systems.
1. Re-connect the CKP sensor.
3. Jumper the CKP B+ supply circuit at the PCM
harness connector to the battery positive voltage
terminal using a fused jumper wire. Refer to Using
4. Jumper the CKP ground circuit at the PCM harness
connector to the battery ground terminal.
5. Probe the CKP sensor signal circuit with the DMM
J 39200 set to the 40V AC scale.
Crank
the engine.
6.
Is the voltage within the specified range?
Yes
No
Go to Step 11
Go to Step 7
Go to Step 15
Go to Step 10
4.0-6.0V
1. Test for an open or a short to ground in the CKP
ignition feed circuit. Refer to Circuit Testing in Wiring

Systems.
2. If you find an open or a short to ground, repair the
Wiring Systems.
1. Test for an open or a poor connection in the CKP
ground circuit. Refer to Testing for Continuity or
Wiring Systems.
2. If you find an open or poor connection, repair the
condition as necessary. Refer to Wiring Repairs or
'
Go to.Step .16
Go to Step 15
Go to Step 16
Go to Step 15
Go fo Step 16
Go to Step 11
1. Test the CKP sensor signal circuit for the following:
10
An open
A short to ground
A short to voltage
2. If you find a concern with the signal circuit, repair the
Wiring Systems.
Engine
6-1561

Step
Action
11
Important: The CKP System Variation Learn Procedure

must be performed anytime the relationship between the
CKP sensor and the CKP reluctor wheel is changed. Refer
to CKP System Variation Learn Procedure.
1. Remove the CKP sensor. Refer to Crankshaft
2. Visually inspect the CKP Sensor for the following
conditions:
Physical damage
Loose or improper installation
Wiring routed too closely to secondary ignition
components
3. If a condition is located, repair as necessary.
12
Visually inspect the CKP sensor reluctor wheel for

damage.
13
1. Inspect for poor connections at the CKP sensor.

Wiring Systems.
Value(s)
Yes
No
Go to Step 16
Go to Step 12
Go to Step 16
Go to Step 13
Go to Step 16
Go to Step 14
1. Replace the CKP Sensor. Refer to Crankshaft

\)
2. Perform the CKP System Variation Learn Procedure.
14
Refer to CKP System Variation Learn Procedure.

15
16
17
Go to Step 16

Replace the PCM.
1. Select the Diagnostic Trouble Codes (OTC) option

and the Clear OTC Information option using the
scan tool.
3. Select the Specific OTC option under the Diagnostic
Trouble Code (OTC) option using a scan tool.
OTC as specified in the supporting fext, if applicable.
Does the scan tool indicate that this test passed?
Select.the Capture Info option and the Review Info option

Go to Step 16
Go to Step 17
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1562
Engine Ccmtrols - 5.7l
Engin.e
DTC P0336 Crankshaft Position (CKP) Sensor Performance
Solid State
Position
Crankshaft
Solid State
(CMP)
B
A
Position
Sensor
(CKP)
A
B
0.35
Sensor
0.35
0.35
BRNNVHT 633
DK BLU/ 1869
LTGRN 1867
WHT
0.35
0.35 PNK/BLK 632
0.35 RED 631
YELi 1868
BLK
12
21
~ C_KP Sen:; - I
1
1
61
-1 ~e~e~~~e-
Signal Input
- - - - -- - - --- -- -
_ Low
-
..
Ignition
~~=~~~
I~~
I
-1
73
C1
~e~e;e~c~ - -;;P Sensor
_ Low
-
39
C2
-
[SJ
0
~ - ~ Powertrain
I ,Control
Signal Input
Ignition
Feed
IL 0c
ICamshaft
Feed
Module
I
1 (PCM)
I~
12V
I~
~-------------------------------------J
582388
Circuit Description
The Crankshaft Position Sensor is mounted in the
right rear of the engine block behind the starter.
The CKP sensor works in conjunction with a
24X reluctor wheel mounted on the rear of the
crankshaft. The CKP sensor has a B+ power supply, a
ground, and a signal circuit.
As the crankshaft rotates, the reluctor wheel teeth
interrupt a magnetic field produced by a magnet within
the sensor. The sensor's internal circuitry detects
this and produces a signal which the PCM reads. The
PCM uses this signal to accurately measure
crankshaft velocity which is a variable used in order to
detect misfire, and control spark and fueling.


The PCM determines that the CKP sensor signal is
out of range for less than 1 second.

Failure Records.
Conditions f.or Clearing the Mll/DTC

that the diagnostic runs and does not faiL
A last test failed (current .OTC) clears when the
A History. DTC clears after 40 consecutive
Use a scan tool in order to clear th.e MIL/DTC.
Diagnostic Aids
Important:
the PCM connector gaskets when . .
gaskets are .install~d correctly. The gaskets
in Wiring Systems.
The following conditions may cause this DTC to set:
Poor connections: Refer to Testing for Intermittent
Crankshaft reluctor wheel damage or improper
installation.
reluctor wheel.
The engine running out of fuel.
If the crankshaft rotates backwards, this DTC will
set. This condition is only with vehicles equipped
with a manual transmission. This condition
can occur when a vehicle is on an incline and the
clutch is released and an engine stall occurs.
Engine
Excess crankshaft end play causes the CKP sensor

reluctor wheel to move out of alignment with the CKP
sensor. This could result in any one of the following:
A no start
e A start and stall
Erratic performance
Test Description
diagnostic table.
2. This step verifies that the malfunction is present.
3. This step tests for EMI (Electro Magnetic
Interference) on the CKP sensor circuits.
6-1563
6. Vertical lines across the face of the sensor could

indicate foreign material passing between the
CKP sensor and the reluctor wheel. Non vertical
lines across the face of the sensor may indicate a
crack in the CKP sensor. Either of these
conditions causes this DTC to set.
7. Damage to the reluctor wheel would affect the
CKP sensor output. To inspect the reluctor wheel,
remove the starter and rotate the crankshaft
while viewing the reluctor wheel through the CKP
sensor hole. If you cannot determine if the
reluctor wheel is damaged, the oil pan may have
to be removed. If this condition exist, refer to
Engine Mechanical for crankshaft replacement.
DTC P0336 Crankshaft Position (CKP) Sensor Performance

Step
Action
..
Value(s)
Yes
No
Go to Step 2
Go to A
Powet1rain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 9
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 9
Go to Step 6

Important: If OTC P0335 is also set, diagnose OTC P0335

before proceeding with this OTC.
2. Idle the engine for 2 minutes.
Does the scan tool indicate that OTC P0336 failed this
ignition?
1. Visually/physically inspect all circuits going to the

Crankshaft Position sensor for the following:
Routed too.close to secondary ignition wires or
components
Routed too close to after-market add on electrical
equipment
Routed too close to solenoids, relays and motors.
2. If you find incorrect routing, correct the harness
routing.
1. Inspect for a poor connection at the CKP sensor.

Systems.

Wiring Systems.
Systems.
61564
Engine

DTC P0336 Crankshaft Position (CKP) Sensor Performance (cont'd)
Step
Action
Important: The CKP System Variation Learn Procedure
Value(s)
No
Yes
must be preformed anytime the relationship between the

CKP sensor and the CKP reluctor wheel is changed. Refer
to CKP System Variation Learn Procedure.
1. Remove the CKP sensor. Refer to Crankshaft

2. Inspect the CKP.sensor for signs of damage.
Is the CKP sensor damaged?

Inspect the crankshaft reluctor wheel for damage.
Is the reluctor wheel damaged?
1. Replace the CKP Sensor. Refer to Crankshaft

8
2. Perform the CKP System Variation Learn Procedure.
Go to Crankshaft
and Bearings
Removal in
Engine
Mechanical-,5.7L
Go to Step 7
Go to Crankshaft
and. Bearings
Removal in
. Engine
..
Mechanical-5. 7L
Go to Step 8
..
Go to Step 9

the Clear OTC option using the scan tool.


10
diagnosed?
.
-
Go to Step 10
Goto the
applicable
OTC table
Goto Step 2
(
..
System OK
Engine
Engine Controls~ 5.7L
6-15_65
Solid State
? Position
Crankshaft
~----------_J__.
. (CKP)
A
B
0.35
DKBLU/ 1869
WHT
0.35
_J
Solid State
. ._.. Position
Camshaft
..____________
B
fMrl
(CMP)
Sensor
L!.w
0.35
C
Sensor
BRNNVHT 633
0.35
LT GRN 1867
b.35 PNK/BLK 632
0.35 RED 631
YELJ 1868
BLK
12
21
~ Cs!<PSe-n~;- - -l~e~e~e~:eI
1gna11nput
CONN ID
C1=BLU
C2=RED
I
I
L
~ ow
61
73
C1
- - - - - - - - -- - - - - -1 ~;e;e~c~ - -cs~M.-P sensor. - Low

1gna11 nput
Ignition
~
Feed
39 .C2
- - - ~ Powertrain
. I Control
Ignition
Module
I (PCM)
Feed
1
12V
jJ;
I~
~------------------------------------
582388
Circuit Description
The Camshaft Position (CMP) sensor is mounted

through the top of the engine block at the rear of the
valley cover. The CMP sensor works in conjunction
with a 1X reluctor wheel on the camshaft. The reluctor
wheel is inside the engine immediately in front of
the rear cam bearing. The PCM provides a 12 volt
power supply to the CMP sensor as well as a ground
and a signal circuit.
The CMP sensor determines whether a cylinder is on
a firing stroke or on an exhaust stroke. As the
camshaft rotates, the reluctor wheel interrupts a
magnetic field produced by a magnet within the
sensor. The sensors internal circuitry detects this and
produces a signal which the PCM reads. The PCM
uses this 1X signal in combination with the Crankshaft
Position (CKP) sensor 24X signal in order to
determine crankshaft position and stroke. This
diagnostic monitors for a loss of Camshaft Position
sensor signal.
this condition.
The engine speed is less than 4,000 RPM.

The PCM detects that a CMP to CKP mis-match has
occurred for 10 seconds.

Failure Records.

.. Use a scan tool in order to clear the MIUDTC.
6-1566
Engine
Diagnostic Aids
Test Description
Important:
in Wiring Systems.
Poor connections: Refer to Testing for Intermittent
Camshaft reluctor wheel damage.
reluctor wheel.

diagnostic table.
2. This step verifies that the malfunction is present.

3. This step tests for EMI (Electro Magnetic
Interference) on the CMP sensor circuits.
6. Damage to the reluctor wheel would affect the
CMP sensor output. Vertical lines across the
face of the sensor could indicate foreign material
passing between the CMP sensor and the
reluctor wheel. This condition would cause this
OTC to set. Replace the CMP sensor if damage to
the sensor is evident.
Engine
Engine Controls - 5.7.L
6-.1567

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 9
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 9
Go to Step 6
Go to Camshaft
Replacement in
Engine
Mechanical 5.7L
Go to Step 7
Important: If there are any other CMP DTCs set,

diagnose those DTCs first.
Does the scan tool indicate that DTC P0341 failed this
ignition?
1. Visually/Physically inspect all circuits going to the

Camshaft Position sensor for the following:
Routed too close to secondary ignition wires or
components
Routed too close to after-market add on electrical
equipment
Routed too close to solenoids, relays and motors
2. If you find incorrect routing, correct the harness
routing

Wiring Systems.
4

Systems.

Replacement in Engine Mechanical 5.7L.
2. Inspect for a poor connection at the CMP sensor.
Systems.
1. Remove the CMP sensor. Refer to Camshaft

2. Inspect the CMP reluctor wheel for damage.
Is the CMP reluctor wheel damaged?


the Clear DTC option using the scan tool.
DTC as specified in the supporting text, if applicable.
using the s.can tool.
diagnosed?
Go to Step 8
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1568
Engine
DTC P0342 Camshaft Position (CMP) Sensor Circuit low Voltage
Camshaft
...__ _ _ _Solid
_State
_ _ _ _ __, Position
A
c (CMP)
8
Sensor
0.35
BRN/WHT 633
Crankshaft
State_ _ ___._ Position
.___ _ _Solid
__
(CKP)
A
B
c
Sensor
0.35
0.35
DKBLU/ 1869
LTGRN 1867
WHT
0.35 PNK/BLK 632
0.35
YELi 1868
BLK
~
I
:
12
C1
-;~P Sensor -
~ Low
lgoition
Feed
CONN ID
C1=BLU
C2~RED
L:w
0.35 RED 631
61
73
- - - - - - - - - - - - - - -1 ~e;e:e~c~ -
2
21
-l;e~e~e~~e-
c~.PS~n;;..- Signal Input
Low
39
C2
Ignition
Feed
12V
~ Powertrain
Control
Signal Input
I Module
I {PCM)
1
Ji,.
P
I~
~-------------------------------------J
582388
Circuit Description
The Camshaft Position sensor is mounted through the
top of the engine block at the rear of the valley
cover. The CMP sensor works in conjunction with a
1X reluctor wheel on the camshaft. The reluctor wheel
is inside the engine immediately in front of the rear
cam bearing. The PCM provides a 12 volt power
supply to the CMP sensor as well as a ground and a
signal circuit.
Camshaft rotates, the reluctor wheel interrupts a
sensor. The sensors internal circuitry detects this arid
Position sensor 24X signal in order to determine
crankshaft position and stroke. This diagnostic
monitors for a loss of Camshaft Position sensor signal.
this condition.


The PCM detects the Cam signal is stuck low when
the signal should be high for 5 seconds.

conditions to the F.reeze Frame and updates the
Failure Records.

Diagnostic Aids
Important:
in Wiring Systems.
Engine
The following may cause this OTC to set:

Poor connections/terminal tension at the sensor.
~ Camshaft reluctor wheel damage
O The sensor coming in contact with the
reluctor wheel
4. If the duty cycle is present at the PCM connector,

the Camshaft Position sensor B+ reference and
ground circuits are OK.
5. This step tests the Camshaft Position sensor B+
reference circuit.
6. This step tests the Camshaft Position sensor
ground circuit.
9. This step tests for a short to B+ on the Camshaft
Position sensor signal circuit.
Test Description
diagnostic table.
6-1569
10. This step tests for a short to ground on the

Camshaft Position sensor signal circuit.
2. This step verifies that the fault is present.
DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage

Step
Action

2. Idle the engine.
3. Monitor the CAM signal input - High to Low transition
in the Engine Data List 1 using the scan tool.
Does the scan tool parameter increment?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 17
Go to Step 5
1. Turn ON the ignition with the engine OFF.

4. Idle the engine.
5. Operate thE3 vehicle within the conditions required for

where applicable, are listed in Conditions for Setting
the OTC.
ignition?
1. Disconnect both PCM connectors. Refer to PCM
2. Jumper the Camshaft Position sensor ground circuit
at the PCM connector C1 (sensor side) to a known
good ground.
3. Jumper the Camshaft Position sensor ignition feed
circuit at the PCM connector C2 (sensor side) to B+
4. Measure the duty cycle from the Camshaft Position
sensor signal circuit with the J 39200 DMM,
Does the DMM display a duty cycle within the specified
range while cranking the. engine?
45-55%
6-1570
Step
Engine
DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage (cont'd)
Value(s)
Action
Yes
No

2. Reconnect the PCM connectors. Refer to PCM
3. Remove the intake manifold in order to gain access
to the Camshaft Position sensor. Refer to Intake
Manifold Replacement in Engine Mechanical 5.7L.
5
4. Disconnect the Camshaft Position sensor electrical

connector.
B+

6. Measure the voltage from the Camshaft Position
sensor B+ supply circuit to the battery ground with
the DMM.
Does the DMM display the specified voltage?
Measure the voltage from the Camshaft Position sensor

B+ supply circuit to the Camshaft Position sensor ground
circuit with the DMM.
Test for an open in the Camshaft Position sensor ground

circuit. Refer to Testing for Continuity in Wiring Systems.
Go to Step 9
Go to Step 7
Go to Step 13
Go to Step 17
Go to Step 12
Go to Step 17
Go to Step 10
Go to Step 14
Go to Step 15
Go to Step 11
Go to Step 18
Go to Step 16
Did you find an open ground circuit?
Go to Step 8
B+
Test for an open or a short to ground in the Camshaft

Position sensor B+ reference circuit. Refer to Circuit
Go to Step 6
D.id you find the circuit open or shorted to a ground?

2. Measure the voltage at the Camshaft Position sensor

signal circuit to ground with the DMM.
1V

10
Probe the CMP signal circuit with the test lamp J 34142-8
connected to battery voltage.
11

3. Test the continuity of the Camshaft Position sensor
signal circuit with the DMM. Refer to Testing for
12
2Q
...
Repair the open or short to ground in the Camshaft

Position sensor B+ reference circuit. Refer to Wiring

13
Repair the open in the Camshaft Position sensor ground

Go to Step 20
-
14
Repair the short to voltage in the Camshaft Position

sensor signal circuit. Refer to Wiring Repairs in Wiring
Systems.
Repair the short to ground in the Camshaft Position sensor
16
Go to Step 20

Repair the open in the Camshaft Position sensor signal
Go to Step 20

15
Go to Step 20
Go to Step 20
Engine
6-1571
DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 20
Go to Step 19

Wiring Systems.
17
18
19

Systems.
Replace the Camshaft Position sensor. Refer to Camshaft


Replace the PCM.
Go to Step 20
Go to Step 20

the. Clear DTC Information option using the scan tool.
20

applicable.
21
diagnosed?
Go to Step 21
Go to Step 2
Go to the
applicable
DTC Table
System OK
6-1572
Engine
DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage
Solid State
] Camshaft
Position
(CMP)
Sensor
Crankshaft
'
B
A
Position
(CKP)
c'
A
B
0.35
Sensor
0.35
0.35
BRN/WHT 633
DKBLU/ 1869
LTGRN 1867
WHT
0.35
0.35 PNK/BLK 632
0.35 RED 631
YELJ 1868
BLK
~
Solid State
-1
12 .,. - -- -21- '- - - - - - 2

61
.
73
_, - - - - - - - - - - - - - - - - . - - - - - - - -C!<f' Se:S-or-
Signal Input
I
I
I
I
-1
;e1::e -. - - - - - - - -
= Low
Ignition
Feed
I CONN IOI
IC1=BLU
C2=RED
12V
- C1
39
!LocJ
~
N
C2
;ef;e:e- ~MP s-;n;;;r - - - - ,.. - - - ~ Powertrain

Low
Signal Input
Control
I Module
~
Ignition
Feed
I {PCM)
I ,&
I
I ~
~-------------------------------------J
582388
Circuit Description
cover. The CMP sensor works in conjunction with a
1X reluctor wheel on the camshaft. The reluctor wheel
is inside the engine immediately in front of the rear
cam bearing. The PCM provides a 12 volt power
supply to the CMP sensor as well as a ground and a
signal circuit.
sensor. The sensors internal circuitry detects this and
Position sensor 24X signal in order to determine
crankshaft position and stroke. This diagnostic
monitors for a loss of Camshaft Position sensor signal.
this condition.


The PCM detects the Cam signal is stuck high when
the signal should be low for 5 seconds.

O The PCM records the operating conditions at the
Failure Records.

~

e A last test failed (current OTC) clears when the
Diagnostic Aids
Important:

in Wiring Systems.
Engine

Poor connections/terminal tension at the sensor.
Camshaft reluctor wheel damage
9 The sensor coming in contact with the
reluctor wheel
4. If the duty cycle is present at the PCM connector,

the Camshaft Position sensor B+ reference and
ground circuits are OK.
5. This step tests the Camshaft Position sensor B+
reference circuit.
6. This step tests the Camshaft Position sensor
ground circuit.
9. This step tests for a short to B+ on the Camshaft
Position sensor signal circuit.
Test Description
diagnostic table.
6-1573

Camshaft Position sensor signal circuit.
DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 17
Go to Step 5


2. Idle the engine.
3. Monitor the CAM signal input - High to Low transition
in the Engine Data List 1 using the scan tool.
Does the scan tool parameter increment?

4. Idle the engine.
the OTC.
ignition?
1. Disconnect both PCM connectors. Refer to PCM

2. Jumper the Camshaft Position sensor ground circuit
at the PCM connector C1 (sensor side) to a known
good ground.
3. Jumper the Camshaft Position sensor ignition feed
circuit at the PCM connector C2 (sensor side)to B+
4. Measure the duty cycle from the Camshaft Position
sensor signal circuit with the J 39200 DMM.
Does the DMM display a duty cycle within the specified
range while cranking the engine?
45-55%
6-1574
Engine
DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage (cont'd)
Step
Action
Value(s)
B+
Measure the voltage from the Camshaft Position sensor

B+ supply circuit to the Camshaft Position sensor ground
circuit with the DMM.
B+
Test for an open in the Camshaft Position sensor ground,

circuit. Refer to Testing for Continuity in Wiring Systems.
Did you find an open ground circuit?
Test for an open or a short to ground in the Camshaft

Position sensor B+ reference circuit. Refer to Circuit
Did you find the circuit open or shorted to a ground?

2. Measure the voltage at the Camshaft Position sensor
signal circuit to ground with the DMM.
1V
10
Probe the CMP signal circuit with the test lamp J 34142-B
connected to battery voltage.
11

3. Test the continuity of the Camshaft Position sensor
signal circuit with the DMM. Refer to Testing for
12
13
14
15
16
Yes
No

2. Reconnect the PCM connectors. Refer to PCM
3. Remove the intake manifold in order to gain access
to the Camshaft Position sensor. Refer to Intake
4. Disconnect the Camshaft Position sensor electrical
connector.
6. Measure the voltage from the Camshaft Position
sensor B+ supply circuit to the battery ground with
the DMM.
'
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 7
Goto Step 13
Go to Step 17
Go to Step 12
Go to Step 17
Go to Step 10
Go to Step 14
Go to Step 15
Go to Step 11
Go to Step 18
Go to Step 16
2Q
Repair the open or short to ground in the Camshaft

Position sensor B+ reference circuit. Refer to Wiring
Repair the open in the Camshaft Position sensor ground

Repair the short to voltage in the Camshaft Position

Systems.
Repair the short to ground in the Camshaft Position sensor

Repair the open in the Camshaft Position sensor signal

Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 20
(
-
Go to Step 20
Engine
6-1575
DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage (cont'd)
Action
Step
Value(s)
Yes
No
Go to Step 20
Go to Step 19

Wiring Systems.
17
18
19

Systems.
Replace the Camshaft Position sensor. Refer to Camshaft

Replace the PCM.
Go to Step 20
Go to Step 20
1. Select the Diagnostic Trouble Code (OTC} option and

20
21
3. Select the Diagnostic Trouble Code (DTC} option and

applicable.
using the.scan tool.
diagnosed?
Go to Step 21
Go to Step 2
Go to the
applicable
OTC Table
System OK
6-1576
EngineControls -5~7L
Engine

... - -
!Loe
- , Engine Wiring
INJ 1
I Harness Junction
MiniFuse I Block 2
I Power
I :~~~u:;;
I lnWiring
I Systems
I
I
15A
~ -
Reference
Low
lJ
Powertrain
C1 ;,BLU I Control
C2=RED I Module
1(PCM)
~
1 L ...~
- P;M-
p:F~:- -------------~8 B;r;: -
B1_____
rn~:rk
L.---------------- ------.a~
812D21 ____c______
r ._____
[SJ
-
I Ignition
Control
I 1
08
Ignition
Conlroi
Signal
=~
Ignition
Feed
A C100
0.8 PNK 639
=:5=NHK
L.--------.a
0.8PNK/WHT 639
Power
Distribution
Reference
Low
A_Gr_ou_nd_ _ ___.
---c------------
Ignition
Coil/
Module
1
----is1231
Ignition
Coil/Modules
3,5,7
8126
C106
0.8 BLK 550

8100
3BLK 550
0.8 BLK
550
3BLK
G112. 450
Ground
Distribution
Schematics
In Wiring
Systems
(
582277
Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition
Control (IC) circuits. The PCM commands the IC
circuit low when a spark event is requested. This
causes the IC module to energize the ignition coil to
create a spark at the spark plug. Each ignition
coil/module has the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This DTC
sets when the IC circuit is out of range.


The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.

Failure Records.

Engine
5.;1577
Diagnostic Aids
Test Description
Important:
in Wiring Systems.

diagnostic table.

4. This step verifies the integrity of the ignition
control circuit and the PCM output.
5. This step te.sts for a short to ground on the
ignition control circuit.
6-1578
Engine Controls;- 5.7l
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to.A
Powertrain On
Board
Diagnostic (OBD)
System Check

Important: lfall the Ignition Control (IC) DTCs are set

at the same time, inspect the IC ground circu.its or the
B+ circuits for an open.
2. Idle the engine.
3. Monitor the (IC) Ignition Control status for the cylinder
with the ignition control DTC using the scan tool in
the Misfire Data List.
Does the scan tool indicate Fault?

the OTC.
ignition?
>
Go to Step 4
Go to Step 3
1. Turn OFF the engine.

2. Disconnect the ignition coil/module electrical
connector.
3. Measure the frequency at the ignition control signal
circuit using the DMM on the DC Hertz setting. Refer
to Measuring Frequency in Wiring Systems.
4. Idle the engine.
Is the frequency within the specified range?
Measure the voltage at the ignition control signal circuit

using the DMM.
Is the voltage greater than the specified value?
1V

3. Test the continuity from the IC circuit (at the ignition
coil/module electrical connector) to the PCM
connector using the DMM. Refer to Testing tor
Test the resistance from the IC circuit (at the ignition

coil/module electrical connector) to ground using the DMM.
Does the DMM indicate OL?
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz
Engine
6-1579
DTC P0351 Ignition Coil 1 Control Circuit (cont'd)

Value(s)
Step
Action
Probe the Ignition feed circuit for the coil/module using the
test lamp J 34142-8 connected to battery ground. Refer to
Probing Electrical Connectors in Wiring Systems.
Probe the ground circuit for the coil/module using the test
10
Repair the Ignition feed circuit for an open between the

ignition coil/module electrical connector and the splice.
11
Repair the ground circuit for an open between the ignition

coil/module electrical connector and the splice. Refer to
Yes
No
Go to Step 9
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18
Go to Step 18
1. Inspect for a poor connection at the coil/module.
12
13
14
15
16
17

Systems.
Go to Step 18
Replace the ignition coil/module. Refer to Ignition Coil

Repair the Ignition Control circuit for a short to voltage.

Repair the Ignition Control circuit for an open or grounded


Wiring Systems.
Systems.

Replace the PCM.

Go to Step 13
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
18
1. Seleet the Diagnostic Trouble Code (OTC) option and

4. Operate the vehic.le within the Conditions for Running
applicable.
19
diagnosed?
Go to Step.19
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1580
Engine
Engine Controls - .5.7l
DTC P0352 Ignition Coil 2. Control Circuit

I"
I
.I
I
!..-----
-~
, Engine Wiring
1
INJ 2
Harness Junction
MiniFuse I Block 2
Power
Distribution J11
Schematics
In Wiring . J10
Systems
15A.,
I
-
~ -
cl
0.8 PNK 839

A C101
0.8 PNK 839
I
I Ignition
Control
I 2
.............
Reference
~.
!..----------------
Distribution
lJ.
- P;Mc1 =BLu .
C2=RED
1Powertrain
I Control
I
Module
I. (PCM)
,. ~ .
=
~
------.1~
=:S:NK ::09 0.8AE0Nv:r~1~ ~~:~~:=.~r~:o

Bl. ...... ........ ~81251
H
S12D4l ____C
Ignition
Feed
Reference
Low
G_r_ou_nd_ _ ___,
rn~ru~k
C107
...
Ignition
Control
Signal
.
.
_
___
r
..
Ignition
Coil/
Module
2
Ignition
Coil/Modules
4,6,8
8127
A C107
0.8 BLK 550
S100
3 BLK 550
0.8 BLK
550
3BLK
G112 450
Ground
Distribution
Schematics
In Wiring
Systems
(
582282
Circuit Description
A power feed
A ground circuit
Sequencing and timing are PCM controlled. This OTC


. grounded, open or shorted to a voltage.

"' The PCM illuminates the malfunction indicator
e The PCM records the operating conditions at the
Failure Records.

.. Use a scan tool in order to clear the MIUOTC.
Engine
')
6-1581
Diagnostic Aids
Test Description
Important:
in Wiring Systems.

diagnostic table.
6-1582
Engine
DTC P0352 Ignition Coil 2 Control Circuit

Step
Action
Value(s)
No
Yes

'
Go. to Step
Important: If all the Ignition Control (IC) DTCs are set

at the same time, inspect the IC ground circuits or the
2. Idle the engine.
with the ignition control DTC using the scan tool in
.z
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3



the DTC.

ignition?
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15

connector.

3.0-20 Hz
4. Idle the engine.

5

using the DMM.
1V


connector using the DMM. Refer to Testing for

Engine

Step
Action
lamp J 34142-B connected to B+. Refer to Probing
11
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18

Gb to Step 9
10
No
Value(s)

Yes
Go to Step 18

12

Systems.
13

Go to Step 18

Go to Step 18

Go to Step 18
15
14
Go to Step 13
Gq to Step 18

16

Wiring Systems.
Systems.
Go to Step 18
Did yoll find and correct the condition?
17

Replace the PCM.
..
Go to Step.17
Go to Step 18


3. $elect the Diagnostic Trouble Code (DTC) option and
18


applicable.
19
diagnosed?
Go to Step 19
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1584
Engine

r
I
I
~s~m_:. _ _
_ ___
15A
0.8 PNK/WHT 639

A C100
0.8 PNK 639
8102
~ ;ontrol
... -
Reference
Low
----:-r-ou_nd_ _ _ _
P;;-M- ~ Powertrain
C1=BLU
I
c2=RED
l]
_
Control
Module
I
1(PCM)
~:~1;:9
_ _ _ _ _ _ _ _ _ _ ~e:rence
Ignition
Control
Signal
0.8 LT 8::1~1-~3- - - - - - - - - - - - - - - - - ~~8-
s12021 ___ c_______s_l____
I Ignition
0.5 PNK 639

H
Ignition
Feed
1
1
.-~-~w-tr~-~uti-.o-n..,
~;:~ts
.,Engine
Wiring
I
INJ 1
Harness Junction
MiniFuse 1 Block 2
- - - - Power
Distribution
Je
Schematics
lnWiring
JS
= ____
~~
--i$12s l
E C106
-- ---Ignition
Coil/
Module
3
rn~ru:'
------
Ignition
Cod/Modules
1,5,7
8126
A C106
0.8 BLK 550
0.8 BLK
8100
550
3BLK 550
3BLK
G112 450
Ground
Distribution
Schematics
In Wiring
Systems
(
582285
Circuit Description
A power feed
A ground circuit



failure on the second consecutiv.e ignition
Failure Records.

lamp (MIL} OFF aftnr 3 consecutive ignition cycles
that the diagnostic runs arid does not fail.
Engine
Diagnostic Aids
Test Description
Important:
in Wiring Systems.

diagnostic table.
6-1586
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check


2. Idle the engine.
with the ignition control OTC using the scan tool in

the DTC.
Specific DTC option, then enter the OTC number
ignition?

connector.
4. Idle the engine.
'
'
Go to Step 4
Go to Step 3
(
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz

using the DMM.
1V


coil/module electrical connector) to ground using the OMM.
Engine
6-1587

Step
Action
Value(s)
10

'

11

Systems.
12
14
15
I
16
17
18
19
Go to Step 9
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18
Go to Step 18

Replacement (5. 7 L) in Engine ElectricaL


Go to Step 13
Go to Step 18
Go to Step 18
Go to Step .18

Wiring Systems.
Systems.

Replace the PCM.
1. Select theDiagnostic Trouble Code (DTC) option and
applicable:
Go to Step 18
diagnosed?
Go to Step 17
Go to Step 18
No
Go to Step 18
Did you find and co.rrect t.he condition?

13
Yes
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1588
Engine
Engine Controls - 5.7L .
IHot With Ignition Relay Energized!

.. - - - - -
INJ 2
"" 1 Harness Junction
""
1 Block 2
MiniFuse
I Power
I Distribution
Schematics
I lnWiring
I Systems
I
I
15A
L.---------'
0.8 PNK 839
r -
.. -
- -
I
I
A C101
0.8 PNK 839
I
I Ignition
----....
Control
I 4
L.----------------
Distribution
~:?.:;tics
0.5 PNK 839

H
BT ___
512041---c
PCM
C1=BLU
.,
Powertrain
I Control
I Module
~~I
I (PCM)
~
1~
------J~
C107
-------------------------iS12s
Ignition
Coil/
Module
:_r_ou_nd_ _ _ _ 4
Ignition
Control
Signal
r . . ,.___
rn~r.:
.. -
g-~ GRN/W:~r~:~:--- --- ---- --~-~-~~~~:~1~230
S109
Ignition
Feed
Reference
Ll!1
Reference
Low
Ignition
Coil/Modules
2,6,8
8127
A C107
0.8 BLK 550
8100
3BLK 550
0.8 BLK
550
3BLK
450
G112
Ground
Distribution
SchemaflCS
In Wiring
Systems
(
582287
Circuit Description
A power feed
A wound circuit



Failure Records.
Conditions for Clearing the MILJDTC

Engine
Diagnostic Aids
J Important:
in Wiring Systems.
6-1589
Test Description
diagnostic table.
6'"1590
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powerirain. On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3
Did you perform the Powertrain on:Board


at the same time, inspectthe IC ground circuits or the
2. Idle the engine.

the OTC.
ignition?

connector.
4. Idle the engine.
(
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz

using the DMM.
1V


Engine
6-1591
Step
Action
Value(s)
10

11

12
1. Inspect tor a poor connection at the coil/module.

Systems.
13

14

Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18
Go to Step 13
Go to Step 18
Go to Step 18
-

Testing tor Intermittent and Poor Connections in
Wiring Systems.
Systems.

Replace the PCM.
18

applicable.
19
Select the Capture Info option and the Revfew Info option
diagnosed?
17
Go to Step 9
Go to Step 18

16
No
Go to Step 18

15
Yes
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
6;.1592
Engine

.- ; 0 -
15 A
L.----- ____ ..
r--------------'"'. --- ---I

I
I Ignition
Power
Distribution
L.
8102
.._
0.5 PNK 639

H
S12D2l ___
Control
5
Ignition
Feed
Ignition
Control
Signal
D
~;:1::9
Reference
Low
0.8 DK G:~r~1-~5- - - - - - - - - - - - - - - - - ~-8
c1 =BLU
C2=RED
Powertrain
I Control
I Module
I (PCM)
I
-=-
.1
U:!J
-BT ----------------- ----- -is,~ l

C
c_
P;M- . ~
0.8 PNK/WHT 639

A C100
0.8 PNK 639
~=~~tics
1
!NJ 1
I Harness Junction
MiniFuse
Block
I D1w~b 11
stnuon
I Schematics
I In Wiring
I Systems
Reference
Low
r----A_Gr_ou_nd_ _ ___.
Ignition
Coil/
Module
rn~iu;'
C106
Ignition
Coil/Modules
1,3,7
8126
C106
0.8 BLK 550

S100
3BLK 550
0.8 BLK
550
3BLK
450
G112
Ground
Distribution
Schematics
In Wiring
Systems
(
582291
Circuit Description
A power feed
A ground circuit


Action Taken When the .DTC Sets

Failure Records.

Engine
6-1593
Diagnostic Aids
Test Description
Important:
~ For any test that requires probing the PCM or
in Wiring Systems.

diagnostic table.
6-1594
Engine

Step
Action
Value(s)
Yes

. Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
If. all the Ignition Control (IC) DTGs are set

Important:

2
2. Idle the engine.

Go to Step 4
Go to Step 3


the OTC.

ignition?
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15

connector.

3.0-20 Hz
4. Idle the engine.

5

using the DMM.
1V



Engine
6-1595

Step
Action
test lamp J 34142-B connected to battery ground. Refer to
iO

11

12

Systems.
13


14
15
Value(s)

17
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18
Go to Step 18
Go to Step 13
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
18

the Clear OTC Information option
using
the scan tool.
,,,,
'
the Specific OTC option, then enter .the OTC number

applicable.
19
diagnosed?
'
Go to Step 9
Go to Step 18

Wiring Systems.
Refer to Repairing Connector Terminal$ in Wiring
Systems.
Replace the PCM.
No
Go to Step 18
16
Yes
'
Go to Step 19
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1596
Engine
IHot With Ignition Relay Energl~ed i

'" - - - - I Power
Distribution J11
I Schematics
I lriWiririg
J10
~ ~s~~
15A
_ ___
Ignition
Feed
-:- -
1
1
I Ignition
~ Powertrain
":' -
-P-;M-
C1=BLU
Control
I
C2=RED
Module
I
1 (PCM)
[]
09 0.8 LT BLU~t
0.5 PNK 839

H
E C107
Ignition
Control
Signal
rn~~
.
Ll:!J
~-:------~-~B.-R::Z ~.:~ ----~ ~

1
1
I~~-c~-~ ~- sl:_::..:. _: _::_.:__::_::_-..: _::_:_ .: .: S12sl
s,
81204
0.8 PNK 839

A C101
0.8 PNK 839
-~-~-z-~-f-0:...
INJ 2
1 Harness Junction
1 Block 2
MiniFuse
Reference
Low
Ground
'----____.
Ignition
Coil/
Module
Ignition
Coil/Modules
2,4,8
...
8127
A C107
0.8BLK 550
8100
3BLK 550
0.8 BLK
550
3BLK
450
G112
Ground
Distribution
Schemafus
In Wiring
Systems
(
582294
Circuit Description
GOntrols the ignition system operation. The PCM
A power feed
.. A ground circuit
An ignition contro.1 (IC) circuit


grounded; open or shorted to a voltage.
.. All conditions met for less than 1 second.

cycle that the diagnostic runs. and fails.
time the diagnostic fails. The .first time the
cycle, the PCM records the operating condi1ions
Failure Records.
Conditions .for Clearing the MIUDTC

Engine
)
6.;.1597
Diagnostic Aids
Testoescription
Important:
in Wiring Systems.

diagnostic table.

6-1598
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain. On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3


2. Idle the engine.

the OTC.
Specific OTC option, then enter the DTC number
ignition?

connector.
4. Idle the engine.
(
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz

using the DMM.
1V


Engine
6-1599

Step
Action
Value(s)
10
11
Go to Step 9
Go to Step 10
.
Go to Step 12
Go to Step 11
Go to Step 18

No

Yes
Go to Step 18

12
13

Systems.
Go toStep 18

Go to Step 18

16
17

Replace the PCM.
Go to Step 18

Wiring Systems.
Systems.
Go to Step 18

15

14
Go to Step 13
Go
to Step 18
Go to Step 17
Go to Step 18

18
19

4. Operate t.he vehicle within the Conditions for Running
applicable.
Does the scari tool indicate that this test ran and passed?
diagnosed?
Go to Step 19
Goto Step 2
Go to the
applicable
DTC table
System OK
5.,.1600
Engine

'" - - - - -
I Power
Distribution
I Schematics
I lnWiring
~s~m.:_ _
1
INJ 1
J9
Harness Junction
1Block 2
MiniFuse
JS
15A
_ ___
0.8 PNK/WHT 639

A C1 oo
0.8 PNK 639
,.6
=~s;iK ::2
-~-:e-l~u-tio_n...,
s1202l ___
.. -
.. -
.. -
.. -
.. -
.. -
.. -
l1
0.8 R;r~~~- --------------:~.-~;r;:
I
I
Ignition
Control
Signal
r . ____
rn~:~
Reference
Low
A_Gr_ou_n_d_ _ _
C1=BLU
c2=RED
Ignition
~ ~ntrol
_ _ _ _ _ _ _ _ _ _ ~~:rence
_-=-
c_______s_l:-- -- -- ----- ----------------ts,23
Ignition
Feed
PCM.
Ignition
Coil/
Module
7
____
"
Powertrain
1 Control
IM d
o ule
I
1(PCM)
. :....
.
Ignition
Coil/Modules
1,3,5
.-----8126
A C106
Ground
Distribution
0.8 BLK 550 0 _8 BLK

S100v------.......
3 BLK 550 55o
3BLK
G112
45
Schematics
In Wiring
Systems
(
582296
Circuit Description
., A power feed
" A ground circuit
" An ignition control (IC) circuit


" All conditions met for less than 1 second.

The PCM illuminates the malfunction indica1or
Failure Records.
CondiUons for Clearing the MIL/DTC

Engine
6-1601
Diagnostic Aids
Test Description
Important:
surfaces befo.re servicing the PCM. Inspect
in Wiring Systems.

diagnostic table.
5. This step tests for a .short to ground on the
6-1602
Engine

Step
Action

1
Value(s)
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 4
Go to Step 3

the OTC.
ignition?
'
(
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz

using the DMM.
1V


No

2. Idle the engine.

connector.
4. Idle the engine.
Yes
Engine
6-1603

Step
Action
Value(s)
lamp J 34142-B connected to B+. Refer to Probing
10
11

No
Go to Step 9
Go to Step 10
Go to Step 12
.Go to Step 11

Yes
..
Go to Step 18
Go to Step 18

12

Systems.

13
14

Go to Step 18
Go to Step 18

15

Go to Step 18
Go to Step 18
'

Wiring Systems.
16
17

Systems.
Important:. Program the replacement PCM. Refer to PCM

Replace the PCM.
Go to Step 13
Go to Step 18
Go to Step 17
Go to Step 18
1. Select the Diagnostic.Trouble Code (OTC) option and

18


applicable.
19
diagnosed?
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1604
Engine
(
~
'------0.8 PNK
- - ..I
839
A C101
0.8 PNK 839
I Ignition
Control
I 8
n. - - -
....--.....
~~
Distribution
~:?:~ts
- - .... - - - - - - - - - - - - - - - - -P;M-
I
I
I]
Reference
L
- -
8109
0.8 PPL/W:~r~1-~8- - - - - - - - - - - - -
0.5 PNK 839

H
~ Powertrain
c1 =BLU I Control
C2=RED I Module
I (PCM)
.3w_ -
- ~- - - - -
~-~-~~~~:~1~:o
E
C107
s1204l ___ c_ ---al-- - --------- --- ------- --ts,~

Ignition
Feed
Ignition
Control
Signal
Reference
Low
----:-r-ou_nd_ _ __,
Ignition
Coil/
Module
rn~ru;"
.s
lJ!J
A..
P
Ignition
Coil/Modules
2,4,6
S127
A C107
0.8BLK 550
S100
3 BLK 550
G112
0.8 BLK
550
3BLK
450
Ground
DlstributlQn
Schematbs
In Wiring
Systems
(
582301
Circuit Description
A power feed
A ground circuit


" The PCM detects the ignition control circuit is

Failure Records.

Engine
6-1605
Diagnostic Aids
Test Description
Important:
gaskets are. installed correctly. The gaskets
in Wiring Systems.

diagnostic table.
6~1606
Engine Controls - 5.7t
Engine

Step
Action
Value(s)
Yes
No
Go to. Step 2
Go to A.
Powertrain. On
Board
Diagnostic.(OBD)
System C]1eck
Go to Step 4
Go to Step 3

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits or the B+
circuits for an open.
2. Idle the engine.

the OTC.
ignition?

connector.
4. Idle the engine.
(
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 14
Go to Step 6
Go to Step 7
Go to Step 15
Go to Step 16
Go to Step 15
3.0-20 Hz

using the DMM.
1V


Engine
6-1607

Step
Action
test lamp J 34142-B connected to battery ground. Refer to
Va!ue(s)
lamp J 34142-8 connected to 8+. Refer to Probing
10

11

Yes
No
Go to Step 9
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 18
."
Go to Step 18

Systems.
12
13
.
14
15
16
17
Go to Step 18



i. Inspect for a poor connection at the PCM. Refer to

Testing for Intermittent andPoor Connections in
Wiring Systems.
Systems.

Replace the PCM.
Go to Step 13
Go to Step 18
-
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18


18
19

4. Operate the. vehicle within the Conditions for Running
applicable.
Does the scan tool indicate that this .test ran and passed?
using the scan tool..
diagnosed?
Go to Step 19
Go to Step 2
Go to the
applicable
OTC table
System OK
..
6-1608
Engine

Circuit Description
The PCM tests the EGR system during deceleration
by momentarily commanding the EGR valve open. The
pressure in the intake manifold increases when the
EGR valve is open. The PCM monitors the Manifold
Absolute Pressure (MAP) sensor signal during
the EGR system diagnostic in order to determine the
amount of EGR flow. The PCM calculates an error
based on the difference between the actual MAP
increase and a predetermined value. The PCM records
the error and adjusts an internal fail counter towards
the fail threshold if the error is too great. The PCM sets
a DTC P0401 when the fail counter exceeds the fail
threshold. The number of test samples required
to exceed the fail threshold varies according to the
magnitude of the detected flow errors.
The PCM allows only one EGR flow test sample to be
taken during an ignition cycle. Following a scan tool
Clear Info or a battery disconnect the PCM allows
twelve test samples during the first ignition cycle in
order to aid in verifying a repair.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0405, P0500, P0502, P0503, P0562,
P0563, P1404 are not set.
.. The ignition voltage is between 11.7 and 18 volts.
.. The BARO is more than 70 kPa.
G The ECT is between 60C (140F) and
11 ?C (243F).
" The IAT is less than 65C (140F).
" The TP sensor angle is less than 1.1 percent.
The engine speed is between 800 RPM and
2,000 RPM.
" The engine vacuum (BARO minus MAP) is
between 60 kPa (9 psi) and 83 kPa (12 psi).
" The IAC position is steady.
" The vehicle speed is between 42 km/h (26 mph)
and 113 km/h (70 mph).
The change in VSS is less 6 km/h (4 mph).
" The change in MAP is less than 0.5 kPa.
" The A/C clutch status is steady.
" Not in fuel deceleration cut-off.

" The change in the MAP is less than a
predetermined value during the EGR flow test.
.. All conditions. present for 2 seconds.

lamp (MIL) when the diagnostic runs and fails.
O
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

A History DTG clears after 40 consecutive
Diagnostic: Aids
Important:
prevent contaminate intrusion into the PCM.
component harness connector, use the J 35616-A
connector test adapter kit. Using this kit prevents
damage to the harness/component terminals.
Refer to Using Connector Test Adapters in Wiring
Systems.
1. Use a scan tool in order to clear info. Run the
EGR flow test in order to verify a repair. Keep
the followlng items in mind when running the EGR
flow test:
The PCM runs the EGR flow test during a
gradual deceleration.
The PCM runs the EGR flow test during a
closed throttle condition.
The PCM runs the EGR flow test at vehicle
speeds between 42 km/h (26 MPH) and
113 km/h (70 MPH).
Several deceleration cycles will be necessary
to run a sufficient number of EGR flow test
samples (9-12).
Vacuum restriction to the MAP sensor.
A restriction to the MAP sensor can cause the
EGR flow test to fail due to insufficient MAP
changes being monitored during the test.
Inspect for objects blocking the vacuum 10 the
MAP sensor.
An engine that is running poorly may cause
this DTC to set.
Poor connections or a damaged harness.
" If the harness appears to be OK, observe the
Actual EGR Position display on the scan tool
while moving connectors and wiring harnesses
related to the EGR valve. A change in the
display indicates the location of the
malfunction.
3. For an intermittent, refer to Symptoms.
Engine
6-1609
Test Description
diagnostic table.
2. This OTC is set when the PCM does not detect a
predetermined change in MAP when the EGR
valve is commanded. A malfunctioning MAP
sensor may cause this OTC to set.
.
Step

Action
Is there any MAP DTC's set?
1. Inspect the exhaust system for modification of original

installed parts or leaks. Refer to Exhaust System
Inspection in Engine Exhaust.
2. Repair the exhaust system as necessary if you locate
Value(s)
No
Go to Step 2
Go to the A
Powerlrain On
Board
Diagnostic (080)
System Check
Go to the
applicable DTC
Go to Step 3
Go to Step 7
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 7
Go to
Diagnostic Aids
Go to Step 8
Go to Step 2
Go to the
applicable
DTC table
System OK
a problem.
1. Inspect the EGR valve gasket and pipes for leaks.

2. 1.f you locate a problem, clean or replace the EGR
system components as necessary. Refer to EGR
System Cleaning.
Yes

Re{)lacement.
5
2. Visually and physically inspect the following items for

a leak and/or a restriction:
The EGR pintle
The EGR valve passages
1. Remove the EGR inlet and outlet pipes from the
exhaust manifold and the intake manifold.

2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. Correct the condition as necessary if a condition is
found. Refer to EGR System Cleaning.
the Clear DTC option using the scan tool.

. the Specific DTC option, then enter the OTC number
4. Operate vehicle within the Conditions for Running this
diagnosed?
6.;1610
Engine

B
Exhaust Gas
~~~)ulation
Valve
. .___._I
I..__I. . .___. . .l_______O
,....~---.
0.35 BLK 407
~ -
Ground
-=-
E ]
0.35 GRY 435
-r----;-J-1;- --~:,~ -r--
--t]~v---.
Ground
PCM
c1=BLU
D 10.35 BR~ 11456
C2=RED
LliJ
-~-~~-~;; ~1-~ __ ?? C~.35RE~ 1-6~~--------:J~
41
~~~o~r-
I
I
II
sv
ReIerence
EG; Pintle
p os1t1on
..
Signal
EGA Valve
ControI
C2
-=-
~~~~:~rain
I Module
I (PCM)
I
I
.I
>
~--------------------------------J
582396
Circuit Description
The ability of the PCM to control the EGR valve is
verified with this test. The PCM calculates an
error based on the difference between the actual EGR
position and the desired EGR position. The PCM
sets this OTC if the error is too great.

The desired EGR position is more than O percent.
.Conditions for Setting the DTC

The difference between the desired EGR position
and the actual EGR position is more than
20 percent.
The failure counter is more than a
predetermined value.

The PCM disables the EGR for the ignition cycle.
Lamp (MIL) on the second consecutive drive cycle
the diagnostic runs and fails.
" The PCM records the operating conditions the
first time the diagnostic fails. The PCM stores
this information in the Freeze Frame and/or the
Failure Records. If the diagnostic reports a failure
on the second consecutive ignition cycle, the
PCM records the operating conditions at the time
of the failure. The PCM writes the conditions
to the Freeze Frame and updates the Failure
records.

A History OTC clears after 4o consecutive

Use a scah tool in order to clear the MIUOTC.
Diagnostic Aids
Important:
" For any test that requires probing the PCM or a
connector test adapter kit Using this kit prevents
damage. to the hamess/c:omponent terminals.
Systems.
Test Description
Diagnostic Table.
2. This step determines if the EGR valve can be
commanded open.
3. Excessive resistance in the EGR control circuit or
the EGR ground circuit will result in the EGR not
responding correctly to the commanded EGR
position.
4. This step tests the EGR Valve control circuit.
5. This step tests the EGR Valve ground circuit.
6. Excessive resistance in the control circuit or the
ground circuit will cause this OTC to set. With
the EGR commanded to 100% the test lamp
should light with full intensity. Connect the test
lamp across the battery terminals and compare the
test lamp intensity to the EGR control circuit
intensity.
Engine
6-1611
OTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 6
Goto
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 14
Go to Step 16
Go to Step 15
Go to Step 7
Go to Step B
Go to Step 16
Go to Step 11
Go to Step 9
Go to Step 12
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 18

1. Idle the engine.

2. Command the EGR valve to 50% using the scan tool.
Does the engine run rough or stall?
10.
1. Idle the engine.

2. Command the EGR valve to 50% using the scan tool.
3. Monitor the Actual EGR position on the scan tool.
Is the Actual EGR Position within the specified range?
48-52%

4. Test the continuity of the EGR valve control circuit
using the DMM. Refer to Testing for Continuity in
Wiring Systems.
Is the resistance within the specified range?
0-2Q
Test the continuity of the EGR valve ground circuit using

the DMM. Refer to Testing for Continuity in Wiring
Systems.
Is the resistance within the specified range?
0-2Q

3. Probe the EGR control circuit using the J 34142-8
test lamp connected to ground. Refer to Probing
5. Command the EGR to the specified value using the
scan tool.
100%
Probe the EGR ground circuit using the J 34142-8 test

lamp connected to B+. Refer to Probing Electrical

3. Test the continuity of the EGR valve control circuit
Wiring Systems.
Does the DMM display continuity?
Test the continuity of the EGR valve control circuit using

the DMM connected to ground. Refer to Testing for
Test for continuity from the EGR control circuit to all other
circuits in the. PCM harness connector. Refer to Testing for
Does the DMM display continuity to any other circuit in the
PCM harness connector?
6-1612
Engine Controls - 5. 7l
Engine
DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance (cont'd)
Step ..
Action
Value(s)
1.. Turn OFF the ignition.

3. Test the continuity of the EGR valve ground circuit
using .the DMM. Refer to Testing for Continuity in
Wiring Systems.
12
Repair the EGR valve control circuit for an open, short to

ground or short to another circuit. Refer to Wiring Repairs
in Wiring Systems.
13
Repair the open in the EGR valve ground circuit. Refer to

11
14
15
.
16
17
18
Go to Step 13
-.
Go to Step 20
Repair the high resistance in the EGR valve ground circuit.


Wiring Systems.
necessary. Refer to. Repairing Connector Terminals. in
Wiring Systems.
Did find and correct the condition?
Go to Step 18
Go to Step 20

Replacement.
No
Repair the high resistance in the EGR valve control circ::uit.

1. Inspect for poor connections at the EGR v.alve

electrical connector. Refer to Testing for Intermittent
.
Wiring Systems.
Yes
Go to Step 20
-
Go to Step 20
..
Go to Step 20
Go to Step 17
..
.Do to Step 20
Go to .Step 20
Go to Step 19
19

Replace the PCM.
20

21
using thescan tool.
Does the .scan tool display any DTCs that you have not
diagnosed?
Go to Step 20
Go to Step 21
Go to the
. applicable
OTC table
Go to Step 2
System OK
Engine
6-1613
B
1____0
. . I~E~.~~.
...l_i___._.___
0.35 BLK 407
~~~--?~
Ground -=-
C1=BLU
C~.35RE~
~~I~
5V
Reference..
-=-
EGA Pintle
Position
Signal
C2
-r --~
Ground -=-
..
.
c2=RED
1~~~-~------~1
1
;
PCM
0.35 GRY 435
-T: ---;-J-
-~~~-~;;
I
I
I
EGA Valve
Control
~w.n:~rain
6.
I Module
l(PCM)
J.
1 ,1,,AII.
I ~
I
L--------------------------------J
Circuit Description
An Exhaust Gas Recirculation (EGR) system is used
in order to lower Oxides of Nitrogen (NOx) emission
levels. The EGR system accomplishes this by feeding
small amounts of exhaust gas back into the
combustion chamber. High combustion temperatures
cause NOx. Combustion temperatures are reduced
when the air/fuel mixture is diluted with the
exhaust gases.
The EGR valve is designed to accurately supply
exhaust gases to the engine without the use of intake
manifold vacuum. The EGR valve controls the
exhaust flow into the intake manifold from the exhaust
manifold through an orifice with a PCM controlled
pintle. The PCM controls the pintle position using
inputs from the Throttle Position (TP) sensor,
the Manifold Absolute Pressure (MAP) sensor and, the
Engine Coolant Temperature sensor. The PCM
commands the EGR valve in order to supply the
correct amount of exhaust gas recirculation for
the current engine operating conditions. This can be
monitored on a scan tool as the Desired EGR Position.
The PCM monitors the position of the EGR valve
through a feedback signal. The PCM supplies
a 5.0 volt reference and a ground to the EGR valve. A
voltage signal representing the EGR valve pintle
position is sent to the PCM from the EGR valve. This
feedback signal can also be monitored on a scan
tool and is the actual position of the EGR pintle. The
Actual EGR Position should always be near the
commanded or Desired EGR Position.

The ignition voltage is more than 11. 7 volts.

The EGR feedback signal voltage is less
than 0.14 volts.
All conditions are present for 10 seconds.
IMA1J
__11....
D 10.35 BR~ !1456
~. -~.~.~o;I -- ~TI~---41
IL0 c
582396

Failure Records.

Diagnostic Aids
Important:
Systems.
6-1614
Due to the moisture associated with exhaust systems,

the EGR valve may freeze and stick in colder
weather at times. After the vehicle is brought into a
warm shop for repairs, the valve warms and the
concern disappears. By monitoring the Actual EGR
and Desired EGR Positions on a cold engine with
a scan tool, the fault can be verified easily.
Test Description
diagnostic table.
2. If DTC P1635 sets at the same time, this indicates
that the 5 voltage reference circuit is either
shorted to a ground or shorted to a voltage. The
5 volt reference circuit is internally connected
within the PCM. The MAP sensor circuits may be
causing this OTC to set. Refer to DTC P1635
for further diagnosis.
E11gine
since the DTC .set. The Fail Counter and Pass
5. If the scan tool displays 5 volts, the EGR pintle

position signal, 5 volt reference circuit, and the
PCM are OK.
6. If the scan tool displays 5 volts, the EGR pintle
position signal circuit and the PCM are OK.
Engine
Step .
6-1615
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 11
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 14
Go to Step 8
2. Idle the engine.

2

Did DTC P1635 fail this ignition cycle?
Monitor the EGR pintle position voltage on Engine 1 Data
List on the scan tool.
Is the EGR pintle position voltage below the
specified value?
0.14V

5. Operate the vehicle. within the conditions required for
the DTC.
ignition?
2. Jumper the 5 volt reference circuit and the EGR pintle

5
signal circuit together at the EGR valve harness

connector.
3. Observe the EGR pintle position voltage display on
the scan tool.
Is the EGR pintle position voltage near the
specified value?
1. Connect the test lamp J 34142-B between B+ and the

EGR pintle position signal circuit at the EGR valve
harness connector.
the scan tool.
5 Volts
5 Volts
same side as the manufacturer's logo. Refer.to PCM

3. Test the 5 volt reference circuit for the.following:
an open
O a short to a ground
a short to a voltage
4. If you find the 5 volt reference circuit is open or
shorted, repair the circuit as necessary. Refer to
6-1616
Engine
DTC P0405' Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 10
Go toStep 14
Go to Step 13
Go to Step 14
Go to Step 12
1. Inspect the 5 volt reference circuit for a poor

connection at the PCM .. Refer to Testing for

Wiring Systems.

3. Test the EGR pintle position signal circuit for the
following:
Open circuit
Short to a ground
4. If you find the EGR pintle position signal circuit is
open or shorted to a ground, repair the circuit as
Systems.
10
1. Inspect the EGR pintle position signal circuit for a

Intermittent and Poor C9nnections in Wiring Systems.
Wiring Systems.
1. Inspect for poor connections at the EGR valve. Refer

Wiring Systems.
11

Wiring Systems.

12

Replacement.
13

Replace the PCM.
Go to Step 14
Go to Step 14

14


applicable.
15
diagnosed?
Go to Step 15
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1617
DTC P0410 Secondary Air Injection (AIR) System

iHot At All Times!
'" - - - - - - I ~:=~~;,~t;i~ition
I Wiring Systems
:
- - - - , Engine
AIR PUMP I Wiring
MiniFuse I Harness
1 ORN 1440
Junction
1OR:11440
30
L------------.1~0~1
C105
3 ORN 1440
8177
30RN 1440
3 ORN 1440
- - - ,. Engine
.--....----.....--, AIR
I Wiring
85 Pump I Harness
EB
F8
___
DJ
B
0.35 PNK/BLK 429
Junction
: Block 2
Relay I
L---
C101
Secondary
Air Injection
(AIR) Bypass
Valve
0.35 BAN 436

[
~:condary ,. 3_? ______
I
_.I
Injection
0.35 BAN 436
(AIR)
Pump
Air
Solenoid
Relay
--.._ Control
I
I
Air
Bypass
Valve
-.._Control
PCM
C1=BLU
C2=RED
~-----------------J
3 RED 78
3 BLK 150
8113
~ _~ _______ ,
_ __..
3 BLK 150
Ground Distribution
Schematics In
Wiring Systems
Powertrain
Control
Module
(PCM)
r------'
G106
~
582474
Circuit Description
The engine operates tor more than 2 seconds.
An AIR pump is used on this vehicle to lower tail pipe

emissions on start-up. The PCM supplies a ground
to the AIR pump relay, which energizes the AIR pump.
The PCM monitors the H02S voltages to diagnose
the AIR system.
During the AIR test the PCM activates the AIR pump
during closed loop operation. When the AIR is
activated, the PCM monitors the H02S voltages and
short term fuel trim values for both banks of the
engine. If the AIR system is operating properly, the
H02S voltages should go low and the short term fuel
trim should go high.
If the PCM determines that the H02S voltages tor
BOTH banks did not respond as expected during the
tests, DTC P0410 sets. If only one sensor responded,
the PCM sets either a DTC Pi 415 or Pi 416 to
indicate on which bank the AIR system is inoperative.
The engine run time is more than 15 seconds after

closed loop operation.

DTCs P0101, P0102, P0103, P0107, P0108,
. P0112, P0113, P0117, P0118, P0121, P0122,
. P0123, POi7i-P0175, P0200, P0300, P0335,
P0336, P0351-P0358,P0443, P0500, P0502,
P0503, P1258, and H02S DTCs not set.

The maximum air flow is 22 g/s.
The ECT is between 66C (15iF) and
110C (255F).
The IAT is more than -10C (14F).
The engine load is less than 42.5 percent.
Not operating in power enrichment mode OR
deceleration fuel cut-off mode.
In short term Fuel Trim cells 1, 2, and 5.

H02S voltage does not go below 222 mV for
i second, when the AIR pump turns ON
during closed loop operation.
Short term fuel trim does not change a
predetermined value, when the AIR pump turns
ON during closed loop operation.
6-1618
Engine

diagnostic fails, the PCM stores. this information in
Failure Records.

Diagnostic Aids
Important:
diagnosing/replacing the PCM, Ensure that the
Systems.
Excessive resistance in any circuit related to the

AIR system may cause this DTC to set. Listen
for an audible click as the AIR solenoid and
the AIR relay are commanded ON and OFF. If
either component does not operate when
commanded ON and OFF, and no other OTC is
set, inspect the related circuits for excessive
resistance.
The scan tool offers three modes of AIR output
controls. AIR Pump Relay, AIR Solenoid, and
AIR System. Select the AIR System function for
all AIR diagnostics.
If air is present at both outlet hoses when the AIR
system is enabled, inspect the AIR check valves
and pipes for damage or restrictions.
For underhood fuseblock terminal identification,
refer to Electrical Center Identification Views in
Wiring Systems.
Test Description
The.numbers below refer to the step numbers on the
diagnostic table.
2. The AIR pump fuse is located in the engine 'Niring
harn.ess junction block #1.
3. If the AIR pump fuse is OK, then diagnose
OTC P0412 or P0418 first.
5. The AIR pump relay is located in the engine
wiring harness junction block #2.
13. Inspect for intermittent shorts to ground or
connections, if the AIR pump functions properly.
22. Inspect the circuits for a short to ground between

the AIR pump fuse and the AIR pump relay.
Also inspect the circuit for a short to ground
betw~en the splice and the AIR solenoid valve.
Engine
6-1619
DTC P0410 Secondary Air Injection (AIR) System

Action
Step

1
Is the AIR Pump fuse OK?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go .to Step 15
Go to
DTCP0412
Secondary Air
Injection (AIR)
Solenoid Control
Circuit or
OTC P0418
Secondary Air
Injection (AIR)
Pump Relay
Control Circuit
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 6
Go to Step 19
Go to Step 26
Go to Step 7
Go to Step 8
Go to Step 20
Go to Step 29
Go to Step 21
Go to Step 10
Go to Step 25
Is OTC P0412 or P0418 also set?

4
3. Enable the AIR system with a scan tool in output

controls.
Does the AIR pump turn ON?
Important: Refer to Electrical Center Identification Views

in Wiring Systems for relay terminal identification.
2. Disconnect the AIR pump relay.
4. Probe the AIR pump relay B+ supply circuit terminal

(switch side of relay) using the test lamp J 34142-8
conriected to a ground. Refer to Using Connector
Jumper the B+ terminal to the AIR pump feed circuit at the

relay harness connector using a fused jumper wire. Refer
to Using Fused Jumper Wires in Wiring Systems.
Does the AIR pump turn ON?
1. The jumper still installed.

2. Disconnect the AIR pump electrical connector.
3. Probe terminal A of the AIR pump electrical connector

using the test lamp J 34142-8 connected to battery
ground. Refer to Using Connector Test Adapters in
Wiring Systems.
1. The jumper still installed.
2, Connect the test lamp J 34142-B from terminal A to

terminal B of the AIR pump harness connector.
1. Disconnect the vacuum source from the AIR solenoid

valve. Refer to AIR Solenoid Valve Replacement.
2. Connect a vacuum gauge to the vacuum source.

Is an engine vacuum displayed on the vacuum gauge?
6-1620
Engine

DTC P04l0 Secondary Air Injection (AIR) System (cont'd)
Step
10
Action
2. Reconnect the vacuum source to the AIR
solenoid valve.
3. Disconnect the vacuum hose to the AIR shut off valve
at the AIR solenoid valve.
4. Connecta vacuum gauge to the AIR solenoid
valve port.
Value(s)
11
12
13
14
15
No
Go to Step 11
Go to Step 28
Go to Step 12
Go to Step 25

6. Enable the AIR system with a scan tool in output
controls.
Is an engine vacuum indicated on the vacuum gauge
when the AIR system is enabled?
2. Reconnect the vacuum hose to the AIR
solenoid valve.
3. Disconnect the vacuum hose from the AIR Shut-off
valve. Refer to Secondary AIR Injection Shut Off
Valve Replacement.
4. Connect a vacuum gauge to the AIR shut off supply
vacuum hose.
6. Enable the AIR system with the scan tool in output
controls.
Is an engine vacuum indicated on the vacuum gauge
when the AIR system is enabled?
Yes

2. Install the vacuum hose to the AIR shut OFF valve.
3. Disconnect the AIR supply hose (from the AIR pump)
at the connector (located near the left wheel well).
controls.
Is air present at the AIR shut off valve supply hose?
1. Connect the AIR shut off valve supply hose.

2. Disconnect both AIR hoses from the AIR pipe check
valves.
controls.
Is air present at both hoses?
1. Inspect the AIR hoses for restrictions or damage.

2. If you find an AIR hose restricted or damaged, repair
as necessary.

2. Remove the AIR pump relay from the underhood
electrical center 2.
3. Remove the AIR pump fuse from the underhood
electrical center 1.
4. Disconnect the AIR solenoid harness connector.
5. Probe the battery feed terminal for the AIR pump
relay harness connector with the test lamp J 34142-8
connected to B+.
Go to Step 24
Go to Step 13
Go to
Diagnostic Aids
Go to Step 14
Go to Step 31
Go to Step 27
(
Go to Step 22
Go to Step 16
Engine
6-1621
OTC P0410
Secondary Air Injection (AIR) System (cont'd)
.
Step
16
17
18
Action
Value(s)
1. Disconnect the AIR pump harness connector.

2. Probe the AIR pump electrical connector terminal A
(harness side) with the test lamp J 34142-B
connected to B+.

2. Re-install the following components/electrical
connector:
A new AIR pump fuse
The AIR pump relay
The AIR solenoid
controls.
Does the AIR pump fuse open?
1. Connect the AIR pump electrical connector.

2. Enable the AIR pump with a scan tool in output
controls.
Repair the open circuit between the fuse and the relay.
Repair the open circuit between the AIR pump and the
AIR relay. Refer to Wiring Repairs in Wiring Systems.
Repair the faulty ground connection or the open ground

Repair the short to ground in the ignition feed circuit. Refer

Repair the short to ground in the circuit between the AIR

pump relay and the AIR pump. Refer to Wiring Repairs in
Wiring Systems.
1. Inspect the AIR inlet hose and AIR outlet hose from
the AIR pump for restrictions or damage.
2. Repair the restriction or damage to the AIR hose.
25
Repair the vacuum hose as necessary.

26
Replace the AIR pump relay.

27
Replace the AIR Shut-off valve. Refer to Secondary AIR

Injection Shut Off Valve Replacement.
Replace the AIR solenoid valve. Refer to AIR Solenoid

Valve Replacement.
20
21
22
23
24
28
No
Go to Step 23
Go to Step 17
Go to Step 28
Go to Step 18
Go to Step 30
Go to
Diagnostic Aids
Does the AIR pump fuse open?

19
Yes
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
Go to Step 31
-
Go to Step 31
6-1622
Step
29
Engine

DTC P0410 Secondary Air Injection (AIR) System (cont'd)
Value(s)
Yes
Action
1. Inspect for poor connections at the AIR pump
2. Repair the poor connection as necessary. Refer to
Replace the AIR pump. Refer to Secondary AIR Injection

Pump Replacement

30
No
Go to Step 31
Go to Step 30
Go to Step 31

scan tool.

31

Trouble Code (OTC) option using a scan tool.

Go to Step 32
32
Go to the
applicable
OTC table
System OK
Engine
6-1623
DTC P0412 Secondary Air Injection (AIR) Solenoid Control Circuit

lHot At All Times!
~
~w; ;;;tr;uti-;;-n - '."'" - - - -
AIR PUMP
Wmng
MiniFuse I Harness
Schematics In
I Wring Systems
I
1
L
30A
___
I
.
Junction
.,1Block 1
$177
3 ORN 1440
3 ORN 1440
C101
-------AIR
I Wiring
30
85 Pump I Harness
:
I
L--- ---ES
F8
Secondary
Air In.j.ection
[ ] (AIR) Bypass
Valve
B
0.35 PNK/BLK 429
Relay I
Junction
: Block 2
- Fs - - - - si - - - ., Engine
C105
1OR: 11440
3 ORN 1440
fi::l
L::'.J
1 ORN 1440
~ E~Qine
0.35 BRN 436
/!------~-~-------,
~~condary
Injection
Air
I
Solenoid
(AIR)
1 " T Relay
Pump
I
--.._ Control
---.1
0.35 BRN 436
I
I
____________________...... 3 BLK
8113
Air
Bypass
" f Valve
-.._ Control
~
150
Ground Distribution
_ _..,. Schematics In
Wiring Systems
3 BLK 150
r-----..a
PCM
I
I
C1=BLU
C2=RED
~-----------------J
Powertrain
3 RED 78
,..._
G106
Control
Module
(PCM)
~
582474
Circuit Description
The PCM controls the relay by grounding the control
circuit via an internal switch called a driver. The
has a fault line which the PCM monitors. When the
PCM commands a component ON, the voltage of the
control circuit should be low (near O volts). When
the PCM commands the control circuit to a component
OFF, the voltage potential of the circuit should be
high (near the battery voltage). If the fault detection
circuit senses a voltage other than what is expected,
the fault line status changes causing the OTC
to set.

18 volts.

All the above conditions are present for a minimum
of 5 seconds.

e The PCM records the operating conditions at the
Failure Records.

6-1624
Engine
Diagnostic Aids
Important:
., Remove any debris from the PCM connector
Systems.
" The scan tool offers three modes of AIR output
controls. AIR pump relay, AIR solenoid, and
AIR system.

refer to Electrical Center Identification Views in.
Wiring Systems .
Test Description
diagnostic table.
3. Listen for an audible click when the solenoid valve
operates. Be sure that both the ON and the OFF
states are commanded. Repeat the commands
as necessary.
5. Tests for voltage to the AIR solenoid valve.
AIR solenoid valve.
7. Tests if a ground is constantly being applied to
the AIR solenoid valve.
DTC P0412 Secondary Air Injection (AIR) Solenoid Control Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0410
Secondary Air
Injection (AIR)
System
G.o to Step 3
Go to Step 4
Go to Step 5
Go to Step 5
Go to
Intermittent
Conditions

Inspect the AIR pump fuse

Is the AIR pump fuse open?

3. With a scan tool, command the AIR solenoid valve
ON and OFF.
Does the AIR solenoid valve turn ON and OFF with each
command?

data for this OTC.
4. Operate the vehicle within the Conditions for running
the OTC as specified in the supporting text or as
close to the Freeze Frame and/or Failure Records
data that you observe.
Does the OTC reset?
..
..

2. Disconnect the AIR solenoid valve electrical
connector.
3. Turn ON the ignition, with the ignition OFF.
4. Probe the AIR solenoid valve B+ supply circuit with
the test lamp J 34142-8 connected to ground. Refer

AIR solenoid valve and the B+ supply circuit of the
AIR solenoid valve.
2. With a scan tool, command the AIR solenoid valve
ON and OFF.
command?
..
Go to Step 6
. Go to Step 12
Go to Step 10
Go to Step 7
Engine
6-1625
OTC P0412 Secondary Air Injection (AIR) Solenoid Control Circuit (cont'd)
Step
Value(s)
1. Test the control circuit of the AIR solenoid valve for

the following:
short to voltage
an open
1. Test the control circuit of the AIR solenoid valve for a

short to ground. Refer to Circuit Testing in Wiring
Systems.
Did you find and correct the condition? .
10
1. Inspect for poor connections at the AIR solenoid

valve. Refer to Testing for Electrical lntermittents in
Wiring Systems.
11

Testing for Electrical lntermittents in Wiring Systems.
12
Repair the B+ supply circuit for the AIR solenoid valve.

Replace the AIR solenoid val.ve. Refer to AIR Solenoid

Valve Replacement.
14

Replace the PCM.
15

2. Operate the vehicie within the Conditions for Running
as specified in the supporting text.
16
With a scan tool, review the Stored information

(Capture Info).
Does the.scan tool display any DTCs that you have not
diagnosed?
13
Action
command?
Yes
No
Go to Step 9
Go to Step B
Go to Step 15
Go to Step 11
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 15
Go to Step 15
Go to Step 2
Go to Step 16
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
6":.1626
Engine
DTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit
IHot At All TimesI

r - - - - - - I Power Distribution
- - - - ., Engine
I
Wiring
Harness
I
H6
so A
I Junction
~ ____________ ~ Block 1
Schematics In
I Wiring Systems
AIR PUMP
MiniFuse I
3 ORN 1440
Wiring
Harness
I Junction
I Block 2
- - - - - - - , , - - , AIR
I
85 Pump I
F8
!..---
C101
'" - Fs - - - - ~ - - - ., Engine
EB
C105
Secondary
Air lnje..ction
[ ] {AIR) Bypass
Valve
3 ORN 1440
,__....,._______,,,_ae_.
1 ORJ1.MO
30RN 1440
$177
Relay
1 ORN 1440
B.
0.35 PNK/BLK 429

A
1
J
0.35 BRN 436
! ______ ~ _~.- ______ .,
;:condary r 3
Injection
___ .
I
1
(AIR)
Pump
0.35 BRN 436
I
I
I
Air
Solenoid
Relay
--.._ Control
=
" f
"
Air
Bypass
Valve
--~ Control
=
-f
PCM
C1=BLU
C2=RED
I
I
!..------ __________ ..
3 RED 78
3 BLK 150
8113
_ __.,..
3 BLK 150
Ground Distribution
Schematics In
Wiring Systems
Powertrain
Control
Module
(PCM)
r-----..1
G106
582474
Circuit Description
The PCM controls the relay by grounding the control
circuit via an internal switch called a driver. The
the driver is to supply the ground
primary function
for the controlled component. Each driver has a
fault line which the PCM monitors. When the PCM
commands a component ON, the voltage of the control
circuit should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
the battery voltage). If the fault detection circuit senses
voltage other than what the PCM is expects, the
fault line status changes causing the DTC to set.
The relay controls the high current flow to the
AIR injection pump. This allows the PCM driver to only
have to control the relatively low current used by
the relay.
of

" The engine speed is more than 400 RPM.
18 volts
Action Taken When .the DTC Sets

time the diagnostic fails. The first time the .
diagnostic fails, the PCM stores this informa1ion in
failure on the second consecutive. ignition
at the tlme of the failure. The .PCM writes the
conditions to the Freeze.Frame and updates the
Failure Records.

A last test failed (current DTC) clears when 1he
A History DTC clears.after 40 consecutive

.. All the above conditions are present for a minimum
of 5 seconds.
Engine
Diagnostic Aids
')
Important:
Systems.
The scan tool offers three modes of AIR output
controls. AIR pump relay, AIR solenoid, and
AIR system.
6-1627

refer to Electrical Center Identification Views in
Wiring Systems.
Test Description
diagnostic table.
Be sure that both the ON and the OFF states are
commanded. Repeat the commands as
necessary.
5. Tests for voltage at the coil side of the AIR
pump relay.
AIR pump relay.
7. Tests if a ground is constantly being applied to
. the AIR pump relay.
DTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit
Action
Step

1
Inspect the AIR pump fuse

Is the AIR pump fuse open?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
DTCP0410
Secondary Air
Injection (AIR)
System
Go to Step 3
..

3. With a scan tool, command the AIR pump relay ON
and OFF.
Does the AIR pump relay turn ON and OFF with each
command? ..

data for this DTC.
the DTC as specified in the supporting text or as
close to the Freeze Frame and/or Failure Records
Does the DTC reset?
1.
2.
3.
4.

Disconnect the AIR pump relay.
Turn ON the ignition, with the ignition OFF.
Probe the AIR pump relay B+ supply circuit with the
test lamp J 34142-8 connected to ground. Refer to
Go to Step5
Go to Step 5
Go to
Intermittent
Conditions
Go to Step 6
Go to Step 12
Go to Step 10
Go to Step 7

1 . Connect a test lamp between the control circuit of the
AIR pump relay and the B+ supply circuit of the AIR
pump relay.
2. With a scan tool, command the AIR pump relay ON
and OFF.
command?
Go to Step 4
6-1628
Engine
DTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit (cont'd)
Step
Action
Value(s)

command?
1. Test the control circuit of the AIR pump relay for the
following:
short to voltage
an open
1. Test.the control circuit of the AIR pu,mp relay for a

Systems.
1. Inspect for poor connections at the AIR pump relay.

Refer to Testing for Electrical lntermittents in Wiring
Systems.
11

Testing tor Electrical lntermittents in Wiring Systems.
12
Repair the B+ supply circuit for the AIR pump relay. Refer
Replace the AIR pump relay. Refer to Secondary Air

Injection Pump Relay Replacement.
Important: Program the replacement PCM. Refer to PCM :

Replace the PCM.
10
13
14
15
16

as specified in the supporting text.
(Capture Info).
diagnosed?
Yes
No
Go to Step 9
Go.to Step B
Go to Step 15
Go to Step .11
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 15
Go to Step 1q
..
Go to Step 2
Go .to Diagnostic
Trouble
Code (OTC)
List/Type
Go to Step 16
;
System OK
Engine
6.;;1629
DTC P0420 Catalyst System low Efficiency Bank 1

Circuit Description
In order to. maintain a reasonably low emissions of

Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx), the engine controls system
uses a three-way catalytic converter. The catalyst
within the converter promote~ a chemical reaction
gas. This reaction converts them into harmless
watervapor and Carbon Dioxide. The catalyst also
reduces NOx, converting it to Nitrogen. The PCM
monitors this process using Bank 1 H02S #2. Bank 1
H02S #2, located in the exhaust stream past the
three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst. This determines the catalysts ability to
convert exhaust emissions effectively. If the catalyst is
functioning correctly, the Bank 1 H02S #2 signal
will be far less active than that produced by Bank 1
H02S #1. This indicates that the three-way catalytic
converters oxygen storage capacity is below a
threshold considered acceptable.
When the conditions for running this DTC are met, the
following occurs:
The PCM captures the current mar H02S
rich/lean status.
The Air Fuel ratio transitions from rich to lean or
lean to rich depending on the capture rear
H02S rich/lean status.
The Air Fuel ratio transitions a second time
opposite the first Air Fuel ratio transition.
O The PCM captures the response time (the time
the H02S goes from below 300 mV to above
600 mV and from 600 mV to below 300 mV) of the
front and rear Heated Oxygen sensors when
the Air Fuel ratio transitions occurred.
The PCM measures the time it takes the rear
H02S voltage to cross a reference rich/lean
threshold minus the time it takes the front H02S
voltage to cross the same rich/lean threshold.
The time difference from the front and rear H02S
is the oxygen storage capacity of the catalyst.
This DTC sets if the time exceeds a predetermined
threshold.

DTCs, P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0171, P0172, P0174, P0175,
P0200, P0230, P0300, P0325, P0327, P0332,
P0335, P0336, P0341, P0342, P0343,
P0351-P0358, P0401, P0404, P0405, P0410,
P0412, P0418, P0440, P0442, P0443, P0446,
P0449, P0500, P0704, P0801, P0803, P1258,
P1336, P1404, P1415, P1416, P1441 and H02S
DTCs not set.
The engine is operating for longer than
400 seconds.
.. The ECT is between 80C (176F) 120C.(248F).

The IATis between-15C (5F) and
.
75C (167F).
" Engine speed is more than 900 RPM for a
minimum of 22 seconds (manual transmission) or
25 seconds (Automatic Transmission) since
the end of the last idle test.

.The BARO is rnore than 74 kPA.
The fuel system is operating in closed loop.

The PCM determines the oxygen storage capability of
the catalytic converter has degraded below a
calibrated threshold.
.Action Taken When the DTC Sets

Records.

warmsup cycles, if this or any other emission
Diagnostic Aids
If the H02S parameter is monitored using a scan tool
while this diagnostic is running, the H02S voltages
may be fixed low or high.
Test Description
diagnostic table.
4. Before replacing the Three-Way Catalytic
Converter, correct any conditions which may have
damaged the catalyst.
6-1630
Step
Engine

Value(s)
Action
Yes
Go to Step 2
Go.to A
Powertrain Oh
Board
Diagnostic (OBD)
System Check
Go to the
applicable
DTC table
Go to Step 3
Go to Step 5
Go to Step 4

Verify that the three-way catalytic converter is an
original equipment part.
Inspect the three-way catalytic converter for damage
(dents, severe discoloration caused by excessive
temperature, holes, etc.).
Insure that the internal three-way catalytic converter
rattle caused by damaged catalyst is not present.
Inspect the exhaust system for leaks, damage, or
loose or missing hardware (area from converter to
H02S #2 primarily). Refer to Exhaust System
Insure that the H02S #1 and the H02S #2 are secure
and that the pigtails and wiring are not damaged or
contacting the exhaust.
No
Replace the catalytic converter. Refer to Oxidation

Catalytic Converter Replacement (5. 7 L Left) in Engine
Exhaust.

3. Select the Diagnostic Trouble Code {DTC) option and
applicable.
diagnosed?
Go to Step 5
Goto Step 6
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
s~1 s31

Circuit Description
In order to maintain a reasonably low emissions of
Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx), the engine controls system
uses a three,way catalytic converter. The catalyst
gas. This reaction converts them into harmless
water vapor and Carbon Dioxide. The catalyst also
reduces NOx, converting it to Nitrogen. The PCM
monitors this process using Bank 2_ H02S #2. Bank 2
H02S #2, located in the exhaust stream past the
three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst. This determines the catalysts ability to
convert exhaust emissions effectively. It the catalyst is
functioning correctly, the Bank 2 H02S #2 signal
will be tar less active than that produced by Bank 2
H02S #1. This indicates that the three-way catalytic
converters oxygen storage capacity is below a
threshold considered acceptable.
When the conditions tor running this OTC are met, the
following occurs:
The PCM captures the current rear H02S
rich/lean status.
The Air Fuel ratio transitions from rich to lean or

lean to rich depending on the capture rear
H02S rich/lean status.
The Air Fuel ratio transitions a second time
opposite the first Air Fuel ratio transition.
The PCM captures the response time (the time
the H02S goes from below 300 mV to above
600 mV and from 600 mV to below 300 mV) of the
front and rear Heated Oxygen sensors when
the Air Fuel ratio transitions occurred.
The PCM measures the time it takes the rear
H02S voltage to cross a reference rich/lean
threshold minus the time it takes the front H02S
voltage to cross the same rich/lean threshold.
The time difference from the front and rear H02S
is the oxygen storage capacity of the catalyst.
This OTC sets it the time exceeds a predetermined
threshold.
DTCs, P0101, P0102, P0103, P0107, P0108,

P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0171, P0172, P0174, P0175,
P0200, P0230, P0300, P0325, P0327, P0332,
P0335, P0336, P0341, P0342, P0343,
P0351-P0358, P0401, P0404, P0405, P0410,
P0412, P0418, P0440, P0442, P0443, P0446,
P0449, P0500, P0704, P0801, P0803, P1258,
P1336, P1404, P1415, P1416, P1441 and H02S
OTCs not set.
The engine is operating for longer than
400 seconds.
The ECT is between 80C (176F) 120C (248F).

The IAT is between-15C (5F} and
75C (167F).
Engine speed is more than 900 RPM tor a
minimum of 22 seconds (manual transmission) or
25 seconds (Automatic Transmission) since
the end of the last idle test.
The. BARO is more than 74

. kPA.
.
The fuel system is operating in closed loop.

The PCM de_termines the oxygen. storage capability of
the catalytic converter has degraded below a
calibrated threshold.

The PCM illuminates the malfunction .indicator
lamp (MIL} when the diagnostic runs and fails.
The PCM records the operating conditions. at the
Records.

lamp (MIL} OFF aft.er 3 c6nsecutiveJgnition cycles
that the diagnostic runs and does.not fail.
A last test failed (current OTC} clears when the
warm-up cycles, it this. or any other emission
Diagnostic Aids
If the H02S parameter is monitored using a scan tool
while this diagnostic is running, th_e H02S voltages
may be fixed low or high.
Test Description
diagnostic table.
4. Before replacing the three-way catalytic converter,
make sure that any conditions which may have
caused the catalyst to be damaged have
been corrected.
6-1632
Engine
DTC P0430 Catalyst System Low Efficiency Bank 2

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to the
applicable
OTC table
Go to Step 3
Go to Step 5
Go to Step 4
Did you perform the Powertrain On-Board .


Verify that the three-way catalytic converter is an
original equipment part.
Inspect the three-way catalytic converter for damage
such as dents, severe discoloration caused by
excessive temperature, holes, etc.
Insure that internal three-way catalytic converter rattle
caused by damaged catalyst is not present.
Inspect exhaust system for leaks, damage, or loose or
missing hardware in the area from the converter to the
H02S #2 primarily. Refer to Exhaust System
Insure that the H02S #1 and the H02S #2 are secure
and that their pigtails and wiring are not damaged or
contacting the exhaust.
Replace converter. Refer to Oxidation Catalytic Converter

Replacement (5. 7 L Right) in Engine Exhaust.
Go to Step 5
1. Select the Diagnostic Trouble Code {OTC) option and

applicable.
diagnosed?
Go to Step 6
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1633
I Hot With lgn 1 Relay Energized I

~ Pow-;;r Distrib:;iio;;I Schematics In
Wiring systems
- - - - ~ ~Qine
ENG CTRL I
mng
MlnlFuse Harness
1s A
- -
.;... _ _ _ J
02
C200B
C200D
0.5 PNK 239
Junction
Block 2
A2
0.5 PNK 239

P100
8182 _ _ _0_.5_P_N_K_--irni--~
239
C405B
C405D
0.35 PN: 239
AI
Evapora.tive
Emission
(EVAP)
Canister
0.5 PNK 239

G C100
!Automatic I
0.5 PNK 239
Power
Distribution
In Wiring
Systems
0.5 PNK
239
S107
0.5 PNK 239
A
Evaporative
Emission
[ ] (EVAP)
Canister
~~~~=
BI
LJiJ
1~:~e
0.35 WHT 1310

B
82
0.5 WHT
C
C405D
C405B
1310
C230
0.5WHT11310
0.35 DK GRN/W~: ~2~- - - - - - - - - ________________4_*:110
'" - - - - - 8/AP -,- - - - - - - - - - - - -EVAP -, - - I

I
I
I
PCM
C1=BLU
C2=RED
Canister
Purge
Valve
Control
-,1
.,,.
Canister
Vent

Valve
Control .
.,,.
--1
~ Powertrain
Control A
Module Jiii"
I (PCM) ~
L-----------------------~-----J
582399
Circuit Description
The PCM tests the EV AP system for the following

condilions:
Large and small leaks
" Excess vacuum
" Purge flow during non-commanded conditions
" Fuel Level and Fuel Pressure sensor faults
O EVAP Purge and Vent Valve faults
The PCM monitors the Fuel Tank Pressure sensor in
order to determine the level of vacuum/pressure in
the EVAP system. The PCM commands both .the
EVAP Purge Solenoid and the EVAP Vent Valve ON
when the Conditions for Running the OTC are met
in order to apply an engine vacuum to the EVAP
system: The PCM commands the EVAP Purge
Solenoid OFF once the system has reached a
predetermined level of vacuum. This test verifies if a
vacuum can be achieved in the EVAP system.
Failure to develop a vacuum may be caused by a
large leak or a restriction. This OTC sets after twice
failing the above test.
" DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122, P0123, P0125, P0420,
P0430, P0500, P0502, P0503, P0562, P0563,and
H02S OTCs are not set.
The ignition voltage is between 10 volts and
17 volts.
The fuel level is between 15 percent and 85

percent of full capacity.
(39F) and 30C (86F).
The intake air temperature is between 4C (39F)
and 30C (86F).
The start up engine coolant and intake air
temperatures are within 9C (16F) of each other.

Important: This OTC does NOT report a first failed
test. A first fail of this OTC will have a scan tool status
as Not Run. Use the scan tool data display parameter
of EVAP Test Result to determine if this OTC has
failed or passed for this ignition cycle.
The EVAP system cannot develop a vacuum that is
more than a predetermined value.

Records.
6-1634

A last test failed (current DTC) clears when. the
Diagnostic Aids
Important:
Systems.
An accurate indication of fuel level is required for the
PCM to properly Pass or Fail this DTC. Always
diagnose fuel level sensor DTCs before performing
this DTC diagnostic table. Always inspect for fuel level
sensor DTCs stored as History.
Perform a physical inspection of the EVAP system.
A loose, missing, defective, or incorrect fuel
tank cap
" A loose or missing EV AP service port cap.
" A loose, missing, or damaged schrader valve.
" Incorrectly routed or defective EVAP system
vacuum and vapor lines
.. A malfunctioning or damaged vapor canister
.. A damaged fuel sender 0-ring
Inspect for charcoal release from the vapor canister.
Refer to the EVAP System Cleaning procedure.
Excessive resistance in any circuit related to the EVAP
system may cause this DTC to set. Listen for an
audible click as the EV AP vent solenoid and the EVAP
purge solenoid are commanded using the scan tool.
If either component does not operate when
commanded ON and OFF, and no other DTC is set,
inspect the related circuits for excessive resistance.
Engine
The vacuum and pressure in the EV AP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches of Hg (mercury) and
pressure in psi (pounds per square inch). The following
table shows how the values compare:
in. H20
1 in. H20
5 in: H20
10 in. H20
. 15 in. H20
in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10in.Hg
psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.
Conditions for Running the Service Bay Test

" The Service Bay Test may have to be performed
in cold ambient air temperatures when the
vehicle is running a winter grade fuel. The scan
tool displays a message when the service bay test
does not run.
- The battery voltage is between 10.5 and
17.5 volts.
- The fuel level is between 15 percent and
85 percent of the full capacity.
- The engine temperature is between 3.5C
(38F) and 35C (95F).
The scan tool displays Test Aborted if any of the
above conditions are not met.
.. Using Freeze Frame and/or Failure Records data
you cannot duplicate the DTC, the information
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
.. For an intermittent, refer to Symptoms.
Test Description
Diagnostic Table.
3. It may be necessary to partially lower the fuel tank
to inspect the upper portion of the tank and the
EVAP line connections.
4. An intermittent leak or restriction is indicated if the
vehicle passes the Service Bay Test. A fuel tank
cap that is loose or off causes this DTC to set.
If the Service Bay Test can not be run, proceed to
step 5. If a fault is not currently present the
diagnostic table steps will return you to step 3.
(.
Engine
12. This step tests for a leak at the top of the fuel
tank, at the fuel filler hose, and the fuel cap. Place
the u.ltrasonic leak detector in these areas.
Refer to the information supplied with the EVAP
pressure/purge diagnostic cart on proper setup
and adjustment procedures.
13. With pressure applied it may be necessary to
disconnect the EVAP lines at the components
to verify that a line or component is not restricted.
A restriction would prevent a vacuum (or the
Step 10 test pressure) from forming in the
fuel tank.
\)

19. A Fuel Tank Pressure sensor that does not
correctly respond to pressure (or vacuum) causes
this OTC to set.
The Fuel Tank Pressure sensor range is from
7.5 in. H20 of pressure to -17.5 in. H20 of
pressure (vacuum).
In order to test the Fuel Tank Pressure sensor for
vacuum response, command the EVAP Purge
Solenoid Valve ON with the engine running
and quickly SEAL the system. Leaving the EVAP
Purge Solenoid Valve ON for a longer period
of time allows a greater level of vacuum to
develop.
6-1636
Engine
OTC P0440 Evaporative Emission (EVAP) System

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to the
applicable
OTC table
Go to Step 3
Go to Step 21
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5

Are any other EVAP system DTC's stored in history?
1. Inspect the EVAP system for the following conditions:

A loose; incorrect, defective or missing fuel
tank cap.
Disconnected, improperly routed, kinked or
damaged EVAP system purge lines.
A damaged EV AP system component.
A loose, missing, or damaged service port dust
cap and/or schrader valve. Refer to the test
description for additional information.
2. Repair the EVAP system if needed.
Important: Ensure. that The Conditions for Running the

Service Bay test are met before proceeding with this
diagnostic. Refer to Diagnostic Aids.
Perform the EVAP system Service Bay Test using a
scan tool.
Does the EVAP diagnostic pass the Service Bay Test?
Important: The DTCs must be cleared from the PCM in

order to use the output control function on the scan tool.
1. Clear the DTCs using a scan tool.
3. Remove the EVAP Purge line from the EVAP Purge
Solenoid Valve.
4. Connect the J 23738-A hand held vacuum pump to
the vacuum port of the EVAP Purge Solenoid Valve.
5. Attempt to apply a vacuum up to the specified value
using the hand vacuum pump.
Can the value specified be obtained and held?
10 in Hg
Important: If an audible solenoid click cannot be heard

and OTC P0443 is not set, inspect the EVAP canister
purge solenoid circuits for high resistance.
1. Connect a vacuum gauge to the EVAP Purge
solenoid valve.
2. Idle the engine.
3. Command the EVAP Purge Solenoid Valve to
50% using a scan tool.
Is the vacuum measured on the gauge the same or more
12 in Hg

2. Remove the vacuum source from the EVAP Purge
Solenoid.
4. Idle the engine.
12 in Hg
Go to Step 6
Go to Step 15
Go to Step 8
Go to Step 7
Go to Step 15
Go to Step 14
Engine
6-1637
DTC P0440 Evaporative Emission (EVAP) System (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 9
Go to Step 18
Go to Step 12
Go to Step 10
Go to Step 16
Go to Step 11
Go to Step 21
Go to Step 17
Go to Step 21
Go to Step 13
2. Reconnect the EVAP purge line to the EVAP purge

solenoid.
3. Lower the fuel tank to gain access to the EVAP

canister. Refer to EVAP Canister Replacement.
8
4. Disconnect the EVAP purge line from the EVAP

Canister (line from the EVAP purge solenoid valve).
5. Connect the J 23738-A vacuum pump to the EVAP
purge line from the EVAP purge solenoid valve.
6. Using the J 23738-A vacuum pump, attempt to apply
a vacuum up to the specified value.
Can the specified value of vacuum be obtained and held?
5 in Hg

2. Disconnect the fuel tank vapor line from the EVAP
Canister.
3. Plug the EVAP canister port for the fuel tank
vapor line.
purge port on the EVAP canister.
6. Command the EVAP Vent Valve ON (closed) using a
scan tool.
7. Using the J23738-A vacuum pump, attempt to apply
10
1. Leave the system connected as in Step 9.

2. Disconnect the vent line at the EVAP Vent Valve.
3. Plug the vent line.
using the J 23738-A vacuum pump.
11
1. Inspect the EVAP Vent line from the canister to the

EVAP Vent Valve for leaks or missing/damaged
0ririg seals.
2. If you find a condition repair the EVAP system as
necessary.
5 in Hg
5 in Hg
Important: The following steps require the J 41413 EVAP

pressure/purge diagnostic station and the J 41416
12
ultrasonic leak detector.

Always zero the EVAP pressure and vacuum (in. H20)
gauges on the J 41413 EVAP pressure/purge diagnostic
station before proceeding with diagnosis.
2. Remove the plug and the hand vacuum pump.
3. Reconnect all the EVAP components.
4. Connect the J 41413 EVAP pressure/purge diagnostic
station to the EV AP system service port.
scan tool.
6. Continuously attempt to pressurize the EVAP system
by leaving the EVAP pressure/purge diagnostic
station control knob in the pressurize position.
7. Using the J 41416 ultrasonic leak detector locate and
repair EVAP system leak.
6-1638
Engine
DTC P0440 Evaporative Emission (EVAP) System (cont'd)

Step
13
14
15
16
17
18
19
20
21
22
Action
1. Inspect the EVAP system for restrictions. Refer to
Test Descriptions.
2. Repair as needed.
Repair the vacuum source to the EVAP Purge
Solenoid Valve.
Important: Inspect the EVAP Purge Solenoid Valve and
the purge line for carbon contamination. Refer to
Diagnostic Aids.
Replace the EVAP Purge Solenoid Valve. Refer to EVAP
Canister Purge Solenoid Valve Replacement.
Replace the EVAP Vent Valve. Refer to EVAP Vent Valve
Replacement.
Replace the EVAP Vapor Canister. Refer to EVAP
..
Replace the EVAP line from the EVAP Purge solenoid
valve to the EV AP canister. Refer to Fuel Hose/Pipes
Assembly Replacement (Rear).
.
1. With the EVAP system pressurized, compare the
EVAP pressure/purge diagnostic station pressure
gauge (in. H20) reading to the Fuel Tank Pressure
sensor reading on the scan tool.
2. Compare the readings with the system depressurized.
Refer to the Test Description.
Does the Fuel Tank Pressure sensor indicate the actual
amount of pressure in the EVAP system?
Replace the Fuel Tan.k Pressure sensor. Refer to Fuel
2. Idle the engine at the normal operating temperatun=i.
applicable.
Review the captured info on the scan tool.
Does the scan tool indicate any DTCs that have not been
diagnosed?
Value(s)
Yes
No
Go to Step 21
Go to Step 19
Go to Step 21
Go to Step 21
Go to Step 21
Go to Step 21
Go to Step 21
(
Go to Step 3
Go to Step 20
Go to Step 21
Go to Step 22
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1639

( Hot With lgn 1 Relay Energized
r - - - - - - I Power Distribution
Schematics In
: Wiring Systems
- .,
Engine
02
ENG CTRL I Wiring
MiniFuse Harness
1
Junction
15 A
_ _ _ _ .,I Block 2
1a. _ _ _ _ _ _ _ _
0.5 PNK 239

P100
8182 _ _ _0_._5_P_N_K_--1111--239
0.5 PNK 239
G C100
!Automatic I
C200B
C200D
0.5 PNK 239.
A2 C405B
C405D
0.35 PN: 239
AI
Evaporative
Emission
[ ] (EVAP)
Canister
0.5 PNK 239
Power
Distribution
In Wiring
Systems
0.5 PNK
239
BI
S107
~:~e
0.35 WHT 131 o
0.5 PNK 239

A
Evaporative
Emission
[ ] (EVAP)
0.5 WHT 1310
BI
0.5
B
B2
r~ter
C405D
C405B
~l~37:
0.35 DK GRN/W~: ~2-8- - - - - - - - - - - - ____ - ________4_;rc:110
8/AP -; - - - - - - - - - - - - -EVAP -, - - - , Powertrain
r - - - - I
PCM
Canister
I C1=BLU
Purge
I C2=RED
Valve
Canister
Vent
Valve
Control
I Control
I Module ~
--1
--1 1.(PCM) ~
~-----------------------------J
Control
.,,.
-=-
582399
Circuit Description
The PCM tests the EV AP system for the following
conditions:
Large and small leaks
EKcess vacuum
Purge flow during non-commanded conditions
Fuel Level and Fuel Pressure sensor faults
" EVAP Purge and Vent Valve faults
The PCM monitors the Fuel Tank Pressure sensor in
order to determine the level of vacuum/pressure in
the EVAP system. The PCM commands both the
EVAP Purge Solenoid and the EVAP Vent Valve ON
when the Conditions for Running the DTC are met
in order to apply an engine vacuum to the EVAP
system. The PCM commands the EVAP Purge
Solenoid OFF once the system has reached a
predetermined level of vacuum. The EV AP system
should HOLD the vacuum in the sealed system. The
PCM sets this OTC in order to indicate a small
leak if the EV AP system fails to hold a predetermined
level of vacuum for a predetermined length of time.
This DTC sets after failing the above test twice.

DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122, P0123, P0125, P0420,
P0430, P0500, P0502, P0503, P0562, P0563, and
H02S DTCs are not set.
Vehicle speed less than 113 Kph (70 mph).

TP sensor angle less than 75 percent.
The fuel level is between 15 percent and
85 percent of full capacity.
(39F} and 30C (86F).
and 30C (86F}.
The start up engine coolant temperature and
intake air temperature are within 9C (16F)
of each other.

The vacuum in the EVAP system decays (leaks) at
too fast a rate.
Important: This OTC does NOT report a first failed
test. A first fail of this OTC will have a scan tool status
as Not Hun. Use the scan tool data display parameter
of EVAP Test Result to determine if this OTC has
failed or passed for this ignition cycle:

lamp (MIL} when the diagnostic runs and fails.
Records.
O
6-1640
Engine

Diagnostic Aids
Important:
Systems.
PCM to properly Pass or Fail this DTC. Always
diagnose fuel level sensor DTCs before performing
this DTC diagnostic table. Always inspect for fuel level
sensor DTCs stored as History.
Perform a physical inspection of the E:VAP system.
tank cap
Incorrectly routed or defective EVAP system
A malfunctioning or damaged vapor canister
A damaged fuel sender 0-ring
The vacuum and pressure in the EV AP system is
table illustrates how the values compare:
in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20
in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10in.Hg
psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.

The Service Bay Test may have to be performed
does not run.
17.5 volts.
(38F) and 35C (95F).
The scan tool displays Test Aborted if any o1 the
Using Freeze Frame and/or Failure Records data
you cannot duplicate the DTC, the information
miles since the DTC set. The Fail Counter
observed. This will isolate when the DTC failed.
Test Description
Diagnostic Table.
3. It may be necessary to partially lower the fuel tank

to inspect the upper portion of the tank and the
EVAP line connections.
vehicle passes the Service Bay Test A fuel tank
cap that is loose or off causes this DTC to set.
12. This step tests for a leak at the top of the fuel
tank, at the fuel filler hose, and the tu.el cap. Plaqe
the ultrasonic leak detector in these areas.
Refer to the information supplied .with the EVAP
pressure/purge diagnostic cart on proper setup
and adjustment procedures.
13. With pressure applied it may be necessary to
disconnect the EVAP lines at the components
to verify that a line or component is not restricted.
A restriction would prevent a vacuum (or the
Step 10 test pressure) from forming in the
fuel tank.
Engine

this DTC to set.
7.5 in. H20 of pressure to -17.5 in. H20 of
pressure (vacuum).
6-1641

vacuum response, command the EVAP Purge
and quickly SEAL the system. Leaving the EV AP
develop.

Step
Action
Value(s)
Yes

Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to the
applicable
DTC table
Go to Step 3
Go to Step 21
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 15
Go to Step 8
Go to Step 7
Are any other EVAP system DTC's. stored in history?

2
No
A loose, incorrect, defective or missing fuel

tank cap.
Disconnected, improperly routed, kinked or
damaged EVAP system purge lines.
A loose, missing, or damaged service port dust
cap and/or schrader valve. Refer to the test
description for additional information.
2. Repair the EVAP system if needed.
Did you find and repair the condition?.
Important: Ensure that The Conditions for Running the
Service Bay test are met before proceeding with this
diagnostic. Refer to Diagnostic Aids.
Perform the EVAP system Service Bay Test using a
scan tool.
Does the EVAP diagnostic pass the Service Bay Test?
Important: The DTCs must be cleared from the PCM in

order to use the output control function on the scan tool.
1. Clear the DTCs using a scan tool.
3. Remove the EVAP Purge line from the EVAP Purge
Solenoid Valve.
4. Connect the J 23738-A hand held vacuum pump to
the vacuum port of the EVAP Purge Solenoid Valve.
using the hand vacuum pump.
Can the value specified be obtained and held?
10 in Hg
Important: If an audible solenoid click cannot be heard

and DTC P0443 is not set, inspect the EVAP canister
purge solenoid circuits for high resistance.
1. Connect a vacuum gauge to the EVAP Purge
solenoid valve.
2. Idle the engine.
3. Command the EVAP Purge Solenoid Valve to 50%
using a scan tool.
12 in Hg
6.;.1642
Engine C.ontrols
5.7L
Engine
DTC P0442 Evaporative Emissi.on (EVAP) System Small leak Detected (cont'd)
Step
Action
Yes
No
Go to Step 15
Go to Step 14
Value{s)
2. Remove the vacuum source from the EVAP Purge

Solenoid.
4. Idle the engine.
12 in Hg
...
10
.1. Turn OFF the ignition.

2. Reconnect the EVAP purge line to the EVAP purge
solenoid.
3. Lower the fuel tank to gain access to the EVAP
canister. Refer to EVAP Canister Replacement.
4. Disconnect the EVAP purge line from the EVAP
Canister (line from the EVAP purge solenoid valve).
purge line from the EVAP purge solenoid valve.
5 in Hg

2. Disconnect the fuel tank vapor line from the EVAP
Canister.
3. Plug the EVAP canister port for the fuel tank
vapor line.
4. Connect the J 23738-A vacuum pump to the EV AP
purge port on the EVAP canister.
scan tool.
. Can the specified valueof vacuum be obtained and held?
5 in Hg
1.
2.
3.
4.
Leave the system connected as in Step 9.

Disconnect the vent line at the EVAP Vent Valve.
Plug the vent line.
Attempt to apply a vacuum up to the specified value
using the J 23738-A vacuum pump.
Can the. specified value of vacuum be obtained and held?
Go to Step 9
Go to Step 18
Go to Step 12
Go toStep 10
Go to Step 16
Go to Step 11
Go to Step 21
Go to Step 17
5 in Hg
1. Inspect the EVAP Vent Hne from the canister to the

11
EVAP Vent Valve for leaks or missing/damaged

0-ring seals.
2. If you find a condition repair the EV AP system as
necessary.
Engine
6-1643
DTC P0442 Evaporative Emission (EVAP) System Small Leak Detected (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 21
Go to Step 13
Go to Step 21
Go to Step 19
Important: The following steps require the J 41413 EVAP

pressure/purge diagnostic station and the J 41416
ultrasonic leak detector.
12
Always zero the EVAP pressure and vacuum (in. H20)

gauges on the J 41413 EVAP pressure/purge diagnostic
station before proceeding with diagnosis.
2. Remove the plug and the hand vacuum pump.
3. Reconnect al.I the EV AP components.
4. Connect the J 41413 EVAP pressure/purge diagnostic
station to the EVAP system service port.
5. Comman.d the EVAP Vent Valve ON (closed) using a
scan tool.
6. Continuously attempt to pressurize the EVAP system
by leaving the EVAP pressure/purge diagnostic
station control knob in the pressurize position.
7. Using the J 41416 ultrasonic leak detector locate and
repair EV AP system leak.
1. Inspect the EVAP system for restrictions. Refer to
Test Descriptions.
13
2. Repair as needed.
Repair the vacuum source to the EVAP Purge

Solenoid Valve.
15
Important: Inspect the EVAP Purge Solenoid Valve and

the purge line for carbon contamination. Refer to
Diagnostic Aids.
16

Replacement.

18
Replace the EVAP line from the EVAP Purge solenoid

valve to the EVAP canister. Refer to Fuel Hose/Pipes
Assembly Replacement (Rear).
19
1. With the EVAP system pressurized, compare the

EVAP pressure/purge diagnostic station pressure
gauge (in. H20) reading to the Fuel Tank Pressure
sensor reading on the scan tool.
2. Compare the readings with the system depressurized.
Refer to the Test Description.
amount of pressure in the EVAP system?
Replace the Fuel Tank Pressure sensor. Refer to Fuel

14
17
20
Go to Step 21
Go to Step 21
Go to Step 21
Go to Step 21.
Go.to Step 21
Go to Step 3
Go to Step 20
Go to Step 21
6.;1644
Engine
DTC P0442 Evaporative Emission (EVAP) System Small leak Detected (cont'd)
Step .
Action
Value(s)
21

the Specific OTC option, then enter the DTC numb!'H
applicable.
22
Review the captured info on the scan tool.

Does the scan tool indicate any DTCs that have not been
diagnosed?
Yes
No
Go to Step22
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
I Hot With lgn 1 Relay Energized l

~ Pow-;r Distrib::.iio;;-
I Schematics In
Wiring Systems
:
1sA
L _
IL 0 c
- - - - ~ ~Qine
ENG CTRL I
Iring
MlnlFuse Harness
_
___
02
C200B
C200D
0.5 PNK 239
A2. C405B
C405D
0.35 PN: 239
0.5 PNK 239

o.5PNK
Evaporative
Emission
[ ] (EVAP)
Canister
0.5 PNK 239
!Automatic!
C100
0.5 PNK 239
Power
Distribution
In Wiring
Systems
0.5 PNK
239
L2!.I
AI
P100
s1 a2111---2-3-9----1111-___.
G
Junction
., Block 2
:
BI
$107
0.5 PNf 239
~:~e
0.35 WHT 1310
Evaporative
Emission
[ ] (EVAP)
Canister
B
82
0.5 WHT
C
' BI ~~re:
C405D
C405B
1310
C230
0.5WHifi310
0.35 DK GRN/W:. ~2~- _______________________4_5 c:110
.. - - - - - 8/AP -,. - - - - - - - - - - - - -.;;AP. -,- - -
PCM
I C1 =BLU
I C2=RED
canister
Purge
Valve
Control
---T
canister
Vent
Valve
Control
---1
.,,.
.
~ Powertrain
Control
A.
I Module p
I (PCM) ~
I
~-----------------------------J
582399
Circuit Description
A voltage is supplied directly to the EVAP Canister
Purge Valve. The PCM controls the solenoid by
grounding the control circuit via an internal switch
called a driver. The primary function of the driver is to
supply the ground for the controlled component.
Each driver has a fault line which the PCM monitors.
The voltage of the control circuit should be low
(near Ovolts) when the PCM commands a component
ON. The voltage potential of the circuit should be
high (near the battery voltage) when the PCM
commands the control circuit to a component OFF. If
the fault detection circuit senses a voltage other
than what the PCM is expects, the fault line status
changes causing the DTC to set. The EVAP
purge solenoid valve is pulse width modulated (PWM):
The PCM controls the EVAP purge solenoid valve
duty cycle by controlling the amount of solenoid purge
valve ON time. The scan tool displays the amount
of ON time in a percentage. This value is the amount
of available vacuum that will be applied to the
EVAP system.
Conditions for Running the .DTC

18.0 volts.

Th.e conditions are presentfor a minimum of
5 seconds ...

Failure Records.
6-1646

Diagnostic Aids
Engine
aid in determining how many .miles since the DTC set.
Test Description
Important:
Systems.
Test the solenoid ignition feed circuit and control
circuit for excessive resistance if an audible click
cannot be heard when the solenoid is commanded ON
and OFF.

diagnostic table.
as necessary. The Fuel Tank Pressure sensor
parameter on the scan tool can also be used to
determine if the EVAP purge solenoid is operating.
You should be able to see the pressure/vacuum
change when you command the solenoid on.
4. This step tests for voltage at the EV AP purge
solenoid. The ENG IGN fuse supplies power to the
coil side of the EVAP purge solenoid.
5. This step verifies that the PCM is providing
ground to the EVAP purge solenoid.
6. This step tests if a ground is constantly being
applied to the EVAP purge solenoid.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Intermittent
Conditions


2. With the scan tool, command the solenoid to 50%
and then to 0%.
Does the solenoid respond to the commanded positions?
1. Review the Freeze Frame and/or Failure records data

for this OTC.
close to the Freeze Frame and/or Failure records
1.
2.
3.
4.

Disconnect the EVAP purge solenoid.
Turn On the ignition, with the engine OFF.
Probe the coil side feed circuit of the EVAP purge
solenoid with a test lamp connected to a good
ground.
(
Go to Step 5
Go to Step 11
Engine
6-1647
DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Control Circuit (cont'd)
Step
Action
Value(s)

EVAP purge solenoid and the coil side feed circuit of
the EV AP purge sole.noid.
2. With a scan tool, command the EVAP purge solenoid
to 50% and then to 0%.
Does the test lamp respond to each scan tool command?

command?
1. Test the control circuit of the EVAP purge solenoid

for a short to voltage or an open. Refer to Circuit
Testing in Wiring Systems:
1. Test the control circuit of the EVAP purge solenoid

for a short to ground. Refer to Circuit Testing in
Wiring Systems.
1. Inspect for poor at the connections at the solenoid.

Wiring Systems.
10
1. Inspect for poor at the connections at the PCM. Refer

Wiring Systems.
Wiring Systems.
11
Repair the coil side feed circuit of the EVAP purge

solenoid. Refer to Wiring Repairs in Wiring Systems.
Replace the solenoid. Refer to EVAP Canister Purge

Solenoid Valve Replacement.
12
Yes
No
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
.
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 13
Go to Step 14
GO to Step 14
13

Replace the PCM.
14
1. Use a scan tool in order to clear the DTCs.

OTC as specified in the supporting text.
Does the OTC reset?
15

(capture info).
diagnosed?
Go to Step 14
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
6-1648
Engine
! Hot With lgn 1 Relay Energized I

.- Power
- - -Distribution
- - - - I
Schematics In
: Wiring Systems
1
L
IL c
- - - - .,I Engine
ENG CTRL I Wiring
MiniFuse Harness
1
1s A
Junction
_ _ _ _ .,I Block 2
02
C200B
C200D
0.5 PNK 239
Power
Distribution
In Wiring
Systems
AII
Evaporative
Emission
[ ] (EVAP)
Canister
0.5 PNK 239

__
o._5_P_N_K_ _ _..
8107
239
0.5 PNK 239
A
Evaporative
Emission
[ ] (EVAP)
Canister
C405B
C405D
0.35 PN: 239
0.5 PNK 239

G C100
!Automatic!
[5:]
A2
0.5 PNK 239

P100
S18211111---0_.5_P_N_K_~u,-~
239
BI
~:~e
0.35 WHT 1310

8 C405D
B2IC405B
0.5 WHT 1310
C C230
~~r~:
0.5
w1-1rl1310
0.35 DK GRN/W~: ~2-8- - - - - - - - - - - _- - - - - - ______4_*:110
.- - - - - - 8/AP -; - - - - - - - - - '." " - - - EV.AP -, - - - .,I Powertrain
I
PCM
I C1=BLU
I C2=RED
I
Canister
Purge O
Valve
- T
Control
..
Canister
Vent
Valve
Control
Control
--.1-=-
I Module Jiff"
I (PCM) ~
I
L-----------------------------J
582399
Circuit Description
The PCM monitors the performance of the EV AP
system by applying a predetermined level of vacuum
to the EVAP system and then monitors the vacuum
decay rate. The PCM sets this DTC if the vacuum
decay rate is greater than a predetermined value.
DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122, P0123, P0125, P0420,
P0430, P0452, P0453, P0500, P0502, P0503,
P0562, P0563, or H02S DTCs are not set.
The ignition voltage is between 1O and 17 volts.
The engine coolant temperature is between 4 C
(39F) and 30C (86F).
and 30C (86F).
The start up engine coolant temperature and the
intake air temperature are within 9C ( 16F) of
each other.

The EV AP vacuum decay rate is more than a
predetermined value when the vent solenoid
is commanded open.
.. The conditions are present for more than
2 seconds.
OR
O
The vacuum present in the EV AP system is more
than a predetermined value when the vent
sole.noid is commanded open during normal purge.
.. The conditions are present for more than
4 seconds.
Important: This DTC does not report a first failed test.
A first fail of this DTC will have a scan tool status
as Not Run.

.G The PCM records the operating conditions at the
R~o~s.
O
Engine
. A History OTC clears after 40 consecutive
Diagnostic Aids
Important:
the PCM connector gaskets when diagnosing/
replacing the PCM. Ensure that the gaskets are
installed correctly. The gaskets prevent
contaminate intrusion into the PCM.
.. For any test that requires probing the PCM or a
damage to the harness/component terminals. Refer
to Using Connector Test Adapters in Wiring
Systems.
A fuel tank pressure sensor ground circuit that is open
will cause this OTC to set. The Fuel Tank Pressure
sensor and the Fuel Level sensor share the same
ground. IF OTC P0463 is also set, inspect the common
ground for an open.
PCM to properly Pass or Fail this OTC. Always
diagnose the fuel level sensor OTCs before performing
this OTC diagnostic table. Always inspect for fuel
level sensor OTCs stored as History.
Perform a physical inspection of the EV AP system.
tank cap
Incorrectly routed or defective EV AP system
A stuck closed EVAP Vent Valve
A restricted or blocked EV AP system hose
A restricted or stuck closed fuel tank rollover
valves
A malfunctioning or damaged vapor canister
The vacuum and pressure in the EVAP system is
shows how the values compare:
in. H20
1 in. H20
5in. H20
10 in. H20
15 in. H20
in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg
psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.
6-1649
The Service Bay Test may have to be performed

does not run.

17.5 volts.
(38F) and 35C (95F).
The scan tool displays Test Aborted if any of the
O
Using Freeze Frame and/or Failure Records data

you cannot duplicate the OTC, the information
miles since the OTC set. The Fail Counter
observed. This isolates when the OTC failed.
Test Description
Diagnostic Table.
vehicle passes the Service Bay Test. A fuel tank
cap that is loose or off causes this OTC to set.
5. Testing the vapor canister. and the EVAP Vent
Valve for restriction.
this OTC to set. An open Fuel Tank Pressure
sensor ground circuit will cause this OTC to set. If
the Fuel Tank Pressure sensor does not
respond to pressure (or vacuum) inspect the
ground circuit for an open.
7.5 in. H20 of pressure to -17.5 iri. H20 of
pressure (vacuum).
vacuum response, command the EV AP Purge
and quickly SEAL the system. Leaving th_e EV AP
develop.
6-1650
Engine

DTC P0446 !Evaporative Emission (EVAP) Vent System Performance
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 13
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step.5
Go to
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage


Improperly routed, kinked or damaged EVAP
purge and tank vent lines.
2. Repair the EVAP system as necessary if you find a
condition.
Important: Ensure that The Conditions for Running the

Service Bay Test are met before proceeding with this
diagnostic: Refer to Diagnostic Aids.
Perform the EVAP system Service Bay Test.
Does the vehicle pass the Service Bay Test?
2. Remove the fuel tank cap.

4

4. Monitor the fuel tank pressure sensor voltage, with a
scan tool.
Is the fuel tank pressure sensor voltage less than the
specified value?
4V
2. Lower the fuel tank. Refer to Fuel Tank
Replacement.
3. Disconnect the fuel tank vapor and the EVAP purge
lines from the EVAP vapor canister.
4. Plug the canister fitting for the fuel tank vapor line.
5. Connect the hand held vacuum pump J 23738-A to
the EVAP purge line canister fitting.
7. Command the EVAP Vent Valve ON (closed) using
the scan tool.
8. Attempt to apply and hold the specified amount
of vacuum using the hand held vacuum
pump J 23738-A.
9. Command the EVAP Vent Valve OFF (open) while
monitoring the. hand held vacuum pump gauge.
Does the vacuum drop from the specified value when the
EVAP Vent Valve is opened?
5 in Hg
Go to Step 8
Go to Step 6.
Go to Step 10
Go to Step 7
Go to Step 13
Go to Step 11
1. Leave the system as connected in step 4.
2. Disconnect the vent line at the EVAP Vent Valve.
3. Plug the vent line.

4. Attempt to apply and hold the specified amount
of vacuum using the hand held vacuum
pump J 23738-A.
5. Remove the plug from the vent line while monitoring
the hand held vacuum pump gauge.
Does the vacuum drop from the specified value when the
vent line is unplugged?
1. Inspect the EVAP Vent line from the canister to the
EVAP Vent Valve for restrictions.
2. Repair as necessary if you find a condition.
5 in Hg
Engine
6-1651
DTC P0446 Evaporative Emission (EVAP) Vent System Performance (cont'd)

)
Action
Step
Value(s)
Yes
No
Go to Step 13
Go to Step 9
Go to Step 3
Go to Step 12
1. Test the fuel tank vapor line for a restriction.

Important: The following steps require the EVAP
pressure/purge diagnostic station J 41413.
Always zero the EVAP Pressure and Vacuum (in. H20)
gauges on the EVAP pressure/purge diagnostic station
before proceeding with diagnosis. Refer to the
users guide.
2. Remove the plug and the hand held vacuum pump.
3. Reconnect the EVAP vapor canister purge and

vent lines.
4. Connect the EVAP pressure/purge diagnostic station
to the EV AP system service port.
5. Operate the vehicle until the EVAP Purge Solenoid
Valve can be commanded ON with a scan tool.
6. Command the EVAP Purge Solenoid Valve ON with

the engine running and quickly SEAL the system with
the scan tool.
Important: Refer to test description for further information.
7. Compare the EVAP pressure/purge diagnostic
station's vacuum gauge (in. H20) to the vacuum
shown on the scan tool from the Fuel Tank Pressure
sensor while the system is sealed.
amount of vacuum in the EVAP system?
)
10
11

Replacement.

Go to Step 13

12
Go to Step 13
Go to Step 13

13
14

applicable.
diagnosed?
Go to Step 14
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1652
Engine
I Hot With lgn 1 Relay Energized I

~ Pow-;r Disi:ib;;iio;;- - -
!Loe
- - - - ~
ENG CTRL I
MiniFuse
E~Qine
Wmng
Harness
1s A
: Junction
_ ___ .. Block 2
I Schematics In
Wiring Systems
.. _ _ _ _ _ _ _ _
D2
0.5 PNK 239

P100
S1821111----0_._5_P_N_K___m1---'
239
0.5 PNK 239
G C100
!Automatlci
C2008
C200D
0.5 PNK 239
A2 C405B
C405D
0.35 PN: 239
0.5 PNK
239
S107
0.5 PNK 239
A
Evaporative
Emission
[ ] (EVAP)
BI
~~ft
'"
BI ~!~e
0.35 WHT 1310

B C405D
82 C405B
0.5 WHT 1310
0.5
WH~l~:::
_$:11
- - - - - EVAP -, - - - - - - - - - - - - -EVAP -,- - - , Powertrain

PCM
I C1=BLU
I
I
Evaporative
Emission
(EVAP)
Canister
0.35 DK GRN/W~: ~2-8- - - - - - - - - - - - - - - - - - - - - - - - _4

~
AI
0.5 PNK 239
Power
Distribution
In Wiring
Systems
C2=RED
Canister
Purge
Valve
Control
-=-
Canister
Vent
.,
Valve
--T
Contr.ol
I Control A
I Module II"'
I (PCM) ~
~---------------~-------------J
582399
Circuit Description
A voltage is supplied directly to the EV AP Canister
Vent valve. The PCM controls the solenoid by
The voltage of the control circuit should be low
(near O volts) when the PCM commands a component
ON. The voltage potential of the circuit should be
high (near the battery voltage) when the PCM
commands the control circuit to a component OFF. If
the fault detection circuit senses a voltage other
than what the PCM is expects, the fault line status
changes causing the OTC to set.

18.0 volts.

" The PCM detects that the commanded state of
The conditions are present for a minimum of
5 seconds.

the Failure Records. If the diagnostic repotis a
Failure Records.


O
Engine
Diagnostic Aids
Important:
prevent water intrusion into the PCM.
Systems.
Test the solenoid ignition feed circuit and control
circuit for excessive resistance if an audible click
cannot be heard when the solenoid is commanded ON
and OFF.
aid in determining how many miles since the OTC set.
6-1653

Test Description
diagnostic table.
as necessary.
4. This step tests for voltage at the coil side of the
EVAP vent solenoid. The ENG CNTRL fuse
supplies power to the EVAP vent solenoid.
ground to the EVAP vent solenoid.
applied to the EVAP vent solenoid.

Step
Action

2. With the scan tool, command the solenoid ON
and OFF.
Does the solenoid turn ON and OFF when commanded?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to
Intermittent
Conditions
Go to Step 5
Go to Step 11

for this DTC.
3

close to the Freeze Frame and/or Failure recqrds
data. that you observe.
..
Replacement.
4. Disconnect the solenoid electrical connector.
6. Probe the coil side feed circuit of the EVAP vent
solenoid with a test lamp that is connected to a good
ground.
6-1654
Engine

DTC P0449 Evaporative Emission (EVAP) Vent Solenoid Control Circuit (cont'd)
Step
Action
Value(s)

EV AP vent solenoid and the coil side feed circuit of
the EVAP vent solenoid. Refer to Probing Electrical
2. With a scan tool, command the EVAP vent solenoid
ON and OFF.
command?

command?
1. Test the control circuit of the EV AP vent solenoid for

a short to voltage or an open. Refer to Circuit Testing
in Wiring Systems.
1. Test the control circuit of the EVAP vent solenoid for

a short to ground. Refer to Circuit Testing in Wiring
Systems.
1. Inspect for poor connections at the EVAP vent

solenoid. Refer to Testing for Intermittent and Poor
10

Wiring Systems.
12
13
14
15
Repair the coil side feed circuit of the EVAP vent solenoid.
Replace the EVAP vent solenoid. Refer to EVAP Vent

Valve Replacement.

Replace the PCM.

Does the OTC reset?

(capture info).
diagnosed?
No
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 13

11
Yes
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
Engine
6-1655

Fuel
0.35 GRY
S244
Level ..
~----------------------~-----~
Sensor
720 0.35 GRY 720
G3, C405B
Gr
C405A
0.5 OR~/~L;}4~9- ___ ,Fuel
I Tank
[5]Fue1Tank
Pressure
Sensor
I
I
I
I Unit
I
I
0.35 GRY 720
-~rB-{----~
0.5 GRY/BLK 416
0.5 DK GRN
o.35G~
.474 ------------
1890
C405A
0.35DKG~~1::s
t~:-------- - ~:~-~~-~:~ :-----~~ ~~: :110

---tl; ----------- i---------I -0.35 G:
~
I
I
&. -
~ ~~~:~rain
Fuel
5V
Feed
I PCM
Tank
Pressure
-.- -
IC1=BLU
C2=RED
= -
I
I
Fuel
Ground
j!
I Module ,,,.4..
I (PCM) ~
=- -
.II
582326
Circuit Description
The Fuel Tank Pressure sensor changes resistance
values based on the fuel tank pressure (or vacuum). A
vacuum is considered negative pressure.
The PCM provides a 5.0 volt reference and a ground.
The Fuel Tank Pressure sensor signal varies
between ground and 5.0 volts as fuel tank pressure
varies. The Fuel Tank Pressure sensor voltage
increases as the fuel tank pressure decreases
(negative pressure, or vacuum). The Fuel Tank
Pressure sensor voltage decreases (positive pressure,
low voltage) as the fuel tank pressure increases.
The PCM uses the Fuel Tank Pressure sensor voltage
for EVAP system leak detection. This OTC sets
when the Fuel Tank Pressure sensor signal goes
below a predetermined value.


The Fuel Tank Pressure sensor voltage is less
0.1 volts.
All conditions present for more than 5 seconds.

Failure Records.

@
6-1656
Engine
Diagnostic Aids
Test Description
Important:
Systems.
The Fuel Tank Pressure Sensor range is from 7.5 in.
H20 of pressure to -17.5 in. H20 of pressure
(vacuum).
measured in inches of water (H20). Most gauges
measure vacuum in inches of mercury (Hg) and
pressure in pounds per square inch (psi). Thefollowing

diagnostic table.
that the 5.0 volt reference circuit is either shorted
to ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected within the
PCM. The A/C Refrigerant Pressure sensor
may be causing this OTC to set.
in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20
in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg
(
\

5. If the scan tool displays 5.0 volts, the Fuel Tank
Pressure sensor signal, 5.0 volt reference
circuit, and the PCM are OK.
6. If the scan tool displays 5.. 0 volts, the Fuel Tank
Pressure sensor signal circuit and the PCM
are OK.
7. Disconnecting the PCM al.lows using the OMM in
order to test. the continuity of the circuits. This
psi
0.0361 psi
0.180 psi
0.361 psi
0.541 psi
Engine
6-1657

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP16395
Volt Reference 2
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Go to Step 11
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 19
Go to Step 8

2. Idle the engine.

2
3. Monitor the Diagnostic trouble Code (DTC)

Monitor the Fuel Tank Pressure sensor voltage using the

scan tool.
Is the Fuel Tank Pressure sensor voltage below the
specified value?
0.10V

4. Idle the engine.

the DTC.

ignition?
1. Disconnect the Fuel Tank Pressure sensor jumper
harness at the body pass through connector. Refer.to
Outside left of rear floor pan, toward of rear axle in
Wiring Systems.
2. Jumper the 5.0 volt reference circuit and the Fuel

5
Tank Pressure sensor signal circuit together at the

body pass through connector (PCM side of harness).
5.0V
3. Observe the Fuel Tank Pressure sensor voltage

Is the Fuel Tank Pressure sensor voltage near the
specified value?
1. Connect the J 34142-B test lamp between B+ and the
Fuel Tank Pressure sensor signal circuit at the body
pass through connector.
5.0V

specified value?

3. Test the 5.0 volt reference circuit for an open or short

to ground. Refer to Circuit Testing in Wiring Systems.
4. If you find the 5.0 volt reference circuit is open or

shorted to ground, repair the circuit as necessary.
s. 1658
Engine
Step
..
'10
'11
'12
'13
14
Action
Value(s)
'1 . Inspect the 5.0 volt reference circuit for a poor

.. 2. Repair the terminal as necessary. Refer to Repairing
Connector Terminals in Wiring Systems.
'1. Turn OFF the ignition.

3. Test the Fuel Tank Pressure sensor signal circuit for
the following:
e Open circuit
Short to ground
Short to another Ci circuit.
4. If you find the Fuel Tank Pressure sensor signal
circuit is open or shorted to ground, repair the circuit
Systems.
'1. Inspect the Fuel Tank Pressure sensor signal circuit

for a poor connection at the PCM. Refer to Testing
for Intermittent and Poor Connections.
Wiring Systems.
'1. Inspect for a poor connection at the body pass

through connector. Refer to Testing for Intermittent
Wiring Systems.
i. Turn OFF the ignition.

2. Re-connect the Fuel Tank Pressure sensor jumper
harness to the body pass through connector.
3. Lower the fuel tank to gain access to the Fuel Tank
Pressure sensor. Refer to Fuel Tank Replacement.
4. Disconnect the Fuel Tank Pressure Sensor.
6. Jumper the Fuel Tank Pressure sensor 5 volt
reference circuit and signal circuit together at the Fuel
Tani< Pressure sensor connector.
using a scan tool.
specified value?
5.0V
Measure the Fuel Tank Pressure sensor 5.0 volt reference

circuit between the Fuel Tank Pressure sensor connector
and body ground using the DMM.
Does the DMM display a voltage near the specified
voltage?
5.0V
Repair the open or grounded Fuel Tank Pressure sensor

Yes
No
Go to Step 19
Go to Step 18
Go to Step 19
Go to Step 10
Go to Step 19
Go to Step 18
Go to Step 19
Go to Step 12
Go to Step 16
Go to Step 13
Go to Step 14
Go to Step 15
Go to Step 19
Engine
6-1659
Step
Action
15
Repair the open or grounded Fuel Tank Pressure sensor

5.0 volt reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Value(s)
16

Wiring Systems.
Go to Step 19

17

Go to Step 19
18
Replace the PCM.

Go to Step 17
Go to Step 19

No

1. Inspect for a poor connection at the Fuel Tank
Pressure sensor harness connector. Refer to Testing
for Intermittent and Poor Connections in Wiring
Systems.
Yes
Go to Step 19
1 . Select the Diagnostic Trouble Code (OTC) option and


19


applicable.
20
diagnosed?
Go to Step 20
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1660
Engine

$244
Fuel
0.35 GRY
Level-----------------------------,
Sensor
720
IL0 c
0.35 GRY 720

G3 C405B
[S]
IN
G}C405A
0.5 ORN/BLK 469
r - ;
- - - - - , Fuel
I
I
I
I
[5]Fue1Tank
Pressure
Sensor
I Tank
I Unit
I
I
-~tsi_---
0.35 GRY 720
0.5 GRY/BLK 416

D
035 G:{ 474 ___________ .0.35 DKG~~~B ----------+C230

035
~:;5-~~-~:1 :~-------~.;;~:r:'10
-1- -- ~ 6~~:i.rainJ.
G:};-------------
~
I
I
1890
0.5 DK GRN
..
H C405A
--_tl
_v_
- - - - - - - - - - -
5V
Feed
;u;.1----:---Tank
Pressure
PCM
C1=BLU
C2=RED
Fuel
Ground
b--------------------~---------
I M(POCdu)le , ...4.
IM~
~--J
582326
Circuit Description
The Fuel Tank Pressure sensor changes resistance
values based on the fuel tank pressure (or vacuum). A
vacuum is considered negative pressure.
The PCM provides a 5.0 volt reference and a ground.
The Fuel Tank Pressure sensor signal varies
between ground and 5.0 volts as fuel tank pressure
varies. The Fuel Tank Pressure sensor voltage
increases as the fuel tank pressure decreases
(negative pressure, or vacuum). The Fuel Tank
Pressure sensor voltage decreases (positive pressure,
low voltage) as the fuel tank pressure increases.
The PCM uses the Fuel Tank Pressure sensor voltage
for EVAP system leak detection. This DTC sets
when the Fuel Tank Pressure sensor signal goes
above a predetermined value.


" The Fuel Tank Pressure sensor voltage is more
than 4.90 volts.
O All conditions present for more than 5 seconds.

Failure Records.

Engine
Diagnostic Aids
Important:
Systems.
An open Fuel Tank Pressure sensor ground circuit will
not set this DTC. A Fuel Tank Pressure sensor that
does not respond to pressure changes may indicate a
circuit condition. '
The Fuel Tank Pressure Sensor range is from 7.5 in.
.H20 of pressure to -17.5 in. H20 of pressure
(vacuum).
determining how. many ignition cycles the diagnostic
') reported a pass and/or a fail. Operate the vehicle
meas.ure vacuum in inches of Hg (mercury) and
in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20
in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
.1.10 in. Hg
psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.
6-1661
Test Description
diagnostic table.
If DTC P1635 sets at the same time, this indicates
that the 5.0 volt reference circuit is either
shorted to ground or shorted to a voltage. The
.5 volt reference circuit is internally connected
within the PCM. The A/C Refrigerant Pressure
sensor may be causing this DTC to set. Refer to
DTC Pi 635 for further diagnosis.
data may aid in locating an. intermittent condition.
Records data. can help detefrmin'e how many miles
since the DTC set. The Fail Counter arid Pass
ignition cycles. the diagnostic reported a pass
speed, temperature,etc.) th.at you observed. This
will isolate w.hen the DTC failed.
4. This step tests whether the signal circuit is
shorted to a voltage.
5. This step tests Whether a ground circuit is
available for the Fuel Tank Pressure sensor at the
body pass through connector.
9. This step tests whether a ground circuit is
available for the Fuel Tank Pressure sensor.
6-1662
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to,Step 4
Goto
Diagnostic Aids
Go to,Step 5
Go to Step 11

'
1. Turn' ON the ignition leaving the engine OFF.
2. Monitor the Fuel Tank Pressure sensor voltage using

2
the scan tool.
4.3V
Is the Fuel Tank Pressure sensor voltage above the

specified value?
2. Revfew the Freeze Frame and/or Failure Records
data for this OTC ,and observe the parameters.

,3. Turn OFF th~ ignition for 15 seconds.
4. Idle the engine.
5. ,Operate the vehicle within the conditions required for
to meet before the PCM will run. this diagnostic,
where applicable, are listed in Condition$ for Running
the OTC.
ignition?
1. Disconnect the Fuel Tank Pressure sensor jumper
harness at the body pass through connector. Refer to
Outside left of rear floor pan, toward of rear axle in
Wiring Systems.
displayed on the scan tool.
Is the Fuel Tank Pressure sensor voltage below the
specified value?
1.0V
,.
Probe the sensor ground circuit at the body pass through

connector (PCM side) with the J 34142-B test lamp
connected to B+.
Measure the voltage at the 5.0 volt reference circuit at the
body pass through connector. to the battery ground using
the DMM.
Go to Step 12
Go to Step 7
Go to Step 19
Go to Step 20
Goto Step 8
5.0V

1. Inspect for a poor connections at the body pass
throl)gh connector. Refer to Testing for Intermittent
necessary. Refer to Connector Repairs in Wiring
Systems.
Go to Step 6
Engine
6-1663
DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage (cont'd)
\I
Step
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 14
Go to Step 10
Go to Step 15
Go to Step 17
Go to Step 16
Go to Step20
Go to Step 13
Go to Step 21
Go to Step 13
Go to Step 21
Go to Step 14

2. Re-connect the Fuel Tank Pressure sensor jumper
harness to the body pass through connector.
3. Lower the fuel tank to gain access to the Fuel Tank
Pressure sensor. Refer to Fuel Tank Replacement.
4. Disconnect the Fuel Tank Pressure Sensor electrical

connector.
1.0V

using a scan toot.
ts the Fuel Tank Pressure sensor voltage below the
specified value?
Probe the Fuel Tank Pressure sensor ground circuit with

the J 34142-B test tamp connected to B+ at the Fuel Tank
Pressure sensor jumper harness (PCM side).
ts the test tamp illuminated?
10
Measure the voltage at the Fuel Tank Pressure sensor

5.0 volt reference circuit to the battery ground using the
DMM. Refer to Measuring Voltage in Wiring Systems.
5.0V
ts the voltage near the specified value?
11
1. Test the Fuel Tank Pressure sensor signal circuit for

a short to voltage or a short to the 5 volt reference
circuit between the body pass through connector and
the PCM. Refer to Measuring Voltage in Wiring
Systems.
2. Repair the Fuel Tank Pressure sensor signal circuit if

the circuit is shorted. Refer to Wiring Repairs in
Wiring Systems.
same side as the manufacturers logo. Refer to PCM
12
2. Test for continuity of the Fuel Tank Pressure sensor

ground circuit between the body pass through
connector and .the PCM. Refer to Testing for
2Q
3. Repair the open or excessive resistance if the Fuel

Tank Pressure sensor ground circuit measures over
the specified value. Refer to Wiring Repairs in Wiring
Systems.
Testing for Intermittent and Poor Connections In
Wiring Systems.
13

Systems.
14
15

Replace the PCM.
ts the action complete?
Repair the poor connection or the signal circuit for a short
to voltage in the Fuel Tank Pressure sensor jumper
harness. Refer to Wiring Repairs in Wiring Systems.
ts the action complete?
Go to Step 21
Go to Step 21
6-1664
Engine

DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage (cont'd)
Step
16
Action
Repair the poor connection or open ground circuit in the
Fuel Tank Pressure sensor jumper harness. Refer to
Value(s)
17
i8
19

20
Go to Step 21
Go to Step 21
Go to Step 19
Go to Step 21

Repair the 5 volt reference circuit for a short to voltage
between the PCM and the jumper harness. Refer to Wiring
Go to Step 21
1. Inspect for a poor sensor ground terminal connection

at the Fuel Tank Pressure sensor jumper harness
connector. Refer to Testing for Intermittent and Poor
Wiring Systems.
No

Repair the 5 volt reference circuit in the Fuel Tank
Pressure jumper harness for a short to voltage. Refer to
Yes
Go to Step 21

21
22

applicable.
diagnosed?
Go to Step 22
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1665
DTC P0461 Fuel level Sensor Performance

8244
0.35 GRY 720
F3
0.35 GRY 720
0.5B~I651
....
--
- - - .....-1--. Fuel
Fuel Tank
Unit
I
Level
Sensor I
I
I
I
Fuel Tank
Pressure
Sensor
L--B ----..1
0.35 GRY 720
0.5 PPLI30
A C405A
A3IC405 B
0.35 PPL 1589
p~t~- ---_ -_ -_ - _- _- _- _- _- _---_

J
035
c~o
id
~ ~:~~~~rr
10
-:~l~~~a:
:~~~~1Jf T- --------c~~:L: - --~ -----~~~=d_I_ -
u
L--------------------------------..1
Input
C2=RED
I (PCM)
~
582325
Circuit Description
The Fuel Level Sensor changes resistance based on
fuel level. The Fuel Level Sensor has a signal
circuit and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
ThePCM monitors the changes in this voltage caused
by changes in the resistance of the sensor in order
to determine fuel level.
high, therefore, the PCM senses a high signal voltage
(fuel tank full). When the fuel tank is empty, the
sensor resistance is low, and the PCM senses a low
signal voltage (fuel tank empty).
The PCM uses inputs from the Fuel Level Sensor in
order to calculate the total fuel remaining in the
fuel tank. This information is then sent to the fuel
gauge. The Fuel Level information is also used
for misfire and EV AP diagnostics.
This diagnostic tests for a stuck fuel level sensor
signal. The PCM sets this OTC if the fuel level signal
appears to be stuck based on a lack of signal
variation expected during normal operation.
Conditions. for Running the DTC

More than 150 miles have been accumulated.

The fuel level in the fuel tank does not decrease by at
least 3.0 liters (3/4 gallon).

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The malfunction indicator lamp (MIL) will not
illuminate.
information in the Failure Records.

A History OTC will clear after 40 consecutive
warm-up cycles, if no failures are reported by this
or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
O Use a scan tool in order to clear the MIUOTC.
s.:1666
Engine
Diagnostic Aids
Important:
Systems.
OTC set.

vehicle speed, temperature etc.) that you observed .
Test Description
diagnostic table.
DTC P0461 Fuel Level Sensor Performance

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

1. Disconnect the Fuel Tank jumper harness from the

body pass through connector. Refer to Outside left of
rear floor pan, toward of rear axle in Wiring Systems.
2. Jumper the fuel level signal circuit to a known good
ground.
3. Monitor the Fuel Level sensor parameter using the
scan tool.
Is the Fuel Level sensor at the specified value?
o.ov
1. Jumper the Fuel Level sensor signal circuit and the

ground circuit together at the body pass through
connector.
2. Monitor the Fuel Level sensor parameter using the
scan tool.
Is the Fuel Level sensor at the specified value?
O.OV
1. Remove the tank fuel level sensor. Refer to Fuel

Damage to the Fuel Tank jumper harness.
Poor connections at.the Fuel Pump Tank Module.
A stuck Fuel Level sensor (i.e. the fuel strainer
interfering with the sender float arm.)
Foreign material in the fuel tank (ice)
A deformed fuel tank.
3. If you find a condition, repair the condition as
necessary.
(
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 6
'
Go to Step 10
Go to Step 7
Engine
6-1667
DTC P0461 Fuel Level Sensor Performance (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 8

2. Test the Fuel Level signal circuit for excessive

resistance. Refer to Testing for Continuity in Wiring
Systems.
3. If you find a circuit condition, repair the circuit as
Systems.
2. Test the Fuel Level ground circuit for excessive
resistance.
3. If you find a circuit condition, repair the circuit as

Systems.
Replace the Fuel Level sensor. Refer to Fuel Level Sensor

Replacement.
Go to Step 10

Wiring Systems.

Wiring Systems.

Replace the PCM.
Goto Step 10
Go to Step 9
Go to Step 10


10

applicable.
Go to Step 11
11
diagnosed?
Go to Step2
Go to the
applicable
OTC table
System OK
.
6-1668
Engine
DTC P0462 Fuel level. Sensor Circuit Low Voltage

5244
!Loe
0.35GRY 720
F3
058~1651
Level
Sensor
0.35GRY 720
- - - - "'Fuel Tank
: Unit
Fuel
A
Fuel Tank
Pressure
Sensor
L--B ----.1
0.35GRY 720
0.5 PPLI30
A C405A
A3IC405 B
0.35 PPL 1589
J1-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~Gic;:~o
0.35 PPL 1589

54 C2
0.35 GRY 720

23 C1
-u-v ------------------------1- --,
r I Fuel
I
I
Level
Input
CONN ID
C1=BLU
C2=RED
Fuel
Ground
Powertrain
I Control
I Module
I (PCM) ~
-6.,..
L--------.-----------------------.1
Circuit Description
The PCM monitors changes in this voltage caused by
changes in the resistance of the sensor to determine
fuel level.
high, therefore, the PCM will sense a high signal
voltage (fuel tank full). When the fuel tank is empty,
the sensor resistance is low, and the PCM senses
The PCM uses inputs from the Fuel Level Sensor to
calculate the total fuel remaining in the fuel tank.
This information is then sent to the fuel gauge via the
class 2 circuit. The Fuel Level information is also
used for misfire and EV AP diagnostics.
This OTC sets when the PCM senses a signal voltage
(
582325

The Fuel Level Sensor voltage is below 0.39 volts.
All conditions present tor 6.0 minutes.

The PCM stores th.e OTC information into memory
illuminate.


Engine
Diagnostic Aids
Important:
Systems.
OTC set.
6-1669

This will isolate when the OTC faJled.
Test Description
Diagnostic Table.
DTC P0462 Fuel Level Sensor Circuit Low Voltage

Step
Action
Did you perform t.he Powertrain On-Board

3. Monitor the Fuel Level sensor display on the
scan tool.
Is the Fuel Level sensor voltage above the
specified value?
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
SystJm Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
0.39V

the OTC.
ignition?
1. Disconnect the Fuel Level sensor jumper harness at

the body pass through connector. Refer to Outside
left of rear floor pan, toward of rear axle in Wiring
Systems.
2. Observe the Fuel Level sensor display on the
scan tool.
Is the Fuel Level sensor near the specified value?
5V
6-1670
Engine
DTC P0462 Fuel level Sensor Circuit low Voltage (cont'd)

Step
Action
Value(s)
Yes
No

3. Test t.he Fuel Level sensor .signal circuit for continuity

to ground. Refer to Testjng for Continuity in Wiring
Systems.
4. If you find the Fuel Level sensor signal circuit is

grounded, repair the circuit as necessary. Refer to
Go to Step 9
Go to Step B
Go to Step 9
.Go to Step 7
1. Lower the fuel tank .to gain access if necessary. Refer

to Fuel Tank Replacement.
2. Inspect the fuel tank jumper harnes.s for the following:

Broken or rubbed through wires.

Oid you find and correct the condition?

Replacement.

Replace the PCM.
Go to Step 9
Go to Step 9


9


applicable.
Go to Step 10
10
diagnosed?
Go to Step 2
...
Go to the
applicable
OTC table
System OK
Engine
6-1671

8244
0.35 GAY 720
F3
0.35 GAY 720
L....'.!il
058~1651
....
--
- - - -
.--1--. Fuel
Fuel Tank
Unit
Level
Sensor I
I
I
I
L--B ----..1
Fuel Tank
Pressure
Sensor
0.35 GRY 720
0.5 PPLI30
A C405A
: E~:~14 j- - - - - - - - -c~~:L~10---------~~~~nd
I --:
~~~~~a;
I (PCM) ~
u
L--------------------------------..1
Input
C2=RED
582325
Circuit Description

changes in the resistance of the sensor to determine
fuel level.
high, therefore, the PCM will sense a high signal
voltage (fuel tank full). When the fuel tank is empty,
the sensor resistance is low, and the PCM senses
The PCM uses inputs from the Fuel Level Sensor to
calculate the total fuel remaining in the fuel tank.
This information is then sent to the fuel gauge via the
class 2 circuit. The Fuel Level information is also
used for misfire and EVAP diagnostics.
sensor.

The Fuel Level Sensor voltage is above 2.9 volts.
The condition present for 6 minutes.

illuminate.

s.:.1672
Diagnostic Aids
Important:
Systems.
DTC set.
Engine
Test Description
Diagnostic Table.
3. This. step determines if the fault is present.
5. Inspect the Fuel level signal circuit for short to the
Fuel Pump ignition feed circuit.

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4

i. Install the scan tool.

2
Did OTC Pi 635 and Pi 639 Fail This Ignition cycle?
i. Install the scan tool.

3. Monitor the Fuel Level sensor display on the
scan tool.
Is the Fuel Level Sensor voltage above the
specified value?
2.9V


the OTC.
the Specific OTC option; then enter the OTC number
ignition?
.
-
(
Go to Step 5
Go to
Diagnostic Aids
Engine
6-1673
DTC P0463 Fuel Level Sensor Circuit High Voltage (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 14
Go to Step 6
Go to Step 11
Goto Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 16

3. Disconnect the fuel tank jumper harness at the body

pass through connector. Refer to Outside left of rear
floor pan, toward of rear axle in Wiring Systems.
5V

5. Measure the voltage from the Fuel Level signal circuit
to a known good ground using the DMM.
Is the Fuel Level sensor signal voltage above the
specified value?
1. Jumper the Fuel Level sensor terminals together at
the body pass through connector (PCM side).
2. Observe the Fuel Level sensor parameter on the

scan tool.
OV
Is the Fuel Level sensor voltage. near the specified value?
Jumper the Fuel Level sensor signal circuit (PCM side) to

a known good ground.
ov
Is the Fuel Level sensor voltage near the specified value?


3. Test the Fuel Level sensor signal circuit for an open.

Is the Fuel Level sensor signal circuit open?
Repair the Fuel Level sensor signal circuit. Refer to Wiring

Go to Step 18

10

3. Test the Fuel Level sensor ground circuit for an open.

Is the Fuel Level sensor ground circuit open?
1. Inspect the fuel tank jumper harness for poor
connections at the body pass through connector.
11

Systems.
Go to Step 15
Go to Step 16
Go to Step 18
Go to Step 12
Go to Step 18
Go to Step 13

Replacement.
2. Inspect the fuel tank jumper harness for the following
conditions:
Damage to the fuel tank jumper harness.
12
Poor connections at the fuel level sender

assembly. Refer to Testing for Intermittent and
Open circuit in the fuel tank jumper harness.

Broken or rubbed through wires.
6-1674
Step
Engine

DTC P0463 Fuel level Sensor Circuit High Voltage (cont'd)
Yes
Value(s)
Action
Replacement.
Repair the Fuel Level sensor signal circuit for a short to

Repair the Fuel Level sensor ground circuit. Refer to

16

Wiring Systems.
Systems.
17

Replace the PCM.
18

applicable.
diagnosed?
13
14
15
19
No
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 18
Go to Step 17
Go to Step 18
(
Go to Step 19
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6.-1675

Refer to Engine Controls Schematics, Cooling Fans
Circuit Description
The cooling fan system in this vehicle provides for
two separate modes of operation. These are the low
speed fan and the high speed fan operating modes.
The low speed mode operates both fans at half speed
by using a series circuit configuration. The high
speed mode operates both fans at full speed by using
a parallel circuit configuration. These two operating
modes are accomplished using 3 fan control relays.
This system which uses three relays to control two fan
motors appears complicated. To aid in better
understanding this system it is suggested to follow the
circuits in the schematic as you read the description.
Th.is will aid in understanding the two distinct modes of
operating the relays and coolant fans.
Low speed fan operation is established when the
PCM commands Fan Relay #1 ON by grounding
circuit 335 with an internal driver (relays #2 and #3
are left OFF). This closes the relay switch and allows
current to flow from the battery, through the switch
contacts on circuit 409 to the Left Hand cooling
fan. Current flow continues out of the fan motor on
circuit 532 to relay #3. The unenergized relay #3
switch contacts allow current to flow to circuit 504. This
provides power to the Right Hand cooling fan motor.
The low side of the RH cooling fan completes the
circuit to ground on circuit 150. This circuit is a series
circuit which allows half speed operation for each
fan since each fan motor will use half of the supplied
battery power.
High speed operation is established when all
three relays are energized. Relays #2 and #3 share
the same control circuit to the PCM. This is circuit 473.
As in the low speed mode, Relay #1 supplies current
flow .to the LH cooling fan on circuit 409. Current
flow continues through the motor on circuit 532 to
relay #3 which is now energized. The switch has now
provided a path for current to flow through circuit
150 directly to ground. This circuit now only has the
LH fan motor to power and allows it to run at full
speed. Relay #2 is also energized and provides current
flow on circuit 504 to the RH cooling fan. This fan
now has its own dedicated circuit and will operate at
full speed. This mode is operating as a parallel circuit.

e

18.0 volts.

\

The PCM records the operating cond.itions at the
Failure Records.

A last test failed (current DTC) .clears when the
warm-up cycles, if this or any at.her emission
Diagnostic Aids .
Important:

the PCM connector gaskets when .
Systems.
Test Description
diagnostic table.
cooling fan relay 1. The cooling fan mini fuse
supplies power to the coil side of the cooling fan
relay 1.


ground to the cooling fan relay 1.
The conditions must be present for a minimum of

5 seconds.
6. This step tests if ground is constantly being

applied to the cooling fan relay.
6,;.1676
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check .
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Intermittent
Conditions
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 6
Go to Step B
Go to Step 7
Go to Step 14
G.o to Step 1O
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12

2. With a scan tool, command the cooling fan relay 1

2
ON and OFF.
Does the cooling fan relay turn ON and OFF with each
command?

data for this DTC.
4. Operate .the vehicle within the same Conditions for
Does the DTC reset?

2. Disconnect the cooling fan relay 1 from the
underhood electrical center.
4. Probe the coil side feed circuit of the cooling fan relay
with a test lamp that is connected to a good ground.
Refer to Probing Electrical Connectors in Wiring
Systems.

cooling fan relay and the coil side feed circuit of the
cooling fan relay.
2. With a scan tool, command the cooling fan relay ON
and OFF.
command?

command?
1. Test the control circuit of the cooling fan relay for an

open. Refer to Circuit Testing in Wiring Systems.
Did you find and correct the c.ondition?
1. Test the control circuit of the cooling fan relay for a

Systems.
1. Inspect for poor connections at the cooling fan relay.

Engine
6-1677
OTC P0480 Cooling Fan Relay 1 Control Circuit (cont'd)

Step
Action
Value(s)

Testing for lntermittentand Poor Connections in
Wiring Systems.
Repair the coil side feed circuit of the cooling fan relay.
12
Replace the cooling fan relay 1.

13

Replace the PCM.
14

the. DTC as specified in the supporting text.
Does the. DTC reset?
15
With a scan tool, review the Stored .Information

(capture info).
diagnosed?
10
11
Yes
No
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
6-1678
Engine

Circuit Description
This will aid in understanding the two distinct modes of
contacts on circuit 409 to the Left Hand cooling
fan. Current flow continues out of the fan motor on
circuit 532 to relay #3. The unenergized relay #3
provides power to the Right Hand cooling fan motor.
The low side of the RH cooling fan completes the
circuit to ground on circuit 150. This circuit is a series
circuit which allows half speed operation for each
fan since each fan motor will drop half of the supplied
battery power.
flow to the LH cooling fan on circuit 409. Current

18.0 volts.

" Condition must exist for a minimum of 5 seconds.


time the diagnostic fails ..The first time the
Failure Records.

Diagnostic Aids
Important:

Systems.
Test Description
diagnostic table.
4. This step tests for a control circuit that may be
shorted to ground.
5. This step tests for an open control circuit.
11. The repair is not complete if the scan tool
Engine
6-1679

Step
Action
Value(s)
Is the customer concern that the fans are ON at all times?

Are the fans ON?
Important: For underhood electrical center relay

terminal identification refer to Electrical Center
1. Disconnect engine cooling fan relays #2 and #3 at
the underhood electrical center 1.
2. Probe the control side of the relay #2 at the
underhood electrical center 1 using the test lamp
J 34142-8 connected to ground.

2. Reconnect both relays.
4. Probe the engine cooling fan relay #2 and #3 control
circuit at the PCM harness using test lamp J 34142-B
connected to ground.
Repair the open circuit between the PCM harness

connector and the splice. Refer to Wiring Repairs in Wiring
Systems.
Repair the short to ground in the engine cooling fan

relay #2 and #3 control circuit. Refer to Wiring Repairs in
Wiring Systems.
Repair the short to B+ in the engine cooling fan relay #2

and #3 control circuit. Refer to Wiring Repairs in Wiring
Systems.
1. Inspect the PCM harness connector for poor

Systems.

Replace the PCM.
10
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 5
Go to Step 9
Go to Step 6
Yes
Go to Step 11
Go to Step 11
Go to Step 11
Go to Step 11
Go to Step 10
Go to Step 11
6-1680
Engine
Engine Controls. - 5.7L

DTC P0481 Cooling Fan Relay 2 and 3 Control Circuit (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 12
Go to Step2
Go to the
applicable
OTC table
System OK

2. Idle the engine at ttle normal operating temperature.

11
12

diagnosed?
Engine
6-1681
Vehicle Speed
L!.til
~ Sensor {VSS)
r- -
- -
A' C2
0.35 PPL/WHT 821

0.35
LTGRN/ 822
BLK
21
20
C2
.. - - - - - - )ss =---=----..:=vs~ - - - - ., Powertrain

I I PCM I
1c1 8 LU I
High
=
C2=RED
Low
I Control
I Module JI>
I (PCM) ~
L-----------------J
.Circuit Description
A toothed wheel mounted on the output shaft of the
transmission generates an AC voltage pulse as it
moves past the Vehicle Speed Sensor (VSS). The VSS
contains a permanent magnet surrounded by a coil
of wire, which produces a magnetic field. The toothed
wheel interrupts the magnetic field that generates
an AC voltage pulse. As the. vehicle speed increases
the AC voltage pulse rate also increases.

DTCs P0107, P0108,. P0117, P0118, P0121,
P0122, P0123, P0125, P0506, P0507 are not set.
The engine coolant temperature is more
than 35C (95F).
The engine speed is more than 1,000 RPM.
The TP sensor angle is between 5.0 percent and
100 percent.
The MAP is between 40 kPa and 100 kPa when
the A/C is OFF.
The MAP is between 45 kPa and 100 kPa when
the A/C is ON.

The PCM detects vehicle speed at O km/h (0 mph) for
100 seconds.

the. Failure Records. If the diagnostic reports a
e
582478
at th.e time of the failure. The PCM writes the

Failure Records.

Diagnostic Aids
Important:
Systems.
Test Description
diagnostic table.
2. The ASR/TCS must be disabled when performing

this step. Whenever the ignition key is cycled to
the OFF position and then cycled back ON,
the ASR/TCS system will default ON.
6-1682
Engine
Engine Controls;. 5.7L

Step
Action
4
5
10
11
12
13
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5
Value(s)

2. Raise the drive wheels. Refer to Lifting and Jacking
the Vehicle in General Information.
4. Disable ASR/TCS systems, if so equipped.
5. Idle the engine in gear.
Does the scan tool indicate a vehicle speed above the
specified value?
2. Disconnect the VSS electrical connector.
3. Connect the J 33431-8 signal generator tester to the
VSS harness.
4. Turn ON the ignition, tester ON and set to generate a
VSS signal.
Does the scan tool indicate a vehicle speed above the
specified value?
Repair the faulty VSS connection or faulty VSS.
Measure the voltage from the VSS signal circuit to a
known good ground using the DMM.
Does the DMM indicate the specified value?
Measure the voltage from the VSS signal circuit to the
VSS ground circuit using the DMM.
Check the calibration ID for the most current and/or
incorrect calibration.
Is the most current and proper calibration present?
Replace the PCM.
Repair the signal circuit to the vehicle speed sensor. Refer
Repair the ground circuit to the vehicle speed sensor.
Install proper calibration and/or most current:
4. Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text, if
applicable.
diagnosed?
0.0 mph
(0.0 km/h)
0.0 mph
(0.0 km/h)
Go to Step 12
5.0V
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 10
Go to Step B
Go to Step 11
5.0 V
Go to Step 12
Go to Step 12
Go to Step 12
Go to Step 12
Go to Step 13
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1683
DTC P0506 Idle Speed low

Idle Air
Control
(IAC)
Valve
Stepper
Motor
Coil
A
'
C'
Coll
B
0.35 LT GRN/WHT
1749
,,
A'
0.35 LT GRN/BLK
444
79
78
77
76
C2
-----"'------"----I"'--------------
0.35 l T BLU/BLK
1748
0.35 LT BLU/WHT
1747
I
I
I
I
IAC
CollA
High
IAC
CoHA
Low
IAC
CoilB
Low
IAC
CoilB
High
I PCM
IC1=BLU
C2=RED
, Powertrain
I Control
I Module
I I (PCM)
III
}&~
~--------------J~
582475
Circuit Description
The Idle Air Control valve is a PCM controlled stepper
motor located on the throttle body. The stepper
motor drives a valve pintle which protrudes into a
passage that bypasses the throttle plates. The PCM
commands the IAC valve pintle to extend to decrease
the idle speed. The bypass air flow is reduced and
the idle speed decreases as the pintle approaches its
seat. The PCM retracts the IAC valve pintle away
from its seat to increase the idle speed. The retracting
of the IAC valve pintle allows more air to bypass
the throttle plates. The PCM uses the IAC system to
maintain a desired idle speed. This OTC sets when the
PCM detects an engine speed outside of the IAC's
range of control.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0171, P0172, P0174, P0175,
P0220, P0300, P0401, P0404, P0405, P0443,
P0500-P0503, P1414 and P1441 are not set.
.. The engine coolant temperature is more
1han 60C (140F).
The intake air temperature is more
1han -10C (14 F).
" The ignition voltage is between. 9.0 and 17.0 volts
" The vehicle speed is no more than
1 mph (1.6 km/h).
The throttle position is less than 1 percent.

The actual idle speed is 100 RPM less than the
desired idle speed.
All of the above conditions are present for
5 seconds.

failure. on the second consecutive ignition
Failure Records.

that the diagnostic runs and does not fail. .
Engine
6-1684
Diagnostic Aids
Test Description
Important:

diagnostic table.

Systems.

DTC P0506 idle Speed low

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

Important: If any MAF/MAP sensor DTCs are set go to

appropriate diagnostic table.
i. Idle the engine:
2. Command the engine speed up to i 500 RPM, down
to 500 RPM, up to i 500 RPM, and then EXIT using
the scan tool.
Does the engine speed correspond, within iOO RPM, with
each command?
Is the engine RPM more than i 00 RPM above

desired RPM?
i. Inspect for the following conditions:

Vacuum leaks
Throttle plates not closing properly
A faulty PCV valve
i. Inspect for the following conditions:

O Excessive deposits in the throttle body.
condition etc.).
i. Start and idle the engine.

2. Disconnect the IAC harness connector and install the
appropriate IAC node light from kit J 37027-A.
3. Command the RPM up to i 500, down to 500 and up
to i 500 using the scan tool while observing the
node light.
Do both of the LEDs on the node light cycle red and
green, but never OFF?
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 13
Go to Step 6
Go to Step 13
Go to Step 6
Go to Step 7
Go to Step 8
Engine
6-1685
DTC P0506 Idle Speed low (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 10
Go to Step 13
Go to Step 11
Important: During the following test it is possible to

overextend the IAC valve pintle until it falls out of the
worm drive. If this occurs, manually screw the pintle shaft
into the worm drive about 2 turns to get it started, align the
keyways on the shaft with the keys in the housing and
gradually retract the pintle using the IAC driver tool.
2. Remove the IAC valve.

3. Connect the IAC Vc).lve to the IAC Driver tool from
kit J 37027-A.
4. Hold the IAC valve with a finger over the pintle in
case it is pver extended. Using the driver tool retract

and extend the pintle.
Does the pintle move steadily with each flash of the IAC
driver light?
1. Inspect the IAC circuits for the following conditions:
Faulty connection
Open circuits
Short to B+
Short to ground
1. Inspect the IAC passages for the following:
Blockages
Heavy deposits
2. Clean the passages as necessary. Refer to Throttle
Body Cleaning Procedure.
1D
11
Replace the IAC valve. Refer to /AC Valve Replacement

Wiring Systems.
Wiring Systems.
Go to Step 13
-
12
Replace the PCM.

Go to Step 13
Go to Step 13

Go to Step 12
Go.to Step 13


13


applicable.
14
diagnosed?
Go to Step 14
Go to Step 2
Go to the
applicable
OTC table
System OK
6~1686
Engine
J
Coil
Coil
B
Idle Air
Control
(IAC)
Valve
Stepper
Motor
L.J1J
0.35 LT GRN/WHT
1749
B
0.35 LT GRN/BLK
444
~--!~_, ___ ?? .. _J~J C2

I'" IAC - - 1Ac- - - 1Ac - - IAC - I
0.35 l T BLU/BLK
1748
0.35 LT BLU/WHT
1747
Coll A
High
Coll A
Low
Coil B
Low
Coil B
High
IC1=BLU
~-
PCM
, Powertrain
I Control
I Module
I I (PCM)
I'
- C~=~E~
~~
582475
Circuit Description
The Idle Air Control valve is a PCM controlled. stepper
motor located on the throttle body. The stepper
motor drives a valve pintle which protrudes into a
passage that bypasses the throttle plates. The PCM
commands the IAC valve pintle to extend to decrease
the idle speed. The bypass air flow is reduced and
the idle speed decreases as the pintle approaches its
seat. Th.e PCM retracts the IAC valve pintle away
from its seat to increase the idle speed. The retracting
of the IAC valve pintle allows more air to bypass
the throttle plates. The PCM uses the IAC system to
maintain a desired idle speed. This DTC sets when the
PCM detects an engine speed outside of the IAC's
range of control.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0171, P0172, P0174, P0175,
P0200, P0300, P0401, P0404, P0405, P0443,
P0500-P0503, P1404, and P1441 are not set.
than 60C (140F).
The intake air temperature is more
than -10C (14F).
The ignition voltage is between 9.0 and 17.0 volts
The vehicle speed is no more than
1 mph (1.6 km/h).
The throttle position is less than 1 percent.

.. The actual idle speed is 200 RPM more than the
desired idle speed.
O All of the above conditions are present for
5 seconds.

time the diagnostic fails, The first time the
the Failure Records. If the diaghostic reports a
at the time of the failure_, The PCM writes the
Failure Records.

that the diagnostic runs. and does not fail.
Engine
6-1687
Diagnostic Aids
Test Description
Important:
Systems.

diagnostic table.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 13
Go to Step 6
Go to Step 13
Go to Step 6
Go to Step 7
Go to Step 8

1
Important: If any MAF/MAP sensor DTCs are set go to

appropriate diagnostic table.
1. Idle the engine.
2. Command the engine speed up to 1500 RPM, down
to 500 RPM, up to 1500 RPM, and then EXIT using
the scan tool.
each command?
Is the engine RPM more than 100 RPM above

desired RPM?
--
Vacuum leaks
Throttle plates not closing properly
A faulty PCV valve
condition etc.).
2. Disconnect the IAC harness connector and install the

appropriate IAC node light from kit J 37027-A.
3. Command the RPM up to 1500, down to 500 and up
to 1500 using the scan tool while observing the
node light.
Do both of the LEDs on the node light cycle red and
green, but never OFF?
6.;.1688
Engine
DTC P0507 Idle Speed High (cont'd)

Step
Action
Important: During the following test it is possible to

overextend the IAC valve pintle until it falls out of the
worm drive. If this occurs, manually screw the pintle shaft
_into the worm drive about 2 turns to get it started, align the
keyways on the shaft with the keys in the housing and
gradually retract the pintle using the IAC driver tool.
2. Remove the IAC valve.
3. Connect the IAC valve to the IAC Driver tool from
kit J 37027-A.
4. Hold the IAC valve with a finger over the pintle in
case it is over extended. Using the driver tool retract
and extend the pintle.
Does the pintle move steadily with each flash of the IAC
driver light?
Value(s)
Yes
No
Go to Step 9
Go to Step 10
Go to Step 13
Go.to Step 11
1. Inspect the IAC circuits for the following conditions:

Faulty connection
Open circuits
Short to B+
Short to ground
2: If you find a condition, repair as necessary.
10
1. Inspect the IAC passages for the following:

Blockages
Heavy deposits
2. Clean the passages as necessary. Refer to Throttle
Body Cleaning Procedure.
Replace the IAC valve. Refer to fAC Valve Replacement

(
Go to Step. 13
Go to Step 13

Wiring Systems.
Wiring Systems.
ii
..
_Go to Step 12
Go to Step 13 ..
,,
12

Replace the PCM.
13

applicable.
14
diagnosed?
Go
to Step 13
Go to Step .14
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1689

Refer to Engine Controls Schematics, A/C Compressor
Control for complete circuit details.
Circuit Description
The A/C system uses an A/C refrigerant pressure
sensor mounted in the high side of the A/C system to
monitor A/C refrigerant pressure. The PCM utilizes
this information in order to turn ON the engine coolant
fans when the A/C refrigerant pressure is high.
The PCM supplies a 5.0 volt reference and ground to
the sensor. As the A/C pressure increases or
decreases, the resistance of the sensor changes and
varies the amount of signal returning to the PCM.
The PCM monitors the A/C refrigerant pressure sensor
signal circuit and can determine when the A/C
pressure is too high or too low. The PCM disables the
A/C compressor clutch and sets a OTC P0530
when the pressures are out of range (high or low) for
a predetermined time. The PCM disables the A/C
compressor in order to prevent A/C compressor
damage.

The PCM detects .an A/C request.

A/C refrigerant pressure sensor indicates A/C
refrigerant pressure is below 3.0 psi for 5 seconds.
OR
A/C refrigerant pressure sensor indicates A/C
refrigerant pressure is above 445 psi for 5 seconds.

O The malfunction indicator lamp (MIL) will not
illuminate.

Diagnostic Aids
Important:
Systems.
If the test did not fail this ignition cycle, move the
related electrical harnesses and the connectors while
monitoring a scan tool.
Test Description
diagnostic table.
3. The normal A/C voltage is between 1.0 and
1.8 volts. If the A/C voltage is within the range,
review the Freeze Frame/Failure Records data in
order to determine when the OTC P0530 set.
5. If the A/C pressure/voltage stays high after
disconnecting the A/C refrigerant pressure sensor
electrical connector, this indicates the signal
circuit is shorted to a voltage.
7. This step tests for a good ground circuit.
8. This step tests the integrity of the A/C refrigerant
pressure sensor signal circuit.
11. If you have thoroughly tested the 5 volt reference
circuit (for opens, shorts to ground, PCM
connections etc.) and tests OK, then replace
the PCM.
12. If you have thoroughly tested the ground circuit for
opens and the PCM connections are OK, then
replace the PCM.
6-1690
Engine

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step3
Go to Cooling
Insufficient, AIC
System in HVAC
Go to
DTCP16395
Volt Reference 2
Circuit
Go to Step 4
Go to Step 5
Go to Step 6

Measure the refrigerant within the A/C system. Refer to

Cooling Insufficient, A/C System, in H.VAC.
Is the refrigerant within the specified levels?

2. Idle the engine.
information using the scan tool.
Did DTC P1639 Fail This Ignition cycle?

2 .. Monitor the A/C High Side using the scan tool.
Does the scan tool indicate the A/C High Side between the
specified range?
0.1-1.8V

data for this DTC and note the parameters.
3. Start the engine and operate the vehicle within the
conditions required for this diagnostic to run, and as
close to the conditions recorded in Freeze
Frame/Failure Records as possible. Special operating
conditions that need to be met before the PCM will
run this diagnostic, where applicable, are listed in
conditions for running the DTC.
specific DTC option, and enter the DTC number using
the scan tool.
ignition?
Disconnect the A/C refrigerant pressure sensor electrical

connector.
Does the scan tool indicate the A/C High Side less than
1V
(
Go to Step 6
Go to
Diagnostic Aids
Go to Step 7
Go to Step 11
.
Measure the voltage from the A/C refrigerant pressure

sensor 5 volt reference circuit to the battery ground using
the DMM.
5V

sensor 5 volt reference circuit to the sensor ground circuit
using the DMM.
5V
Jumper the 5 volt reference circuit to the A/C refrigerant

pressure sensor signal circuit using a fused jumper wire.
Refer to Using Fused Jumper Wires in Wiring Systems.
Does the scan tool indicate the A/C High Side voltage at
5V
10
Repair the faulty A/C refrigerant pressure sensor

connection or faulty sensor. Refer to A/C Refrigerant
Pressure Sensor Replacement in Heating, Ventilation, and
Air Conditioning.
11
Repair the short to voltage in the A/C refrigerant pressure

Systems.
Go to Step B
Go to Step 12
Go to Step 9
Go to Step 13
Go to Step 10
Go to Step 14
Go to Step 15
Go to Step 15
Engine
6-1691
DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit (cont'd)
Step
Action
Value(s)
12
Important: Inspect the PCM engine grounds for being

secure and clean.
Repair the 5 volt reference circuit to the A/C refrigerant
pressure sensor. Refer to Wiring Repairs in Wiring
Systems.
13
Repair the ground circuit to the A/C refrigerant pressure

Repair the signal circuit to the A/C refrigerant pressure


applicable.
diagnosed?
14
15
16
No
Yes
Go to Step 15
.
-
Go to Step 15
-
Go to. Step 15
Go to Step 16
Go to Step 3
Go to the
applicable
OTC table
System OK
6-1692
Engine
DTC P0562 System Voltage low

Refer to Engine Controls Schematics, 5. 7L Power,
Ground and MIL for complete circuit details.
Circuit Description
The PCM continuously monitors the system voltage.
The system voltage information is taken from the
PCM's ignition feed circuits. Voltages below 8.0 volts
or above 18.0 volts causes improper system
operation and/or component damage. The PCM
operates in a default mode if a PCM voltage OTC sets.
The PCM disables most outputs to protect the
hardware if the system voltage is high. A scan tool
may not display data if system voltage is below
8.0 volts. Use a OMM to monitor the system voltage in
order to verify if the fault is currently present. A low
voltage may cause a stalling condition, or other
driveability concerns.

The engine run time is longer than 1O seconds.
The engine speed is more than 1,000 RPM.
The vehicle speed is more than 8 km/h (5 mph).

The PCM senses system voltage below 8.0 volts.
All the above conditions are present for
5seconds.

The PCM stores OTC P0562 in memory when the
diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM will record the operating conditions at
the time the diagnostic fails. The PCM stores
this information in Failure Records.
The PCM will command a high idle speed.
The transmission defaults to third gear.
The TCC operation is inhibited.
A History OTC will clear after 40 consecutive .

or any othe.r non-emission. related diagnostic.
Diagnostic Aids
Important:
Systems.
An extremely low .voltage (below 7.5 volts) may cause
the loss of serial data and the MIL may not function.
An open ignition feed circuit causes a no start and the
MIL will not illuminate. A low system voltage may
cause other DTCs to set.
Test Description
diagnostic table.
2. Ensure the battery is at a full state of charge
before proceeding with this diagnostic. Monitoring
the Ignition 1 voltage with the scan tool will
help isolate the condition. If B+ is displayed on
the scan tool, then the wiring and PCM are OK.
Engine
6-1693
DTC P0562 System Voltage Low

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to A
Diagnostic
Starting Point Engine Electrical
in Engine
Electrical .
Go to Step 3
Did you pertorm the Powertrain On-Board

-
Important: If OTC P1637 is also set, refer to OTC P1637

Generator L-Terminal Circuit for further diagnosis. Ensure
the Battery is fully charged before proceeding with this
diagnostic.
Monitor the Ignition 1 Voltage using the scan tool.
Does the scan tool display the specified value?
B+
Inspect the PCM IGN fuse

Is the fuse open?
1. Turn OFF the ignition,

Replaceme,:,t!Programming.
3. Turn ON.the ignition leaving the engine OFF.
4. Measure the voltage at terminal (CH 9) for the
ignition feed circuit using the DMM. Refer to
Measuring Voltage in Wiring Systems.
B+
Test the continuity of the Ignition feed circuit using the

DMM. Refer to Testing for Continuity in Wiring Systems.
Does the DMM display continuity below the
specified value?
50
1. Repair the ignition feed circuit to the PCM for an

open or a short to ground. Refer to Wiring Repairs in
Wiring Systems.
2. Replace the PCM IGN fuse if necessary.
)
6
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 9

Wiring Systems.
Wiring Systems.
Go to Step 9

Replace the PCM.

applicable.
10
diagnosed?
..
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1694
Engine
DTC P0563 System Voltage High

Refer to Engine Controls Schematics, 5.7L Power,
Ground and MIL for complete circuit details.
Circuit Description
The PCM continuously monitors the system voltage.
The system voltage information is taken from the PCM
ignition feed circuits. Since voltages below 8.0 volts
or above 18.0 volts, could cause improper system
operation and/or component damage, the PCM
operates in a default mode if a PCM voltage OTC
sets. If the system voltage is high, the PCM disables
most. outputs to protect the hardware. A scan tool
may not display data if system voltage is outside this
range. Use a OMM to monitor system voltage to
verify if the fault is currently present. A high voltage
may cause a stalling condition, or other driveability
concerns.


.. The PCM senses the system voltage is above
18.0 volts.
All the conditions are present for 5 seconds.

The PCM stores OTC P0563 in the PCM memory
illuminate.
The PCM will record the operating conditions at
the time the diagnostic fails. The PCM stores
this information in Failure Records.
The PCM disables most outputs.
The transmission defaults to third gear.
The TCC operation is inhibited.
The PCM will cycle the cooling fans ON and OFF
every few seconds during the time the condition
is present.


Diagnostic Aids
Important:
prevent contamlnate intrusion into the PCM.
Refer to Using Connector Test Adapters in Wiring .
Systems.
Inspect the generator voltage sense circuit for high
resistance or loose connections. These could cause an
intermittent overcharging condition. Refer to A
Diagnostic Starting Point - Engine Electrical in Engine
Electrical.
Test Description
diagnostic table.
2. This step tests for excessive generator output.
The voltage should remain below 18.0 volts.
Engine
6-1695
DTC P0563 System. Voltage High

Step
Action

Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Goto Step 3
Important: If OTC P1635 and/or P1639 are set, refer to

OTC P1635 5 Volt Reference 1 Circuit and/or OTC P1639
5 Volt Reference 2 Circuit for further diagnosis.
1. Turn OFF all the accessories.

2. Measure the battery voltage at the battery using
the DMM.
18V
3. Operate the engine speed above 2000 RPM.

Is the battery voltage less than the specified value?
Repair the Charging system. Refer to A Diagnostic
Starting Point - Engine Electrical in Engine Electrical.
Is the repair completed?

applicable.
diagnosed?
Go to Step 4
Go to Step 5
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1696
Engine

Circuit Description
The PCM EEPROM contains data which is essential

to running the engine and transmission. The PCM
continuously checks the integrity of this data.
Replace the PCM.

The ignition switch is in the crank position or the run
position.
Diagnostic Aids
Replace the PCM even if this OTC exists only in
history.
For. an intermittent, refer to Symptoms.
Test Description
The PCM is unable to correctly read data from the

flash memory.

diagnostic table.
2. This OTC indicates an internal PCM condition.

Records.
DTC P0601 Control Module Read Only Memory {ROM)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check

1

2
Replacement!Pfdgramming.
Replace the PCM.
Go to Step 3

3


using the scan toql.
diagnosed?
Go to Step 4
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine Controls - 5~ 7l
Engine
6-1697

Circuit Description

related diagnostic does not report any failures,
This OTC indicates that the PCMs internal EEPROM

is not flashed with any vehicle software. If you
install a service PCM and do not flash the EEPROM,
the engine will not run. This DTC indicates that an
un-flashed PCM causes the engine cranks but will not
run situation.

The ignition switch is in the run position.
Test Description
No software data is present in the PCM.

diagnostic table.
3. If the flashing routine fails, verify that the
equipment used is functioning properly and that all
cable connections are clean and tight. Also,
make sure that the software you download is
correct for the PCM being flashed. If everything is
OK, and a second attempt fails, the PCM is
faulty.

Records.
e

Step
Action
Value(s)
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Flash the PCM with the correct software. Refer to PCM

Does OTC P0602 reset?
1. Verify that the equipment being used is functioning

properly and that all the cable connections are clean
and tight.
2. Attempt to flash the PCM again.
Does OTC P0602 reset?

Replace the PCM.

applicable.
Does the scan tool display any OTCs that you have not
diagnosed?
Yes
Go to Step 5
Go to Step 6
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1698
Engine

Circuit Description

Records.
The PCM performs an internal self-test on it's Random

Access Memory (RAM) or read/write memory. If this
self-test fails, this DTC sets.

The ignition voltage is more than 1O volts.
The ignition is ON for 5 seconds.

The internal RAM test fails.

Replace the PCM.
Test Description
diagnostic table.
2. This DTC indicates an internal PCM condition.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

1

Replace the PCM.

4. Operate vehicle within the Conditions for Running t.he
diagnosed?
Go to Step 3
Go to Step 4
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1699
DTC P0608 Vehicle Speed Output Circuit
Export
Chevroie!J
.,Cruise
I vss I Control Jt,.
I Input I Module M
.-
16
"'Radio
.- - "'Instrument
I vss I Cluster
I
I
Jt,
I Input I
L. -
..I
BB
C3
4c,~
~
.- - "'Body
I Control
I
i
1. Module JI>
N
._ - ..1(BCM)~
[SJ
C6
.C3
, ,..
P100
0.35 DK GRN/WHT 817
0.35 DK GRN/WHT 817
0.35 DK GRN/WHT 817
0.35 DK GRN/WHT 817

A1 C200A
C200D
0.35 DK GRN/WHT 817
8242
0.35 DK GRN/WHT 817

K C220
110
0.35 DK GRNJ\IVHT+ :
~
s:l8c2- - - - - -vssOutput
PCM
C1=BLU
C2=RED
e. - .... - - .. - - -
..1
Powertrain
I Control
Jt,
M d I
O ue
(PCM) ~
582481
Circuit Description
Various components apply a voltage to the Vehicle
Speed Output circuit. The PCM creates the Vehicle
Speed Output signal by rapidly grounding this
circuit via an internal switch called a driver. The driver
opera1es at the same rate as the VSS signal input.
The various components recognize the voltage being
pulled to ground as an indication of vehicle speed.
The driver supplies the ground for the component
being controlled. Each driver has a fault line which the
PCM monitors. When the PCM commands a
component ON, the voltage of the control circuit
should be low (near O volts). When the PCM
battery voltage). If the fault detection circuit senses a
voltage other than what is expected, the fault line
status changes causing the DTC to set.

.. The ignition voltage is between 6.0 volts and
18.0 volts.
O

The condition must be present for a minimum of
5 seconds.

" The PCM stores the DTC information into memory
illuminate.

" A History DTC will clear after 40 consecutive
A last test failed (Current DTC) will clear when the
" Use a scan tool in order to clear the MIUDTC ..
6-1700
Engine
Diagnostic Aids
Test Description
Important:
Systems.

diagnostic table.
3. This step is verifying a voltage to the PCM.
5. This step is testing for a short to ground.
Engine
6-1701
DTC P0608 Vehicle Speed Output Circuit

Step
Action
Value(s)
Yes
l\lo
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 8
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to A
Diagnostic
Cluster in
Instrument
Panel, Gauges,
and Console


2. Raise the drive wheels. Refer to Lifting and Jacking
the Vehicle in General Information.
4. Disable the ASR/TCS systems, if so equipped.
5. Idle the engine in gear.
Does the vehicle speedometer indicate a vehicte speed?

4. Measure the Voltage from the vehicle speed circuit
using the DMM.
Does the DMM display above the specified value?
9.6V
1. Remove the Instrument Cluster. Refer to IP Cluster

Replacement in Instrument Panel, Gauges, and
Console.
2. Test the continuity of the vehicle speed circuit using
Systems.
Test the continuity of the vehicle speed circuit using the

DMM connected to battery ground. Refer to Testing for
Repair the open vehicle speed circuit. Refer to Wiring

Repair the grounded vehicle speed circuit. Refer to Wiring


Wiring Systems.
Wiring Systems.

Replace the PCM.
diagnosed?
10
Go to Step 10
Go to Step 10
Go to Step 10
Go to Step 9
Go to Step 10
Go to the
applicable
DTC table
System OK
6-1702
Engine

Circuit. Description
A voltage is.supplied directly to the A/C compressor
clutch relay coil. The PCM controls the relay by
When the PCM commands a component ON, the
voltage of the control circuit should be low (near
O volts). When the PCM is commanding the control
circuit to a component OFF, the voltage potential of the
circuit should be high (near battery voltage). If the
fault detection circuit senses a voltage other than what
the circuit expects, the fault line status changes
causing the OTC to set.
The relay controls the high current flow to the A/C
compressor clutch. This allows the PCM driver to only
have to handle the relatively low current used by
the relay.

The engine speed is greater than 400 RPM.
18.0 volts.

Condition must exist for a minimum of 5 seconds.

when the diagnostic runs .and fails.
" The malfunction indicator lamp (MIL) will not
illuminate.

Diagnostic Aids
Important:
the PCM connector. gaskets when
diagnosing/replacing .the PCM. Ensure that the
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness/component
in Wiring Systems.
Test Description
The numbers below refer to the step. numbers on the
diagnostic table.
2. Liste.n for an audible click when the relay operates.
A/C relay. The A/C Cruise mini fuse supplies
power to the coil side of the A/C relay.
ground to the A/C relay.
6. This step tests if ground is constantly being
applied to the A/C relay.
Engine
6-1703

Step
Action
Value(s)

data for this DTC.
4. Operate the vehicle within the same Conditions for
Does the DTC reset?

2. Disconnect the A/C relay from the underhood
electrical center.
4. Probe the coil side feed circuit of the A/C, relay with a
test lamp that is connected to a good ground. Refer

A/C relay and the coil side feed circuit of the
A/C relay.
and OFF.
command?

command?
1. Test the control circuit of the A/C relay for an open.

1. Test the control circuit of the A/C relay for a short to

ground. Refer to Circuit Testing in Wiring Systems.
1. Inspect for poor connections at the A/C relay. Refer

Wiring Systems.
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Goto
Intermittent
Conditions
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12
1. .Turn ON the ignition, with the engine OFF.

and OFF.
Does the A/C relay turn ON and OFF with each
command?
Yes
6-1704
Engine
DTC P0645 Air Conditioning (A/C) Clutch Relay Control Circuit (cont'd)
Step
Action
Value(s)
Yes
No
10

Wiring Systems.
2: If you find a condition, repair as necessary. Refer to
11
Repair the coil side feed circuit of the NC relay. Refer to

12
Replace the NC relay.

13

Replace the PCM.
14

the DTC as specified in the supporting text.
Does the DTC reset?
15
With a scan tool, review the Stored Information

(capture info).
diagnosed?
Go to Step 13
.Go to Step 14
Go to Step 14
I
Go to Step 14
Go to Step 14
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
Engine
6-1705
DTC P0650 Malfunction Indicator Lamp (Mil) Control Circuit
,. - - - - I
1
I
:f
I
L-
- - ., Instrument
Malfunction
Indicator
Lamp (MIL)
(SERVICE
ENGINE SOON)
I
I
Cl USter
>
I"'~
I~
LI.I
------.1
A8I
0.35 BRN/WHT 419

B
C230
P110.
0.35 BRN/WHT 419

46 C2
~
- MIL - - - - - Control
-PCM -
Powertrain
Control
C1=BLU
c2=RED
'------------.1
Module
(PCM)
>
582267
Circuit Description
A voltage is supplied directly to the malfunction
indicator lamp (MIL}. The powertrain control
module (PCM) controls the lamp by grounding the
has a fault line which is monitored by the PCM. When
the PCM is commanding a component ON, the
voltage of the control circuit should be near O volts.
When the PCM is commanding the control circuit to a
component OFF, the voltage potential of the circuit
should be near battery voltage. If the fault detection
circuit senses a voltage other than what is expected,
the fault line status will change causing the DTC
to set.

18.0 volts.

The conditions are present for a minimum of
5seconds.

The PCM stores OTC P0650 in memory on the
second consecutive ignition cycle that the
diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL} will not
illuminate.

Failure records.

A History DTC will clear after 40 consecutive
" A last test failed (Current OTC) will clear when the
Diagnostic Aids
Important:
Systems.
If the ignition feed circuit is suspected of being open,
inspect for lamps on the same circuit not illuminating.
Test Description
diagnostic table.
2. Command both the ON and the OFF states.
8. If you do not find trouble in the control circuit or
the connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.
6-1706
Engine
DTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 5

10
Important: If the 1/P is completely inoperative, refer to A

Diagnostic System Check - Instrument Cluster in
Instrument Panel, Gauges, and Console.
2. Command the indicator lamp ON and OFF using the
Scan tool.
Does the indicator lamp turn ON and OFF with each
command?

opposite side of the manufacturer's logo Refer to
Is the indicator lamp OFF?
Probe the indicator lamp control circuit in the PCM

harness connector with a fused jumper wire connected to
ground. Refer to Using Fused Jumper Wires in Wiring
Systems.
Is the indicator lamp ON?
Repair the short to. ground in the indicator lamp control

1. Inspect for poor connections at .the PCM. Refer to

Testing tor Intermittent and Poor Connections in
Wiring Systems.
Wiring Systems.

Faulty indicator lamp
Open ignition feed to the indicator lamp
Control circuit open or shorted to B+

Replace the PCM.
1. Select the Diagnostic Troubl.e Code (OTC) option and

diagnosed?
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 9
Go to Step 8
Go to Step 9
Go to Step 9 .
Go to Step 10
Go to the
applicable
OTC table
Go to Step 2
(
System OK
Engine Controls - 5,7L
Engine
6-1707
DTC P0704 Clutch Switch Circuit
r - - - - ...., , Cruise
I
""
0.35 BLK/WHT 451
Clutch
I Control
Anticipate I (Clutch)
t____ . Switch
Switch
0.35GR~I~
A
--------------
C270
0.35 BLK/WHT 451
.------I
I
I
I
I
I
0.8 BLK/WHT 451
.Ii.
0.8 BLK/WHT 451
0.35 GRY 48
8215
Ground
Distribution
Schematics
--------------4
C220
P110
~
___ _
In Wiring
0.35 GRY 48
8110
Systems
32 Ci
3 BLK 451
G110
-c;c; - - - -
I
I
Switch
Signal
I
"" -
1
-
--- -
= - - , Powetrain
I Control
01 :BLU
I Module ..
PCM
I (PCM) ~
C2-RED
-
.I
582489
Circuit Description
1he Clutch Pedal Position Switch is a normally closed
switch. The PCM applies a voltage (B+) to the
Clutch Pedal Position Switch circuit. When the Clutch
Pedal Position Switch is depressed (clutch pedal
released) the circuit is open and the PCM senses a
high voltage. When the Clutch Pedal Position Switch is
released (clutch pedal depressed) the Clutch Pedal
Position Switch contacts close, causing the applied
voltage to go low.
The PCM determines if the Clutch Pedal Position
Switch has failed by not sensing a clutch switch
transition. The PCM monitors vehicle speed from Oto
a predetermined speed.

I\Jo VSS DTCs.
Conditions for Setting th~ DTC

Vehicle speed goes from O mph to more than
24 mph and back to O mph for 2 seconds without
the PCM detecting a clutch transition ..
This occurs 7 times before the diagnostic reports
a fault.


illuminate.
6-1708
Engine Cc:mtrols - 5.7l

Use a scan tool in order to clearthe MIUOTC.
Engine
Test Description
diagnostic table.
Diag11ostic Aids
Important:
Systems.
DTC P0704 Clutch

Switch Circuit
.
Action
Step
Value(s)
Yes
No
Go to Step 2
Goto A
Powertrain On
Board
Diagnostic (080)
System Check
Goto
Diagnostic Aids
Go.to Step 3
Go to Step 14
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 8


3. Monitor the clutch pedal position switch parameter
4. Depress and release the clutch pedal several times.
Does the scan tool display change states when the clutch
pedal is depressed and released?
Inspect the adjustment of the clutch pedal position switch.

Refer to Clutch Pedal Position Switch Replacement in
Clutch.
Was an adjustment necessary?
'1.
Turli OFF the ignition.

2 . Disconnect the clutch pedal position switch
connector.
4. Measure the voltage from the clutch pedal position
signal circuit using the DMM. Refer to Measuring
Voltage in Wiring Systems.
B+
1. Jumper the clutch pedal position switch

terminals together using a fused jumper wire. Refer to
2. Monitor the clutch pedal position switch parameter
using a scan tool.
Does the scan tool display the Clutch Switch Released?
Engine
6-1709
DTC P0704 Clutch Switch Circuit (cont'd)

Step
6
Action
Test the continuity of the clutch pedal signal circuit using
the DMM connected to ground. Refer to Testing for
Value(s)

3. Test the continuity of the clutch pedal signal circuit
Wiring Systems.
B+
Test the continuity of the clutch pedal ground circuit using

Systems.
1. Inspect for poor connections at the clutch pedal

position switch connector. Refer to Testing for
Systems.
10

Wiring Systems.
Systems.
11
Repair the clutch pedal position switch signal circuit. Refer

Go to Step 7
Go to Step 10
Go to Step 11
Go to Step 9
Go to Step 12
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Replace the clutch pedal position switch. Refer to Clutch

Pedal Position Switch Replacement in Clutch.
14

Replace the PCM.
15

scan tool.
16
13
Go to Step 11
Go to Step 15
Repair the clutch pedal position switch ground circuit.

12
No
Yes
Go to Step 15
Go to Step 15
Go to Step 15
Go to Step 16
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1710
Engine
DTC P0801 Reverse Inhibit Solenoid Control Circuit
IHot With Ignition Relay Energiz~d I

'" -P.;,e-;- - I
Distribution
I Schematics
I In Wiring
I Systems
ID
. LJ
- - - ., Engine
ENG SEN . I Wiring
MlniFuse 1Harness
I Junction
20A
I Block
L----- -----'
0.8 PNK 539
C105
0.8 PNK 539

Power
Distribution
Schematics
In Wiring
Systems
8104
~--
0.8PNK 539
[m
0.8 PNK 539
[m
'" - ; - - - - - - - - - - A - - - - . . Manual
1
1
:
Reverse
Inhibit
_Solenoid
11
0.35 L/GR:11652
44 C2
~
1
- -1'- ;v;;;s;;n;b
/
0
1;- -
Solenoid Control
----f
- .. -
- -
I
I Transmission
0.35 GR:t.587
79 C1
-,
-s; ;ift- - - - - ~ PCowetr~in
--1~
.. - -
II
Skip
Shift
Solenoid
- . - .... - .. -
Solenoi.d Control
PCM
C1=BLU
C2=RED
..... - - - ~ -
I ontro
I Module
I (PCM)
I ~
.. . a ~
(
582491
Circuit Description
A voltage is supplied directly to the Reverse Inhibit
solenoid. The PCM controls the solenoid by grounding
the control circuit via an internal switch called a
driver. The driver supplies the ground for the
component being controlled. Each driver has a fault
line which the PCM monitors. When the PCM
commands a component ON, the voltage of the control
circuit should be low (near O volts). When the PCM
commands the control Circuit to a component OFF, the
When the Reverse Inhibit solenoid energizes, the
operator can shift the transmission into reverse. The
PCM enables the Reverse Inhibit solenoid whenever
vehicle speed is below 5 mph. When the vehicle speed
is above 5 mph, the PCM de-energizes the solenoid,
which prevents the operator from shifting the
transmission into reverse.

The engine speed is more than.400 RPM.
18.0 volts.

Condition must exist for a minimum of 5 seconds.

The PCM stores the DTC information into. memory
" The malfunction indicator lamp (MIL) will not
illuminate.

.. A History DTC will clear after 40 consecutive
O A last test failed (Current DTC) will clear when the
Engine
5,.1111
Diagnostic Aids
Test Description
Important:
Systems.
Low system voltage can cause this OTC to set. When
reviewing captured data, verify if a low system
voltage condition was present at the time the OTC
was stored in memory.

diagnostic table.
2. Listen for an audible clicl\When the solenoid
states are commanded. Rep~at the commands
as necessary.
Reverse Inhibit solenoid. The ENG SEN fuse
supplies power to the coil side of the Reverse
Inhibit solenoid.
ground to th.e Reverse Inhibit solenoid.
6. This step tests if a ground is constintly being
applied to the Reverse Inhibit solenoid.
OTC P0801 Reverse Inhibit Solenoid Control Circuit

Step
Action
Values
Yes

1. Start the engine and idle at the normal operating

temperature.
and OFF.
No
Go to Step 2 ..
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3 .
Go to Step 4
..

for this OTC.
3


2. Disconnect the solenoid electrical connector.
4. Probe the coil side feed circuit of the Reverse Inhibit
ground.

Reverse Inhibit solenoid and the coil side feed circuit
of the Reverse Inhibit solenoid. Refer to Probing
2. With a scan tool, command the Reverse Inhibit
solenoid ON and OFF.
command?

command?
Go td Step 4
Go to
Intermittent
Conditions
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
6-1712
Engine

DTC P0801 Reverse Inhibit Solenoid Control Circuit (cont'd)
Action
Step
1. Test the control circuit of the Reverse Inhibit solenoid

for a short to voltage or an open. Refer to Circuit
Values
Yes
No
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 13
1. Test the control circuit of the Reverse Inhibit solenoid

for a short. to ground. Refer to Circuit Testing in
Wiring Systems.

1. Inspect for poor connections at the Reverse Inhibit


Wiring Systems.
10


11
Repair the coil side feed circuit of the Reverse Inhibit

solenoid. Refer to Wiring Repairs in Wiring Systems.
12
Replace the Reverse Inhibit solenoid. Refer to Reverse

Lockout Solenoid in Manual Transmission MM6.
13
(
-
Go to Step 14
Important: Program the replacement PCM.

Programming.
Go to Step 14
Go to Step 14

14

DTC as specified in the supporting text.
Does the DTC reset?
15

(capture info).
diagnosed?
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
Engine
6-1713
DTC P0803 Skip Shift Solenoid Control Circuit
0.8 PNK 539

B
C105
0.8 PNK 539

Power
Distribution
Schematics
In Wiring
Systems
8104
-1111---------~
-+- - -
0.8PNK 539
i" -
0.8 PNK 539

-
-;
1
[ ] Reverse
I
Inhibit
11
[ ] Skip
Shift
II
Solenoid
Solen~id
I Br
Bt
0.35 GRY 587
44 C2
~
"'Manual
1
Transmission
I
0.35 L/GRN 1652
I
1
"--1~
79 C1
- -,C ;v:s;;n;:;;b;;- f
I
.a
Solenoid Control
-,
-s; ;ift- - - - - ~ Powetrain
--1
~
Solenoid Control
PCM
Control
I
I Module
1 (PCM)
~~I~
c1 =BLU
~----------------------J~
582491
Circuit Description
A vol1age is supplied directly to the Skip Shift solenoid
coil. The PCM controls the solenoid by grounding
the control circuit via an internal switch called a driver.

Ignition voltage is more than 6.0 volts but less
than 18.0 volts.

All conditions exist for a minimum of 5 seconds.

The PCM stores the DTC information into memory
The malfunction indicator lamp (MIL) w.ill not
illuminate.
0

.. A History DTC will clear after 40 consecutive
A last test failed (Current DTC) will clear when the.
6-1714
Engine
Diagnostic Aids
Test Description
Important:
Systems.
Low system voltage can cause this OTC to set. When
reviewing captured data, verify if a low system
voltage condition was present at the time the DTC
was stored in memory.
For an intermittent condition, re-fer to Symptoms.

diagnostic table.

as necessary.
Skip shift solenoid. The ENG SEN fuse supplies
power to the coil side of the Skip shift solenoid.
ground to the Skip shift solenoid.
applied to the Skip shift solenoid.
DTC P0803 Skip Shift Solenoid Control Circuit

Step
Values
Action

'
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
1. Start the engine and idle at the normal operating

temperature.
and OFF.

for this OTC.

2. Disconnect the Skip shift solenoid electrical
connector.
4. Probe the coil side feed circuit of the Skip shift
ground.

Skip shift solenoid and the coil side feed circuit of the
Skip shift solenoid. Refer to Probing Electrical
2. With a scan tool, command the Skip shift solenoid
ON and OFF.
command?

command?
(
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Intermittent
Conditions
Go to Step 5
Go to Step 11
Go to Step 9
Go to Step 6
Go to Step 8
Go to Step 7
Engine
6-1715
DTC P0803 Skip Shift Solenoid Control Circuit (cont'd)

Step
Action
1. Test the control circuit of the Skip shift solenoid for a

short to voltage or an open. Refer to Circuit Testing
in Wiring Systems.
1. Test the control circuit of the Skip.shift solenoid for a

Systems.
1. Inspect for poor connections at the Skip shift

10

Wiring Systems.
11
Repair the coil side feed circuit of the Skip shift solenoid.
Replace the Skip shift solenoid. Refer to Gear Select/Skip

Shift Solenoid Replacement in Manual Transmission MM6.
13
Important: Program the replacement PCM.

Programming.
14

Does the OTC reset?
15

(capture info).
diagnosed?
12
Values
Yes
No
Go to Step 14
Go to Step 10
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 12
Go to Step 14
Go to Step 13
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 2
Go to Step 15
Go to Diagnostic
Trouble
Code (OTC)
List/Type
System OK
6-1716
Engine
DTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage
'" - - -sv - "' Powertrain
IAT
I S~nsor
~~n~-
sl
I Module
I (PCM)
-~
25 'c2
rn
control
IL 0 c
~
N
lnlake
Air
Temperature
,e.~
(IAT)
0.35 TAN 472
Sensor
0.35 PPL 719

8128
0.35 PPL
719
0.35 PPL 719

57
A/C
~
Refrigerant
Pressure
Sensor
C2
" --- ---., Powertrain

-1I
I
I I Control
r-
PCM
IC1=BLU
I~' Module
"
(PCM) ~
Sensor
. . C2=RED
Ground ...... __ ..
582415
Circuit Description
semiconductor device which changes resistance based
on temperature (a thermistor). The IAT sensor
mounts in the air intake passage of the engine air
induction system. The IAT sensor has a signal circuit
and a ground circuit. The PCM applies a voltage
determine the intake air temperature.
resistance is high, and the PCMs signal voltage is only
pulled down a small amount through the sensor to
ground. The PCM senses a high signal voltage
(low temperature). When the intake air is warm, The
sensor resistance is low, and the signal voltage is
pulled down a greater amount. This causes the PCM
to sense a low signal voltage (high temperature).
sensor.

OTCs P0102, P0103, P0117, P0118, P0500,
.. The engine run time is more than 100 seconds.
" The engine coolant temperature is more
than 0C (32F).
.. The mass air flow is less than 15 g/s.

The intake air temperature is less
than -35C (-31 F).
.. The intermittent condition exists for a total of
1 second during a 20 second time period.

illuminate.

Diagnostic Aids
Important:
Systems .
Temperature vs Resistance .
Engine
Test Description
diagnostic table.
6-1717
4. When moving the related wiring harnesses,

visually/physically inspect the wiring for the
following:
2. If OTC PO'l '13 also failed this indicates a hard

failure is present. When a hard failure is present,
both the hard and intermittent DTCs set.
.. Wire insulation that is rubbed through, causing

an intermittent short.
3. When moving related connectors,

visually/physically inspect connectors for the
following:
(backed out).
Improperly formed or damaged terminals.
Carefully reform or replace all connector
terminals in the related circuits in order to
insure proper terminal contact tension.
Poor terminal to wire connection. Inspect for
poor crimps, crimping over wire insulation
rather than the wire.
Dirt or corrosion on the terminals. Inspect for
missing connector seals and for damage to
the connector seals.

Wiring broken inside the insulation.
DTC P1111 intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0113
Intake Air
Temperature (/AT)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5

1
Did DTC P0113 Fail This Ignition cycle?

2. Observe the affected sensor value on a scan tool
while moving the related harness connectors (at the
component and the PCM).
Does the sensor value change abruptly while a related
connector is being moved?
Observe the affected sensor value on a scan tool while

moving the related wiring harnesses.
Does the sensor value change abruptly while moving the
related electrical harnesses?
6-1718
Engine
DTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage (cont'd)
Step
Action
Value(s)

the DTC.
Specific DTC option, th(,m enter the DTC number
ignition?
Repair the damaged connectors/terminals. Refer to

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.
1. Re-inspect all the related circuits and the connectors.

2. Replace the sensor/component if all the circuits have
been tested thoroughly and no faults can be found.
1.. Select the Diagnostic Trouble Code (DTC) option and

the DTC as specified in the supporting text; if
applicable.
10
diagnosed?
Yes
No
Go to Step 8
Go 1o
Diagnostic Aids
Go to Step 9
Go to Step 9
Go to Step 9
Go to Step 10
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1719
DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent low Voltage
r -
II
Powertrain
I Control
IAT
I S~nsor
~ ~n~
Jsv - "'
25
C2
Module
(PCM)
rn
~ ~
~
0.35 TAN 472
Intake
Air
Temperature
(IAT)
Sensor
0.35 PPL 719

A/C
0.35 PPL
8128 ------II'" Refrigerant
719
Pressure
Sensor
0.35 PPL 719
C2
57
r -
'F - - - - - - - "' Powertrain
1C t I
I on ro
A
Sensor
c2-RED
Module p,
~ Ground_ _ - ___ ~ (PCM) ~
PCM
C1=BLU
582415
Circuit Description
semiconductor device which changes resistance based
on temperature (a thermistor). The IAT sensor
mounts in the air intake passage of the engine air
induction system. The IAT sensor has a signal circuit
and a ground circuit. The PCM applies a voltage
determine the intake air temperature.
resistance is high, and the PCMs signal voltage is only
pulled down a small amount through the sensor to
ground. The PCM senses a high signal voltage
(low temperature). When the intake air is warm, the
sensor resistance is low, and the signal voltage
is pulled down a greater amount. This causes the PCM
to sense a low signal voltage (high temperature).
normal operating range of the sensor, this DTC sets.

DTCs P0102, P0103, P0117, P0118, P0500,
than 0C (32F).
The vehicle speed is at least 40 km/h (25 mph).
The mass air flow is less than 15 g/s.

The intake air temperature is less
than -35C (-31 F).
The intermittent condition exists for a total of

.. The malfunction indicator lamp (MIL) will not
illuminate.

" A last test failed (Current DTC) will clear when the
Diagnostic Aids
Important:
Systems.
5.;1720
Test Description
diagnostic table.
2. If DTC P0112 also failed this indicates a hard
following:
" Poor mating of the connector halves or a
(backed out).
.. Improperly formed or damaged terminals.
.. Poor terminal to wire connection. Inspect for
" Dirt or corrosion on the terminals. Inspect for
Engine
4. When moving the r~lated wiring harnesses,
following:
Wire insulation that is rubbed through, causing

.. Wiring broken inside the insulation.
DTC P1112 Intake Air Temperature (IAT) Sensor Circuit lntermjttent low Voltage
Action
Step
Value(s)

1
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
OTC P0112
Intake Air
Temperature (/AT)
Sensor Circuit
Low Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step5
Did DTC P0112 also set?
2. Observe the affected sensor value on a scan tool

while moving related harness connectors (at the

Observe the affected sensor value on a scan tool while

Engine
6-1721
DTC P1112 Intake Air Temperature (!AT) Sensor Circuit Intermittent Low Voltage (cont'd)
Step
Action
Value(s)
Yes
No
Go to Step 8
Go to
Diagnostic Aids
i. Turn ON the ignition leaving the engine OFF.

the DTC.
ignition?


Systems.

2. Replace the sensor/component if all the. circuits have

applicable.
10
diagnosed?
Go to Step 9
-
Go to Step 9
Go to Step 9
Go to Step 10
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1722
Engine
sl
[I]
0.35 YEL 410
IL 0 c
Engine Coolant
Temperature (ECT)
Sensor
[S]
N
'---1 r---1-----,
0.35 BLK 407
74
I ECT
I Sensor
80
ECT
Sensor
Ground -=-
Is~~
C1
PCM I
C1=BLU
C2=RED
I
I
I
I
Powertrain
Control
Module
(PCM)
A.
I~
L----------------J~
585397
Circuit Description

contains a semiconductor device which changes
resistance based on temperature (a thermistor). The
ECT sensor mounts in the left bank cylinder head near
the front of the engine. The ECT sensor has a
signal circuit and a ground circuit. The PCM applies a
voltage (about 5.0 volts) on the signal circuit to the
sensor. The PCM monitors changes in this voltage
caused by changes in the resistance of the sensor in
order to determine the engine coolant temperature.
When the engine coolant is cold, the sensor
(thermistor) resistance is high, and the PCMs signal
voltage is only pulled down a small amount through the
sensor to ground. The PCM senses a high signal
voltage (low temperature). When the engine coolant is
warm, the sensor resistance is low, and the signal
voltage is pulled down a greater amount. This causes
the PCM to sense a low sJgnal voltage (high
temperature).

The Engine Coolant Temperature is more than
139C (282F) for less than a second.
Acti.on Taken When the DTC Sets

illuminate.
Conditions for Clearing the .Mll/DTC

Engine
Diagnostic Aids
Important:
Systems.
Electromagnetic interference (EMI) can cause an
intermittent DTC. Inspect the related circuits for being
too close to secondary ignition wires and the
generator.
Test Description
)

diagnostic table ..
2. If OTC P01 l7 also failed this indicates a hard
6-1723

following:
(backed out).
" Improperly formed or damaged terminals.
Dirt or corrosion on the terminals. Inspect for
following:
Wire insulation that is rubbed through, causing
'" Wiring broken inside the insulation.
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check

-
Go to
OTC P0117
Engine Coolant
Temperature (ECT)
Sensor Circuit
Low Voltage
Go to Step 3
2. Observe the affected sensor value on the scan tool

3

Observe the affected sensor value on the scan tool while
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5
6-1724
Engine
DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage (cont'd)
Action
Step
Value(s)
Yes
No


this diagnostic to run, and a,s close to the conditions
the OTC.

ignition?
Go to Step B


Systems.
1.. Re-inspect all the related circuits and the connectors.


Go to Step 9

Go to Step 9
Go to Step 9
Go to
Diagnostic Aids

applicable.
10
Selectthe Capture Info option and the Review Info option

diagnosed?
Go to Step 10
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine Controls~. 5.7L
Engine
6-1725
OTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage
JLoc I
[11
0.35 YEL 410
Engine Coolant
Temperature (ECT)
Sensor
LliJ
0.35 BLK 407

74
80
,. - - - sv- - - - - I
I
I ECT
I Sensor
I Signal
TT
.lJ
ECT
i-----.,
C1
PCM
Sensor
G=od a
C1=BLU
C,eR,O
Powertrain
I Control
I Module
I {PCM)
I
A
I
L----------------J~
585397
Circuit Description

contains a semiconductor device which changes
resistance based on temperature (a thermistor). The
ECT sensor mounts in the left bank cylinder head near
the front of the engine. The ECT sensor has a
signal circuit and a ground circuit. The PCM applies a
voltag~ (about 5.0 volts) on the signal circuit to the
sensor. The PCM. monitors changes in this voltage
caused by changes in the resistance of the sensor in
order to determine the engine coolant temperature.
Engine operates longer than 60 seconds.
When the engine coolant is cold, the sensor

(thermistor) resistance is high, and the PCMs signal
voltage is only pulled down a small amount through the
sensor to ground. The PCM senses a high signal
voltage (low temperature). When the engine coolant is
warm, the sensor resistance is low, and the signal
voltage is pulled down a greater amount. This causes
the PCM to sense a low signal voltage (high
temperature).
When the PCM senses. a signal voltage higher than the

s

The engine coolant temperature IS less than
-35C (-31 F) for less than a second.
Action Taken . When the DTC Sets

" The malfunction indicator lamp (MIL). will not
illuminate.
9 The PCM records the operating conditions at the
s

A History OTC will clear .after 40 consecutive
or any other non-emission related diagnostic,
6-1726
Diagnostic Aids
Important:
Systems.
. Electromagnetic interference (EMI) can cause an
intermittent OTC. Inspect the related circuits for being
generator.
Test Description
diagnostic table.
2. If OTC P0118 also failed this indicates a hard
both the hard and intermittent OTCs set.
Engine
following:
(
" Poor mating of the connector halves or a

(backed out).
0 Poor terminal to wire connection. Inspect for
O Dirt or corrosion on the terminals. Inspect for
the connector seals .
following:
.. Wire insulation that is rubbed through, causing
" Wiring broken inside the insulation.
If you canno.t duplicate the OTC, the information
since the OTC set. The Fail Counter .and Pass
ignition cycles the. diagnostic: reported a pass
(
,freeze frame. conditions (RPM, load, vehicle
Step
Action
Value(s)
Yes
No
Goto Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0118
Engine Coolant
Temperature (ECT)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5

Did DTC P0118 also set?

2. Observe the affected sensor value on the scan tool
Observe the affected sensor value on the scan tool while

Engine
6-1727
(cont'd)
Step
Action
Value(s)

the DTC.
ignition?


Systems.


applicable.
10
diagnosed?
Yes
No
Go to Step 8
Go to
Diagnostic Aids
Go to Step 9
Go to Step 9
Go to Step 9
Go to Step 10
Go to Step 2
Go to the
applicable
DTC table
System OK
~-1728
Engine
DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage
sv - - - - - - ., Powertrain
Control
:I
r- - - -
TP Sensor
sv
I Reference
""-
- -
: (PCM)
Ic l
_______ ., /&
mil
8 VC1
0.35 GRY 596
8116
0.35 GRY
596
Antllock
Brakes
Schematics
In Brakes
0.35 GRY 596
I
r5J
A.
IL 0 c
I
I Module
.ll
Throttle
Position (fP)
Sensor
B
0.35 BLK 4 52
0.35 DKBLU 417

0.35 DKBLU
8118
417
0.35 BLK
8119
452
0.35 DKBLU 417
0.35BLK 4 52
24 C2
60 C1
. . -TP - '."" - - - - I
I
I
I. -
- -
Cj~~~
1
.Control
Module J.
(PCM) ~
c2:RED
. Sensor
Ground
-
Antllock
Brakes
Schematics
In Brakes
-1'- - - - - - - - ., Powertrain
,!.
Sensor1
Signal
_
I
I
-
.,
582456
Circuit Description
The Throttle Position (TP} sensor is a potentiometer.
TP sensor Signal voltage should be about 0.6 volt at
idle. The TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT}.
DTC sets.

The ignition switch is in the Run position.

.. The TP sensor voltage is more than 4.8 volts.
0
The intermittent condition exists for a total
of 1 second during a 20 second time period.

" The malfunction indicator lamp (MIL} will not
illuminate.
., The PCM records the operating conditions at the

O A last test failed (Current DTC) will clear when the
Diagnostic Aids
Important:
~ Remove any debris from the PCM connector
prevent contaminate intrusion .into the PCM.
Systems.

intermittent DTC. Inspect the related circuits for being
generator.
Engine
Test Description
Number(s) below refer to step numbers on the
diagnostic table.
2. If OTC P0123 also failed this indicates a hard
both the hard and intermittent DTCs will set.
following:
(backed out).
Dirt or corrosion on terminals. Inspect for
missing connector seals and for damage to the
connector seals.
6-1729
4. When moving related wiring harnesses,

visually/physically inspect wiring for the following:
Wire insulation that is rubbed through,
causing an intermittent short.
.. Wiring broken inside the insulation.
the DTC cannot be duplicated, the information
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
were noted. This will isolate when the DTC failed.
If this DTC runs and passes the diagnostic, the
scan tool will not indicate any information
under DTC Status.
DTC P1121 Throttle Position {TP) Sensor Circuit Intermittent High Voltage
.
Step
Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?
Value(s)
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
DTCP0123
Throttle
Position (TP)
Sensor Circuit
High Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5
Yes

2. Turn the ignition ON, engine OFF.
3. Using a scan tool, observe affected sensor value
while moving related harness connectors (at
component and PCM).
Does sensor value change abruptly while a related
Using a scan tool, observe affected sensor value while

moving related wiring harnesses.
Does sensor value change abruptly while moving related
electrical harnesses?
6-1730
Engine
DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage (cont'd)
Step
Action
1. Turn the ignition ON, engine OFF, review Freeze
Frame and/or Failure Records data for this OTC and
note parameters.
2. Turn the ignition OFF for 15 seconds.
conditions required for this diagnostic to run, and as
Conditions for Running the OTC.
Value(s)
Repair damaged connectors/terminals. Refer to Connector

.Repairs in Wiring Systems.
Repair faulty wiring. Refer to Wiring Repairs in Wiring

Systems.
1. Re-inspect all related circuits and connectors.

2. If all the circuits have been tested thoroughly and no
faults can be found, replace the sensor/component.

applicable.
10
diagnosed?
No
Go to Step 8
Goto
Diagnostic Aids
4. Using the scan tool, select OTC, Specific, then enter

the OTC number which was set.
ignition?
Yes
Go to Step 9
Go to Step 9
Go to Step 9
(
-
Go to Step 10
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1731
DTC P1122 Throttle Position (TP) Sensor Circuit Intermittent low Voltage
r -
- - - - - - - ., Powertrain
v
I Control
I Module
: (PCM)
:I TP SensorIs
sv
I Reference
L -
._....,.....,
Ic '
-------.a.~
C1
~
0.35 GRY 596
8116
0.35 GAY~
596
Anti lock
Brakes
Schematics
In Brakes
0.35 GRY 596
B"
0.35 BLK 4 52
0.35 DK BLU
8118
417
$119
417
0.35 DK BLU
24 C2
I
I
L2w
417
0.35 DK BLU
"ii
Throttle
Position (TP)
Sensor
452
0.35 BLK 4 52
60
-T;;- - - - - - - Sensor1
Signal
0.35 BLK
Anlilock
Brakes
Schematics
In Brakes
-.f - - -P;;-M- - -
~
Sensor
Ground
. Cj-BLU
c2:RED
~ Powertrain
Control A
I Module . Jiii
I (PCM) ~
~---~--------------J
582456
Circuit Description
TP sensor Signal voltage should be about 0.6 volt at
idle. The TP sensor voltage should increase to

tP sensor voltage is less than 0.2 volts for 0.3 second.

.. TP sensor voltage is less than 0.2 volts.
~ The intermittent condition exists for a total of

illuminate.
inrormation in the Failure Records.
O
Con.ditions for Clearing the MIUDTC

.. A History OTC will clear after 40 consecutive
diagnostic runs arid does not fail.
" Use a scan tool in order to clear .the MIUOTC.
Diagnostic Aids.
Important:
prevent.contaminate intrusion into the PCM.
connector test.adapter kit. Using this kit prevents
Systems.
intermittent OTC, Inspect the related circuits for being
generator.
6-1732
Engine
Test Description
Number(s) below refer to step numbers on the
diagnostic table.
2. If DTC P0122 also failed this indicates a hard
both the hard and intermittent DTCs will set.
The engine must be operating longer than
30 seconds before inspecting if the DTC set.
following:
(backed out).
" Improperly formed or damaged terminals. All
connector terminals in the related circuits
should be carefully reformed or replaced to
insure proper contact tension.
rather than the wire .
.. Dirt or corrosion on terminals. Inspect for
missing connector seals and for damage to the
connector seals.
4. When moving related wiring harnesses,

visually/physically inspect wiring for the following:
Wire insulation that is rubbed through,
causing an intermittent short.
Wiring broken inside the insulation.

the DTC cannot be duplicated, the information
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehide
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
were noted. This will isolate when the DTC failed.
DTC P1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P0122
Throttle
Position (TP)
Sensor Circuit
Low Voltage
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5
Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
-

2

2. Turn the ignition ON leaving the engine OFF.
3. Using a scan tool, observe affected sensor value
while moving related harness connectors (at
component and PCM).
Does sensor value change abruptly while a related
Using a scan tool, observe affected sensor value while

moving related wiring harnesses.
Does sensor value change abruptly while moving related
electrical harnesses?
Engine
6-1733
DTC P1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage (cont'd)
Action
Step
Value(s)
Yes
No
Go to Step 8
Go to
Diagnostic Aids
1. Turn the ignition ON leaving the engine OFF. Review

Freeze Frame and/or Failure Records data for this
OTC and note parameters.
2. Turn the ignition OFF tor 15 seconds.
conditions required tor this diagnostic to run, and as

Conditions tor Running the OTC.
4. Using the scan tool, select OTC, Specific, then enter

the OTC number which was set.
Does the scan tool indicate that this diagnostic tailed this
ignition?
6


Systems.
Go to Step 9
Go to Step 9

1. Re-inspect all the related circuits and connectors.
2. If all the circuits have been tested thoroughly and no

faults can be found, replace the sensor/component.
Go to Step 9


9


applicable.
10
Select the Capture Into option and the Review Info option
diagnosed?
Go to Step 10
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1734
Engine
(
~
Fuse Block
Details
Cell 11
.----------------- - - - - - - .. -
;a;k;; -
I
Lett Front
I
I H02S
H02S
0.8
PNK 539
69Io 8
B
0.8
- - - ., Powertrain
CONN ID I Control
C1=BLU
I Module
C2=RED i (PCM)
.. -_-:..:-_:-_-: - - - -- -- - - - .,
High
PPL/WHT
Low
291c1
TAN/WH: 1653
.. -
I
I
I
I
I
I
I
I
I
J7
ENG SEN
Fuse 10
20 A
J6.
-
1
I
-
,J
Wmng
Harness
Junction
Block 2
0.8 PNK 539

8
0.8 PNK 539
'f
1665
Bank 1 H02S #2
Bank 2 H02S 111
Bank 2 H02S #2
Bank #1
left Front
Heated Oxygen
Sensor (H02S) #1
C
0.8
Pow"';r - - - - - - - - - -- ~ Ef:Qine
I .Distribution
Schematics
I
in Wiring
I Systems
BLKl~4_5_o______________
0.8 BLKt=4~,-:
I
I
I
I
===.= =- ~-. .
G=M
Distribution
._._ce....
11 ...
14_....
582459
Circuit Description
'The PCM monitors the Heated Oxygen Sensor

(H02S} activity for 100 seconds. During this monitor
period the PCM counts the number of times that
the H02S switches form rich to lean and lean to rich.
A OTC P1133 sets when the PCM determines that
the H02S did not switch enough times.
A lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to more than
less than 300 mV.
The PCM determines that within 100 seconds the

H02S lean to rich switches are less than 10 and rich
to lean switches are less than 10.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P0506,
P0507, P1258 not set.
The engine speed is more than 1,000 RPM
but less than 2,300 RPM.
50C (122F).
The MAF is between 20 g/s and 50 g/s.
The EVAP purge duty cycle is more than
O percent.

Failure Records.

Engine
6-1735
Diagnostic Aids
Test Description
Important:
Systems:
Inspect the H02S signal circuit for being shorted to a
PCM ground. The H02S signal circuit shorted to a
PCM ground will not cause a H02S low DTC to set,
but will set a switching DTC.
A malfunction in the H02S heater circuits will cause a
DTC P1133 to set. Inspect the H02S heater circuits
for intermittent opens/connections. Refer to Testing for
for proper operation. This supply of oxygen is provided

diagnostic table.

to run.
3. When DTCs 1133 and P1153 are set at the same
time, it is a good indication that a fuel
5. This step tests whether a good ground circuit is
available.
6. This step tests the integrity of the signal circuit to
the PCM.
the PCM.
is also a possibility of silicone contamination.

Step
Action
Value(s)
1. Inspect for an exhaust system leak. Refer to Exhaust

System Inspection in Engine Exhaust. After you
inspect the exhaust system, return to this diagnostic.
necessary.

Test the terminal tension at the H02S and at
the PCM.
Go to Step 3
Goto
Diagnostic Aids
Go to Step 8
Go to Step 4
Go to Step 14
Go to Step 5
Go to Step 14
Go to Step 6

supporting text.
4. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool. .
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Yes
6,,;1736
Step
Engine

.
DTC P1133 H02S insufficient Switching Bank 1 Sensor 1 (cont'd)

Value(s)
Yes
Action

good ground.
specified range?
specified value?
Fuel contamination
Replace the affected heated oxygen sensor. Refer to
Heated. Oxygen Sensor (H02S) Replacement Bank 1
to a battery ground using the DMM. Refer to
specified value?
Repair the high signal circuit for a short to ground or
shorted to a voltage. Refer to Heated Oxygen
connections. Refer to Heated Oxygen Sensor (H02S)
Wiring R(:Jpairs in Wiring Systems.
the faulty PCM connections. Refer to Heated Oxygen
i. Select the Diagnostic Trouble Code (OTC) option and
the Clear Dl~C Information option using the scan tool.
applicable.
diagnosed?
No
350-550 mV
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
200 mV
10
11
12
13
14
15
Go to Step 14
5 Volts
Go to Step 12
Go to Step 11
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 15
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1737

Hot
Rel
i Ignition
Ener ized
~ Pow-;r - .. - - - - - - - - ~ E~Qine
Fuse Block
Details
Cell11
I Distribution
I Schematics
in Wiring
I Systems
' '
'
~--------------
- - - - - - -I
r - ~a-;;-k;; - - - - - - - - - , Powertrain I
I
Left Front
I
I H02S
H02S
High
0.8.
PNK 539
Low
.. - _-: .:-_ :-- -: -
691
B
CONN ID
C1=BLU
C2=RED
.. -
2s1c1
08
TAN/WH: 1653
.. -
I Control
I Module
I (PCM)
J
J>
0.8
I
I
I
Wiring
Harness
Junction
.. - - - - - - - - - - - - .. Block 2
0.8 PNK 539

B
I
I
I
I
I
I
I
0.8 PNK 539
Bank 1 H02S #2
Bank 2 H02S #1
Bank 2 H02S #2
Bank #1
left Front
Heated Oxygen
Sensor (H02S) #1
J6
ENG SEN
Fuse 10
20 A
'f
0.8
PPL/WHT 1665
J7
T
I
I
I
I
I
I
BLK450
0.8 BlKt~4~,-~
=====_
~-<II ....,,,.G..,.rou-nd.,....--,
Distribution
Cell 14
582459
Circuit Description
The PCM monitors the Heated Oxygen

Sensor (H02S) activity. During the monitor period the
PCM counts the number of times that the H02S
responds from rich to lean and from lean to rich and
adds the amount of time it took to complete all
transitions. With this information, an average time for
all transitions can be determined. The PCM then
average to obtain a ratio. A DTC P1134 sets if
the HD2S ratio is not within range.
The PCM determines that the H02S transition time

ratio is not at the expected value.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P0506,
P0507, P1258 not set.
.. The engine speed is more than 1,000 RPM
50C (122F).
Opercent.

Failure Records.

6-1738
Engine
Diagnostic Aids
Test Description
Important:
Systems.

diagnostic table.
to run.
H02S can cause a OTC to set.
available.
the PCM.
the PCM.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 8
Go to Step 4
Go to Step 14
Go to Step 5

1


supporting text.
4. Monitor the Diagnostic Trouble Code (OTC)

necessary.

Test the terminal tension at the H02S and at the

Connections in. Wiring Systems.

Did you find an.d correct the condition?
Go to Step 14
Go to Step 6
Engine
6-1739

Step
Action
good ground.
specified range?
Value(s)
No
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
350-550 mV

specified value?
200mV

Fuel contamination
e Use of improper RTV sealant

to a battery ground using the DMM J 39200. Refer to
specified value?
5V
10

11
12


14
i. Select the Diagnostic Trouble Code (OTC) option and

applicable.
15
diagnosed?
13
Yes
Go to Step 14
Go to Step 12
Go to Step 11
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 14
Go to Step 15
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine

DTC P1153 H02S Insufficient Switching Bank 2 Sensor 1 .

'" Po;er- -
I
I
Distribution
J7
Schematics in
..I Wiring Systems J6
ENG SEN
Fuse 1o
20 A
Engine Wiring
I Harness Junction
I Block 2
.,
___________ ..
LliJ
0.8 PNK 539
.- -
B
0.8 PNK 539
I
I
I
'" -
I
I
I..
Fuse Block
Details
Cell11
_.,.
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
-B;k-;; - 2
Right Front
- - CONN ID
C1=BLU
C2=RED
.,
______________
..
t'o~s
~~~s
26r--~-~
Powertrain
I Control
I Module
I (PCM) ~
>
-p~~11~~6
0.8 TAN11667
0.8 PNK 539
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
0.8 BLK 450
L -
&'-----,---------'
'
BLK 450 ' - ____
-4 Ground
-
'
'."' _
'."'" -
-4
Distribution
Cell 14
(
582470
Circuit Description
The PCM monitors the Heated Oxygen Sensor

(H02S) activity for 100 seconds. During this monitor
period the PCM counts the number of times that
the H02S switches form rich to lean and lean to rich.
A OTC P1153 sets when the PCM determines that
the H02S did not switch enough times.
A lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to greater than
less than 300 mV.
The PCM determines that within 100 seconds the

H02S lean to rich switches are less than 10 and rich
to lean switches are less then 10.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P1258
not set.
The engine run time is more than 2 minutes.
The engine speed is more than 1,000 RPM but
less than 2,300 RPM.
50C (122F).
O percent.

atthe time of the failure. The PCM writes the
Failure Records.

Engine
6-1741
Diagnostic Aids
Test Description
Important:
the PCM connector gaskets when diagnosing/
replacing the PCM. Ensure that the gaskets are
installed correctly. The gaskets prevent
Systems.
Inspect the H02S signal circuit for being shorted to a
PCM ground. The H02S signal circuit shorted to a
PCM ground will not cause a H02S low OTC to set,
but will set a switching OTC.
A malfunction in the H02S heater circuits will cause a
OTC P1153 to set. Inspect the H02S heater circuits
for intermittent opens/connections. Refer to Testing for
An oxvgen supply inside the H02S is necessary
for proper operation. This supply of oxygen is provided

diagnostic table.
to run.
3. When OTCs P1133 and P1153 are set at the
H02S can cause a OTC to set.
available.
the PCM.
the PCM.
caused by silicone in the fuel. If the sensors.

Step
Action
Did you perform the Powertra,in On-Board
Value(s)

necessary.

. Test the terminal tension at the H02S and at
the PCM.
Go to Step 2
PowertrainOn
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 8
Go to Step 4
Go to Step 14
Go to Step 5
Go to Step 14
Go to Step 6
'
No
Goto A

supporting text.
4. Monitor the Diagnostic Trouble Code {DTC)
Yes
6-1742
Engine

Step
10
11
12
13
14
15
Action
good ground.
specified range?
specified value?
Fuel contamination
. Use of improper RTV sealant
Replace the affected heated oxygen sensor. Refer to
specified value?
shorted to a voltage. Refer to Heated Oxygen Sensor
(H02S) Wiring Repairs in Wiring Systems.
the $pecific DTC option, then enter the DTC number
applicable.
diagnosed?
Value(s)
Yes
No
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
350-550 mV
200mV
Go to Step 14
5V
Go to Step 12
Go to Step 11
Go to Step 14
Goto Step 14
Go to Step 14
Go to Step 14
Go to Step 15
Go to Step 2
Go to the
appiicable
DTC table
System OK
Engine
6-1743
iHot With lgn Relay Energized
... ;;0
I
I._
;,r- - - -- - - - - - - , Engine Wiring
Distribution
J7
Schematics in
Wiring Systems J6
ENG SEN
Fuse 1
20 A
I Harness Junction
I Block 2
___________ .I
l....Jil
0.8 PNK 539
,.... -
B
0.8 PNK 539
Fuse Block
Details
Cell11
-II>
r -
---------------------,
I
I
I
r - -
I
I
I ~~s
...
-B;k-;2- - - - - - - - - , Powertrain
Right Front
CONN ID
I Control
I Module ~
I (PCM) ~
C1=BLU
C2=RED
~~~s
'---------------.1
Bank 1 H02S #1
Bank 1 H02S #2
Bank 2 H02S #2
26r--;_~-p~~11~~6
0.8 TAN 11667

A
0.8 PNK 539

D
Bank#2
Right Front
Heated Oxygen
Sensor (H02S)#1
c
a--------------'
0.8 BLK 450
L -
'
BLK 450' ' - ______

-
- -
-<ti '"""'Gr...,..ou...,..nd:---.
-<ti
Distribution
Cell 14
582470
Circuit Description .... :

Sensor (H02S) activity for 100 seconds. During
times that the H02S responds from rich to lean and
complete all transitions. With this information, an
average time for all transitions can be determined. The
PCM then divides the rich to lean average by the
lean to rich average to obtain a ratio. A DTC P1154
sets if the H02S ratio is not within range.
The PCM determines that the H02S transition time

ratio is not at the expected value.

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0200, P0335, P0336, P0351-P0358, P0506,
P0507, P1258 not set.
The engine speed is more than 1,000 RPM
The engine coolarit temperature is more than
50C (122F).
.. The EV AP purge duty cycle is more than
Opercent.

Failure Records.

related diagnostic does not report any failures .
6-1744
Engine
Diagnostic Aids
Test Description
Important:
Systems.
connections should be inspected tor breaks or
Sensor (H02S)' Wiring Repairs in Wiring Systems.

diagnostic table.
test may take 5 minutes tor the diagnostic
to run.
same time, it is a good indication that f;l fuel
available.
the PCM.
the PCM.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
system Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 8
Go to Step 4
Go to Step 14
Go to Step 5

1
Important: If any DTCs are set (except Pi 134), refer to

supporting text.

necessary.

Test the terminal tension at the H02S and at
the PCM.
(
Go to Step 14
Go to Step 6
Engine
6-1745

Step
Action
i. Disconnect the H02S.

good ground.
specified range?
Value(s)
No
Go to Step 7
Go to Step 10
Go to Step 13
Go to Step 9
350-550 mV

specified value?

Fuel contamination
1. R~move the jumper wire from the H02S low circuit.

specified value?
5V
10

11
12

Replace the H02s: Refer to Heated Oxygen

14

applicable.
15
diagnosed?
13
Yes
200mV
Go to Step 14
Go to Step 12
Go to Step 11
Go to Step 14
Go to Step 14
Go to Step 14
-
Go to Step 14
Go to Step 15
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1746
Engine
DTC P1258 Engine Coolant Overtemperature - Protection Mode Active

Circuit Description
Diagnostic Aids
In order to reduce the engine temperature the PCM

has the ability to disable a number of fuel injectors
during an engine over temperature condition. The PCM
considers the engine over temperature whenever
the ECT reaches a predetermined temperature. This
OTC sets in order to show that the PCM detected
an over temperature condition and that the system
engaged the protection mode.
Important:

OTCs P0117, P0118, POi 25 are not set.

132C (270F).
The above conditions present for more than
10 seconds.

Lamp (MIL) when the diagnostic runs and fails.
Records.
The PCM alternately disables four fuel injectors.

related diagnostic d.oes not report any failures.

Systems.
The PCM enables the Engine Coolant Over
temperature mode when coolant temperature exceeds
132C (270F). Engine damage still could occur if
the customer operates the vehicle too long in
an overheat condition. Ensure no engine mechanical
conditions exists after the overheat condition is
repaired.
If an overheating condition exists, repair the overheat
condition and change the engine oil and filter.
Refer to Engine Overheating in Engine Cooling, and
Engine Oil and Oil Filter Change in Engine
Mechanical 5.7L.
Test Description
diagnostic table.
1. A cooling system over heating condition will
enable the engine protection mode.
DTC P1258 Engine Coolant Overtemperature - Protection Mode Active

Step
Action
Value(s)
Yes
No
Go to Engine
Overheating in
Engine Cooling
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check

Engine
6-1747
IPosition
Camshaft
Solid State
,
Crankshaft
(CMP)
B"
A
Position
Sensor
s
{CKP)
A'
0.35
Sensor
0.35
BRN/WHT 633
0.35
DKBLU/ 1869
LTGRN 1867
WHT
0.35 PNK/BLK 632
0.35 RED 631
0.35
YELJ 1868
BLK
Solid State
_____________
-1-____---,_? ---------1
;f;;;
12 ____ _?J
'" -CKP &!,.;orI

1
Signal Input
ICONN IOI
IC1=BLU
I
I~~
~1_ ~ _______ ?? C1
;: - CMP s';n~r 0
0 0
~::rence
Ignition
Feed
Low
39
-
!Loe I
rs:J
A
C2
1"" - - - ., Powertrain
Signal Input
Ignition
Feed
I
I
Control
Module
(PCM)
I
I~
12V
I~
~-------------------------------------J
582388
Circuit Description
The Crankshaft Position (CKP) sensor sends pulses to
the PCM as the reluctor wheel teeth rotate past the
CKP sensor. The PCM uses the CKP pulses to
synchronize the ignition and fuel injector operation,
and to time the interval between each CKP pulse. The
PCM determines when an excessive change in
crankshaft speed occurs by comparing each new time
interval with the previous interval. A misfire causes
an unexpected change in the crankshaft speed.
A certain amount of acceleration/deceleration is
expected between each firing stroke, but if the
crankshaft speed changes more than an expected
amount, the PCM interprets this as a misfire.
The interval between CKP sensor pulses is extremely
small. At high engine speeds, slight variations in
the following components make misfire detection
difficult:
Important: A PCM power disconnect with the ignition

ON may erase the stored pulse value and set the
DTC P1336.
Disconnecting the PCM will not erase the learned
Crankshaft Position System Variation as long as the
ignition switch is in the OFF position.
Important: Reprogramming the PCM does not require
running the Crankshaft Position System Variation
Learn Procedure unless the PCM is new or from
another vehicle.
A OTC P1336 sets if the Crankshaft Position System
Variation is not within an acceptable range, or can
not be learned.

There are no crankshaft position (CKP) or camshaft
position (CMP) sensor DTCs.
Crankshaft
The PCM has not learned the Crankshaft Position

System Variation.
Reluctor wheel
CKP sensor
The PCM learns variations during the Crankshaft
Position System Variation Learning Procedure. The
PCM compensates for these variations when
performing detect misfire calculations. Only a scan
tool can command the PCM to perform the Crankshaft
Posi1ion System Variation Learning Procedure again.
Perform the learning procedure after the following
actions:
A PCM replacement
o Any operation or repair involving the crankshaft,
1he CKP sensor, or the CKP sensor to reluctor
wheel gap relationship.
" An engine replacement.
The ignition switch is in the ON position until the
battery is drained.

a The PCM records the operating conditions at the
Records.

6-1748
Engine
Diagnostic Aids
Important:
Systems.
If the PCM receives an incorrect crankshaft to
camshaft ratio the PCM will not allow the scan tool
to enable the learn procedure.
If the Crankshaft Position System Variation Learn
Procedure cannot be learned, inspect for the following
conditions:
A chipped or damaged reluctor wheel
Incorrect alignment of the CKP sensor to the
reluctor wheel
.. Excessive crankshaft run-out
Interference in the signal circuit to the CKP sensor
Incorrect ratio of crankshaft to camshaft pulses
Engine diagnostic misfire is not operable when
the engine is above 1000 RPM and DTC P1336 is set.
When the learn procedure is in progress and the

engine speed is at 4000 RPM, a decrease in engine
speed will occur. During the engine coastdown,
the PCM monitors the CKP sensor signal and stores
the pattern. This pattern is used to determine if
the crankshaft speed variations are due to misfire.
Test Description
diagnostic table.
2. The PCM enables the learn process after 65C
(150F) is reached. Engine deceleration occurs
when the learn procedure is in progress. The PCM
monitors and records the CKP sensor signal
during engine coast-down conditions.
3. Test in Progress on the scan tool indicates the
PCM is performing the learn procedure. If the
PCM receives an incorrect crankshaft to camshaft
pulse ratio, an incorrect transmission range
signal input, corrupted communication, or no
change in the brake switch input, the learn
procedure will not be allowed.
4. If a repair is necessary due to a condition which
prevented the learn procedure from enabling,
the Crankshaft Position System Variation Learning
Procedure must be performed.
5. The ignition must be in the OFF position for at
least 1O seconds after the learn procedure is
complete and the engine RPM has returned to
idle. The PCM saves the signal data after
these conditions are met.
Engine
6-1749

Step
Action
Yes
Go to Step 2
No
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to Step 5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 6
Go to
Diagnostic Aids
Value(s)
Perform the Crankshaft Position System Variation Learning

Procedure as follows.
2. Apply the vehicle's parking brake.
4. Close the hood.
5. Place the vehicle's transmission in Park (A/T) or
Neutral (MIT).
Idle
the engine until the specified engine coolant
6.
temperature value is reached.
8. Apply the brakes for the duration of the procedure.
Important: While the learn procedure is in progress,
release the throttle immediately when the engine starts to
decelerate. The engine control is returned to the operator
and the engine will respond to throttle position after the
learn procedure is complete.
9. Enable the Crankshaft Position System Variation
Learning Procedure with the scan tool.
10. Slowly raise the engine RPM to the specified value.
11. Immediately release the throttle when the engine
speed decreases.
Does the scan tool indicate Learn Status: Learned This
Ignition?
Attempt the Crankshaft Position System Variation Learn
Procedure as many times as the specified value. Refer to
CKP System Variation Learn Procedure.
Does the scan tool indicate Learn Status: Learned This
Ignition?
Inspect the Crankshaft Position (CKP) sensor and the
crankshaft reluctor wheel for damage. Refer to
Diagnostic Aids.
Did you find any damage?
Turn OFF the ignition for 15 seconds.
Replace the Crankshaft Position (CKP) sensor and/or
reluctor wheel. Refer to Crankshaft Position (CKP) Sensor
Replacement.
applicable.
Does the scan tool indicate that this diagnostic ran and
passed?
diagnosed?
65C (150F)
4000 RPM
Go to Step 7
Go to Step 7
Go to Step B
Go to Step 2
Go to the
applicable
DTC table
System OK
6.;1750
Engine

Circuit Description
The PCM detects engine misfire by detecting variations

in crankshaft deceleration between firing strokes.
For accurate detection of engine misfire the PCM must
distinguish between crankshaft deceleration caused
by actual misfire and deceleration caused by
rough road conditions. The ABS Brake System can
detect if the vehicle is on a rough road based on wheel
acceleration/deceleration data supplied by the wheel
speed sensors. If the ABS system detect~ r~ugh
.
road above a predetermined threshold, this information
is sent to the PCM via serial data. The PCM can
then take the rough road into account when calculating
misfire. Even if the ABS is malfunctioning and
cannot detect rough roads, the misfire diagnostic will
continue to run. However, if a misfire OTC sets,
this additional OTC also sets indicating that rough road
data was not available during the misfire calculation
due to an ABS System malfunction.

OTCs P0101, P0102, P0103, P0121, P0122,
P0123, P0335, P0336, P0742 not set.
The vehicle speed is greater than 10.0 mph.
The engine load is less than 60 percent.
The engine misfire is detected (OTC P0300 set).
The engine speed is less than 3200 RPM.

An ABS system malfunction exists preventing the
PCM from receiving rough road detection data.

illuminate.

lamp (MIL) OFF 13-fter 3 consecutive igni~ion cycles

diagnostic runs and does not fail:
" A History OTC clears after 40 consecuti~e.
warm-up cycles, if this or any other em1~s1on
related. diagnostic does not report any failures.
.. Use a scan tool in order to clear the MILJOTC.
Diagnostic Aids
Test Description
diagnostic table.
1. Service the ABS system before diagnosing for a
misfire, because an actual engine misfire may
or may not exist. The following two e~ample~
illustrate how this OTC can be set with or without
an actual engine misfire:
There was an actual engine misfire during an
ABS system malfunction.
The vehicle operator drove on a rough road,
the ABS system could not detect this due to ,
a malfunction, and the PCM interpreted
the variations in crankshaft speed caused by
the rough road as a misfire.

Step
Action
Value(s)

1
Yes
No
Go to A
Diagnostic
System
Check - ABS in
Antilock Brake
System.
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Engine
6-1751

Circuit Description
The PCM detects engine misfire by detecting variations
in crankshaft deceleration between firing strokes.
For accurate detection of engine misfire the PCM must
distinguish between crankshaft deceleration caused
by actual misfire and deceleration caused by
rough road conditions. The ABS Brake System can
detec1 if the vehicle is on a rough road based on wheel
acceleration/deceleration data supplied by the wheel
speed sensors. If the ABS system detects rough
road above a predetermined threshold, this information
is sent to the PCM via serial data. The PCM can
then take the rough road into account when calculating
misfire. Even if serial data communication between
the ABS System and the PCM is malfunctioning
and the PCM can not receive the rough road data, the
misfire diagnostic continues to run. However, if a
misfire OTC sets, this additional OTC also sets
indicating that the rough road data was not available
during the misfire calculation due to a serial data
malfunction.

The vehicle speed is above 1O mph.
The engine speed is below 3200 RPM.
The engine load is less than 60 percent.
Engine misfire is detected (OTC P0300 set).

A serial data malfunction exists preventing the
PCM from receiving rough road detection data.
The above conditions met for 20 seconds.

.. The malfunction indicator lamp (MIL) will not
illuminate.

O

Diagnostic Aids
Test Description
diagnostic table.
1. Service the ABS system before diagnosing for a
misfire, because an actual engine misfire may
or may not exist. The following two examples
illustrate how this OTC can be set with or without
an actual engine misfire:
., There was an actual engine misfire during an
ABS system malfunction.
" The vehicle operator drove on a rough road,
the ABS system could not detect this due to
a malfunction, and the PCM interpreted
the variations in crankshaft speed caused by
the rough road as a misfire.
OTC P1381 Misfire Detected - No Communication with Brake Control Module

Step
Action
Value(s)

j
Yes
No
Go to A
Diagnostic
System
Check - ABS in
Antilock Brake
System.
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
6-1752
Engine

B
0__ I~E~~~
I.
_!:_. ._~~~~=1;
.
. . ._____
0.35 BLK 407

41
Ground -=-
C1=BLU
DI0.35 BR~11456
0.35 GRY 435
C~.35RE~ 1~~~--------~~
C2
~~I~
~ 6~~:~rain
Ground -=-
1 Module
B{PCM}
PCM
c2=RED
.
SV
Reference
11....
EI
-r----;-J-1;--- -r--
-~~~-~;; ~1-~ __ ??
-~:~o~r- --ti-;;----
I
I
I
!Loe
EG; Pinlle
Position
Signal
EGRValve
Control
JI;
I~
~--------------------------------J
I
582396
Circuit Description
This diagnostic tests for an EGR valve that is stuck
open. The PCM tests for a stuck open valve when the
desired EGR position is at O percent. The PCM
determines that the EGR valve is stuck open if the
actual EGR position and the learned closed EGR
position vary by more than a predetermined value. The
PCM attempts to clear any obstructions from the
valve. To clear the obstruction the PCM waits for the
EGR desired position to be greater than 20 percent.
Once the. desired EGR position is more than
20 percent the PCM commands the EGR valve to
100 percent then back to O percent. The PCM does
this three times. The PCM retests for a stuck EGR
valve when the desired EGR position returns to
O percent. A failure counter increments if the stuck
EGR valve condition is still present. This OTC
sets when the counter reaches a predetermined value.

The ignition voltage is more than 11. 7 volts.

The actual closed EGR pintle position voltage is
0.29 volts more than the desired closed EGR pintle
position voltage

e

warm-up cycles, .if this or any other emission
., Use a scan tool in order to clear the MIUDTC.
Diagnostic Aids
Important:

Systems.

Records.
Engine
Test Description
diagnostic table.
ground or shorted to a voltage. The 5 volt
the PCM.
3. This step tests for open EGR valve when the
valve should be closed.
you cannot duplicated the OTC, the information
6-1753

5. This step tests for an EGR pintle position voltage
that is out of range. The EGR pintle position
voltage should be between 0.14 and 1.07 volts
at idle.
8. This tests whether the ground circuit is available
to the EGR valve. Inspect for poor electrical
connections at the EGR valve.

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
OTC P1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 13
Go to Step 15
Go to Step 6
Go to Step 7
Go to Step 7
Go to
Diagnostic Aids
bid you perform the Powertrain On-Board

-
Important: Inspect the EGR pintle position signal circuit

for an intermittent condition before proceeding with this
diagnostic table. An intermittent condition with the signal
circuit causes this OTC to set.
2. Idle the engine.
.3. Monitor the Diagnostic Trouble Code (OTC)
Idle the engine.

Is the idle quality poor?
1. Idle the engine.

Does the idle quality return to normal?

the scan tool.
Is the EGR pintle position voltage within the
specified value?
data for this OTC and record the parameters.
4. Idle the engine.
the OTC.
ignition?
0.14-1.07 V
6-1754
Engine
Step
Action
the scan tool.
Is the EGR pintle position voltage below the
specified value?
Probe the EGR pintle position ground circuit at the EGR
valve harness connector with the J 34142-8 test lamp
connected to B+. Refer to Probing Electrical Connectors in
Wiring Systems.
Value(s)
Yes
No
0.14V
Go to Step 8
Go to Step 10
.,
,.
Go toStep,9
.. Go to Step 11
.
10
11
12
13
14
Measure the voltage at the 5 volt reference circuit to

ground using the DMM.
5V
Important: The short to voltage may be eliminated when

the PCM is disconnected, if the signal circuit is shorted to
another C1 circuit.
4. Test for a short to voltage on the EGR pintle position
signal circuit.
5. If you find the EGR pintle position signal circuit
shorted, repair the circuit as necessary. Refer to
1. Test for an open EGR pintle position ground circuit.

2. If you find the EGR pintle position ground circuit
open, repair the circuit as necessary. Refer to Wiring

2. Disconnect the PCM connector Ci located on the
3. Inspect the EGR pintle position ground circuit for a
4. If you find a poor connection at the EGR valve
ground circuit, repair the connection as necessary.
Refer to Connector Repairs in Wiring Systems.

PCM Repfacement!Programming.
3. Test the EGR valve ground circuit for a short to
voltage.
4. If you find the ground circuit shorted, repair the circuit
Systems.

Go to Step 14
Go to Step 16
'<
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 12
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 17
Go to Step 18
Engine
6-1755
Step
Value{s)
15
1. Remove the EGR valve.

2. Inspect the EGR valve for debris that is interfering
with the valve movement. Refer to EGR System
Cleaning.
16

Replacement.
17

Replace the PCM.
18

applicable.
the scan tool.
diagnosed?
19
Action
Yes
No
Go to Step 18
Go to Step 16
Go to Step 18
Go to Step 18
Go to Step 19
Go to Step 2
Go to the
applicable
OTC table
System OK
6-1756
Engine
DTC P1415 Secondary Air Injection (AIR) System Bank 1

Circuit Description
the AIR system.
If the PCM determines that t.he H02S voltages for
both banks did not respond as expected during
the tests, DTC P041 O sets. If only one sensor
responded, the PCM sets either a DTC P1415 or
P1416 to indicate on which bank the AIR system is
inoperative.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0171-P0175, P0200, P0300, P0325,
P0327, P0332, P0335, P0336, P0351P0358, P0420, P0430, P0500, P0502, P0503, and
H02S DTCs not set.
The engine operates tor more than 2 seconds.
Engine run time is more than 20 seconds
after closed loop operation.
Maximum air flow is 22 g/s.
ECT is between 66C (151 F) and 120c (248F).
IAT is more than -10C (14F).
Ignition voltage is more than 11. 7 volts.
The air fuel ratio is 14.7:1
In short term Fuel Trim cells 1, 2, 5 or 20.

H02S voltage does not go below 222 mV tor
0.9 seconds, when the AIR pump turns ON during

Th.e. short termJuel trim does not change more
than a predetermined value, when the AIR
pump turns ON during closed loop operation.

.. lamp (MIL) on the second consecutive igritiori
cycle that the diagnostic. runs and fails ..
time the diagnostic fails.. The firstt[me the
the Failure Records. If the. diagnostic reports a
. at the time of the failure. The PCM writes the
Failure Records.
'

lamp (MIL) OFF after 3 consecutive igniU:on cycles
that the diagnostic runs. and does not fail.
O Use a scan tool in order to clear the MIUDTC.
Diagnostic Aids
" An obstruction in the exhaust manifold may
restrict the amount of air flow necessary to affect
the H02S voltage. If you suspect this, remove
the air pipe from the manifold and inspect
the passage.
Test Description
diagnostic table.
3. A check valve that flows in both directions causes
heat damage to the Al R system components.
Engine
Engine Controls. - 5.7l 6-1757

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 6
Go to Step 4
Goto Step 7
Go to Step 5

Important: Before proceeding with this diagnostic table,

ensure that the AIR pump is operating and that air is
present at the outlet of the AIR pump. If the AIR pump is
inoperative refer to OTC P0410 Secondary Air
Injection (AIR) System for further diagnosis.
2. Idle the engine in Closed Loop.
2
350mV
4. Monitor the Bank 1 Sensor 1 (Left Front) H02S

voltage display on the Engine 1 Data List using a
scan tool.
5. Enable the AIR system using a scan tool.
6. Observe and record the Bank 1 Sensor 1 (Left Front)

H02S voltage, as the AIR system is enabled.
Does the H02S voltage drop below the specified value?
Visually/physically inspect all hoses and pipes for:
Being connected
Clamps are secure on pipes and hoses

No kinks, holes, or pinched hoses/pipes
Components with evidence of heat damage

Did you locate the condition?
1. Disconnect the hose from the check valve at the left

exhaust manifold.
Is air present at the hose outlet?
Repair the restriction or blockage in AIR hoses/pipes
between the left exhaust manifold and the point where the
system branches to both sides of the engine.
Go to Step 8
Repair the condition found.

Replace the check valve. Refer to AIR Check Valve/Pipe
Replacement - Bank 1.
Go to Step 8
Go to Step B

1. Select the Diagnostic Trouble Code (DTC} option and


applicable.
diagnosed?
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1758
Engine

Circuit Description
the AIR system.
If the PCM determines that the H02S voltages for
both banks did not respond as expected during
the tests, DTC P0410 sets. If only one sensor
responded, the PCM sets either a DTC P1415 or
P1416 to indicate on which bank the AIR system is
inoperative.

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0171-P0175, P0200, P0300, P0325,
P0327, P0332, P0335, P0336, P0351P0358, P0420, P0430, P0500, P0502, P0503, and
H02S DTCs not set.
The engine operates for more than 2 seconds.
Engine run time is more than 20 seconds
after closed loop operation.
Maximum air flow is 22 g/s.
ECT is between 66C (151F) and 120C (248F).
IAT is more than -10C (14F).
Ignition voltage is more than 11.7 volts.
The air fuel ratio is 14. 7:1
In short term Fuel Trim cells 1, 2, 5 or 20.

H02S voltage does not go below 222 mV for
0.9 seconds, when the AIR pump turns ON during
The short term fuel trim does not change more
than a predetermined value, when the AIR
pump turns ON during closed loop operation.

Failure Records.
Conditions for Clearing the. Mll/DTC

that the diagnostic runs .and does not fail.
Diagnostic Aids
An obstruction in the exhaust manifold may
restrict the amount of air flow necessary to affect
the H02S voltage. If this is suspected, remove
the air pipe from the manifold and inspect
the passage.
Test Description
The numbers below refer to t.he step numbers on the
diagnostic table.
3. A check valve that flows in both directions causes
heat damage to the AIR system components.
Engine
6-1759

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 7
Go to Step 5

-
Important: Before proceeding with this diagnostic table,

ensure that the AIR pump is operating and that air is
present at the outlet of the AIR pump. If the AIR pump is
inoperative Refer to OTC P0410 Secondary Air
Injection (AIR) System for further diagnosis.
1. Install scan tool.
2. Engine idling in Closed Loop.
3. Turn OFF all accessories.
4. Monitor the Bank 2 Sensor 1 (Right Front) H02S
voltage display on the Engine 1 Data List using a
scan tool.
6. Observe and record the Bank 2 Sensor 1 (Right
Front) H02S voltage, as the AIR system is enabled.
Does the H02S voltage drop below the specified value?
350mV
Visually/physically inspect all hoses and pipes for:

Being connected
~ Clamps are secure on pipes and hoses
0
No kinks, holes, or pinched hoses/pipes
Components with evidence of heat damage
Did you locate the condition?
1. Disconnect the hose from the check valve at the right

exhaust manifold.
Is air present at the hose outlet?
Repair the restriction or the blockage in the AIR

hoses/pipes between the right exhaust manifold and the
point where the system branches to both sides of the
engine.
Repair the condition found.

Replace the check valve. Refer to AIR Check Valve/Pipe

Replacement - Bank 2.
1. Select the Diagnostic TrO\Jble Code (DTC) option and

applicable.
diagnosed?
Go to Step 8
Go to Step 8
Go to Step 8
Go to Step 9
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1760
Engine
! Hot With lgn 1 Relay Energized I

~ Pow-;r Distrib;o-; - -
- - - - , Engine
ENG CTRL : Wiring
MiniFuse Harness
1
Schematics In
: Wiring Systems
1s A
L-------- ____
02
C200B
C200D
0.5 PNK 239
Junction
I
JBlock2
0.5 PNK 239

P100
s1a2--~-o_._5_P_N_K~--1111--_.
239
0.5 PNK 239
G C100
IAutomatic!
Power
Distribution
In Wiring
Systems
0.5 PNK 239

0.5 PNK
239
S107
0.5 PNK 239
Evaporative
Emission
(EVAP)
1~~t
l2!il
A2. C405B
AI C405D
0.35 PN: 239
Evaporative
Emission
[ ] (EVAP)
Canister
BI
~:~e
0.35 WHT i 310
B C405D
82 C405B
0.5 WHT 1310
osW:,l~~:
0.35 DK GRN/W~: ~2~- - - - - - - - - - - - - - - _____ - ____4_;rc:110
'" - - - - - 8/AP -;- - - - - - - - - - - - -EVAP -,- - - ,I Powertrain

I
PCM
I C1=BLU
I C2=RED
I
Canister
Purge e
Valve
Control
---.1
~
canister
Vent
,.
Valve
Control
Control
---.1
~
I Module p
I (PCM) ~
I
L-----------------------------J
(
582399
Circuit Description
The PCM monitors the amount of vacuum/pressure in
the EV AP system by monitoring the fuel tank
pressure sensor signal. The PCM seals the EVAP
system by commanding the EVAP Purge Solenoid
OFF and the EV AP vent valve ON. The PCM monitors
the fuel tank pressure sensor in order to determine
if the EVAP Purge Solenoid is leaking vacuum to the
EVAP system. This OTC sets if the vacuum in the
EVAP system is more than a predetermined
value within a predetermined time.
The start up engine coolant and intake air

temperatures are within 9C (16F} of each other.
.. The TP sensor angle is less than 75 percent
during the weak vacuum test.
The vehicle speed is less than 90 mph during the
weak vacuum test.

The EVAP system develops a vacuum more than a
predetermined value when purge is not commanded.
0

DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122, P0123, P0125, P0420,
P0430, P0500, P0502, P0503, P0562, P0563 and
H02S DTCs are not set.
17.0 volts.
(39F} and 30C (86F).
O
and 30C (86F).

Failure Records.
Engine

)

A last test failed (current DTC) clears. when the
Diagnostic Aids
Before replacing any components, visually/physically
inspect for the following:
Mis-routed harness.
Rubbed through wire insulation
Broken wire inside the insulation
Kinked or damaged vacuum hoses
6-1761
Physically damaged system components

Inspect components and vacuum lines for traces.
of carbon or other contaminants. The presence
of foreign material may be causing a restriction in
the system or preventing the solenoid valve
from closing properly. Either condition may cause
a DTC to set.
For an intermittent condition, refer to Symptoms:
Test Description
Diagnostic Table.
2. This step tests for a EVAP Purge Solenoid Valve
that is leaking vacuum to the EV AP system
when EV AP system purge is not commanded by
the PCM.
Inspect for possible carbon contamination of the
EVAP Purge Solenoid Valve and the purge line.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids

-
1. Disconnect the EVAP Purge line from the EVAP

Purge Solenoid Valve.
2. Connect a vacuum gauge (in. Hg.) to the solenoid
purge port. '
2
3. Idle the engine.

4. Command the EVAP Purge Solenoid Valve OFF with
a scan tool.
Does the vacuum gauge indicate a vacuum?
Important: Inspect for carbon contamination. Refer to

EVAP System Cleaning.
1 . Select the Diagnostic Trouble Code (DTC) option and

applicable.
diagnosed?
Go to Step 4
Go to Step 5
Go to the
applicable
OTC table
Go to Step 2
System OK
6-1762
Engine
DTC P1539 Air Conditioning (A/C) Clutch Feedback Circuit High Voltage
Circuit Description
The PCM activates the A/C clutch relay when the
PCM detects an A/C request. Voltage is present at
both the A/C compressor clutch and the A/C
clutch status terminal at the PCM when the relay is
activated.
A OTC P1539 sets if the PCM detects a voltage on
the A/C clutch status terminal when the system has not
requested the A/C.
A short to voltage at any point in the A/C status
circuit, or the A/C relay contacts are stuck, sets a
OTC P1539.

The A/C is not requested.

Voltage is detected on the A/C status circuit for more
than 15 seconds after the PCM has disengaged
the A/C clutch relay.

The malfunction indicator lamp (MIL} will not
illuminate.
Diagnostic Aids
The A/C status circuit goes to the A/C compressor
clutch .. and to the A/C clutch relay. Inspect all
circuits going to these components.
.. For an intermittent condition, refer to Symptoms.
Test Description
diagnostic table.
2. If the PCM detects a voltage on the A/C status
circuit with the A/C OFF the scan tool indicates
the A/C status as ON.
3. If the scan tool displayed YES in the RAN column
and INT in the FAIL column, this indicates an
intermittent condition is present. Inspect the A/C
status circuit for an intermittent short to B+. Using
the Freeze Frame and/or the Failure Records
data aids in locating an intermittent condition. If
you can not duplicate the DTC, the information
Records data determines how many miles since
the OTC set. The Fail Counter and the Pass
4. The relay is shorted internally if the scan tool
indicates that the test passed.

Engine
6-1763
DTC P1539 Air Conditioning (A/C) Clutch Feedback Circuit High Voltage
Step
Action
Value{s)
Yes
No
Go to Step 2
Goto A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6

-
Important: Diagnose DTC P0645 first if it is set.

2. Idle the engine with the A/C OFF.
3. Monitor the A/C Status display on the Engine 1 Data

List using a scan tool.
Does the scan tool indicate the A/C Status is ON?
4. Idle the engine.
this diagnostic to run, and as close to .the conditions
the DTC.
ignition?
2. Remove the A/C clutch relay.
3. Idle the engine for 30 seconds.
Does the scan tool indicate that OTC P1539 failed?
Repair the short to B+ on the A/C clutch status circuit.
Replace the faulty A/C clutch relay. Refer to Compressor

Relay Replacement in Heating, Ventillation, and Air
Conditioning.

applicable.
diagnosed?
Go to Step 7
Go to Step 7
Go to Step 2
Go to Step 8
Go to the
applicable
OTC table
System OK
6-1764
Engine
OTC P1546 Air Conditioning (A/C) Clutch Feedback Circuit low Voltage
Diagnostic Aids
The PCM commands the A/C ON and the PCM does

not detect a voltage on the A/C clutch status line
for more than 5 seconds.
Important:
Systems.
Test Description
Circuit Description
The PCM will activate the A/C clutch relay when the
PCM detects that A/C has been requested. When
the PCM activates the relay, voltage should be present
at both the A/C compressor clutch and the A/C
clutch status circuit at the PCM.

The A/C is requested.

The malfunction indicator lamp {MIL) will not
illuminate.


diagnostic table.
2. This step tests the operation of the A/C
compressor clutch. The PCM disables the A/C
compressor clutch when this OTC is set.
4. This step tests whether the ignition voltage is

available at the relay.
5. This step determines if the A/C relay is at fault or
the A/C status circuit is at fault. If the A/C clutch
engages, this indicates that the A/C Status
circuit is OK.
6. If the A/C Status is displayed as OFF, this
indicates the A/C status circuit is open between
the splice and the PCM. If the A/C Status is
displayed as ON, this indicates a faulty connection
at the A/C compressor relay or a faulty relay.
Engine
6-1765
DTC P1546 Air Conditioning (A/C) Clutch Feedback. Circuit Low Voltage
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Step 4
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 9
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8

-

2. Idle the engine with the A/C ON for the specified
length of time.
Does the A/C clutch operate properly?
2. Review Freeze Frame and/or Failure Records data
for this OTC and note parameters.
4. Idle the engine.
the OTC.
ignition?
2. Disconnect the A/C clutch relay from the electrical
center 2.
5 minutes
4. Probe the ignition feed circuit at the A/C relay

terminal (switch side of relay) with the test lamp
J 34142-8 connected to ground. Refer to Probing

Jumper the ignition feed circuit to the A/C clutch status
circuit (load) at the underhood electrical center 2 using a
fused jumper wire. Refer to Using Fused Jumper Wires in
Wiring Systems.
Does the A/C clutch engage?
Monitor the A/C Status display on the using the scan tool
with the fused jumper still installed.
Does the scan tool indicate the A/C Status as ON?
Repair the faulty A/C clutch relay connection or replace

the faulty A/C clutch relay. Refer to Repairing Connector
Terminals in Wiring Systems. Or Compressor Relay
Replacementin Heating, Ventillation, and Air Conditioning.
Repair the poor connection or open A/C clutch status

circuit from the splice to the PCM. Refer to Wiring Repairs
or Repairing Connector Terminals in Wiring Systems.
Go to Step 12
Go to Step 12
Go to Step 11
6-1766
Engine
OTC P1546 Air Conditioning (A/C) Clutch Feedback Circuit low Voltage (cont'd)
Step
Action
Value(s)
10
Repair the open in A/C status circuit from A/C relay to

splice. Refer to Wiring Repairs in Wiring Systems.

Replacement/Programming
Replace the PCM.
11
Yes
No
9.
Repair the open ignition feed circuit to A/C relay. Refer to

Go to Step 12
Go to Step 12
Go to Step 12

12
13

applicable.
Does the scan tool indicate that this failed?
Are any DTCs displayed that have not been diagnosed?
Go to Step 2
Go to Step 13
Go to the
applicable
OTC table
System OK
Engine
6-1767
DTC P1626 Theft Deterrent Fuel Enable Signal lost

~Theft-
~ Body
Control
Module
~ (BCM)
Deterrent
I
I
Fuel Enable
I5
L
!1~ _
>,
M
DBIC3
0.35 DK BLU 229
IL 0 c
~
~
C230
P110
0.35 DK BLU 22.9

30 C2
'" -Thett- - - - - - , Powertrain

I
I
I
Deterrent
Fuel
Enable
PCM
C1=BLU
C2=RED
I Control
I Module
I (PCM)
L--------.1 J.
~
582303
Circuit Description
The Vehicle Theft Deterrent system consists of the
Body Control Module (BCM)
Ignition Lock and Key
The Vehicle Theft Deterrent system is designed to
disable vehicle operation if the incorrect key or starting
procedure is used. The Body Control Module (BCM)
enables the crank circuit to the starter and sends
a signal to the PCM if the correct key is being used. If
the proper signal does not reach th.e PCM on the
fuel enable circuit, the PCM will not pulse the injectors
ON and thus not allow the vehicle to continue to
operate, even if the crank circuit is bypassed. The
proper signal is between 40-60 Hz and is measured
using the DMM set to the DC scale.
If a condition with the circuit occurs after the engine is
started and running the PCM will not disable the
fuel injectors. The PCM will continue to enable the fuel
injectors because a correct signal from the BCM
was received by the PCM on startup.

The Engine is in the run or start position.

The PCM does not receive the 40-60 Hz signal
from the Body Control Module
Condition present for less than 1 second

illuminate.
.. The engine starts and then stalls or the starter

does not engage.
If a condition with the circuit occurs after the
engine is started and running the engine will start
on the next ignition cycle.

O

., Use a scan tool in order to clear the MIUDTC.
Diagnostic Aids
Important:
prevents damage to the harness connector
in Wiring Systems.
Inspect the GAGE fuse for an open. An open GAGE
fuse causes OTC P1626 to set and the starter does not
operate. Refer to Testing for Short to Ground in
Wiring Systems.
If the engine starts and then stalls, the Body Control
Module is not suppling the appropriate signal or
the theft deterrent fuel enable circuit is open, shorted
to a ground, or shorted to a voltage.
6-1768
Engine
Test Description
diagnostic table.
2. An engine that does not crank and a DTC P1626
is set, indicates that there is a theft deterrent
system condition. An incorrect ignition key or an
incorrect starting procedure causes a no crank
condition.
3. An engine that does not crank indicates there is a
condition with the Body Control Module.
5. This step determines if the Body Control Module

is capable of sending a signal to the PCM. The
Body Control Module sends the PCM a 40-60 Hz
signal.
6. This step determines if the condition is intermittent

If the engine starts and continues to operate, you
may have corrected the condition during
diagnoses. Inspect all connections at the BCM
and the PCM.
4. This step determines if the Powertrain Control

Module is capable of sending a 5 volt signal
to the BCM.
DTC P1626 Theft Deterrent Fuel Enable Signal Lost

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to A
Diagnostic
in Theij
Deterrent
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step B
Go to
Diagnostic Aids
Go to Step 9

t. Turn ON the ignition leaving the engine OFF.

2. Use a scan tool to clear DTCs.
ignition?
Does the. engine crank?

2. Disconnect the BCM connector. Refer to Body
Control Module Replacement in Body Control
Systems.
3. Turn ON the ignitton leaving the engine OFF.
5 volts
4. Measure the voltage at the fuel enable circuit at the

BCM harne~s connector using the DMM.
Is the voltage near the specified voltage?
1. Turn OFF the Ignition.

3. Turn ON the Ignition leaving the engine OFF.
4. Select the DC volts and the Hertz (Hz) scale using
the DMM.
5. Backprobe one lead of the DMM to the theft deterrent
fuel enable circuit at the BCM harness connector and
the other lead to ground using the DMM.
Is the hertz signal within the specified range?
1. Capture Info using the scan tool.
2. Clear the DTCs.
3. Attempt to start the engine.
Does the engine start and continue to operate?
40-61 Hz
Engine
6-1769
DTC P1626 Theft Deterrent Fuel Enable Signal Lost (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 11
Go to Step 12
Go to Step 10
Test the theft deterrent fuel enable circuit for the following:
An open
A short to ground
A short' to B+
1. Inspect the terminal tension for the fuel enable circuit
at the BCM harness connector. Refer to Testing for

Systems.
1. Inspect the terminal tension for the fuel enable circuit

at the PCM harness connector. Refer to Testing for
9

Systems.
10
11

Replace the PCM.
Replace the Body Control Module. Refer to Body Control
Module Replacement in Body Control Systems.
Go to Step 12
Go to Step 12
Js the action complete?

1. Seh;ict the Diagnostic Trouble Code (DTC) option and

12


applicable.
Does the, scan tool indicate that this test ran and passed?
13
diagnosed?
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
Engine
6-1770

Powertrain ""
sv .............. sv - - .... - - - 12v... - ......... - - - . . - - sv - "'
si.r .. - ........ -
~~~Module
TP
5V
~ . _ ........ Reference
a.
J. (PCM) 1
0.35 GR~ ~:16
EGA
Valve ,
_ _ _ _ _ Control --
471C1
0.35
0.35 GAY 416

0.35 GRY 596
D
Schematics
In Brakes
_:11 I f
Antilock
Brakes
Schematics
In Brakes
0.35
BLK 452
0.35 DK BLU 417

$118---'
0.35 DK BLU
24 C2
TP- , - ... -
Sensor
1 Signal
I
I
... -
Exhaust Gas
Recirculation
(EGR)
Valve
0.35 GRY 435

55 C1
0.35 BLK 407
41
32 C2
-1~;;..-~;;R___ --~;R-1- ... EGRr;;..--~A~-...;;-;_ ... ""

Sensor
Ground
sensor
Ground ""
Pintle
Position
Signal
-=-
Valve ""
Ground
-=-
C1
0.35 LT GRN 432

41
,Manifold
Absolute
________......., Pressure
(MAP)
8
A
Sensor
0.35 BRN 1456

0.35 BLK 407
0.35 BLK 452

60
48
fMZl
L.2riJ
0.35 GRY 416
RE:11:6
0 I .-1-~------..
---S119
417
MAP
5V
... _ ... _ _ ... __ Reference
s.ni~li-'
c
l1
EGA
5V
:-_ ':" Reference
Sensor
Signal
""
-r" C1.
54
CONN ID
C1=BLU
C2=REO
~ Powertrain
MAP
'.
Sensor I
Ground I
Control
Module
(PCM)
}.
.. ___________ -----------------------------JI ~
(
582390
Circuit Description
The PCM uses a common 5.0 volt reference 1 circuit
as a sensor feed. This circuit supplies 5 volts to
the following sensors:
The TP sensor
The MAP sensor
The EGR valve
The PCM monitors the voltage on the 5.0 volt
reference 1 circuit This. OTC sets if the voltage is out
of range.


The 5.0 volt reference circuit is out of range.
All above conditions are present for more than
2 seconds.

cycle that the diagnostic runs. and fails.
cycle, the PCM records the operati11g conditions
Failure Records.

related diagnostic does not report any failures .
Engine
Diagnostic Aids
Important:
in Wiring Systems.
Test Description
diagnostic table.
2. The 5 volt reference circuits for the sensors are
connected together inside the PCM. Both
DTCs P1635 and Pi 639 set at the same time,
indicates a 5 voltreference circuit is shorted
to a voltage.
connected together inside the PCM. When
only P1635 is set, this indicates a short to ground
on one of the 5 volt reference circuits.
6-1771
4. This step isolates the 5 volt reference circuit from

the sensor signal circuit.
5. This step determines if the 5 volt reference circuits
or the fuel level sensor signal circuit are only
shorted when the fuel pump is enabled. You may
have to enable the fuel pump a couple of times
to see if the voltages increase. Inspect the
fuel pump harness thoroughly for being shorted to
the fuel tank pressure sensor and/or the fuel
level sensor.
6. The Data list can be changed while in output
controls. Select the MORE soft key to select
the next Data list. This procedure is necessary to
view all parameters. Refer to scan tool users
guide for detailed information.
8. The 5 volt reference circuits may be shorted to
another PCM circuit. The shorted circuit may
not be apparent when the PCM harness connector
is disconnected. Testing continuity from each
5 volt reference circuit isolates the shorted circuit.
For detailed circuit information, refer to
appropriate full page schematics.
9. For detailed circuit information, refer to appropriate
full page schematics.
15. This step is testing for a component failure.
Disconnecting each component individually
isolates which component might be causing this
OTC to set.
DTC Pi635 5 Volt Reference 1 Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check .
Go to Step5
Go to Step 3
Go to Step 9
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids


4. Monitor the DTCs using a scan tool.
Did. both DTCs P1635 and P1639 fail this ignition?
Important: If DTCs P1635 and P1639 set go to step 5. If

only OTC P1635 sets go to step 9.
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option.
Does the scan tool indicate that OTC P1635 or P1635 and
P1639 set this ignition?
6-.t772
Engine

DTC P1635 5 Volt Reference 1 Circuit (cont'd)
Step
Action
Value(s)

2. Monitor the voltages for the following sensors using a
scan tool:
The Fuel Level sensor
The Fuel Tank Pressure sensor
O The EGR Pintle Position sensor
The TP sensor
The MAP sensor
The A/C refrigerant pressure sensor
Does the scan tool display any of the voltages at or above
5V
1. Turn OFF the engine leaving the ignition ON.

2. Monitor the following voltages using a scan tool:
MAP sensor
TP sensor
EGR position sensor
Fuel Tank Pressure sensor
Fuel Level sensor
3. Enable the fuel pump using the scan tool.
Do any of the voltages increase when the fuel pump was
turned ON?
.7 .

2. Disconnect the PCM harness connectors. Refer to
3. Turn ON the ignition leaving the engine OFF:
4. Connect the DMM to ground.
5. Probe the other lead of the DMM to each 5 volt
reference circuit at the PCM harness connector for
The MAP sensor
The EGR valve
The TP sensor
Do any of the circuits measure greater than the
specified value?
Yes
No
Go to Step 18
Go to Step 6
Go to Step 11
Go to Step 7
5.1V
Go to Step
12
Goto Step 8
Engine Controls .; 5. 7L
Engine
6-1773

Step
..
Action
Value(s)
Yes
No
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 10
Go to Step 13
Go to Step 15
Important: Before proceeding remove the following fuses:
10
11
12
13
14
PCM Ignition
PCM Battery
1. Disconnect the following component electrical
connectors:
The MAP sensor
The TP sensor
The EGR valve
2. Test continuity from each 5 volt reference circuit to all
other PCM circuits at the PCM harness connectors
using the DMM. Example: probe one lead to the MAP
sensor 5 volt reference (at the PCM harness
connector) circuit and probe the other lead to each
terminal at the PCM harness connector. This must be
performed for each 5 volt reference circuit. Refer to
Do any of the circuits indicate a resistance within the
specified range?

3. Connect the J 34142-8 test lamp to B+.
4. Probe the J 34142-B test lamp to the PCM connector
5 volt reference circuits for the following components:
The MAP sensor
The EGR valve
The Throttle Position sensor
Does the test lamp illuminate for any of the circuits?
Test continuity from each 5 volt reference circuit to all
other PCM circuits at the PCM harness connector using
Systems. This must be performed for each 5 volt reference
circuit.
specified range?
0-20
0-2Q
Repair the short between the fuel pump circuit and the
appropriate 5 volt reference circuit or signal circuit. Refer
Repair the short to voltage on the appropriate 5 volt

reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Repair the short between the appropriate 5 volt reference

circuit and the PCM circuit that had continuity. Refer to
Repair the short to ground on the appropriate 5 volt

Systems.
Go to Step 19
Go to Step 19
Go to Step 19
Go to Step 19
6-1774
Engine

Step
Action
15
Important: Repeat this procedure for each component.

1. Reconnect the PCM harness connectors.
2. Clear the Diagnostic Trouble Codes using a
scan tool.
3. Disconnect the following components (one at a time):
The MAP sensor
The TP sensor
The EGR valve
5. Monitor the Diagnostic Trouble Codes using a
scan tool.
Does the scan tool indicate that OTC Pi 635/Pi 639 passed
with the component disconnected?
16
Replace the component for which the Diagnostic Trouble

Code passed. Refer to the appropriate replacement
procedure.
Value(s)
17
18
Repair the short to voltage on the appropriate signal

No
Go to Step 16
Go to Step 17
Go to Step 19

Replace the PCM.
Yes
Go to Step 19
Go to Step 19

scan tool.

19
3. Select the Diagnostic Trouble Code (OTC) option

using a scan tool.

the OTC as specified in the supporting text if
applicable.
20
Go to Step 20
Go to Step 2
Go to the
applicable
OTC table
System OK
Engine
6-1775
DTC P1637 Generator L-Terminal Circuit

rT- .,
I urn I
Generator
On
I Input I
1..-.11
s'
0.35 RED 225
15
C2
~ - - - - - Ge;er;0 ; - ,,
I PCM I
Terminal
1
I
1=BLU
L output
I...
1cC2=RED I
Powertrain
Control
Module
I PCM)
_________ .J(
,!. .
585396
Circuit Description
The L-terminal circuit from the generator is a discrete
circuit (a discrete circuit has no splices and only
one source and one destination) into the PCM. The
PCM applies ignition voltage to the generator
L terminal circuit. A small amount of current flows from
this circuit through the generator windings to create
a magnetic field which starts the generator process.
When the generator is at operating speed and
producing voltage, a solid state switch for the
L terminal circuit in the generator opens and the PCM
detects that the initial startup current flow has
stopped.
The PCM expects to detect low voltage on the
L terminal circuit prior to the generator rotating at
operating speed and conversely expects the circuit to
be at ignition voltage potential when the generator
is operational. When the PCM detects a fault (circuit
shorted to ground, or circuit shorted to a voltage),
this DTC will set.

Engine operating.

The PCM detects an improper voltage on the
generator L terminal circuit.

illuminate.

A History DTC will clear after 40 consecutive
A last test failed (Current DTC) will clear when the

Diagnostic Aids
Important:
.For any test that requires probing the PCM or
prevents damage fo the harness connector
in Wiring Systems.
A generator fault, such as a shorted output diode,
malfunctioning regulator, open or shorted rotor,
or open sense lead may cause a low battery charge.
Refer to A Diagnostic Starting Point - Engine
Electrical in Engine Electrical. for further information
and generator diagnosis.
Use a scan tool in order to diagnosis the generator
circuits. A scan tool displays Generator
L-Terminal Inactive when there is a concern with the
L-terminal circuit.
Test Description
Diagnostic Table.
2. This step determines if a fault is present.
12. A poor connection at the generator causes no
output.
6-1776
Engine
OTC P1637 Generator l-Terminal Circuit

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to A
Diagnostic
in Engine
Electrical
Go to Step 11
Go to Step 5


2
3. Monitor the Generator L terminal parameter using a

scan tool.
Does the scan tool display the Generator L terminal as
Inactive?
Probe the Generator battery feed circuit using the
J 34142-8 test lamp connected to ground. Refer to

3


generator.
3. Measure the voltage to ground at the generator
harness connector terminal Busing the DMM. Refer
Is the voltage the same or more than the value specified?
10V

3. Test for continuity from the generator circuit at the
PCM harness connector to the B terminal of the
generator harness. connector using the DMM. Refer
Does the DM.M indicate continuity?
Test for continuity from terminal B at the generator

harness connector to battery ground using the DMM. Refer
Repair the short to ground in the generator circuit. Refer to

Repair the open/high resistance in the generator circuit.

1. Inspect for poor connections at the PCM harness

Systems.
10
Go to Step B
Go to Step 7
Go to Step 9
-
Go to Step 13
Go to Step 13
Go to Step 13
important: Program the replacement PCM. Refer to PCM

Replace the PCM.
Go to Step 6
Go to Step 10
Go to Step 13
Engine
6-1777
DTC ?1637 Generator L~Terminal Circuit (cont'd)

)
Action
Step
Value(s)
Yes
No
Go to Step 13
Go to Step 12
1. Inspect for poor connections at the generator

11
2. If you find a poor connection, repair the connection

as necessary. Refer to Connector Repairs in Wiring
Systems.
12
Replace the generator. Refer to Generator

Go to Step 13


13

4. Operate the vehicle within the conditions for running

this OTC as specified in the supporting text, if
applicable.
14
diagnosed?
Go to Step 14
Go to Step 2
Go to the
applicable
DTC table
System OK
6-1778
Engine
'" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertrain
~
IC
NC Refrigerant
: Pressure
I
Module
I (PCM)
Fuel Tank
Pressure Sensor
5V
~Reference_
I
ontro
----------------5.'.:,R!;e.'.:n~-
-~
Ji.
ITT
Llil
45 -----------------------------~:~~:~3~0~
0.35 GRYI474
03 C405B
D IC405A
0.5 GRY/B~K 416
0.35 GRY 474

B
Fuel Tank
Pressure
Sensor
________.......I
B 10.5 ORN/Bi:1469
0.5 DK GRN 890
H
G C405A
H3
G3 C405B
0.35 RED/BLK 380

0.35 PPL 719
r.
-0.35
0.35 DK GRN 890

H
8128--- IAT
Sensor
1
-
Gt.
0.35 GRY 720
-- - - - - - P110
64 C2
23 C1
57 C2
-
Cell 14
0.35 DK GRN 890
14
Ground
Distribution
0.35 GRY 720
0.35 PPL 719
~ NC Refrigerant - -
GRYF20
- Fuel Tank -
~ Powertrain
1
!
~------~---------------------~-------J
I
I
Pressure
Sensor
Signal
Sensor
Ground
CONN ID
C1=BLU
C2=RED
Pressure
Sensor
Signal
Sensor
Ground
Control
4
I Module Jiii"
I (PCM) ~
582393
Circuit Description
The PCM uses a common 5.0 volt reference circuit as
a sensor feed to the Fuel Tank Pressure sensor
and the A/C Refrigerant Pressure sensor.
The PCM monitors the voltage on the 5.0 volt
reference circuit. This DTC sets if the voltage is out
of range.

The engine operating.

The 5.0 volt reference circuit is out of range.
The above condition is present for more than
2 seconds.

Failure Records.
O
Engine
Diagnostic Aids
Important:
in Wiring Systems.
A fuel level sensor signal circuit that is shorted to B+
may set this OTC.
6;..1779
If no circuit conditions can be found, test the affected

component.
Test Description
diagnostic table.
connected together inside the PCM. Both
DTCs P1635 and P1639 set at the same time,
indicates a 5 volt reference circuit is shorted to a
voltage.
5. This step determines if a 5 volt reference circuit is
shorted to ground.
6. This step tests for a signal circuit shorted to
voltage.
7. The 5 volt reference circuits may be shorted to
another PCM circuit. The shorted circuit may
not be apparent when the PCM harness connector
is disconnected. Testing continuity from each
5 volt reference circuit isolates the shorted circuit.
11. This step is testing for a component failure.
Disconnecting each component individually
isolates which component might be causing this
OTC to set.

Step
Action
Value(s)
Yes
No
Go to Step2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP1635 5
Volt Reference 1
Circuit
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids

-

4. Monitor the DTCs using a scan tool.
Did both DTCs P1635 and P1639 fail this ignition?

the OTC.
Does the scan tool indicate the OTC set this ignition?
6-1780
Engine

Step
Action
3. Connect the J 34142-8 test lamp to B+.
4. Probe the PCM connector 5 volt reference circuits for
Value(s)
Test continuity from each 5 volt reference circuit to all

other PCM circuits at the PCM harness connector using
the DMM. Example: probe one lead to the A/C refrigerant
pressure sensor 5 volt reference (at the PCM harness
connector) circuit and probe the other lead to each
terminal at the PCM harness connector. This must be
performed for each 5 volt reference circuit. Refer to
specified range?
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 10
Go to Step 11
0-2Q
Repair the short to voltage on the appropriate signal

10
Repair the short between the appropriate 5 volt reference

circuit and the PCM circuit that had continuity. Refer to
11
Important: Repeat this procedure for each component.

1. Reconnect the PCM harness connectors.
2. Clear the Diagnostic Trouble Codes using a
scan tool.
3. Disconnect the following components (one at a time):
The MAP sensor
The TP sensor
The EGR valve
5. Monitor the Diagnostic Trouble Codes using a
scan tool.
Does the scan tool indicate that DTC P1635/P1639 passed
with the component disconnected?
Go to Step 8
Repair the short to ground on the appropriate 5 volt

Systems.
No
The A/C Refrigerant Pressure sensor

The Fuel Tank Pressure sensor.
2. Connect the J 34142-8 test lamp to battery ground.
3. Probe the PCM connector signal circuits for the
The A/C Refrigerant Pressure sensor
The Fuel Tank Pressure sensor.
Yes
Go to Step 14
Go to Step 14
Go to Step 14
(
Go to Step 12
Go to Step 13
Engine
6-1781

Step
12
13
14
15
Action

Replace the PCM.
1. Select the Diagnostic Trouble Codes (DTC) option

and the Clear DTC Information option using the
scan tool.
3. Select the Specific DTC option under the Diagnostic
the DTC as specified in the supporting text if
applicable.
Symptoms
Important Preliminary Checks Before Starting
')
Value(s)
Replace the component for which the Diagnostic Trouble

Code passed. Refer to the appropriate replacement
procedure.
Perform A Powertrain On Board Diagnostic (080)

System Check before using the Symptom Tables, and
verify all of the following are true:
The PCM and MIL (SeNice Engine Soon) are
There are no DTCs stored.
Ensure that the engine coolant temperature is not
above 132C (270F). 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 four cylinders at a time to
keep engine temperatures from reaching
damaging levels. The customer perceives Engine
Coolant Over temperature-Fuel Disabled Mode
as a lack of power, miss, or rough idle. If the
engine operates in Engine Coolant Over
temperature-Fuel Disabled Mode, refer to Engine
Overheating in Engine Cooling.
The scan tool data is within the normal
operating range.
Verify the customers concern, and locate the
correct symptom in the table of contents. Inspect
the items indicated under that symptom.
Several of the symptom procedures ask for a
thorough Visual/Physical inspection. This step
is extremely important - it can lead to correcting a
condition without further inspections and can
save valuable time.
Yes
No
Go to Step 14
Go to Step 14
Go to Step 13
Go to Step 2
Go to the
applicable
DTC table
System OK
" If the condition exists as a start and stall, search

for DTCs related to the vehicle theft deterrent
system. Inspect for improper installation of
electrical options such as lights, cellular
phones etc.
O
Use the following tables when diagnosing a

symptom concern.
If you cannot isolate the condition with the

appropriate table, refer to Intermittent Conditions
for further diagnosis.
- Intermittent Conditions
- Hard Start
- Surges/Chugg/es
- Lack of Power, Sluggishness, or Sponginess
- Detonation/Spark Knock
- Hesitation, Sag, Stumble
- Cuts Out, Misses
- Poor Fuel Economy
- Poor Fuel Fill Quality
- Rough, Unstable, or Incorrect Idle and
Stalling
- Dieseling, Run-On
- Backfire
6-.1782
Engine

Intermittent Conditions
Action
Inspections
Definition: The condition is not currently present but is indicated in DTC History.
OR
There is a customer concern, but the symptom can not currently be duplicated (if the condition is not DTC related).
This step is an important aid for locating a condition without extensive testing.
Perform a visual/physical inspection of the following items:
Wiring harness for damage or cuts.
A misrouted harness that is too close to high voltage/high current devices such
as secondary ignition components, motors and generators. These components
may induce electrical noise on a circuit that could interfere with normal circuit
operation.
Vacuum hoses for proper routing, connections, splits or kinks.
Verify the Mass Air Flow (MAF) sensor is installed correctly. The arrows on the
housing should point toward the engine.
Air leaks at the throttle body mounting area, MAF, and the intake manifold
sealing surfaces.
PCM and body grounds for being clean and tight.
Battery connections are clean and tight.
Charging System for proper operation. Refer to A Diagnostic Starting Point Engine Electrical in Engine Electrical.
Harness/Connector Inspection
Many intermittent conditions occur with harness/connector movement caused by

vibration, engine torque, rough pavement or component operation. Refer to
Testing for Electrical lntermittents in Wiring Systems.
Excessive circuit resistance can cause a component to be inoperative. If the
suspect component does not respond to scan tool commands, then inspect all
related circuits for excessive resistance. Refer to Testing for Continuity in. Wiring
Systems.
Duplicating Failure Conditions
Freeze Frame/Failure Records data (where applicable) can be used to duplica1e the
conditions under which a DTC sets.
1. Review and record Freeze Frame/Failure Records data

2. Clear DTCs using the scan tool.
3. Turn Off the ignition for 30 seconds.
4. Operate the engine as close to the conditions that were noted in Freeze
Frame/Failure Records. The engine must also be operating within the
conditions for running the DTC, refer to Conditions for Running the DTC.
5. Monitor the DTC Status for the DTC being tested. The scan tool will indicate
Ran, when the enabling conditions have been met. The scan tool will also
indicate whether the OTC passed or failed.
The J 42598 Vehicle Data recorder allows the customer, or the technician, to
drive the vehicle and capture data as the intermittent condition occurs. Pressing
a button on the Vehicle Data Recorder, while the intermittent condition is
present, records PCM data which can be used to isolate th.e condition.
O
An. alternate method is to drive the vehicle with the DMM J 39200 connected to
the suspected circuit. An abnormal reading on the DMM when the condition
occurs, may help you locate the condition.
Compare the Freeze Frame/Failure Records with the typical values in the Scan
Tool Data List.
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 individually 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 further investigation.
Refer to the scan tool user instructions for more information on the Snapshot
function.
Engine
6-1783
Intermittent Conditions (cont'd)
Action
Inspections
Intermittent Malfunction Indicator
Lamp (MIL) with NO DTCs
The following conditions may cause an intermittent MIL and no DTCs:

O Electrical system interference caused by a malfunctioning relay, PCM controlled
solenoid or switch.
Improper installation of non-factory (aftermarket) add on accessories such as
cellular phones, alarms, lights, or radio equipment.
O The Malfunction Indicator Lamp (MIL) circuit intermittently shorted to ground.
Poor PCM grounds.
Additional Inspections
Test for an open diode across the A/C compressor clutch and for other open diodes.
Inspect for improper installation of non-factory (aftermarket) add on accessories such
as cellular phones, alarms, lights, or radio equipment.
Excessive circuit resistance can cause a component to be inoperative. If the suspect
component does not respond to scan tool commands, then inspect all related circuits
for excessive resistance. Refer to Testing for Continuity in Wiring Systems.
Test the generator for a bad rectifier bridge that may induce AC electrical noise to
the electrical system. Refer to A Diagnostic Starting Point - Engine Electrical in
Engine Electrical.
Hard Start
Checks
Action
DEFINITION: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary
Refer to Important Preliminary Checks Before Starting in Symptoms.

O Inspect the PCM grounds for being clean, tight and in the proper locations.
O Search for bulletins.
Sensor/System
Test the Engine Coolant Temperature (ECT) sensor for being shifted in value.
Connect a scan tool. Compare the Engine Coolant Temperature against the
Intake Air Temperature (IAT) on a cold engine. The ECT and IAT sensor values
should be within 3C (5F) of each other. If the ECT sensor is out of range
with the IAT sensor, test the resistance of the ECT sensor. Refer to
Temperature vs Resistance for resistance specifications. Replace the ECT
sensor if the resistance is not within the specification. If the sensor is within the
specification, repair ECT signal circuit for high resistance.
Inspect the Mass Air Flow sensor installation. A MAF sensor that is incorrectly
installed may cause a hard start. Important: The embossed arrows on the MAF
sensor indicate the direction of the intake air flow. The arrows must point toward
the engine. Install the MAF in the proper direction. Refer to MAF Sensor
Replacement.
The Camshaft Position Sensor (CMP) may cause a long engine crank time if the
PCM does not receive a CMP signal.
Test the exhaust system for a restriction. Refer to Restricted Exhaust.
Fuel System
Test the fuel pump relay operation. The fuel pump should turn ON for 2 seconds
when you turn on the ignition. Refer to Fuel Pump Electrical Circuit Diagnosis.
A faulty .in-tank fuel pump check valve allows the fuel in the lines to drain back
to the tank after the engine stops. To test for this condition, refer to Fuel System
Diagnosis.
Inspect both injector fuses for being open. An open injector fuse causes
four injectors and four ignition coils not to operate. Replace the fuse. Inspect the
injector circuits and the ignition coil circuits for an intermittent short to ground.
Test for incorrect fuel pressure. Refer to Fuel System Diagnosis.
Test for a restricted fuel filter. Refer to Fuel System Diagnosis.
Test for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
6-1784
Engine

Hard Start (cont'd)
Checks
Ignition System
Action
four ignition coils and four injectors not to operate. Replace the fuse. Inspect the
ignition coil circuits and the injector circuits for an intermittent short to ground.
Inspect for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition {El) System Diagnosis.
Remove the spark plugs and inspect for the following:
- Correct heat range; refer to Spark Plug Usage in Engine Electrical.
- Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Refer to Spark Plug Visual Diagnosis in Engine Electrical.
Determine the cause of the fouling before replacing the spark plugs. If the spark
plugs are gas fouled, refer to OTC P0172 Fuel Trim System Rich Bank 1 or
OTC P0175 Fuel Trim System Rich Bank 2. If the spark plugs are coolant or oil
fouled, refer to Oil Consumption Diagnosis in Engine Mechanical-5.7L or Loss of
Coolant in Engine Cooling.
Inspect for bare or shorted ignition wires. Refer to Spark Plug Wire Resistance
Inspect for loose ignition coil grounds. Refer to Electronic Ignition (El) System
Diagnosis.
Engine Mechanical
Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil

Consumption Diagnosis in Engine Mechanical-5.7L.
Test for low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical-5.7L.
Combustion chambers for excessive carbon buildup. Clean the chambers using
top engine cleaner. Follow the instructions on the can.
- Cylinder heads
- Camshaft
- Pistons, etc.
Refer to Engine Mechanical-5.7L.
Surges/Chuggles
Checks
Action
DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal position.
Preliminary

Inspect the PCM grounds for being clean, tight and in the proper locations.
Be sure the driver understands the operation of the Transmission Torque
Converter Clutch (TCC) and NC compressor operation as explained in the
owners manual. Inform the customer how the TCC and the NC clutch operates.
Sensor/System
Monitor the Heated Oxygen Sensors (H02S} voltages. The Heated Oxygen
Sensors (H02S} should respond quickly to different throttle positions. If the
sensors do not respond, inspect the H02S for silicon or other contaminates from
fuel or the use of improper RTV sealant. The sensors may have a white
powdery coating and result in a high but false signal voltage (rich exhaust
indication). The PCM then reduces the amount of fuel delivered to the engine
causing a severe driveability condition. For more information, Refer to
Information Sensors/Switches Description.
Inspect the MAF sensor connections. Repair or replace terminals. Refer to
Engine
6-1785
Surges/Chuggles (cont'd)
Checks
Action
..
Fuel System

Diagnosis.
Inspect that each injector harness is connected to the correct injector/cylinder
according to the firing order (firing order: 1-8-7-2-6-5-4-3). Relocate injector
harnesses as necessary.
Inspect the items that cause an engine to run rich (long term fuel trim near
-13%). For a rich condition, refer to OTC P0132H02S Circuit High .Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Inspect items that can cause an engine to run lean (long term fuel trim near
24%). For a lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.
Ignition System
Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply the water.
Test for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition (El) System Diagnosis.
- Wet plugs
- Cracks
-Wear
- Improper gap
- Burned.electrodes
- Heavy deposits
An improper spark plug gap causes a driveability condition. Gap the spark plugs
using a wire gauge gap tool (J 41319). Refer to Spark Plug Replacement in
Engine Electrical.
fouled, refer to Oil Consumption Diagnosis in Engine Mechanical-5.?L or Loss of
- Coolant in Engine Cooling.
Diagnosis.
Engine Mechanical
Ensure that the engine coolant temperature is not above 132C (270F). 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 four cylinders at a time to keep engine temperatures from
reaching damaging levels. The customer perceives Engine Coolant Over
temperature-Fuel Disabled Mode as a lack of power, miss, or rough idle. If the
engine operates in Engine Coolant Over temperature-Fuel Disabled Mode, refer to
Engine Overheating in Engine Cooling.
Additional Checks
Visually/physically inspect vacuum hoses for splits, kinks, and proper

connections and routing as shown on Vehicle Emission Control Information
label. Refer to Emission Hose Routing Diagram.
$
Test the Transmission Torque Converter Clutch (TCC) operation. A TCC
applying too soon can cause the engine to spark knock. Refer to A Diagnostic
Starting Point - Automatic Transmission in Automatic Transmission-4L60-E.
'
'
'
6-1786
Engine

lack of Power, Sluggishness, or Sponginess
Checks
Action
DEFINITION: Engine delivers less than expected power. Little or no increase in speed when the accelerator pedal is pushed
down part way.
Preliminary Checks

Remove the air filter element and inspect for dirt or for being restricted. Refer to
Air Cleaner Element Replacement a:nd replace as necessary.
Fuel System Checks
Diagnosis.
Inspect items that cause an engine to run rich (long term fuel trim near -13%).
For a rich condition, refer to OTC P0132 H02S Circuit High Voltage Bank 1
Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Inspect items that can cause an engine to run lean (long term fuel trim
near 24%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Sensor/System
Use a scan tool in order to monitor the KS system for excessive spark retard activity.
Refer to Knock Sensor (KS) System Description.
Ignition System
ignition coil circuit and the injector circuits for an intermittent short to ground.
O Wet down the secondary ignition system with water from a spray bottle. Wetting
the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as water is applied.
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
An improper spark plug gap causes a driveability condition. Gap the spark
plugs using a wire gauge gap tool. Refer to Spark Plug Wire Harness
fouled, refer to Oil Consumption Diagnosis in Engine Mechanical-5.?L or Loss of
O Inspect for loose ignition coil grounds. Refer to Electronic Ignition (El) System
Diagnosis.
Engine
6-1787
Lack of Power, Sluggishness, or Sponginess (cont'd)

Action
Checks
Engine Mechanical
Ensure that the engine coolant temperature is not above 132C (270F). 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 four cylinders at a time to keep engine temperatures
from reaching damaging levels. The customer perceives Engine Coolant Over
temperature-Fuel Disabled Mode as a lack of power, miss, or rough idle. If the
engine operates in Engine Coolant Over temperature-Fuel Disabled Mode, refer
to Engine Overheating in Engine Cooling.
Consumption Diagnosis in Engine Mechanical-5.?L.
Low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical-5.?L.
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks
Inspect the exhaust system for possible restrictions. Inspect for the following:
- Inspect the exhaust system for damaged or collapsed pipes. Refer to
- Inspect the exhaust manifold for a collapsed inner wall. Refer to Exhaust
Manifold Clean and Inspect in Engine Mechanical-5.?L.
- Inspect the mufflers for heat distress or possible internal failure. Refer to
Internal Muffler Rattles/Loss of Power in Engine Exhaust.
- Inspect for possible plugged Three-Way catalytic converters by comparing
exhaust system back pressure on each side of engine. Test the back
pressure by removing AIR c.heck valves near exhaust manifolds or the
Heated Oxygen sensors. Refer to Restricted Exhaust in Engine Exhaust.
Test the Transmission Torque Converter Clutch (TCC) operation. Refer to
A Diagnostic Starting Point - Automatic Transmission in Automatic
Transmission-:-4L60-E .
6-1788
Engine
Checks
Action
DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening.
Preliminary Checks
Fuel System

Inspect the PCM grounds for being clean, tight, and in the proper locations.
If the scan tool readings are normal (refer to supporting text of the Powertrain
On-Board Diagnostic (OBD) System Check) and there are no engine mechani.cal
faults, fill the fuel tank with a known high quality fuel that meets the vehicle's
minimum octane requirements. Refer to Fuel System Specifications. Road test
the vehicle and re-evaluate the vehicle's performance.

Diagnosis.
Inspect the items that can cause an engine to run lean (long term fuel trim
near 24%). For a lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Ignition System
Inspect the spark plugs for the proper heat range. Refer to Spark Plug Usage in
Engine Electrical.
Inspect for obvious overheating conditions:

Low engine coolant. Refer to Draining and Filling Cooling System (5. 7 L) and
Coolant Concentration Testing in Engine Cooling for the type and amount of
engine coolant to be used.
Restricted air flow to the radiator. or restricted coolant flow through the radiator.
Refer to Radiator Cleaning in Engine Cooling.
Engine Mechanical
Inspect for the following engine mechanical conditions:
Inoperative electric cooling fan. Refer to Electric Cooling Fan Diagnosis.

Low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical-5. 7L.
Combustion chambers for excessive carbon buildup. Clean the combustion
chamber by using top engine cleaner. Follow the instructions on the can.
Inspect for incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Refer to Engine Mechanical-5.?L.
Additional Checks
Test the Park/Neutral Position (PNP) switch operation. Refer to PNP Switch
Diagnosis.
Test the Transmission Torque Converter Clutch (TCC) operation. A TCC
applying too soon can cause the engine to spark knock. Refer to A Diagnostic
Starting Point - Automatic Transmission in Automatic Transmission-4L60-E.
Engine
6-1789
Action
Checks
DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually
more pronounced when first trying to make the vehicle move, as from a stop. May cause the engine to st1:1ll.if severe .
enough.
Preliminary
Sensor/System

Inspect the PCM grounds for being clean, tight, and in the proper locations.
Test the MAP sensor operation.
Fuel System

Diagnosis.
Test the fuel injectors. Refer to Fuel lnj Coil Test - ECT Between
Inspect the items that cause an engine to run rich (long term fuel trim
near -13%). For a rich condition, refer to OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
lnspectthe items that can cause an engine to run lean (long term fuel trim
Ignition System
components. Look/listen for arcing or misfiring as you apply water.
Electronic Ignition (El) System Diagnosis for the procedure.
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
using a wire gauge gap tool. Refer to Spark Plug Replacement in Engine
Electrical.
Diagnosis.
Inspect the engine thermostat for proper operation and heat range. Refer to
Thermostat Diagnosis in Engine Cooling.
Additional Checks
Test the generator output voltage. Refer to A Diagnostic Starting Point - Engine
Electrical in Engine Electrical for the procedure. Repair the charging system if the
generator output voltage is less than 9 volts or more than 16 volts.
6-1790
Engine
Cuts Out, Misses
Checks
Action
DEFINITION: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases.
This condition is not normally felt above 1500 RPM or 48 km/h (30 mph). The exhaust has a steady sputtering sound at idle
or low speed.
Preliminary

Remove the air filter element and inspect for dirt or for being restricted. Reier to
Air Cleaner Element Replacement. Replace as necessary.
Fuel System
Inspect the fuel injectors. Refer to Fuel lnj Coil Test - ECT Between
.
Diagnosis.
Inspect items that cause an engine .to run rich (long term fuel trim near -13%).
Sensor 1 and DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Bank 1 Sensor 1 and DTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.
Sensor/System
Use a scan tool in order to monitor the KS system for excessive spark retard activity.
Refer to Knock Sensor (KS) System Description.
Ignition System
down the secondary ignition system may help locate damaged or deteriora1ed
- Correct heat range-refer to Spark Plug Usage in Engine Electrical.
- Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Refer to OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1 in Engine
Electrical.
Electrical.
Visually/Physically inspect the secondary ignition for the following:
- Ignition wires arcing to ground
- Ignition wires for proper routing
- Ignition coils for cracks or carbon tracking
Engine
6-1791
Cuts Out, Misses (cont'd}

Action
Checks
Engine Mechanical
Inspect engine mechanical for the following:

- Test the engine compression. Refer to Engine Compression Test in Engine
Mechanical-5. 7L.
- Sticking or leaking valves. Refer to Valve Train Diagnosis in Engine
Mechanical-5.?L.
- Worn camshaft lobes. Refer to Valve Train Diagnosis in Engine
Mechanical-5. 7L.
- Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L.
- Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L.
- Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical-5..?L
- Broken valve springs. Refer to Valve Train Diagnosis in Engine
Mechanical-5. 7L.
- Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical-5. 7L.
- Camshaft
- Cylinder heads
- Pistons, etc.
Refer to Engine Mechanical-5.?L for diagnosis procedures.
Additional Checks
Inspect exhaust system for possible restrictions. Inspect for the following:
- Inspect the exhaust system for damaged or collapsed pipes, Refer to
pressure by removing AIR check valves near exhaust manifolds or the
Electromagnetic Interference (EMI) on the reference circuit can cause an engine
miss condition A sudden increase in RPM with little change in actual engine
RPM change indicates EMI is present. Inspect for high voltage components near
Ignition Control circuits if a condition exists.
Inspect the intake manifold and the exhaust manifold passages for casting flash.
Refer to Exhaust Manifold Clean and Inspect and Intake Manifold Clean and
Inspect in Engine Mechanical-5.?L.
Poor Fuel Economy

Checks
Action
DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, fuel economy is
noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.
Preliminary

Check the PCM grounds for being clean, tight, and in the proper locations. Refer
Check the owners driving habits .
..., Is the A/C ON or the Defroster mode ON full time?
- Are the tires at the correct pressure?
- Is there excessively heavy loads being carried?
- Is the acceleration rate too much, too often?
Remove the air filter element and check for dirt or for being restricted. Refer to
6-1792
Engine
Checks
Fuel System
Action
Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT Between
Check for incorrect fuel pressure. Refer to Fuel System Diagnosis.
Check for a restricted fuel filter. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Check that each injector harness is connected to the correct injector/cylinder
Check for foreign material accumulation in the throttle bore, coking on the
throttle valve, or on the throttle shaft. Also inspect for throttle body tampering.
Refer to Throttle Body Cleaning Procedure.
Check items that cause an engine to run rich (long term fuel trim near -13%).
For a rich condition, refer to DTC P0132 H02S Circuit High Voltage Bank f
Sensor/System
Ignition System
Check the type, quality and alcohol content of the fuel. Oxygenated fuels have
lower energy and may deliver reduced fuel economy. Refer to Fuel System
Specifications and Alcohol/Contaminants-in-Fuel Diagnosis.
Check the air intake system and crankcase for air leaks.
Check the crankcase ventilation valve for proper operation. Place a finger over
the. inlet hole in the valve end several times. The valve shouid sr:1ap bacf If no(
replace the valve.
Check for proper calibration of speedometer. Connect Signal Generator
J 33431-8 to the VSS electrical connector. Turn ON the ignition with the tester
ON and monitor the speedometer. The speedometer should indicate 86 km/h
(54 mph). If not, refer to A Diagnostic System Check - Instrument Cluster in
Use a scan tool in order to monitor the KS system for excessive spark retard
activity. Refer to Knock Sensor (KS) System Description.
Check for proper ignition voltage output with spark tester J 26792. Refer to
Remove the spark plugs and check for the following:
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
'
An improper spark plug gap will cause a driveability problem. Gap the spark
plugs using a wire gauge gap tool (J 41319). Refer to Spark Plug Replacement
in Engine Electri,cal.
Determine the cause of the fouling before replacing the spark plugs if the spark
plugs are gas, coolant, or oil fouled. Refer to OTC P0172 Fuel Trim System Rich
Bank 1 or OTC P0175 Fuel Trim System Rich Bank 2 for diagnosis of the rich
condition. Refer to Spark Plug Visual Diagnosis in Engine Electrical for diagnosis
of coolant or oil fouled spark plugs.
Visually/Physically inspect the secondary ignition for the following:
'
Wetting down the secondary ignition system with water from a spray bottle may
help locate damaged or deteriorated components. Look/listen for arcing or
misfiring as you apply water.
Check for loose ignition coil grounds. Refer to Electronic Ignition (El) System
Diagnosis.
Engine
6-1793

Action
Checks
Check the engine coolant level for being low. Refer to Draining and Filling
Cooling System (5. 7 L) in Engine Cooling.
Check the engine thermostat for proper operation and heat range. Refer to
Engine Mechanical
Chec.k engine mechanical for the following:

- Check compression. Refer to Engine Compression Test in Engine
Mechanical.
-
Sticking or leaking valves. Refer to Valve Train Diagnosis.

Worn camshaft lobes. Refer to Valve Train Diagnosis.
Valve timing. Refer to Valve Train Diagnosis.
Bent push rods. Refer to Valve Train Diagnosis.
Worn rocker arms. Refer to Valve Train Diagnosis.
Broken valve springs. Refer to Valve Train Diagnosis.
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks
Visually (physically) check the vacuum hoses for splits, kinks, and proper
connections and routing as shown on Vehicle Emission Control
Information label.
Check the Transmission Torque Converter Clutch (TCC) operation. The scan
tool should indicate a RPM drop, when the system commands the TCC ON.
Refer to A Diagnostic Starting Point - Automatic Transmission in Automatic
Transmission-4L60-E.
Check the exhaust system for a possible restriction. Check for the following:
- Inspect the exhaust system for. damaged or collapsed pipes. Refer to
Manifold Clean and Inspect in Engine Exhaust.
Internal Muffler Rattles/Loss of Power in Engine Exhaust.Internal Muffler
Rattles/Loss of Power
- Inspect for possible plugged Three-Way catalytic converters by comparing the
exhaust system back pressure on each side of the engine. Check the back
pressure by removing the AIR check valves near the exhaust manifolds.
Refer to Restricted Exhaust.
miss condition. A scan tool can usually detect EMI by monitoring the engine
RPM. A sudden increase in RPM with little change in actual engine RPM
change, indicates EMI is present. Check for high voltage components near
Ignition Control circuits if a problem exists.
Check PNP switch circuit. Refer to PNP Switch Diagnosis.
Check for faulty motor mounts. Refer to Engine Mount Inspection in Engine
Mechanical for inspection of mounts.
Check the intake and the exhaust manifold passages for casting flash. Refer to
Exhaust Manifold Clean and Inspect, and Exhaust Manifold Clean and Inspect in
Engine Mechanical.
Check the brake system for dragging or improper operation. Refer to Hydraulic
Brake Diagnostic System Check in Hydraulic Brakes.
6-1794
Engine
Poor Fuel Fill Quality
Problem
Causes
DEFINITION: Difficulty when refueling the vehicle.

Difficult to fill

The EVAP canister vent solenoid is stuck closed.

Overfill
The
The
The
The
Pre-mature shut-off of the fuel

dispensing nozzle

The EVAP canister vent solenoid is stuck closed.
Fuel Spit Back
The check. valve is stuck open.

fill limiter vent valve is stuck open.
fill limiter vent valve is leaking.
The check valve is leaking.

Liquid fuel in EVAP canister

Liquid fuel leak
Fuel Odor
The EVAP canister is saturated.
The
The
The
The
fuel filler hose is loose or torn.
fill limiter vent valve is stuck open.
Engine
6-1795
Rough, Unstable, or Incorrect Idle and Stalling

Checks
Action
DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Preliminary Checks

Remove and Inspect the air filter element for dirt, or for being restricted. Refer to
Fuel System
Test the fuel injectors. Refer to Fuel lnj Coil Test - ECT Between
Diagnosis.
harnesses as necessary:
Inspect items that cause an engine to run rich (long term fuel trim near -13%).
Sensor/System
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.
Use a scan tool in order to monitor KS system for excessive spark retard
Ignition System
Electronic Ignition (El) System Diagnosis for the procedure.
Remove spark plugs and inspect for the following:
-Wet plugs
-Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Electrical.
Visually/Physically inspect secondary ignition for the following:
Diagnosis.
6-1796
Engine

Checks
l;ngine Mechanical
Action
O

Mechanical-5. 7L.
Mechanical-5.?L.
Mechanical-5.?L.
- Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L
- Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L.
- Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L.

Mechanical-5. 7L.
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks
Inspect the exhaust system for possible restrictions. Inspect for the following:
- Inspect the exhaust system for damaged or collapsed pipes. Refer to
pressure by removing AIR check valves near exhaust manifolds or the

miss condition A scan tool can usually detect EMI by monitoring the engine
change, this indicates that EMI is present. Inspect for high voltage components
near Ignition Control circuits if a condition exists.
Test the PNP switch circuit. Refer to PNP Switch Diagnosis.
Inspect for faulty engine mounts. Refer to Engine Mount Inspection in Engine
Mechanical-5. 7L.
Inspect the intake and the exhaust manifold passages for casting flash. Refer to
Exhaust Manifold Clean and Inspect and Intake Manifold Clean and Inspect in
Engine Mechanical-5. 7L.
Dieseling, Run-On
Checks
Action
DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If the engine runs smooth, test the
ignition switch and the ignition switch adjustment.
Preliminary Checks
Fuel System

Refer .to Engine Controls Schematics.
Inspect the injectors for a leaking condition. Refer to Fuel System Diagnosis for the
proper procedure.
Engine
6-1797
Backfire
Checks
Actions
DEFINITION: Fuel ignites in the intake manifold or in the exhaust system, making a loud popping noise.
Preliminary Checks

O Search for bulletins.
Refer to Engine .Controls Schematics.
Fuel System

Diagnosis.
O
Sensor/System
Test the Secondary Air Injection (AIR) system. Refer to OTC P0410 Secondary
Air Injection (AIR) System.
Inspect the air intake system and crankcase for air leaks.
Test the crankcase ventilation valve for proper operation. Place a finger over the
inlet hole in the valve end several times. The valve should snap back. If not,
replace the valve.
Verify proper calibration of speedometer. Connect Signal Generator J 33431-8
to VSS electrical connector. Ignition ON, tester ON and monitor the
speedometer. The speedometer should indicate 86 km/h (54 mph). Refer to A
Diagnostic System .Check - Instrument Cluster in Instrument Panel, Gauges and
Console.
Use a scan tool in order to monitor the KS system for excessive spark retard
Ignition System
Inspect for an intermittent ignition system malfunction in the following circuits:
- Ignition control circuit.
- Power arid ground to the ignition coils.
O
Remove spark plugs and inspect for the following:
- Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
O An improper spark plug gap causes a driveability condition. Gap the spark plugs
using .a wire gauge gap tool. Refer to Spark Plug Replacement in Engine
Electrical.
Determine. the cause of the fouling before replacing the spark plugs. If the spark
Visually/Physically inspect secondary ignition for the following:
- Ignition coils arcing to ground
O Wet down the secondary ignition system with water from a spray bottle. Wetting
components. Look/listen for arcing or misfiring as you apply the water.
Diagnosis.
6-1798
Engine

Backfire (cont'd)
Checks
Actions
Inspect the engine coolant level for being low. Refer to Draining and Filling
Cooling System (5.7 L) in Engine Cooling.
Test the engine thermostat for proper operation and heat range. Refer to
Engine Mechanical

Mechanical-5. 7L.
Mechanical-5. 7L.
Mechanical-5. 7L.
- Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical-5.?L.
- Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical-5.7L.
- Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical-5.?l.
Mechanical-5.?L.
..
Additional Checks
- Camshaft
- Cylinder heads
- Pistons, etc .
Visually (physically) Inspect the vacuum hoses for splits, kinks, and proper
connections and routing as shown on Vehicle Emission Control
Information label.
Inspect the intake manifold and the exhaust manifold passages for casting flash.
Refer to Exhaust Manifold Clean and Inspect and Intake Manifold Clean and
Inspect in Engine Mechanical-5.?L.
Test the Transmission Torque Converter Clutch (TCC) operation. The scan 1ool
should indicate an RPM drop when the TCC is commanded ON. Refer to A
Diagnostic Starting Point - Automatic Transmission in Automatic
Transmission-4L60-E.
Inspect the exhaust system for possible restrictions. Inspect the following:
- Inspect the exhaust system for damaged or collapsed pipes. Refer to Exhaust
System Inspection in Engine Exhaust.
Manifold Clean and Inspect in Engine Exhaust.
exhaust system back pressure on each side of engine. Test back pressure by
removing AIR check valves near exhaust manifolds or the Heated Oxygen
sensors. Refer to Restricted Exhaust in Engine Exhaust.
miss condition. A scan tool can usually detect EMI by monitoring the engine
change, may indicate that EMI is present. Inspect for high voltage components
near Ignition Control circuits if a condition exists.
Test the PNP switch circuit. Refer to PNP Switch Diagnosis.
Inspect for faulty engine mounts. Refer to Engine Mount Inspection in Engine
Mechanical-5. 7L.
Engine
6-1799
A/C Request Circuit Diagnosis

\
For complete circuit details refer to A/C Compressor
Diagnostic Aids
Control.
Important:
in Wiring Systems.
Ensure no PCM DTCs are stored before using this
table. The PCM will not activate the A/C clutch with a
stored OTC.
.Circuit Description:
The A/C clutch relay is PCM controlled to delay A/C
clutch engagement after the A/C is turned ON.
This allows the PCM to adjust engine RPM before the
A/C clutch engages. The PCM will engage the A/C
clutch any time A/C has been requested unless any of
the following conditions exist:
High coolant temperature
O
Low A/C system pressure
High A/C system pressure

Wide open throttle
High engine RPM
Test Description
When the heater and A/C control is placed in the A/C

mode and the engine is operating, a 12 volt signal
is sent to the PCM. When the PCM receives this signal
the PCM will ground the A/C clutch relay control
circuitttoleneA/rgicze the A/tCYrEeSlay. This is shown on the
scan oo as
reques
When a request for A/C has been detected by the

PCM, the PCM will ground the A/C clutch relay control
circuit, the relay contacts will close, and current will
flow through the relay to the A/C compressor clutch.

diagnostic table.
2 . A/C DTCs will disable the A/C system. Repair A/C
DTCs before proceeding.
3. The request circuit is shorted to a voltage if the
scan tool displays A/C request as YES.
5. A condition exists with the request circuit between
the PCM and ttie HVAC Programmer, or the
HVAC Programmer is malfunctioning if the test
lamp did not illuminate.
A/C Request Circuit Diagnosis

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to the
applicable
DTCtable
Go to Step 3
Go to Step 8
Go to Step 4
System OK
Go to Step 5
Go to Step 10
Go to Step 6

Are any A/C DTCs set?
2
2. Idle the engine with the A/C OFF.
3. Monitor the A/C request status using the scan tool.
Turn ON the A/C.


4. Probe the A/C request circuit at the PCM electrical
harness connector using the DMM connected to
ground.
5. Turn the A/C to the ON position.
Does the DMM display near the specified value when the
A/C is enabled?
B+
6-1800
Engine

A/C Request Circuit Diagnosis (cont'd)
Step
Action

2. Disconnect the HVAC Programmer. Refer to Control
Assembly Replacement in HVAC Systems-Manual.
3. Test the A/C request circuit for continuity between the
HVAC Programmer and the PCM using the DMM.
Probe the A/C. request circuit at the PCM harness

connector using the J 34142-8 test lamp connected to B+.
Refer to Probing Electrical Connectors in Wiring Systems.
Value(s)
Yes
No
Go to Step 7
Go to Step 11
Go to Step 12
Go to Step 9
System OK
Go to Step 9
1. Inspect the A/C request circuit for a short to voltage.
Important: Before replacing the HVAC Programmer, refer

to A Diagnostic Starting Point in HVAC Systems-Manual.
Replace the HVAC Programmer. Refer to Control
Assembly Replacement in HVAC Systems-Manual.
10

Wiring Systems.
2. it ybu find a poor connection repair the terminal as
Wiring Systems.
11
Repair the open A/C request circuit between the HVAC

Programmer and the PCM. Refer to Wiring Repairs in
Wiring Systems.
12
Repair the grounded A/C request circuit between the

HVAC. Programmer and the PCM. Refer to Wiring Repairs
iri Wiring Systems.

Replace the PCM.
13
,.
2. If you find the A/C request circuit shorted repair the

condition as necessary. Refer to Wiring Repairs in
Wiring Systems.
System OK
System OK
Go to Step 13
System OK
System OK
System OK
Engine
6-1801
A/C Refrigerant Pressure Sensor Circuit Diagnosis

)

Circuit Description
The AJC system uses an A/C refrigerant pressure
sensor mounted in the high side of the A/C system to
monitor A/C refrigerant pressure. The PCM utilizes
this information in order to disable the A/C compressor
clutch when the A/C system pressure is out of
range. The PCM also uses A/C refrigerant pressure
sensor to enable the engine coolant fans when the A/C
refrigerant pressure is high.
The PCM supplies a 5 volt reference, a signal circuit,
and a ground circuit to the A/C refrigerant pressure
sensor. As the A/C pressure increases or decreases,
the resistance of the sensor changes and varies
the amount of signal voltage detected by the PCM.

Poor connections; Refer to Testing for Intermittent
Mis-routed harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
If the test did not fail this ignition cycle, move the
related electrical harnesses and the connectors while
monitoring a scan tool.
Test Description
diagnostic table.
Diagnostic Aids
Important:
connect9r test adapter Kit. Using this kit
prevents damage to the harness/component
in Wiring Systems.
3. The normal A/C voltage is between 1.0 and

1.8 volts.
5. If the A/C pressure/voltage stays high after
disconnecting the A/C refrigerant pressure sensor
electrical connector, this indicates the signal
circuit is shorted to a voltage.
7. This step tests for a good ground circuit.
8. This step verifies the integrity of the A/C
refrigerant pressure sensor signal circuit.
11. If you have thoroughly inspected the 5.0 volt
reference circuit (for opens, shorts to ground, PCM
connections etc.) and is OK, then replace
the PCM.
12. If you. have thoroughly inspected the ground
circuit for opens and the PCM connections
are OK, then replace the PCM.
A/C Refrigerant Pressure Sensor Circuit Diagnosis

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
DTCP16395
Volt Reference 2
Circuit
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 16
Go to
Diagnostic Aids
Go to Step 6
Go to Step 10


2
2. Idle the engine.

3. Monitor the OTC Information using the scan tool.
2. Monitor the A/C High Side parameter using the
scan tool.
Does the scan tool indicate the A/C High Side Pressure
voltage within the specified range?
0.1-1.BV
Move related harnesses while monitoring the A/C High

Pressure voltage.
Does the scan tool indicate that the sensor values change
while moving related electrical harnesses?
Disconnect the A/C refrigerant pressure sensor electrical

connector. Refer to A/C refrigerant pressure sensor in
HV AC Systems with A/C-Manual or Automatic.
Does the scan tool indicate the A/C High Side less than
1V
6~1802
Engine Controls ' 5.7L
Engine
A/C Refrigerant Pressure Sensor Circuit Diagnosis (cont'd)

Step
Action
Value(s)
5V

sensor 5 volt reference circuit to the sensor ground circuit
using the DMM.
5V
Jumper the 5 volt reference circuit to the A/C refrigerant

pressure sensor signal circuit using a fused jumper wire.
Does the scan tool indicate the A/C High Side voltage at
5V
Repair the faulty A/C refrigerant pressure sensor

connection or faulty sensor. Refer to A/C Refrigerant
Pressure Sensor Replacement in Heating, Ventillation, and
Air Conditioning.
10
Repair the short to voltage in the A/C refrigerant pressure

Systems.
Is. the action complete?
Repair the A/C refrigerant pressure sensor 5 volt reference

Repair the A/C refrigerant pressure sensor ground circuit.

Repair the A/C refrigerant pressure sensor signal circuit.

12
13
No

sensor 5 volt reference circuit to the battery ground using
the DMM.
11
Yes
Go to Step 7
Go to Step 11
Go to Step 8
Go to Step 12
Go to Step 9
Go to Step 13
System OK
System OK
System OK
Go to Step 14
System OK
Go to Step 14
System OK
Go to Step 14
System OK
Go to Step 15
1. Inspect for a poor sensor ground terminal connection

14
15
at the PCM connector. Refer to Testing for

Wiring Systems.

Replace the PCM.
System OK
1. Inspect for a poor sensor connection or PCM

16

Wiring Systems.
System OK
Engine
6-1803

Circuit Description

This will aid in understanding the two distinct modes of
contacts on circuit 409 to the Left Hand (LH) cooling
fan. Current flow continues out of the fan motor
on circuit 532 to relay #3. The unenergized relay #3
provides power to the.Right Hand (RH) cooling fan
motor. The low side of the RH cooling fan completes
the circuit to ground on circuit 150. This circuit is a
series circuit which allows half speed operation
for each fan since each fan motor will drop half of the
supplied battery power.
flow to the LH cooling fan on circuit 409. Current

Diagnostic Aids
If the owner complained of an overheating problem,
determine if the complaint was due to an actual
boil over, or the warning indicator light illuminated, or
the engine coolant temperature gauge .indicated
overheating. The gauge accuracy can also be checked
by comparing the Engine Coolant Temperature (ECT)
sensor reading using a scan tool and comparing
its reading with the gauge reading. If the engine is
actually overheating and the gauge indicated
overheating, but the cooling fan is not coming ON, the
Engine Coolant Temperature (ECT) sensor has
probably shifted out of calibration and should be
replaced.
If the engine is overheating and the cooling fans are
ON, the cooling system should be checked, refer
to Engine Overheating in. Engine Cooling.
The PCM will command low speed fans ON at 108C
(226F) and OFF at 103C (217F) and, high speed
.
fans ON at 113C (235F) and OFF at 108C (226F).
Test Description
diagnostic table.
2. The PCM will enable the engine cooling fans
when certain Diagnostic Trouble Codes are
set. Go to applicable OTC Table first before
100C (212F) before proceeding with diagnosis.
6-1804
Engine

Electric Cooling Fan Functional Check
Step
Action
Value(s)
Yes
No
Go to Step2
Goto A
Powettrain On
Board
Diagnostic (080)
System Check
Go to applicable
DTC Table
Go to Step 3

Are any DTCs set?

Important: Engine coolant temperature must be. below the
specified value for all of the cooling fan diagnoses.
1. Idle the engine.
2. Turn the A/C OFF.
3. Monitor the A/C Request parameter using the
scan tool.
100C (212F)
Go to A/C
Request Circuit
Diagnosis
Does the scan tool display the A/C request as YES?
Command the cooling fan relay #1 ON using a scan tool.

Are both cooling fans ON?
Command the cooling fan relays #1 , #2 and #3 ON using

a scan tool.
Do both cooling fans switch to high speed?
1. Using a scan tool, exit outputs.

2. Idle the engine leaving the A/C OFF.
Turn the A/C ON.

..
Does the scan tool display A/C request as YES?
9
I
Go to Step 4

Go to Cooling
Fan. table #1
Go to Step 5
Go to Step 6
Go to Cooling
Fan table #2
Go to Step 7
Go to Cooling
Fan table #3
Go to Cooling
Fan table #1
Go to Step 8
System OK
Go to Step 9
Go to A
Diagnostic
$tatting Point in
HVAC Systems.
Go to AIC
Request Circuit
Diagnosis
Engine
Test Description
The numbers below referto the step numbers in the

diagnostic table.
2. This step determines if the cooling fan relay
contacts are stuck closed.
3. This step determines ifthere is a short to voltage
on circuit 532.
6-1805
4. Any test that requires probing a component or a

Test Adaptor Kit J 35616-A. Using this kit
terminals. Refer to Using Connector Test
Adapters.
5. Thi~ step determines if the cooling fan relay
contacts are stuck closed.

Step
Action
Value(s)
Yes
No
Go to Step2
Go to
Cooling Fan
Functional Check
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 7
Go to Step B
Go to Step 10
Go to Step 9
:t

2. Disconnect the cooling fan relay #1.
Are both of the cooling fans OFF?
Disconnect the cooling fan relay #3.

..

3. Disconnect the left cooling fan electrical connector.
4. Probe the cooling fan electrical connector terminal B
using the test lamp J 34142-8 connected to ground.
Disconnect the cooling fan relay #2.

Replace the cooling fan relay #1. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete
Go to
Cooling Fan
Functional Check
Repair circuit 409 for a short to B+. Refer to Wiring

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check
10
Replace the cooling fan relay #2. Refer to Cooling Fan

Go to
Cooling Fan
Functional Check
6-1806
Engine
Test Description
3. This step tests for an inoperative cooling fan relay.

diagnostic table.
5. This step tests for an open left cooling fan motor.

When the left cooling fan terminals are connected,
the right cooling fan should. operate on
high speed.
2. Any test that requires probing a component or a

Test Adaptor Kit J 35616-A. Using this kit
terminals. Refer to Using Connector Test
Adapters.
7. This step is testing for a short to ground between

the left cooling fan motor and cooling fan
relay #3.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to
Cooling Fan
Functional Check
1
2. Disconnect cooling fan relay #1.
3. Probe the cooling fan relay #1 terminal 83 at the
underhood electrical center using the test lamp
Does the. test lamp illuminate?

this table.
Connect a fused jumper wire between the cooling fan relay
#1 terminals 83 and C1 at the underhood electrical center.
Do both cooling fans turn ON?

2. Disconnect the left cooling fan electrical connector.
3. Probe the left cooling fan electrical connector
terminal 8 using the test lamp J 34142-8 connected
to ground.

2. Probe the cooling fan relay #3 terminal CS using the
test lamp J 34142~8 connected to 8+.
1. Install the cooling fan relay #3.

this table.
2. Connect a fused jumper wire between left cooling fan
electrical connector terminals A and 8. Refer to Using
Fused Jurnper Wires in Wiring Systems.
Does the right cooling fan turn ON?

2. Probe the cooling fan relay #3 terminal CS at the
Important: Leave the jumper in place for remainder of

this table.
Connect a fused jumper wire between the cooling fan
relay #3 terminals CS and 89 at the underhood electrical
center. Refer to Using Fused Jumper Wires in Wiring
Systems.
Go to.Step 3
Go to Step 11
Go to Step 12
Go to Step 4
Go to.Step 5
Go to Step 13
Go to Step 22
Go to Step 6
Go to Step 14
Go to Step 7
Go to Step B
Go to Step 16
Go to Step 17
Go to Step 9
Engine
6-1807

\)
Action
Step
1. Disconnect the right cooling fan electrical connector.

2. Probe the right cooling fan electrical connector
9
terminal B using the test lamp J 34142-B connected

to ground.
Value(s)
Probe the right cooling fan electrical connector terminal A

using the test lamp J 34142-B connected to B+.
12
Repair the cooling fan relay B+ supply circuit. Refer to

Replace the #1 Cooling fan relay. Refer to Cooling Fan
13
14
Replace the LH fan motor. Refer to Cooling Fan Motor

Replacement - Electric in Engine Cooling.
Go to
Cooling Fan
Functional Check
16
18
Replace the #3 cooling fan relay. Refer to Cooling Fan

1. Inspect for poor connections at the right cooling fan
motor. Refer to Testing for Intermittent and Poor
Wiring Systems.
Replace the RH fan motor. Refer to Cooling Fan Motor

Replacement - Electric in Engine Cooling.
Repair the open ground circuit. Refer to Wiring Repairs in
Wiring Systems.
21
22
Go to Step 15
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to Step 19
1,
Goto
Cooling Fan
Functional Check
Goto
Cooling Fan
Functional Check

Repair the short to ground between the left cooling fan
motor and relay #3. Refer to. Wiring Repairs in Wiring
Systems.
Go to
Cooling Fan
Functional Check

Repair the open circuit between the cooling fan relay #3
and the RH cooling fan motor. Refer to Wiring Repairs in
Wiring Systems.
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
20

19
Go to
Cooling Fan
Functional Check

17
'

Repair the open circuit between the LH cooling fan
electrical connector terminal A and the cooling .fan relay #3
terminal C8. Refer to Wiring Repairs in Wiring Systems.
Go to Step20

15
Go to Step 18
Go to
Cooling Fan
Functional Check

1. Inspect for poor connections at the left cooling fan
motor. Refer to Testing for Intermittent and Poor
Wiring Systems.
Go to Step 21

Repair the open circuit between the cooling fan relay #1
and the left cooling fan motor. Refer to Wiring Repairs in
Wiring Systems.
Go to Step 10
11
No

10
Yes
6~1808
Engine
Test Description
diagnostic table.
9. This step tests the cooling fan relay #2 control

circuit.
5. This step tests the cooling fan relay #3 control

circuit.

Step
Action
Yes
No
Go to Step 2
Go to
Cooling Fan
Functional Check
Value(s)

2. Command thl'l cooling fan relays #1, #2 and #3 ON
Is the right cooling fan .operating at high speed?
Is the left cooling fan 'operating at high speed?
10
11
1. Remove the cooling fan relay #3.

1. Probe the cooling fan relay #3 terminal C10 at the

J 34142-8 connected to 8+.
2. Command the cooling fan relays #2 and #3 ON using
the scan tool.
Connect a fused jumper wire between the cooling fan

relay #3 terminals C8 and 810 at the underhood electrical
center. Refer to Using Fused Jumper Wires in Wiring
Systems.
Does the left cooling fan turn ON?
Probe the cooling fan relay #3 terminal 810 at the

underhood electrical center using the test lamp J 34142-8
connected to 8+.
Go to Step 3
Go to Step 8
Go to
Cooling Fan
Functional Check
Go to Step 4
Go to Step 5
Go to Step 11
Go to step 6
Go to Step 13
Go to Step 16
Go to Step 7
Go to Step 17
Go to Step 15
Go.to Step 9
Go to Step 11
Go to Step 10
Go to Step 13
Go to Step 12
Go to Step 14
'

3. Probe the cooling fan relay #2 terminals C4 and C6
at the underhood electrical center using the test lamp
Does the test lamp illuminate for both terminals?

J 34142-8 connected to 8+.
2. Command the cooling fan relays #2 and #3 ON using
the scan tool.
Jumper the cooling fan relay #2 terminals C4 and 86 at

the underhood electrical center using a fused jumper wire.
Repair the cooling fan relay 8+ circuit for an open. Refer

to Wiring Repairs in Wiring System.
Go to
Cooling Fan
Functional Check
6-1809
Eng_ine

Action
Step
Replace the #2 Cooling fan relay. Refer to Cooling Fan

12
.
Repair the cooling fan relay control circuit for an open.
Refer to Wiring Repairs in Wiring System.
13
No
Value(s)
Yes
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
14
Repair circuit 504 for an open. Refer to Wiring Repairs in

Wiring System.
15
Repair the open ground circuit between cooling fan relay

#3 and the splice. Refer to Wiring Repairs in Wiring
Systems.
16
Replace the #3 cooling fan relay. Refer to Cooling Fan

Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
1. Inspect for poor relay connections at the underhood

electrical. Refer to Testing for Intermittent and Poor
Wiring Systems.
17
..
Is. the action complete?
Go to
Cooling Fan
Functional Check
6-1810
Engine
PCM Controlled Generator Diagnosis

'" - ,,.Generator
I Turn I
On
Input
L-J
Ll:!I
0.35 RED 225
15
C2
.----------, Powertrain
I
PCM
C1 =BLU
C2=RED
Generator
Terminal
L Output
I Module
Control
I.
._ _________ ., (PCM)
~
~
565396
Circuit Description
Diagnostic Aids
The L-terminal circuit from the generator is a discrete

circuit (a discrete circuit has no splices and only
one source and one destination) into the PCM. The
PCM applies ignition voltage to the generator
L terminal circuit. A small amount of current flows from
this circuit through the generator windings to create
a magnetic field which starts the generator process.
When the generator is at operating speed and
producing voltage, a solid state switch for the
L terminal circuit in the generator opens and the PCM
detects that the initial startup current flow has
stopped.
The PCM expects to detect low voltage on the
L terminal circuit prior to the generator rotating at
operating speed and conversely expects the circuit to
be at ignition voltage potential when the generator
is operational. When the PCM detects a fault (circuit
shorted to ground, or circuit shorted to a voltage),
the battery lamp will illuminate.
Important:
A generator fault, such as a shorted output diode,
malfunctioning regulator, an open or shorted rotor, or
an open sense lead may cause a low battery
charge condition. Refer to A Diagnostic Starting Point
- Engine Electrical in Engine Electrical.
Test Description
Diagnostic Table.
2. This step determines if a fault is present.
11 . A poor connection at the generator causes no
output.
Engine
6-1811
PCM Controlled Generator Diagnosis

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
DTCP1637
Generator LTerminal Circuit
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to A
Diagnostic
in Engine
Electrical


3. Monitor the Generator L terminal parameter using a
scan tool.
Does the scan tool display the Generator L terminal as
Inactive?
Measure the voltage at the battery using the DMM.

Is the battery voltage within the specified range?
Probe the Generator battery feed circuit using the

J 34142-B test lamp connected to ground. Refer to
13-15V

generator.
3. Measure the voltage to ground at the generator
harness connector terminal B using the DMM. Refer
Is the voltage the same or more than the specified value?
10V

3. Test the continuity from the generator circuit at the
PCM harness connector to the B terminal of the
generator harness connector using the DMM. Refer
Repair the open/high resistance in the generator circuit.

Go to Step 10
Go to Step 6
Go to Step 8
Go to Step 7
System OK
1. Inspect the terminal contact tension at the PCM

I
harness connector. Refer to Testing for Intermittent

Systems.
System OK
Go to Step 9
Replace the PCM.
System OK
1. Inspect the terminal contact tension at the generator
10
11

Systems.
Replace the generator. Refer to Generator
Rep/acem1:mt (5. 7 L) in Engine Electrical.
System OK
Go to Step 11
System OK
6-1812
Engine
PNP Switch Diagnosis

Auto Trans
Shift Lock
Control
Schematics in
Automatic
Transmission
IL 0 c
[S]
IN
0.35
r - - - - - - - .,Park/
I
~
I Neutral
IP/"
1 Position
II ~
, D,-
2 /' I Switch
.,,R
__ 'N@
I
I
. ---c---
I
I1,,
BLK/WHT 451
0.5 ORN/BLK 434

0.5 ORN/BLK
8234
434
H
C220
8215
- - - - - - ,
0.8 BLK/WHT 451
E C220
Ground Distribution
Schematics In
Wiring Systems
0.8 BLK/WHT 451
_ _ _ _ _ _ _ ..
P1i0
_ _ _ _ _ _ .J
0.5
ORN/ 434
BLK
0.5
ORN/BLK 434
34
C1
'" - PNP - - - - - - - - - ., Powertrain

I
I
I
Switch
Signal
. PCM
c 1=BLU
C2=RED
I Control
I Module (PCM)
I
1.----------~-.8 ~
~
(
604564
_Circuit Description
Diagnostic Aids
The Park/Neutral Position (PNP) switch contacts are

closed fo ground in park and neutral. The PCM applies
a voltage (about 12.0 Volts) to the switch. When the
gear selector is in the park or neutral position, the
PNP switch is closed and the PCM senses low signal
voltage. When the gear selector is in reverse or a
drive range, the PNP switch opens, and the PCM
senses high signal voltage. The PCM will increase the
idle air rate to compensate for the additional load
on the engine when the transmission is in gear.
Important:
Some of the PCMs other uses for the PNP signal are:
Vehicle Speed Sensor (VSS) diagnostics
Exhaust Gas Recirculation (EGR) operation

in Wiring Systems.
A PNP switch that does not close or an open circuit
may cause the engine idle speed to drop when
the vehicle is shifted into gear.
A switch that will not open or the signal circuit shorted
to ground will cause the EGR system to be
inoperative, possibly resulting in excessive
spark knock.
Inspect all related wiring and connectors including the
connections at the PCM. These may cause an
intermittent malfunction. Inspect for damaged,
corroded or pushed out terminals.
Engine
6-1813
PNP Switch Diagnosis

Step
Action
Value(s)
Shift the transmission into Drive.

Does the scan tool indicate Drive?
1. Disconnect the Park/Neutral Position switch

connector. Refer to Park/Neutral Position Switch
Replacement in Automatic Transmission-4L60-E.
2. Jumper the PNP harness connector terminals A
and B using a fused jumper wire. Refer to Using
Does the scan tool indicate Park/Neutral?
Probe terminal B in the PNP switch harness connector

using a fused jumper wire connected to ground. Refer to
Does the scan tool indicate Park/Neutral?
1. Leave the fused jumper wire in place.

4. Probe the PNP circuit at the PCM harness connector
using the test lamp J 34142-8 connected to B+.
Disconnect the Park/Neutral Position switch connector.

Does the scan tool indicate Drive (R-D321)?

Does the scan tool indicate Drive (R-D321 )?

Wiring Systems.
Wiring Systems.
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check.
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 7
Go td Step 10
Go to Step 5
Go to Step 13
Go to Step 6
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 8
Go to Step 12
Go to Step 15
Go to Step 16
Go to Step 15

3, Transmission in Park. Observe the scan tool
parameter.
4. Place the transmission in Neutral. Observe the scan
tool parameter.
Does the scan tool indicate Park/Neutral for both
positions?
Yes
6-1814
Engine

PNP Switch Diagnosis (cont'd)
Step
10
Action
1. Inspect for faulty connections at the PNP switch or
PNP switch out of adjustment. Refer to Testing for
Intermittent and Poor Connections in Wiring Systems
and Park/Neutral Position Switch Adjustment in
Automatic Transmission-4L60-E.
Wiring Systems.
Value(s)
Repair the PNP signal circuit shorted to ground. Refer to

Repair the open PNP ground circuit. Refer to Wiring

Replace the PNP switch. Refer to Park/Neutral Position

Switch Replacement in Automatic Transmission.
15

Replace the PCM.
16
Operate the vehicle within the conditions under which the

original symptom was noted.
Does the system now operate properly?
12
13
14
No
Go to Step 16
Go to Step 14
Repair the open PNP signal circuit. Refer to Wiring

11
Yes
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 16
Go to Step 16
..
System OK
Go to Step 2
Engine
6-1815
Engine Oil Level Sensor/Switch Diagnosis
025BRJ174
-
-; ;:: 2
Engin.e
Oil
[ ] Level
8 Switch
11
701
r- -
I
I
I
I
L -
~~~el
C1
-
PCM
C1=BLU
C2=RED
i . .&.
I Jll6'
Switch
Input
-
,Powertrain
I
Control
I Module
I (PCM)
.I~
0.35 BLK/WHT 451

Ground
Distribution
Cell14
..-- -
$110
3 BLK 451
G110
585389
Circuit Description
The Oil Level switch is a normally.open switch. When
the oil level is within an acceptable range the Oil
Level switch closes .. The switch opens when
the engine oil level drops below a predetermined
amount. The PCM tests the Engine Oil Level switch
circuit with the ignition ON (engine OFF). The
PCM monitors the engine coolant temperature to
ensure proper engine oil drain back. to the oil pan.
When the engine is colder the engine oil drain
back process takes a greater amount of time.
The PCM sends a message (via Class 2) to the IPC
to turn ON the Oil Level indicator when the engine
oil level drops below a predetermined value and the
conditions for running the test are met.
Conditions for Testing for Low Engine Oil

DTC P0117 and P0118 are not set.
T.he ignition is ON with the engine OFF.
The PCM compares the last ignition OFF engine
coolant temperature (stored temperature) to the
Ignition ON engine coolant temperature.
If the PCM determines the Ignition ON engine
coolant temperature is cooler then Ignition
OFF engine coolant temperature by a
predetermined amount, the PCM tests the Engine
Oil Level sensor circuit. The following table
illustrates the required temperatures to .enable the
Engine Oil Level test:
Low Engine Oil Level Coolant Temperature Enable

Conditions
Minimum Stored
Ignition ON
Temperature to
Temperature
Temperature
Run Test
Difference
-40C (-40F)
-15C (5F)
25C (45F)
-28C (-i8F)
-15C (5F)
13C (23F)
-6C to 130C
-16C to 140C
10C (18F)
(3F to 284F)
(21 F to 266F)
Conditions for Illuminating the Low Oil

level Indicator
The PCM detects a low oil level condition for 1
ignition cycle.
Conditions for Clearing the low Engine Oil

level Indicator
Repair the engine low oil level circuit or low oil
level condition as necessary.
Allow the engine to reach operating temperature
90C (194F).
Turn OFF the engine.
The ignition must remain OFF for a minimum of
1 hour.
The PCM tests the engine oil level circuit at
ignition ON to determine the engine oil level
is within range.
The engine coolant temperature should decrease
by 10c (18F). When you turn the ignition ON
the conditions for performing the test should
be met and the Low Engine Oil indicator clears.
6-1816
Engine
Diagnostic Aids
Test Description

diagnosing/replacing the module. Ensure that the
Systems.
e Inspect for poor connections; Refer to Testing for
Systems.
~ Corrosion
.. Mis-routed harness
Rubbed through wire insulation

diagnostic table.
6. This step tests the Oil Level sensor signal circuit
between the PCM and the sensor.
7. This step tests the Oil Level sensor ground circuit
between the PCM and the sensor.
8. This step tests for an open in the Oil Level sensor
signal circuit between the PCM and the Oil Level
sensor.
9. This step tests the Oil Level signal circuit for a
short to ground.
18. This step Clears the Low Oil Level message. The
engine coolant temperature should decrease by
10C (18F).
Engine Oil level Sensor/Switch Diagnosis

Action
Step

1
1. Ensure the vehicle is on a level surface.

2. Inspect the engine oil level.
Value(s)
No
Go toStep 2
Goto A
Powertrain On ..
Board
, Diagnostic (OBD)
. System Check
Go to Step 3
Go to Step 17
..

2. Monitor the Engine Oil Level parameter using a
scan tool.
...
Yes
'
Is the oil level within range?
Does the scan tool display Low Oil Level as YES?
Is the customers concern that the engine oil level was low
and the Low Oil Level indicator never illuminated?
Is the customers concern that oil was just added or that an

oil change was just done and the Low Oil Level indicator
did not clear?
Go to Step 6
Go to Step 4
Go to Step' 6
Go to Step 5
Go to Step 18
Go to
Diagnostic Aids

3. Disconnect the Oil Level sensor electrical connector.

6
Refer to Engine Oil Level Sensor Replacement

(5. 7 L) in Instrument Panel, Gauges and Console.
B+
4. Measure the voltage at the signal circuit at the

Engine Oil Level sensor electrical connector to a
known good ground using the DMM. Refer to
Measure the voltage from the signal circuit to the ground

circuit at the Engine Oil Level sensor electrical connector
using the DMM. Refer to Measuring Voltage in Wiring
Systems.
Go to Step 7
Go to StepB
Go to Step 10
Go to Step 11
B+
Engine
Step
Engine Oil Level Sensor/Switch Diagnosis (cont'd)

Action
Value(s)

3. Test continuity of the Engine Oil Level sensor signal
circuit using the DMM. Refer to. Testing. for Continuity
in Wiring Systems.
Does the DMM .indicate continuity?
Probe the Engine Oil Level sensor signal circuit using the
Test Lamp connected to B+.
1. Test the terminal tension of the Oil Level sensor

as necessary. Refer to Repairing Connector
Terminals in Wiring Systems.
Repair the open ground circuit. Refer to Wiring Repairs in

Wiring Systems.
Repair the open signal circuit. Refer to Wiring Repairs in

Wiring Systems.

14
1. Inspect the PCM for faulty connections. Refer to

Wiring Systems.
2. If faulty connections are found, repair as necessary.
Systems.
15
lmpmtant: Program the replacement PCM. Refer to PCM

Replace the PCM.
16
Replace the Engine Oil Level sensor. Refer to Engine Oil

Level Sensor Replacement (5. 7 L) in Instrument Panel,
Gauges and Console.
17
Add the appropriate amount of oil.

10
11
12
13
18
6-1817

2. Allow the engine to reach the specified temperature.
Important: The ignition must remain OFF for a minimum
of one hour.
3. Turn OFF the ignition for one hour.
Yes
No
Go to Step 9
Go to Step 12
Go .to Step 13
Go to Step 14
Go to Step 18
Go to Step 16
Go to Step 18
-
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 15
Go to Step 18
Go to Step 18
Go to Step 18
90C (194F)
System OK
6-1818
Engine

Circuit Description
The scan tool first energizes the fuel pump and then
the injectors for a precise amount of time allowing
a measured amount of fuel into the manifold.
This causes a drop in system fuel pressure that can
be recorded and used to compare each injector.
Test Description
fire and personal injury. The towel wm absorb

specified range, go to Fuel System Diagnosis.

the fuel pressure does not reach a steady value,
go to Fuel System Diagnosis.
reading from the first pressure reading.

fuel boiling.
Engine
6-1819

Step
Action
Value(s)

Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
(50-95 Degrees F)
Go to.Step 4
Go to Step 5

specified value?
94C (201 F)

specified value?
94C (201 F)

8. Again energize the fuel pump using the scan tool.
2 seconds. Repeat step 8 as necessary in order to achieve
the highest possible fuel pressure.
specified value?
Go to Step 5
'
380-410 kPa
(55-60 psi)
Go to Step 6
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Fuel
System
Diagnosis
380-410 kPa
(55-60 psi)
'
6-1820
Engir1e
Fuel Injector Balance Test with Tech 2 (cont'd}

Action
Value(s)

Turn ON the ignition leaving the engine OFF.
Select Special Functions from the scan tool menu.
Select Fuel Systems.
Select Injector Balance Test.
Select an injector to be tested.
Press Enter. This will prime the fuel pump.
Record the fuel pressure indicated by the fuel
9. Energize the fuel injector by depressing the Pulse

Injector button on the scan tool. This will energize the
injector and decrease the fuel pressure.
pressure gauge after theJuel pressure gauge needle
reading.
11. Press Enter again to bring you back to the Select
Injector screen.
1O kPa (1.5 psi)
Notice: Do not repeat any portion of this test before

running the engine in order.to prevent the engine from
flooding.
is either higher than the average pressure drop or lower
1O kPa (1.5 psi)
Step
Yes
No
1.
2.
3.
4.
5.
6.
7.
8.
Replace the faulty fuel injector(s). Refer to Fuel Injector

Replacement.
(
Go to Step 8
Go to Symptoms
Go to.Step 9
Go to Symptoms
System OK
Engine
6-1821
Fuel Injector Balance Test with Special Tool
1
FUEL INJECTOR
-
- .TESTER +
LOW VEHICLE BATTERY
READY TO TEST
TEST IN PROGRESS

CoilTellt
Balance Test
4amp
2.Samp
0.5-2.5
4amp
amp
O.Samp
B+
PUSH TO START TEST
J 39021
17713
Legend
(1) First Reading
Test Description
pressure connection in order to reduce .the risk of
fuel boiling.
(2) Second Reading

specified range, go to Fuel System Diagnosis.
the fuel pressure does not reach a steady value,
go to Fuel System Diagnosis.
reading from the first pressure reading. Refer to
the illustration above.
6-1822
Engine
Fuel Injector Balance Test with Special Tool

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C
{50-95 Degrees F)
Go to Step 4
Go to Step 5

1

specified value?
94C (201F)

specified value?
94 C (201 F)

8. Again energize the fuel pump using the scan tool.
2 seconds. Repeat step 8 as necessary in order to achieve
the highest possible fuel pressure.
380-410 kPa
(55-60 psi)
specified value?
380-410 kPa
(55-60 psi)
Go to Step 5
Go to Step 6
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Fuel
System
Diagnosis
Engine
6-1823
Fuel Injector. Balance Test with Special Tool (cont'd)

Step
Action
Value(s)
Yes
No
Go to Step 8
Go to Symptoms
Go to Step 9
Go to Symptoms
1. Connect the J 39021 fuel injector tester to a fuel

injector.
injector tester to the Balance Test 0.5-2.5 amp
position.
3. Energize the fuel pump using the scan tool in order to
pressurize the fuel system.

is the 1st pressure reading (refer to (1) in the
illustration).
5. Energize the fuel injector by depressing the Push to
Start Test button on the fuel injector tester.

has stopped moving. This is the 2nd pressure reading
(refer to (2) in the illustration),
10 kPa (1.5 psi)
7. Repeat steps 1 through 6 for each fuel. injector.


Notice: Do not repeat any portion of this test before

running the engine in order to prevent the engine from
flooding.

is either higher than the average pressure drop or lower
Replacement.
1O kPa (1.5 psi)
System OK
6-1824
Engine
J 39200DMM
LOWVEHICLEBATIERY
READY TO TEST
TEST IN PROGRESS
CJCJCJ
mvn..,.
4t
V-DC
V-AC

Coi,ITest
CJD CJ CJ
FUEL INJECTOR
- TESTER +
mA
A
OFF
Balance Test
4amp
4amp
2.Samp
O.Samp
0.5-2.S
amp
PUSHTOSTARTTEST
00
'+
B+
J 39021
(
17707
Test Description
between 10C and 35C (50F and 95F),
refer to Fuel lnj Coil Test - ECT Outside
the test. The voltage displayed by the DMM should
be within the specified range (refer to the
Example). The voltage displayed by the DMM
rhay increase throughout the test as the fuel

injector windings warm. and the resistance of the
fuel injector windings changes. An erratic
voltage reading (large fluctuations in voltage that
do not stabilize) indicates an intermittent
connection within the fuel injector.
Resistance
Ohms
11.4-12.6
Fuel injector
Number
1
2
3
4
5
6
7
Voltage Specification at 10C-35C

(50F-95F)
5.5-6.6V
Voltage Reading
Pass/Fail
6.3
5.9
6.2
6.1
4.8
6.0
5.0
5.3
p
p
p
p
F
p
F
F
Engine Controls.; 5.7l
Engine
6-1825
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to Step 3
Go to Fuel lnj
Coil Test - ECT
Outside
10-35 Degrees C
(50-95 Degrees F)
Go toStep 4
Go to Fuel
Injector Balance
Test with Tech 2
orFuel.lnjector
Balance Test
with Special Tool

-

Is the engine coolant temperature within the specified
limits?
Relief Procedure.
3. Access th.e fuel injector electrical connectors as
required.
ground.
6. Connect the leads from the J 39200 Digital Multi
Meter (DMM) to the fuel injector tester. Refer to the
illustration associated with the test description.
10C-35C
(50F-95F)
5.5-6.6V

injector tester.
10. Observe the voltage reading on the DMM.
Did any fuel injector have an erratic voltage reading (large
fluctuations in voltage that do not stabilize) or a voltage
reading outside of the specified limits?

Replacement.
Go to.Fuel
Injector Balance
Test with Tech 2
or Fuel Injector
Balance Test with
Special Tool
6-1826
Engine
J 39200 DMM
LOW VEHICLE BATTERY
READY TO TEST
TEST IN PROGRESS
CJCJCJCJ
.ct CJCJCJ
FUEL INJECTOR
- TESTER +
mvo..,.
V-DC
mA
A
V-AC
Coil Test
4amp
2.Samp
o.Samp
Balance Test
4amp
PUSH TO START TEST
00
0.5-2.5
amp
B+
J 39021
(
17707
Test Description
injector. If the engine coolant temperature
is between 10C-:-35C {50F-95F), refer to Fuel
lnj Coil Test - ECT Between 10-35 Degrees C
(50-95 Degrees F).
the test. The voltage displayed by the DMM may
increase throughout the test as the fuel injector
windings warm and the resistance of the fuel
injector windings changes. An erratic voltage
reading (large fluctuations in voltage that do not
stabilize) indicates an intermittent connection
within the fuel injector. From the voltages
recorded, identify the highest voltage, excluding
any voltages above 9.5 volts. Subtract each

voltage that is not above 9.5 volts from the highest
voltage. Record each subtracted value (refer to
the Example). The subtracted value for any
fuel injector must not exceed 0.6 volt. A fuel
injector with a subtracted value that is greater than
0.6 volt is faulty. Replace the fuel injector. A fuel
injector with a recorded voltage above 9.5 volts is
also faulty. Replace the fuel injector.
Highest Voltage Reading

7.1 V
Injector
Number
Voltage
9.8
1
6.6
2
6.9
3
4
5.8
7.0
5
7.1
6
7
9.6
6.0
8
Acceptable Subtracted
Value Above/Below
10C-35C (50F-95F)
0.6 V
Subtracted
Value
Pass/Fail
F
p
p
F
p
p
F
1.1
0.5
0.2
1.3
0.1
0.0
Engine
Step
Action

2. Check. the engine coolant temperature.
Is the engine coolant temperature outside the specified
limits?

Relief Procedure.
3. Access the fuel injector electrical connectors as
required.
ground.
6. Connect the leads from the J 39200 Digital Multi
Meter (DMM) to the fuel injector tes.ter. Refer to the
illustration associated with the test description.
injector tester.
10. Observe the. voltage reading on the DMM.
13. Identify the highest voltage reading recorded other
than those above 95 volts.
14. Subtract any other voltage reading recorded from the
highest voltage reading recorded.
15. Repeat step 14 for all the remaining fuel injectors.
Is any value that resulted from subtraction greater than the
specified value?
Replace any fuel injector that had any of the following:

A subtracted value exceeding 0.6 volts.
An initial reading above 9.5 volts.
An erratic reading.
Refer to Fuel Injector Replacement.
Value(s)
Yes
No
Go to Step 2
Goto A
PoweHrain On
Board
Diagnostic (OBD)
System Check
Go to Step 3
Go to Fuel .lnj
Coil Test - ECT.
Between
10-35 Degrees C
(50-95 DegreesF)
Go to Step 4
Go to Fuel
Injector Ba/E:1.nce
Test with Tech 2
or Ft.iel Injector
Balance Test
with Special Tool
10C-35C
(50F-95F)
0.6V
Go to Fuel
Injector Balance
Test with Tech 2
or Fuel Injector
Balance Test with
Special Tool
s~1s2s
Engine
Fuel Tank leak Check

Caution: Place a dry ct,emic:al (Class BJ fire
extinguisher near the area before performing a
Fuel Tank Leak Check. Before removing the
fuel tank for a suspected leak, make sure that the
fuel pipes or the tubes are not leaking onto the
tank. Once removed, make sure that the fuel is not
leaking around the fuel sender 0-ring. Failure to
follow these precautions may result in personal
injury.
Important: This check requires a fuel sender

assembly, a fuel sender seal, a fuel fill pipe, a fuel fill
hose, fuel fill hose clamps and a fuel filler cap to
be installed in the fuel tank.
11. Connect a piece of hose to the EVAP pipe (3) on

the fuel sender assembly.
Notice: Do not submerge the fuel tank assembly in

water in order to check for leaks in the fuel tank.
Submerging the fuel tank in water may damage the
electrical components mounted on the fuel tank.
12. Apply a soap solution to the outside of the
fuel tank.
13. Apply 10 kPa (1112 psi) air pressure to the piece of
hose on the fuel sender EVAP pipe. Air bubbles
appearing from the fuel tank indicate a leak.
14. Replace the fuel tank if it is leaking. Refer to Fuel
Tank Replacement.
Alcohol-in-fuel can be detrimental to fuel system
components and may cause driveability problems such
as hesitation, lack of power, stall, no start, etc. The
problems may be due to fuel system corrosion
and subsequent fuel filter plugging, deterioration of
rubber components, and/or air-fuel mixture leaning.
Commercial fuel uses various types and
concentrations of alcohol. Some types of alcohol are
more detrimental to fuel system components than
others. If you suspect an excessive amount of alcohol
in the fuel as the cause of a driveability condition,
use the Alcohol-in-Fuel Testing Procedure to detect the
presence of alcohol in the fuel.
Alcohol-in-Fuel Testing Procedure
376978

Procedure.
Replacement.
5. Remove the EV AP vent valve. Refer to EVAP
Vent Valve Replacement.
6. Remove the EVAP canister. Refer to EVAP
7. Remove the fuel feed pipe (4), the fuel return
pipe (2), and the fuel sender EVAP pipe to fill
limiter vent valve (3).
8. Plug the fuel feed pipe and the fuel return pipe on
the fuel sender assembly.
9. Plug the fill limiter vent valve nipple (10).
10. Plug the over pressure relief valve hose (9).
Draw the fuel sample from the bottom of the tank in

order to detect any water present in the tank. The
sample should be bright and clear. If the sample
appears cloudy, or contaminated with water (as
indicated by a water layer at the bottom of the sample),
do not use this procedure. Refer to Fuel System
Cleaning.
1. Fill a 100 ml cylinder with fuel to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid
volume to 100 ml. Install a stopper on the cylinder.
3. Shake the cylinder vigorously for
10 to i 5 seconds.
4. Carefully loosen the stopper to release the
pressure.
5. Close the stopper and shake the cylinder
vigorously again for 10 to 15 seconds.
6. Put the graduated cylinder on a level surface for
approximately 5 minutes to allow adequate liquid
separation.
If alcohol is present in the fuel, the volume of the
lower layer, which would now contain both alcohol and
water, will be more than 10 ml. For example, if the
volume of the lower layer increases to 15 ml, this
indicates at least 5 percent alcohol in the fuel. The
actual amount of alcohol may be somewhat more
because this procedure does not extract all of
the alcohol from the fuel.
Engine
6-1829
Engine Speed Output Circuit Diagnosis

r .. '."' ~ -
Electronic
I Engine
I Brake Control
I Module (EBCM)
Speed
Input
>
a., _ _ _ ..
'14.
11
0.35
WHT
121
w!fraction
Control
G
Q.35
C1Q5
WHTI 121
10
C2
- - - Engine
- . - - - "'Powertrain
1Ccmtrol
PCM
speed
C1 =BLU
Output
I Module
_ _ _ _ _ _ _ _ _ ..I (PCM) ~
Ia., _ C2=RED
r I
I
~ -
>
582323
Circuit Description
Diagnostic Aids
The PCM creates the Engine Speed Output signal by

rapidly grounding this circuit via an internal switch
called a driver.
battery voltage).
Important:
diagnosing/replacing the PCM. Ensure.tht the
Test Adapters.in Wiring Systems.
Test Description
diagnostic table.
3. This step is verifying a voltage from the Instrument
Cluster.
5. This step is testing for a short to ground.
6-1830
Engine

Engine Speed Output Circuit Diagnosis
Step
1.
Action
Vali.le(s)
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 7
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 6
Go to A
Diagnostic
Cluster in
Instrument Panel
Gauges and
Console.

-
Important: If the 1/P is completely inoperative, refer to A

With the engine running, does the vehicles tachometer
indicate engine RPM?

4. Measure the Voltage from the engine speed circuit
using the DMM J 39200
B+
1. Remove the Instrument Cluster. Refer to IP Cluster

Replacement in Instrument Panel, Gauges and
Console.
2. Test the continuity of the engine speed circuit using
the DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.
Does the DMM disf:ilay continuity?
Test the continuity of the engine speed circuit. using the

DMM J 39200. Refer to Testing for Continuity in Wiring
Systems.
Repair the engine speed circuit for an open or a short to


Wiring Systems.
Wiring Systems.

Replace the PCM.
diagnosed?
Yes
Go to Step 9
Go to Step 9
Go to Step 7
Go to Step 9
Go to the
applicable
DTC table
System OK
Engine
6-1831
I I
Vehicle Speed Output Circuit Diagnosis
CHEVROLET
Cruise
I vss I Control
r -
'" - , Radio
I vss I
L. -
K-I . . ~
,.
16
EXPORT
L0 c
'" - , Body
'" - , Instrument
vss I Cluster
I vss I Control
I Input I Module
I Input I
I Input I Module
...
C3 .
)/>
I Input I
C~ -C3(BjM)
L. -
88
..J
LJiJ
,,._&
DK GRN/WHT 817
DK GRN/WHT 817
DKGRN/WHT 817
DK GRN/WHT 817
DK GRN/WHT 817
DK GRN/WHT 817
DK GRN/WHTI817
50 C2
r - - I
vss - - - - - - - - , Powertrain
Output
I
I
L------
I Control
I Module /6
C2= RED
I (PCM) ~
--.--.I
CONN ID
c1=BLU
373028
Circuit Description
Various components apply a voltage to the Vehicle
Speed Output circuit. The PCM creates the Vehicle
Speed Output signal by rapidly grounding this
circuit via an internal switch called a driver. The driver
operates at the same rate as the VSS signal input.
The various components recognize the voltage being
pulled to. ground as an indication of vehicle speed.
. being controlled. When the PCM commands a
component ON, the voltage of the control circuit should
be low (ne~r O volts). When the PCM commands
the control circuit to a component OFF, the voltage
potential of the circuit should be high (near battery
voltage).
Diagnostic Aids
Important:

J.35616-A connector test adapter kit. Using this kit
in WiringSystems.
aid in locating an intermittent cond.ition. If you
cannot duplicate. the condition, the information included
in the Freeze Frame and/or Failure Records data
can aid in determining how many miles since
the condition occurred.
Test Description
diagnostic table.
3. This step tests for a voltage to the PCM.
5. This step tests for
a short to ground.
6-1832
Engine
Vehicle Speed Output Circuit Diagnosis

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (OBD)
System Check
Go to
Diagnostic Aids
Go to Step 3
Go to Step 8
Go to Step 4

Important: If the IPC is completely inoperative, refer to A

Instrument Panel, Gauges and. Console.
2. Raise the drive wheels.
4. Disable the ASR/TCS systems (if so equipped).
5. Allow the engine to idle in gear.
Does the vehicles speedometer indicate vehicle speed?

4. Measure the voltage from the Vehicle Speed Output
circuit at the PCM harness connector, using the
DMM. Refer to Measuring Voltage in Wiring Systems.
B+

2. Remove the IPC. Refer to IP Cluster Replacement in
3. Test the continuity of the Vehicle Speed Output circuit
between the PCM harness connector and the 1/P
harness connector, using the DMM. Refer to Testing
for Continuity in Wiring Systems.
Test the continuity of the Vehicle Speed Output circuit

between the PCM harness connector and the 1/P harness
connector, using the DMM connected to battery ground.
1. Inspect for a poor connection at the IPC. Refer to

Wiring Systems.
Wiring Systems.
Repair the Vehicle Speed Output circuit for an open or

short to ground. Refer to Wiring Repairs in Wiring
Systems.

Wiring Systems.
necessary. Refer to.Repairing Connector Terminals in
Wiring Systems.

Replace the PCM.
(
Go to Step 5
Go to Step 7
Go to Step 7
Gd to Step6
Go to A.
Diagnostic
C.luster in
Instrument
Panel, Gauges
and Console
..
System OK
System OK
System OK
Go to Step 9
System OK
Engine
6-1833
Electronic Ignition (El) System Diagnosis

Re.fer to Engine Controls Schematics, Ignition
Coils/Modules, Bank 1 or Ignition Coils/Modules,
Bank 2 for complete circuit details.

9
Circuit Description
A Crankshaft Position (CKP) sensor determines the
engine crankshaft position. The sensor is mounted and
protrudes into the rear of the engine block. The
sensor is near a slotted wheel on the crankshaft. The
rotation of the slotted wheel causes a magnetic
flux change in the sensor. This produces a voltage
signal from the electronic Ignition Control
Module (ICM). The signal creates the reference pulses
needed by the Powertrain Control Module (PCM).
These signals trigger the correct ignition coil to fire, at
the correct time.
controls the ignition system operation. There are eight
Ignition Control (IC} circuits, one per cylinder, that
connect the PCM and the ignition coil/modules. Each
ignition coil/module has a power feed, a chassis
ground circuit, and a reference low circuit. The PCM
causes a spark to occur by grounding the IC
circuit, which signals the ignition module to trigger the
ignition coil and fire the spark plug. The PCM
controls the sequencing and timing.
Diagnostic Aids
Important:
su.rfac'3s before servicing the PCM. Inspect
Inspect for poor connections. Refer to Testing for

Systems.
Corrosion
Mis-routed harness
.. Rubbed through wire insulation
O

cannot duplicate the condition, the information included
in the Freeze Frame and/or Failure Records data
can help determine how many miles since the
condition occurred. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle speed,
temperature etc.) that you observed. This will isolate
when the condition occurred.
Test Description
The .numbers below refer to the step numbers on the
diagnostic table.
3. Monitoring the Misfire Current Counters
determines if a fault is present.
4. A good indication that the fuse is open ls more
than 2 of the Misfire Current Counters are
incrementing on one side of the engine. Inspect
.the ignition feed circuit for a grounded ci.rcuit.
8. If the fuse is open and no condition can be found
with the ignitiOn coil/module circuits, inspect the
injector circuits for being grounded. The INJ1 fuse
and INJ2 fuse feed the ignition coil/module
circuits and injector circuits.
Electronic Ignition (El) System Diagnosis

Ste~
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Powertrain On
Board
Diagnostic (080)
System Check
Go to the
applicable
OTC table
Go to Step 3

Diagnostic (OBD) $ystem Check?
-
Are DTCs P0200, P0300, P0335, P0336, P0351 P0358 set?
6-1834
Engine
Electronic Ignition (El) System Diagnosis (cont'd)

Step
Action
Value(s)
Are the Misfire Current Counters incrementing for 2 or

more cylinders on one bank of the engine?

2. Disconnect the ignition coil/module electrical harness
connector that corresponds to the Misfire Current
Counter(s) that was incrementing.
4. Probe the ignition feed circuit at the ignition
coil/module electrical connector ui,ing the test lamp
J 34142-8 connected to battery ground. Refer to
Using the test lamp J 34142-8 probe the ignition feed

circuit at the ignition coil/module electrical connector to the
ignition coil/module ground circuit.
Using the test lamp J 34142-8 probe the ignition feed

circuit at the ignition coil/module electrical connector to the
ignition coil/module reference low circuit.
1. Inspect for an open ignition coil/module fuse (INJ1

or INJ2).
2. Locate and repair the ignition feed circuit for
grounded circuit if the fuse is open. Refer to Wiring
3. Replace the fuse.
Repair the open in the ignition feed circuit between the

fuse block and the splice. Refer to Wiring Repairs in
Wiring Systems.
1. Disconnect the main ignition coil/module 8-way

connector.
2. Probe the ignition feed circuit at the ignition
coil/inodufe main 8-way connector using the test lamp
J 34142-8 connected to battery ground (fui,e side of
harness). Refer to Probing Electrical Connectors in
Wiring Systems.
Repair the open circuit between the main 8-way harness

connector and the ignition coil/module connector. Refer to
10
11
No
Important: This table assumes that there are no injector

circuit malfunctions or mechanical malfunctions. If you
were not sent here from DTC P0300, refer to OTC P0300
Engine Misfire Detected before proceeding with this table.
If more than one cylinder is misfiring on one side of the
engine, inspect the ignition coil/module ground circuit for
an open.
2. Idle the engine.
3. Using a scan tool, monitor all the Misfire Current
counters on the misfire data list. There are a total of
8 counters, one counter per cylinder.
Are any of the Misfire Current counters incrementing?
Yes
Go to Step 4
Go to
Diagnostic Aids
Go to Step 8
Go to Step 5
Go to Step 6
Go to Step 10
(
Go to Step 7
Go to Step 13
Go to Step 21
Go to Step 17
System OK
Go to Step 9
System OK
Go to Step 11
Go to Step 12
System OK
Engine
6-1835
Electronic Ignition (El) System Diagnosis (cont'd)

Action
Step
Value(s)
12
Repair the open ignition feed circuit between the fuse

block (open fuse) and the main ignition coil/module 8-way
harness connector. Refer to Wiring Repairs in Wiring
Systems.
13

connector.
2. Using the test lamp J 34142-8 probe the ignition feed
circuit to the ignition coil/module ground circuit at the
ignition coil/module main electrical 8-way connector.
Refer to Probing Electrical Connectors in Wiring
Systems.
Yes
No
System OK
Go to Step 14
Go to Step 16
System OK
Go to Step 15
1. Inspect for a poor connection at the main ignition

14
coH/module electrical 8-way connector. Refer to

Wiring Systems.
2. Repair poor connections as necessary. Refer to
15
Repair the open ground circuit between the main 8-way

connector and the ignition coil/module connector. Refer to
16
Repair the open ground circuit between the ground and

the main 8-way connector. fiefer to Wiring Repairs in
Wiring Systems.
17

connector.
2. Using the test lamp J 34142-8 probe the ignition feed
circuit at the ignition coil/module main electrical 8-way
connector to the ignition coil/module reference low
circuit.
18
1. Inspect for a poor connection at the main ignition

coil/module electrical 8-way connector. Refer to
Wiring Systems.
2. If a poor connection is found, repair as necessary.
Refer to Connector Repairs in Wiring Systems.
Did you find and correct .the condition?
Repair the open reference low circuit between the main

8-way connector and the ignition coil/module connector.
19
20
Repair the open reference low circuit between the PCM

and the splice. Refer to Wiring Repairs in Wiring Systems.
System OK
System OK
Go to Step 18
System OK
Go to Step20
Go to Step 19 .
System OK
System OK
21
1. Inspect for poor connections at the ignition

coil/module harness connector. Refer to Testing for
2. Repair poor connections as necessary. Refer to
22
Replace ignition coil/module. Refer to Ignition Coil

System OK
Go to Step 22
System OK
6-183ij
Engine Controls.,. 5.7L
Engine

Procedures
The System Status table shows the DTCs that must

run in order for the System Status to indicate a system
test has been Completed.
System Status For Satisfying the Federal

Inspection/Maintenance (1/M) Regulations
System Status
The scan tool System Info menu includes the System

Status selection.
Several states require that the vehicle pass
on-board (OBD II system) tests for the major
diagnostics prior to having a vehicle 1/M emission
inspection. Some areas may require that the vehicle
pass the OBD II system tests and the 1/M emission
inspection in order to renew license plates.
Using a scan tool; the technician can obs.erve the
System Status (Complete or Not Complete) in order to
verify that the vehicle meets the criteria which
complies with the local area requirements. Using the
System Status display, monitor any of the following
systems or a combination of the systems (depending
on vehicle make and model) for 1/M Readiness:
Cataiyst
Heated Oxygen Sensor (H02S) Heater
Exhaust Gas Recirculation (EGR)
Evaporative Emission (EV AP)
Secondary Air Injection System (AIR)
Important: The System Status display indicates only if

the PCM has completed the required tests (DTCs).
The System Status display does not necessarily mean
that the test has passed. If a failure indication is
present for a OTC associated with one of the above
systems, that test has failed. Diagnosis and repair are
necessary in order to meet the 1/M requirement.
Verify that the vehicle passes all of the diagnostic tests
associated with the displayed System Status prior to
returning the vehicle to the customer.
Following a OTC Info Clear, battery disconnect, or a
control module replacement, all of the System
Status information will be set to Not Complete.
Refer to tile diagnostic support information associated
with each OTC inorder to obtain the Conditions for
Running the OTC. The vehicle operating conditions
that the system must meet in order for a OTC to
run are the Conditions for Running the OTC.
System Status
'
Catalyst
H02S
H02S Heater.
..
DTC(s) Used to Set

System Status
P0420, P0430
P0133, P0153, P1133,
P1134, P1153, and P1154 .
P0135, P0141, P0155,
and P0161
EGR System
P0401
EVAP System
P0440, P0442, P0446,

P 1441 , or the Service
Bay Test
AIR System
P0410
Scan Tool Tests

The scan tool for some systems depending upon the
vehicle make and model include the Service Bay
Tests. Use the Service Bay Tests in order to
test certain systems and resetthe System Status to
this vehicle. Refer to the Service Bay Tests for
important preliminary instructions.
Service Bay Test

Service Bay Tests are included on the scan tool for
some EVAP systems depending upon the vehicle
make and model. They may be used to test certain
EVAP systems and reset the System Status to
this vehicle.
Important: Ensure the vehicle meets the following

requirements before performing the EVAP.Service Bay
Test. Failure to meet the necessary requirements
may cause inaccurate test results or a EVAP Service
Bay Test which will not run completely. This could
lead to mis-diagnosis and unnecessary parts
replacement.
The EVAP Service Bay Test can be performed when
the vehicle meets the following conditions:
., The Powertrain OBD System Check has been
performed
" There are no DTCs set
.. The battery voltage is between 10.5 and 17.5 volts
" The fuel level is between 15 percent and
85 percent.
.. The powerup engine coolant temperature (ECT) is
less than 80C (176F)
Use the scan tool to perform the EV AP Service Bay
Test. The instructions for performing the EVAP Service
Bay Test will be displayed on the scan tool.
Engine
6-1837
Repair Instructions
)
Service of the PCM should normally consist of either
replacement of the PCM or EEPROM programming.
If the diagnostic procedures call for the PCM to
be replaced, the PCM should be checked first to see if
it is the correct part. If it is, remove the faulty PCM
and install the new service PCM.
THE SERVICE PCM EEPROM WILL NOT BE
PROGRAMMED. OTC P0601 and P0602 indicates the
EEPROM is not programmed or has malfunctioned.
Important: The following must be performed anytime
the PCM is replaced:
1. Program the PCM
2. The Idle Learn Procedure
3. The CKP System Variation Learn Procedure
4.. The Engine Oil Life Reset Procedure
5. The Functional Check
The following must be performed anytime the PCM is
disconnected, reprogrammed or loses power:
1. The Idle Learn Procedure
2. The Functional Check

Important: Ensure that the hood is free of
contaminates (moisture) before servicing the PCM.
The moisture flows into the PCM connector body when
the PCM is disconnected and the hood is opened.
Removal Procedure
Important: Remove any debris from the PCM
connector surfaces before servicing the PCM. Inspect
the PCM module connector gaskets when
gaskets are installed correctly. The gaskets prevent
Notice: Do not touch the connector pins or soldered

components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage
to the PCM.
Notice: In order to prevent internal damage to the
PCM, the ignition must be OFF when disconnecting or
reconnecting the PCM connector.
2. Disconnect the PCM connectors.
416074
6-1838
Engine
3. Remove the mounting fasteners from the PCM
bracket.
187250
4. Remove the PCM and mounting bracket assembly

from the engine compartment.
5. Remove the PCM (1) from the mounting
bracket (2).
415726
2
Notice: Do not touch the connector pins or soldered

components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage
.
to the PCM.
Notice: In order to prevent internal damage to the
PCM, the ignition must be OFF when disconnecting or
reconnecting the PCM connector.
1. lnstal.1 the PCM (1) to the mounting bracket (2).
415726
Engine
Engine Controls.,. 5.7l
6-1839

Notices.
2. Install the PCM and mounting bracket assembly
into the vehicle.
Tighten
Tighten the mounting bracket fasteners to
7 Nm(62 lb in).
187250
3. Reconnect the PCM connectors.

Tighten
Tighten the PCM connector end fasteners to
8 Nm (70 lb in).
5. If a new PCM is being installed, program the PCM.
41Ji074
6-1840
Engine
PCM Programming
1. Ensure the following conditions have been met:
The battery is fully charged.
The ignition is ON.
The cable connection at the Data Link
Connector (DLC) is secure.
2. Program the PCM using the latest software
matching the vehicle. Refer to Techline
terminal/equipment users instructions.
2.1. If the PCM fails to program, proceed as
follows:
Ensure that all PCM connections
are OK.
Check the Techline terminal/equipment
for the latest software version.
Attempt to program the PCM. If the PCM
still cannot be programmed properly,
replace the PCM. The replacement PCM
must be programmed.
2.2. Program the replacement PCM.
3. Perform the CKP System Variation Learn
Procedure if a new PCM is installed. Refer to CKP
System Variation Learn Procedure.
4. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
5. Perform the Engine Oil Life Reset procedure if a
new PCM is installed. Refer to Engine Oil Life
Monitor Reset Procedure.
Functional Check
1. Clear the Diagnostic Trouble Codes (DTCs).
2. Perform the On-Board Diagnostic System Check.
3. Start the engine and idle for one minute.
4. Scan for DTCs using the scan tool.
CKP System Variation Learn Procedure

Important: While the learn procedure is in progress,
release the throttle immediately when the engine
starts to decelerate. The engine control is returned to
the operator and the engine will respond to throttle
position after the learn procedure is complete.
2. Apply the vehicle's parking brake.
4. Close the vehicle's hood.
5. Place the vehicle's transmission in Park (A/T) or
Neutral (MIT).
6. Idle the engine until the engine coolant
temperature reaches 65C (150F).
8. Apply the brakes for the duration of the procedure.

Important: If the CKP System Variation Learn
Procedure cannot be completed successfully, refer to
OTC P1336 Crankshaft Position (CKP) System
Variation Not Learned for additional diagnostic
information.
9. Enable the Crankshaft Position System Variation
Learn Procedure with the scan tool.
10. Slowly raise the engine speed to 4000 RPM.
11. Immediately release the throttle when the engine
speed decreases.
12. Turn OFF the ignition for 15 seconds after the
learn procedure is completed successfully.
PCM Idle learn Procedure

Idle Learn Procedure
Anytime the powertrain control module (PCM) or the
battery is disconnected, the PCM loses power, or
the PCM is reprogrammed, the PCM's learned
idle position is lost. The engine idle is unstable when
the learned idle position is lost.
Perform the following procedure in order to return the
learned idle to the correct position:
2. Restore the PCM battery feed.
3. Turn OFF the NC controls.
4. Set the parking brake and block the drive wheels.
6. Ensure that the engine coolant temperature is
7. Shift the transmission into Drive.
8. Allow the engine to idle for 5 minutes.
9. Shift the transmission into Park.
11. Turn OFF the engine for 30 seconds.
Manual Transmission
2. Restore the PCM battery feed.
3. Turn OFF the NC controls.
4. Set the parking brake and block the drive wheels.
5. Place the transmission in Neutral.
7. Ensure that the engine coolant temperature is
9. Turn OFF the engine for 30 seconds.
Engine
6-1841
ECT Sensor Replacement
Removal Procedure
4. Disconnect the electrical connector from the ECT
sensor.
50967
Notice: Use care when handling the coolant sensor.

Damage to the coolant sensor will affect the operation
of the 1uel control system.
50974
Notice: Use care when handling the coolant sensor.
Damage to the coolant sensor will affect the operation
of the fuel control system.
1. Coat the Engine Coolant Temperature (ECT)
sensor threads with sealer P/N 12346004 or
the equivalent.
Notices.
Tighten
Tighten the ECT sensor to 23 N-m (17 lb ft).
50974
6..;1842
Engine
5. Start the engine and inspect for leaks.
6. Perform the idle learn procedure. Refer to PCM
50967
MAF Sensor Replacement

1
Removal Procedure
Important: Take care when handling the MAF sensor.
Do not dent, puncture, or otherwise damage the
Honeycell located at the air inlet end of the MAF
sensor. Do not touch the sensing elements or allow
anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of
a non-silicone based lubricant on the air duct only, to
aid in installation. Do not drop or roughly handle
the MAF sensor.
i. Release Air Cleaner Housing front latches (4).
2. Remove the retainers (1) holding the resonator to
radiator core support (3).
243934
3. Disconnect the MAF sensor (1) electrical

connector.
4. Remove the clamp from the MAF sensor (1) at
the resonator.
5. Remove the clamp from the MAF sensor (1) at
the air intake duct.
6. Remove the MAF sensor (1).
242662
Engine
6-1843
Important: The embossed arrows on the MAF sensor
indicate the proper air flow direction. The arrows
must point toward the engine.
,
,
1. Install the MAF sensor (1) into the air intake duct
arid resonator.
2. Install the clamp at the MAF sensor (1) to the air
intake duct.
3. Install the clamp at the MAF sensor (1) to the
resonator.
242662
4. Install the retainers (1) holding the resonator (2)

to radiator core support (3).
5. Secure the Air Cleaner Housing front latches (4).
243934
6-1844
Engine

MAP Sensor Replacement
Removal Procedure
1. Remove the PCV heat exchange cable

fastener (3).
2. Remove the PCV hose (2) from the throttle body.
3. Remove the PCV hose (5) from the right
bank port.
4. Re.lease the PCV hose assembly from the
mounting brackets (4).
5. Move the PCV hose assembly (1) aside.
492232
55819
Engine
6-1845
7. Twist the MAP sensor forward in order to release

the sensor from the retainer.
8. Pull the sensor upward.
58838
Important: Lightly coat the MAP sensor seal with
clean engine oil before installing the sensor.
1. Install the MAP sensor. Push the MAP sensor
down in order to engage the sensor into the
retainer.
58838
55819
6-1846
Engine
3. Position the PCV hose assembly.(1) for

reassembly.
4. Insert the PCV hose assembly to the mounting
brackets (4).
5. Install the PCV hose (5) to the right bank port.
6. Install the PCV hose (2) to the throttle body.

and Notices.
7. Install the PCV heat exchange cable fastener (3).
Tighten
Tighten the PCV heat exchange cable fastener to
12 N-m (106 lb in).
492232

Replacement Bank 1 Sensor 1
247432
Notice: The heated oxygen sensors each use a

permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor.
Damage or removal of the pigtail or the connector
affects proper operation of the heated oxygen sensor.
Handle the oxygen sensor carefully. Do not drop
the oxygen sensor. Keep the in-line connector and the
louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of any
type, Do not repair the wiring, the connector, or
the terminals. Replace the oxygen sensor if the pigtail
wiring, the terminals, or the connector is damaged.
Proper oxygen sensor operation requires an external
air reference. This external air reference is obtained
by way of the oxygen sensor signal and heater wires.
Any ,attempt to repair the wires, the connectors, or
the terminals results in the obstruction of the air
reference and degrades the oxygen sensor
performance. A dropped oxygen sensor is a bad
oxygen sensor.
Engine
6-1847
Removal Procedure
Important: The heated oxygen sensor may be difficult
to remove when the engine temperature is below
48C (120F). Exces$ive force may damage the
threads in the exhaust manifold or exhaust pipe. It
may be necessary to lower the exhaust system to gain
sufficient access to a H02S and/or it's connector.
1. Coat the threads of the heated oxygen sensor
with anti-seize compound P/N 5613695, or
equivalent if necessary.

Notices.
2. Install the heated oxygen sensor.
Tighten
Tighten the H02S to 41 Nm (30 lb ft).
247432

Damage or removal of the pigtail or the connector.
type. Do not repair the wiring, the connector, or
Any attempt to repair the wires, the connectors, or
oxygen sensor.
222951
6-1848
Engine
Removal Procedure
48C (120F). Excessive force may damage the
222952
Notices.
222952
Tighten
Tighten the H02S to 41 Nm (30 lb ft).
Engine
6-1849

222951


oxygen sensor.
6-1850
Engine
Removal Procedure

may be necessary to lower the exhaust system 10 gain
222953
222954
Notices.
Tighten
Tighten the H02S to 41 -m (30 lb ft).
222954
Engine
6-1851

222953

contaminants. Do not use clea.nihg solvents of any
oxygen sensor.
Removal Procedure
threads in the exhaust manifold or exhaust pipe. It.,
2. Disconriect the H02S electrlcal connector.
222946
6-1852
Engine
222948
the heated. oxygen sensor threads. The compound
compound applied to the thread.s. If a sensor is
removed from an engine .and if for any reason is to be
Notices.
222948
222946
Tighten
Tighten the H02S to 41 N-m (30 lb ft).
Engine
Engine Controls - s~7l
6-1853
TP Sensor Replacement
) Removal Procedure
Notice: The TP sensor is an electrical component. Do

not soak the TP sensor in any liquid cleaner or
solvent as damage may result.
2. Remove the TP sensor attaching screws (5).
3. Remove the TP sensor (6).
4. Remove the TP sensor 0-ring seal (7).
216230
1. Install the TP sensor 0-ring seal (7) on the TP
sensor (6).
2. lnstallthe TP sensor (6) on the throttle body (1)
with the throttle valve in the closed position.
Make sure the TP sensor lever lines up with the
TP sensor drive lever on the throttle shaft.
)

Notices.
3. Install the TP sensor attaching screws (5).
Tighten
Tighten the TP sensor attaching screws to
2 N-m (18 lb in).
4. Connect the TP sensor electrical connector.
5. Perform the TP sensor learn procedure (traction
control equipped vehicles only). Refer to Scan
Tool Diagnostics in Antilock Brake System.
216230
IAT Sensor Replacement

Removal Procedure
1. Disconnect the IAT sensor (2) electrical connector.
2. Carefully back out the IAT sensor (2) from the
intake air duct.
242662
6-1854
Engine
1. Install the IAT sensor (2) into the intake air duct.
2. Connect the IAT sensor (2) electrical connector.
242662
IAC Valve Replacement

1
Removal Procedure
1.
2.
3.
4.
3
216230
Disconnect the IAC valve electrical connector.

Remove the IAC valve attaching screws (4).
Remove the IAC valve (3).
Remove the IAC valve 0-ring seal (2).
Notice:
Do Not push or pull on the IAC valve pintle on
IAC valves that have been in service. The
force required to move the pintle may damage the
threads on the worm drive.
Do Not soak the IAC valve in any liquid cleaner or
solvent, as damage may result.
5. Clean the IAC valve 0-ring sealing surface, the
pintle valve seat, and the air passage.
Clean the IAC valve using GM
cleaner 1052626 or GM X-66A. Use a shop
towel or parts brush to remove heavy deposits .
0
If the air passage has heavy deposits,
.
remove the throttle body for complete cleaning.
O Shiny spots on the pintle or seat are normal;
and do n.ot indicate misalignment or a bent
pintle shaft.
6. Inspect the IAC valve 0-ririg for cuts, cracks, or
distortion. Replace the 0-ring if it is damaged.
Engine
6-1855
Important: If installing a new IAC valve, be sure to

replace it with an identical part. The pintle shape of the
IAC valve and the diameter of the IAC valve are
designed for the specific application.
1. Measure the distance between the tip of the IAC
valve pintle and the mounting surface. If the
distance is more than 28 mm, use finger pressure
to slowly retract the pintle. The force required
to retract the pintle of a new valve will not cause
damage to the valve.
17065
2. Lubricate the IAC valve 0-ring (2) with clean

.engine oil.
3. Install the IAC valve 0-ring (2) on the IAC
valve (3).
4. Install the IAC valve (3).
5. Apply Loctite 262 to the IAC valve attaching
screw threads if necessary.

Notices.
6. Install the IAC valve attaching screws (4).
Tighten
Tighten the IAC valve attaching screws to
3 Nm (27 lb in).
7. Connect the IAC valve electrical connector.
/die Learn Procedure.
3
216230
Accelerator Controls Cable Replacement

Removal Procedure
2. Disconnect the accelerator cable (3) from the
accelerator pedal lever (2).
3. Squeeze the accelerator cable cover tangs (1)
and push the cable through the dash panel.
4. Disconnect the accelerator cable from the intake
manifold bracket.
--12613
5..1856
Engine
5. Remove the accelerator cable from the slot in the
accelerator cable bracket.
6. Disconnect the accelerator cable from the throttle
body lever.
7. Remove the accelerator cable.
173436
1. Install the accelerator cable (3) through the dash
panel. Snap the retainer (1) through the
dash panel.
2. Install the accelerator cable (3) through the slot
in the accelerator pedal !eyer (2). Seat the
retainer (4) in the accele.rator pedal lever (2).
12613
3. Connect the accelerator cable to the throttle

body lever.
4. Slide the accelerator cable into the slot on the

accelerator cable bracket. Snap the locking tab
into position.
5. Connect the accelerator cable to the ihtake
manifold bracket.
6. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
bind between full closed throttle and wide
open throttle.

173436
Engine
6-1857

Removal Procedure
2. Disconnect the accelerator cable from the
accelerator pedal lever.
3. Remove the retainer clip from the accelerator
pedal pivot pin.
4. Remove the accelerator pedal from the accelerator
pedal lever.
1. Install the accelerator pedal to the accelerator
pedal lever.
2. Install the retainer clip to the accelerator pedal

pivot pin.
3. Connect the accelerator cable to the accelerator
pedal lever.
4. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
bind between full closed throttle and wide
open throttle.
Throttle Body Assembly Replacement

Removal Procedure
1. Partially drain the cooling system in order to
remove the hoses at the throttle body. Refer
to Draining and Filling Cooling System (5. 7 L) in
Engine Cooling.
2. Disconnect the IAT sensor and the MAF sensor
electrical connectors.
208553
6-1858
Engine
3. Remove the air fntake duct.
208569
4. Disconnect the TP sensor (2) and IAC valve (1)

5. Disconnect the crankcase ventilation hose from
the throttle body.
243938
6. Disconnect the cruise control cable at the throttle

body lever.
(
296575
Engine
6~1859
7. Disconnect the accelerator control cable at the

throttle body lever.
173436
8. Disconnect the coolant hose from the vapor

vent pipe.
220621
9. Disconnect the coolant hose from the radiator.
220620
6-1860
Engine
222051
10. Remove the throttle body attaching bolts.

11. Remove the trottle body and the gasket. Discard
the gasket.
Notice: In order to prevent damage to the sealing
surfaces, carefully use sharp tools in cleaning the old
gasket from the aluminum surfaces.
Important:
Do Not soak the throttle body in cold immersion
type cleaner. The throttle valve has a factory
applied sealing compound (DAG material is applied
to the outside edge of the valve and the throttle
bore) to prevent air bypass at closed throttle.
Strong solvents or brushing will remove the
material. To clean the throttle body following
disassembly, use a spray type cleaner such as
GM X-66A or GM 1052626. Use a shop towel to
remove heavy deposits.
The TP sensor and the IAC valve are electrical
components and should NOT come in contact with
solvent or cleaner, as damage may result.
12. Clean the gasket sealing surfaces.
1. Install the throttle body with a new gasket.
Notices.
2. Install the throttle body attaching bolts.
Tighten
Tighten the throttle body attaching bolts to
12 N-m (106 lb in).
222051
3. Connect the coolant hose to the radiator.
220620
Engine
6-1861
4. Connect the coolant hose to the vapor vent pipe.
220621
5. Connect the accelerator control cable to the

throttle body lever.
173436
6. Connect the cruise control cable to the throttle

body lever.
296575
6-1862
Engine
Engine Controls - 5. 7l
7. Connect the crankcase ventilation hose to the

throttle body.
8. Connect the TP sensor (2) and the IAC valve (1)
243938
208569
10. Connect the IAT sensor and the MAF sensor

12. With the engine OFF, check to see that the
accelerator pedal is free. Depress the accelerator
pedal to the floor and release.
208553
Engine
Throttle Body Cleaning Procedure

Important: Over extended time and mileage, deposits
may accumulate on the back of the throttle valve
plate. The source of the deposit is EGR gas. Typically
these deposits pose no problem. Occasionally the
deposit may accumulate to a point where perceived
pedal effort is effected. This procedure should not
be performed on vehicles with low mileage, under
80,450 kilometers (50,000 miles).
Notice: Do not insert any tools into the throttle body

bore in order to avoid damage to the throttle
valve plate.
2. Inspect the throttle body bore and the throttle
valve plate for deposits. It is necessary to open
the throttle valve to inspect all surfaces.
Notice: Do not use any solvent that contains Methyl
Ethyl Ketone (MEK). This solvent may damage
fuel system components.
3. Clean the throttle body bore and the throttle valve
plate using a clean shop towel with GM Top
Engine Cleaner, P/N 1052626 or AC-Delco
Carburetor Tune-Up Conditioner, P/N X66-P, or
equivalent product.
Fuel Pressure Relief Procedure

and tile fuel line fittings with a shop towel before
Tools Required
J 34730-1A Fuel Pressure Gauge
2. Disconnect the negative battery cable in order to
avoid possible fuel discharge if an accidental
attempt is made to start the engine.
3. Loosen the fuel filler cap in order to relieve the
fuel tank vapor pressure.
4. Connect the J 34730-1A fuel pressure gauge to
the fuel pressure valve. Wrap a shop towel
around the fitting while connecting the gauge in
order to avoid spillage.
5. Install the bleed hose of the gauge into an
approved container.
6. Open the valve on the gauge to bleed the system
pressure. The fuel connections are now safe for
servicing.
7. Drain any fuel remaining in the gauge into an
approved container.
208569
6-1864
Engine
(Metal Collar)
Removal Procedure
Tools Required
.. J 37088-A Tool Set, Fuel Line Quick-Connect
Separator
1. Relieve the fuel system pressure before servicing
any fuel system connection. Refer to the Fuel
2. Slide the dust cover from the quick-connect fitting.
12773

eye injury.
3. Blow dirt out of the fitting using compressed air.
12776
4. Choose the correct tool from J 37088-A Tool Set

for the size of the fitting. Insert the tool into the
locking tabs.
(
12780
Engine
6-1865
5. Pull the connection apart.

Notice: If it is necessary to remove rust or burrs from
a fuel pipe, use emery cloth in a radial motion with
the fuel pipe end in order to prevent damage to
the 0-ring sealing surface.
6. Using a clean shop towel, wipe off the male
pipe end.
7. Inspect both ends of the fitting for dirt and burrs.
Clean or replace the components as required.
12782
pipe end.
12784
2. Push both sides of the fitting together to cause

the retaining tabs to snap into place.
12786
6-1866
Engine
3. Once installed, pull on both sides of the fitting to
make sure the connection is secure.
12787
4. Reposition the dust cover over the quick-connect

fitting ...
12789

(Plastic Collar)
Removal Procedure
Tools Required
1. Relieve the fuel system pressure before servicing
any fuel system connection. Refer to the Fuel
Pressure Relief Procedure .
compressed air in order to prevent eye injury.
2. Using compressed air, blow any dirt out of
the quick-connect fitting.
... ..
'
~<:/
155410
Engine
6-1867
Important: Plastic quick connect fittings can be

\)
released either by squeezing the plastic retainer

release tabs. (step 3) or by using the appropriate
J 37088~A Fuel Line Quick-Connect Separator Tool
(step 4).
3. Squeeze the plastic retainer. release tabs.
12777
4. Choose the correct tool from J 370$8-ATool Set

for the size of the fitting, Insert the tool into the
locking tabs. The plastic retainer will remain on
the female connector.
12780
5. Pull the connecti.on apart.
12778
6-1868
Engine Cdntrols - 5.7L
Erigine
fuel pipe end.
155425
2. Push both sides of the quick-connect fitting

together in 'order to cause the retaining
tabs/fingers to snap into place.
21855
3. Once installed, pull on both sides of the

quick-connect fitting in order to make sure the
connection is secure.
(
155399
Engine
6-1869
In-Line Fuel Filter Replacement

Removal Procedure
Important:
There is no service interval for fuel filter
replacement Only replace a restricted fuel filter.
Inspect the fuel tarik internally and clean the fuel
tank if you find' a restricted fuel filter.
Tools Required
,
1. Disc;cmnect the negative battery cable.
.
2. Relieve the .fuel system pressure. Refer to the
...
Fuel Pressure.Relief Procedure,

3. Raise the vehicl.e. Refer to Lifting and Jacking the
4. Clean all the fuel filter connections and the
fuel pipes in order to avoid possible contamination
of the fuel system. .
5. Disconnect the quick.:;connect fitting at the fuel
6. Disconnect the threaded fitting (1) from the fuel
'
filter outlet.
8. Slide the fuel filter (2) from the bracket (4).
9. Remove the fuel pipe Oaring.
12603
1. Slide the fuel filter (2) into the bracket (4):
2. Remove the caps .from the fuel pipes.
3. LlJbricate t.he new fuel pipe 0-ring with clean
engine oil.
4. Install the fuel pipe 0-ring.

Notices.
5. Connect the threaded fitting (1) to the fuel filter
outlet.
'
Tighten
Tighten the fuel filter fitting to 30 Nm (22 lb ft).
6. Connect the quick-connect fitting to the fuel filter
inlet (3). Refer to Quick ConnecJFittfng(s) Service
(Plastic Collar).
7. Lower.the vehicle.
10.1. Turn the ignition switch ON for 2 seconds.
10.2. Turn the ignition switch OFF for
10 seconds.
10.3. Turn the ignition switch ON.
12603
6.-1870
Engine
Fuel Tank Draining Procedure
Tools Reqired
381os1

Caution: Never drain or store fuel in an open
container. Always use an approved fuel storage
container in order to reduce the chance of fire
or explosion.
Notice: Do not run the fuel pump unless the fuel
pump is submerged in fuel in order to prevent damage
to the fuel pump.
2. Install the J 42960-2 Fuel Flapper Door Holder
into the fuel fill pipe in order to hold the door open.
3. Insert the J 42960,1 Fuel Drain Hose into the fuel
tank until the hose reaches the bottom of the
fuel tank.
4. Use an air operated pump device in order to drain
as much fuel through the fuel fill pipe as possible.
Fuel Tank Replacement

Removal Procedure
Tools Required
Procedure.
21288
6. Remove the fuel tank fill pipe support bracket bolt.

7. Remove the exhaust system from the catalytic
converter back. Refer to Muffler Replacement in
Engine Exhaust.
8. Remove the exhaust pipe heat shield and the
exhaust muffler heat shield. Refer to Exhaust
Pipe and Muffler Heat Shields Replacement
in Engine Exhaust.
327608
Engine
6-1871
9. Clean all fuel pipe connections and surrounding

areas before disconnecting the fuel pipes in order
to avoid possible contamination of the fuel
system.
11. Disconnect the EV AP purge pipe ( 1) at the rear
356450
12. Disconnect the fuel feed pipe at the fuel filter inlet.
327204
14. Remove the rear pipe clip.
355809
6-1872
Engine
15. Disconnect the fuel sender and the fuel pressure
sensor. ~lectrical connectors at the pass through
connector.
327144
16. With the aid of an assistant, support the fueltank.

Notice: Do not bend the fuel tank straps. Bending the
fuel tank straps may damage the straps.
17. Remove the fuel tank strap attaching bolts from
the underbody brackets.
18. Lower the fuel tank straps.
19. Remove the fuel tank.

20. Place the fuel tank in a suitable work area.
(
327609
Engine
6-1873
21 .. Disconnect the hose from the EVAP canister vent

solenoid.
22. Remove the EVAP canister vent solenoid from the
fuel tank bracket.
376991
23. Disconnect the .fill limiter vent valve pipe from the
EVAP canister..
,
. .
remove the EV AP canister.
25. Disconnect the fuel feed pipe (4), the fuel return
pipe (2), and the EVAP pipe (3) fromthe fuel ..
sender:
26. Disconnect the EV AP pipe frqrn the fill limiter vent

valve pipe (10).
27. Remove the fuel and EVAP pipes from the

fuel tank.
connectors (1 ).
29. Remove the fuel sender electrical harness (8)
from the fuel tank.
376978
6;.1874
Engine
30. Remove the fuel sender assembly from the 1uel

tank. Refer to Fuel Sender Assembly
Replacement.
376982
31. Remove the fuel fill hose to fuel tank clamp (1).
32. Remove the fuel fill pipe and hose from the
fuel tank.
376980

Notices.
1. Install the fuel fill pipe and hose to the fuel tank.
Tighten
Tighten the fuel fill hose clamp (1) to
2.5 N-m (22 lb in).
376980
Engine
6-1875
2. Install the fuel sender assembly to the fuel tank.

Refer to Fuel Sender Assembly Replacement.
Tank Leak Check.
376982
4 .. Install the fuel sender electrical. harness (8) to the

fuel tank.
5. Connect the fuel sender electrical connectors (1).
6. Install the fuel feed pipe (4) and the fuel return
pipe (2) to the fuel sender and the fuel tank clips.
7. Conn~ct. the EVAPJ)ipe (3) to the fuel sender.

8. Connect the EVAP pipe to the fill limiter vent valve
pipe (10).
376978

install the EVAP canister.
10. Connect the fill limiter vent valve pipe to the
EV AP canister.
376984
6;.1876
Engine
11. Install the EVAP canister vent solenoid to the fuel

tank bracket.
12. Connect the hose to the EVAP canister vent
solenoid.
376991
13. With the aid of an assistant, position and support

the fuel tank.
14. Position the fuel tank straps up.
15. Install the fuel tank strap attaching bolts.

Tighten
Tighten the fuel tank strap attaching bolts to
33 N,m (24 lb ft).
327611
16. Connect the fuel sender and the fuel pressure

sensor electrical connectors at the pass through
connector.
327144
Engine
6-1877

18. Connect the fuel feed pipe at the fuel filter inlet.
327204

20. Connect the fuel return pipe (2) at the rear
356450
21. Install the fuel and EVAP pipes into the pipe clip.
22. Align the fuel and EVAP pipes into a flat position.
23. Install the pipe clip bolt.
Tighten
Tighten the pipe clip bolt to 5.5 Nm (49 lb in).
355809
6-1878
Engine
24. Install the fuel tank fill pipe support bracket bolt.
Tighten
Tighten the fuel tank fill pipe support bracket bolt
to 10 N-m (89 lb in).
25. Install the exhaust system heat shields and
attaching screws. Refer to Exhaust Pipe and
Muffler Heat Shields Replacement in Engine
Exhaust.
26. Install the exhaust system. Refer to Ml.iffier

Replacement in Engine Exhaust.
,
327608
27.
28.
29.
30.
31.
32.
Install the fuel filler pipe shield.

Lower the vehicle.
Inspect for leaks.
32.1. Turn the ignition switch ON. tor 2 seco.nd~.
10 seconds.
32.3. Turn the ignition .switch ON.
33. Perform the idle learn procedure. Refer to PCM .
21288
Fuel Tank Pressure Sensor Replacement

Removal Procedure
Tools Required
J 34730-tA Fuel Pressure. Gauge.
Caution: Refer to the Battery Disconnect Caut;r;,n

2. Relieve the fuel system pressure. Referto the
Procedure.
Replacement.
370970
Engine
6-1879
5. Disconnect the fuel pressure sensor electrical

connector.
1. Install the fuel pressure sensor (1).
2. Connect the fuel pressure sensor electrical
connector.
Replacement.
10 seconds.
8. Perform the idle learn procedure: Refer to PCM
370970
Fuel Level Sensor Replacement

Removal Procedure
)
Tools Required
Procedure.
Replacement.
7. Remove the fuel level sensor electrical connector
retaining clip (9).
8. Disconnect the fuel level sensor electrical
connector (8) from under the fuel sender cover.
fuel level sensor (5}.
370970
6-1880
Engine

1. Install the fuel level sensor (5).

2. Install the fuel level sensor retaining clip (6).
3. Connect the fuel level sensor electrical
connector (8).
4. Connect the fuel level sensor electrical connector
. .
retaining clip (9).
5. Connect the fuel pump electrical connector (7).

6. Install the fuel sender assembly. Refer to
Fuel Sender Assembly Replacement.
7. Perform the fuel tank leak check; Refer to. Fuel

Tank Leak Check.

Replacement.
370970
9.
10.
11.
12.

Inspect for leaks.
12.1. Turn the ignition S\l\'itch. ON for 2 seconds.
12.2. Turn the ignition switch OFF fo.r
10 seconds.
12.4. Check.for fuel leaks.
13. Perform the idle learn procedu~e. Refer to PCM
Fuel Strainer Replacement
Removal Procedure
Tools Required
~ J 39765 Fuel Sender Lock Nut Wrench
370970

in Cations and Notices.
1. Disconnect the negative battery cable ..
2. Relieve the f.uel system pressure: Refer to the
3. Drain .the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fue/Tank
Replacement.
5. Remove the fuel sender assembly. Referfo Fuel
6. Note the.position of.the fuel strainer (4) on the
fuel pump.
7. Support the fuel sencler asseml;>ly with one hand.
and grasp the strainer (4) with the othe,chand.
8. Pull the .strainer off the pump. Discard the strainer
after inspection.
.
9. Inspect the strainer. Replace a contamiriated
Engine
6-1881
1. Install a new fuel strainer (4) in the same position
as noted during disassembly. Push the strainer on
is fully seated.
Tank Leak Check.
Replacement.
10 seconds.
370970
Fuel Tank Pump Module Replacement,

Removal Procedure
Tools Required
J 39765 Fuel .Sender Lock Nut Wrench
Procedure.
Replacement.
6. Note the position of the fuel strainer (4) on the
fuel pump.
.
.
.
.
7. Support the fuel sender assembly with. one hand
a.nd grasp the strainer (4) with the other hand.
8. Pull the strainer off the pump. Discard the strainer
after inspection.
9. Inspect the strainer. Replace a contaminated
10. Remove the fuel pressure regulator retaining
clip (2).
11. Remove the fuel pressure regulator (3) from the
housing on the fuel return pipe.
370970
6-,1882
Engine.
13. Remove the fuel level sensor electrical. connector
retaining clip (9).
14. Disconnect the fuel lev,el sensor electrical
connector (8) from un.der the fuel sender cover.
fuel level sensor'(5):

Installation Proc:edure
1.
2.
3.
4.
Install the fuel pressure sensor (1 },

Install the fuel level sensor (5).
Install the fuel level sensor retaining .clip (6).
Connect the fuel level sensor electrical
connector (8).
5. Connect the fuel level sensor electrical. connector

ietaining clip (9).
6. Connect the fuel pump electrical corihector (7).
7. If needed, clean the fuel pressure regulator
filter screen with gasoline.
8. Lubricate the fuel pressure regulator large and

small 0-rings vvith Clean engine oil.
9. Install the fuel pressure regulator (3)into the
housing 9n the fuel return pipe.
10. Install the fuel pressure regulator retaining dip (2).
370970
Important: Always install a new fuel strainer when

replacing the fuel tank fuel pump module.
11. Install a new fue.1 strainer (4) in the same position
as noted during disassembly. Push the .strainer on
is fully seated.
13. Perform the fuel tank leakcheck. Refer to Fuel
Tank Leak Check.
Replacement.
17. Connect the negative battery cable:
18.1. Tumthe ignition switch ON for 2 seconds.
10 seconds.
18.3.
Turn the ignition
switch ON.
, '
.
18.4 .. Check for fuel leaks.
'
Engine
6-1883
Fuel Sender Assembly Replacement

Removal Procedure
Tools Required

Procedure.
Replacement.
5. Disconnect the fuel feed pipe (4), the fuel return
pipe (2), and the EVAP pipe (3) from the fuel
sender.
connectors (1) from the fuel sender.
7. Remove the fuel sender assembly retaining ring
using the J 39765 Fuel Sender Lock Nut Wrench.
376978
376981
6;;1884
Engine
Notice: Do Not handle the f~el sender assembly by

the fuel pipes. The amount of leverage generated by
handling the fuel pipes could damage the joints:
8. Remove the fuel sender assembly.
Caution: Drain the fuel from the fuel sender

assembly into an.approved container in order to
reduce the risk of fire and personal. injury.
Never store the fuel in an open container~
376982
9. Remove the fuel sender seal.

10. Discard the fuel sender seal.
11 . Clean the seal sealing surfaces:
376983
Caution: In order to redu<:;e the risk of fire and
leak, always replace the fuel sender gasket when
reinstalling the fuel sender assembly.
Notice: With extreme care align the fuel sender seal
in the fuel tank groove. Properly align the tab on
the fuel sender in the notch on the fuel tank.
Misalignment of the fuel sender seal or the fuel sender
could damage the fuel tank sender tabs. Replace
the fuel tank if the fuel tank fuel sender tabs are
damaged.
1. Install the new fuel sender seal on the fuel tank.
376983
Engine
6-1885
Important: The fuel pump strainer must be in a

horizontal position when the fuel sender is installed in
the tank. When installing the fuel sender assembly,
assure that the fuel pump strainer does not block full
travel of the float arm.
2. Install the fuel sender. assembly into the. fuel tank.
376982
3. Install the fuel sender assembly retaining ring

using the J 39765 Fuel Sender Lock Nut Wrench.
iank Leak Check.
376981
5. Connect the fuel sender electrical.connectors (1)

to the fuel sender.
6. Connect the fuel feed pipe (4), the fuel return
pipe (2), and the EVAP pipe (3) to the fuel sender.
7. Install the fuel tank. Refer to .Fuel Tank
Replacement.
10 seconds.
376978
6-1886
Engine
Fuel Pulse Dampener Replacement
Removal Procedure
Tools Required
J 34730-1A Fuel Press.ure Gauge
3. Clean any dirt from the fuel pulse dampener
retaining ring.
4. Remove the fuel pulse dampener retaining ring.
5. Discard the fuel pulse dampener retaining ring.
6. Remove the fuel pulse dampener from the fuel rail.
7. Remove the fuel pulse dampener 0-ring.
8. Discard the fuel pulse dampener 0-ring.
217098
'-..'\
\.~ ....
1. Install the new 0-ring on the fuel pulse dampener.

2. Lubricate the fuel pulse dampener 0-ring with
clean engine oil.
3. Push the fuel pulse dampener into the fuel rail.
4. Install the new fuel pulse dampener retaining ring.
10 seconds.

217098
Fuel Hose/Pipes Replacement (Chassis)

Removal Procedure
Tools Required
J 37088-A Tool Set, Fuel Line Quick-Connect
Separator
Procedure.
4. Clean all the fuel pipe connections and the

surrounding areas before disconnecting the pipes
in order to avoid possible contamination of the
fuel system.
172963
Engine
Engine Controls - 5. 7L 6~1887
5. Disconnect the engine .compartment fuel feed

pipe (2) frorri the chassis fuel feed pipe (3).
Refer to Quick Connect Fitting(s) Service (Metal
Collar).
6. Raise the vehicle, Refer to Lifting and J,acking the
7. Remove the rear fuel pipe shield attaching

nuts (3) and bolt (6).
8. Remove the rear fuel pipe shield (4).
9. Remove the front fuel pipe shield attaching
nuts (1 ).
10. Remove the front fuel pipe shield (2).
7c1
173551
11. Disconnect the fuel .feed pipe (1) from the outlet
side of the fuel filter (2). Discard the 0-ring.
12603
6-1888
Engine
13. Remove the fuel pipe attaching hardware and the
fuel pipes. Note the position of the fuel pipes for
installation.
356450
Important:
When replacing the fuel pipes, always replace
them with original equipment or parts that meet the
GM specifications for those parts. The replacement
pipes must have the same type of fittings as the
original pipes in order to ensure the integrity of the
connection.
steel tubing. Only tubing meeting the 124-M
required.
1. Position the fuel pipe to the frame rail.
173403

Notices.
clip stud.

clip stud.
173409
Engine
6.. 1889

clip stud.
Tighten
Ti,ghten the 3 studs to 5 Nm (44 lb in).
173412
5. Align the fuel pipe to the number 5 and

number 6 position.
6. Install the front pipe clip b.olts.
Tighten
4.5 Nm (40 lb in).
355819
7. Align the fuel pipe to the number4 position clamp.

Tighten
355800
6-1890
Engine
9. Connect the fuel return pipe (2) at the rear quick
connect fitting. Refer to Quick Connect Fitting(s)
356450
10. Connect the fuel feed pipe (1) to the fuel filter (2).
Tighten
Tighten the fuel feed pipe fitting to
30 Nm (22 lb ft).
(
'
12603
11. Install the fuel pipes into the rear pipe clip.
12. Align the fuel pipes in a flat position.
Tighten
Tighten the rear pipe clip bolt to 5.5 Nm (49 lb in).
355809
Engine
6;.1891
14. Position the front fuel pipe shield (2) to the 3 fuel
15. Install the pipe shield nuts (1 ).
Tighten
Tighten the pipe shield nuts to 5 Nm (44 lb in).
16. Position the rear fuel pipe shield (4) to the fuel

Tighten
5.Nm (44 lb in).
7?

5 N-m (44 lb in).
173551

10 seconds.

172963

(Engine Compartment)
Removal Procedure
Tools Requir~d
Separator


3. Clean all the engine compartment connecting fuel
pipe connections and the surrounding areas
before disconnecting in order to avoid possible
172963
6-1892
Engine
pipe (2) at the fuel rail (1 ). Refer to Quick
Connect Fitting(s) Service (Metal Collar).
pipe (2) at the chassis fuel feed pipe (4). Refer
to Quick Connect Fitting(s) Service (Metal Collar).
6. Cap the fuel pipes in order to prevent possible fuel

system contamination.
1 . Remove the caps from the fuel pipes.
pipe (2) to the fuel rail (1 ). Refer to Quick Connect
Fitting(s) Service (Metal Collar).

6.2. T.urn the ignition switch OFF for
10 seconds.
172953

Fuel Hose/Pipes Assembly

Replacement (Rear)
Removal Procedure
Tools Required
" J 34730-1A Fuel Pressure Gauge
" J 42960-1 Fuel Tank Drain Hose
" J 42960-2 Fuel Flapper Door Holder

1 . Disconnect the negative battery cable.

Procedure.
Raise
the vehicle. Refer to Lifting and Jacking the
4.
7
376978
5. Clean all the fuel pipe and hose connections and

the surrounding areas before disconnecting in
order to avoid possible contamination of the fuel
system.
Replacement.
7. Remove the fuel feed pipe (4) and the fuel return
pipe (2) from the fuel sender pipes.
8. Remove the fuel feed and return pipes from the
fuel tank.
Engine
Engine Controls -.5.7l
6-1893
2. Connect the fuel feed pipe (4) and the fuel return
pipe (2) to the fuel sender pipes.
3. Install the fuel feed and return pipes into the fuel
tank clips.
Replacement.
10 seconds.
10. Perform the idle learn procedure. Referto PCM
376978
Fuel Filler Hose Replacement

Removal Procedure

3. Clean all the fuel pipe and hose connections and
the surrounding areas before disconnecting in
order to avoid possible contamination of the fuel
system.
173450
6-1894
Engine

21288
6. Remove the fuel fill hose clamps (1, 2).

7. Remove the fuel fill hose from the fuel tank and
the fuel fill pipe.
8. Cap the fuel tank opening.
376980
1. Uncap the fuel tank opening.
2. Install the fuel fill hose to the fuel tank and the
fuel fill pipe.

Notices.
3. Install the fuel fill hose clamps (1, 2).
Tighten
Tighten the fuel fill hose clamps to
2.5 N-m (22 lb in).
(
376980
Engine
6-1895
4. Install the fuel fillpipe shield.

Tighten
Tighten the fuel fill pipe shield bolt to
2.5 Nm (22 lb in).
21288

7. Perform the idleJearn procedure. Refer. to PCM
173450
Fuel System Cleaning

Tools Required
J34730~1A Fuel Pressure Gaug'e
J 39765 Fuel Send~r Lo.ck Nut Wrench

J42960-1 Fuel Tank Drain Hose
J 42960-2 Fuel Fl~ppe.r Door .1:iolder
Important:
Only use oil free compressed air to blow out the
fuel pipes.
Inspect the fuel tank internally and clean the fuel
tank if you find a plugged fuel filter.

6-1896
Engine
Procedure.
Replacement.
5. Remove the fuel sender assembly. Refer to. Fuel

6. Inspect the fuel pump strainer. Replace a

contaminated strainer and inspect ,the fuel pump.
7. Inspect the fuel pump inlet for dirt and debris.
Replace the fuel pump if you find dirt or debris
in the fuel pump inlet.
Important: When flushing the fuel tank, handle the

fuel and water mixture as a hazardous material.
Handle the fuel and water mixture in accordance with
all applicable local, state, and federal laws and
regulations.
8. Flush the fuel tank with hot water.
9. Pour the water out of the fuel sender assembly
opening. Rock the tank to be sure that removal
of the water from the tank is complete. . . ..
10. Install the fuel sender assembly: Refer to Fuel

Replacement.
'
12.
13.
14.
15.

Inspect for leaks.
15:1. Turn the ignition switch ON for 2 seconds.
10 seconds.

Replacement
Removal Procedure
Tools Required
1. Clean the area around the fuel pressure
connection with GM X-30A or equivalent.
Caution: Refer to the Battery Disconnec(Caution
2. Disconnect the negative battery .cable.
4. Remove the fuel pressure connection valve using

a standard valve core removal and installation tool.
(
217118
Engine
1. Install the fuel pressure connection valve
assembly using a standard valve core removal and
installation tool.
4. Inspect for le.aks.
10 seconds.
5. Install the. fuel pressure con_nection valve cap.
217118
Fuel Rail Assembly Replacement

Removal Procedure
Tools Required
Separator
An eight digit identification number is stamped on the
fuel rail assembly. Refer to this model identification
number if servicing or part replacement is required.
217103


3. Before removal, clean the fuel rail assembly with
a spray type engine cleaner, GM X-30A or
equivalent, if necessary. Follow the package
instructions. Do. not soak fuel rails in liquid
cleaning solvent.
172963
6".'.1898
Engine
Notice:
Remove the fuel rail assembly carefully in order to
prevent damage to the injector electrical connector
terminals and the injector spray tips. Support
the fuel rail after the fuel rail is removed in order
to avoid damaging the fuel rail cbrnponents'. ..
Cap the fittings and plug the holes when ser.iicing
the fuel system in order to prevent dirt and other
contaminants from entering open pipes and
passages.
4. Disconnect the fuel feed hose (2) from the fuel
rail (1 ). Refer to Quick Connect Fitting(s) Service
(Metal Collar).
5. Disconnect the accelerator cable from the throttle
body and the accelerator cable bracket (without
traction control).
6. Move the accelerator cable aside.
(
173436
7. Disconnect the electrical connectors from the fuel

injectors. Identify the connectors to their
corresponding injectors to ensure correct
sequential injector firing order after reassembly.
8. Disconnect the electrical harness from the fuel rail
brackets.
9. Remove the fuel rail attaching bolts.
10. Remove the fuel rail assembly.
11. Remove the injector lower 0-ririg seal from the
spray tip end of each injector.
12. Discard the 0-ring seals.
222050
Engine
6-1899
1. Lubricate the new lower injector 0-ring seals with
clean engine oil.
2. Install the new 0-ring seals on the spray tip end
of each injector.
3. Install the fuel rail assembly to the intake manifold.
4. Apply a 5 mm (0,020 in) band of GM
P/N 12345382 threadlock or equivalent to the
threads of the fuel rail bolts.

Notices.
5. Install the fuel rail attaching bolts.
Tighten
Tighten the fuel rail attaching bolts to
10 N-m (89 lb in).
6. Connect the injector electrical connectors.
Install each connector on the proper injector in
order to ensure correct sequential injector
firing order.
Rotate the injectors as required in order to
avoid stretching the wire harness.
7. Connect the electrical harness to the fuel rail
brackets.
8. Connect the accelerator cable to the throttle body
and the accelerator cable bracket (without traction
control).
222050
173436
6-1909
Engine
9. Connect the fuel feed hose (2) to the fuel raiUu.(;!I

pipe (1 ). Refer to Quick Connect Fitting(s) Service
(Metal Collar).
1o. Tighten the fuel filler cap.
12 .. Inspect for leaks.
12.1. Turn the ignition switch ON for 2 .seconds.
10 seconds.
13. Perform the Idle Learn Procedure. Referto PCM
172963
Fuel Pressure Regulator Replacement

Removal Procedure
Tools Required
370970

Procedure.
Replacement.
6. Remove the fuel pressure regulator retaining
clip (2).
7. Remove the fuel pressure regulator (3) from the
Engine
6-1901
1. Lubricate the new fuel pressure regulator large
and small 0-rings with clean engine oiL
2. Install the new fuel pressure regulator large and
small 0-rings on the fuel pressure regulator.
3. Install the new fuel pressure regulator filter
screen.
4. Install the fuel pressure regulator (3) into the
5. Install the new fuel pressure regulator retaining
clip (2) .
6; .Install the fuel sender assembly. Refer to Fuel
7.
8.
9.
10.
11.
12.
13.

Perform the fuel tank leak check. Refer to Fuel
Tank Leak Check
Install the fuel tank. Refer to Fuel Tank
Replacement.
Inspect for leaks.
12.1. Turn the ignition switch ON for 2. seconds.
10 seconds.
Perform the idle learn procedure. Refer to PCM
Idle Learn procedure.
370970
Fuel Injector Replacement

Removal Procedure
Notice: Use care in removing the fuel injectors in
order to prevent damage to the fuel injector electrical
connector pins or the fuel injector nozzles. Do not
immerse the fuel injector in any type of cleaner. The
fuel injector is an electrical component and may
be damaged by this cleaning method.
Important: The engine oil may be contaminated with
fuel if the fuel injectors are leaking.
Tools Required

3. Remove the fuel rail assembly. Refer to Fuel Rail
4. Spread the injector retainer clip to release the
injector from the fuel rail.
5. Remove the fuel injector.
6. Discard the injector retainer clip.
7. Remove the injector 0-ring seals from both ends
of the injector. Discard the 0-ring seals.
217114
6-1902
Engine

1
Important: When ordering new fuel injectors, be sure

to order the correct injector for the application being
serviced.
The fuel injector assembly is stamped with a part
number identification (2), a manufacturing date (3), a
week code (1 ), and a production plant number (4).
69058
1. Lubricate the new injector 0-ring seals with clean

engine oil.
2. Install the new injector O-ring seals on the
injector.
3. Install a new retainer clip on the injector.
4. Push the fuel injector into the fuel rail injector
socket with the electrical connector facing
outward. The retainer clip locks on to a flange on
the fuel rail injector socket.
5. Install the fuel rail assembly. Refer to Fuel Rail
217114

8. Inspect fOf leaks.
8.2. "Turn the ignition switch OFF for
10 seconds.
Engine Controls -,5.7L 6-1903
Engine
Replacement
)
Removal Procedure
1. Disconnect the EV AP purge solenoid to throttle
body pipe.
419414
2. Disconnect the engine compartment EVAP pipe

(5) at the EV AP purge solenoid (6).
)
6
172963
3. Disconnect the EVAP purge solenoid electrical

connector.
4. Remove the EV AP purge solenoid from the
bracket.
218763
6-:1904
Engine
1. Install the EVAP purge solenoid valve to the
bracket.
2. Connect the electrical connector to the EVAP
purge solenoid valve.
218763

at the EVAP purge solenoid (6).
(
6
172963
4. Connect the EVAP purge solenoid to throttle

body pipe.
419414
Engine
6-1905
EVAP Vent Valve Replacement

) Removal Procedure
Tools Required


Procedure.
Replacement.
5. Disconnect the EV AP canister vent valve electrical
connector (2).
6. Slide the vent hose clamp (1) back.
7. Disconnect the vent hose from the EVAP
vent valve.
8. Remove the. EVAP canister vent valve from the
EVAP canister vent valve bracket.
385622
376991
6-1906
Engine

1. Install the EVAP canister vent valve to the EVAP

canister vent valve bracket.
2. Connect the vent hose to the EVAP canister

vent valve.
3. Slide the vent hose clamp (1) back into position.
4. Connect the EVAP canister vent valve electrical
connector (2).
Replacement.
6; Refill the fuel tank.
10 seconds.
376991
385622
EVAP System Hoses/Pipes Replacement

Engine Compartment EVAP Pipe Removal
Procedure
Tools Required
Separator
1. Clean all the EV AP pipe connections and the
surrounding areas before disconnecting in order to
avoid possible contamination of the EVAP system.
2. Disconnect the engine compartment EVAP pipe (5)
at the EVAP canister purge valve (6). Refer to
Quick Connect Fitting(s) Service (Plastic Collar).
3. Disconnect the engine compartment EVAP pipe (5)
at the chassis EVAP pipe (3). Refer to Quick
Connect Fitting(s) Service (Plastic Collar).
4. Cap the EVAP pipes in order to prevent possible
EVAP system contamination.
172963
Engine
6-1907
Engine Compartment EVAP Pipe Installation

Procedure
1. Remove the caps from the EVAP pipes.
2, Connect the engine compartment EVAP pipe (5)
to the EVAP canister purge valve (6). Refer to
Quick Connect Fitting(s) Service (Plastic Collar).
172963
Chassis EVAP Pipe Removal Procedure

Tools Required
J 37088-A Tool. Set, Fuel Line Quick-Connect

Separator
1. CJe.an all t.he EV AP pipe connections. and. the

pipes in order to avoid possible contamination of
the EVAP system.
2. Disconnect the engine compartment EVAP

pipe (5) from the chassis EVAP pipe (4); Refer to
QLJick Connect Fitting(s) Service (Plastic.
Collar).
172963
4. Remove the
nuts (3) and
5. Remove the
6. Remove the
nuts (1 ).
7. Remove the
rear fuel pipe shield attaching

bolt (6).
rear fuel pipe shield (4).
front fuel pipe shield attaching
front fuel pipe shield (2).
7e:'
173551
6-1908
Engine
9. Remove the EVAP pipe attaching hardware and
the EVAP pipe. Note the position of the pipe for
installation.
356450
Chassis EVAP Pipe Installation Procedure

Important:
When replacing the EVAP pipes, always replace
them with 'original equipment or parts that meet
the GM specifications for those parts. The
replacement pipes must have the same type of
fittings as the original pipes in order to ensure the
integrity of the connection.
steel tubing. Only tubing meeting the .124-M
required.
1. Position the EVAP pipe to the frame rail.
173403

Notices.
clip stud.
clip stud.
173409
Engine
6-1909

clip stud.
Tighten
Tighten the 3 studs to 5 N-m (44 lb in).
173412
5. Align the EVAP pipe to the number 5 and

number 6 position.
6. Install the front pipe clip bolts.

Tighten
4.5 Nm (40 lb in).
355819
7. Align the EVAP pipe to the number 4

position clamp.
Tighten
355800
6-1910
Engine

356450
10. Install the EV AP pipe into the rear pipe clip 1

11. Align the fuel and EVAP pipes in a flat position.
Tighten
Tighten the rear pipe clip bolt to 5.5 N-m (49 lb in).
355809
13. Position the front fuel pipe shield (2)to the 3 fuel
14. Install the pipe shield nuts (1 ).
Tighten
Tighten the pipe shield nuts to 5 N-m (44 lb in).
15. Position the rear fuel pipe shield (4) to the fuel
Tighten
5 Nm (44 lb in).
5 Nm (44 lb in).
7~
173551
Engine
6-1911

172963
Rear EVAP Pipes and Hose Removal

Procedure
Tools Required

Procedure.
5. Clean all the fuel and EVAP pipe and hose
connections and the surrounding areas before
disconnecting in order to avoid possible
Replacement.
7. Remove the EVAP purge pipe (7) from the EVAP
canister.
8. Remove the EVAP canister vent solenoid hose (5).
9. Remove the EVAP pipe to fill. limiter vent valve
pipe (3).
10. Cap the EV AP pipes in order to prevent possible
EVAP system contamination.
376978
6-1912
Engine

Rear EVAP Pipes and Hose Installation
Procedure
376978
1. Remove the caps from the fuel and EV AP pipes.

2. Install the EVAP pipe to fill limiter vent valve
pipe (3).
3. Install the EVAP canister vent solenoid hose (5).
canister.
Replacement.
10 seconds.
EVAP Canister Replacement

1
Removal Procedure
376978
Tools Required
O J 42960-2 Fuel Flapper Door Holder
Procedure.
Replacement.
5. Disconnect the fill limiter vent valve pipe (6) from
the EVAP canister.
6. Disconnect the EVAP purge pipe (7) from the
EV AP canister.
7. Disconnect the vent hose (5) from the EV AP.
canister.
Engine
6-1913
8. Carefully bend the bracket in order to remove the

EVAP canister from the bracket.
376984
ln~tallation Procedure
1. Install the EVAP canister to the bracket.
376984
2. Connect the vent hose (5) to the EV AP canister.

canister.
4. Connect the fill limiter vent valve pipe (6) to the
EVAP canister.
Replacement.
10 seconds.
7
376978
6-1914
Engine
EVAP System Cleaning
Tools Required
J 41413 EVAP Pressure/Purge Diagnostic Station
Notice: Use the EV AP Pressure/Purge Diagnostic

Station J 41413 in order to provide a clean, dry,
low pressure gas source. Do not substitute any other
pressurized gas source. Damage may result to the
EVAP system.
20803
172963
Important: Whenever the DTC diagnostics lead to a

no trouble found or to EVAP purge solenoid
replacement, proceed with the following EV AP
canister diagnostics.
1. Remove the EVAP canister purge solenoid valve.
Refer to EVAP Canister Purge Solenoid Valve
Replacement.
2. Lightly tap the EVAP canister purge solenoid on a
clean work area.
3. Look for carbon particles or carbon dust exiting
from either of the vacuum ports.
Reinstall the EVAP purge solenoid if no carbon
release is evident. Continue with the published
service manual DTC procedures.
Continue with this service procedure if carbon
is being released from the EV AP purge
solenoid.
4. Remove the EVAP canister from the vehicle.
Refer to EVAP Canister Replacement.
5. Turn off the main cylinder valve (1) on the
J 41413 EVAP purge/pressure diagnostic station.
6. Disconnect the black hose (4) that connects the
nitrogen cylinder to the J 41413 cart at the
pressure regulator (5) by unscrewing the knurled
nut on the regulator.
7. Connect a section of vacuum hose to the open
fitting of the J 41413 pressure regulator (5).
8. Disconnect the engine compartment EVAP
pipe (5) at the chassis EVAP purge pipe (4)
9. Connect the other end of the vacuum hose to the
chassis EVAP purge pipe (4).
10. Turn on the main nitrogen cylinder valve.
11. Continue to blow any debris from the purge pipe
for 15 seconds.
12. Return the J 41413 EVAP purge/pressure
re-installing the black hose disconnected in
step 6.
13. Replace the EVAP canister purge solenoid valve.
Refer to EVAP Canister Purge Solenoid Valve
Replacement
14. Replace the EVAP canister: Refer to EVAP
Engine
6-1.9.15
15. Connect the J 41413 EVAP purge/pressure

diagnostic station to the vehicle EVAP
service port.
16. Turn the 4 position switch to Purge.
17. Idle the engine at the normal operating
temperature.
18. Open the throttle until engine speed reaches
2000 RPM.
19. Observe the H20 vacuum gauge on the EVAP
cart. The vacuum should read greater than
15in. H20.
Check the vacuum supply to the EVAP purge
solenoid valve if the vacuum is less than
15 in. H20.
Continue with the published service diagnostics
if the vacuum is greater than 15 in. H20.
21046

Replacement
Removal Procedure
Important: The PCM tdle Learn Procedure must be

performed whenever the battery is disconnected. Refer
to CKP System Variation Learn Procedure. Perform
the CKP System Variation Learn Procedure when the
Crankshaft Position sensor is removed or replaced.
2. Remove the starter. Refer to Starter Motor
211621
3. Disconnect the Crankshaft Position (CKP) sensor

56592
6-1916
Engine

4. Remove the CKP sensor retaining bolt.
5. Remove the CKP sensor.
55322
1. Install the CKP sensor.
Notices.
2. Install the CKP sensor retaining bolt.
Tighten
Tighten the CKP sensor to 25 N-m (18 lb ft),
55322
3. Connect the CKP sensor electrical connector.
56592
Engine
6-1917
4. Install the starter. Refer to Starter Motor

6. Perform the CKP System Variation Learn
Proceaure. Refer to CKP System Variation Learn
Procedure.
'
'
211621

Replacement
Removal Procedure

3. Remove the Camshaft Position (CMP) sensor
Important: Clean the area around the CMP before

removal in order to avoid debris from entering
the engine.
4. Remove the CMP sensor retaining bolt.
5. Remove the CMP sensor.
55308
1. Install the CMP sensor.
Notices.
2. Install the CMP sensor retaining bolt.
Tighten
Tighten the CMP retaining bolt to 25 Nm (18 lb ft).
3. Connect the CMP sensor electrical connector.
4. Install the intake manifold. Refer to Intake Manifold
Replacement in Engine Mechanical 5. 7L.

55308
6-1918
Engine

Knock Sensor (KS) Replacement
Removal Procedure

Manifold Replacement in Engine Mechanical5.7L.
3. Remove the Knock Sensor wiring harness
assembly.
54608
4. Remove the Knock Sensor.
54612
Notices.
1. Install the Knock Sensor.
Tighten
Tighten the Knock Sensor to 15 N-m (11 lb ft).
54612
Engine
2. Install the Knock Sensor wiring harness assembly.
3. Install the intake manifold. Refer to Intake

4. Connect the negative battery cable. Refer

to Battery Negative Cable Disconnect/Connect
54608
Secondary AIR Injection Pump

Replacement
Removal Procedure
2. Remove the left hand side lower close-out panel.
3. Remove the hoses from the AIR pump.
243928

AIR. pump.
5. Disconnect the electrical connector from the AIR
Bleed Valve Solenoid.
245568
6-.1920
Engine
6 .. Remove the AIR pump mounting bolts from the

bracket.
7. Remove the AIR pump.
256161
1. Install the AIR pump.

Notices.
2. Install the mounting bolts.
Tighten
.
Tighten the AIR pump bolts to 9.0 Nm (80 lb in).
256161
3. Connect the e.lectric connectors to the AIH pump ..
245568
Engine
6-1921
4. Connect the hoses to the AIR pump.

5. Install the left hand side close-out panel.
7. Check the AIR system for proper operation.
243928
AIR Check Valve/Pipe Replacement Bank2

Removal Procedure
Caution: Allow the engine to cool before servicing
the secondary air injection AIR system in order
to reduce the chance of severe burns.
1. Remove the clamps and AIR hoses from the AIR
system right pipe.
2. Disconnect the Al R hose from the check valve.
3. Unscrew the check valve from the AIR pipe.
4. Remove the right AIR pipe from the manifold.
5. Before replacing a check valve, test the valve for
proper operation.
5.1. Install a vacuum pump to the nipple side of
the check valve, AIR pump side.
5.2. Pump the vacuum pump to 1O inches Hg.
and observe the gauge.
5.3. Replace the check valve if the vacuum
bleeds down to zero within 5 seconds.
178464
Notices.
1. Screw the check valve onto the AIR pipe.
Tighten
Tighten the check valve to 23 Nm (17 lb ft).
2. Connect the right AIR pipe to the exhaust

manifold.
Tighten
Tighten the AIR pipe to the exhaust manifold to
20 N-m (15 lb ft).
3. Install the hose and the clamp to the check valve.
178464
6-1922
Engine
AIR Check Valve/Pipe Replacement -
Bank 1
Removal Procedure
Caution: Allow the engine to cool before servicing

the secondary air injection AIR system in order
to reduce the chance of severe burns.
1. Remove the check valve clamp.
Disconnect the AIR hose from the check valve.
Unscrew the check valve from the AIR pipe.
Remove the left AIR pipe from the manifold.
Before replacing a check valve, test the valve for
proper operation.
5.1. Install a vacuum pump to the nipple side of
the check valve, AIR pump side.
5.2. Pump the vacuum pump to 10 inches Hg.
and observe the gauge.
5.3. Replace the check valve if the vacuum
bleeds down to zero within 5 seconds.
2.
3.
4.
5.
178463
Notices.
1. Screw the check valve onto the AIR pipe.
Tighten
Tighten the check valv_e to the AIR pipe to
23 Nm (17 lb ft).
,
2. Connect the AIR pipe to the exhaust manifold.

Tighten
Tighten the AIR pipe to the exhaust manifold to

20 Nm (15 lb ft).
3. Install the AIR hose to the check valve.
4. Install the check valve clamp.
178463
Secondary Aii Injection Pump Relay

Replacement
Removal Procedure
2. Remove the cover from the underhood electrical
center #2 (2).
3. Remove the AIR pump relay.
255043
Engine
6-1923
2. lns1all the AIR pump relay.
3. lns1all the cover to the underhood electrical
center #2 (2).
255043
Secondary AIR Injection Shut Off Valve

Replacement
Removal Procedure
1. Remove the vacuum line from the AIR Pump Shut
Off Valve (4) vacuum port.
3
604931
2. Remove the AIR Hose (2) from the AIR Pump

Shut Off Valve inlet port.
4
604923
6-1924
Engine
3. Remove the AIR Hoses from the AIR Pump Shut
Off Valve outlet ports.
604925
4. Loosen but do not remove the retaining bolt at the

rear of the cylinder head for the AIR pump Shut
Off Valve bracket.
5. Remove the retaining nut forthe AIR Pump Shut
Off Valve bracket.
6. Remove the AIR Pump Shut Off Valve.
604928
Notices.
1. Install the AIR Pump Shut Off Valve.
Tighten
1.1. Tighten the AIR Pump Shut Off Valve
retaining bolt to 20 N-m (14 lb ft).
1.2. Tighten the AIR Pump Shut Off Valve
retaining nut to 12 Nm (8 lb ft).
604928
Engine
6-1925
2. Install the AIR Hoses to the AIR Pump Shut Off

Valve outlet ports.
604925
3. Install the AIR Hose (2) to the AIR Pump Shut Off
Valve inlet port.
4
604923
4. Install the vacuum line to the AIR Pump Shut Off

Valve (4) vacuum port.
3
604931
6-1926
Engine
AIR Solenoid Valve Replacement
Removal Procedure
1. Disconnect the AIR solenoid valve (5) electrical
connector.
2. Remove the vacuum hose from the AIR solenoid
valve vacuum port.
3. Depress the locking tab for the AIR solenoid valve
bracket.
4. Remove the AIR solenoid valve.
3
604931
1. Install the AIR solenoid valve.
2. Install the vacuum hoses to the AIR Solenoid
valve vacuum ports.
3. Connect the AIR solenoid valve (5) electrical
connector.
3
604931
EGR Valve Replacement

Removal Procedure
Important: Do not try to disassemble the EGR valve.
Service only as a complete assembly.
Important: Carefully note the position of the EGR
valve before removal. Do not rotate the EGR
valve 180 degrees.
i. Remove the electrical connector.
2. Remove the valve to flange attaching bolts.
Notice: The EGR valve is an electrical component.
Soaking the EGR valve in a liquid cleaner or a solvent
causes damage to the valve.
4. Remove the flange gasket.
5. Clean the EGR valve gasket surface.
178487
Engine
6-1927
)
1. Install the new flange gasket

2. Install the linear EGR valve.

Notices.
3. Install the valve to flange bolts.
Tighten
3.1. Tighten the bolts the first time to
10 N-m (89 lb in) each.
3.2. Tighten the bolts a final time to
25 Nm (18 lb ft) each.
4. Install the electrical connector.
178487
EGR Pipe Replacement

Removal Procedure
Caution: Avoid breathing fumes and swallowing

EGR exhaust deposits when removing components
for cleaning as bodily injury may result.
Replacement.
2. Remove the EGR pipe to intake manifold bolts.
3. Remove the EGR pipe to exhaust manifold bolts.
4. Remove the EGR pipe mounting bolts from
the right cylinder head.
5. Remove the EGR pipe.
178489
1.
2.
3.
4.
Install the EGR

Install the EGR
Install the EGR
Install the EGR
Replacement.
pipe.
pipe to exhaust manifold bolts.
pipe to intake manifold bolts.
valve. Refer to EGR Valve
178489
6-1928
Engine
EGR System Cleaning
178489
Caution: Avoid breathing fumes and swallowing

EGR exhaust deposits when removing components
for cleaning as bodily injury may result.
2. Depress the pintle several times using a pencil
eraser or other suitable soft instrument. The
pintle should move in and out smoothly. Replace
the valve if it exhibits tendencies to stick. Refer
to EGR Valve Replacement.
3. Try to rotate the EGR valve connector housing.
Repeat for the coil housing. Replace the valve if
it exhibits any looseness. Refer to EGR Valve
Replacement.
4. Inspect the EGR valve pintle and seat for deposits.
Use a cloth or other suitable soft device to
remove the deposits. Remove all loose particles.
Replace the valve if the deposits are such
that the pintle/base interface can not be cleaned
adequately to allow the pintle to seal against
the seat. Damage to the powdered metal EGR
valve base occurs if cleaned with solvents, sharp
tools, wire brush/wheel or sand blasting.
Cleaning by these methods is not recommended.
5. Remove the EGR pipe.
6. Clean the passages with a wire brush. Remove all
loose particles.
7. Install the EGR pipe.
Air Cleaner Element Replacement

1
Removal Procedure
1. Release the top cover latches (4).
2. Lift the top of the air cleaner housing (5) up.
3. Pull out the air filter element. Ensure the air filter
frame remains with the housing.
4. Inspect the air filter element for dust, dirt, or
water. Clean or replace the air filter element if
required.
243934
Engine
6-1929
1. Install the air filter element into the air cleaner
housing.
2. Install the air cleaner housing top cover (5) to the
lower assembly. Ensure the rear locating tabs on
the air cleaner cover slip into the retainers
located on the lower portion of the air cleaner
housing.
3. Secure the top cover latches (4).
243934
Air Cleaner Assembly Replacement

1
Removal Procedure

engine.
1. Release the top cover latches (4).
2. Remove the plastic rivets (1) securing the air
intake resonator (2).
3. Loosen the clamp at the air duct between the
MAF sensor and the resonator (2).
243934
4. Disconnect the IAT sensor (2) connector.

5. Lift the top of the air cleaner housing and the
resonator off as an assembly.
)
242662
5;.1930
Engine
6. Remove the 4 fasteners securing the air cleaner
assembly (3) to the tie bar.
7. Lift the lower air cleaner assembly off.
243934
1. Position the lower air cleaner assembly (3) onto
the tie bar. Ensure the rubber isolators fit properly
on to the top of the radiator.
2. Fasten the lower air cleaner assembly (3) to the

tie bar support.
3. Secure the upper air cleaner and resonator
assembly (2) to the MAF sensor
4. Secure the resonator to the lower air cleaner
assembly using the plastic rivets (1 ).
243934
5. Connect the IAT sensor (2) connector.

6. Tighten the clamp on the air duct at the MAF
sensor (1 ).
(
242662
Engine
6-1931
7. Secure the top cover latches (4). Ensure the rear

locating tabs on the air cleaner cover slip into the
retainers located on the lower portion of the air
cleaner housing.
243934
Engine Oil life Monitor Reset Procedure

Description
The PCM monitors various engine parameters to
determine when an oil change should be done. The
PCM sends a message to the Instrument Panel
Cluster (IPC) when an oil change is needed. The PCM
monitors the following to determine when an oil
change should occur:
Engine Speed
Engine coolant temperature
Engine load
" Intake Air Temperature
O Vehicle mileage
Resetting The Oil life Monitor

Important:
Repair any TP sensor DTCs before proceeding
with the reset procedure.
" If the Engine Oil Life Monitor is reset due to a
PCM replacement, advise the customer. The
customer has two options:
- Change the engine oil and filter.
- Determine when the last engine oil change
occurred. Monitor the vehicle mileage and
change the engine oil and filter at the
next recommended service interval.
2. Cycle the accelerator pedal from a closed throttle
to a wide open throttle (WOT) 3 times within
5 seconds. The Change Oil message flashes for
5 seconds when reset.
3. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Change in Engine Mechanical.
6-1932
Engine

Powertrain Control Module Description
The Powertrain Control Module (PCM) is designed to
maintain exhaust emission levels while maintaining
excellent driveability and fuel efficiency. The PCM
controls the following operations:
Fuel control
Ignition Control (IC)
Knock Sensor (KS) system
Automatic transmission shift functions
Manual transmission: 1-4 Upshift and Reverse
Inhibit
Cruise Control Enable (if so equipped)
Generator
" Evaporative Emission (EV AP) Purge
AJC Clutch Control
Cooling Fan Control
" Secondary Air Injection (AIR)
Exhaust Gas Recirculation (EGR)
On-board diagnostics for powertrain functions.
Powertrain Control Module
187237
The Powertrain Control Module (PCM) is located in

the engine compartment. The PCM is the control
center of the vehicle.
The PCM constantly monitors the information from
various sensors and controls the systems that
affect vehicle performance and emissions. The PCM
also performs the diagnostic functions for those
systems. It can recognize operational problems and
will alert the driver through the MIL (Malfunction
Indicator Lamp) when a malfunction has occurred.
When the PCM detects a malfunction, it stores
a diagnostic trouble code (DTC) which will help identify
problem areas. This is done to aid the technician in
making repairs.
The PCM supplies either 5.0 or 12.0 volts to power
various sensors or switches. This is done through
resistances in the PCM. The resistance is so high in
value that a test lamp will not illuminate when

connected to the circuit. In some cases, even an
ordinary shop voltmeter will not give an accurate
reading because its resistance is too low. Therefore, a
digital voltmeter (J 39200) with a minimum of
10 megaohms input impedance is required to ensure
accurate voltage readings.
The PCM controls output circuits such as the injectors,
IAC, cooling fan relays, etc. by controlling the
ground or the power feed circuit through transistors or
a device called an Output Driver Module.
Torque Management
Torque Management is a function of the PCM that
reduces engine power under certain conditions. Torque
Management is performed for the following reasons:
To prevent over stressing the powertrain
components.
., To prevent damage to the vehicle during certain
abusive maneuvers.
To reduce engine speed when the IAC is out of
the normal operating range.
The PCM monitors the following sensors and engine
parameters to calculate engine output torque:
Air/Fuel ratio
Mass Air Flow
.. Manifold Absolute Pressure
" Intake Air Temperature
" Spark Advance
" Engine Speed
" Engine Coolant Temperature
O A/C Clutch Status
The PCM monitors the torque converter status, the
transmission gear ratio, and the engine speed in order
to determine if torque reduction is required. The
PCM retards the spark as appropriate to reduce engine
torque output if torque reduction is required. The
PCM also shuts off the fuel to certain injectors
to reduce the engine power In the case of an abusive
maneuver.
The following are instances when engine power
reduction is likely to be experienced:
During tra.nsmission upshifts and downshifts.
Heavy acceleration from a standing start.
The IAC is out of the normal operating range.
When the driver is performing harsh or abusive
maneuvers such as shifting into gear at high
throttle angles or shifting the transmission from
reverse to drive to create a rocking motion.
The driver is unlikely to notice the torque management
actions in the first two instances. The engine power
output will be moderate at full throttle in the other
two cases.
The PCM calculates the amount of spark retard
necessary to reduce the engine power by the desired
amount. The PCM disables the fuel injectors for
cylinders i, 4, 6, and 7 in the case of an abusive
maneuver.
Engine
6-1933
PCM Function
Maintenance Schedule
The PCM supplies a buffered voltage to various

sensors and switches. The PCM controls most
components with electronic switches which complete a
ground circuit when turned ON.
Refer to the General Motors Maintenance Schedule of

the appropriate service category for the maintenance
that the owner or technician should perform in order to
retain emission control performance.
PCM Service Precautions
Visual and Physical Underhood Inspection
The PCM is designed to withstand normal current

draws associated with vehicle operations. Avoid
overloading any circuit. When testing for opens or
shorts, .do not ground any of the PCM circuits unless
instructed. When testing for opens or shorts, do
not apply voltage to any of the PCM circuits unless
instructed. Test these circuits with a digital voltmeter
J 39200 only, while the PCM connectors remain
connected.
Perform a careful visual and physical underhood

inspection when performing any diagnostic procedure
or diagnosing the cause of an emission test failure.
This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual and physical inspection:
" Inspect all vacuum hoses for the following
conditions:
- Correct routing
- Pinches
- Cuts
- Disconnected
O Inspect all wires in the engine compartment for
the following items:
- Proper connections
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
This visual and physical inspection is very important.
Preform the inspection carefully and thoroughly.
Aftermarket (Add-On) Electrical And Vacuum

Equipment
Aftermarket (Add-On) Electrical and Vacuum
Equipment is defined as any equipment installed on a
vehicle after leaving the factory t.hat connects to
the vehicle's electrical or vacuum systems. No
allowances have been made in the vehicle design for
this type of equipment.
Notice: Do not attach add-on vacuum operated
equipment to this vehicle. The use of add-on vacuum
equipment may resultin damage to vehicle
components or systems.
Notice: Connect any add~on electrically operated

equipment to the vehicle's electrical system at
the battery (power and ground) in order to prevent
damage to the vehicle.
Add-On electrical equipment, even when installed to
these strict guidelines, may still cause the Powertrain
system to malfunction. This may also include
equipment not connected to the vehicle's electrical
system such as portable telephones and radios.
Therefore, the first step in diagnosing any Powertrain
problem is to eliminate all aftermarket electrical
equipment from the vehicle. After this is done, if the
problem still exists, diagnose the problem in the normal
manneL
Engine Controls Information

The driveability and emissions information describes
the function and operation of the PCM.
The engine controls Information contains the following:
Component Location.s
" Wiring Diagrams
" PCM Terminal End View and Terminal Definitions
" Powertrain OnsBoard Diagnostic (OBD)
System Check
Diagnostic Trouble Code Tables (DTCs)
The Component System includes the following items:
" Component and circuit description
" On-vehicle service for each sub-system
" Functional checks and Diagnostic Tables
The DTCs also contain diagnostic support information
containing circuit diagrams, circuit or system
information, and helpful diagnostic information.
System Status and Drive Cycle For

Inspection/Maintenance
The System Status selection is included in the scan
tool System Info menu.
Several states require that the 1/M (OBD II system)
pass on-board tests for the major diagnostics prior to
having a vehicle emission inspection. This is also
a requirement to renew license plates in some areas.
Using a scan tool, the technician can observe the
System Status (complete or not complete) in order to
verify that the vehicle meets the criteria to comply
with local area requirements. Using the System Status
display, any of the following systems or combination
of systems may be monitored for 1/M Readiness:
The Catalyst
The EV AP system
"The H02S
The H02S Heater
., The EGR System
The AIRsystem
6-1934
Engine
Important: The System Status display indicates only

whether or not the test has been completed. The
System Status display does not necessarily mean that
the test has passed. If a Failed Last Test indication
is present for a OTC associated with one of the above
systems, diagnosis and repair is necessary in order
to meet the 1/M requirement. Verify that the vehicle
passes all of the diagnostic tests associated with the
displayed System Status prior to returning the
vehicle to the customer. Refer to the Typical Drive

Cycle table (more than one drive cycle may be
needed) to use as a guide to complete the 1/M System
Status tests.
Following a OTC info clear, System Status will clear

for one or all of these systems. Following a battery
disconnect or a PCM replacement, all System Status
information will clear.
Typical Drive Cycle

Diagnostic Time Schedule for 1/M Readiness
What is Monitored?
Vehicle Drive Status
Cold Start, coolant temperature less than 50C (122F)

Idle 2.5 minutes in Drive (Auto) Neutral (Man), A/C and rear
defogger ON
H02S Heater, Misfire, Secondary Air, Fuel Trim,

EVAP Purge
A/C off, accelerate to 90 km/h (55 mph), 1/2 throttle.
Misfire, Fuel Trim, Purge
3 minutes of Steady State - Cruise at 90 km/h (55 mph)
Misfire, EGR, Secondary Air, Fuel Trim, H02S, EVAP Purge
Clutch engaged (Man), no braking, decelerate to

32 km/h (20 mph)
EGR, Fuel Trim, EVAP Purge
Accelerate to 90-97 km/h (55-60 mph), 3/4 throttle
Misfire, Fuel Trim, EVAP Purge
5 minutes of Steady State Cruise at 90-97 km/h (55-60 mph) Catalyst Monitor, Misfire, EGR, Fuel Trim, H02S,
EVAP Purge
Decelerate, no braking. End of Drive Cycle
Total time of OBD II Drive Cycle 12 minutes
Primary System Based Diagnostics

There are primary system based diagnostics which
evaluate the system operation and their effect on
vehicle emissions. The primary system based
diagnostics are listed below with a brief description of
the diagnostic functionality.
Oxygen Sensor Diagnosis

Diagnose the Fuel Control Heated Oxygen Sensors
for the following conditions:
Heater Performance (time to activity on cold start)
" Slow Response
" Response Time (time to switch R/L or UR)
" Inactive Signal (output steady at bias voltage approximately 450 mV)
Signal Fixed High
Signal Fixed Low
Diagnose the Catalyst Monitor Heated Oxygen
Sensors for the following functions:
" Heater Performance (time to activity on cold start)
Signal fixed low during steady state conditions.
o Inactive Sensor.
Heated Oxygen Sensors (Pre-Catalyst)

The main function of the Pre-Catalyst Heated Oxygen
Sensor (H02S) is to provide the PCM with exhaust
stream information in order to maintain proper fueling
to hold emissions within acceptable levels. These
oxygen sensors are always located between the
exhaust manifold and the catalytic converter. After the
sensor reaches the operating temperature, the
sensor generates a voltage inversely proportional to
the amount of oxygen present in the exhaust gases.
EGR, EVAP Purge
The PCM uses the signal voltage from the fuel control
heated oxygen sensors in a closed loop in order to
adjust the fuel injector pulse width. While in a closed
loop, the PCM can adjust fuel delivery in order to
maintain an air to fuel ratio which allows the
best combination of emission control and driveability.
If the oxygen sensor pigtail wiring, connector or
terminal are damaged, replace the entire oxygen
sensor assembly. Do not attempt to repair the wiring,
connector, or terminals. In order for the sensor to
function properly, the sensor must have a clean air
reference provided to it. This clean air reference
is obtained by way of the oxygen sensor wires. Any
attempt to repair the wires, connectors or
terminals could result in the obstruction of the air
reference. Any attempt to repair the wires, connectors
or terminals would degrade oxygen sensor
performance.
Catalyst Monitor Heated Oxygen Sensors

In order to control emissions of Hydrocarbons (HC),
Carbon Monoxide (CO), and Oxides of Nitrogen. (NOx),
the system uses a three-way catalytic converter.
The catalyst promotes a chemical reaction which
oxidizes the HC and CO present in the exhaust gas,
converting them into harmless water vapor and carbon
dioxide. The catalyst also reduces NOx, converting
it to nitrogen. Catalyst Monitor H02S ( Post Catalyst
H02S) are always located downstream of the catalytic
converter.
Engine
The PCM has the ability to monitor this process using

the post catalyst heated oxygen sensors. The
pre-sensors produce an output signal which indicates
the amount of oxygen present in the exhaust gas
entering the three-way catalytic converter. The post
sensor produces an output signal which indicates the
oxygen storage capacity of the catalyst. This in
turn indicates the catalyst's ability to convert exhaust
gases efficiently. If the catalyst is operating
efficiently, the pre H02S signal will be far more active
than that produced by the post H02S.
6-1935
The catalyst monitor diagnostic is sensitive to the

Exhaust leaks
H02S Contamination
O
Alternative fuels (Ethanols and Methanols)
Exhaust system leaks may cause the following:

Prevent a degraded catalyst from failing the
diagnostic
" Cause a false failure for a normally functioning
catalyst
In addition to catalyst monitoring, the post heated

oxygen sensor has a limited role in controlling
fuel delivery. If the post H02S signal indicates a high
or low oxygen content for an extended period of
time while in a closed loop, the PCM adjusts the fuel
delivery slightly in order to compensate.
Some of the contaminants that may be encountered

are phosphorus, lead, silica, and sulfur. The presence
of any of these contaminants will reduce catalyst
efficiency and lead to emission failures.
Catalyst Monitor Diagnostic Operation
Three-Way Catalyst Oxygen Storage Capacity
" Prevent the diagnostic from running
The catalyst monitor diagnostic measures oxygen

storage capacity of the catalyst converter ..In order to
do this, the heated sensors are installed before
and after the Three-Way Catalyst (TWC). Voltage
variations between the sensors allow the PCM
to determine the catalyst emission performance.
A good catalyst (e.g. 95% hydrocarbon conversion

efficiency) shows a relatively flat output voltage on the
post-catalyst heated oxygen sensor (H02S} signal
circuit. A degraded catalyst (65% hydrocarbon
conversion) shows a greatly increased activity in
output voltage from the post catalyst H02S.
The post-catalyst H02S is used to measure the
oxygen storage and release capacity of the catalyst. A
high oxygen storage capacity indicates a good
catalyst. Low oxygen storage capacity indicates a
failing catalyst. The TWC and the H02S must be at
operating temperature in order to achieve reliable
oxygen sensor voltages like those shown in the
Three-Way Catalyst Oxygen Storage Capacity graphic.
The PCM performs the catalyst diagnostic at idle
when the conditions for running the diagnostic are met.
Refer to Conditions for Running the OTC in
OTC P0420 Catalyst System Low Efficiency Bank 1 or
OTC P0430 Catalyst System Low Efficiency Bank 2.
During the catalyst diagnostic the PCM captures
the current rear H02S rich/lean status. The Air Fuel
ratio transitions from rich to lean or lean to rich
depending on the initial captured rich/lean status. The
Air Fuel ratio transitions a second time opposite
the 1irst Air Fuel ratio transition. During this diagnostic
the scan tool will display H02S voltages going
from full rich to full lean. This condition is normal
during this diagnostic.
As a catalyst becomes less effective in promoting

chemical reactions, the catalyst's capacity to store and
release oxygen generally degrades. The catalyst
mqnitor diagnostic is based on a correlation between
conversion efficiency and oxygen storage capacity.
________
14442
The PCM must monitor the Three-Way Catalyst

system (TWC) for efficiency. In order to accomplish
this, the PCM monitors the pre-catalyst and
post-catalyst oxygen sensors. When the TWC is
operating properly, the post-catalyst (2) oxygen
sensor will have significantly less activity than the
pre-catalyst (1) oxygen sensor. The TWC stores
oxygen during its normal reduction and oxidation
process. The TWC releases oxygen during its normal
reduction and oxidation process. The PCM calculates
the oxygen storage capacity using the difference
between the pre-catalyst and post-catalyst oxygen
sensor's voltage levels.
6-1936
Engine

Misfire Monitor Diagnostic Operation
/
14446
Whenever the sensor activity of the post-catalyst (2)

oxygen sensor nears the sensor activity of the
pre-catalyst (1) oxygen sensor, the catalysts efficiency
is degraded.
Aftermarket H02S characteristics may be different
from the original equipment manufacturer sensor. This
may lead to a false pass or a false fail of the catalyst
monitor diagnostic. Similarly, if an aftermarket
catalyst does not contain the same amount of precious
metal content as the original part, the correlation
between oxygen storage and conversion efficiency
may be altered enough to set a false DTC.
The misfire monitor diagnostic is based on crankshaft

rotational velocity (reference period) variations.
The PCM determines crankshaft rotational veloci1y
using the crankshaft position sensor and camshatt
position sensor. When a cylinder misfires the
crankshaft slows down momentarily. By monitoring the
crankshaft and camshaft position sensor signals,
the PCM can calculate when a misfire occurs.
For a non-catalyst damaging misfire, the diagnostic is
required to monitor a misfire present for between
1000-3200 engine revolutions.
For catalyst damage misfire, the diagnostic responds
to the misfire within 200 engine revolutions.
Rough roads may cause false misfire detection. A
rough road applies sudden torque variations to
the drive wheels and drivetrain. This torque can
intermittently decrease the crankshaft rotational
velocity. The ABS system detects uneven speed
between the vehicles wheels and sends data via the
serial data bus to the PCM to disable the misfire
monitor until the rough road is no longer detected.
On automatic transmission equipped vehicles,
the Torque Converter Clutch (TCC) will disable
whenever a misfire is detected. Disabling the TCC
isolates the engine from the rest of the drive line and
minimizes the effect of the drive wheel inputs on
crankshaft rotation.
When the TCC is disabled as a result of misfire
detection, the TCC will re-enabled after approximately
3200 engine revolutions if no misfire is detected.
The TCC remains disabled whenever the misfire is
detected, with or without a DTC set. This allows
the misfire diagnostic to reevaluate the system.
Engine
CYL1
MISFIRES
CYL2
MISFIRES
0-200-0
6-1937
. . CYLS 5-8
CYL 3
CYL
(AS APPLICABLE)
MISFIRES MISFIRES
MISFIRES
4000
~
~
~
~
~
~
~
~
~
~
~
~
~
~
HISTORY
HISTORY
4
HISTORY
0
HISTORY
4
HISTORY
0
1356
\ //
IDENTIFY
AND fill
CHECKS
ACCUMULATORS
ACCUMULATOR
CRANKSHAFT
POSITION SENSOR
CAMSHAFT
RUN
MISFIRE
DIAGNOSIS
REPORT
MISFIRE
DIAGNOSTIC
EXECUTIVE
SETS
DTC
POSITION SENSOR
17379
Whenever a cylinder misfires, the misfire diagnostic

counts the misfire and notes the crankshaft position at
the time the misfire occurred.
A current and a history misfire counter is maintained
for each cylinder. The misfire current counters (Misfire
Cur #1 - 8) indicate the number of firing events out
of the last 200 cylinder firing events which were
misfires. The misfire current counters displays real
time data without a misfire DTC stored. The misfire
history counters (Misfire Hist #1 - 8) indicate the total
number of cylinder firing events which were misfires.
The misfire history counters displays O until the misfire
diagnostic has failed and a DTC P0300 is set. Once
the misfire DTC sets, the misfire history counters
will be updated every 200 cylinder firing events. The
Misfire counters graphic illustrates how these
misfire counters are maintained.
When crankshaft rotation is erratic, the PCM detects a

misfire condition. Because of this erratic condition,
the data that is collected by the diagnostic can
sometimes incorrectly identify which cylinder is
misfiring. The Misfire Counters graphic shows there
are misfires counted from more than one cylinder.
Cylinder #1 has the majority of counted misfires. In this
case, the Misfire Counters would identify cylinder #1
as the misfiring cylinder. The misfires in the other
counters were just background noise caused by the
erratic rotation of the crankshaft. If the number of
accumulated misfires is sufficient for the diagnostic to
identify a true misfire, the diagnostic will set
DTC P0300 - Misfire Detected. The illustration depicts
an accumulation in the history buffers.
6-1938
If two cylinders in sequential firing order are both

misfiring, the first misfiring cylinder will accumulate
misfires in its buffer but the second misfiring cylinder
will not. This is because the PCM compares a misfiring
cylinder with the cylinder 90 degrees prior to it in the
firing order. Therefore the PCM would be comparing
crankshaft speed of the second misfiring cylinder to an
already suspect cylinder. The PCM however, will be
able to detect both misfiring cylinders after the engine
exceeds 2000 RPM. This is because the PCM then
starts to compare misfires to the opposing cylinder
rather than the previous cylinder in the firing order.
Use Techline equipment to monitor the misfire counter
data on applicable vehicles. Knowing which specific
cylinder(s) misfire can lead to the root cause. Using the
information in the misfire counters, will identify which
cylinder(s) are misfiring. If the counters indicate
cylinders number 1 and 4 misfired, look for a circuit or
component common to both cylinders.
The misfire diagnostic may indicate a fault due to a
temporary fault not necessarily caused by a vehicle
emission system malfunction. Examples include
the following items:
Contaminated fuel
Running out of fuel
Fuel fouled spark plugs
Basic engine fault
Fuel Trim System Operation

The Fuel Trim system monitors the averages of
short-term and long-term fuel trim values. If these fuel
trim values stay at their limits for a calibrated period
of time, a malfunction is indicated. The fuel trim
diagnostic compares the average of short and
long-term fuel trim values. If either value is within the
thresholds, a pass is recorded. If either value is
outside the thresholds, a rich or lean fuel Trim DTC
will set.
Comprehensive Component
Monitor Diagnostic
Comprehensive component monitoring diagnostics are
required to monitor emissions-related input and
output Powertrain components.
Engine
Input Components
The PCM monitors the input components for circuit
continuity and out-of-range values. This includes
performance checking. Performance checking refers to
indicating a fault when the signal from a sensor
does not seem reasonable (i.e. a Throttle Position (TP)
sensor that indicates high throttle position at low
engine loads or MAP voltage). The input components
may include but are not limited to the following
sensors:
The Vehicle Speed (VSS) sensor
The Accelerator Pedal Position (APP) sensor (if
so equipped)
" Mass Air Flow (MAF) sensor
Crankshaft Position (CKP) sensor
Knock Sensor (KS)
Throttle Position (TP) sensor
Engine Coolant Temperature (ECT) sensor
Camshaft Position (CMP) sensor
Manifold Absolute Pressure (MAP) sensor
In addition to the circuit continuity and rationality
check, the ECT sensor is monitored for its ability to
achieve a steady state temperature to enable
closed loop fuel control.
Output Components
Diagnose the output components for the proper
response to PCM commands. Components where
functional monitoring is not feasible will be monitored
for circuit continuity and out-of-range values if
applicable.
Output components to be monitored include, but are
not limited to the following circuits:
Idle Air Control (IAC) Motor
EV AP system
Electronic transmission controls
A/C relay
Cooling fan relay
VSS output
MIL control
Cruise control inhibit (if so equipped)
Information Sensors/Switches Description

All of the sensors and the input switches can be
diagnosed through the use of a scan tool. The
following is a short description of how the sensors and
switches can be diagnosed by using a scan tool.
The scan tool can also be used in order to compare
the values for a normal running engine with the engine
being diagnosed.
Engine
6-1939
13578
Legend
(1) ECT Electrical Connector
(2) Connector Tab
{3) Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is a thermistor
(a resistor which changes value based on temperature)
mounted in the left cylinder head. Low coolant
temperature produces a high resistance,
100,000 ohms at -38C (-39F), while high
temperature causes low resistance, 70 ohms
at 13DC (266F).
The PCM supplies a 5.0 volt signal to the engine
coolant temperature sensor through a resistor in the
PCM and measures the voltage. The voltage will
be high when the engine is cold. The voltage will be
low when the engine is hot. The PCM calculates
the engine coolant temperature by measuring
the voltage. The engine coolant temperature affects
most systems the PCM controls.
The scan tool displays engine coolant temperature in
degrees. When the engine starts the engine coolant
temperature should rise steadily to about 90C (194F)
then stabilize when the thermostat opens. The
engine coolant temperature and intake air temperature
parameter displays should be close to each other if
the engine has not been run for several hours
(overnight). The following DTCs set when the PCM
detects a malfunction in the ECT sensor circuit:
DTC P0117 ECT Sensor Circuit Low Voltage.
DTC P0118 ECT Sensor Circuit High Voltage.
DTC P0125 Excessive Time to Closed Loop.
O
DTC P1114 ECT Sensor CKT Intermittent Low

Voltage.
" DTC P1115 ECT Sensor CKT Intermittent High

Voltage.
Specifications contains a table to check for sensor
resistance values relative to temperature.
13487

amount of air which passes through it. The PCM uses
this information to determine the operating condition
of the engine in order to control the fuel delivery.
A large quantity of air indicates acceleration. A small
quantity of air indicates deceleration or idle.
The scan tool reads the MAF value and displays it in
grams per second (g/s). The MAF sensor displays
between 6 - 9 g/s at idle on a fully warmed up engine.
The MAF sensor values should change rather
quickly on acceleration, but the MAF sensor values
should remain fairly stable at any given engine speed.
One or more of the following DTCs set when the
PCM detects a malfunction in the MAF sensor circuit:
DTC P0101 Mass Air Flow System Performance.
DTC P0102 MAF Sensor Circuit Low Frequency.
DTC P0103 MAF Sensor Circuit High Frequency.
6-1940
Engine
13643
Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Electrical Harness Connector
The Intake Air Temperature (IAT) sensor is a
thermistor which changes value based on the
temperature of air entering the engine. Low
temperature produces a high resistance,

100,000 ohms at -38C (-39F). A high temperature
causes low resistance, 70 ohms at 130C (266F). The
PCM supplies a 5.0 volt signal to the sensor through
a resistor in the PCM and measures the voltage.
The voltage will be high when the incoming air is cold,
and low when the air is hot. The PCM calculates
the incoming air temperature by measuring the IAT
voltage. The IAT sensor signal is used to adjust spark
timing according to incoming air density.
The scan tool displays the temperature of the air
entering the engine, which should be close to ambient
air temperature when the engine is cold. The
temperature should rise as underhood temperature
increases. The engine coolant temperature and intake
air temperature parameter displays should be close
to each other if the engine has not been run for several
hours (overnight).
The following OTCs set when the PCM detects a
malfunction in the IAT sensor circuit:
OTC P0112 IAT Sensor Circuit Low Voltage.
OTC P0113 IAT Sensor Circuit High Voltage.
OTC P1111 IAT Sensor Circuit Intermittent High

Voltage.
OTC P1112 IAT Sensor Circuit Intermittent Low
Voltage.
Specifications contains a table to check for sensor
resistance values relative to temperature.
Engine
6-1941
)
247435
The Manifold Absolute Pressure (MAP) sensor (1)

responds to changes in the intake manifold pressure.
The pressure changes as a result of engine load
and speed. The map sensor converts this to a voltage
output.
A closed throttle on engine coast down produces a
relatively low MAP output voltage. A wide open throttle
produces a high MAP output voltage. This high
output voltage is produced because the pressure
inside the manifold is the same as outside the
manifold. The MAP is inversely proportional to what is

measured on a vacuum gauge. The MAP sensor is
used for the following:
Altitude determination.
" Ignition timing control.
Speed density fuel management default.
OTC P0107 MAP Sensor Circuit Low Voltage or
OTC P0108 MAP Sensor Circuit High Voltage set
when the PCM detects a malfunction in the MAP
sensor circuit.
6-1942
Engine
Heated Oxygen Sensors (H02S) Cutaway
Front Heated Oxygen Sensors (H02S)
5
1
13576
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Four Wire In-Line Connector

Heater Termination
Water Shield Assembly
Sensor Lead
Flat Seat Shell
Seat Gasket
Outer Electrode and Protective Coating
Rod Heater
Inner Electrode
Zirconia Element
Insulator
Clip Ring
Gripper
The Heated Oxygen Sensors are mounted in the

exhaust system where they can monitor the oxygen
content of the exhaust gas stream. The oxygen
present in the exhaust gas reacts with the .sensor to
produce a voltage output. This voltage should
constantly fluctuate from approximately 100 mV (high
oxygen content= lean mixture) to 900 mV (low
oxygen content= rich mixture). The heated oxygen
sensor voltage can be monitored with a scan tool. By
monitoring the voltage output of the oxygen sensor,
the PCM calculates the fuel pulse width command
to give to the injectors (lean mixture/low
H02S voltage = rich command, rich mixture/high
H02S voltage= lean command).
The PCM sets the following OTCs when the PCM
detects an H02S signal circuit that is low:
OTC P0131 H02S Circuit Low Voltage Bank 1
Sensor 1.
" OTC P0151 H02S Circuit Low Voltage Bank 2
Sensor 1.
Sensor 2.
Sensor 2.
detects an H02S signal circuit that is high:
.. OTC P0132 H02S Circuit High Voltage Bank 1
Sensor 1.
OTC POi 52 H02S Circuit High Voltage Bank 2
Sensor 1.
OTC POi 38. H02S Circuit High Voltage Bank 1
Sensor 2.
OTC P0158 H02S Circuit High Voltage Bank2
Sensor 2.
detects no H02S activity:
OTC P0.134 H02S Insufficient Activity Bank 1
Sensor 1.
" OTC P0154 H02S Insufficient Activity Bank 2
Sensor 1.
OTC P0140 H02S Insufficient Activity Bank 1
Sensor 2.
.. OTC P0160 H02S Insufficient Activity Bank 2
Sensor 2.
A fault in the heated oxygen sensor heater element or
its ignition feed or ground results in an increase in
time to Closed Loop fuel control. This may cause

increased emissions, especially at start-up. The
following OTCs set when the PCM detects a
malfunction in the H02S heater circuits:
OTC POi 35 H02S Heater Circuit Bank 1 Sensor 1.
OTC P0155 H02S Heater Circuit Bank 2
Sensor 1.
OTC P0141 H02S Heater Circuit Bank 1 Sensor 2.
" OTC P0161 H02S Heater Circuit Bank 2
Sensor 2.
Engine
The PCM also has the ability to detect the following
H02S problems:
H02S response
Switching
6-1943
Transition time
Incorrect ratio voltages
The PCM stores a DTC that indicates degraded H02S
performance if any of the above is detected.
Rear Heated Oxygen Sensors (H02S)

to monitor this process using the Bank 1 H02S 2 and
the Bank 2 H02S 2 heated oxygen sensors. The
front H02S sensors produces an output signal which
indicates the amount of oxygen present in the
exhaust gas entering the three-way catalytic converter.
The rear H02S sensors produces an output signal
which indicates the oxygen storage capacity of
the catalyst; this in turn indicates the catalysts ability
to convert exhaust gases efficiently. If the catalyst
is operating efficiently, the front sensors will produce a
far more active signal than that produced by the
rear sensors.
The catalyst monitor sensors operate the same as the
fuel control sensors. Although the Bank 1 H02S 2
and Bank 2 H02S 2 sensors main function is catalyst
monitoring, they also play a limited role in fuel
control. If a sensor output indicates a voltage either
above or below the 450 millivolt bias voltage for
an extended period of time, the PCM will make a slight
adjustment to fuel trim to ensure that fuel delivery is
correct for catalyst monitoring.
The PCM performs the catalyst diagnostic at idle
when the conditions for running the diagnostic are met.
During the catalyst diagnostic the PCM captures the
current rear H02S rich/lean status. The Air Fuel
ratio transitions from rich to lean or lean to rich
depending on the initial captured rich/lean status. The
Air Fuel ratio transitions a second time opposite the
first Air Fuel ratio transition. During this diagnostic the
scan tool will display H02S voltages going from full
rich to full lean. This condition is normal during
this diagnostic.
13572
The Throttle Position (TP) sensor (2) is a

potentiometer. The TP sensor is connected to the
throttle shaft (3) on the throttle body. The PCM (1)
calculates throttle position by monitoring the voltage on
the signal line. The TP sensor signal changes as the
throttle valve angle is changed (accelerator pedal
moved). The TP sensor signal voltage is low at a closed
throttle position. The TP sensor signal voltage
increases as the throttle valve opens so that at Wide
Open Throttle (WOT), the output voltage should be
above 4.0 volts.
The PCM calculates fuel delivery based on throttle
valve angle (driver demand). A broken or loose
TP sensor may cause intermittent bursts of fuel from
an injector. This may cause an unstable idle
because the PCM detects the throttle is moving.
The following DTCs set when the PCM detects a
malfunction with the TP sensor circuits:
DTC P0121 TP Sensor Circuit Insufficient Activity.
DTC P0122 TP Sensor Circuit Low Voltage.
DTC P0123 TP Sensor Circuit High Voltage.
DTC P1121 TP Sensor CKT Intermittent High
Voltage.
DTC P1122 TP Sensor CKT Intermittent Low
Voltage.
Park/Neutral Position (PNP) Switch

(Automatic Transmission).
The PNP switch indicates to the PCM when the
transmission is in park, neutral, or drive. This
information is used for the EGA and IAC valve
operation. The PNP switch is part of the neutral/start
and backup light switch assembly.
Important: Idle quality will be affected if the vehicle is

driven with the PNP switch disconnected. Having
the switch disconnected may also cause a VSS DTC
to set.
6-1944
Engine
Fuel level Sensor
370970
legend
(1)
(2)
(3)
(4)
(5)
(6)
Fuel Pressure Sensor

Fuel Pressure Regulator Retaining Clip
Fuel Strainer
Fuel Level Sensor
Fuel Pump Electrical Connector
Retaining Clip
(7) Fuel Pump Electrical Connector
(8) Fuel Level Sensor Electrical Connector
(9) Fuel Level Sensor Electrical Connector
Retaining Clip
18839
The Fuel Tank Pressure sensor is a sensor much like

the MAP sensor. The Fuel Tank Pressure sensor
measures the difference between the outside
air pressure and the air pressure (or vacuum) in the
fuel tank.
The Fuel Tank Pressure sensor mounts to the fuel
tank sending unit. A three wire electrical harne.ss
connects the sensor to the PCM. The.PCM supplies a
5.0 volt reference voltage and a ground to the
sensor. The sensor will return a voltage between 0.1
and 4.9 volts on the signal circuit.
Knock Sensors (KS)
The PCM uses the fuel level sensor input in order to

determine the amount of fuel in the fuel Jank. The PCM
disables the engine misfire diagnostic when the fuel
level is too low and the EV AP system diagnostic when
the fuel level is either too high or too low. The PCM
also controls the fuel gauge based on the fuel
level input.
13635
A Knock Sensor (KS) system is used in order to

control spark knock. The KS system is designed to
retard spark timing up to 20 degrees in order to reduce
spark knock in the engine. This allows the engine to
use maximum spark advance to improve driveability
and fuel economy.
Engine
6-1945
The knock sensor system is used to detect engine

detonation. The knock sensors produce an AC voltage
which is sent to the PCM. The PCM retards the
spark timing based on signals from the KS sensors.
The amount of AC voltage produced by the sensors is
determined by the amount of knock. The PCM then
adjusts the Ignition Control (IC) to reduce the
spark knock.
The VSS produces an AC voltage signal that increases

with vehicle speed. The PCM processes this signal
and sends it to the following components:
Instrument Panel
Radio control head
Chime Module
A/C Request Signal
Crankshaft Position Sensor (CKP)
The A/C request circuit signals the PCM when an A/C

mode is selected at the A/C control head. The
PCM uses this information in order to enable the A/C
compressor clutch and to adjust the idle speed
before turning ON the A/C clutch. The PCM disables
the A/C compressor clutch if the A/C request signal
is not available to the PCM.

This signal is used by the PCM in order to control the
cycling of the compressor. It will also enable the
cooling fans when the A/C compressor head pressure
reaches a predetermined value. DTC P0530 sets if
a fault is present in the A/C refrigerant pressure sensor
circuit The PCM disables the A/C compressor
clutch when the PCM sets an A/C system DTC.
Vehicle Speed Sensor (VSS)
55322
...
...._f)
..
The crankshaft position sensor provides the PCM with

crankshaft speed and crankshaft position. The PCM
utilizes this information in order to determine if an
engine misfire is present. The PCM monitors the CKP
sensor for momentarily drop in crankshaft speed in
order to determine if a misfire is occurring. A
DTC P0300 sets when the PCM detects a misfire.
The PCM also monitors the CKP sensor signal circuit
for malfunctions. The PCM sets a DTC P0335 or a
DTC P0336 when the CKP sensor is out of the normal
operating range.
-....
'--
13640
The Vehicle Speed Sensor (VSS) is a pulse counter

type input that informs the PCM how fast the vehicle is
traveling. The VSS system uses an inductive sensor
mounted in the tail housing of the transmission
and a toothed reluctor wheel on the tail shaft. The
teeth of the reluctor wheel alternately interfere with the
magnetic field of the sensor creating an induced
voltage pulse as the reluctor rotates.
6-1946
Engine
Engine Co.ntrols - 5.7l

Description
Camshaft Position Sensor (CMP)
55308

cover and works in conjunction with a 1X reluctor
wheel on the camshaft. The reluctor wheel is inside
the engine immediately in front of the rear cam
bearing. The PCM provides a 12 volt power supply to
the CMP sensor as well as a ground and a signal
circuit.
The PCM uses the Camshaft Position sensor in order
to determine whether a cylinder .is on a firing or
exhaust stroke. The reluctor wheel interrupts a
magnetic field produced by a magnet within the CMP
sensor as the camshaft rotates. The CMP sensor's
internal circuitry detects this and produces a
signal which is the PCM reads. The PCM uses this 1X
signal in combination with the Crankshaft Position
sensor 24X signal in order to determine the crankshaft
position and stroke. This diagnostic for the Camshaft
Position sensor checks for a loss of Camshaft Position
sensor signal. The PCM also monitors the CMP
sensor signal circuit for malfunctions. The following
OTCs set when the PCM detects a CMP sensor that is
out of the normal operating range.
" OTC P0341 Camshaft Position Sensor (CMP)
Circuit Performance.
" DTC P0342 Camshaft Position Sensor (CMP)
Circuit Low Voltage.
.. OTC P0343 Camshaft Position Sensor (CMP)
In order to improve engine operation, and protect the

A/C compressor and A/C clutch during Wide Open
Throttle (WOT) performance, the A/C compressor
operation is controlled by the PCM.
This A/C system consists of the following components:
The heater and A/C control
.. The A/C clutch relay
The A/C compressor clutch
The PCM
When the heater and A/C control is placed in the A/C
mode, a request signal is sent to the PCM. The
PCM then energizes the A/C clutch relay, unless
abnormally high or low A/C pressure is detected by the
A/C refrigerant pressure sensor. The PCM also
turns the cooling fans ON when A/C is requested. The
A/C clutch relay is controlled by the PCM so that
the PCM can increase idle speed before turning ON
the A/C compressor clutch or disable .the A/C
compressor clutch during WOT, or high coolant
temperature.
The PCM energizes the A/C clutch whenever the
engine is running less than 3950 RPM and A/C has
been requested. The PCM will not energize the
A/C clutch whenever any of the following conditions
are present:
" Throttle Angle greater than 86 percent.
A/C head pressure greater than 414 psi or less
than O psi (as determined by the A/C refrigerant
pressure sensor). The PCM re-enables the
A/C system when the A/C high side pressure is
less than 249 psi.
Ignition voltage less than 10 volts.
Engine speed greater than 4294 RPM.
.. ECT greater than 125C (257F). The PCM
re-enables the A/C at 121 C (250F).
The scan tool is used in diagnosing the A/C system.
The PCM has the ability to display the foUowing
parameters:
" A/C request input to the PCM
A/C compressor status
" A/C system refrigerant pressure
" A/C clutch ON or OFF status
Engine
Engine Cooling Fan Description - Electric
The electric cooling fans are used to cool engine
coolant flowing through the radiator. The fans are also
used ro cool the refrigerant flowing through the A/C
condenser.
The electric cooling fans are controlled by the PCM.
The PCM controls the ground path for the three cooling
fan relays. The relays are used to control the high
current flow to power the cooling fan motors. Both fans
operate together. When minimum cooling is required,
the PCM energizes cooling fan relay #1 and both
fans operate at low speed, since the fans are
connected in series through cooling fan relay #3.
Cooling fan relay #2 is open (not energized) and is not
used for low speed operation of the fans. When
maximum cooling is required, the PCM energizes all
three cooling fan relays. The left fan is still powered
through cooling fan relay #1, but is now grounded
through cooling fan relay #3. The right fan is
now powered directly through cooling fan relay #2 and
both fans operated at high speed.
The PCM will also enable the cooling fans after the
ignition is turned off. When the engine coolant
temperature exceeds 113C (235F) and the ignition is
turned off, the cooling fans will be enabled on low
speed for 150 seconds.
Low Speed Cooling Fans

The low speed cooling fans are controlled by the PCM
based on the following inputs:
The A/C system.
The Engine Coolant Temperature (ECT) sensor.
The Vehicle Speed Sensor (VSS).
The PCM will turn the cooling fans on low speed when
any of the following conditions exist at idle:
Certain PCM Diagnostic Trouble Codes (DTCs)
are set.
The ECT above 108C (226F).
The A/C high side pressure above 215 psi.
Once the low speed fans are turned ON by Engine
Coolant Temperature, the PCM will turn the fans OFF
when that temperature has dropped about 4C (7F).
If the low speed cooling fans are turned ON by
high A/C head pressure, the PCM will turn the fans
OFF when the pressure has dropped to 190 psi.
The minimum ON time for the low speed cooling fans
is 50 seconds.
The cooling fans are turned OFF at certain vehicle
speeds. Adequate airflow through the A/C condenser
and radiator occurs with vehicle movement to
properly cool the A/C refrigerant and engine coolant
without the assistance of the cooling fans.
High Speed Cooling Fans

The High Speed Cooling Fans are controlled by the
PCM based on the following inputs:
The A/C system.
.. The Engine Coolant Temperature (ECT) sensor.
The Vehicle Speed Sensor (VSS).
6-1947
The PCM will enable both fans on high speed when

any of the following conditions exist:
Certain PCM Diagnostic Trouble Codes

(DTCs) set.
The ECT above 112C (234F).
.. The A/C high side pressure above 248 psi.
Once the high speed cooling fans are turned ON by
the Engine coolant temperature, the PCM will turn the
fans OFF when that temperature has dropped about
4C (7F). If the high speed cooling fans are turned ON
by high A/C head pressure, the PCM will turn the
fans OFF when the pressure has dropped to 208 psi.
The minimum ON time for the high speed cooling
fans is 30 seconds.
Fuel Supply Component Description

System Overview
pump, located in the fuel tank with the fuel sender
assembly, pumps fuel through an in-line fuel filter to
the fuel rail assembly. The pump provides fuel at
a pressure greater than is needed by the injectors. The
fuel pressure regulator, part of the fuel sender
assembly, keeps fuel available to the injectors at a
regulated pressure. A separate pipe returns unused
fuel to the fuel tank.
Fuel Tank
376993
The fuel tank stores the fuel supply. The fuel tank is
located in the rear of the vehicle. The fuel tank is held
in place by two metal straps that attach to the frame.
The fuel tank is molded from high density polyethylene.
Fuel Tank Filler Pipe

The fuel tank filler pipe has a built-in restrictor and
deflector in order to prevent refueling with leaded fuel.
6-1948
Engine Controls.- 5.7l
Engine
Fuel Filler Cap
The fuel pump and reservoir assembly (3).

e The fuel pressure regulator (2).
" The fuel pump strainer (4).
Fuel Sender
173450
Notice: If a fuel tank filler cap requires replacement,

use only a fuel tank filler cap with the same features.
Failure to use the correct fuel tank filler cap can
result in a serious malfunction of the fuel and EVAP
system.
The fuel tank filler pipe has a tethered fuel filler cap.
The cap requires a quarter of a turn to remove it.
A torque-limiting device prevents the cap from being
over tightened. To install the cap, turn the cap
clockwise until you hear three audible clicks. This
indicates that the cap is correctly torqued and
fully seated.
370964
The fuel sender consists of a float (5), a wire float

arm (6), and a fuel level sensor (7). The position of the
float arm indicates the fuel level and a signal is sent
to the display in the vehicle instrument cluster,
The EVAP pipe of the fuel sender has a pressed in
roll-over valve. The roll-over valve prevents fuel
from entering the evaporative emission canister if the
vehicle rolls over by shutting OFF the EVAP pipe
to the canister.
Fuel Pump
The fuel pump is rnounted inside the fuel reservoir on

the fuel sender. The fuel pump is an electric high
pressure gerotor pump. The fuel pump pumps fuel to
the fuel rail assembly at a specified flow and
pressure. Excess fuel returns to the fuel tank by the
return pipe. The fuel pump delivers a constant flow of
fuel to the engine even during low fuel conditions
and aggressive vehicle maneuvers. The PCM controls
the electric fuel pump operation through a fuel
pump relay: The fuel pump flex pipe acts to dampen
the fuel pulses and noise generated by the fuel pump.
Fuel Pressure Regulator Assembly
370964
The fuel sender assembly is inside the fuel tank

attached to the top of the fuel tank. The fuel sender
assembly consists of the following major components:
The fuel level sensor (7).
The fuel tank pressure sensor (1 ).
The fuel pressure regulator attaches to the fuel return

pipe on the fuel sender assembly. The fuel pressure
regulator is a diaphragm operated relief valve. A
software bias compensates the injector on-time
because the fuel pressure regulator is not referenced
to manifold vacuum. The injector pulse width varies
with the signal from the MAP sensor. With the ignition
ON and the engine OFF, system fuel pressure at
the pressure test connection should be
380-410 kPa (55-60 psi). if the pressure is too low,
poor performance could result. If the pressure is
too high, excessive odor and a Diagnostic Trouble
Code (OTC) P0132, P0152, P0172 or P0175
may result. Refer to Fuel System Diagnosis for
information on diagnosing fuel pressure conditions.
Engine Controls - 5]l
Engine
Fuel Pump Strainer
The fuel pump strainer attaches to the lower end of

the fuel pump and reservoir assembly. The fuel pump
strainer is made of woven plastic. The functions of
the fuel pump strainer are to filter contaminants and to
wick fuel. The fuel pump strainer is self-cleaning
and normally requires no maintenance. Fuel stoppage
at this point indicates that the fuel tank contains an
abnormal amount of sediment or water. Clean the fuel
tank and replace a plugged fuel pump strainer with
a new one.
The chassis fuel pipes are located under the

vehicle. The chassis fuel feed pipe connects
the rear fuel feed pipe to the engine compartment
connecting fuel feed pipe. The chassis fuel
return pipe connects the fuel feed pipe at the
outlet of the fuel filter to the rear fuel return pipe.
These pipes are constructed of steel.
.. The engine compartment connecting fuel pipe
connects the chassis fuel feed pipe to the
engine fuel rail. This fuel pipe is constructed
of nylon.
Nylon Fuel Pipes
In-Line Fuel Filter

2
)
12628
The fuel feed pipe has a steel fuel filter installed

ahead of the fuel injection system. The paper filter
element (2) traps particles in the fuel that may damage
the injectfon system. The filter housing (1) is made
to withstand maximum fuel system pressure, exposure
to fuel additives, and changes in temperature. The
fuel filter has a quick-connect inlet fitting and a
threaded outlet fitting. The threaded fitting is sealed
with an 0-ring. There is no service interval for fuel filter
replacement. Replace a restricted fuel filter.
Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the
fuel rail assembly. The fuel return pipe carries fuel
from the T-connector located on the outlet side of the
fuel filter back to the fuel tank. The fuel pipes
consist of three sections:
lhe rear fuel pipe assemblies are located from
the top of the fuel tank to the chassis fuel
pipes. The rear fuel pipes are constructed of nylon.
6-1949

Personal Injury:
s If nylon fuel pipes are nicked, scratched or
damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new fuel plpes, Do Not
hammer directly on the fuel harness body clips
as it may damage the nylon pipes resulting
in a possible fuel leak.
towel before using a torch near them. Also,
higher than 115C (239F) for more than
extended period.
Before connecting fuel pipe fittings, always
reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings
located in the female connector will swell and
lubricated.)
Nylon fuel pipes are designed to perform the same job
as the steel or flexible fuel pipes or hoses that they
replace. Nylon pipes are constructed to withstand
maximum fuel system pressure, exposure to
fuel additives, and changes in temperature. There are
three sizes of nylon pipes used: 3/8 in ID for the
fuel feed, 5/16 in ID for the fuel return, and 1/2 in ID
for the vent. Heat resistant rubber hose and/or
corrugated plastic conduit protect the sections of the
pipes that are exposed to chafing, high temperature or
vibration.
Nylon fuel pipes are somewhat flexible and can be
formed around gradual turns under the vehicle.
However, if nylon fuel pipes are forced into sharp
bends, the pipes will kink and restrict the fuel
flow. Also, once exposed to fuel, nylon pipes may
become stiffer and are more likely to kink if bent too
far. Take special care when working on a vehicle with
nylon fuel pipes.
6-1950
Engine
Quick-Connect Fittings
Quick-connect fiUings provide a simplified means of
installing and connecting fuel system components. The
fittings consist of a unique female connector and a
compatible male pipe end. 0-rings, located inside the
female connector, provide the fuel seal. Integral
locking tabs or fingers hold the fittings together.
On-Board Refueling Vapor Recovery

System {ORVR)
(
1
Fuel Pipe 0-Rings

0-rings seal the threaded connections in the fuel
system. Fuel system 0-ring seals are made of special
material. Service the 0-ring seals with the correct
service part.
EVAP Pipes and Hoses

The EVAP pipes extend from the fuel sender assembly
and the EVAP canister vent solenoid to the EVAP
canister. These pipes are located on top of the
fuel tank. The EVAP purge pipe extends from the
EVAP canister on top of the fuel tank to the EVAP
purge solenoid in the engine compartment. The rear
pipes and the engine compartment pipe are
constructed of nylon. The chassis EVAP purge pipe is
constructed of steel. The EVAP canister vent
solenoid connects to the EVAP canister with a section
of rubber hose.
Enhanced Evaporative Emission (EVAP)

Service Port
6
5
178033
The On-Board Refueling Vapor Recovery

System (ORVR) is an on board vehicle system
designed to recover fuel vapors during the vehicle
refueling operation. The flow of liquid fuel down
the fuel filler pipe provides a liquid seal which prevents
vapor from leaving the fuel filler pipe. An EVAP pipe
transports the fuel vapor to the EVAP canister for
use by the engine. Listed below are the ORVR system
components with a brief description of their operation:
EVAP Canister (1) - the EVAP canister receives
refueling vapor from the fuel system, stores the
vapor and releases the vapor to the engine
upon demand.
EVAP Pipes (2) - transports fuel vapor from the
fuel tank to the EVAP canister.
Fuel Filler Pipe (3) - the pipe which carries fuel
from the fuel nozzle to the fuel tank.
Check Valve (4) - the check valve limits fuel "spit
back" from the fuel tank during the refueling
operation by allowing fuel flow only into the fuel
tank. This check valve is located at the bottom of
the fuel filler pipe.
Modular Fuel Sender Assembly (5) - this
assembly pumps fuel to the engine from
the fuel tank.
21046
The enhanced EVAP service port is located in the

EVAP pipe in the engine compartment near the purge
solenoid. The service port is identified by a green
colored cap. The port contains a schrader valve and a
fitting to allow the connection of the J 41413 EVAP
Pressure/Purge Diagnostic Station for diagnosis of the
evaporative emission system.
Engine
Fill Limiter Vent Valve (FLVV) (6) - this valve
acts as a shut off valve. The FLVV is located
on the top of the fuel tank. This valve is not
serviced separately. The FLVV has the following
functions:
- Controls the fuel tank fill level by closing the

primary vent from the fuel tank.
- Prevents fuel from exiting the fuel tank via
the EV AP pipe to the canister.
. - Provides fuel-spillage protection in the event
of a vehicle rollover by closing the vapor
path from the tank to the EVAP canister.
" Over Pressure ReliefValve (7) - the over
pressure relief valve provides venting of excessive
fuel tank pressure. The valve is located on top
of the fuel tank next to the FLVV. This valve is not
serviced separately.
Fuel Metering Modes of Operation

Modes of Operation
The PCM looks at voltages from several sensors to
determine how much fuel to give the engine. The fuel
is delivered under one of several conditions called
modes. The PCM controls all modes.
Starting Mode
With the ignition switch in the ON position (before

engaging the starter), the PCM energizes the
fuel pump relay for two seconds allowing the fuel
pump to build up pressure. The PCM first checks
speed density, then switches to the Mass Air
Flow (MAF) sensor. The PCM also uses the Engine
Coolant Temperature (ECT), Throttle Position (TP),
and Manifold Absolute Pressure (MAP) sensors
to determine the proper air/fuel ratio for starting. This
ranges from 1.5:1 at -36C (-33F) to 14.7:1 at
94C (201 F) running temperature. The PCM controls
the amount of fuel delivered in the starting mode
by changing the pulse width of the injectors. This is
done by pulsing the injectors for very short times.
Clear Flood Mode

If the engine floods, clear the engine by pushing the
accelerator pedal down all the way. The PCM
then pulses the injectors at an air/fuel ratio of 20:1.
The PCM holds this injector rate as long as the throttle
stays wide open and the engine speed is below
300 RPM. If the throttle position becomes less than
80 percent, the PCM returns to the starting mode.
6-1951
Run Mode
The run mode has two conditions called Open Loop
and Closed Loop. When the engine is first started, and
engine speed is above a predetermined RPM, the
system begins Open Loop operation. The PCM jgnores
the signal from the H02S and calculates the air/fuel
ratio based on input~ from the ECT, MAF, MAP,
and TP sensors. The system stays in Open Loop until
meeting the following conditions:
Both H02S have varying voltage output, showing
that they are hot enough to operate properly.
(This depends on temperature.)
e The ECT sensor is above a specified temperature.
0
A specific amount of time has elapsed after
starting the engine.
Specific values for the above conditions exist for each
different engine, and are stored in the Electrically
Erasable Programmable Read Only
Memory (EEPROM). The system begins Closed Loop
operation after reaching these values. In Closed
Loop, the PCM calculates the air/fuel ratio (injector
on-time) based on the signal from various sensors, but
mainly the H02S. This allows the air/fuel ratio to
stay very close to 14. 7: 1.
Acceleration Mode
When the driver pushes on the accelerator pedal, air
flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, the PCM increases the pulse width to the
injectors to provide extra fuel during acceleration.
The PCM determines the amount of fuel required
based on throttle position, coolant temperature,
manifold air pressure, mass air flow and engine speed.
Deceleration Mode
When the driver releases the accelerator pedal, air
flow into the engine is reduced. The PCM looks at the
corresponding changes in throttle position, manifold
air pressure and mass air flow. The PCM shuts
OFF fuel completely if the deceleration is very rapid,
or for long periods (such as long closed throttle
coast-down). The fuel shuts OFF in order to protect
the warm-up three-way catalytic converters.
Battery Voltage Correction Mode

When battery voltage is low, the PCM compensates
for the weak spark delivered by the ignition system in
the following ways:
Increasing the amount of fuel delivered.
" Increasing the idle RPM.
.. Increasing ignition dwell time.
Fuel Cutoff Mode

To prevent possible engine damage from over-speed,
the PCM cuts off fuel from the injectors when the
engine speed is above approximately 5800 RPM. Also,
see Rapid Deceleration in Deceleration Mode.
6-1952
Engine
Fuel Injectors

Description
The fuel metering system consists of the
following parts:
The fuel supply components (fuel tank, pump,
pipes).
The fuel pump electrical circuit.
.. The fuel rail.
The fuel injectors.
" The fuel pressure regulator.
The throttle body.
The Idle Air Control (IAC) valve.
The Throttle Position (TP) sensor.
System Overview
pump, located in the fuel tank with the fuel sender
assembly, pumps fuel through an in-line fuel filter to
the fuel rail assembly. The pump provides fuel at
a pressure greater than is needed by the injectors. The
fuel pressure regulator, part of the fuel sender
assembly, keeps fuel available to the injectors at a
regulated pressure. A separate pipe returns unused
fuel to the fuel tank.
The top-feed fuel injector assembly is a solenoid

operated device, controlled by the PCM, that me1ers
pressurized fuel to a single engine cylinder. The
PCM energizes the injector solenoid, which opens a
ball valve, allowing fuel to flow past the ball valve, and
through a recessed flow director plate. The direc1or
plate has multiple machined holes that control the fuel
flow, generating a conical spray pattern of finely
atomized fuel at the injector tip. Fuel is directed at the
intake valve, causing it to become further atomized
and vaporized before entering the combustion
chamber. An injector stuck partly open can cause a
loss of pressure after engine shutdown. Consequently,
long cranking times would be noticed on some
engines.
Fuel Pulse Dampener
Fuel Pump Electrical Circuit

When the ignition switch is in the ON position (before
engaging the starter), the PCM energizes the fuel
pump relay for two seconds, causing the fuel pump to
pressurize the fuel system. If the PCM does not
receive ignition reference pulses (engine cranking or
running) within two seconds, it shuts OFF the fuel
pump relay, causing the fuel pump to stop.
Fuel Rail Assembly

1
216234
The fuel pulse dampener attaches inside a housing on

the fuel rail assembly. The fuel pulse dampener is
diaphragm operated, with fuel pump pressure
on one side and spring pressure on the other side.
The function of the dampener is to dampen fuel
pulsation.
Accelerator Controls
The accelerator control system is cable operated.
There are no linkage adjustments, therefore use the
specific cable for each application.
217109
The fuel rail assembly attaches to the engine .intake

manifold. The fuel rail assembly performs the following
functions:
" It positions the injectors (1) in the intake manifold.
" It distributes fuel evenly to the injectors.
" It integrates the fuel pulse dampener (2) into the
fuel metering system.
Engine
Throttle Body Assembly
2
216232
The throttle body assembly attaches to the intake

manifold. The throttle body controls air flow into the
engine, thereby controlling engine output. The vehicle
operator opens the throttle valve within the throttle
body through the accelerator controls. During engine
idle, the throttle valves are almost closed. A fixed
air bypass orifice and the Idle Air Control (IAC)
valve (2) handle the air flow control. Engine coolant
flows through the coolant cavity on the bottom of
the throttle body in order to prevent throttle valve icing
during cool weather operation. The throttle body
also provides the location for mounting the Throttle
Position (TP) sensor ( 1).
6-1953
pintle (3), in, towards the seat (to decrease air flow);
or out, away from the seat (to increase air flow), a
controlled amount of air can be bypassed. If engine
speed is too low, more air is bypassed to increase
RPM. If engine speed is too high, less air is bypassed
to decrease RPM. The PCM moves the IAC valve
in small steps, called counts. These can be measured
and displayed by a scan tool, which plugs into the
Data Link Connector (DLC). The PCM calculates the
proper position of the IAC valve during idle based
on battery voltage, coolant temperature, engine load,
and engine RPM. If the RPM drops below specification
and the throttle valve is closed, the PCM senses a
near stall condition and calculates a new valve position
in order to prevent stalling.
Engine idle speed is a function of total air flow
into the engine. Idle speed is based on IAC
valve pintle position + crankcase ventilation valve
flow + throttle valve opening + bypass orifice
air flow + calibrated vacuum loss through
accessories.
Controlled idle speed is programmed into the
PCM, which determines the correct IAC valve
pintle position to maintain the desired idle speed
tor all engine operating conditions and loads.
The minimum idle air rate is set at the factory with
a stop screw. This setting allows enough air flow
by the throttle valves to cause the IAC valve
pintle to be positioned a calibrated number
of steps (counts), from the seat, during controlled
idle operation.
If the IAC valve is disconnected and reconnected
with the engine running, the idle speed may be
wrong. If this occurs, reset the IAC valve by
depressing the accelerator pedal slightly, start and
run the engine tor five seconds, then turn the
ignition OFF for ten seconds.

The TP sensor attaches to the side of the throttle
body opposite the throttle lever. It senses the throttle
valve angle and relays that information to the
PCM. The PCM requires knowledge of throttle angle
to generate the required injector control signals
(pulses).
Short Term Fuel Trim Description
ao
3
2
OO..__ _ _ ___,
10172
The purpose of the IAC valve is to control engine idle

speed, while preventing stalls due to changes in
engine load. The IAC valve (1 ), mounted in the throttle
body, controls the bypass air around the throttle
valve (2). By moving a conical valve known as a
The short term fuel trim (FT) is a PCM erasable

memory register. The neutral value tor the short term
FT is O percent. Any deviation from O percent
indicates the short term FT is changing the injector
pulse width. The amount of pulse width change
depends on how far the short term fuel trim value is
from O percent. The short term FT is rich when
the scan tool indicates a negative number. The short
FT is lean when the scan tool indicates a number
greater than 0. The short term FT changes the injector
pulse width by adding to or subtracting from the
base pulse width equation. As the PCM monitors the
oxygen sensors input, it is constantly varying the
short term FT value. The value is updated very quickly,
therefore the short term FT only corrects for short
term mixture trends. The correction of long term
mixture trends is the function of long term FT.
6-1954
Engine Controls
Engine
5.7L
When the PCM determines that the short term FT is

out of the operating range, 1 of the following DTCs
will set:
DTC P0171 FT System Lean Bank 1
DTC P0172 FT System Rich Bank 1
DTC P0174 FT System Lea.n Bank 2
Long Term Fuel Trim Description

The long term fuel trim (FT) is a matrix of cells
arranged by RPM and MAP. Each cell of the long
term FT is a register like the short term FT. As
the engine operating conditions change, the PCM will
switch from cell to cell to determine what long term
FT factor to use in the base pulse width equation.
While in any given cell, the PCM also monitors
the short term FT. If the short term FT is far enough
from O percent, the PCM will change the long term FT
value. Once the long term FT value is changed, it
should force the short term FT back toward O percent.
If the mixture is still not correct (as judged by the
PCM), the short term FT will continue to have a large
deviation from the ideal O percent In this case, the
long term FT value will continue to change until
the short term FT becomes balanced. Both the short
term FT and long term FT have limits which vary
by calibration. If the mixture is off enough so that long
term FT reaches the limit of its control and still
cannot correct the condition, the short term FT would
also go to its limit of control in the same direction.
If the mixture is still not corrected by both short term
FT and long term FT at their extreme values, a
FT DTC will likely result. When the PCM determines
that the long term FT is out of the operating range, the
following DTCs will set:
Under the conditions of power enrichment, the PCM
sets the short term FT to O percent and freezes it there
until power enrichment is no longer in effect. This is
done so the Closed Loop factor and the long term FT
will not try to correct for the commanded richness
of power enrichment.
works in conjunction with the MAP sensor to determine

air density. As the intake manifold pressure increases,
the air density in the intake manifold also increases
and additional fuel is required. This information
from the IAT and MAP sensors is used by the PCM to
control injector pulse width.

Description
II
~L.. ~.::.::..-:._-_-_-_-_=:L _- _J _L _J
Speed Density System Description

The speed density system is only needed when there
is a mass air flow (MAF) sensor malfunction. If the
PCM detects a malfunction with the MAF sensor
circuit, the PCM will default to speed density fuel
management.
Three sensors provide the PCM with the basic
information for the fuel management portion of its
operation. That is, 3 specific signals to the PCM
establish the engine speed and air density factors.
The engine speed signal comes from the ignition
system. Air density is derived from IAT and MAP
sensor inputs. The IAT sensor measures the air
temperature that is entering the engine. The IAT signal
12722
Legend
(1) Purge Line
(2) Vapor From Fuel Tank
(3) Air
The Evaporative Emission (EV AP) Control system
used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the fuel
tank to an activated carbon (charcoal) storage
device (canister) to hold the vapors when the vehicle
is not operating.
Engine
When the engine is operating, the fuel vapor is purged

from the carbon element by intake air flow and
consumed in the normal combustion process.
EVAP Canister
1
6-1955
EVAP System
The evaporative system includes the following
components:
Fuel tank
O Evaporative emission canister vent solenoid
Fuel tank pressure sensor
Fuel pipes and hoses
Vapor lines
Fuel cap
Evaporative emission canister
Purge lines
Purge valve solenoid
EVAP System Operation

@
@
1)
-0,
\I
@
@
AIR FLOW FROM

AIR SEPARATOR
m+,
218763
The EV AP purge solenoid valve allows manifold

vacuum to purge the canister. The Powertrain Control
Module (PCM) supplies a ground to energize the
EVAP purge solenoid valve (purge on). The EVAP
purge solenoid control is Pulse Width
Modulated (PWM) or turned on and oft
several times a second.
FUEL VAPOR
- - . PURGED VAPOR
11795
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Purge Tube to Solenoid

Butter Tube
Charcoal Bed
EVAP Charcoal Canister
Volume Compensator
Fresh Air Inlet from Air Separator
Liquid Fuel Trap
Vapor Tube from Fuel Tank
6-1956
Engine
The fuel level sensor input to the PCM is used to
determine if the fuel level in the tank is correct to run
the EVAP diagnostic tests. To ensure sufficient
volume in the tank to begin the various diagnostic
tests, the fuel level must be between 15 and
85 percent.
The PCM monitors the fuel tank pressure/vacuum
level via the fuel tank pressure sensor input.
Results of Incorrect Operation
18839
The EVAP canister purge PWM duty cycle varies

according to the operating conditions determined by
the mass air flow, the fuel trim, the engine coolant
temperature, and the intake air temperature. For
certain EVAP tests, the diagnostic will be disabled if
the TP angle increases to above 75 percent.
The evaporative leak detection diagnostic strategy is
and monitoring for vacuum decay.
Poor idle, stalling and poor driveability can be

caused by the following:
- Malfunctioning purge solenoid.
- Damaged canister.
- Hoses/lines split, cracked and/or not
connected properly.
Evidence of fuel loss or fuel vapor odor can be
caused by the following:
- Liquid fuel leaking from the fuel lines
- Cracked or damaged canister
- Inoperative canister control valve
- Vacuum hoses that are:
- Disconnected
- Mis-routed
- Kinked
- Deteriorated
- Damaged
Engine
6-1957
Fuel Tank Assembly with EVAP Canister
421732
Legend
(1)
(2)
(3)
(4)

Hose (EVAP Canister to Vent Solenoid)
EVAP Vent Valve
Fuel Tank Harness
The evaporative leak d<3tection diagnostic strategy is

and monitoring vacuum decay.
The PCM monitors vacuum level via the fuel tank
pressure sensor input. At an appropriate time,
the EVAP purge solenoid and the EVAP vent solenoid
are turned on, allowing engine vacuum to draw a
small vacuum on the entire evaporative emission
system. After the desired vacuum level has been
achieved, the EV AP purge solenoid is turned
off, sealing the system. A le.ak is detected by
monitoring for a decrease in vacuum level over a
given time period, all other variables remaining
constant. A small leak in the system causes
DTC P0442 to be set.
(5)
(6)
(7)
(8)
EVAP Canister
Fuel Tank
Overpressure Relief Valve
If the desired vacuum level cannot be achieved in the

test described above, a large leak or a faulty EV AP
purge solenoid is indicated. This can be caused by the
Disconnected or faulty fuel tank pressure sensor.
Mi$sing or faulty fuel cap.
Disconnected, damaged, pinched, or blocked
EVAP purge line.
Disconnected or damaged EVAP vent hose,
Disconnected, damaged, pinched, or blocked fuel
tank vapor line.
Disconnected or faulty EVAP canister solenoid.
Disconnected or faulty EVAP vent solenoid.
Open ignition teed circuit to the EV AP vent or
purge solenoid.
Damaged EVAP canister.
Any of the above conditions sets OTC P0440.
6-1958
A restricted or blocked EV AP canister vent path is

detected by drawing vacuum into the EVAP system.
The PCM turns off the EVAP vent solenoid and
the EVAP purge solenoid (EVAP vent solenoid Open,
EVAP purge PWM O percent). The PCM monitors
the fuel tank pressure sensor input. With the EVAP
vent solenoid open, any vacuum in the system should
decrease quickly unless the vent is blocked. A
blockage is caused by the following conditions:
Faulty EVAP vent solenoid (stuck closed).
Plugged, kinked, or pinched vent hose.
Shorted EVAP vent solenoid driver circuit.
Plugged evaporative canister.
If any of the above conditions are present,
OTC P0446 sets.
The PCM checks for conditions that cause the EVAP
system to purge continuously by commanding the
EVAP vent solenoid on and the EV AP purge solenoid
off (EVAP vent solenoid CLOSED, EVAP purge
PWM O percent). If fuel tank pressure level increases
during the test, a continuous purge flow condition
is indicated. This can be caused by the following
conditions:
EVAP purge solenoid leaking.
EVAP purge and engine vacuum source lines
switched at the EVAP purge solenoid.
EVAP purge solenoid driver circuit grounded.
If any of the above conditions are present,
OTC P1441 sets.
Refer to the appropriate DTCs for further diagnostic
procedures regarding the EVAP system.
Visual Check of Evaporative Emission

Canister
Cracked or damaged, replace the canister.
Fuel leaking from the canister, replace canister
and check lines and line routing.
Electronic Ignition (El) System Description

Ignition System Overview
advance of the ignition system. The Electronic ignition
system has the following advantages over a
mechanical distributor system:
No moving parts.
Less maintenance.
Remote mounting capability.
" No mechanical load on the engine.
More coil cool down time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation time.
Engine
The electronic ignition system does not use the
conventional distributor and coil. The ignition system
consists of the following components/circuits:
" Eight ignition coils/modules
Eight Ignition Control (IC) circuits
Camshaft Position (CMP) sensor
1X Camshaft reluctor wheel
~ Crankshaft Position (CKP) sensor
24X Crankshaft reluctor wheel
Related connecting wires
Crankshaft Position Sensor and

Reluctor Wheel
65872
The Crankshaft Position (CKP) sensor is located in the

right rear of the engine, behind the starter. The CKP
sensor is a dual magneto resistive type sensor.
This sensor is not speed dependent. The dual micro
switches monitor both notches of the reluctor wheel for
greater accuracy. The CKP sensor works in
conjunction with a 24X reluctor wheel. The reluctor
wheel is mounted on the rear of the crankshaft.
The 24X reluctor wheel uses two different width
notches that are 15 degrees apart. This Pulse Width
Encoded pattern allows cylinder position identification
within 90 degrees of crankshaft rotation. In some
cases, cylinder identification can be located in
45 degrees of crankshaft rotation. This reluctor wheel
also has dual track notches that are 180 degrees
out of phase. The dual track design allows for quicker
starts and accuracy.
Engine
The PCM also receives a 4X signal from the

Crankshaft Position sensor. The PCM utilizes the
4X signal for the following:
Misfire
Tachometer output
Spark control
Fuel control
Certain diagnostics
synchronizatio11 and looks for an increase in engine
does. not detect an increase in engine speed, the PCM
stroke and re-synchronizes to the opposite cam
position. A slightly longer cranking time may be a
symptom qf this condition.
6-1959

all cylinders by using the Cranl<shaft Position sensor
stroke and re-synchronizes to the opposite cam
position. A slightly longer cranking time may be a
symptom of this condition.
Ignition Coils/Module
211648
55308
The Camshaft Position (CMP) sensor is mounted

through the top of the engine block at the rear of the
valley cover. The CMP sensor works in conjunction
with a 1X reluctor wheel on the camshaft. The
CMP sensor is used to determine whether a cylinder
is on the firing or the exhaust stroke. As the
sensor. The CMP sensor internal circuitry detect.s this
and produces a signal which is used by the PCM.
The PCM uses this signal in combination with the CKP
24X signal to determine crankshaft position and
stroke.
The ignition system on this vehicle features a multiple

coil ignition and is known as coil near plug. The
secondary ignition wires are short compared with a
distributor ignition system wire. Eight ignition
coils/modules are individually mounted above each
cylinder on the rocker covers. The coils/modules
are fired sequentially. There is an Ignition Control (IC)
circuit for each ignition coil/module. The eight ignition
control circuits are connected to the PCM. All
ignition timing decisions are made by the PCM, which
triggers each coil/module individually. The ignition
coil/modules are supplied with the following circuits:
Ignition feed circuit
Ignition control circuit
Ground circuit
Reference low circuit
6-1960
Engine

Ignition Information
65292
The ignition feed circuits are fused separately for each

bank of the engine. The two fuses also supply
power to the injectors for that bank of the engine.
Each coil/module is serviced separately.
This system puts out very high ignition energy for plug
firing. The ignition wires are shorter so less energy
is lost to ignition wire resistance. Also, since the firing
is sequential, each coil has seven ignition events to
saturate as opposed to the three in a waste spark
arrangement. Futhermore, no energy is lost to
the resistance of a waste spark system.
There are important considerations to point out whe'n

servicing the ignition system. The following
Noteworthy Information will list some of these to help
the technician in servicing the ignition system.
The ignition coils secondary voltage output
capabilities are very high - more than 40,000 volts.
Avoid body contact with secondary high voltage
ignition components when the engine is running,
or personal injury may result!
The 24X crankshaft position sensor is the most
critical part of the ignition system. If the sensor
is damaged so that pulses are not generated, the
engine will not start!
.. Crankshaft position sensor clearance is very
important! The sensor must not contact the
rotating interrupter ring at any time, or sensor
damage will result. If the interrupter ring is bent,
the interrupter ring blades will destroy the s.ensor.
Ignition timing is not adjustable. There are
no timing marks on the crankshaft balancer or
timing chain cover.
Be careful not to damage the secondary ignition
wires or boots when servicing the ignition
system. Rotate each boot to dislodge it from the
plug or coil tower before pulling it from either
a spark plug or the ignition coil. Never pierce a
secondary ignition wire or boot for any testing
purposes! Future problems are guaranteed
if pinpoints or test lights are pushed through the
insulation for testing.
Circuits Affecting Ignition Control
To properly control ignition timing, the PCM relies on

the following information:
Engine load (manifold pressure or vacuum)
Atmospheric (barometric) pressure
Engine temperature
Intake air temperature
Crankshaft position
Engine speed (RPM)
The Ignition Control (IC) system consists of the
Ignition coil/modules
24X crankshaft position sensor
All connecting wires
The Ignition Control utilizes the following to control
spark timing functions:
24X signal - The 24X crankshaft position sensor
sends a signal to the PCM. The PCM uses this
signal to determine crankshaft position. The PCM
also utilizes this signal to trigger the fuel
injectors.
Ignition Control (IC) circuits - The PCM uses these
circuits to trigger the ignition coil/modules. The
PCM uses the crankshaft reference signal
to calculate the amount of spark advance needed.
The PCM is responsible for maintaining proper spark

and fuel injection timing for all driving conditions.
To provide optimum driveability and emissions, the
PCM monitors input signals from the following
components to calculate Ignition Control (IC) spark
timing:
The Intake Air Temperature (IAT) sensor
The Mass Air Flow (MAF) sensor
.. The Knock Sensor
The Trans Range inputs from Transaxle Range
switch
The Throttle Position (TP) sensor
The Vehicle Speed Sensor (VSS)

An Ignition control circuit that is open, grounded, or
shorted to voltage will set an ignition control circuit
OTC. If a fault occurs in the IC output circuit when the
engine is running, the engine will experience a
misfire. OTCs P0351-P0358 will set when a
malfunction is detected with an Ignition Control circuit.
When an Ignition control OTC sets, the PCM
disables the injector for the appropriate cylinder.
(
.
Engine
The PCM uses information from the engine coolant

temperature sensor in addition to RPM to calculate
spark advance values as follows:
High RPM = more advance
Cold engine = more advance
Low RPM = less advance
Hot engine = less advance
Therefore, detonation could be caused by high
resistance in the engine coolant temperature sensor
circuit. Poor performance could be caused by low
resistance in the engine coolant temperature sensor
circuit.
If the engine cranks but will not run or immediately

stalls, the Engine Cranks But Will Not Run diagnostic
table must be used to determine if the failure is in
the ignition system or the fuel system. If DTC P0300,
P0341, P0342, P0343, P0335, P0336 is set, the
appropriate diagnostic trouble code table must be used
for diagnosis.
6-1961
To control spark knock, a Knock Sensor (KS) system

is used. This system is designed to retard spark
timing up to 20 degrees to reduce spark knock in the
engine. This allows the engine to use maximum
spark advance to improve driveability and fuel
economy.
The knock sensor system is used to detect engine
detonation. The knock sensor(s) produce an AC
voltage which is sent to the PCM. The PCM will retard
the spark timing based on signals from the KS
sensors. The amount of AC voltage produced by the
sensors is determined by the amount of knock.
The PCM then adjusts the Ignition Control (IC) to
reduce the spark knock.
Knock Sensor Cutaway
Knock Sensor (KS) System Description

Knock Sensor
'
13690
legend
(1) Shunt Resistor
(2) Piezo Crystal
13635
Varying octane levels in gasoline can cause detonation

in some engines. Detonation is sometimes called
spark knock. Detonation is caused by an uncontrolled
explosion (burn) in the combustion chamber. This
uncontrolled explosion could produce a flame
front opposite that of the normal flame front produced
by the spark plug. The rattling sound normally
associated with detonation is the result of two or more
opposing pressures (flame fronts) colliding within
the combustion chamber. Though light detonation is ,
sometimes considered normal, heavy detonation could
result in engine damage.
The scan tool has several positions for diagnosing the

KS circuit.
Knock Retard indicates the amount of spark the
PCM is removing from the IC spark advance in
response to the signal from the knock sensors.
Spark indicates the amount of spark advance
being commanded by the PCM on the IC circuit.
DTC P0325 indicates an internal PCM malfunction
related to the KS system. DTCs P0327 and
P0332 indicates that a Knock sensor or Knock sensor
circuit is malfunctioning. If these DTCs are set,
Refer to applicable DTC table.
6-1962
Secondary AIR Injection System

Description
The Secondary Air Injection (AIR) system helps
reduce Hydrocarbon (HC), Carbon Monoxide (CO),
and Oxides of Nitrogen (NOx) exhaust emissions.
It also heats up the 3-way catalytic converters quickly
on engine start-up so conversion of exhaust gases
can occur sooner.
Engine
AIR System (Typical)
AIR Solenoid Valve - The AIR Solenoid Valve is

located at the left rear of the intake manifold.
The AIR Solenoid Valve is controlled by the PCM.
The AIR Solenoid Valve controls the engine
vacuum to the AIR Shut Off Valve. The PCM
provides a ground circuit for the AIR Solenoid
Valve, which allows engine vacuum to be applied
to the AIR Shut Off Valve.
AIR Shut Off Valve - The AIR Shut Off Valve is
mounted to the rear of the left cylinder head.
The AIR Shut Off Valve controls the air flow from
the AIR pump to the check valves. The PCM
enables the AIR Solenoid Valve, which applies
engine vacuum to the AIR Shut Off Valve.
The applied engine vacuum opens the AIR Shut
Off Valve and allows air supplied by the AIR Pump
to flow to the check valves.
The system includes the following:

AIR pump - The AIR pump is mounted to the
lower left front of the engine Compartment
and supplies the air to the AIR system. The
electric air pump pressurizes fresh air and pumps
it to the AIR Shut Off Valve. The AIR pump is
controlled by the PCM. Battery voltage to the AIR
pump is controlled by the AIR pump relay.
When the PCM provides a ground circuit for the
secondary AIR pump relay, battery voltage is
allowed to power up the AIR pump.
4
605865
Legend
(1)
The AIR pump (7) is controlled by the PCM. The PCM

will turn ON the AIR pump by providing the ground
to complete the circuit which energizes the AIR pump
relay. When air to the exhaust ports is desired, the
PCM will turn ON the AIR Solenoid valve and then the
AIR pump.
The PCM turns ON the AIR pump during startup any
time engine coolant temperature is above -10c
(14F). The AIR pump operates for a maximum of
240 seconds, or until the system enters Closed Loop
operation. At the same time the PCM turns the
AIR pump OFF, it also de-energizes the AIR Solenoid .
Valve so no vacuum is applied to the AIR Shut Off
Valve (5).
Check valves - The check valves prev3nt back

flow of exhaust gases into the AIR system in
the event of an exhaust backfire.
Necessary plumbing.
- Hoses
- Pipes
- Clamps
Engine
The AIR system will be disabled under the following
conditions:
When the PCM recognizes a condition and sets a
diagnostic trouble code ..
When the fuel system is operating in Closed Loop.
e The AIR pump has been ON for 240 seconds.
Engine Speed is greater than 2825 RPM.
" MAP is greater than 96 kPa with VSS
over 60 mph.
MAP is less. than 20 kPa.
ECT less than -10C (14F).
3-way catalytic converters over temperature
detected.
Short and lohg term fuel trim are not in the
normal range.
Power enrichment is detected.
6-1963
EGR System Description

EGR Valve

If no air (oxygen) flow enters the .exhaust stream at
the exhaust ports, HC and CO emission levels will be
too high.
Air flowing to the exhaust ports at all times could
increase temperature of the 3-way catalytic converter.
Diagnostic Trouble Codes P0410, P0412, P1415,
and P1416 will set if there is a malfunction in
The AIR pump.
.. The AIR pump relay.
O The AIR shut oft valve.
Hoses or pipes that are leaking.
The Check valves that are leaking.
Circuits going to the AIR pump and the AIR
. pump relay.
" The AIR Solenoid Valve.

Circuits going to the AIR solenoid Vvalve.
AIR Pump
The AIR pump is a regenerative turbine type which is

permanently lubricated and requires no periodic
main1enance.
The engine should be at normal operating temperature
in neutral at idle. Using the scan tool enable the AIR
pump system. Select H02S voltages tor both
Bank 1 and Bank 2 H02S. The H02S voltages for
both sensors should remain under 350 mV because air
is being directed to the exhaust ports. It the H02S
voltages remain low during the Output Test, the AIR
pump and integral stop valve are operating
satis1actorily. If the H02S voltage does not remain low
when the AIR pump is enabled, inspect for the
following:
" For voltage at the Air Pump when it is energized.
For a seized AIR pump.
a Hoses, pipes and all connections tor leaks and
proper routing.
For air flow going to the exhaust ports.
AIR pump for proper mounting.
" Hoses and Pipes tor deterioration or holes.
14441
Purpose
An Exhaust Gas Recirculation (EGR) system is used
in order to lower Oxides of Nitrogen (NOx) emission
levels. The EGR system accomplishes this by feeding
small amounts of exhaust gas back into the
combustion chamber. High combustion temperatures
cause NOx. Combustion temperatures are reduced
when the air/fuel mixture is diluted with the
exhaust gases,.
6-1964
Engine

Diagnosis
Operation
(
1
~---3
~---4
11699
11696
Legend
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
+..__2
Cap-Sensor
Sensor-EGR Pintle Position
Pole Piece-Primary
Bobbin and Coil Assembly
Sleeve-Armature
Valve-Pintle
Armature and Base Assembly
The EGR valve is designed to accurately supply

exhaust gases to the engine without the use of intake
manifold vacuum. The EGR valve controls the
exhaust flow into the intake manifold from the exhaust
manifold through an orifice with a PCM controlled
pintle. The PCM controls the pinUe position using
inputs from the Engine Coolant Temperature (ECT)
sensor, the Throttle Position (TP) sensor, and
the Manifold Absolute Pressure (MAP) sensor. The
PCM commands the EGR valve in order to supply the
correct amount of exhaust gas recirculation for the
current engine operating conditions. This can be
monitored on a scan tool as the Desired EGR Position.
The PCM monitors the position of the EGR valve
through a feedback signal. The PCM supplies
a 5.0 volt reference and a ground to the EGR valve. A
voltage signal representing the EGR valve pintle
position is sent to the PCM from the EGR valve. This
feedback signal can also be monitored on a scan
tool and is the actual position of the EGR pintle. The
Actual EGR Position should always be near the
commanded or Desired EGR Position.
The EGR valve is usually activated under the following
conditions:
The engine is warm.
The engine is above the idle speed.
(1)
(2)
(3)
(4)
Linear EGR Valve

Exhaust Gas
To Cylinders
Pintle
Too much EGR flow causes any of the following

conditions to occur:
The engine stalls after a cold start.
The engine stalls during closed throttle conditions.
The vehicle surges during a cruise condition.
A rough idle.
A DTC P0300 (misfire detected).
Too little or no EGR flow allows the combustion
temperatures to increase. This causes the following
symptoms:
Spark knock (detonation)
Engine overheating
Emission test failure
DTC P0401
Poor fuel economy
The EGR flow diagnosis is included in the DTC P0401
diagnostic table. The EGR pintle position and the
EGR valve control circuit diagnosis are covered
in DTCs P0404, P0405, and P1404. Go to the
appropriate DTC table for diagnosis if an EGR
diagnostic trouble code is stored.
Engine
Crankcase Ventilation System Description
6~1965
Crankcase Ventilation System Routing
A closed crankcase.ventilation system is used to

provide a more complete scavenging of crankcase
vapors. Fresh air from the throttle body is supplied to
the crankcase, mixed with blow-by gases and
then passed through a crankcase ventilation valve into
the intake manifold.
The primary control is through the crankcase
ventilation valve which meters the flow at a rate
depending on manifold vacuum. To maintain idle
quality, the crankcase ventilation valve restricts the
flow when intake manifold vacuum is high. If abnormal
operating conditions arise, the system. is designed
to allow excessive amounts of blow-by gases to back
flow through the crankcase vent tube into the
engine air inlet to be consumed by normal combustion.
The engine ventilation system was developed to
minimize oil consumption and ensure that oil ingestion
could not occur .during vehicle limit handling
maneuverers. Filtered fresh air is routed from up
stream of the throttle blade to the front of the right
rocker cover via a formed rubber hose. To reduce the
potential of oil pullover into the throttle bore area
due to back flow of the ventilation system, the fitting in
the right side rocker cover is located between a
shield from the rocker arms. Blowby gases are routed.
from the rear of both rocker covers, through molded
nylon lines to tee fitting located on the centerline of
the engine at the rear of the intake manifold. From:
there, a single nylon line carries the foul air gases
through an externally mounted, horizontal PCV valve
and enters the intake manifold behind the
throttle body.
4
417539
Legend
(1)
(2)
(3)
(4)
Throttle Body
Fresh Air
PCV Valve
Crankcase Gases
The dual draw system was develop to meet the limited

handling maneuver requirements. During sustained
maximum lateral accelerations, the outboard
rocker cover may fill with oil. The dual draw system
passively switches, allowing the PCV valve to draw on
the rocker cover with the least resistance. This
results in the system drawing on the air filled, or
inboard rocker cover and eliminates oil pullover due to
drawing on the oil-filled outboard rocker cover.
13636
Legend
(1) Check Valve
5.:1955
Engine
PCV System
The PCV valve is connected to the PCV Heat

Exchange cable. The PCV Heat Exchange cable is
mounted to the coolant crossover with a integral
fastener (3). This cable transfers heat to the PCV valve
to eliminate condensation build-up in the PCV
system. This also aids in eliminating throttle body icing.

A plugged PCV valve or hose may cause:
Rough idle
Stalling or slow idle speed
Oil leaks
Sludge in engine
A leaking valve or hose would cause:
Rough idle
0
Stalling
High idle speed
(
492232
Engine
Air Intake System Description

Air Cleaner location
218754
Legend
The air intake system draws outside air through the
front of the remotely mounted air cleaner assembly (1)
and filter element. The air is then routed through
the MAF sensor and then into thethrottle body to the
intake manifold. The air is then directed into the intake

manifold runners, through cylinder heads and into
the cylinders.
6-1968
Engine

Air Cleaner Housing and Resonator
11
10
(
247788
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Air cleaner housing top cover

Seal
Air intake duct to resonator
Clamp
Air intake duct to top cover retainer
Clamp
Air intake resonator
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Air intake duct to throttle body

Mass Airflow (MAF) sensor
Isolator
Air cleaner housing lower assembly
Front retaining clips
Air filter element frame
Air filter element
If the Mass Air Flow (MAF) sensor is installed

backwards, the system will go rich. An arrow cast into
the plastic portion of the sensor indicates proper air
flow direction. The arrow must point toward the engine.
Engine
.Engine Controls 5.7L
6-1969
Illustration
Illustration
J 23738-A
J 34730-1A
Vacuum Pump
Fuel Pressure Gauge
J 26792
J 34730-2C
Spark Tester
Injector Test Light
5381
5390
J 28742-A
J 34730-E
Weather Pack
Terminal Remover
Fuel Pressure Gauge Kit
5377
5396
J 33431-8
J 35314-A
Signal Generator and

Instrument Panel Tester
Exhaust Back Pressure

Tester
13544
5382
J 34142-8
J 35616-A
Test Light
Connector Test Adapter Kit
8917
6-1970
Engine
Engine Controls - 5.7L.

Illustration
Illustration
(
J 35689-A
Metri-Pack Terminal Kit
5395
J 39194-8
Oxygen Senso~ Wrench
5388
J 37027-A
IAC Motor Analyzer
J 39200
Digital Multimeter
J 37088-A
Fuel Line Quick Connect
Separator
J 39765
Fuel Sender Lock Nut
Wrench
5399
12366
16891
J 37287
Inlet and Return Fuel Line
Shut-off Adapters
13541
J 41413
Pressure/Purge Diagnostic
Station
227620
J 39021
Fuel Injector Coil/Balance
Tester
5380
J 41416
Ultrasonic Leak Detector
69758
Engine
Illustration
Illustration
J 42960-1
Fuel Tank Drain Hose
382673
382677
P/N 7000081
Tech 2 Kit
50062
J 42960-2
Fuel Flapper Door Holder
6-1971
6-1972
Engine
Engine Exhaust
Engine Exhaust
Specifications
Specification
Metric
Application
"
English
Catalytic Converter Hanger Bolt
41 N-m
30 lb ft
Catalytic Converter Heat Shield Bolt
2.0Nm
18lbin
Catalytic Converter Nut
25Nm
18 lb ft
End Link Nut
23Nm
17 lb ft
Engine Mount Heat Shield Nut
10 N-m
89lbin
Exhaust Heat Shield Bolt
2.0Nm
18 lb in
Exhaust Manifold Pipe Bolt
30Nm
22 lb ft
Exhaust Manifold Pipe Nut
35Nm
26 lb ft
Exhaust Muffler Clamp Bolt
48Nm
35 lb ft
Exhaust Muffler Hanger Bolt
10 N-m
891bin
Exhaust Muffler Heat Shield Bolt
2.0Nm
181bin
Exhaust Pipe Hanger Nut
20Nm
15 lb ft
Exhaust Pipe Hanger Bracket Bolt
9.5 N-m
84lbin
Exhaust Pipe Heat Shield Bolt
2.0Nm
181bin
42Nm
31 lb ft
Rear Axle Torque Arm Bracket Nut
45Nm
33 lb ft
Rear Shock Nut
90 Nm
66 lb ft
Torque Arm Bolt
130 N-m
96 lb ft
Torque Arm Nut
132 N-m
97 lb ft
Wheel Nut
120 Nm
89 lb ft

Application
GM SPO Group Number
Catalytic Converter Front Hanger Bracket (3.8L)
3.000
Catalytic Converter Gasket (5.7L)
3.000
Catalytic Converter Hanger
3.000
Catalytic Converter Hanger Bracket (5.7L)
3.000
Catalytic Converter Heat Shield
3.000
Exhaust Heat Shield
3.000
Exhaust Manifold Pipe Seal (3.8L)
3.000
Exhaust Muffler
3.000
Exhaust Muffler Hanger
3.000
Exhaust Muffler Hanger Insulator
3.000
Exhaust Muffler Heat Shield
3.000
Exhaust Pipe Hanger Bracket
3.000
Exhaust Pipe Heat Shield
3.000
3.000
Three Way Catalytic Converter
3.000
Engine
Engine Exhaust
6-1973
Pontiac Tailpipe Clearance
Exhaust System Clearances

Chevrolet Tailpipe Clearance
395058
395057
Measure the clearance from the rear fascia (1) to the

top of tailpipe (2).
Specification
Without RPO WU8 specification should be
40.0 mm (+/- 5.0 mm), 1.575 in (+/- 0.197 in).
With RPO WU8 specification should be
35.0 mm (+/- 5.0 mm), 1.378 in (+/- 0.197 in).
Measure the.clearance from the rear fascia (1) to the

top of the tailpipe (2).
Specification
Without RPO WS6 specification should be
40.0 mm(+/- 5.0 mm), 1.575 in (+/- 0.197 in).
With RPO WS6 specification should be
35.0 mm (+/- 5.0 mm), 1.378 in (+/- 0.197 in).
6-1974
Engine Exhaust
Engine

Vibration or Rattling
Step
Value(s)
Action
Check for loose and/or misaligned components.

Are there any loose and/or misaligned components?
1 . Align the components.

2. Tighten the connections.
3. Check the following components for damage:
The hangers
The mounting brackets
The clamps
Is the exhaust system vibrating or rattling?
Yes
Go to Step 2
No
-
System OK
Restric.ted Exhaust
Step
Action
Value(s)
Inspect the exhaust system.

Is the exhaust pipe kinked or bent anyplace?
Replace the exhaust pipe.

Is the exhaust system restricted?
Inspect the muffler.

Is the muffler restricted?
1. If a restriction is likely, remove the muffler and

visually inspect it.
2. If the damage to the muffler is not repairable, replace
the muffler.
Inspect the end of the tailpipe.

Is the end of the tailpipe obstructed?
Remove the obstruction, or if the end of the tailpipe is

crimped, straighten the outlet.
Inspect the catalytic converter for obstructions, which may

have occured as a result of a serious engine manlfunction.
Is the catalytic converter obstructed?
1 . Replace the catalytic converter.

2. Correct the engine malfunction.
1.s the exhaust system restricted?
Yes
No
Go to Step 2
Go To srep 3
Go to Step 3
System OK
Go to Step 4
Go to Siep 5
Go to Step 5
System OK
Go to Step 6
Go to Slep 7
Go to Step 7
System OK
Go to Step 8
System OK
Engine Exhaust
Engine
6-1975
Exhaust Noise
Step
Action
Value(s)
When cold and after a warmup, check for heat shields that
contact the exhaust pipes.
Are the heat shields misaligned or loose?
Tighten the heat shield fasteners to the value given.

Is there still exhaust noise?
Check for leaks at the manifold or the pipe connections.

Are there leaks?
Tighten the leaking connections according to

specifications. Refer to Fastener Tightening Specifications
Is there still a exhaust noise?
Inspect the muffler.

Is the muffler burned or blown out?
Replace the muffler. Refer to Muffler Replacement.

Look for a burned or rusted exhaust pipe.

Is the exhaust pipe burned or rusted?

Is there still exhaustnoise?
Check for a leak at the exhaust crossover pipe at the

manifold flange.
Is there a leak?
10
Repair the leak.

11
Check for a cracked or broken manifold.

Is the manifold cracked or broken?
12
Replace the exhaust manifold. Refer to Exhaust Manifold

Replacement (Left), Exhaust Manifold Replacement (Right)
in Engine Mechanical - 3.8L or Exhaust Manifold
Replacement (Left), Exhaust Manifold Replacement (Right)
in Engine Mechanical - 5.7L.
Check for a leak between the manifold and the

cylinder head.
Is there a leak?
Tighten the manifold-to-cylinder head fasteners to

specifications: Refer to Fastener Tightening Specifications.
13
14
2 Nm (18 lb in)
Yes
No
Go to Step 2
Go to Step 3
Go to Step 3
System OK
Go to Step 4
Go to Step 5
Go to Step 5
System OK
Go to Step 6
Go to Step 7
Go to Step 7
System OK
Go to Step 8
Go to Step 9
Go to Step 9
System OK
Go to Step 10
Go to Step 11
Go to Step 11
System OK
Go to Step 12
Go to Step 13
..
Go to Step 13
System OK
Go to Step 14
System OK
6-1976
Internal Muffler Rattles/Loss of Power

Value(s)
Action
Step
Engine
Engine Exhaust
1. Remove the muffler.

2. Visually inspect the muffler.
Yes
No
Is there a restriction in the muffler?
Go to Step2
Go to Step 3
Go to Step 3
System OK
Go to Step 4
System OK
2
3
Does the vehicle still have a loss of power and/or internal

rattles?
Inspect the catalytic converter.
Is the honeycomb broken in the catalytic converter?

Replace the catalytic converter.
For the three-way catalytic converter, refer to Catalytic
Converter Replacement (3.8 L).
~
For the oxidation catalytic converter, refer to Oxidation

Catalytic Converter Replacement (5. 7 L Left) or
Oxidation Catalytic Converter Replacement (5. 7 L
Right).
Does the vehicle still have a loss of power and/or internal
rattles?
System OK
Exhaust Leakage
Action
Step
Check for a leaks at the pipe joints.

Are there any leaks?
Tighten the fasteners at the leaking joint(s) to
specifications. Refer to Fastener Tightening Specifications.
Are there still a leaks?
Value(s)
Yes
Go to Step 2
No
-
System OK
Repair Instructions
Exhaust System Inspection
Inspect the exhaust pipes, the catalytic
converter(s), the muffler, and the tailpipe for the
- Cracked joints
- Broken welds
- Corrosion damage (Corrosion damage could
cause leaks in the exhaust system.)
Inspect the clamps, the brackets, and the
insulators for the following conditions:
- Broken bolts
- Stripped bolt threads
- Corroded bolts
The exhaust system (including the heat shield)

must be free of the following conditions:
- Leaks
- Binding
- Grounding
Excessive vibration
These conditions may occur if any of the following
components are loose or damaged:
- Flange bolts or flange nuts
- Heat shields
- Brackets
- Pipes
If any of these conditions exist, inspect the tailpipe
alignment. Align and replace any components
necessary, including new manifold seals, nuts, and
gaskets.
Engine Exhaust
Engine
6-1977
Exhaust Crossover Pipe

Replacement (5.7 L)
Removal Procedure
Information.
2. Remove the catalytic converter hanger bolts.
3. Remove the catalytic converter hanger.
550693
4. Loosen the exhaust manifold pipe nuts (1)

(left side).
550682
5. Loosen the exhaust manifold pipe nuts (1)

(right side).
550687
6-1978
Engine
Engine Exhaust
6. Remove the catalytic converter nuts (1) (left side).
550700
7. Remove the catalytic converter nuts (1)

(right side).
8. Slide the crossover pipe rearward.

9. Remove the crossover pipe off the studs on the
left and right catalytic converters.
10. Slide the crossover pipe out of the exhaust

muffler.
i
550702
1. Slide the crossover pipe into the exhaust muffler.
2. Install the crossover pipe over the studs on
the left and right catalytic converters.
3. Slide the crossover pipe forward to align the
components.

Notices.
4. Install the catalytic converter nuts (1) (right side).
Tighten
Tighten the catalytic converter nuts (1) (right side)
to 25 N-m (18 lb ft).
(
550702
Engine Exhaust
Engine
61979
5. Install the catalytic converter nuts (1) (left side).
Tighten
Tighten the catalytic converter nuts (1) (left side)

550700
6. Tighten the exhaust manifold pipe nuts (1)

(right side).
Tighten
Tighten the exhaust manifold pipe nuts (1)
(right side) to 35 N-m (26 lb ft):
)
2
550687
7. Tighten the exhaust manifold pipe nuts (1)

(left side).
Tighten
Tighten the exhaust manifold pipe nuts (1)
(left side) to 35 Nm (26 lb ft).
550682
6-1980
Engine Exhaust
Engine
8. Remove the catalytic converter hanger.
Tighten
Tighten the catalytic converter hanger bolts to
41 Nm (30 lb ft).
550693
Catalytic Converter Replacement (3.8 L)

Removal Procedure
Information.
2. Remove the exhaust manifold pipe bolts at the
exhaust manifolds.
3. Remove the exhaust pipe gaskets.
222949
4. Remove the connector position assurance (CPA)

retainer.
5. Disconnect the heated oxygen sensor electrical
connector.
(
222946
Engine
Engine Exhaust
6-1981
6. Remove the heated oxygen sensor from the

three way catalytic converter.
7. Loosen the muffler clamp bolt at the three way
catalytic converter.
222948

9. Remove the catalytic converter hanger from the
hanger bracket.
21664
10. Twist and slide out the three way catalytic
converter from the exhaust muffler.
21662
6-1982
Engine Exhaust
Engine
1. Twist and slide the three way catalytic converter
into the exhaust muffler.
21662
2. Install the catalytic converter hanger to the hanger

bracket.

Notices.
3. Install the catalytic converter hanger bolts.

Tighten
41 Nm (30 lb ft}.
21664
4. Install the exhaust manifold pipe bolts at the

exhaust manifolds ..
Tighten
Tighten the exhaust manifold pipe bolts to
30 N-m (22 lb ft) alternating back and forth from
the left to the right manifolds.
5. Tighten the exhaust muffler clamp bolt at the
three way catalytic converter.
Tighten
Tighten the exhaust muffler clamp bolt to
48 Nm (35 lb ft).
(
222949
Engine
Engine Exhaust
6-1983
6. Install the heated oxygen sensor to the three way

catalytic. converter.
Tighten
42 Nm (31 lb ft).
222948
7. Connect the heated oxygen sensor electrical

connector.
8. Install the CPA retainer.
222946

Replacement (5.7 L Left)
Removal Procedure
1. Remove the exhaust crossover pipe. Refer to
Exhaust Crossover Pipe Replacement (5. 7 L).

retainer.
3. Disconnect the heated qxygen sensor electrical
connector.
4. Remove the heated oxygen sensor from the left
)
550706
6-1984
Engine
Engine Exhaust
5. Remove the exhaust manifold pipe nuts (1 ).
6. Remove the catalytic converter gasket (2).

7. Remove the left catalytic converter.
550682
1. Install the left catalytic converter gasket (2).
2. Install the left catalytic converter.
Notices.
3. Install the exhaust manifold pipe nuts (1 ).
Tighten
Tighten the exhaust manifold pipe nuts (1) to
35 Nm (26 lb ft).
550682
4. Install the heated oxygen sensor to the left

Tighten
42 Nm (31 lb ft).
5. Connect the heated oxygen sensor electrical
connector.
6. Install the CPA retainer.
7. Install the exhaust crossover pipe. Refer to
(
550706
Engine Exhaust
Engine
6-1985

Replacement (5.7 l Right)
)
Removal Procedure
1. Remove the exhaust crossover pipe. Refer to
Exhaust Crossover Pipe Replacement (5.7 L).
retainers.
3. Disconnect the heated oxygen sensors electrical
connectors.
4. Remove the heated oxygen sensors from the right
222953
5. Remove the exhaust manifold pipe nuts (1 ).

6. Remove the catalytic converter gasket (2).
7. Remove the right catalytic converter.
)
2
550682
1. Install the catalytic converter gasket (2).
2. Install the right catalytic converter.
Notic~: Refer to Fastener Notice in Cautions and
Notices.
3. Tighten the exhaust manifold pipe nuts (1 ).
Tighten
Tighten the exhaust manifold pipe nuts (1) to
35 N-m (26 lb ft).
)
550682
6-1986
Engine
Engine Exhaust
4. Install the heated oxygen sensors to the right

Tighten
42 Nm (31 lb ft).
5. Connect the heated oxygen sensors electrical
connectors.
6. Install the CPA retainers.
7. Install the exhaust crossover pipe. Refer to
550704
Muffler Replacement
Removal Procedure
Information.
2. Remove the track bar. Refer to Track Bar
3. Remove the drivers side rear tire.
4. Support the rear axle with jack stands.
222971
5. Remove the passenger side rear stabilizer var

end link.
(
222972
Engine
Engine Exhaust
6-1987
6. Disconnect the passenger side rear shock from

the rear axle.
222973
7. Remove the torque arm bolts at the rear axle.

Lower the rear axle slightly.
222974
8. Remove the passenger side rear coil spring and

bushing.
222975
6-1988
Engine Exhaust
Engine
9. Remove the left exhaust hanger from the
underbody.
222976
10. Loosen the exhaust muffler clamp, (5.7 L shown,

3.8 L similar).
11. Lower the rear axle enough to remove the muffler.
12. Remove the muffler by rotating and sliding the
muffler out from behind the vehicle.
13. Transfer the exhaust hanger(s) to the new muffler.
550689
1. Install the exhaust muffler to the vehicle,
(5.7 L shown, 3.8 L similar).
2. Raise the rear axle.
Notices.
3. Tighten the exhaust muffler clamp.
Tighten
Tighten the exhaust muffler clamp bolt to
48 Nm (35 lb ft).
(
550689
Engine
Engine Exhaust
6-1989
4. Install the left exhaust muffler hanger to the

underbody.
Tighten
Tighten the exhaust muffler hanger bolts to
10 N-m (89 lb in).
222976
5. Install the passenger side rear coil spring and

bushing.
222975
6. Raise the axle completely.

7. Install the torque arm bolts at the rear axle.
Tighten
Tighten the torque arm bolts to
130 Nm (96 lb ft).
Tighten to torque arm nuts to
132 N-m (97 lb ft).
222974
6-1990
Engine Exhaust
Engine
8. Connect the passenger side rear shock to the
rear axle.
Tighten
Tighten the rear shock nuts to 90 Nm (66 lbft).
222973
9. Connect the passenger side rear stabilizer bar

end link.
Tighten
Tighten the end link nut to 23 N-m (17 lb ft).
10. Remove the rear axle support.
222972
11. Install the drivers side rear tire

Tighten
Tighten the wheel nuts to 120 N-m (89 lb ft).
12. Install the track bar. Refer to Track Bar
(
222971
Engine
Engine Exhaust
5;.1991
Converter Hanger Assembly Replacement

(3.8 L Automatic)
Removal Procedure
Information.
2. Support the catalytic converter.
4. Remove the catalytic converter hanger from the
front hanger bracket.
21664
5. Remove the rear axle torque arm nuts.

6. Remove the rear axle torque arm bracket bolts.
7. Remove the catalytic converter front hanger
bracket from the vehicle.
222998
1. Install the catalytic converter front hanger bracket
to the vehicle.
2. Install the rear axle torque arm bracket bolts.
and notices.
3. Install the rear axle torque arm bracket nuts.
Tighten
Tighten the rear axle torque arm bracket nuts to
45 N-m (33 lb ft).
222998
6-1992
Engine Exhaust
Engine
4. Install the catalytic converter hanger .to the front
hanger bracket.
Tighten
41 N-m (30 lb ft).
6. Remove the support from the catalytic converter.
21664
Converter Hanger Assembly Replacement

(3.8 l Manual)
Removal Procedure
Information.
4. Remove the hanger from the bracket.
21664
5. Remove the rear axle torque arm bracket nuts.

6. Remove the catalytic converter front hanger
bracket.
(
222996
Engine
Engine Exhaust
6-1993
1. Install the catalytic converter front hanger bracket.

Notices.
Tighten
Tighten the rear axle torque arm bracket nut to
45 Nm (33 lb ft).
222996
3. Install the hanger to the bracket.
Tighten
Tighten the converter hanger bolts to
41 Nm (30 lb ft).
21664

Replacement (5.7 l)
Removal Procedure
Information.
4. Remove the hanger from the bracket.
550693
6-1994
Engine Exhaust
Engine
5. Remove the rear axle torque arm bracket nuts.
6. Remove the catalytic converter hanger bracket.
222993
1. Install the catalytic converter hanger to the
bracket.
2. Install the catalytic converter bracket to the rear

axle torque arm bracket.

Notices.
Tighten
Tighten the rear axle torque arm bracket nut to

45 N-m (33 lb ft).
222993
4. Install the catalytic converter. hanger bolts.

Tighten
41 N-m (30 lb ft).
(
550693
Engine
Engine Exhaust
6-1995

Replacement (3.8 L)
Removal Procedure
Information.
2. Support the exhaust muffler.
3. Remove the exhaust muffler hanger bolts:
222976
4. Remove the exhaust muffler rubber hanger from

the muffler.
222982
1. Install the exhaust muffler rubber hanger to the
muffler.
222982
6;.1996
Engine Exhaust
Engine
Notices.
2. Install the exhaust muffler hanger bolts..
Tighten
Tighten the exhaust muffler hanger bolts to
1O N-m (89 lb in).
3. Remove the exhaust muffler support.
222976

Replacement (5.7 L)
Removal Procedure
Information.
2. Support the exhaust muffler.
3. Remove the exhaust pipe hanger nut.
222989
4. Remove the exhaust pipe hanger bracket bolts.

5. Remove the exhaust muffler interior hanger
bracket.
(
222977
Engine
Engine Exhaust 6-1997
1. Install the exhaust muffler interior hanger bracket.
Notice: Refer to Fastener Notice in. Cautions and

Notices.
2. Install the exhaust pipe hanger bracket bolts.
Tighten
Tighten the exhaust pipe hanger bracket bolts to
10 N-m (89 lb in).
222977
3. Install the exhaust pipe hanger nut.

Tighten
Tighten the exha.ust pipe hanger nut to
20 Nm (15 lb ft).
4. Remove the support from the exhaust muffler..
222989
Engine Mount Heat Shield

Replacement (5. 7 L)
Removal Procedure
Information.
2. Remove the engine mount heat shield nuts.
220590
6-1998
Engine
Engine Exhaust

Notices.
Tighten
1O Nm (89 lb in).
220590
Converter Heat Shield Replacement

Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic
Converter Replacement (3.8 L) or Oxidation
Catalytic Converter Replacement (5. 7 L Right).
2. Remove the catalytic converter heat shield bolts.
3. Remove the catalytic converter heat shield.
223001
1. Install the catalytic converter heat shield.
Notices.
2. Install the converter heat shield bolts.
Tighten
Tighten the catalytic converter heat shield bolts to
2 N-m (18 lb in).
3. Install the catalytic converter. Refer to Catalytic
(
223001
Engine
Engine Exhaust
6-1999
Exhaust Heat Shield Replacement

Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic
2. Remove the exhaust heat shield bolts (2 and 3).
223003
3. Unhook the exhaust heat shield from the converter

heat shield.
4. Remove the exhaust heat shield.
223006
1. Install the exhaust heat shield.
2. Hook the exhaust heat shield to the converter
heat shield.
223006
6-2000
Engine Exhaust
Engine
Notices.
3. Install the exhaust heat shield bolts (2 and 3).
Tighten
Tighten the exhaust heat shield bolt to
2 Nm (18 lb in).
4. Install the catalytic converter. Refer to Catalytic
223003

Replacement
Removal Procedure
1. Remove the exhaust muffler. Refer to Muffler
Replacement.
2. Remove the exhaust pipe heat shield bolts.
3. Remove the exhaust pipe heat shield.
21701
4. Remove the exhaust muffler heat shield bolts. ,
(
223008
Engine
Engine Exhaust
6-2001
5. Remove the exhaust muffler heat shield bolt.
223010
6. Remove the exhaust muffler heat shield bolts and

bracket.
7. Remove the exhaust muffler heat shield.
223012
1. Install the exhaust muffler heat shield.

Notices.
2. Install the exhaust muffler heat shield bracket
and bolts.
Tighten
Tighten the muffler heat shield bolts to
2 N-m (18 lb in).
223012
6-2002
Engine Exhaust
Engine
3. Install the exhaust muffler heat shield bolt.
Tighten
Tighten the exhaust muffler heat shield bolt to
2 N-m (18 lb in).
223010
4. Install the exhaust muffler heat shield bolts.
Tighten
Tighten the exhaust muffler heat shield bolts to
2 N-m (18 lb in).
223008
5. Install the exhaust pipe heat shield.

6. Install the exhaust pipe heat shield bolts.
Tighten
Tighten the exhaust pipe heat shield bolts to
2 N-m (18 lb in).
7. Install the exhaust muffler. Refer to Muffler
Replacement.
//;::-- ....
///
'\
.,///
/.,1.,1
I//
,,,
//.,1
/ , / @ti"t">-- -; / / \
""''
',
I
I
1r>,
_'.,(B, -----
' t: __
f
'.I//
"< /
'
:-..
~---~ ' , , _____ .. ---
..
__' .......
~ ,~
(
21701
Engine
Engine Exhaust
6-2003

Exhaust System Description
Muffler Description
The exhaust system design will vary according to the

model of vehicle. The exhaust system uses a
flange and seal joint coupling to secure the exhaust
pipe to the engine exhaust manifolds. The exhaust
system is suspended by hangers that are attached to
the underbody. The hangers allow some movement
of the exhaust system.
The muffler controls the exhaust noise level. The

exhaust muffler is a tri-flow design.
3.8L vehicles not equipped with RPOs Y87 and
W68 use a single outlet muffler.
3.8L vehicles equipped with PROs Y87 and W68
use a dual outlet muffler.
5.7L vehicles equipped with RPOs VP6, WS6 and
WU8 use a single outlet muffler.
5. 7L vehicles equipped without RPOs VP6, WS6
and WU8 use a dual outlet muffler.
The muffler used on this vehicle must be serviced with
the exhaust pipe they can not be serviced separately.
Notice: Replacement of exhaust system parts must

be OEM standard to ensure that the vehicle operates
as designed.
Catalytic Converter Description

Caution: Prolonged operation of a misfiring or
flooded engine may cause the catalytic converter
to overheat. Damage to the catalyst, the operating
vehicle, or personal injury may result.
Notice: When jacking or lifting the vehicle from the
frame side rails, be certain that the lift pads do
not contact the catalytic converter. This may damage
the converter.
Notice: The catalytic converters require the use of
unleaded fuel only. Using leaded fuel will damage the
catalytic converters and other emission system
components.
The catalytic converter is an emission control devise.
The catalytic converter is added to the exhaust
system on unleaded fuel vehicles to reduce pollutants
from the exhaust gas stream. The catalyst in the
monolith converter in not serviceable.
The three-way catalytic converter burns three types of
exhaust gases:
Carbon monoxide (CO)
.. Hydrocarbons (HC)
Oxides of nitrogen (NOx)
The oxidation catalytic converter burns the same
gases, but uses an air pump/smog pump to force
added oxygen into the catalytic converter. The
additional oxygen forces the converter to run hotter
and to burn exhaust gases more effectively.
A single bed ceramic monolith style brick catalytic
converter is used in combination with two types
of catalyst
" Oxidation catalyst
Three-way (reduction/oxidation) catalyst
The catalysts have coatings that contain platinum and
palladium. These coatings burn the unwanted
exhaust emissions.
Hangers Description
Important: The installation of the exhaust system
hangers is very important, as improperly installed
hangers can cause annoying vibrations that can be
difficult to diagnose.
The type of hanger used to support the exhaust
system on this vehicle is a conventional rubber block.
The rubber block is a rigid hanger with a feature
that supports the exhaust system in case a rubber
block is broken. The rubber mounts allow some
exhaust system movement, but not the transfer of
noise or vibration into the passenger compartment.
Clamps Description
Caution: Exhaust may enter the vehicle and cause
personal injury if the slip joints are not coated
with exhaust system sealer before assembly.
Important: Apply sealer GM P/N 9985020 or
equivalent to the slip joint connection.
When installing a new exhaust component on any
model, check for proper alignment. Rattles and noise
vibrations in the exhaust system are usually caused
by the misalignment of parts. When installing the
components, leave all bolts and nuts loose until all
parts are properly aligned.
The clamp used to connect the catalytic converter to
the exhaust muffler is a single nut compression clamp.
6-2004
Engine
Engine Exhaust
BLANK
INDEX
A
Abbreviations andTheir Meanings ..................... 0-22
A/C Refrigerant Pressure Sensor Replacement .... 1-72
A/C System
Diagnosis
Noise ......................................................... 1-24
Accelerator and Servo Control Module (ASM)
Replacement ............ .......... .... .... ... . 5-236
Accelerator Controls
Ca.ble Replacement (5.7L) ... , ..... ,............... 6-1855
Pedal Replacement (3.8L) ................. ,........ 6s1241,
6-1244, 6-1245
Pedal Replac:ement (5.7L) ................. ,........ 6-1857
Accumulator Replacement ................. ,.. : .......... 7 1-78
Acid Rain' ...................... , ............ ,.................. 8-1139
Actuator Replacement
Liftgate Lock . ...... ..... .............. .. ..... .. ...... ..... 8-11 06
Adjustment .
.
. .
Rack Bearing Pre load - Power .Steering ......... 2-35
Temperature Control Cable (A/C - Manual) ....1-132
Adjustments
Clutch Pre$sure Piate ............... : .................. 7-401
Park/Neutral Position. Switch.
Automatic Transmission - 4L60-E ............. 7-309
Shift Cab.le
Automatic Transmission - 4L60-E , ............ 7-303
AIR
Check Valve/Pipe Replacement
Bank 1 (5.7L) ... ,., .. , ................................. 6-1922
Bank 2 (5.7L) ..... : ................ ;,.,; ....... ,..... ,. 6-1921
Air Baffle Assemblies and Deflectors
(Engine Cooling) ...... , ........... 6-661, 6-662

Air Cleaner
Assembly Replacement(5.7L) .... ,.... , .. ,....... 6-1929
Element Replacement (3.8L) ...................... 6-1298
Element Replacement (5. 7L) , ..................... 6-1928
Intake Duct Replacement (3.8L) ................. 6-1299
Air Deflector Replacement
Radiator ....................................................... 8-871
Air Inlet Grille Panel Replacement ................... 8-871
Air Outlet Replacement - Right [:)e~ogger
(A/C , Manual) ................................ 1-138
Air/Wind Noise
Diagnm;is
Air Pressure Test .............. ,.: ..................... 8-783
Air/Wind Noise , .............................. : .......... 8-783
Soap Suds or Bubble Test ....................... 8-783
Tracing Powder or Chalk Test .................. 8-783
.
Alignment
Checking Frame to Body Alignment ........... 8-1149
Alignment Checking
Frame and Underbody ............................... 8-1149

Aluminum Wheel
.
.
Hub Cap Replacement ... ,............................... 3-64
Porosity Repair ................ ,............................. 3-64
Refinishing ..................................................... 3-64
Amplifier Replacement .......................... 8-338, 8-339
Antenna
Schematic
Power .. .. ... ...... ... ......... .... ...... ....... .... ........ . . 8~285
Antenna Mast Cleaning ................................... 8-351
Antenna Mast Replacement

Fixed .. ... ..... ... ..... ....... ... ... .... ..... . .. ... .. .... .. .. ... 8-348
Power .................................. ........................ 8-349
Antenna Motor Replacement
Power .... .... .... ..... ... .... .... .. ..... ... .. .. .. ..... .. ... .. .. 8-350
Antenna Replacement
Fixed .................................... : ......... :............ 8-349
Antilock B.rake System
Adjuster Assembly Replacement ................... 5~239
Brake Pressure Modulator Valve
Replacement .. ... ... ..... .. .. .. ... ... .... .. .. . 5-237
Cable Adjustment Procedure .. ,..... :............... 5-241
Component Locations .. .. .. .. ... .. .... . .. .. .. .. .. .. ... .. 5-110
Component Views .. .. ... ... .... .... .. . ... .. . .... ... ... .. . 5-114
Connector End Views ................................... 5-122
Description
Abbreviations and Definitions .................... 5-249
ABS System ..... ...... .. .. ... ... .. ... . .. ... ... .... .. .. .. 5-249
ABS System Operation ................. ,......... :. 5-251
Basic Knowledge Required ....................... 5-249
General ... ..... .... ...... .... .. ... .. .. .. .. .. .. ... .... .. .. .. 5-249
Service Precautions .................................. 5~248
Diagnosis
ABS. Indicator Inoperative with
No OTC Set .. ... .. .. ... .. ... .. .. .. ... .... ... .. . 5-227
ABS Indicator On No OTC Set .................. 5-225
ASR Indicator Inoperative with No
OTC Set ....... .. .... .... . ... ... . .... .. ... .. .. .. . 5-220
ASR Indicator On with No OTC Set .......... 5-218
Diagnostic Starting Point ........................... 5-125
Diagnostic System Check .................... , .... 5-129
Diagnostic Traub.le Code (OTC) List/Type ... 5-127
Electromagnetic Interference .. . ... .. .... ... ... . .. 5-128
Enhanced Diagnostics ................ ,............. 5-.128
Initialization Sequence .............................. 5-128
Low Traction Indicator Inoperative ............. 5~231
Low Traction Indicator On All of the Time .... 5-229
No Communication with EBCM ................. 5-223
Scan Tool Data Definitions ....................... 5-126
Scan Tool Data List .. ... .... .. ... .. .. .. ... ... . .. .. ... 5-125
Scan Tool Diagnostics .......... , ................... 5-125
Self-Diagnostics ........................................ 5-128
Symptoms ................... , ............................ 5-212
JCS Indicator Inoperative with
No OTC Set..................................... 5-215
JCS Off Indicator On with No DTC Set ..... 5-213
Electronic Brake Control Module
Replacement ......... , . ,............... ,. .. ... 5-233
GM SPO Group Numbers .............................. 5-97
Schematic
ABS Schematic Icons . ... .... ... .. .. .. .... ... ... . .. ... 5-97
Schematics ... ...... ..... . .. .... .... ... ... .. ... .. .... .. .. . . .. .. 5-98
Special Tools , .............................................. 5-255
Specifications
ABS Diagnostic Specifications .................... 5-97
Fastener Tightening .................................... 5-97
Wheel Speed Sensor
Jumper Harness Replacement ................. 5-243,
5-244, 5-245
Ring Replacement .................................... 5-246
Wheel Speed Sensor Replacement ... 5-241 , 5-242
Anti-Theft Labeling ..... . ... ... .... .... .. .. .. .. .... ... .. .. .. ... 0-14
Arrows and Symbols, Description ........................ 0-4
Ashtray Lamp Bulb Replacement ..................... 8-221
2
Ashtray Replacement
Front Floor Console ..................................... 8-618
Ashtray/Lighter Replacement
Console ....................................................... 8-619
Assist Rod Ball Stud Replacement
Hood ........................................ ; ...... .... ... .. ... 8-868
Assist Rod Replacement
Hood ........................................................... 8-867
Audible Warnings
Diagnosis
Key-in-Ignition Chime On with
LF Door Closed ..... .. .... ... ..... .... .. .. ... 8-583
Key-in-Ignition Chime Always On .............. 8-582
Key-in-Ignition Chime Inoperative .............. 8-582
Lights On Chime Inoperative .................... 8-584
Lights On Chime On with
Ignition in Run ................................ 8-584
Auto Trans Shift Lock Control .......................... 7-288
Circuit Description ........................................ 7-375
Schematics
Column Mounted ........................................ 7-73
Shift Lock Control
Component Views ..................................... 7-105
Automatic Transmission - 4L60-E
2:..4 Servo ..................................................... 7-321
Accumulator Assembly, Spacer Plate,
and Gaskets .... .... .... ... ... ..... .... ... . .... 7-349
Automatic Transmission Related
Connector End Views ..................... 7-109
Brake Transmission Shift Interlock
Solenoid Replacement . ... .. .. .. ... ... .. . . 7-292
Case Extension Assembly Installation ........... 7-355
Component Location ...................................... 7-77
Component Location Table ............................. 7-74
Control and Shift Solenoids Replacement ..... 7-342
Description
Adapt Function ......................................... 7-375
Definitions and Abbreviations .................... 7-372
Electrical Connector .................................. 7-379
Electronic Component ............................... 7-376
Identification Information ......... ; ................. 7-374
Transmission General Information ............. 7-372
Diagnosis
1st Gear Range Only - No Upshift ............ 7-279
2nd /3rd Gears Only or
1st/4th Gears Only ......................... 7-281
2nd Gear Start .......................................... 7-286
2nd Gear Start Switch and Indicator
Lamp Circuit Check ........................ 7-261
3-2 Flare or Tie-Up .................................. , 7-281
AT Oil Cooler Flushing and Flow Test ...... 7-275
Case Porosity Repair .............................. ,. 7-275
Clutch Plate Diagnosis .............................. 7-271
Delay in Drive and Reverse ...................... 7-287
Diagnostic Starting Point Automatic Transmission .................. 7-109
Diagnostic Starting Point Automatic Transmission Shift
Lock Control System ...................... 7-111
Diagnostic Trouble Code (OTC) List/Type ... 7-120
Type Definitions .............................. 7-120
Drives in Neutral ............. :......................... 7-286
INDEX
Automatic Transmission - 4L60-E (cont.)
Diagnosis (cont.)
Engine .Coolant in Transmission :............... 7-272
Engine Starts in Gear ............................... 7-287
Fluid Leak ................................................ 7-272
Flywheel/Torque Converter Vibration Test ... 7-270
Front Oil Leak .......................................... 7-287
Harsh Garage Shift ................................... 7-'283
Harsh Shifts ............................................. 7-279
Inaccurate Shift Points ............................ :. 7-279
Line Pressure Check Procedure ............... 7-265
No 2-3 Shift or 2-3 Shift Slips, Rough
or Hunting ...................................... 7:281
No 3-4 Shift, Slips or Rough 3-4 Shift ...... 7-282
No Drive in All Ranges ............................. 7-287
No Drive in Drive Range .......................... 7-287
No First or Second Gear/No Third or
Fourth Gear .................................... 7-281
No Fourth Gear, or Slips in Fourth Gear .... 7-286
No Gear Selection .................................... 7-287
No Overrun Braking , Manual 3~2-1 .......... 7-283
No Park .................................................... 7-286
No Part Throttle or Delayed Downshifts .... 7-283
No Reverse or Slips in Reverse ............... 7-282
No Second Gear, No Fourth Gear,
and No Reverse Gear ................. ,.. 7-281
No Third Gear ........................................... 7-286
No Torque Converter Clutch Apply ........... 7-283
No Torque Converter Clutch Release ....... 7~285
Noise and Vibration Analysis ..................... 7-271
Oil Out the Vent ....................................... 7-286
Oil Pressure High or Low ......................... 7-278
Powertrain On Board Diagnostic (OBD)
System Check Automatic Transmission .................. 7-109
Ratcheting Noise ...................................... 7-287
Road Test Procedure ............................... 7~265
Shift Lever Indicates Wrong Gear ............. 7-287
Shift Solenoid Leak Test ........................... 7-275
Slip/Flare in Any Gear .............................. 7-286
Slipping or Rough 1-2 Shift ...................... 7-280
Slips in 1st Gear ....................................... 7-279
Symptom Diagnosis .................................. 7-276
Symptoms - A/T Shift Lock Control ........... 7-288
Third Gear Only ........................................ 7-281
Torque Converter Clutch Shudder ............. 7-285
Torque Converter Clutch.(TCC)
Intermittent - OK Cold/Slips Hot ...... 7-286
Torque Converter Clutch (TCC) Slip 100 RPM Slip ................................. 7-285
Torque Converter Clutch (TCC) Slip
with Stall/Stumbl.e .......................... 7-285
Torque Converter Diagnosis Procedure ..... 7-268
Transmission Fluid Checking Procedure .... 7-263
Transmission Overheats ............................ 7-278
Transmission Scan Tool
Data Definitions ................... 7-114, 7-117
Transmission Scan Tool Data List .... 7-111, 7-112
Vibration in Reverse and
Whining Noise in Park .................... 7-286
Do Not Use Air Tools ................................... 7-372
El,ectronic Component Views .......................... 7-76
Extension Housing Rear Oil Seal ................. 7-354
Filler Tube Replacement .................... 7-326, 7-328
INDEX
Automatic Transmission - 4L60-E (cont.)

Floor Shift Control Knob Replacement ......... 7-291
Floor Shift Control Replacement .. :................ 7-305
Fluid/Filter Changing ............ , ....................... 7-311
Flywheel to Torque Converter Bolts .............. 7-334
lnline Harness Connector End View ............. 7-106
Internal Connector End Views ...................... 7-107
Oil Cooler Line Replacement ....... : ... :.......... : 7-313
Oil Pan Replacement ..... ...... ... ............ ......... 7-335
Park Lock Cable Replacement .... ........ ......... 7-293
Park/Neutral Position Switch Adjustment.. ..... 7-309
Park/Neutral Position Switch Replacement ... 7-308
Parts Cleaning and Inspection ......... ,........
7-290
Pressure Regulator Replacement ....... , ......... 7-.324
Replacement ., ................................... 7-359, 7-366
Schematic
Controls Schematic Diagrams ........ ,....... ,.... 7-68
Schematic Icon Table ......................... , ....... 7-67
Shift Cable Adjustment ,: ... :.................. :..... , .. 7-303
Shift Cable Replacement .......................... ,... 7-300
Special Tools ...... ." ................ : .............. : ......... 7-380
Specifications
Component Resistance ...... .. ............. .......... 7-66
Fluid Capacity ............... : ...................... ;..... 7-64
General ............ ,,., ..... ............................... ::7-64
Line Pressure ........................................ :.... 7-66
Range Reference Table .............................. 7-64
Shift Solenoid Valve State and Gear Ratio .... 7-65
Shift Speed Table ....................................... 7-65
TFP Manual Valve Position Switch Logic ... ; 7-66
TFT Sensor ............. :.................................. 7-63
Torque Converter Clutch PWM Solenoid,
TCC Solenoid, andWiring Harness ... 7-345
Torque Converter Cover
Replacement ........................ 7-331, 7-333
Valve Body and Pressure Switch
Replacement ... ,.............................. 7-336
Vehicle Speed Sensor Replacement ............. 7-358
Vent Hose Replacement ........... '. ................... 7-320
Axle Replacement
..
Rear Drive Axle ......................... ,................... 4-46
a
Backup Lamp Bulb Replacenieht .......... 8-211, 8-212
Balancing Tires and Wheels ........... : .... : ............. 0-71
Ball Joint Replacement,
.
., .
.
Lower Front Suspension ................... 3-23
Ball Joint Replacement,
.
Upper Front Suspension ..... , ........ ,.:;. 3-20

Basecoat/Clearcoat Paint Systems ;................ 8-1135
Battery
.
..
.Battery Charge Low or

Completely Discharged ................... 6-719
. Cable Replacement ..... 6-723, 6-727, :?~729; 6-732
Charging ......................... ,.,, ......... ,,: ...... , .... ,. 6-718
Common Causes of Failure ................. ,....... 6-692
Description ................................. ,., ... ,............ 6-781
Hqld Down Retainer Replac:emenr............... , 6-734
. Hydrometer Displays .Dark. or Yellow Dot ...... 6-700
'Hydrometer Displays Yellow Dot ........... :....... 6-694
Jump Starting
in Case of Emergency ........... 6-720
..
Battery (cont.)
Load Test - Parasitic ................................. , .. 6-700
Negative Cable Disconnect .......................... 6-722
Not Operating Properly ................................ 6-696
Replacement ................................................ 6~735
Terminal Check ........................................... 06-693
Tray and Hold-Down Retainer Description .... 6-782
Tray Replacement ........................................ 6-738
Visual Inspection .......................................... 6-693
Battery Operation ... .. ... .... ... .. .. ... ...... .. . ... . ... ... .. . 6-781
Battery Temperature vs Voltage Drop .............. 6-675
Battery Usage Specifications ........................... 6-67 4
Belt, Drive, Replacement (3.8L) ........................ 6-47
Belt Reveal Molding Replacement ..... 8-1071, 8-1072
Blade Element Cleaning .................................. 8-269
Blower
Diagnosis
High Speed Inoperative (A/C - Manual) .... 1~122
Inoperative at Any Speed (A/C - Manual) ..... 1.. 119
Operates at High Speed Only
(A/C - Manual) ............................... 1"121

Operates Continuously (A/C - Manual) ...... 1-123
Operates in One Speed Only
(A/C - Manual) ........................ : ...... 1-121
Motor and Fan Assembly Replacement
(A/C - Manual) ............................... 1125
Resistor Replacement (A/C - Manual) .......... 1-124
Blower Motor
Controls Circuit Description (A/C - Manual) . .. .. 1-150
Diagnosis
Noise ................................................... -' .... 1-21
Relay Replacement (Non-A/C) ....................... 1-"87
Body Control Module
Description
Circuit ....................................................... 8-544
Body Control Module Programming/RPO
Configuration .................................. 8"543
Body Control Module Replacement .................. 8"541
Body Control System
Body Control Module Component Views ....... 8-530

Body Control Module Components ............... 8-527
Body Control Module Connector End Views :; .. 8-531
Diagnosis
Cannot Enter BCM Diagnostics ........ : .... ,... 8-539

Clearing DTCs .......................................... 8-535
Diagnostic Starting Point Body Control System ..... .. .. .. .... ... .. .. 8-534
Displaying DTCs ....................................... 8-534
DTC List : ..... ,.. ... .. ..... .. ... ... ... .... .. .. ... ... ... .. .. 8-535
Symptoms - Body Control System .. ... ... .. .. 8-539
Schematics
Body Control Module ................................ 8-521
Body Control Module Schematic Icons ...... 8-520
Specifications
GM SPO Group Numbers .... -' ................. 8-520
Body Dimensions .. ... .. ..... .. ... ... .. ...... .. .. .. ... ... .. . 8-1142
Body Front End
Description
General .................................................... 8-877
Specifications
Fastener Tightening .................................. 8-849
GM SPO Group Numbers ..................... : .. , 8-850
Body Measurements ............. 8-1150, 8-1158, 8-1167
4
Body Rear End
Component Views ...................................... 8-1081
Components . . .. ... ... .. . ..... .. .. .... .. ... ... ... .. .... ... . 8-1079
Connector End Views ................................. 8-1084
Description ................................................. 8-1111
Rear Compartment Lid Release Circuit ... 8-1111
Diagnosis
Diagnostic Starting Point Body Rear End . .. ... .. .... ... .. .. .. .... ... . 8-1084
Rear Lid Ajar Indicator Always On .......... 8-1088
Rear Lid Ajar Indicator Inoperative .......... 8-1089
Symptoms - Body Rear End . .. .... .. ..... . ... . 8-1084
Schematic
Schematic Icons ................... , ................. 8-1076
Specifications
Fastener Tightening ................................ 8-1075
GM SPO Group Numbers ....................... 8-1076
Body Side
Door Molding Replacement .......................... 8-771
Brake Caliper
Bracket Replacement ............................ 5-76, 5-77
Inspection ...................................................... 5-69
Overhaul ............................. ,................. 5-70, 5-73
Replacement ......................................... 5-63, 5-66
Brake Master Cylinder
Description . ... . ... .. ... .. .. ... ... ... .. ... .. .... .. ... .. . ... . .. . . 5-52
Brake Pad Inspection ....................................... , 5-58
Brake Pads Replacement ......................... 5-58, 5-60
Brake Pedal Bracket Replacement .................... 5-32
Brake Pedal Replacement ............................ , .... 5-28
Brake Pedal Travel
Hydraulic Brakes ............................................ 5-20
Brake Rotor Refinishing ............................ 5-79, 5-80
Brake Rotor Replacement ........................ 5-77, 5-78
Brake Warning System
Schematics . ... ... . .... .. . .... .. .. ... .. .... .. .... . .... .... .. .. ... 5-7
BTSI
Diagnosis
Always On with Ignition in RUN ................ 7-289
Bumper Replacement
Rear Suspension .. .. .. .. .. .. .. .... ... .. .. ... .... .. .... ... .. 3~44
Bumpers
Air Deflector Replacement
Front Fascia ............................................. 8-830
Description
Bumper and Fascia ...................... ,........... 8-848
Energy Absorber Replacement
Front ........................................................ 8-837
Rear .............................................. 8-845, 8-846
Fascia Grille Replacement
Front Lower .............................................. 8-835
Fascia Replacement
Front ........................ , .................... 8-831, 8-833
Rear .............................................. 8-839, 8-842
Impact Bar Replacement
Front ........................................................ 8-836
Rear ......................................................... 8-847
License Bracket Replacement
Rear .......................................................... 8-838
License Pocket Cover Replacement
Front ........................................................ 8-835
Specifications
GM SPO Group Numbers ......................... 8-829
INDEX
c
Cable Replacement
Accelerator Controls (5. 7L) ......................... 6-1855
Hood Latch Release .................................... 8-863
Park Brake :' 5-88, 5-90
Cage Nut Service, Damaged ......................... 8-1186
Replacement (3.8L) ................. ,..... 6-1294
Replacement (5.7L) ..................... ,. 6-1917
Cargo Area Front Trim Panel
Replacement . .... ..... .. ... .. ... 8-1 063, 8- i 064
Cargo Area Side Trim Panel Replacement ..... 8-1065
Carpet Replacement
Rear Center Trim Panel ................ 8-1067, 8-1068
Cassette Player
Cleaning Tape Head and Capstan ................ 8-341
Cassette Player Care and Cleaning ................. 8-340
Caster and Camber Adjustment, Front .............. 3-11
Catalytic Converter Replacement ................... 6-1980
Caution, Notice and Important, Definition of .. ,........ 3
CD Changer Replacement
Remote .. ..... ............. ... ... ...... ... . .... .... . 8-342, 8-344
Charging System
Operation ..................................................... 6-783
Charging System Description ......................... ;. 6-782
Cleaning
Fabric Trim ................................................ 8-1074
Glass Surfaces ........................................... 8-1074
Removal Of Specific Stains ........................ 8-1074
Cleaning Agents ............................................ 8-1074
Cleaning Leather Trim ................................... 8-1074
Cleaning the Headliner .................................. 8-1074
Cleaning Vinyl Trim ....................................... 8-1073
Clearcoat Repair without Repainting .............. 8-1138
Clearcoat Thickness ...................................... 8-1140
Closeout/Insulator Panel Replacement
Left .............................................................. 8-589
Right ............................................................. 8-588
Clutch
Actuator Cylinder Replacement .................... 7-395
Anticipate Switch Replacement ..................... 7-397
Clutch Pressure Plate Adjustment ................ 7A01
Clutch Pressure Plate and Clutch
Driven Plate Replacement .... 7-399, 7-400
Description
Clutch Driven Members ............................ 7-404
Clutch Driving Members ............................ 7-404
Clutch Operating Members ....................... 7-404
Hydraulic Clutch ....................................... 7-404
Hydraulic Clutch Fluid ............................... 7-404
Principal Components ............................... 7-404
Diagnosis
Actuator Fluid Leaks ................................. 7-388
Does Not Disengage ................................ 7-382
Grabbing (Chattering) ............................... 7-384
Master Cylinder Fluid Leaks ..................... 7-388
Noisy During Engagement ........................ 7-386
Pedal Hard to Push .................................. 7-387
Pedal Spongy ........................................... 7-389
Pedal Squeaky ......................................... 7-390
INDEX
Clutch (cont.)
Diagnosis (cont.)
Pedal Stays on Floor
(Clutch Disengaged) ....................... 7-386
Pedal Sticks or Binds ......... ............. ..... ... . 7-389
Pedal Travels to Floor
(Fluid in Master Cylinder) ............... 7-388
Preliminary Checking Procedure ............... 7-382
Rapid Driven Plate Wear .......................... 7-390
Rattle (Trans Click) ................................... 7-385
Release Bearing Noisy
w/ Clutch Engaged ......................... 7-385
Slipping ......... ,.......................................... 7-383
Spin Down Time ....................................... 7-382
Unable to Select Gears ............................ 7-389
Housing Replacement ...... ... .... ............... ...... 7-398
Hydraulic Clutch Bleeding ............................ 7-391
Master Cylinder Replacement ....................... 7-393
Pedal Position Switch Replacement ............. 7-397
Pedal Replacement ............ ,......................... 7-391
Pilot Bearing Replacement ........................... 7-403
Release Bearing Replacement ..................... 7-402
Special Tools ............................................... 7-405
Specifications
Sealers, Adhesives and Lubricants ........... 7-382
Clutch Anticipate Switch Replacement (3.8L) .... 6-1297
Clutch Rotor and/or Bearing Install ........... 1-50, 1-52
Clutch Rotor and/or Bearing Removal ...... 1-37, 1-38
Coding Keys and Lock Cylinders ....................... 0-27
Coil Rear Suspension ....................................... 3-55
Coil Spring Insulators Replacement
Rear Suspension .. .......... ...... .............. .. ......... 3-56
Coil Spring Replacement
Rear Suspension ........................................... 3-55
Coin Holder Replacement
Front Floor Console . .......... ....... .. ........ ........ . 8-630
Collision Repair
Radiator Support
Description ... .. ... ......... ....... .............. ... ..... 8-1220
Compact Disc Care and Cleaning ................... 8-346
Compressor Clutch Coil Install ...... ,.......... 1-53, 1-55
Compressor Clutch Coil Removal ............. 1-40, 1-41
Compressor Clutch Plate and Hub
Assembly Removal ........ . ...... .. 1-35, 1-36
Compressor Clutch Plate/Hub
Assembly Replacement ........... 1-48, 1-49
Compressor Control Switches Install .................. 1-59
Compressor Control Switches Removal ............. 1-47
Compressor Control Valve Assembly Install ....... 1-47
Compressor Control Valve Assembly Removal ... 1-42
Compressor Hose Assembly
Replacement ........................ , .. 1-65, 1-68
Compressor Leak Testing .................... ,............. 1-60
Compressor Mounting Bracket
Replacement ......................... : . 1-61 , 1-64
Compressor Pressure Relief Valve Install .......... 1-59
Compressor Pressure Relief Valve Removal ...... 1-46
Compressor Relay Replacement ........................ 1-71
Compressor Replacement ........................ 1-29, 1-32
Compressor Sealing Washers Replacement ....... 1-65
Compressor Shaft Seal Install .... .... ....... ... 1-56, 1-57
5
Compressor Shaft Seal Removal .............. 1-43, 1-45
Condenser Replacement ................................... 1-74
Console
Armrest Replacement
Front Floor ............................................... 8-624
Ashtray/Lighter Replacement ........................ 8-619
Bracket Replacement
Front Floor ............................................... 8-623
Coin Holder Replacement
Front Floor ............................................... 8-630
Cup Holder Replacement
Front Floor ............................................... 8-629
Power Accessory Port Replacement
Front Floor ............................................... 8-629
Replacement
Front Floor ............................................... 8-621
Storage Bin Replacement ............................. 8-617
Trim Plate Replacement
Front Floor .................................... 8~624; 8-628
Console Compartment Door
Latch Replacement ..................................... , 8-616
Control Arm Bushings Replacement
Rear Suspension ........................................... 3-46
Control Arm Replacement
Rear Suspension
Lower ......................................................... 3-45
Control Arm Replacement, Lower .: .................... 3-31
Control Arm Replacement, Upper ...................... 3-29
Control Assembly Replacement
(A/C - Manual) ............................... 1-126
Control Module References ............................... 8-34
Conversion Table, English/Metric ., ....................... 0-3
Coolant
Description .............................................. :.... 6-66.9
Heater Description .......................... ,............ 6-670
Recovery Pipe Replacement
(Engine Cooling) ............................. 6.-613
Recovery Reservoir Replacement
(Engine Cooling) ............................. 6-61 O
Recovery System Description ... ... .. ..... ..... ..... 6-669
Coolant Heater
Cord Replacement (Engine Cooling) ... 6-666, 6-667
Coolant Heater Replacement
(Engine Cooling) .................. 6-663, 6-664
Cooling System Draining and Filling ..... 6-608, 6-609
Courtesy Lamp Replacement
Rear Quarter, ........................................... ,... 8-224
Cover Replacement
Trim Panel Opening ................................... 8-1091
Inspection (3.8L) ........................... 6-1298
Replacement (3.8L) ....................... 6-1293
Replacement (5. 7L) ....................... 6-1915
Crankshaft Position System Variation
Learn Procedure (3.8L) ................. 6-1234
Crankshaft Position System Variation
Learn Procedure (5.7L) ................. 6-1840
Crossmember Brace Replacement
Front .......................................................... 8-1176
Crossmember Replacement ........................... 8-1178
INDEX
Cruise Control
Cable Adjustment .............................. 8-748,
Cable Replacement ........................... 8-737,
Component Locations ...................................
Component Views ........................................
Connector End Views ...................................
Description
System Circuit ..........................................
System Description ...................................
System Operation .....................................
Diagnosis
Cruise Control Inoperative/
Malfunctioning Using J 42958
Cruise Control Tester .....................
Diagnostic Starting Point Cruise Control ................................
Inoperative/Malfunctioning .........................
Symptoms - Cruise Control .......................
Module Replacement ...................................
Release Switch Adjustment ..........................
Release Switch Replacement .. .... .... ..... .... .. ..
Schematic
Icons ........................................................
Schematics ..................................................
Special Tools ...............................................
Specifications
Fastener Tightening ..................................
GM SPO Group Numbers .........................
Cup Holder Replacement
Front Floor Console .....................................
8-749
8-742
8-716
8-717
8-721
8-752
8-751
8-751
8-727
8-722
8-723
8-722
8-731
8-750
8-749
8-713
8-714
8-753
8-713
8-713
8-629
D
Data Link Communications
Component Views . ... ... . .. .. ... .... .... ... ..... .... ... .. .. 8-20
Components ... .. .. ... .... .. .. . ... ..... .. ..... .. .. .... ... .. ... 8-18
Connector End Views .................................... 8-21
Description
Circuit ........................................................ 8-34
Diagnosis
Diagnostic Starting Point ............................. 8-22
DTC List ... ... . ... ... .... .. . .. .. .... .... .... .. ..... ... ... .... 8-22
Scan Tool Does Not Communicate
w/Class 2 Data Line .. .... ... ..... .... .. ... .. 8-31
Scan Tool Does Not Power Up .................. 8-30
Schematic Icons ............................................ 8-15
Special Tools ................................................. 8-34
Data Link Connector (DLC)
Schematics . .. .. ... .. ... ... .. .. . ... ..... .... ... ... ...... .. .. ... 8-16
Daytime Running Lamps
Ambient Light Sensor Replacement .............. 8-220
Control Module Replacement ....................... 8-177
Decimal and Metric Equivalents .......................... 0-3
Definition of Caution, Notice and Important ............ 3
Defogger
Right Air Outlet Replacement
(A/C - Manual) ............................... 1-138
Description of Arrows and Symbols .... ... ..... ... ..... . 0-4
Diagnosis
Ball Stud Check . .. .. .. ... . .. . .. . .. ... ... .. .. ... .. .. .. .. .. .. . 3-17
Inoperative ................................................... 7-288
Inoperative - Both ........................................ 8-905
Strategy Based Diagnosis .............................. 0-32
Tire Wear, Abnormal or Excessive ................... 3-4
Diagnostic Work Sheets ...................................... 0-5

Differential Carrier Replacement
Rear Drive Axle ............................................. 4-28
Disc Brakes
Bra.ke Caliper
Inspection ............................ , ...................... 5-69
Overhaul ........................................... 5-70, 5-73
Replacement ..................................... 5-63, 5-66
Brake Rotor Replacement ..................... 5-77, 5-78
Burnishing Pads and Rotors .......................... 5-62
Description ..................................................... 5-82
Diagnosis
Brake Rotor Lateral Runout Check ............. 5-57
Brake Rotor Thickness Variation Check ...... 5-57
Brake Rotor Tolerance ............................... 5-57
Refinishing Brake Rotors ....................... 5-79, 5-80
Special Tools ................................................. 5-83
Specifications
Component ... ....... ... ...... ..... ... ... ... ... ...... .. ..... 5-56
Dome and Reading Lamp Bulb Replacement ..... 8-221
Dome Lamp Replacement ............................... 8-226
Door Lamp Replacement ................................. 8-222
Door Lock Switch Replacement ........... 8-912, 8-913
Door Locks
Diagnosis
All Power Door Locks Inoperative ............. 8~895
Power Door Locks Switch Lock
Function Inoperative - One ............. 8-897
Power Door Locks Switch Unlock
Function Inoperative ....................... 8-897
One ...................................................... 8-897
Door Opening Frame Replacement
Side .................................. 8-1204, 8-1205, 8,1208
Door Replacement
Fuel Filler .................................................. 8-1095
Door Service ................................................. 8-1211
Door Sill Plate Replacement .......................... 8-1067
Doors
Description
Power Door Locks Circuit ......................... 8-934
Power Mirrors Circuit ................................ 8-935
Power Windows Circuit ............................. 8-934
Diagnosis
Both Power Windows Inoperative .............. 8-905
Diagnostic Starting Point - Doors .............. 8-894
Power Door Locks .................................... 8-896
Do Not Lock ......................................... 8-896
Do Not Unlock ............ :......................... 8-896
Power Mirrors lnop in Up/Down
Direction - One .................... 8-902, 8-904
Power Windows ........................................ 8s909
Express Function Inoperative ................. 8-909
Inoperative From LF Switch ................... 8-910
Power Windows Inoperative Right Front ..................................... 8-908
Power Windows Inoperative from
RF Switch ...................................... 8-910
Symptoms - Doors .................................... 8-894
Door Handle Replacement
Inside ....................................................... 8-922
Door Hinge Replacement .................. 8-920, 8-921
Door Replacement ....................................... 8-919
INDEX
Doors (cont.)
Door Seal Replacement .... ....... .. . ... .. .. .... .... .. 8-930
Inside Handle Bezel Replacement ................ 8~915
Lock Actuator Replacement .......................... 8-925
Lock Replacement ................................. :.. ;.. 8-924
Lock Striker Adjustment ............................... 8-926
Mirror Face Replacement .................. 8-933, 8-934
Mirrors Replacement .................................... 8-932
Power Door Systems Component Views ..... , 8-886
Power Door Systems Components ........... ;... 8-884
Power Door Systems Connector End Views.. :., 8-890
Schematic
Door Locks ................................... .... :....... 8:881
Outside Mirrors ............................... 8~882, 8-883
Power Door Systems Schematic. Icons ...... 8:.879
Power Windows ....................................... ,8-880
Special Tools ........................................... ;... 8~936
Specifications .
Striker Replacement ..................................... 8-926
Trim Panel Replacement
Door ......................................................... 8-917
Water Deflector Replacement
Door ......................................................... 8~918
Weatherstrip Replacement
Door ....................................................... ,.. 8,931
Window Regulator Motor Replacement ......... 8-928
Window Regulator Replacement ................... 8-927
Window Replacement ............................... ;... 8-928
Drain Channel. Replacement .......................... 8~1001
Drain Cock Replacement (Engine Cooling) ...... 6-652
Draining and Filling Cooling System
(Engine Cooling) ................... 6-608, 6s609
Drive. Belt Replacement - 3.8L ...................... , ... 6-47
DrumlRotor Imbalance ....................................... 0-50
DTC 12 ............................................................ B-536
DTC 21/31 ....................................................... 8~103
DTC 22/32 .. . ... .... ....... ... ...... ..... ... ... ...... . 8-105, a~108
DTC 23/33 " 8-759
DTC 24/34 .......................................................... 9-8
DTC 25/35 ........................................................ 8-687
DTC 41 .......................................................... 8-653
DTC 42 .. .. ... .. ....... .. ..... ..... ........ ..... ... ...... ... ...... 8-654
DTC 43 . ... .. ... .. ...... .. ... .... .......... ............. .... ..... 8-655
DTC 44 ........................................................... 8-656
DTC 45 .. ... ... .. .......... ... .. ........ .... ............. .... .... . 8-.657
DTC 55 ........................................................... 8-538
DTC BOO 16 ....................................................... 9~38
DTC B0017 ..................................................~ ... ; 9-41
DTC B0018 ....................................................... 9-44
DTC 80022 ........................................................ 9~47
DTC 80024 ....................................................... 9-50
DTC 80026 ....................................................... 9-53
DTC 80051 ....................................................... 9-56
DTC 80053 ...................................................... , 9-57
DTC 80670 ....................................................... 9..:58
DTC B1000 ................................................ ,.... 8-5313
DTC B1000 ..................................................... 8-563
DTC 81001 ....................................................... 9-59
DTC C0035 .. .. ... ...... .... ..... ........ ........... ... ... ..... .. 5-130
DTC C0036 ..................................................... 5-133
DTC C0040 -' 5-136
DTC C0041 ..................................................... 5-139
7
DTC C0045 . ...... ... ... ..... ... .... .. ..... .. .. .. .. .. .. ... .. . .. . 5-142
DTC C0046 ..... .... ... .. .. .... .. .... .... ... .. .. .. .. .. ... .. . .. .. 5-145
DTC C0050 ... ..... ... .. ..... .. .. ... ... ..... . .. .. .. .. ... .. .. .. .. 5c148
DTC.C0051 ..................................................... 5-151
DTC C0055 ................................................ ,.... 5-154
DTC C0056 ..................................................... 5-157
DTC C0060 . ...... ... ... .. ... ... .... .. .... . ... .. .. .. .. .. ... . .. ... 5-160
DTC C0065 .....................................................,. 5-161
DTC C0070 ... .... . .. .... .... .. .. ... ... ... ... .. . .. .. .. ... .. .. .. .. 5-162
DTC C0075 ...................................................,. 5-163
DTC C0080 . .... .... ... ... ... .... .. .... ... ... .. .. .. .. .. .... .. . ... 5-164
DTC C0085 ,.. ..... ... ... ...... ... .. ... ..... .. .. . ... .. ... ... . .. . 5-165
DTC C0090' .. ..... ... ... ..... ... .... .. ..... .. .. .. .. .. ... ... . .. .. 5-166
DTC C0095 . ..... .... ... .... .... ... ... .... ... .. .. .. .. .. ... .. .. . . 5-167
DTC C0100 ..................................................... 5-168
DTC C0105 ..................................................... 5-169
DTCC0110 ..................................................... 5-170
DTC C0121 .................................................... ; 5-173
DTC'C0161 5-175
DTC C0166 ..................................................... 5-178
DTC C0171 ..................................................... 5-179
DTC C0181 ..................................................... 5-180
DTC C0182 ..................................................... 5-183
OTC C0236 .... .... .... .. ...... ... .. .... ... ... .. .. .. .. .... .. . ... 5-185
DTC C0237 ..................................................... 5-188
DTC C0238 . ..... .... ... .... ..... ... .. ..... ... .. .. .. .. ... ... .. .. . 5-190
OTC C0239 ..... ... .... .... ..... ... .. .... ... ... . ... .. .. ... .. . ... 5-192
DTC C0240 .. ..... ... ... ..... .... ... .. ..... .. ... . ... .. ... .. .. .. . 5-194
DTC C0241 ..................................................... 5:.195
DTC C.0244 ..................................................... 5-199
DTC C0245 . ..... .... ... ... .. .... ... .. ..... ... .. .. .. ... .. ... .. .. . 5-202
DTC C0266 .... .... .... ... ..... ... ... .. .. ... .. .. .. .. .... .. .. ... . 5-205
DTC C0550 .. ..... ... ... ...... .. .... ... .... ... . ... .. ... .. .. .. .. . 5-208
DTC C0896 . ..... .... ... .... .... ... ... .... .. ... .. .. ... .. ... .. .. . 5-209
DTC C0901 ..................................................... 5-21.1
DTC P0101 ..................................................... 6-857
DTC P0101 ................................................... 6-1411
DTC P0102 ...................................................... 6-861
DTC P0102 ................................................... 6-1416
DTC P0103 ......................................... 6-864, 6-1420
DTC P0107 ......................................... 6-867, 6-1423
DTC P0108 ......................................... 6-870, 6-1427
DTC P0112 ...................................................... 6-872
DTC P0112 .................................................... 6-1431
DTC P0113 , ........................................ 6-874, 6-1434
DTC P0117 ......................................... 6-877, 6-1438
DTC P0118 ......................................... 6-879, 6-1441
DTC P0121 ................................................... 6-1445
DTC P0122 ................................................... 6-1449
DTC P0123 ................................................... 6-1453
DTC P0125 ......................................... 6-882, 6-1457
DTC P0131 ......................................... 6-885, 6-1460
DTC P0132 ......................................... 6-887, 6-1463
DTC P0133 ......................................... 6-890, 6-1467
DTC P0134 ......................................... 6-893, 6-1471
DTC P0135 ......................................... 6-896, 6-1475
DTC P0137 ......................................... 6-899, 6-1478
DTC P0138 ..................................................... 5..:902
DTC P0138 ................................................... 6-1482
DTC P0140 ..................................................... 6-905
DTC P0140 ................................................... 6-1486
DTC P0141 ..................................................... 6-908
DTC P0141 ................................................... 6-1490
DTC P0151 ......................................... 6-911, 6-1493
8
OTC P0152
OTC P0152
OTC P0153
OTC P0154
OTC P0154
OTC P0155
OTC P0157
OTC P0158
OTC P0160
OTC P0161
OTC P0171
OTC P0172
OTC P0174
OTC P0175
OTC P0175
OTC P0200
OTC P0201
OTC P0202
OTC P0203
OTC P0204
OTC P0205
OTC P0206
OTC P0218
OTC P0230
OTC P0230
OTC P0300
OTC P0300
OTC P0325
OTC P0327
OTC P0332
OTC P0332
OTC P0335
OTC P0336
OTC P0341
OTC P0342
OTC P0343
OTC P0351
OTC P0352
OTC P0353
OTC P0354
OTC P0355
OTC P0356
OTC P0357
OTC P035.8
OTC P0401
OTC P0403
OTC P0404
OTC P0404
OTC P0405
OTC P0405
OTC P0410
OTC P0412
OTC P0418
OTC P0420
OTC P0430
OTC P0440
OTC P0442
OTC P0443
OTC P0443
OTC P0446
OTC P0449
OTC P0449
OTC P0452
OTC P0452
INDEX
..................................................... 6-913
................................................... 6-1496
......................................... 6-916, 6-1500
..................................................... 6-919
............................................... ; ... 6-1504
......................................... 6-922, 6-1508
.................................................... 6-1511
................................................... 6-1515
................................................... 6-1519
................................................... 6-1523
......................................... 6-925, 6-1526
......................................... 6-928, 6-1529
......................................... 6-931, 6-1532
...................................................... 6~934
................................................... 6-1535
. . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . 6-1538
..................................................... 6~937
.. .. . .. .. . . .. . .. . .. . . .. . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . 6~940
. . . . . . .. . . . . .. . .. .. . . .. . .. . . . . . . . .. . . . . . . . .. . . . . . . . . . 6-943
.. . . . . . . . . . . . .. .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-946
.. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . .. . 6-949
. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6-952
........................................... 7-122, 7-125
. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .. . . . . . . . . . .. . . . . . .. . 6-1542
. . . . . . . . . . .. .. . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . . . 6-955
. . . . . . . . . . . . .. . . . . . . .. . . .. . . . . .. . . . . . .. . . .. . . . . . . . . 6-1545
. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. 6-958
. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-963, 6-1550
. . . . .. . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . .. .. 6-965, 6-1552
. . . . . . . . . . .. . . . . . . . . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . . . . . 6-968
. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . 6-1555
............................................. : . . . . . 6-1558
......................................... 6-971, 6~1562
. .. . . .. . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6~97 4, 6-1565
. . .. . . . . . .. . . . . . . . . . . . .. . . .. . . . . . . . . . .. . . . . . . . . . . . . 6-1568
................................................. , . . 6-1572
................................................. :. 6-1576
. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-1580
. .. .. . .. .. . .. . .. .. .. . . . . . . .. . . .. . .. . . . . . . . . . . . . . . . . 6-1584
................................................... 6-1588
.. . . . . . . . . . . . . .. . . . . . .. . . . .. . . . . . . . . . . . .. . .. . . . . . . . 6-1592
.. .. . .. . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . 6-1596
. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-1600
.. . . .. . . .. . . . . . . . . . . . . . . . . . . . . .. . . . .. . .. . . . . . . . . . . . 6-1604
......................................... 6-978, 6-1608
................................................ : . . . . 6-980
................................................... 6-1610
.. . . . . . .. . . . . .. . . .. . .. .. .. .. . . .. . .. . .. .. . . . . . . . . . . . . . 6-983
................................................... 6-1613
.. .. . . .. . .. . .. .. . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . 6s986
................................................... 6-1617
................................................... 6-1623
................................................... 6-1626
......................................... 6-989, 6-1629
................................................... 6-1631
. . . .. . .. .. .. ... . .. .. .. . .. .. .. .. .. . .. .. . . . 6-992, 6-1633
......................................... 6-997, 6-1639
................................ ,................ ,. 6-1001
.................................................... 6-1645
.. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1004, 6-1648
................................................... 6-1007
. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . .. . . . . . . . . . 6-1652
................................................... 6-1010
. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 6-1655
OTC P0453 ................................................... 6-1013

OTC.P0453 ................................................... 6-1660
OTC P0461 ................................................... 6-1665
OTC P0462 .................... ,.................. 6-1015, 6-1668
OTC P0463 ....................................... 6-1017, 6-1671
OTC P0480 ....................................... 6-1020, 61675
OTC P0481 ................................................... 6-1023
OTCP0481 ................................................... 6-1678
OTC P0500 .... , .................................. 6-1026, 6-1681
OTC P0502 ................. , ...... ,........ , .... , .... 7-128, 7-131
OTC P0503 ...... :. ................................... 7-134, 7-137
OTC P0506 . . .. . . ... . . .. . ... . .. . . . . . . . .. .. . .. .. .. . .. .. . .. . . . . . 6-1028
OTC.: P0506 . . .. . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1683
OTC P0507 . .. .. . ... . . .. . .. . . .. .. . .. . . .. . . . . . . .. . . . .. .. . .. .. .. 6-1030
OTC P0507 ..........,; ........................................ 6-1686
OTC P0530 .................................................... 6-1689
OTC.P0530 ................................................... 6-1032
OTC P0560 . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1035
OTC po562 ................................................... 6-1692
OTC P0563 . . . . . . .. . . . .. . .. . . . ... . . . . .. . .. . .. .. .. . . . . .. . .. .. . . 6-1694
OTC P0567 . . . . . . .. . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6~1038
OTC P0568 . . . . . . .. . . . .. . .. . . . . . . . . . . . . . . . .. ... . . . .. . . . .. . . . . 6-1040
OTC P0571 ................................................... 6-1042
OTC P0601 ............................ ,.......... 6-1046, 6-1696
OTC P0602 ....................................... 6-1047, 6-1697
OTC P0604 .................................. ,....... : ........ 6-1047
OTC P0604 . . . . . . .. . .. . . . . . . .. . . . . .. . . .. .. .. .. . . . . . .. .. .. .. . .. 6-1698
OTC P0606 ......... : ........................................ 6-1048
OTC P0608 .............. .-, ......................... ,......... 6-1699
OTCP0620 ................................................... 6-1049
OTC P0645 ....................... : ......................... :. 6-1702
OTC P0650 .... ;: ................ :. ............... 6-1051, 6-1705
OTC P0704 ....................................... , 6-1054, 6-1707
OTC P0711 ....................................... : ... 7-141, 7-145
OTC P0712 ....................... : ....... ; ........... 7-149, 7-152
OTC P0713 ........................................... 7-155, 7-159
OTC P0719 ........................................... 7-163, 7-166
OTC P0724 ............................................. 7-169, 7-1T1
OTC P0740 ........................................... 7-173, 7-177
OTC P0742 ........................................... 7-181, 7-184
OTC P0748 ........................................... 7-187, 7-191
OTC P0751 ........................................... 7-195, 7-198
OTC P0752 ..................................................... 7-200
OTC P0753 ........................................... 7-202, 7-206
OTC P0756 ..................................................... 7-213
OTC P0756 ..................................................... 7-210
OTC P0757 ..................................................... 7-2t5
OTC P0758 ........................................... 7-217, 7-221
OTC P0785 .. .. .. .. . . .. . . .. . .. .. .. .. . .. .. . .. .. .. . . .. .. 7-225, 7-229
OTC P0801 .................................................. , 6-1710
OTC P0803 . . . . . . .. . . . .. . .. ... .. . . . . .. . . .. .. .. . . .. .. . . .. . . . .. . 6-1713
OTC P1106 .................................................... 6-1057
OTC P1107 .................................................... 6-1059
OTC P1111 .................................................... 6~1061
OTC P1111 .................................................... 6-1716
OTC P1112 .................................................... 6,1719
OTC P1112 .................................................... 6-1063
OTCP1114 .................................................. ,. 6-1722
OTC P1114 .................................................... 6-1065
OTC P1115 ........................................ 6-1067, 6-1725
OTC P1120 .................................................... 6-1069
OTC P1121 .................................................... 6-1728
OTC P1122 .................................................... 6-1731
OTC P1125 .................................................... 6-1073
INDEX
DTC P1133 ....................................... 6-1074, 6-1734

DTC P1134 .................................................... 6-1077
DTC P1134 .................................................... 6-1737
DTC P1153 .................................................... 6-1740
DTC P1153 .................................................... 6-1080
DTC P1154 .................................................... 6~1743
DTC P1154 .................................................... 6-1083
DTC P1220 ................................................... 6-1086
DTC P1221 ................................................... 6-1090
DTC P1258 ................................................... 6-1746
DTC P1271 ................................................... 6-1093
DTC P1272 ......................................... :......... 6-1094
DTC P1273 ................................................... 6-1095
DTC P1275 ................................................... 6-1096
DTC P1276 .. .. .. ... .. . ...... .. . .. .. .. .... .... .. . ... ....... .. 6-1098
DTC P1280 ................................................... 6-1100
DTC P1281 ................................................... 6-1102
DTC P1285 ................................................... 6-1104
DTC P1286 ................................................... 6-1106
DTC P1336 ....................................... 6-1108; 6-1747
DTC P1351 ................................................... 6-1109
DTC P1352 ................................................... 6-1111
DTC P1361 ................................................... 61113
DTC P1362 ................................................... 6-1116
DTC P1374 ............. , ..................................... 6-1119
DTC P1380 ......................... :............. 6-1122, 6-1750
DTCP1381 ................................................... 6-1123
DTC P1381 ................................................... 6-1751
DTC P1404 .............. ,................................ ,.,. 6-1752
DTCP1404 ................................................... 6-1125
DTC P1415 ........ ~ .......................................... 6-1756
DTC P1416 .............................................. ,.... 6-1758
DTC P1441 ....................................... 6-1128, 6-1760
DTC P1514 ................................................... 6-1132
DTC P1515 ................................................... 6-1134
DTC P1516 ................................................... 6-1137
DTC P1517 ................................................... 6-1140
DTC P1518 ................................................... 6-1141
DTC P1519 ............................................. ::: ... 6-1144
DTC P1523 ................................................... 6-1145
DTC P1546 ....................................... 6-1146, 6-1764
DTC P1571 ................................................... 6-1149
DTC P1574 ................................................... 6-1151
DTC P1586 ................................................... 6-1154
DTC P1626 ....................................... 6~1157, 6-1767
DTCP1629 ................................................... 6-1159
DTC P1635 ............................................. ;..... 6-1161
DTC P1635 ................................................... 6-1770
DTC P1637 ................................................... 6-1775
DTC P1639 ................................................... 6-1778
DTC P1639 ................................................... 6-1164
DTC P1689 ................................................... 6-1166
DTC P1810 ........................................... 7-233, 7-237
DTC P1860 ........................................... 7-241, 7-245
DTC P1870 ................................ ,........ ,. 7-249, 7-255
DTC U1000 and DTC U1255 ............. , ............... 8-23
DTC U1001 - U1254 ......................................... 8-26
DTC U1300 ................................... ,;.................. 8-28
DTC U1301 ....................................................... 8-29
E
Emblem Replacement
Front Bumper Fascia ................................... 8-770
End gate Latch Replacement . . ... .. .... ... .. . .. . .. .... 8-1105
Engine Compression Test ................................ 6-272
Engine Compression Test (3.8L) ........................ 6-23
Component Views ........................................ 6-812
Components ... .... .. .... . .. ...... . . ... ... ... ... ... .. .. .. ... . 6-807
Connector End Views ... .. ... .. ... ... ... .. ... . .. . ... .. . . 6-818
Description
Air Intake System ................................... 6-1322
Crankcase Ventilation System (3.8L) ....... 6-1321
Electric Engine Cooling Fan .................... 6-1305
Electronic Ignition System .................... ,.. 6-1314
EVAP Control System (3.8L) ............. , ..... 6-1312
Exhaust Gas Recirculation
System (3.8L) ............................... 6~1320

Fuel Metering Modes ofOperation .......... 6-1309
Fuel Metering System
Component (3.8L) ......................... 6-131 O
Fuel Supply Component .......................... 6-1306
Information Sensors/Switches .................. 6-1300
Knock Sensor System (3.8L) .................. 6-1318
Long Term Fuel Trim ............................ ,. 6~1312
Short Term Fuel Trim ............................. 6-1312
Throttle Actuator Control
System Description ....................... 6-1321
Diagnosis
Alcohol/Contaminants-in-Fuel ................... 6-1226

Backfire ............................................... ,...6-11.85
Cranks but Does Not Run ........................ 6-847
Cruise Control .. . ... .. ... ..... ... . .... .. .. .. . .. .. .. . .. 6-1205
Cuts Out, Misses .................................... 6-l177
Data Link Connector .................................. 6-845
Detonation/Spark Knock ....................... ,. , 6-1175
Diagnostic Starting Point ................. , ....... :. 6-826
Diagnostic Trouble Code (OTC) List/Type ... 6-839
Diagnostic Trouble Code (DTC) Type
Definitions ....................................... 6-838
Dieseling, Run-On ................................... 6-1185
Electric Cooling Fan ..... 6-1197, 6-1198; 6-1199,
6-1200, 6~1202
Engine Oil Level Sensor/Switch ...............6-1210
EV AP Control System ... . ... . .... .. . ... .. . .. ... ... 6-1228
Fuel Injector Balance Test ...................... 6-1217
Fuel Injector Balance Test with Tech 2 ... 6-1220
Fuel Injector Coil Test ............................ 6-1222
ECT Between 10-35 Degrees C ........... 6-1222
ECT Outside 10-35 Degrees C ........... : 6-1224
Fuel Pump Relay Circuit .................... , ...... 6-854
Fuel Quality ............................................ 6-1226
Fuel System ............................................. 6-856
Fuel System Pressure Test ..................... 6~1212
Fuel Tank Leak Check ........ , ............... : ... 6~1226
Hard Start ............................................... 6-1169
Hesitation, Sag, Stumble ......................... 6-1176
Procedures ................................... 6-1231

Lack of Power, Sluggishness,
or Sponginess . .. . .. .. .. .. ... . .. . ... ... .. .. . 6-.1174
Manifold Absolute Pressure
Sensor Circuit ............................... 6-1194
10
Engine Controls - 3.8L (cont.)
Diagnosis (cont.)
No Malfunction Indicator Lamp ..... ,....... :.... 6-843
Poor Fuel Economy ................................ 6-1180
Poor Fuel Fill Quality ............................. 6-1181
Powertrain Control Module ...................... 6-1188
Controlled Air Conditioning ............ 6-1189
Powertrain On Board Diagnostic
System Check ............. :.. ..... .... .. .. ... 6-827
Restricted Exhaust System Check . .. .. ... .. 6-1186
Rough, Unstable, or Incorrect Idle,
Stalling .... .. .. ... .. .... .. .... .. ..... .. ... ... .. . 6-1183
Scan Tool Data Definitions ....................... 6-832
Scan Tool Data List .. : ............................... 6-828
Service Bay Test .................. :................. 6-1231
Surges/Chuggles .................................... 6-1172
Symptoms .............................................. 5c1168
Emission Hose Routing Diagram .................. 6-788
Connector End Views ......... , ........... 6-814
Schematic
Icons . .. .. . .. .. ... .... .. .. .. .... ... .... .. .. .. ... .... .. ... .... 6-790
Schematics ............................................... :.. 6-791
Special Tools .............................................. 6-1322
Specifications
Fastener Tightening .'. 6-786
Fuel System ............................................. 6-787
Temperature vs Resistance ...................... 6-786
Component Views .. .. ... .. .. .. .... .. .. . ... .. ... ... .. ... 6-1354
Components .. ... .... .. .. .. ... ... .... .. ... .... .... ... .. .... 6-1348
Connector End Views ................................. 6-1372
Description
Air Intake System ................................... 6-1967
Crankcase Ventilation System ................. 6-1965
Electronic Ignition System ....................... 6-1958
Engine Cooling Fan- Electric ........... ,,_ ...... 6-1947
EV AP Control System ..................... ........ 6-1954
Exhaust Gas Recirculation System .......... 6-1963
Fuel Metering Modes of Operation .......... 6-1951
Fuel Metering System Component ... .. ... .. 6-1952
Fuel Supply Component .......................... 6-1947
Information Sensors/Switches .................. 6-1938
Knock Sensor System ............................. 6-1961
Long Term Fuel Trim .............................. 6-1954
Secondary Air Injection System .............. 6~1962
Short Term Fuel Trim ............................. 6-1953
Speed Density System .. .. . .. . .. . ..... ... ... .. .... 6-1954
Diagnosis
A/C Refrigerant Pressure Sensor Circuit .... 6-1801

A/C Request Circuit ................................ 6-1799
Alcohol/Contaminants-in-Fuel ................... 6-1828
Backfire .................................................. 6.:1796
Cuts Out, Misses ............................... : ... : 6-1789
Detonation/Spark Knock .. .... ... .. .... .... .. .. .. . 6-1788
Diagnostic Starting Point ......................... 6-1380
Diagnostic Trouble Code (DTC)
List/Type ....................... , ............... 6c1391
.
Type Definitions ,........................... 6-1390
Dieseling, Run-On ................................... 6-1796
Electric Cooling Fan ............................... 6-1803
Engine Cranks but Does Not Run ........... 6-1396
INDEX
Engine Controls - 5.7L (cont.)
Diagnosis (cont.)
Engine Oil Level Sensor/Switch .............. 6-1815
Engine Speed Output Circuit ................... 6-1829
Fuel Injector Balance Test with
Special Tool ............................. ,:,. 6-1821
Fuel Injector Balance Test with Tech 2 ... 6-1818
Fuel Injector Coil Test ...... , ...... , .............. 6-1824
ECT Between 10-35 Degrees C ........... 6-1824
ECT Outside 10-35 Degrees C ...... .', .... 6-1826
Fuel Pump Relay Circuit ..... ,.............. '. .... 6-1402
Fuel System ............... ,......... , ................. 6-1406
Fuel Tank Leak Check ... , .................. '. ..... 6-1828
Hard Start ................... :., ......................... 6-1783
Hesitation, Sag, Stumble ....................... :: 6-1789
Ignition Relay .. ,.................................... :.;'6~1399
Procedures .................................. ; 6-1836
Intermittent Condition .............................. 6-1781
Sponginess ................. ,. ... .. ... .. ..... . 6-1785

PCM Controlled Air Conditioning ..... :....... 6-1946
PCM Controlled Generator ... , .................. 6-1810
PNP Switch ........................... , ............ : ... 6-1812
Poor Fuel Economy ..... " ..... ,.. , ............ , ... 6-1791
Poor Fuel Fill Quality ... :............... ,.... ,, .... 6-1793
Powertrain On Board Diagnostic
System Check ..... ; ........................ 6-138.1
Rough, Unstable, or Incorrect Idle,
Stalling ................................. , .. , .... 6-1795
Scan Tool Data Definitions .. : .................. 6-1386
Scan Tool Data List .............................. ;. 6-1383
Service Bay Test .................................... 6-1836
Surges/Chuggles ......................... :.......... : 6-1784
Symptoms ................... ;: ... , ...... :.............. 6-1781
Vehicle Speed Output Circuit ., ................ 6-1$31
Electronic Ignition System ........................ ::. 6-1833
Emission Hose Routing Diagram ........... ,... , 6-1328
Connector End Views . ,................. 6-1368

Repair
AIR Solenoid Valve Replacement .......... i. 6-1_926
.
Replacement Bank 1 Sensor 1 ...... 6-1846

Replacement Bank 1 Sensor 2 ...... 6-1847
Replacement Bank 2 Sensor 1 .. .. .. 6c1849

Replacement Bank 2 Sensor 2 .....'. 6-1851
Schematic
Icons ........................................ , . ... . .... .. .. . 6-1328

Schematics ................ ,............. , .. '. .... , ......... 6-1329
..
Secondary AIR Injection Shut Off
Valve Replacement, ................. " 6-1923
Special Tools ................................... ,..... : .... 6-1969
Specifications
Fastener Tightening ............ :: .................. 6-1325
Fuel System ........................................ : .. 6:1326
GM SPO Group Numbers .... :: ................. 6-1326
Temperature vs Resistance ...... , .............. 6-1325
Replacement (3.8L) ....................... 6-1235
INDEX
Replacement (5.7L) ....................... 6-1841
Replacement
(Engine Cooling) .................. 6-650, 6-651
Engine Cooling
Component Views ........................................ 6-599
Components ...................... , .............. ,........... 6-598
Connector End Views ... .... .......... .. ... .. .... ... .... 6-600
Description
Air Baffles and Seals ................................ 6-673
Coolant ..................................................... 6-669
Coolant Heater .. .. .. ... .... .. .. ... ... ... .. .. ... .. .... .. 6-670
Coolant Recovery System ......................... 6-669
Cooling Fan Relay ............ ,....................... 6-672
Cooling System .............. ,......................... 6-669
Electric Engine Cooling Fan ...................... 6-671
Engine Coolant Temperature Sensor ........ 6-672
Radiator Assembly ............................... , .... 6-670
Radiator Filler/Pressure Cap Assembly ..... 6-671
Thermostat ............................................ ,.. 6-672
Throttle Body Coolant System .................. 6-670
Water Pump ............................................. 6-672
Diagnosis
Coolant Concentration Testing ............... , .. 6-604
Cooling System Leak Testing ........ : .......... 6-606
Engine Fails To Reach Normal
Operating Temperature ................... 6-604
Loss of Coolant ...... .. .. . .. ...... .... ... .. .... ... ... .. 6-602
Overheating .......................... , ................... 6-601
Pressure Cap Testing ............................... 6-608
Thermostat ................................... ,........... 6-604
Schematic
Cooling Fan ............................. , ............ .... 6-596
Cooling System Icons .. .. .... ... .. . .. .. .. .. .. .. ... .. 6-595
Special Tools ............................................... 6-673
Specifications
Engine Cooling System .............. ,.............. 6-594
Engine Diagnosis
Exhaust Leakage ...................... , ................ 6-1976
Engine Electrical
Component Locations .. ..... ....... .. ... .. . .... ... .. .. .. 6-680
Description
Battery ...................................................... 6-781
Battery Operation ......................................- 6-781
Battery Tray and Hold-Down Retainer ....... 6-782
Charging System ...................................... 6~782
Charging System Circuit .. ...... .. .. ... .. .. .. ... ... 6-783
Charging System Operation ...................... 6-783
Ignition System .............................. 6-783, 6-784
Ignition System Operation ......................... 6-784
Starting System ........................................ 6-780
Starting System Circuit ............................. 6-780
Starting System Operation ........................ 6-780
Diagnosis
Battery Common Causes of Failure .......... 6-692
Yellow Dot .. .. ..... .. .. .. .. .. ..... .... .. .. ... .. . 6-700
Battery Hydrometer Displays Yellow Dot ... 6-694
Battery Load Test - Parasitic .................... 6-700
Battery Not Operating Properly ...... ... ...... .. 6-696
Battery Terminal Check ............................. 6-693
Engine Electrical (cont.)

Diagnosis (cont.)
Battery Visual Inspection ........................... 6-693
Diagnostic Starting Point Engine Electrical ........................... ,. 6-686
Engine Cranks/Cranks Slowly,
but Does Not Start ................ , .. .. .. .. 6-690
Generator Assembly Check .. .. ... .. .. .. . .. .. ... 6-706
Generator Not Operating Properly ............. 6-704
Spark Plug Visual ..................................... 6-707
Spark Plug Wire Harness ......................... 6-709
Starter Motor Noise ............................ ,..... 6-691
Starter No Load Test .............................. ,. 6-692
Starter Solenoid Clicks,
Engine Does Not Crank .................. 6-688
Starter Solenoid Does Not Click .. .. . .... .. ... . 6-687
Symptoms - Engine Electrical ................... 6-686
Generator Brace Replacement ..................... 6-763
Generator Bracket Replacement ....... 6-761, 6-762,
6-763
Generator Replacement .. .. ... .. ... .. .. . .. .. 6764, 6-766
Generator Splash Shield Replacement ......... 6-769
Ground Strap Replacement ...................... ;... 6-759
Ignition Coil Module Replacement ..... ,.......... 6-777
Ignition Coil Replacement .................. 6-775, 6-776
Schematic
Starting and Charging Icons ..................... 6-676
Schematics
Starting and Charging ..................... ,......... 6-677
Spark Plug Replacement .................... :.. .. ..... 6-77 4
Spark Plug Wire Harness
Replacement ............. 6-770, 6-772, 6-773
Special Tools .. .. ... .. .. .. .. .. .. .. .. . .. .. ... ... . .. .. . .. .. .. . 6-785
Specifications
Battery Temperature vs Voltage Drop ....... 6-675
Battery Usage Table .: ............................... 6-674
Fastener Tightening .................................. 6-67 4
Generator Usage .: .................... ,............... 6-675
Spark Plug Usage Table ........................... 6-675
Spark Plug Wire Resistance .................... , _6-676
Starter Motor Usage Table ............... : ....... 6-675
Starting and Charging Component Views ..... 6-682
Starting and Charging
Underhood Fuse Block (UBEC)
.
Replacement ................... ,.. ... .... ... .. 6-741
Engine Exhaust
Catalytic Converter Replacement............ ,... 6-1980
Replacement ....... 6-1991, 6-1992, 6-1993
Converter Heat Shield Replacement ........... 6-1998
Description
Catalytic Converter ............................... , . 6-2003
Clamps .. ... .. .. .. .. ... ... ... ... . .. . ... .. .. ... . ... .... ... 6,2003
Exhaust System ... .. .. .. .. ... .. ... .... .. .. .. ... .. . ... 6-2003
Hangers ............................ ,..................... 62003
Muffler .................................................... 6-2003
Diagnosis
Exhaust Noise ........................................ 6-1975
Internal Muffler Rattles/Loss of Power ..... 6-1976
Restricted Exhaust .. .. .. ... ... .. ... .. ... . .. .. ... ... . 6-197 4
Vibration or Rattling ................................ 6-197 4
Engine Mount Heat Shield Replacement .... 6-1997
12
Engine Exhaust (cont.)
Exhaust Crossover Pipe Replacement ........ 6-1977
Replacement .. ... .. ..... ... ... ... .... .. .. . ... 6-2000
Heat Shield Replacement ........................... 6-1999
Muffler Hangers Replacement ........ 6-1995, 6-1996
Muffler Replacement .................................. 6-1986
Replacement .................... 6-.1983, 6-1985
Specifications
Exhaust System Clearances . ... ..... .. .... .. .. 6-1973
System Inspection ......... , ......... , .................. 6-1976
Engine ID and Partial VIN Location ..... , ...... 0-9, 0-10
Balance Shaft
Bearing and/or Bushing Installation ........... 6-216
Bearing and/or Bushing Removal .............. 6-216
Clean and Inspect .................................... 6-216
Installation (Off-Vehicle) ............................ 6-223
Balance Shaft Removal (Off-Vehicle) ............ 6-183
Camshaft
Bearing Installation (Off-Vehicle) ............... 6-203
Bearing Removal (Off-Vehicle) .................. 6-201
Inspect (Off-Vehicle) ....................... 6-202
Removal (Off-Vehicle) .....,........ ,................. 6-183
Replacement ......................... , .................. 6-121
Crankshaft
Balancer Clean and Inspect ...................... 6-194
Balancer Installation (Off-Vehicle) .............. 6-239
Balancer Removal (Off-Vehicle) ......... ,...... 6-170
Balancer Replacement .......... ,.. .. ... .. .. .. .. ... . 6-105
(Off-Vehicle) ................................... 6-187
Inspect (Off-Vehicle) ....................... 6-192
(Off-Vehicle) ................................... 6-219
Front Cover Oil Seal Replacement ........... 6-108
Front Oil Seal Installation (Off-Vehicle) ..... 6-230
Front Oil Seal Removal (Off-Vehicle) ........ 6-179
Rear Oil Seal and Housing Installation
(Off-Vehicle) .............. ,.................... 6-225
Rear Oil Seal and Housing Removal
(Off-Vehicle) ................................... 6-184
Rear Oil Seal and Housing Replacement ..... 6-135
Rear Oil Seal Installation (Off-Vehicle) ...... 6-226
Rear Oil Seal Removal (Off-Vehicle) ......... 6-184
Cylinder Boring and Honing ......................... 6-191
Cylinder Head
Assemble ................................................. 6-21 O
Disassemble .. ..... .. .. .... . ...... .... ..... .... .... .. ... . 6-205
Removal (Off-Vehicle) ............................... 6-179
Replacement .................................. 6-123, 6-125
Description
Cleanliness and Care ............................... 6-243
Components .. .... .... ..... .... ... .... .. ... .. .... .. . ..... 6-241
Drive Belt System Description .................. 6-241
Installation Precautions ............................. 6-245
INDEX
Engine Mechanical - ;3.8L (cont.)
Description (cont.)
Lubrication ................................................ 6-242
Replacing Engine Gaskets ....... , ................ 6-243
Separating Parts ......... ,................ ,............ 6-244
Service Precautions .................................. 6-244
Thread Repair ................................... ,., .... 6-218
Tools and Equipment ................................ 6-245
Use of RTV and Anaerobic Sealer ....... , .... 6-243
Diagnosis
Base Engine Misfire ............... ; .................. 6-21
Cylinder Leakage Test ................................ 6-31
Drive Belt Tensioner .......................... , .. ... .. 6-42
Engine Compression Test ...... ,,,, ............... ,. 6-23
Engine Noise ............................. ;....... 6-23, 6-25
Oil Consumption .,, .... , ........... ,........... , .. ,.... ,. 6-28
Oil Leak .......... ,.................. :................. , ....... 6-29
Oil Pressure Diagnosis and Testing ....... ,... 6-28
Symptoms - Drive Belt .......... , .................. ,. 6-31
Disassembled Views .............. ,.................... ,. 6-43
(Off-Vehicle) .................................... 6-170
Drive Belt
Diagnosis ................................................. ,. 6-32
Chirping Noise .................. ,............ , ..... ,. 6-32
Excessive Wear ,................... ,., ............. ,. 6-42
Falls Off ............................ ,..................... 6-40
Rumbling .............. ,............... , ......; .......... 6-37
Squeal ............... ,.......... ,........ ,............... ,. 6-34
Vibration .. ,................ ,........ ,...... ,, ......... .,, 6-38
Whine ......................................:.:' 6-36
Idler Pulley Replacement ......... ,, ................. 6-49
Replacement .............................................. 6-47
Tensioner Installation (Off-Vehicle) ..... ,...... 6-238
Tensioner Removal (Off-Vehicle) ............... 6-172
Tensioner Replacement ............................ ,, 648
Engine Block
Clean and Inspect (Off-Vehicle) .... ,........... 6-189
Plug .Installation ........................................ 6-219
Plug Removal (Off-Vehicle) ...... ,................ 6-188
Engine Flywheel
Installation (Off-Vehicle) ,. 6-239
Engine Front Cover Clean and Inspect ... ,.... 6-215
(Off-Vehicle) ............................ ,., ..... 6-229
Engine Front Cover Removal (Off-Vehicle) ... 6-180
Engine Mount
Bracket Replacement ..... ,............................. 6-59
Inspection ................................................. ,. 6-50
Replacement ............................................ ,. 5.51
Engine Replacement ....... ,............................ 6-137
Engine Support Fixture .................................. 6-50
Exhaust Manifold
Clean and Inspect ............... ,.................... 6-214
Installation (Off-Vehicle) ................. 6~232, 6-234
Removal (Off-Vehicle) .................... 6-176, 6-177
Replacement ..................................... 6:82, 6-87
Flywheel
Replacement ............................................ 6-133
Flywheel Clean and Inspect ......................... 6-195
Flywheel Removal (Off-Vehicle) ......... 6-171, 6-172
Front Cover Oil Seal Replacement ............... 6-108
Front Cover Replacement ... , ........................ 6-109
13
INDEX
Engine Mechanical - 3.8L (cont.)
Intake Manifold
Installation (Off-Vehicle) ................. 6-234, 6-235
Replacement ..................................... 6-68, 6-80
Oil and Oil Filter Replacement ......... ,.......... 6-168
Oil Filter
Adapter and Valve Assembly
Installation (Off-Vehicle) .................. 6-228
Removal (Off-Vehicle) ..................... 6-181
Replacement .................... , ............. 6-116
Oil Level Indicator and Tube Installation
(Off-Vehicle) .................................... 6-238
Oil Level Indicator and Tube Removal
(Off-Vehicle) ................................... : 6-172
Oil Level Indicator and Tube Replacement ..... 6-68
Oil Pan
Replacement ... .. ....... .. .. .... .............. .......... 6-127
Oil Pump
Cover and Gear Set Installation
(Off-Vehicle) ................................... 6-228
Cover and Gear Set Replacement ............ 6- i 16
Pipe and Screen Assembly Installation ..... 6-222
Pipe and Screen Assembly Removal
(Off-Vehicle) ................................... 6-185
Pipe and Screen Assembly Replacement .... 6-133
Oil Pump Cover and Gear Set Removal.
(Off-Vehicle) .................................... 6-181
Piston and Connecting Rod Assemble .......... 6-200
Piston and Connecting Rod Disassemble ..... 6-195
Installation ............. ,........................ 6-220
Piston, Connecting Rod and Bearings
. .
Clean/Inspect ...................... ,........... 6-196
Piston Selection ............................................6-198
Rear Oil Seal and Housing Replacement ..... 6-135
Service Prior to Assembly .......... ,................. 6-218
Special Tools ................................................ 6-245
Specifications .............. ,.............. ;..... . ............. 6-16
Fastener Tightening ............... ,.................... 6-15
Sealers, Adhesives, and Lubricants ............ 6-19
Timing Chain
Clean and Inspect ................ ,....... :. 6-203
(Off-Vehicle) ................... : ... ;........... 6-227
(Off-Vehicle) .......... , .......... :.... ,... :;.,. 6-181
Replacement .................................. 6-120

Valve
Lifter Removal (Off-Vehicle) ..... , .. ,............. 6-179
Rocker Arm and Push Rod Removal
(Off-Vehicle) .................... : .............. 6-178
Rocker Arm CoverRemoval (Off-Vehicle) ... 6-178
.
Valve Guide Reaming/Valve and Seat
Grinding ......................................... 6-208
Valve Lifter Installation (Off-Vehicle) ............. 6~230
Valve Lifter Replacement ................ :.... , ........ 6-104
Va.Ive Lifters and Guides Clean and Inspect .... 6-205

Installation (Off~Vehicle) ., .......... ,... ,. 6-231
Replacement . ... ... .... .. ..... .. .. ... .... ... .. .. 6-99

Clean and Inspect .. , ...
6-204
Valve Rocker Arm Cover Clean and
Inspect ........................ ,.............. ,... 6-213
(Off-Vehicle) .................................... 6-232
Valve Rocker Arm Cover Replacement .... 6,93, 6-97
Valve Stem Oil Seal. and Valve Spring
Replacement ............................. , .... 6-101
Water Outlet Installation (Off-Vehicle) ............ 6-238
Water Outlet Removal (Off-Vehicle) .............. 6-173
Water Pump
Installation (Off-Vehicle) ............... :......... ,., 6~237
Removal (Off-Vehicle) ..................... ,......... 6-173
Balancer, Crankshaft, Replacement .............. 6-353
Camshaft
.
Bearing Installation ....................... , ..: .... ,... 6-484

Bearing Removal .............................. ,, ...... 6-479
Inspect ........................... :............... 6-481
Removal (Off-Vehicle) .....................'.......... 6-446
Replacement ................. ,................... .... 6-382
Clutch Pilot Bearing Installation
(Off-Vehicle) ..... ,.............................. 6-575
Clutch Pilot Bearing Removal (Off0 Vehicle) ... 6-421
Crankshaft
Balancer Clean and Inspect ...................... 6-467
Balancer Installation (Off-Vehicle) .............. 6-577
Balancer Removal (Off-Vehicle) .... , ........... 6-419
Balancer Replacement .... ,........ , ................ 6-353
Inspect .............................. ,: .. ;........ 6-458
(Off-Vehicle) ...................... :.. :...... ". 6-532
(Off-Vehicle) .............................. : .... 6-449
Front Oil Seal Installation (OffNehicle) ., ... 6-548
Front Oil Seal Replacement ...................... 6-356
Rear Oil Seal Installation (Off-Vehicle) .,, ... 6-545
Rear Oil Seal Replacement ... , .................. 6-366
Cylinder Boring and Honing (Off-Vehicle) ..... 6-456
,.u, ....... :.......
14
Cylinder Head
Assemble . . .. .. ....... . ... .. .. ... .. ... .. .. .. .. .. .. ... .. .. . 6-497
Disassemble ... ..... .. ... .. ... .... .. ... .. ... ..... .. .. ... . 6-489
Replacement .................................. 6-348, 6-350
Description
.
Cleanliness and Care ............................... 6-585
Drive Belt System Description .. ... .... ... .. .. ... 6-582
Engine Components .. . ... . .. . ... . . ... ... .... .. ... .. . 6-580
Identification .. ...... .. ... .. .. ..... .. ... . .... ..... .. .. ... . 6-583
Installation Precautions ............ :................ 6-587
Lubrication . .. .. ...... .. .. ... .. .... ... .. .. .... ..... .. .. . ... 6-584
New Product Information .......................... 6-582
Replacing Engine Gaskets ........................ 6-585
Separating Parts ....................................... 6-587
Thread Repair ........................... , .............. 6-520
Tools and Equipment ................................ 6-587
Use of RTV and Anaerobic Sealer .... ,. ... .. . 6-586
Diagnosis
Base Engine Misfire ....... ,.......................... 6-270
Engine Compression Test ......................... 6-272
Engine Noise ............................. , .............. 6-272
Oil Consumption ....................................... 6-276
Oil Leak ......................... ,............. , ........... 6-276
Oil Pressure Diagnosis and Testing .......... 6-276
Symptoms - Drive Belt., ............................ 6-278
Valve Train ............................................... 6-274
Disassembled Views . .. .. .. .. .... ... . .. .. . .. .. .. .... .. .. 6-290
(Off-Vehicle) .................................... 6-417
Drive
Diagnosis ............................................ , .. ,. 6~284
Rumbling .......................... ,............. ,...... 6-284
Drive Belt
Diagnosis ................................................ 6-279
Chirping Noise ...................................... 6-279
Excessive Wear .................................... 6-289
Falls Off . .. .. .... ... .. ... .. .... .. .. .. . .... ... ... . ... ... . 6-287
Squeal ................................................... 6-281
Tensioner .............................................. 6-289
Vibration .................................. ,. .... . ... ... . 6-285
Whine .. . .. ... ... .... .. ... . ... ..... .. . ... .... .... . ... ... . 6-283
(Off-Vehicle) ..................................... 6-455
Engine Block Plug Installation ...................... 6-529
Engine Block Plug Removal (Off-Vehicle) ..... 6-451
Engine Mount
Inspection ................................................. 6-302
Replacement .................................. , 6-303, 6-307
Engine Set-Up and Testing .......................... 6-579
Engine Support Fixture ................................ 6-302
Engine Mechanical (5.7L) ........ , ............. 6-302
Exhaust Manifold
Replacement .................................. 6-342, 6-345
INDEX
Engine Mechanical - 5.7L. (cont.)
Flywheel
Replacement (5.7L) .................................. 6-384
Front Cover
Replacement ............................................ 6-357
Fuel Rail and Injectors Installation
(Off-Vehicle) .................................... 6-568
Fuel Rail and Injectors Removal
(Off-Vehicle) ...................... ,............. 6-427
GM SPO Group Numbers ............................ 6-254
Intake Manifold
Replacement ............................................ 6-311
Oil and Oil Filter Change ............................. 6-416
Oil Filter
Oil Filter, Adapter, Pan Cover

Oil Filter, Adapter and Pan Cover
Removal (Off-Vehicle) ..................... 6~439
Oil Level Indicator and Tube
Replacement ............................................ 6-339
Oil Pan
Clean and Inspect ............... ,.................... 6-511
Installation (Off-Vehicle) ........ ,.; ................. 6-548
Replacement ............................................ 6-370
Oil Pump
Assemble ................................................. 6-505
Clean and Inspect ........... ,........................ 6-503
Disassemble ............................................. 6-.501
Replacement .................................. 6-379
Piston and Connecting Rod Assemble .......... 6-476
Piston and Connecting Rod Disassemble ..... 6-468
Piston, Connecting Rod and Bearings
Clean/Inspect ............ 6-470, 6~472, 6-475
Piston Selection ........................................... 6-475
Rear Cover
Rear Cover
Rear Cover
Replacement ............................................ 6-367
INDEX

Repair
Drive Belt Idler Pulley Replacement - AIC .... 6-299
Drive Belt Idler Pulley Replacement ""'
Accessory ............. ... ....... ....... ......... 6-299
Drive Belt Replacement - AIC .. .. .. .. ... .. ..... . 6-298
Drive Belt Replacement - Accessory ......... 6-296
Drive Belt Tensioner Replacement - A/C ... 6-301
Drive Belt Tensioner Replacement Accessory ................................ ,... .. . 6-300
Replacement .. ,....... :..................................... 6-385
Service Prior to Assembly ..... :............. ;........ 6-528
Special Tools ............. :................................. 6-588
Specifications
Engine Mechanical ................. '. ......... , ....... 6-251
Fastener Tightening .... ,............................. 6-249
Sealers, Adhesives, and Lubricants .......... 6-255
Thread Repair ........... ,........... ,.................. 6-257
Throttle Body Installation (Off-Vehicle) .......... 6-568
Throttle Body Removal (Off-Vehicle) ............. 6-426
Timing Chain
Clean and Inspect .......................... 6-485
(Off-Vehicle) ................................... 6-539
(Off-Vehicle) .............. ,....... ,... ,........ 6-445
'
Replacement ........................... ,...... 6-380
Valley Cover
Clean and Inspect .................... ,............... 6-508
Installation (Off-Vehicle) ........... '. ................ 6-562
Removal (Off-Vehicle) ................... ,.... ,...... 6-432
Replacement ............... ,., .... ,......................6-325
Valve Guide ReamingNalve and
Seat Grinding ................................. 6-493

Valve Lifter
Installation (Off-Vehicle) ............. ,., ............ 6-552
Removal (Off-Vehicle) ..................... : ... : ..... 6-438
Replacement .............................. ,. ............ 6-352
Inspect ....................... ,....... .'........... 6-487
Installation (Off-Vehicle) :: .......................... 6-557

Replacement ..................... ,..... ...... ...... ..... 6-334
Clean and Inspect ....... , ............................ 6s509

Installation (Off-Vehicle) ..... ,...... ,.... 6-559, 6-560
Removal (Off-Vehicle) .................... 6-433, 6"434
Replacement., .............. : ........ ,........ 6-326, 6-332
Valve Stem Oil Seal and Valve
Spring Replacement ....................... 6-335
Vapor Vent Pipe Clean and Inspect ........... :. 6-519
Vapor Vent Pipe Installation (Off-Vehicle) ...... 6-563
Vapor Vent Pipe Removal (Off-Vehicle) ........ 6-431
Vapor Vent Pipe Replacement ...................... 6-324
Water Pump
Clean and Inspect ................................ ,... 6-519
15
Engine Mount
Replacement (3.8L) .............................. : ...... ,.. 6-51
Replacement (5.7L) ........................... 6~303, 6-307
Engine Oil Level Sensor Replacement .... 8-631, 8-633
Engine Oil and Oil Filter Change (5.7L) ........... 6-416
Engine Oil and Oil Filter Replacement (3.8L) ... 6-168
Engine Oil Life Monitor - Resetting ....... , ............ 0-39
Engine Oil Life Monitor Reset
Procedure (5.7L) ......................... ,. 6-1931
Engine Replacement (3.8L) ............................. 6-137
Engine Replacement (5.7L) ............................. 6-385
Engine Support Fixture (3.8L) .................. , ........ , .6~50
English/Metric Conversion Table .......................... 0-3
Entertainment
Amplifier Replacement .............. ,.: ...... 8338, 8-339
Antenna Mast Cleaning ................................ 8-351
Antenna Mast Replacement
Fixed ............................................... .... . .. .. 8-348
Power . .... .. .... .... ... .. .. .. ... ... ... .. . ... ... .. .. .. . ... . .. 8-349
Antenna Motor Replacement
Power .. .... ... ... ... ... .. .. ... . .. .. ... .. .. ... .. .. .. .. .. .. ... 8-350
Antenna Replacement
Fixed . .... .. ... .... .... .. . .. ... ... .... .. . .. ... ... .. .. .. .. .. .. 8-349
Cassette Player
Cleaning Tape Head and Capstan ........ ,... 8-341
Cassette Player Care and Cleaning ..............8-340
CD Changer Replacement
Remote .. : ..................................... ,. 8-342, 8-344
Compact Disc Care and Cleaning ................ 8-346
Component Locations ................. ,.. .. . . .. .. ... .. .. 8~286
Component Views .............................. , .. .. . .. . . 8-288
Connector End Views ......................... : ......... 8-299
Description
Cassette Tape Player Operation .............. 8-365,
8366, 8-367
Compact Disc Player Operation ... :. 8~368, 8-370
Power Antenna System ............................ 8-375
Power Antenna System Circuit ... ,... ,, ......... 8-375
Radio Controls Operation ... 8-360, 8~361, 8-362,
. 8-364, 8-365
Radio/Audio System ....................... 8-358, 8-359
Radio/Audio System Circuit ....................... 8.~374
Steering Wheel Controls System Circ.uit .... 8-375
Steering Wheel Controls
System Operation .............. :'. ........... 8-374
Theftlock Operation ...... :...... :: ........ :.... :...... 8-373
Diagnosis
.
.
Antenna Inoperative ....... ,.: ................. ,...... 8~310
Antenna Poor Reception ..... " ....... , ............ 8-311
Compact Disc Inoperative ......................... 8-313
Diagnostic Starting Point Entertainment ..................... ,.. '......... 8-309
One or More Speakers
.
..
Inoperative .... 8-321, 8-322, 8~324, 8-325,
8-326, 8-327, 8-328, 8-329,
8-330, 8-331, 8-332
Radio Display Inoperative,
No Sound from Speakers ,.. ... .. .. . .. .. 8-315
. Radio Display Inoperative,
Speakers Operative ........ ,................ 8-314
Radio Illumination Inoperative with
Park Lamps On .............................. ~F315
Radio Memory Inoperative ........................ 8-314
Speaker General ...................................... 8-319
16
Entertainment (cont.)
Diagnosis (cont.)
Speaker Noise .......................................... 8-319
General ................................................. 8-319
Speakers Inoperative - Subwoofer ............ 8-333
Steering Wheel Controls Illumination
Inoperative ...................................... 8-317
Steering Wheel Controls Inoperative ......... 8~317
Symptoms - Entertainment ........................ 8-309
Tape Player Inoperative ............................ 8-316
Radio Replacement ........................... 8-334, 8-336
Schematic
Icons ....................................................... 8-273
Power Antenna ......................................... 8-285
Radio/Audio System ........... 8-274, 8-275, 8-277,
8-280, 8-282, 8-283
Steering Wheel Controls ........................... 8-284
Speaker Grille Replacement
Rear .............................................. 8-356, 8-357
Speaker Replacement .................................. 8-352
Front ........................................................ 8-353
Rear ......................................................... 8-354
Special Tools ............................................... 8-375
Specifications
Steering Wheel Control Switches
Replacement .................................. 8-346
EVAP
Canister Purge Solenoid Valve
Replacement (5.7L) ....................... 6-1903
Canister Purge Valve Replacement (3.8L) ..... 6-1285
Canister Replacement (3.8L) ...................... 6-1289
Canister Replacement (5. 7L) ...................... 6-1912
System Cleaning (3.8L) .............................. 6-1290
System Hoses/Pipes Replacement (3.8L) ... 6-1288
System Hoses/Pipes Replacement (5.7L) ... 6-1906
Vent Valve Replacement (3.8L) .................. 6-1286
Vent Valve Replacement (5.7L) .................. 6-1905
Evaporator Core Replacement .. ... ... ...... .. .... ... .... 1-79
Evaporator Tube Replacement .......................... 1-69
Exhaust Gas Recirculation
Pipe Replacement (5.7L) ............................ 6-1927
Valve Replacement (3.8L) .......................... 6-1296
Valve Replacement (5. 7L) .......................... 6-1926
Exhaust Manifold Replacement (3.8L) ...... 6-82, 6-87
Exhaust Manifold Replacement (5. 7L) ... 6-342, 6-345
Expansion (Orifice) Tube Filter Replacement ..... 1-70
Exterior Trim
Description
Adhesive Retained Molding and Emblem .... 8-775
Molding/Nameplate Replacement ...... 8-765, 8-766,
8-767, 8-768, 8-769
Specifications
Washing and Waxing ................................... 8-774
Weld Stud Replacement ............................... 8-77 4
INDEX
F
Fan
Cooling Fan Relay Description ..................... 6-672
Cooling Fan Relay Replacement
(Engine Cooling) ............................. 6-633
Electric Cooling Fan Replacement
(Engine Cooling) ............................. 6-627
Electric Engine Cooling Fan Description ....... 6-671
Electric Engine Cooling Fan Motor
Replacement .................................. 6-633
Shroud Replacement (Engine Cooling) ......... 6-652
Fasteners ........................................................ ,. 0-17
Filter Replacement
In-Line Fuel (3.8L) ..................................... 6-1253
In-Line Fuel (5.7L) ..................................... 6-1869
Finish Panel Replacement
Upper Rear Trim ........................................ 8-1070
Floor Panel Reinforcement Replacement ....... 8-1175
Fluid Capacities, Approximate ............................ 0-34
Fluids and Lubricants, Recommended ............... 0-34
Flushing (Engine Cooling) ............................... 6-609
Flywheel Replacement (3.8L) .......................... 6-133
Flywheel Replacement (5.7L) ........................ ;. 6-384
Fog
Switch Replacement
Rear ......................................................... 8-174
Fog .Lamp .................................. 8-194, 8-196, 8-197
Bulb Replacement
Front ........................................................ 8-198
Rear ...................................... , .......... ........ 8-199
Relay Replacement ................................ , ..... 8-178
Replacement
Rear ......................................................... 8-198
Switch Replacement
Front ............................................. 8-172, 8-173
Folding Top
Adjustment ................................................... 8-969
Arm Replacement .... ... .. ..... .. .... .. .. .. ... 8-992, 8-997
Bow Link Replacement ...................... 8-971 , 8-973
Pivot Bracket Replacement ................. ,........ 8-988
Side Front Weatherstrip Replacement ........ 8-1011
Side Rail Assembly Replacement ................. 8-991
Side Rail Link Replacement ......................... 8-980
Side Rail Replacement .............................. , .. 8-974
Stowage Compartment Lid
Latch Replace .................. 8-1005, 8-1006
Weatherstrip Retainer Replacement ............ 8-101 O
Folding Top Bow Replacement ... 8-952, 8-958, 8-964,
8-966, 8-968
Folding Top Cylinder Replacement .................. 8-950
Folding Top Pump with Motor Replacement ..... 8-949
Frame
Floor Panel Reinforcement Replacement .... 8-1175
Frame and Underbody
Description
Centerline ............................................... 8-1187
Datum .................................................... 8-1187
General .................................................. 8-1187
Diagnosis
Alignment Checking ................................ 8-1149
Checking Frame to Body Alignment ........ 8-1149
Special Tools .............................................. 8-1187
17
INDEX
Frame and Underbody (cont.)

Specifications
Asymmetrical Reference Points ............... 8-1148
Body Dimensions ................................. ;.. 8-1142
Symmetrical Reference Points ............... , 8~1148
Frame Dimensions ........................................ 8-1146
Front Bumper Fascia Emblem Replacement .... 8-770
Front Fender
Rear Molding Replacement. .... :.................... 8-771
Front Oil Seal Replacement (5.7L) .................. 6-356
Front Suspension
Component Locations ............... ,.................... 3-16
Description
General ...................................................... 3-40
Diagnosis
Ball Stud Check ......................................... 3. 17
Special Tools ............................................., ... 3.-41
Specifications
GM SPO Group Numbers .... ;............... , ..... ; 3,15
Front Weatherstrip Replacement .................... 8~1012
Fuel Fill Limiter Vent Valve Replacement ....... ;6-1263
Fuel Filler Door
Replacement . ... .. .... ......... ...... .... ................. 8-1095
Fuel Filler Hose Replacement (5.7L) ............ ,. 6-1893
Fuel Filler Pocket Replacement .............. , .... ,. 8-1095
Fuel Filler Tube Replacement .................'. ...... 6-1265
Fuel Filter Replacement, In-Line (3.8L) .......... 6-1253
Fuel Filter Replacement, In-Line (5.7L) :......... 6-1869
Fuel Hose/Pipes
Assembly Replacement (5.7L) .................... 6-1892
Replacement
Chassis (3.8L) ........................................ 6~1272
Chassis (5.7L) ............................................ 6-1886
Engine Compartment (3.8L) ........................ 6-1278
Engine Compartment (5.7L) ......... ,.............. 6-1891
Fuel Injector Replacement (3,8L) ................... 6-1284
Fuel Injector Replacement (5.7L) ................... 6-1901
Fuel Level Sensor Replacement (3.8L) .......... 6-1271
Fuel Level Sensor Replacement (5.7L) .......... 6-1879
Replacement (5. 7L) .................... ,.. fft896

Fuel Pressure Regulator Replacement (3.8L) .... 6-1283
Fuel Pressure Regulator Replacement (5.7L) ... 6-1,900
Fuel Pressure Relief Procedure (3.8L) ...... ,.... ,6-1247
Fuel Pressure Relief Procedure (5.7L) ....... ,... 6-1863
Fuel Pulse Dampener Replacement (5.7L) ..... 6~1886
Fuel Pump Relay Replacement (3.8L) ........... 6-1285
Fuel Pump Strainer Replacement (3.8L) ........ 6-1270
Fuel Rail Assembly Replacement (3.8L) ......... 6-1281
Fuel Rail Assembly Replacement (5.7L) .. ,... ,.. 6-1897
Fuel Sender Assembly Replacement (5.7L) .... 6-1883
Fuel Sender Assembly Replacement (3.8L) .... 6-1267
Fuel Strainer Replacement (5. 7L) .................. 6-1880
Fuel System Cleaning (3.8L) ......................... 6~1280
Fuel System Cleaning (5.7L) ........... , ... , .. ,...... 6-1895
Fuel Tank
Draining Procedure (3.8L) .......................... 6-1254
Draining Procedure (5.7L) ....... ,................. , 6-1870
Pressure Sensor, Replacement (3.8L) ......... 6-1262
Pressure Sensor Replacement (5.. 7L) ......... 6-1878
.Pump Module Replacement (5.7L) ............. 6-1881
Replacement (3.8L) ............................. ,., ..... 6-1255
Replacement (5.7L) ...................... , ............. 6-1870
Fuel Tank Pump Module Replacement (3.8L) ... 6-1268
Fuse Block Access Cover Replac:emenL........... 8-631
Fuse Block Replacement Underhoo<:l (UBEC) ..... ,... , .... ,........... 6-741
G
Garnish Molding Replacement
.Liftgate ....................................................... 8-1109
Windshield Pillar ........................................ 8-1069
General Description, Suspension Diagn'osis ...... :.. 3-9
Generator
Assembly Check ...................... , ... , ............... 6-706
Brace Replacement ...... :.. ... .. ... ... .. ..... .. . ... .... . 6-763
Bracket Replacement ............. 6-761., 6-762; 6-763
Not Operating Properly ........................... :.... 6-704
Replacement .. ... .. .. .. .. .. .. .. ... .. .. . ... ... .. .. 6-764, 6-766
Splash Shield Replacement ...... :., ................. 6-769
Usage Specifications ... :.... :...... ,.. .. ..... .. .... .. .. . 6-675
Glass Surface Cleaning ...................... : .......... 8-1074
GM SPO Group Numl:>ers
Anti lock Brake System ........... , ... .. .. .... . .... .... ... 5-97
Engine Mechanical (5. 7L) ............................. 6-254
H
Hard Top
.
.
Headlin.er Replacement ......... ,..... ,... , ... ,......... 8-948
Hazard Lamp

.
;
Flasher Replacement ... :, .............................. 8-180
Headlamp
Aiming ........ : ..................... , ................. 8~191, 8-194

Bezel Replacement ., ........... , .......... ,..... , ..... ,. 8-190
.Bracket Replacement ........................ 8-869, 8-870
Bulb Replacement ................ , ..... /.................. 8-186
Door Module. Replacement ........ ,.................. 8-176
Housing Panel Replacement ..... 1................. ,. 8-868
Leveling Switch Replacement; .... ,........... 8-171
MotoriActuator Replacement .....,.. ,........ , ...... ;. 8-189
Opening Door Adjustment .............. : ......... ,... 8-188
Opening Door Replacement ................... .".... , .8-186
Repiacement .......... , ................... ,..... .' 8-18"1, 8-183
Switch Replacement .......................... 8~169, 8~.170
Headlamps
Diagnosis
Headlamps Always On
Low or High Beam ......... , .... ,8-133, 8-134,
8-135, 8-136
Headlight
Door Schematics . ... .. . .. .. ... ... .. .. ... .... .... .... ... ... . 8-50
Leveling Schematic .................... , ..... , ............. 8-51
Headlights
.
Schematics ........... ,.. .. ... . ... .. ... .. ... ..... .... . 8-38; .8-39
Headlights - DRL Schematics .... ; ..... 8-40,. 8-41, 8-43
Headliner Cleaning ........................................ 8-1074
18
Headliner Replacement
Hard Top ..................................................... 8-948
Headrest Motor Replacement

Front Seat ..................................... 8-1052, 8-1053
Heat Shield Replacement
Converter .. ... . ......... ... . .... .... ... ... .. ... .... .... .. .. . 6-1998
Engine Mount .......................... , .. ... .... .... .. .. . 6-1997
Exhaust Pipe and Muffler ............ .'.............. 6-2000
Heater
Core Description (Non-A/C) . ... .. . .... .. .. ... .. ... ... . 1-89
Core Replacement (Non-A/C) .. . ... ... .... ... .. ... .. .. 1-88
Hose Assembly Replacement .. ... .. .... ... .. 1-83, 1-85
Heater Replacement Engine (Block) Coolant ........ 6-663, 6-664
Description
A/C System .. .. .. .. .... ... . .... .... .. ... ... .. .... .. .... .. .. 1-89
Accumulator ............................................... 1-93
Compressor .. ... .... .... .. ... .... .. .. .. .. .... .. ... 1-94, 1-95
Condenser ...... . .... .... .... . ... .... ... .. ... ... ... .. .... .. . 1-93
Evaporator .. ... . .... .... ..... ... . .... .. ... ... ... ... .. ... .... 1-93
Expansion (Orifice) Tube ............................ t-93
Handling A/C Compressor .. ... ... .. ... ... .. ... ... .. 1-92
Handling Compressor Oil ............................ 1-91
Handling of Refrigerant Lines and
Fittings ............................................. 1-91
Handling Refrigerant R-134a .................. , .... 1-91
High Pressure Relief Valve ......................... 1-97
Maintaining Chemical Stability ..................... 1-92
0-Ring/Flat Washer .................................... 1-97
Refrigerant Oil Distribution . ... .. ... ... .. .. ... ... ... . 1-92
Refrigerant R-134a ..................................... 1-91
Refrigeration System .. . ... .... .. .. .. .. ... .. .. ... ... .. . 1-90
Relays and Sensors .. ..... .. .. .. .. .. .... .. ... .. ... ... . 1-97
Diagnosis
CCOT A/C System ........................................ 1-5
Cold Drafts on Floor .......................... ;........ 1-27
Cooling Insufficient, A/C System ................. :. 1-7
Cooling Insufficient, A/C System Pressure Zone A .............................. 1~10
Cooling Insufficient, A/C System Pressure Zone B ............. : ................ 1-13
Cooling Insufficient, A/C System Pressure Zone C .. .... .. ... ... ... .. ... .. ... .. . 1-16
Cooling Insufficient, A/C System Pressure Zone D .............................. 1-18
Defrosting Insufficient .... : ............................. 1-21
Heating Insufficient ........................... :......... 1-21
Odor ................................................ ,..... :.... 1-27
Odor Correction . .... . ... ..... ... .... .. .. .. . ... .. ... .. .. .. .. . 1-28
Refrigerant Recovery and Recharging ... .... .. .. . 1-28
Special Tools ................................................. 1::97
Specifications
Fastener Tightening ...................................... 1-3
Fitting and Line Tightening ........................... 1-3
Refrigerant Oil Distribution ............................ 1-4
System Capacities ....... :.. .. .. .. ... ... .. ... .. ... .. .. ... . 1-3
Heating and Ventilation (Non-A/C)
Description
Heater Core ...... .... .... .... ... ... ... .. ... .. ... .. ... .... . 1-89
High Mounted Stop Lamp
Replacement ....................... 8-204, 8-206,
8-208, 8-210
Hinge Pillar Trim Replacement ....................... 8-1062
INDEX
Hinge Replacement
Hood ....... .... .... . .. .... .. ....... .. .. .. .. .. . ... .. .. ... ... .. .. 8-855
Rear Compartment Lid ........................ ,... .. . 8-1101
Rear Lift Window ....................................... 8-1100
Hood
Adjustment ................................................... 8-851
Assist Rod Ball Stud Replacement ............... 8-868
Assist Rod Replacement .............................. 8-867
Bumper Replacement ................................... 8-852
Close Out Filler Replacement ............. ,......... 8-855
Hinge Replacement ...................................... 8-855
Latch Release Cable Replacement ............... 8-863
Latch Replacement
Primary ..................................................... 8-858
Secondary ................................................ 8-862
Replacement ................................................ 8-852
Hood Rear Seal Replacement ......................... 8-872
Hook Replacement, Tow ................... 8-1182, 8-1184
Horn Replacement ........................................... 8672
Horns
Component Locations ................................... 8-667
Description
Circuit ....................................................... 8-674
Operation ................................................. 8-67 4
Diagnosis
Diagnostic Starting Point - Horns .............. 8-668
Horns Always On ..................................... 8-669
Horns Inoperative ......................... ,........... 8-670
Symptoms - Horns .................................... 8-668
Relay Replacement ...................................... 8-673
Schematic
Icons .. ... .. .. .. .. .. . .. . ......... ... .... ... ... ... .. .... ... .. . 8-665
Schematics .................................................. 8-666
Specifications
Hose Routing Diagram
Emission (5. 7L) .......................................... 6-1328
Hose Routing Diagram, Emission (3.8L) .......... 6-788
Hose-Inlet, Replacement, Radiator ........ 6-614, 6-617
Hose-Outlet, Replacement, Radiator ..... 6-620, 6~623
Hub Cap
Aluminum Wheel Hub Cap Replacement ........ 3-64
Hub/Wheel Bearing Replacement, Front ., .......... 3-24
HVAC - Manual
Air Distributor Duct Replacement .................. i-137
Air Outlet Replacement - Floor ..................... 1-188
Air Outlet Replacement - Right Defogger ..... 1-138
Air Outlet Replacement - Side Window ........ 1-139
Blower Control Schematic .............. ,............. 1-103
Blower Motor and Fan Assembly
Replacement .................................. 1-125
Blower Motor Resistor Replacement ... .... ... .. . 1-124
Component Locations ......................... .:........ 1-106
Component Views ................................... :.... 1-108
Compressor Control Schematic .. ... .. .. .. .. .. .. .. . 1-104
Control Assembly Replacement . .. .. .. .. .. .. .. .. . .. 1-126
Control Blower Switch Replacement .. .. .. ... .. .. 1-_129
Control Lamp Bulb Replacement .. .. .. .. .. .. .... .. 1-128
Control Lamp Bulb Wiring Harness
Replacement .... .... .. ... .. ... . .. . .... . ... ... . 1-128
Control Selector Switch Replacement .... ... .... 1-130
INDEX
HVAC - Manual (cont.)

Control Vacuum Harness Replacement ........ 1-142
Control Vacuum Valve Replacement ..... :: ...... 1-130
Defroster Valve Actuator Replacement .......... 1-136
Description
Air Distribution System ...... ....... ..... .... ....... 1144
Blower Controls Circuit ................ :............ F150
Blower Motor ... ........... .... .......... ... ............. 1-145
Blower Motor Resistor ............. ; ............ , ... 1-145
Control Assembly ........................... 1-145, H47
Vacuum Hose Harness ............................. 1-149
Diagnosis
A Diagnostic System Check ...................... 1-115
AJC Compressor Clutch Does Not
Disengage ........ ...... ....... .... ............. 1-118
AJC Compressor Clutch Does Not
Engage ..................................... :..... 1-116
Air Delivery Improper ................................. 1-123
Diagnostic Starting Point ........................ , .. 1-115
Symptoms ................................................ 1-115
Inside Air Valve Actuator Replacement ........ : 1-134
Mode Valve Actuator Replacement , ...... ,. ..... . 1-136
Schematic Icons ........ :.... .. ............ .. .. ... ... .. .... 1-102
Specifications
Temperature Control Cable Adjustment ......... 1-132
Temperature Control Cable Replacement .... ; 1~131
Vacuum Actuator Replacement ............ , ........ 1~135
Vacuum Hose Harness Replacement
(A/C - Manual) ......................... ,..... 1-141
Vacuum Tank Replacement (A/C- Manual) ..... 1-140
HVAC Control Lamp Replacement ..... , ............. 8-224
Hydraulic Brake System
Component Views ............................................ 5-9
Components ......................................... : ......... , 5-8
Connector End Views .. .. .. .. .. .. .. .... ..... .... .... .... . 5-11
Schematic Icons ....................................... :...... 5-6
Hydraulic Brakes
Brake Hose Inspection ............................... ,... 5-38
Description
Brake Fluid and Brake Fluid Handling .. :..... 5-53
Brake Warning System ............................... 5-54
Brake Warning System Circuit .................... 5-54
Master Cylinder ..................... :.. ... ....... .... .. .. 5-52
Vacuum Brake Booster .. .. ...... .. . .. .. .. ... . ... .... . 5-53
Diagnosis
Brake Fluid Leaks ...................................... 5-20
Brake Pedal Travel ..................................... 5-20
Brake System Testing ................................ 5-20
Brake Warning Indicator Always On ........... 5-17
Brake Warning Indicator Inoperative ..... : ..... 5-18
Diagnostic Starting Point Hydraulic Brakes .... , .... ; .................... 5-11
Diagnostic System Check ............... :.. :........ 5~11
Master Cylinder .......................................... 5-21
Symptoms - Hydraulic Brakes ............... ,..... 5~16
Front Brake Hose Replacement ......... :...... ..... 5-39
GM SPO Group Numbers ................................ 5-5
ISO Flares Replacement ..... ..... ... .... ............ ... 5-36
Pipe Replacement ...... ... ...... ........ ... ............. ... 536
Rear Brake Hose Replacement .... 5-40, 5-41, 5-43
Special Tools ................................................. 5-55
19
Hydraulic Brakes (cont.)
Specifications
.
Brake System ...... ,, ....................................... 5-5
Fastener Tightening .......... :...... :.-................... 5-5
System Bleeding .... ,............... , .... : 5-44, 5:-46 1 5-47
. System Flushing ................... , ........... ,; ........... 5-47
. Vacuum Brake Booster Hose Replacement .... 5-50
Vacuum Brake Booster Replacement ............. 5-48
I
Identification, Vehicle .................... ,.,: ......... :......... 0-5
Idle Air Cont.rel Valve Replacement (5.7L) ...... 6-1854
Idle Learn Procedure(5.7L) ........................... 6-1840
Ignition Coil Replacement ............, ........ 6-775, 6-776
Ignition Coil Module Replacement '. ..... ,............ , .6-777
Ignition Coil(s) Replacement (3.8L) ................ 6-1293
Ignition Control Module Replacement (3.8L) .... 6-1292
Ignition Key Lock Cylinder Test ............ :, .. ; ...... 8-700
Ignition System
Description ............ '. .................. ,, . .. ... .. 6~ 783,< 6-784

Operation ................................. ,.......... :........ 6-784
Important, Cauticm_,and Notice, Definition of ,,., ... , ... 3
Instrument Cluste'r
Description
.
. .
Circuit .................... .......... ,: ........ :.. : .. :., .. :... 8-641
. .......... 8-637
Gauge Operation . ... ...... ... .... ..
General .............................................. : ... : ..8-636
Indicator Operation ......................... , ......... 8-638
Instrument Panel
Carrier Replacement ................ , ..... ,... , ......... 8-601
Cluster Replacement ............... ,., ............... ,.. 8-615
Compartment Door Lock Cylinder
Replacement ....... .... .. .. .. .... .. .. ... .. .. .. 8-599
Compartment Lamp Replacement ....... ,.. . ... .. 8-223
Compartment Lat.ch Replacement .. .. .. .. .. .. ... .. 8-598
Compartment Striker Replacement ,.. , . ,... ,, .... B:596
Description ............... ............ : .....: 8_-635
Odometer Repair Label ..... ,................... ,... 8-636
Storage Compartmentooo.t Replacement.: ... 8597
Upper Trim Pad Replacement ...................... 8~599
Instrument Panel Compartment Lamp
Inoperative .. ... .. .... . .... . .. . ...
............ 8-149
Instrument Panel, Gauges. and Console .
Audible Warnings Component Locations ., ..... 8-581
Description
Audible Warnings ....................... '. .............. 8-643

Audible Warnings Circuit ................ '. .. ,..,., .. 8-644
Console ................,.... ,.. ;.................... : ...... : .. 8~644
Diagnosis
CHANGE ENGINE OIL Indicator
Always On ........ :......... , ... ; ........ : ..... , 8-572
CHANGE ENQINE QIL ,indicat9r,.
.. . ..
Inoperative ..... :.. :......... ,,:, .. :,., ....... .... 8-572
CHECK GAGES lndibator Always On ....... 8-573
CHECK GAGES Indicator Inoperative .. ::, . 8-574
Diagnostic Starting Point O lr1stn.:iment
Panel, Gauges and Console ........... 8~561
OTC List ............................................... .'... 8-561
Engine Coolant Temperature Gauge
Always Cold ...... :.... '. ......... : .......... ::, 8-564
Engine Coolant Temperature Gauge
Always Hot ........ : ............................ 8564
20
Instrument Panel, Gauges and Console (cont.)
Diagnosis (cont.)
Engine Oil Pressure Gauge
Always High ........................ 8-565, 8-566
Engine Oil Pressure Gauge
Always Low ... ... ... .. ... .... ... .... .. .... ... .. 8-567
Engine Oil Pressure Gauge Inaccurate
or Inoperative ................................. 8-567
Fuel Gauge Always Indicates Empty ......... 8-568
Fuel Gauge Always Indicates Full ............. 8-569
Instrument Cluster Diagnostic
System Check .. ... .. ... .. .. .. ..... .. ... .... .. 8-562
Low Engine Oil Level Indicator
Always On ... ... ... ... .... ... .... .. .. .... .... .. . 8-57 4
Low Engine Oil Level Indicator
Inoperative ...................................... 8-575
Odometer Inoperative ............................... 8-569
Odometer Inoperative - Trip ...................... 8-570
REDUCED ENGINE POWER Indicator
Always On .. .... ... ... ... ... ... .... .. .... ... .. .. 8-576
REDUCED ENGINE POWER Indicator
Inoperative ...................................... 8-576
Speedometer and/or Odometer
Inoperative ...................................... 8-570
Speedometer Inaccurate
(J 38522 Available) ......................... 8-577
Speedometer Inaccurate
(J 38522 Unavailable) ..................... 8-578
Symptoms - Instrument Panel,
Gauges and Console ... .. .... ... ... ... .. .. 8-563
Tachometer Inoperative ............................ 8-571
Volt Gauge Inaccurate or Inoperative ........ 8-571
Instrument Cluster Component Locations ..... 8-551
Instrument Cluster Component Views ........... 8-553
Instrument Cluster Connector End Views ..... 8-560
Schematic
Audible Warnings ...................................... 8-580
Audible Warnings Schematic Icons ........... 8-579
Instrument Cluster Schematic Icons .......... 8-546
Schematics
Instrument Cluster .................................... 8-547
Analog ................................................ :. 8-547
Special Tools ............................................... 8-645
Specifications
Instrument Panel Service Precautions .............. 8-585
Intake Air Temperature Sensor
Replacement (~.8L) ....................... 6-1240
Intake Air Temperc1ture Sensor
Replacement (5.7L) ....................... 6-1853
Interior Trim
Specifications
GM SPO Group Numbers ....................... 8-'1061
INDEX
J
Jacking and Lifting ............................................ 0~30
K
Key Coding and Lock Cylinders ........................ 0-27
Keyless Entry
Component Location .................................... 8-650
Description
Keyless Entry System Operation ................ 8-662
Remote Keyless Entry System ............. , .... 8-662
Remote Keyless Entry System Circuit ..... ,.. 8-663
Diagnosis
Courtesy Lamps Inoperative with
Transmitter ..................................... 8-658
Diagnostic Starting Point Keyless Entry ..... ,...... , .................... 8-652
Diagnostic System Check ... , ........ ,........... 8-652
OTC List ......................,. ............... ,,. ....... ,... .8-652
Remote Keyless Entry System
Does Not Change Modes ............... 8~(358
Remote Keyless Entry System
Inoperative .................................. ,." 8-659
Symptoms - Key less Entry ......................,.. 8-658
Schematic
Icons ............................... :.... , ....................8-646
Schematics ...............................................,.. 8~647
Special Tools ...................................... , ........ 8-664
Specifications
Keyless Entry Transmitter Programming/
Synchronization .................... , ......... 8-661
Knee Bolster
Deflector Replacement ....................... , ......... 8-590
Replacement
Left .... .. . .... .. .. .. .... . .... .. ... ... ... . ... .... ... . ... ..... . 8-590
Knock Sensor Replacement (3.8L) .................. 6-1295
Knock Sensor Replacement (5.7L) .................. 6:1.9.18
L
Label
Anti-Theft Labeling ......................................... 0-14
Service Parts ID .......................... ,................. 0-14
Label, Vehicle Certification .................................. 0-8
Labels
Replacement, How to Obtain ......................... 0-17
Latch Replacement
Endgate .................................................... . 8-1105
Hood Primary ............................................... 8-858
Hood Secondary ................................. ,........ 8-862
Left ................................................................. 8-590
License Lamp Replacement .......... ,....... 8-212, 8-214
Lift Off Panel
Adjustment ..................................... ,........... 8~.1009
Weatherstrip Replacement .......................... 8-1015
Lift Panel Strut Replacement
Rear .......................................................... 8s tl02
Lift Window Panel Adjustment
Rear .......................................................... 8-1096
Lift Window Panel Hinge Replacement
Rear .......................................................... 8-1100
INDEX
Lift Window Panel Opening Weatherstrip

Replacement
Rear .. ... ..... .. ... .. .. ... .. ... .. ... .... . ..... .. .... ..... .. .. . 8-1110
Lift Window Panel Replacement
Rear .. .. .. ..... ... ... .. ... ........ ..... .. ...... ..... ..... ... .. 8-i 097
Liftgate Garnish Molding Replacement ........... 8-1109
Liftgate Lock Actuator Replacement ............... 8-1106
Liftgate Lock Cylinder Replacement ............... 8-1 i 04
Liftgate Trim Panel Replacement ................... 8-1091
Lifting and Jacking . .. .... .. .... .. ......... ..... ............. .. 0-30
Lift-Out Panels
Mounting Hardware Replacement .. . 8-1003, 8-1004
Lighting Systems
Component Locations .................................... 8-72
Component Views . ......... ........... ..... ............... . 8-80
Connector End Views .................................... 8-95
Description .. .... .. .. ... ......... .......... .... .. ............. 8-229
Backup Lights Circuit ................................ 8-237
Daytime Running Lamps Circuit .... 8-232, 8-233,
.
8-234
Exterior Lights Circuit ..................... 8-235, 8-236
Fog Lights Circuit .... ,................................ 8-234
Headlight Doors Circuit ............................. 8-234
Headlight Leveling Circuit ......................... 8-234
Headlights Circuit ...................................... 8-232
Interior Lights Circuit ................................. 8-237
Interior Lights Dimming Circuit .................. 8-238
Diagnosis
Backup Lamp Inoperative - One ............... 8-114
Backup Lamps Always On .. ..... ..... ... .. ....... 8-i 12
Backup Lamps Inoperative ........................ 8-113
Courtesy Lamps Always On ................. :.... 8-1 i 5
Courtesy Lamps are Inoperative with
IP Dimmer Switch ........................... 8-117
Courtesy Lamps Inoperative .. ..... .............. 8-116
Doors Ajar ... ..... ........ ... .... .............. . 8-118
Rear Compartrnent Lid Open ... ...... . 8~ 120
Courtesy/Reading Lamps Always On ........ 8-121
Courtesy/Reading Lamps Inoperative ........ 8-121
Courtesy/Reading Lamps Inoperative
with Lamp Switch .. ...... ...... ............. 8-118
Daytime Running Lamps Inoperative ......... 8-122
Diagnostic Starting Point Lighting Systems .......... .... .............. 8-102
Diagnostic System Check ......................... 8-102
OTC List .... ;, .. ~ ......................................... 8-102
Exterior Lamps Inoperative - All ................ 8-123
Fog Lamp Indicator Inoperative ...... 8-131, 8-132
Fog Lamp Switch Illumination Lamp
Inoperative ...................................... 8-130
Fog Lamps Always On .. .. .. . ... . ...... .. ... ....... 8-124
Fog Lamps Inoperative - All .......... 8-125, 8-126,
8-127
Fog Lights Inoperative - One ................... 8-129
Hazard Lamps Inoperative ........................ 8-132
Headlamp Door(s) Inoperative ................... 8-144
Headlamps Inoperative " High Beam ......... 8-139
Headlamps Inoperative Low and High Beams ..................... 8-14"1
Headlamps Inoperative - Low Beams ........ 8-137
Headlamps Inoperative - One Lamp .......... 8-140
21
Lighting Systems (cont.)
Diagnosis (cont.)
Headlamps Inoperative In Low Light
Conditions ...................................... 8-142
Headlamps, Parklamps, DRL On with
Park Brake Applied ......................... 8-143
Headlight Doors Inoperative - One Door .... 8-145
Headlight Leveling Inoperative .... ,............. 8-147
Headlight Leveling Inoperative Actuator Switch Illuminated ............. 8-148
Headlight Leveling Inoperative O
One Actuator .................................. 8-146
High Beam Indicator Always On ............... 8-148
High Beam Indicator Inoperative ............... 8-149
Instrument Panel Compartment Lamp
Inoperative ...................................... 8-149
Instrument Panel Lamp
Inoperative - One ........................... 8~151
Instrument Panel Lamps Do Not Dim ........ 8-150
Instrument Panel Lamps Inoperative ......... 8~150
Park Lamps Inoperative ............................ 8-152
Left .......... " -' ..... '" .... .... .. ... .. .... .. .. ... .. .... . 8-152
Right .................................................... 8-153
Park/Turn Lamps Inoperative - Front ......... 8-154
Park/Turn Lamps Inoperative - One Front .... 8-154
Position Lamps Inoperative ....................... 8-155
Left ....................................................... 8-155
Side Marker Lamp Inoperative .................. 8-156
One Lamp .............. -' ............................. 8-156
Stop Lamps Always On ... .. ... ... .... .. ... .. ... ... 8-159
Center High Mounted ............................ 8-158
Stop Lamps Inoperative ............................ 8-156
All ................................................ ; ........ 8-156
CHMSL Operates ................................... 8-158
One ...................................................... 8-157
Symptoms - Lighting Systems .............. , .... 8-111
Tail Lamps Inoperative ............................. 8-159
Let Rear ............................................... 8-159
Right Rear ............................................ 8-160
Turn Lamps Always On .................... ,....... 8-165
Turn Signal and Hazard Lamps
Inoperative ................ : ..................... 8-163
Turn Signal Indicator Always On - Left ..... 8-165
Turn Signal Indicator Always On - Right ... 8-166
Turn Signal Indicator Inoperative ............... 8-166
Left ....................................................... 8-166
Turn Signal Inoperative ............................. 8-161
Left Front ............................................... 8-161
Turn Signal Lamp Inoperative ................... 8-163
Left Rear ................................................ 8-163
Right Front ............................................ 8-162
Right Rear ........................... :................ 8-164
Turn Signal Lamps Inoperative ... :............. 8-160
VF Display Inoperative .... ,......................... 8-168
Radio ............... , .................................... 8-168
VF Displays Do Not Change with
Park Lamps On .............................. 8-167
Schematic
Backup Lights ............................................. 8~66
Exterior Lights ................. 8-52, 8~55, 8-58, 8-62
Fog Lights ....................... 8-45, 8-46, 8-48, 8-49
Headlight Doors ............... :.......................... 8-50
Headlight Leveling .... ,.............. ,: ................. 851
Headlights ......................................... 8-38, 8-39
22
INDEX
Lighting Systems (cont.)

Schematic (cont.)
Headlights - Daytime Running Lamps ........ 8-66,
8-41, 8-43
Icons .......................................................... 8-37
Interior Lights ............................................. 8-67
Interior Lights Dimming ............................... 8-69
Special Tools ............................................... 8-238
Specifications
Bulb Usage ................................................ 8-36
Turn Signal Indicators Inoperative
Right .. ,..................................................... 8-167
Lock Actuator Replacement
Liftgate . . .. . .. .. .. .. .. . .. .. .. .. .. . .. ... .. .. .. .. .. .. . .. .. .. . .. . 8-1106
Lock Cylinder Replacement
Liftgate . ... .. .. .. ... . ... .. . ... .. .. .. .. .. .. . .. .. .. . .. .. .. . .. . .. 8-1104
Lock Cylinders and Key Coding ........................ 0-27
Lock Striker Replacement
Rear Compartment ..................................... 8-1107
Lubricants and Fluids Recommended ................ 0-34
Luggage Screen Support Replacement .......... 8-1069
Lumbar Bladder Replacement ........................ 8-1049
Lumbar Motor Replacement ........................... 8-1047
M
Maintenance and Lubrication
Explanation of Scheduled Services ................ 0-37
Maintenance Items ......................................... 0-35
Maintenance Schedule ................................... 0-35
Owner Checks and Services .......................... 0-39
Periodic Maintenance Inspections ................... 0-41
Maintenance Items ............................................ 0-35
Maintenance Schedule ...................................... 0-35
Replacement (3.8L) ....................... 6-1237
Replacement (5.7L) ....................... 6-1844
Manual Transmission - M49
Backup Lamp Switch ..................................... 7-19
Description ..................................................... 7-30
Diagnosis
Gear Clash When Shifting Gears ................. 7-7
Transmission Does Not Shift into
One Gear ........................................... 7-9
Transmission Jumps Out Of Gear ................ 7-9
Transmission Locked in One Gear .............. 7-11
Transmission Noisy ...................................... 7-8
Transmission Shifts Hard .............................. 7-6
Fluid Level Check .......................................... 7-12
Mainshaft Rear Oil Seal .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-18
Oil Drain and Fill ........................................... 7-22
Replacement . .. .. ... .. .... .. .. ... ... ..... .. ... .... ..... .. .. ... 7-23
Shift Control
Knob Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-18
Shift Control Assembly ................................... 7-13
Shift Control Boot Assembly .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-14
Shift Control Closeout Boot Replacement ....... 7-17
Special Tools ................................................. 7-31
Manual Transmission - M49 (cont.)

Specifications
Lubrication ................................................... 7-5
Support and Mount Assembly ........................ 7-15
Vehicle Speed Sensor .................................... 7-21
Manual Transmission - MM6
Backup Lamp Switch Replacement ................ 7,49
Control Lever Handle Assembly ..................... 7-47
Description ..................................................... 7s61
Diagnosis
Clunk on Acceleration or Deceleration ........ 7-40
Gear Clash When Shifting Gears ................ 7-35
Oil Leak ..................................................... 7-40
Transmission Does Not Shift into
One Gear ......................................... 7-38
Transmission Jumps Out of Gear ............... 7-37
Transmission Locked in One Gear .............. 7-39
Transmission Noisy .................................... 7-35
Transmission Shifts Hard ............................ 7-33
Transmission Shifts Hard into Reverse .... ,., 7-34
Fluid Level Check ............................ ,............. 7-41
Gear Select/Skip Shift Solenoid
Replacement .................................... 7-52
Mainshaft Rear Oil Seal ................................. 7-48
Oil Drain and Fill ........................................... 7-53
Replacement .... .... .... ..... ........ .. .. ... ... .... ... ....... . 7-54
Reverse Lockout Solenoid Replacement ........ 7-51
Shift Control Assembly Replacement .............. 7-44
Shift Control Boot Replacement ..................... 7-45
Shift Control Closeout Boot Replacement ....... 7-46
Shift Control Knob Replacement .................... 7-47
Special Tools ............................. , ................... 7-62
Specifications
Fastener Tightening Specifications .............. 7-32
GM SPO Group Numbers ........... ,............... 7-32
Lubrication .................................................. 7-32
Vehicle Speed Sensor Replacement ............... 7-49
Vent Tube Replacement ................................. 7-53
Marker Lamp
Replacement
Side .. .. ... .. .. .. .. .. ... . .... .. .. .. .. . .. . .. .. . .. .. .. .. .. .. .. . 8-200
Mass Air Flow Sensor Replacement (3.8L) .... 6-1236
Mass Air Flow Sensor Replacement (5.7L) .. ,. 6-1842
Master Cylinder
Bench Bleeding ............................................. 5-25
Fluid Level Sensor Replacement .................... 5-26
Replacement .................................................. 5-24
Reservoir Filling ............................................. 5-22
Reservoir Replacement .................................. 5-23
Meanings of Abbreviations ................................. 0-22
Mirror Face Replacement ..................... 8-933, 8-934
Mirror Replacement
Door ........ ......... .... .............. ... .. ... .... ... ... .. ..... 8-932
Mirrors
Diagnosis
Power Mirrors Inoperative .................. ,...... 8-898
One ...................................................... 8-899
Power Mirrors Inoperative in Left and
Right Direction ........................... ,.... 8-901
One ............................................ 8-901, 8-902
Power Mirror Switch Replacement ................ 8-914
23
INDEX
Molding Replacement
Belt Reveal ................................... 8-1071, 8-1072
Body Side Door ........................................... 8-771
Front Fender Rear ....................................... 8-771
Liftgate Garnish .......................................... 8-1109
Rear Quarter . ... ... .. ... ..... .... .. .......... .... ........ ... 8-772
Rocker Panel ............................................... 8-773
Windshield Pillar Garnish ........................... 8-1069
Mount, Engine, Replacement (5.7L) ...... 6-303, 6-307
Mount, Engine, Inspection (5.7L) ..................... 6-302
N
Noise Diagnosis
Doors ................................................ 8-791, 8-792
Front of Vehicle ................................. 8-785, 8-786
Instrument Panel .................... 8-786, 8-787, 8-788
Rear of Vehicle ........... 8-795, 8-796, 8-797, 8-798
Roof ....................................... 8-792, 8-793, 8-794
Seat .................................................. 8-789, 8-790
Under Vehicle ................................... 8-798, 8-799
Notice, Caution and Important, Definition of ........... 3
0
Oil Consumption Diagnosis (3.8L) ..................... 6-28
Ordering Information, Special Tools ..................... 0-5
Oxygen Sensor Replacement, Heated (3.8L) .... 6-1238
p
Paint Gauges ................................................ 8-1140
Paint/Coatings
Anti~Corrosion Treatment and Repair .......... 8-1135
Basecoat/Clearcoat Paint Systems ............. 8-1135
Clearcoat Repair without Repainting ........... 8-1138
Environmental Fallout
Acid Rain ................................................ 8-1139
Paint Identification ...................................... 8-1138
Specifications
Clearcoat Repair - 3M Products .............. 8-1133
Clearcoat Repair - Meguiar Products ...... 8-1134
Painting
Clearcoat Thickness ................................... 8-1140
Rail Dust Damage Repair .......................... 8-1140
Panel, Plastic ................................................ 8-1113
Panel Reinforcement
Quarter ..................................... ,.... 8-1213, 8-1216
Panel Repair
Backing Patch Fabrication .......................... 8-1123

Gouge or Puncture .................................... 8-1114
Panel Replacement
Air Inlet Grille .............................................. 8-871
Complete ..... .. ... ... . ........ ... ..... ... ....... ........ ... 8-1122
Front Side .................................................... 8-874
Partial ....................................... ,...... ....... .. . 8-1118
Rear End ...................................... 8-1107, 8-1108
Rocker ....................................................... 8-1201
Upper Rear Trim Finish .............................. 8-1070
.Wheelhouse ................................................. 8-876
Park Brake
Actuator Replacement .. ... ... .. ... ... ... .. ... .. ... ... .... 5-94
Backing Plate Replacement ........................... 5-94
Brake Drum Inspection .................................. 5-93
Cable Replacement .. .. ... .. .... ... .. ... .. .... .. .. 5-88, 5-90
Description
System . .. .. .. .... ... ... .. ... .. ... .... .. .. ... .... .. .. .... ... .. 5-96
Lever Replacement .. .. ... .. ... .... .. .. ... .... .. .. .... ... .. 5-86
Shoe Adjustment ............................. :.............. 5-86
Shoe Replacement .. .. ... .. ... ... ... .. ... .... .. .. ... .... .. 5-85
Special Tools ................................................. 5-96
Specifications
Park/Turn Signal Lamp Bulb Replacement ....... 8-204
Park/Turn Signal Lamp Replacement ... 8-201, 8-202,
8-203
PCM Replacement/Programming (5.7L) ......... 6-1837
Pedal Replacement
Accelerator Controls (3.8L) ........... 6-1241, 6-1244,
6-1245
Accelerator Controls (5. 7L) ......................... 6-1857
Pinion Seals and Bearing Annulus
Replacement .................................. ; . 2-45
Plastic Panel Information and Repair
Description
Handling Precautions For Plastic ............. 8-1131
How to Identify Plastic Parts ................... 8-1130
Plastic Identification and Refinishing
Systems .. .. .. ... ... ... .. ... .. .... ... ... ... .... 8-1130
Plastic Repair Precautions ...... .-............... 8~ 1132
Specifications
Repair Materials - Flexible Plastic Part ... 8-1112
Repair Materials - Rigid Plastic Part ....... 8-1112
Plastic Panels .. .. ... ... ... . .. ... ... ... .. ... ... .... ... .. .... .. 8-1113
Plastic Repair Instructions ............................. 8-1113
Plate Replacement
Door Sill ..................................................... 8-1067
Power Door Lock Switch Replacement ... 8-912, 8-913
Power Folding Top
Bow Replacement ................. 8-952, 8-958, 8-964,
8-966, 8-968
Circuit Description ...................................... 8-1019
Cylinder Replacement .................................. 8-950
Inoperative ................................................... 8-946
Operation ................................................... 8-1017
Pump with Motor Replacement .................... 8-949
Schematics .. .. ..... ... .. .. ... ... .. ... .. ... .... .. .... .... ... . 8-939
Power Mirror Switch Replacement ................... 8-914
Power Mirrors
Diagnosis
Inoperative ............................................... 8-898
One ....................................................... 8-899
Inoperative in Left and Right Direction ...... 8-901
One ............................................ 8-901, 8-902
Power Steering
Bleeding the System ...................................... 2-14
Checking and Adding Fluid ............................ 2-13
Control Valve Replacement ................ ,.. 2-24, 2-25
Cooler Pipe Replacement . .. .. ... ... .... .. .... .... ... .. 2-29
Description
Gear ........................................................... 2-48
Pump ......................................................... 2-47
Seal Replacement Recommendations ... ... .. . 2-48
24
Power Steering (cont.)
Diagnosis
Excessive Wheel Kickback or Loose
Steering ............................................ 2-10
Foaming, Milky-Appearing PS Fluid,
Low in Level .................................... 2-12
Gear and Pump Leaks ................................. 2-7
Groan Noise in Steering Pump ................... 2-13
Growl Noise in Steering Pump .............. , .... 2~13
Hissing Noise in Steering Gear ......... ,.......... 2-7
Increase in Effort While Turning .................. 210
Low Oil Pressure Due to Steering Gear ..... 2-12
Low Oil Pressure Due to Steering Pump .... 2-12
Poor Return of Steering Wheel ................... 2-11
Rattle Noise .in Rack and Pinion ................... 2-7
Seal Replacement Rec.ommendations ........... 2s9
Steering Effort Hard in Both Directions ....... 2-11
Steering Wheel Kickback ...... , ............... ,., ... 2-11
System Test Procedure .......... : ....... ;;: ........... 2-9
Too Much Play in Steering ......................... 2-11
Vehicle Leads to One Side or the Other ..... 2-12
Wander or Poor Steering Stability ................ 2-12
Wheel Surges or Jerks While Turning ........ 2-11
Whine Noise in Steering Pump ................... 2-13
Flushing the System ...................................... 2-28
Gear Replacement ................................ 2~32, 2-34
Pulley Replacement ................................. , ..... 2-20
Pump Front Bracket Replacement .................. 2-26
Pump Rear Bracket Replace .......................... 2-27
Pump Replacement ........................... , ... 2-21, 2-22
Rack and Pinion
Boot Replacement ............................ , ......... 2~35
Steering Gear Cylinder Pipe Assemblies/
0-Ring Seals - Off Vehicle ............... 2-43
Rack Bearing Pre load .................................... 2-35
Remote Fluid Reservoir Bracket
Replacement .................................... 2-19
Remote Fluid Reservoir Replacement ............ 2-18
Reservoir Replacement .................................. 2-24
Return Hose Replacement ............................. 2-30
Special Tools ................................................. 2-48
Specifications
Fluid Specifications ...... , ................................ 2-3
Tie Rod Replacement - Inner ......................... 2-41
Tie Rod. Replacement - Outer O Off Vehicle .... 2-38
Power Steering Gear
Disassembled View ...................................... 2-4
Power Steering Pump
Disassembled View ............................... 2-5, 2-6
Power Windows .............................................. 8-905
Diagnosis
Inoperative ................................................ 8-906
Left Front .............................................. 8-906
Inoperative from LF Switch ....................... 8-91 O
Inoperative from RF Switch ....................... 8-910
Inoperative RF from LF Switch ................. 8-907
Inoperative Right Front ............................. 8-908
Power Windows Inoperative ...................... 8-906
Left Front ......... ,.................................... 8-906
INDEX
Power Windows (cont.)
s.witch Replacement .......................... 8-911, 8-912
Air Conditioning Control Diagnosis (3.8L) ... 6,1189
Connector End Views (3.8L) ........................ 6-814
Connecto_r End Views (5.7L) ....... ,............... 6-.1368
Controlled Air Conditioning
Description (3.8L) , ........................ 6~1305
Controlled Generator Description (3.8L) ..... , 6-1306
Controlled Warning Lamps
Description (3.8L) ......................... 6-1304
Description (3.8L) ....................................... 6-1300
Description (5.7L) ....................................... 6-1932
Diagnosis (3.8L) ......................................... 6-1188
Replacement/Programming (3.8L) ............... 6-.1232
Powertrain Control Module Idle Learn
Procedure (5.7L) ........................... 5:1840
Pressure Relief Valve Replacement ............... B-1109
Programming Additional Keys Theft Deterrent ............................... 8-705
Programming/Replacement
Powertrain Control Module (3.8L) ............... 6.-1232
Programming/RPO Configuration of the
Body Control Module ...................... 8-543
Programming/Synchronization
Key less Entry Transmitter ............................. 8-66.1
Propeller Shaft
Description ................................................ :; ... 4-18
Center Bearing ........................................... 4-19
Phasing ...................................................... 4-19
Universal Joint ............................................ 4-19
Diagnosis .. ..... ...... ... .. ..... ... .. . ... ... .. . ... .... .. .. . .. .. .. 4-4
Leak at Front Slip Yoke ............................... 4~5
Noise ........................................................... 4-7
Knock or Clunk Noise ............................ .' .. 4-7
Ping, Snap, or Click Noise ........................ 4-6
Scraping Noise ...... .... .... .. .. ..... . .. .. .... ... .. .. .. . 4-7
Roughness or Vibration ................................ 4-5
Shudder on Acceleration at Low Speed ........ 4-7
Propeller Shaft Replacement, One-Piece .......... 4-8
Propeller Shaft Replacement, Two-Piece ........ 4-10
Special Tools ................................................. 4-20
Specifications
Fastener Tightening ......................... ,............ 4-3
GM SPO Group Numbers ............ : ............... 4-3
Runout Specifications ................................... 4-3.
Universal Joint and Slip Yoke Replacement ... 4-14
Propeller Shaft Balancing Weight Amounts ....., .. 0-42
Propeller Shaft Runout Specifications ................ 0-42
Pump, Fuel, Module Replacement (5.7L) ...... , 6-1881
Q
Quarter Panel Replacement .............. 8-1213,
Quick Connect Fitting Service
Metal Collar (3.8L) .....................................
Metal Collar (5.7L) .....................................
Plastic Collar (3.8L) ....................................
Pla?tic Collar (5.7L) ....................................
8-1216
(
6-1248
6-1864
6-1250
6-1866
25
INDEX
R
)
Radiator
Air Baffle Assemblies and Deflectors ... 6-661, 6-662
Air Deflector Replacement ............................ 8-871
Assembly Description ................................... 6-670
Cleaning (Engine Cooling) .. ,......................... 6-61 o
Filler/Pressure Cap Assembly Description ..... 6-671
Inlet Hose Replacement
(Engine Cooling) ................. , 6-614, 6-617
Outlet Hose Replacement
.
(Engine Cooling) .................. 6-620, 6-623
Replacement (Engine Cooling) ..................... 6-654
Support Replacement (Engine Cooling) ........ 6-658
R.adiator Support Description . .... .... ......... .. ..... 8-1220
Radio Replacement .. ..... .. .... .. ...... .... ... .. 8-334, 8-336
Radio/Audio
'system s.chemat.ics ............... 8-274, 8-275 8-277
8-280, 8-282, 8-283
Rail Replacement
Side ........................................................... 8-1201
Upper ...... :................................................. 8-1188
Rail Sectioning
>Lower ...... :..................................... 8-1196 8-1198
RAP
'
Diagnosis
Diagnostic System Check ...... ... .. .. .. .. ... ... .. 8-758
Rear Compartment Lamp Replacement . ........ .. 8~228
Rear Compartment Lid Hinge Replacement ... 8-1101
Rear Comp~=;:;~~~~t~~-~~-~:~'.~~~ ................ 8 _1107
Rear Compartment Lid Release Inoperative ... 8-1085
Rear Compartment Lid Replacement ............. 8-1099
Rear Compartment Lid Switch Replacement .. .. 8-1090
Rear Crankshaft Oil Seal Replacement (5.7L) .... 6-366
Rear Drive Axle
Axle Housing Inspection ................................. 4-40
Axle Replacement ... ... .. .... ........ .. ... .. .. ..... .. ...... 4-46
Axle Shaft Replacement ................................. 4-26
Backlash Adjustment ...................................... 4-42
Bearings Inspection ........................................ 4-41
Description ..................................................... 4-52
Diagnosis
Noise Diagnosis ........................................ , 4-23
Differential Carrier Replacement ..................... 4-28
Differential Inspection ..................................... 4-41
Drive Pinion Assemble ................................... 4-34
Drive Pinion Disassemble .............................. 4-30
Gear Tooth Contact Pattern Check ................. 4743
Housing Cover and Gasket Replacement ....... 4-25
Inspection Before Disassembly ....................... 4-40
Lu.bricant Level Check ................................... 4-25
Oil Seal and/or. Bearing Replacement ............ 4-36
Pinion and Ring Gear Inspection ................... 4-48
Pinion Depth Adjustment ................................ 4-32
Pinion.Flange Replacement .... , ...................... 4-47
Pinion Oil Seal Replacement ......................... 4-38
Rear Axle Assemble ....................................... 4-36
Rear Axle Disassemble .................................. 4-29
Side'Bearing Preload Adjustment ................... 4-41
Special Tools ................................................. 4-53
Rear Drive Axle (cont.)

Specifications
Pinion Bearing and Differential Bearing
Pre load ... ... ... ... .. ... .... ... .. .. .. .. . ... .. .. .. . . 4-22
Rear Axle ................................................... 4-21
Rear Axle Usage .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. 4-22
Rear End Panel Replacement .. .. .. .. .. . 8-1107, 8-1108
Rear Lift Window
Replacement ................................................ 8-819
Rear Quarter
Molding Replacement ................................... 8-772
Rear Suspension
Special Tools ................................................. 3-60
Specifications
Rear Window
Defogger Braided Lead Wire ............ , ........... 8-825
Reveal Molding Replacement ....................... 8-809
Rearview Mirror
Replacement ................................................ 8-811
Support Replacement ................................... 8-813
Rear11iew Mirror Lamp Replacement ................ 8-225
Relay
Cooling Fan Relay Description ..................... 6-672
Fuel Pump Relay Replacement (3.8L) ........ 6-1285
Horn Relay Replacement ... .. .. .. .. .. .. .. .. .. .. .. .. .. 8-673
Theft Deterrent Relay Replacement .............. 8-702
Relay Replacement
Starter Motor ................................................ 6-710
Release Systems
Schematics ... .... ... ... . ..... ... ... .. ... .. ... . .... . ... . .. . 8-1077
Replacement
Fr~nt ...................................... 8-194, 8-196, 8-197
Retained Accessory Power
Description
Circuit ....................................................... 8-763
Diagnosis
Diagnostic Starting Point - Retained
Accessory Power .. .. ... .. .. ... .. ... ... . .. .. . 8-758
OTC List ................................................... B- 758
RAP Inoperative ....................................... 8"761
RAP On after Timeout .............................. 8-761
Symptoms - Retained Accessory Power .... 8-761
Schematic
Icons . .. ... ... .. .. .. ... .. .... .... ... .. .. ... ... . .. .... . .. ... . . 8-754
Schematics ...................................... :........... 8-755
Rocker Panel
Molding Replacement ................................... 8-773
Rocker Panel Replacement ........................... 8-1201
Roof
Description
Power Folding Top Circuit ....................... 8-1019
Power Folding Top Operation ................. 8-1017
D~noo~
.
Diagnostic Starting Point - Roof .. .. .. .. .. .. .. .. 8-946
Symptoms - Roof ............................. :.. ... .. 8-946
INDEX
26
Roof (cont.)
Power Roof Systems Component
.
Locations................. ,..... ,... ,.,.: ...... ,..... 8-941
Power Roof Systems Component .Views ....... 8-942
Power Roof Systems

Connector End \/iews ............. :....... 8-945
Specifications
.
.
Fastener Tightening .......................... ,....... 8-937
GM SPO Group Numbers .... ,........ '. ........... 8-938
Roof Outer Replacement .............................. 8-1213
Rotor/Drum Imbalance ....................................... 0-50
RPO Code List ............................ , ......... ,,, ........ 0-15
s
Schematic Icons
Data Link Communications ............................. 8-15
Schematics .
Audible Warnings ............ , ...... , ..................... 8-580
Backup Lights .............. :............................ ,; ... 8-66
Body Control Module ....................... ,........... 8-521
Cruise Control ................ ,................... ;.:.: ..... 8-714
Data Link Connector (DLC) ..................... , ... ,.. , 8-16
Defogger ................................................. ,..... 8-802
Door Locks ............................. , ....... , ............ 8-881
Engine Controls (3.8L) ............................... ,. 6-791
Engine Controls (5.7L) ............................... 6-1329
Exterior Lights ..................... 8-52; 8-55, 858, 8-62
Fog Lights ... .:, .................... 8-45, 8-46; 8s48, 8-49
Ground Distribution ....... :: ......... :, ........ ,.: .. ,.... 3:.421
Headlight Doors ............................................. 8-50
Headlight Leveling ................ : ..... ,.................. 8~51
Headlights .......................................... ,.. 8-38, 8-39
Headlights - Daytime
Running Lamps .............. 8~40, 8-41, 8-43
Horns ..................................................... ,:,... 8-666
Instrument Cluster
Analog .......................................... .c, , ..... 8-547
Interior Lights ...............................................,,. 8-67
Interior Lights Dimming ............................. :" 8,69
Keyless Entry .............................................. : 8-647
Lumber Support .......................................... 8-1022
Outside Mirrors ............................ , .... 8-882, 8-883
Power Distribution ............................ :........... 8-402
Power Folding Top .................................... : .. 8s939
Power .Seats .................................. ,.. : .. :..... 8~1021
Power Windows ................ ,.......................... 8880
Release Systems .. ,......... :..... :, ................... 8-.1077
Retained Accessory Power ....................... : ... 8-755
SIR ........................................': ................. :.,.:. 9-30
Theft Deterrent .......................... :...'............... 8-676
Seal Replacement
.
Hood Rear ............... : ................................... 8-872
Seat .Back Latch Replacement
Rear Folding ................................ :............. 8-1057
Seat Back Latch Striker Replacement
.
. .
R
F Id"
,... ..
.
. ear o mg .................................. ,............. 8-1058
Seat Belt
Child Restraint Belt Tether Location .... ~. 9~25, 9-26
Seat Belt Buckle Replacement
Left Front ....................................................... 9-14

Right Front .................................................... 9-15
Seat Belt Retractor Replacement

Left Front .............................................. 9-17, 9-18
Rear .. ..... .. . ....... . .. ... ....... .. ....... .. .. .. .. .. .. .. 9-22, 9-24
Right Front ........................................... 9-19, 9-21
Seat,Belts
Components .............................................. ,..... 9-5
Connector End Views ...................................... 9-5
Description
Seat Belt System ....................................... 9-27
System Circuit ............................................ 9-28
Diagnosis
Diagnostic Starting Point - Seat Belts ........... 9-6
Diagnostic System Check .... ... .. .. . ... ... .......... . 9-6
Diagnostic Trouble Code (DTC) List/Type ..... 9-6
Fasten Safety Belt Chime Always On ......... 9-12
Fasten Safety Belt Chime Inoperative ......... 9-12
Fasten. Safety Belt Indicator Always Qn ...... 9-10
Fasten Safety Belt Indicator Inoperative ...... 9-10
Operational and Functional Checks .............. 9-6
Seat Belt Service Precautions .................... 9-13
Symptoms - Seat Belts .............................. , 9-10
Schematic
Icons ............................................................ 9-3
Schematics .. .... ... .. ....... .. ..... .. .. . .. ... . .. ... .... .. ....... 9-4
Specifications
GM SPO Group Numbers ...................... , ..... 9s3
Seats
Adjuster Mechanism Replacement
Power .............................................. ..,..... 8-1050
Description
Front Seats .. , .......................................... 8-1059
Power Lumbar Circuit ............................. 8-1060
Power Seat Systems Circuit .................... 8-1059
Rear Seats ............................................. 8-1060
Diagnosis
'Diagnostic Starting Point - Seats ............ 8-1029
Lumbar Support ...................................... 8-1033
Does Not Move In or Out .................... 8-1033
Lumbar Support Inoperative ., .................. 8-1032
Power Seat Adjuster Does Not Move
Vertically ....................................... 8-1029
Power Seat Inoperative ........................... 8-1030
Power Seat Inoperative in One Direction ... 8-1031
Symptoms - Seats .................................. 8-1029
Headrest Replacement
Front Seat .................................. 8-1052, 8-1053
Lumbar Bladder Replacement .................... 8-1049
Lumbar Replacement ................................. 8-1047
Power Recliner Replacement
Front Seat ..................................... : ........ 8-1043
Power Seat Systems Component Views ..... 8-1025
Power Seat Systems Components ............. 8-1024
Power Seat Systems
Connector End Views ................... 8-1025
Schematic
Power Seat Systems Schematic Icons .... 8-1020
Schematics
Lumbar Support ...................................... 8-1022
Power Seats ........................................... 8-1021
INDEX
Seats (cont.)
Seat Back
Hinge/Recliner Mechanism
Replacement ....... .. .... ..... .. ... ... .. ..... 8-1042
Front ................................................... 8-1042
Seat Back Recliner Mechanism Replacement
Front ...................................................... 8-1046
Seat Back Replacement
Front ...................................................... 8-1040
Seat Cushion Cover Replacement
Front ...................................................... 8-1039
Seat Cushion Trim Cover and Pad
Replacement .......................... ;...... 8-1039
Seat Replacement
Bucket . .. ... ... ... .. ...... ............ .. .. ... 8-1034, 8-1035
Front Bucket .............................. 8-1036, 8-1037
Shoulder Restraint Guide Replacement
Rear Seat ............................................... 8-1056
Special Tools .............................................. 8-1060
Specifications
Pump Relay Replacement (5.7L) ................ 6-1922
Pump Replacement (5.7L) .......................... 6-1919
Service Parts ID Label . ........ ..... .... ............ ....... . 0-14
Service Port Valve Core Replacement ............... 1-72
Shelf Trim Panel Replacement
Rear .......................................................... 8-1073
Shock Absorber
Replacement - Front ...................................... 3-33
Replacement - Rear ....................................... 3-54
Shoulder Belt Replacement
Rear .............................................................. 9-15
Side Marker Lamp Replacement . ..... .... ... ......... 8-227
Side Weatherstrip Retainer
Protector and Seal ........................ 8-1016
SIR
Component Views .. .... ............. .... ........... ........ 9-32
Components .................................................. 9-31
Connector End Views .. ............ ... ..... ....... ....... 9-33
Description
Special Tools ............................................. 9-98
System Component Description and
Definitions ........................................ 9-95
System Operation ....................... ,................9-94
Diagnosis
A Diagnostic System Check ....................... 9-36
AIR BAG Warning Lamp Circuit
Malfunction ....................................... 9-61
Diagnostic Starting Point ............................. 9-34
OTC List . .. ... ... .. ..... ....... .... ..... .... ..... .. .......... 9-37
Scan Tool Data Definitions ......................... 9-35
Scan Tool Data List ...... ..... ... ........... ........ .. 9-34
Symptoms . .. .... .. ..... ....... ... ..... ........ ... ........ . . 9-60
Disabling the SIR System .............................. 9-64
Enabling the SIR System ............................... 9-66
General Service Instructions .......................... 9-68
Inflatable Restraint Instrument Panel
Inflater Module Replacement ........... 9-72
Inflatable Restraint Sensing and
Diagnostic Module Replacement ., ..... 9-69
27
SIR (cont.)
Inflatable Restraint Steering Wheel
Module Coil Replacement .. .. .. .... . .. .. .. 9-75
Inflatable Restraint Steering Wheel
Module Replacement .. ... .. .. .. .. .. ... .. .. .. 9-74
Inflater Module Handling, Shipping, and
Scrapping ......................................... 9-79
Repairs and Inspections Required After
an Accident ... .. ... .. .. .... ... .. .. .. ... . ... ... . .. 9-78
Schematics .... ... ... .... ... .. .. ... ... ... ... . .. . .. .. .. ... .. .. .. 9-30
Icons .......................................................... 9-29
Service Precautions ....................................... 9-64
Special Tools ................................................. 9-99
Specifications
Fastener Tightening . .. ... .. .. .... ... .. .. .. .. ... .. .. ... . 9-29
Solenoid
Brake Transmission Shift Interlock
Solenoid Replacement
Automatic Transmission (4L60-E) .............. 7~292
Control and Shift Solenoids Replacement
Automatic Transmission - 4L60-E . ... .. .. ... .. 7-342
Spare Tire Replacement
Compact . .. ..... .. .. ... ... ... .. ... .. ... .... .. .. .. .. .... .. .. .. ... 3-68
Spark Plug
Replacement .... ... .. .... ... .. ... . .. ... .. .. .. ... .. .. ... .. ... 6-77 4
Usage ............................. : .... ;....................... 6-675
Visual Diagnosis . .. .... ... .. .. ... .... .. .. .... . .. ... .. .. ... 6-707
Wire Harness Diagnosis ................. : ............. 6-709
Speaker Grille Replacement
Rear ................................................. 8-356, 8-357
Speaker Replacement . ... ... .. ... .... .. .. .. ... .. .. .... . ... 8-352
Front ............................................................ 8-353
Rear ............................................................ 8-354
Special Tools
Antilock Brake System . .. .. .... .. ... .. .. ... .. ... ... .. . 5-255
Automatic Transmission (4L60-E) ................. 7-380
Clutch .. .. ... .. ... .. .. ... .. .... .. ... .. .... .. ... .. ... . ... ... .. .. . 7-405
Cruise Control .. .. ... .. ... ... .. ... ... ... ... .. ... . .... .. .. .. . 8-753
Disc Brakes ... .... .. .. .... ... .. ... .. .... ... .. .. .. ... ... . ... .. . 5-83
Doors .. ... ... ..... .... .. ... ... ... .. ... ... ... ... .. .. .. ... ... . ... . 8-936
Engine Controls (3.8L) ...................... ,........ 6-1322
Engine Controls (5.7L) ............................... 6-1969
Engine Cooling .. ... .. .... .. ... ... ... .. ... .. .. .. ... ... . ... . 6-673
Engine Electrical . .. ... ... .. ... .. .... .. .... . .. ... ... ... . ... 6-785
Engine Mechanical (3.8L) .. . .. . .... .. .. ... .. ... ... . ... 6-245
Engine Mechanical (5.7L) ............................. 6-588
Entertainment . .. .. ... .. .... .. ... .. ... ... ... .. ... .. .. ... .. .. . 8-375
Frame and Underbody ............................... 8-1187
Front Suspension .. ... .... . ... .. ... ... ... .. .. .. .... .. .. ... .. 3-41
General Information ....................................... 0-33
Heating and Ventilation .................................. 1-97
Hydraulic Brakes .. ... .. .... .. ... ... ... ... .. .. .. .... .. .. .. .. . 5-55
Instrument Panel, Gauges and Console ....... 8-645
Keyless Entry ... .. ... .. .... .. ... .. ... ... ... .. .. .. ... ... .. ... 8-664
Lighting Systems . .. ... ... .. ... .. ... ... ... .. .. ... . .. .. .. ... 8-238
Park Brake .... .... .. .... .. ... ... .. ... ... ... .. .. .. .... .. . ... .. . 5-96
Power Steering .. .. ... .. .... .. ... ... ... ... .. .. .. ... ... .. .. . .. 2-48
Propeller Shaft . ... . .... .. ... .. ... .. .... ... .. .. .. .. .. .. . ... .. . 4-20
Rear Drive Axle . ... ... .. ... .. ... .. .... ... .. .. .. .... .. .. .. ... 4-53
Rear Suspension .. ... .. ... ... .. ... ... ... .. .. .. .... .. .. .. ... 3-60
Seats .. .... ..... .... ... .. ... ... ... .. ... ... .. ... .. .. .... .. ... . . 8-1060
28
Special Tools (cont.)
SIR ............................ .-........................... ,........ 9-99
Stationary Windows .............. :, ...................... 8-828
Steering Wheel and Column - Tilt .................. 2-98
Theft Deterrent ......... ,.. : ... : .............. ,............. 8-712
Wheel Alignment .... , .......... >,, ... .', ..... i: ... ,........ ,.: 3-14
Wipers/Washer Systems" 8-271
Special Tools Ordering Information ..: ..... ........... .. : 0-5
Specifications
ABS Diagnostic Specifications
Anti lock Brake System ................................ 5-97
Approximate Fluid Capacities .......... , .............. 0-34
Battery Temperature vs Voltage Drop ........... 6-675
Battery Usage ............................................. , 6~67 4
Body Dimensions .................................. ,.... 81142
Brake System
Hydraulic Brakes .......................................... 5-5
Components
Disc Brakes .......:.................... .-.:.................. 5-56
Engine Cooling ...... , ............... ,: ................ 6-594
Engine Mechanica.l(3.8L) .... :, ....... .' ................. 6-16
Engine Mechanical (5.7L) .. :, ........... , ..... , ....... 6-251
Exhaust System Clearances ....................... 6-1973
Fastener Tightening
3.8L .................................................. :....... 6-15
5.7L .......................................................... 6-249
Anti lock Brake System ................................ 5-97
A\.ltomatic Transmission .... , .... : .. ;................. 7~63
4L60-E ...............................: ...................... 7-63
Body Front End ........................................ 8-849
Body Rear End ...................................... 8-1075
Bumpers ................................................... 8:829
Clutch ....................................................... 7-382
Cruise Control .......................................... 8-713
Disc Brakes ................................................ 5-56
Doors ...................... ,................ ,, ............... 8-878
Engine Control (3.8L) ............................... 6-786
Engine Controls (5.7L) ............................ 6-1325
Engine Cooling ......................................... 6-594
Engine Electrical ....................................... 6-674
Engine Exhaust ........................; ............ ,. 6~1972
Entertainment ............................ , .............. 8-272
Frame and Underbody ........................... , 8-1141
Front Suspension ....................................... 3-15
Heater and Ventilation .................... , ............. 1-3
Horns ............................ .-.......................... 8-665
HVAC - Manual ...................................... ,. 1-101
Hydraulic Brakes ......................................... 5-5
Instrument Panel, Gauges and Console .... 8-545
Interior Trim ............................................ 8-1061
Lighting Systems ........................................ 8-35
Manual Transmission .................................... 7-5
M49 ......................... ~, ... .-: .................... , ..... 7-5
MM6 .................................................., ... 7-32
Park Brake ........................ ,................... ;: .. 5-84
Power Steering ........................................... ,. 2-3
Propeller Shaft ............................................. 4-3
Rear Drive Axle .......................................... 4-21
Rear Suspension ........................ , ............. . 343
Roof .................................................. , ...... 8-937
seat Belts .. ..... .... ... ..... ... .. .. .... ..... ... .. .... .. ...... 9-3
Seats ...................................................... 8-1020
INDEX
Specifications (cont.)
Fastener Tightening (cont.)
SIR ............................................................ 9-29
Stationary Windows .................................. 8-801
Steering Wheel/Column - Tilt ...................... 2-50
Tires and Wheels ....................................... 3-61
Wheel Alignment ........................................ 3-10
Wipers/Washer System , ............................ 8-239
Fluid Capacity
Automatic Transmission .............................. 7-64
4L60-E .................................................... 7-64
Fluid Specifications
Power Steering ............................................. 2-3
Frame Dimensions ..................................... 8-1146
Fuel System
Engine Controls (3.8L) .............................. 6-787
General
Automatic Transmission (4L60-E) ................ 7-64
Generator Usage ......................................... 6-675
Body Control System ................................ 8-520
Body Front End ........................................ 8-850
Body Rear End .... ......... .......... .. .. .. ...... ... 8-1076
Bumpers ................................................... 8-829
Clutch ....................................................... 7-382
Cruise Control .......................................... 8-713
Disc Brakes ............ .................................... 5-56
Doors ....................................................... 8-878
Engine Cooling ......................................... 6-594
Engine Electrical ....................................... 6-676
Engine Exhaust ...................................... 6-1972
Engine Mechanical (3.8L) ........................... 6-18
Entertainment ........................................... 8-272
Exterior Trim ............................................. 8-764
Front Suspension ....................................... 3-15
Heating and Ventilation ................................ 14
Horns ....................................................... 8-665
HVAC - Manual ........................................ 1-101
Hydraulic Brakes .......................................... 5-5
Instrument Panel, Gauges and Console .... 8-546
Interior Trim ............................................ 8-1061
Keyless Entry ........................................... 8-646
Lighting Systems ........................................ 8-36
Manual Transmission (M49) .......................... 7-5
Manual Transmission (MM6) ....................... 7-32
Park Brake ................................................. 5-84
Power Steering ............................................. 2-3
Propeller Shaft ............................................. 4-3
Rear Drive Axle ............ .......... .. .. .... ........ ... . 4-22
Rear Suspension ........................................ 3-43
Roof ......................................................... 8-938
Seat Belts ... ..... .... ....... ......... .. .. .. ... .. ...... ....... 9-3
Seats ...................................................... 8-1020
SIR ............................................................. 9-29
Stationary Windows .................................. 8-801
Steering Wheel/Column - Tilt ...................... 2-50
Theft Deterrent ......................................... 8-675
Tires and Wheels ....................................... 3-61
Lubrication
Manual Transmission (M49) .......................... 7-5
Manual Transmission (MM6) ....................... 7-32
INDEX
Specifications (cont.)
Pinion Bearing and Differential Bearing Preload
Rear Drive Axle .......................................... 4-22
Propeller Shaft Balancing Weight Amounts ..... 0-42
Propeller Shaft Runout ................................... 0-42
Range Reference Table
Rear Axle Usage ........................................... 4-22
Recommended Fluids and Lubricants ............. 0-34
Runout Specifications
Propeller Shaft ............................................. 4-3
Sealers, Adhesives, and Lubricants
Clutch ...................................................... 7-382
Engine Mechanical (3.8L) ........................... 6-19
Engine Mechanical (5.7L) ......................... 6-255
Shift Solenoid Valve State and Gear Ratio
Shift Speed Table
Spark Plug Usage ........................................ 6-675
Spark Plug Wire Resistance ......................... 6-676
Starter Motor
Usage ...................................................... 6-675
Engine Controls (3.8L) .............................. 6-786
Engine Controls (5. 7L) ............................ 6-1325
TFP Manual Valve Position Switch Logic
Thread Repair
Engine Mechanical (5.7L) ......................... 6-257
Tire and Wheel Runout ............. : ............. ,...... ,0-42
Tire Inflation Pressure .................................... 0-34
Tires and Wheels ........................................... 3-61
Wheel Alignment ............................................ 3-10
Spoiler Replacement
Rear ................................. 8-1092, 8-1093, 8-1094
Spring Insulators Replacement CoH
Rear Suspension ........................................... 3-56
Spring Replacement .......................................... 3-55
Squeaks and Rattles
Description
Noise ..... ... .. ..... .... ... ... ... ... ..... .. .... .......... .... 8-800
Diagnosis ... .. ... .... ...... ........ .... ..... ..... .... .. ..... .. 8-785
Stabilizer Shaft
Link Replacement .......................................... 3-20
Replacement .................................................. 3-19
Stabilizer Shaft Link Replacement
Rear Suspension . .. .... ........ ...... ............... ...... . 3-53
Stabilizer Shaft Replacement
Rear Suspension ...... . .... .. ... ....... ............... ..... 3-50
Stain Removal ... .... ... .... ......... ...... .............. .... 8-107 4
Starter Motor
Diagnosis
Solenoid Clicks,
Engine Does Not Crank .................. 6-688
Solenoid Does Not Click ........................... 6-687
No Load Test . ... .. ...... ......... ... ..... .... ..... .. .... ... 6-692
Noise Diagnosis ........................................... 6-691
Pinion Clearance Check ............................... 6-716
.Relay Replacement ...................................... 6-710
Replacement ..................................... 6-711, 6-713
Shield Replacement ..................................... 6-717
29
Starting System
Description ................................................... 6-780
Operation .. ... .... ... ... .... .... ..... ...... .. ..... .. .. .. .. . .. . 6-780
Stationary Windows
Bus Bar Lead Terminal Repair ...................... 8-825
Component Views ........................................ 8-804
Description
Adhesive Service Kit Description ............... 8-826
Extended Method Description ................... 8-826
General ... ..... .. ... .... ... .... ....... .. .... .... ... . .. . .. .. 8-826
Rear Window Defogger ............................. 8-827
Rear Window Defogger Circuit .................. 8-827
Rear Window Defogger Operation ............. 8-827
Reveal Molding ......................................... 8-827
Short Method Description .......................... 8-826
Diagnosis
Defogger Always On - Rear ..................... 8-805
Defogger Grid Lines ................................. 8-807
Defogger Inoperative - Rear ..................... 8-806
Diagnostic Starting Point Stationary Windows ........................ 8-805
Symptoms - Stationary Windows ............... 8-805
Schematics
Defogger ...... ,. ... .... ... .... ..... .... .... .... ... .. .. .. . . 8-802
Special Tools ............................................... 8-828
Specifications
Window Cleaning ......................................... 8-824
Window Polishing ......................................... 8-823
Steering Knuckle Replacement .......................... 3-25
Steering Wheel and Column - Tilt
Column
Replacement ... ... ... ... ...... ..... .... .... .... .. .. . .. ... . 2-68
Description
Ignition Lock System ............. ;.................... 2-97
Steering Wheel and Column ....................... 2-96
Diagnosis
Hazard Switch Does Not Stay On ............. 2-58
Hazard Warning Cannot Be Turned Off ...... 2-58
High Lock Effort ......................................... 2-55
High Lock Effort Between the
Off Lock Positions ...... .. ... ..... ... .. . ... . .. 2-54
High Steering Shaft Effort ........................... 2-55
Housing Scraping Bowl ............................. ,. 2-56
Ignition Switch Cannot Be Set Correctly ..... 2-58
Ignition Switch Does Not Turn .................... 2-58
Ignition Switch Electrical System
Does Not Operate ............................ 2-58
Key Cannot Be Removed in the
Off Lock Position .... .. ... .... .... .... . .. .. . ... 2-54
Lock System Does Not Lock . .. .. ... ..... . .. .. .. .. 2-54
Lock System Does Not Unlock ................... 2-54
Lock Cylinder Can Be Removed
Without Depressing Retainer ............ 2-54
Loose Steering Wheel ............................... 2-56
Loose Steering Wheel
(Every Other Tilt Position) ................ 2-56
Looseness In Steering Column ................... 2-56
Noise in Steering Column ........................... 2-55
Noise When Tilting Steering Column .......... 2-57
30
Steering Wheel and Column - Tilt (cont.)
Diagnosis (cont.)
Steering Wheel Does Not Lock in
Any Tilt Position ............................... 2-58
Steering Wh.eel Not Returning to
Top Tilt Position ................... ,..... ,..... 2-56
Turn Signal Difficult to Operate .... ,.............. 2-57
Turn Signal Does Not Cancel ..................... 2-57
Turn Signal Does Not Indicate
Lane Change ....... : ........................... 2-57
Turn Signal Does Not Stay in
Turn Position .................................... 2-57
Dimmer Switch Assembly - Assemble Off Vehicle ....................................... 2-76
Dimmer Switch Assembly - Disassemble Off Vehicle ....................................... 2-75
Hazard Warning Switch Replacement On Vehicle ....................................... 2-62
Horn Switch Replacement On Vehicle .............................. 2-63, 2-64
Ignition Switch Assembly - Assemble Off Vehicle ............ , .......... ,.. ... .. . ... .. .. 2-75
Ignition Switch Assembly- Disassemble Off Vehicle ....................................... 2-74
Ignition Switch Replacement - On Vehicle ...... 2-59
Inflatable Restraint Coil Centering Off Vehicle .................................. , .... 2-93
Inflatable Restraint Steering Wheel Module
Coil - Assemble - Off Vehicle ........... 2-71
Inflatable Restraint Steering Wheel Module
Coil - Disassemble - Off Vehicle ....... 2-70
Intermediate Steering Shaft Replacement ....... 2-66
Lock Cylinder Set - Assemble ........................ 2-78
Lock Cylinder Set - Disassemble ................... 2-78
Lock Housing Assembly - Assemble Off Vehicle ....................................... 2-88
Lock Housing Assembly - Disassemble Off Vehicle ....................................... 2-87
Pivot and Pulse Switch Assembly Assemble - Off Vehicle ..................... 2-77
Pivot and Pulse Switch Assembly Disassemble - Off Vehicle ................ 2-77
Special Tools ............................................... ,.. 2-98
Specifications
Steering Column Accident Damage Off Vehicle .... ,.................................. 2-94
Steering Column Housing - Assemble c
Off Vehicle ....................................... 2-85
Steering Column Housing - Disassemble Off Vehicle ....................................... 2-84
Steering Shaft, Lower Bearing, Jacket ,
Assemble - Off Vehicle ..................... 2-91
Steering Shaft, Lower Bearing, Jacket .
Disassemble - Off Vehicle ................ 2-89
Steering Wheel Control Sw.itch Assembly
Replacement .. ... ... .. .. ... .. ... .. .. .. .. ... .. .. . 2-.64
Steering Wheel Replacement ......................... 2-6~
Tilt Lever Replacement - On Vehicle .............. 2-62
Tilt Spring - Assemble .................................... 2-81
Tilt Spring - Disassemble .. , ............................ 2-79
Turn Sign Multifunction Signal Lever
Replacement - On Vehicle ................ 2-60
INDEX
Steering Wheel and Column - Tilt (cont.)
Turn Signal and Multifunction Switch Assembly
Assemble - Off Vehicle .. '. .................... 2-73
Turn Signal and Multifunction Switch Assembly
Disassemble - Off Vehicle .................. 2-72
Turn Signal Cancel Cam, Upper Bearing Inner.
Race Assemble - Off Vehicle .......... : ... 2-83
Turn Signal Cancel Cam, Upper Bearing Inner
Race Disassemble - Off Vehicle .......... 2-82
Disassembled View .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. ... 2-52
Replacement .................................. 8-346
Steering Wheel Controls Schematic ........;......... 8-284
Stop Lamp Replacement
High Mounted .............. 8-204, 8-206, 8-208, 8-210
Stoplamp Switch
Adjustment ........................................ , ............ 5-51
Replacement .............................. , .................. 5-50
Strategy Based Diagnosis ................................. 0-32
Striker Replacement
Rear Compartment Lid Lock .. .. .. .. .. .. .. .. .. .. .. . 8-1107
Strut Replacement
Rear Lift Panel ... .. .. .. .. ... .. .. ... .. .. .. .. .. .. .. .. .. .. .. 8-1102
Rear Lift Window Panel .. .. .. .. .. .. .. .. .. .. ... .. .. .. 8-1103
Struts o.r Shock Absorbers
Diagnosis
Bench Test .................................................. 3-8
Leak ........ :............................................ ,....... 3-8
Noisy ........................................................... 3-8
On-Vehicle Testing ....................................... 3-8
Weak ........................................................... 3-7
Sunshade Panel Replacement ....................... 8-1002
Suspension
Description
General ........................................................ 3-9
Diagnosis
Abnormal or Excessive Tire Wear ......., ........ 3-4
Struts or Shock Absorber Bench Test ... .. .. ... 3-8
Struts or Shock Absorbers Leak ................... 3-8
Struts or Shock Absorbers Noisy .................. 3-8
Struts or Shock Absorbers On-Vehicle
Testing ......................................... ,..... 3-8
Struts or Shock Absorbers Wec:1.k .................. 3-7
Trim Height .................................................. 3-4
Front
Description ................................................. 3-40
General ................................................... 3-40
Rear
Description .. .... .... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... 3-59
General ........................ : .......................... 3-59
Switch
Clutch Anticipate Switch Replacement .. ,....... 7-397
Clutch Pedal Position Switch
Replacement .......................... :....... 7-397
Cruise Release Switch Adjustment ............... 8-750
Cruise Release Switch Replacement ............ 8-749
Engine Oil Pressure Switch
Replacement .. .. .. .. .. . .. .. ... . .. ... 8-586, 8-587
Fog Lamp Switch Replacement
Front ............................. :............... 8-172, 8-173
Rear ......................................................... 8-174
Hazard Warning Switch Replacement On Vehicle (Tilt) ............................... 2-62
31
INDEX
Switch (cont.)
Headlamp Leveling Switch Replacement ...... 8-171
Headlamp Switch Replacement ......... 8-169, 8-170
Horn Switch Replacement On Vehicle (Tilt Column) .......... 2-63, 2-64
Ignition Switch Replacement (Tilt Column) ...... 2-59
IP Compartment Lamp Switch Replacement ... 8-585
Park/Neutral Position Switch Adjustment
Automatic - 4L60-E ................................... 7-309
Park/NeutraL Position Switc.h Replacement
Automatic 4L60-E ..................................... 7-308
Power Door Lock Switch
Replacement ........................ 8-912, 8-913
Power Mirror Switch Replacement ........ ,....... 8-914
Power Window Switch Replacement ... 8-911, 8-912
Rear Compartment Lid Switch
Replacement ................ : ... ,............ 8-1090
Steering Wheel Control Switch Assembly
Replacement (Tilt Column) ................ 2-64
Replacement .. ........ ......... .... ....... .... 8-346
Stoplamp Switch Adjustment .......................... 5-51
Stoplamp Switch Replacement ....................... 5-50
Torque Converter Clutch PWM Solenoid,
TCC Solenoid, and Wiring Harness
Automatic Transmission - 4L60-E ............. 7-345
Valve Body and Pressure Switch Replacement
Automatic - 4L60-E ................................... 7-336
Switches
Traction Control Switch
Replacement ... ,.................... 5-246, 5-247
T
Tail Lamp Bulb Replacement ...........................
Tail Lamp Replacement ........................ 8~215,
Temperature Control Cable
Adjustment (A/C- Manual) ...........................
Temperature Sensor Description Engine Coolant ...............................
Theft Deterrent
Component Locations .. ...... ...... ............ ...... .. .
Component Views .... ... ...... ...... ......... .. ....... ...
Connector End Views .. ...... ....... ........ .. ....... ...
Description
Content Theft Deterrent . ....... ............ ........
Content Theft Deterrent Circuit .................
Content Theft Deterrent Operation ... .........
Vehicle Theft Deterrent .............................
Vehicle Theft Deterrent Circuit ..................
Vehicle Theft Deterrent Operation .............
Diagnosis
Content Theft Deterrent Alarm Mode
Always On .. .. ...... .... .. ... ......... .... .. ....
Content Theft Deterrent Alarm Mode
Inoperative ......................................
Diagnostic Starting Point Theft Deterrent ...............................
Diagnostic System Check .........................
DTC List .... ...... . .... .. ...... .... ..... .... .... .... ... ....
Horn Inoperative in CDT Alarm Mode .......
Ignition Key Lock Cylinder Test ................
8-218
8-216
1-132
6-672
8-680
8-682
8-685
8-708
8-71 O
8-708
8-710
8-712
8-711
8-689
8-690
8-686
8-686
8-686
8-691
8-700
Theft Deterrent (cont.)

Diagnosis (cont.)
Lights Inoperative in CDT Alarm Mode ..... 8-691
SECURITY Indicator Inoperative ............... 8-693
Security Indicator LED Inoperative ............ 8-697
SECURITY Indicator Off,
Engine Does Not Crank ................. , 8-694
SECURITY Indicator On, Engine Starts .... 8-696
Shock Sensor Inoperative ......................... 8-698
Symptoms - Theft Deterrent .. ... .. .... .. ... .. .. .. 8-689
System Feature Customization
Inoperative ................... , .................. 8~698
Feature Customization ................ , ................ 8-705
Programming Additional Keys ..... :................. 8-705
Programming Replacement Keys,
Ignition Cylinder, or
Powertrain Control Module . .. ... ... . ... 8-705
Relay Replacement ........... , .. .. ... .. ... .... .. ... .. ... 8-702
Schematic
Icons ... .... ... .. .. ... .... . ... ... .. .... .. .. ... .... ... ... .. . .. 8-675
Schematics ........................ , .. ... .. ... ..... .. .. ... . .. 8-676
Shock Sensor Replacement ... ... .. .. ..... .. ... .. ... 8-703
Special Tools ............................................. 8-712
Specifications
Thermal Bypass Pipes
Replacement (Engine Cooling) . .. ... .... .. .. ... .. .. 6-639
Thermostat
Description . ... ... .. .... ... .. ... ... .. . .. ... .. ... .... .. ... ... .. 6-672
Housing Replacement
(Engine Cooling) . .. .... .. .. ... .... 6-634, 6-637
Replacement (Engine Cooling) . ... .. .... 6~638, 6-639
Thread Inserts ................................................... 0-21
Throttle Body
Assembly Replacement (5.7L) ...... , ............. 6-1857
Cleaning Procedure (5.7) ........................... 6-1863
Coolant System Description .. ... .. ... .... ... . .... .. . 6-670
Replacement (3.8L) ....................... 6~1246
Throttle Body Assembly Replacement (3.8L) .... 6-1245
Throttle Body Heater
Inlet Hose Replacement (Engine Cooling) .... 6~625
Outlet Hose Replacement (Engine Cooling) .. .. 6~626
ihrottlePosition Sensor Replacement (5.7L) .... 6-1853
Thrust Angle Adjustment, Rear .......................... 3-12
Tire
Chain Usage Description . ... ... .. .. ... ..... ... .. .. ... .. 3-71
Description ..................................................... 3~70
Inflation Description ........................................ 3-70
Mounting and Dismounting ............................. 3-68
Placard Description ............................... , ... ... .. 3-72
Replacement
Compact Spare .......................................... 3-68
Rotation ........................... : .............................. 3-69
Tire and Wheel Runout Specifications ..... .. .. .. .. .. 0~42
Tire and Wheel Inspection
Vibration Diagnosis . ... .. . ..... .... .. ... .. .... 0-44

Tire Inflation Pressure Specifications ................. 0-34
Tire Placard .. .... .... .... ... .. .. .. ... .. .. .. .. ... ..... ... .. ... ... ... 0-9
Tire Repair ........................................................ 3-68
Tire Wear
Abnormal or Excessive . .. ... .... .. .. ... .... .... .. ... .. .... 3-4
Tires and Wheel Balancing .. .... .. .. .. ... ..... .. .... . .... . 0-71
32
Tires and Wheels
Description ....................................... ,............. 3-70
. Aluminum Whe.els ...................... ,............. , .. 3-72
Chain Usage ............. ,................................ 3-71
Inflation ................ ,..................... ,............. ; 3-70
P-Metric Sized Tires ................................... 3-71
Replacement Wheels .......... ,............ , .......... 3-72
Tire Placard ....................................... , ........ 3-72
Diagnosis
Radial Tire Lead/Pull Correction .... ,, ........... 3-63
Wheel Mounting Surface Check., ................ 3-62
.Specifications ............................. , ..... .... .. ..... ... 3-61
Fastener Tightening ............. ,, ......... ,........... 3-61
Wheel Removal and Installation ..................... 3-66
Toe Adjustment, Front ............... ,: ....... ,.............. 3-12
Torque Arm Replacement
Rear Suspension .................. ,........................ 347
Tow Hook Replacement .................... 8-1182, 8-1.184
Track Bar Replacement
Rear Suspension ............ , ............................ ,. 3-57
Traction Control Switch Replacement .... 5s246, 5-247
Training Information .......... , ....... , ........................ , 0-5
Transmission - MM6
Support and Mount Assembly ............. ,.......... 7-42
Transmission Floor Shift Control Indicator
Lamp Replacement .................. : ., .... 8-226
Transmission ID and Partial VIN Location ......... 0-12
Transmission Support Replacement ............... 8-1173
Transmission Usage .......................................... 0-13
Transmitter
Battery Replacement
Key less Entry .......... , ............ , ..... , ............ 8-660
.. Programming/Synchronization
Keyless Entry ........................................... 8-661
Trim Cleaning
Fabric ........................................................ 8-1074
.Leather .................................... , .................. 8-1074
Vi"nyl ........... ,................. ,............................. ,. 8-1073
Trim Height Diagnosis .................... :..................... 3-4
Trim Height Specifications .................................. , 3-3
.
Trim Panel. Carpet Replacement
Rear Center ....................... , ......... 8-1067, 8~1068
Trim Panel Opening Cover. Replacement ....... 8-1091
Trim Panel Replacement
Cargo Area Front ........................... 8-1063, 8-1064
Cargo Area Side .. . .. .... . .... ... ... .. ... ... . .. .... .. ... 8-1065
Liftgate ................................................ ,...... 8-1091
Shelf
Rear ........... , ........................................... 8-1073
Trim Plate Bezel Replacement
IP Cluster .......................................... 8-594., 8-595
Trim Plate Replacement
IP Accessory .................................... 8-592, 8-594

IP Accessory Left ......... , ... ,........................... 8-591
INDEX
Trim Replacement
Hinge Pillar ................................... ,............ 8-1062
Turn Signal
Flasher Replacement ................ ,....... 8-179, 8-180
Turn Signal Lamp Bulb Replacement
Rear ......................... ,........................ 8-219, 8-220
u
Underbody Inspection .................................... 8-1185
Upper Rear Trim Finish Panel Replacement ..... 8-'1070
v
Vacuum Brake Booster
Hose Replacement .... ,..... ........ . . .. .. .. .. .... .. .. ... 5-50
Replacement .. .... ....... ..... ... ....... . . .. .. ... ... .... ... .. . 5-48
Vacuum Brake Booster Operation Description .... 5-53
Vacuum Hose Harness.
Replacement (A/C - Manual)., ......... ,............ 1-141
Vacuum Tank Replacement (A/C - Manual) ..... 1-140
Valve Replacement
Pressure Relief .......................................... 8-1109
Vapor Vent Pipe
Clean and Inspect (5.7L) ............................. 6-519
Vapor Vent Pipe Replacement (5.7L) ............... 6-324
Vehicle Certification Label ..... ,............................. 0-8
Vehicle l.dentification ............................................ 0-5
Manual Transmission (M49) ........................... 7-21
Vehicle Speed Sensor Replacement
Automatic Transmission - 4L60-E ................. 7-358
Manual Transmission (MM6) .......................... 7-49
Vibration
Special Tools ................................................. 0-86
Vibration Diagnosis
Balancing Tires and Wheels ........................... 0~71
Basic Terms ................................................... 0-73
Classifying the Vibration ................................. 0-47
Diagnosing First-Order Driveline Vibration ...... 0-51
Diagnosing Second-Order Driveline
Vibration ........................................... 0-61
Diagnostic Information and Proc.edures .......... 0-43
Driveline Vibration Analysis ............. : .............. 0~51
El.ectronic Vibration Analyzer ........... , .............. 0-81
Engine Related Vibration ................................ 0-67
Matching Frequency to Component RPM ., ..... 0-48
Reed Tachometer ........................................... 0-81
Road Test ...................................................... 0-45
Rotor/Drum Imbalance ................................... 0-50
Systematic Approach ............ :......................... 0-43
Tire and Wheel Inspection .................... : ........ 0~44
Tire and Wheel Vibration ............................... 0-70
Types of Road Test Procedures ..................... 0-45
Vibrations That Can Be Felt . ... . .. ... .. ..... .. ...... .. 0-4 7
Vibrations That Make Noise ........................... 0-48
VIN Derivative ..................................................... 0-7
VIN, Partial, Location and Engine ID .......... 0-9, 0-10
33
INDEX
w
)
Washer
Pump Replacement ......................... ,............ 8-254
Solvent Container Replacement ........ , .......... 8-252
Water Pump
.Clean and Inspect ..... ;.................................. 6-519
Description ........................................... ,....... 6-672
Replacement (Engine Cooling) .......... 6-640, 6-642
Waterleaks
Body Waterleak Repair ..... ,.......................... 8-780
Diagnosis
Air Hose Test ..................................... ,..... 8-778
Body Waterleak Repair ............................. 8-776
Dust Leaks ............................................... 8-779
Localized Testing (Spot Testing) .......... ,.... 8-777
Test Preparation ............................. ,: ........ 8-776
Water Hose Test ...................................... 8-778
Generalized Testing ...... ,............. ;................. 8-777
Specifications
Recommended Materials
(Waterleak Repair) .......................... 8-776
Stationary Window Waterleak Repair ............ 8-782
Weatherstrip Waterleak Repair ...................... 8-781
Weather Retainer Replacement
Folding Top ................................................ 8-1010
Weatherstrip Replacement
Door ............................................. ,.............. 8-931
Folding Top Side Front ...... , .............. , ......... 8-1011
Rear Lift Window Panel Opening ............... 8-1110
Wheel
Removal and Installation ................................ 3-66
Wheel Alignment
Description
Camber .... .. .. .. .. . . .. .. ..... .. .. .. . .. . .. .. .. .. . . .. .. .. . .. .. 3-13
Caster .. ... .. .. .. .. .. ... .. .. .. .. ... .. .. .. ... .... .. .. .. . .. . .. .. 3-13
Toe ............................................................ 3-14
Diagnosis
Preliminary Alignment Inspection ................ 3-10
Front Caster and Camber Adjustment ............ 3-11
Front Toe Adjustment ..................................... 3-12
Measuring ...................................................... 3-11
Rear Thrust Angle Adjustment ........................ 3-12
Special Tools ................................................. 3-14
Specifications ....... .... ..... ..... ........ .. .................. 3-1 O
Fastener Tightening .................................... 3-1 O
Wheel Bearing/Hub Replacement - Front ........... 3-24
Wheel Hub Bolt Replacement ............................ 3-18
Wheelhouse
Panel Replacement ...................................... 8-876
Wheelhouse Replacement
Front ............................................. 8-1191, 8-1193
Rear .......................................................... 8-1218
Wheels
Aluminum Wheels Description ........................ 3-72
Replacement Wheels Description ................... 3-72
Windnoise
Exterior ........................................................ 8-784

Interior ......................................................... 8-784
Window Regulator Motor Replacement ............ 8-928
Window Regulator Replacement ....... ,.............. 8-927
Window Replacement
Door ............................................................ 8-928
Windows
Diagnosis
Power Windows Inoperative ...................... 8-907
RF from LF Switch ................................ 8-907
Power Window Switch Replacement ... 8-911, 8-912
Windshield
Reveal Molding Replacement ....................... 8-808
Side Garnish Molding Replacement ... 8-810, 8-811
Windshield Glass Cleaning .............................. 8-269
Windshield Replacement ................................. 8-814
Wiper
Arm Blade Replacement .............................. 8-256
Arm Replacement ........................................ 8-255
Blade Element Cleaning ............................... 8-269
Blade Element Replacement ............. : . .. ... .... 8-257
Chatter Repair ............................................. 8-269
.Motor Cover Replacement .. ... .. ... .. .. .... . .. ... ... . 8-258
Motor Replacement .. ... .. .... .. .. .. ... .. .. .... . .. .. .... . 8-259
Transmission Replacement ........................... 8-264
Wipers/Washer Systems
Component Locations ... . . .. .. ... . .. . .. .. .... .. .. .. ... .. 8-241
Component Views .... .. ... .... ... .. .. ... .. ..... . .. .. ... .. 8-242
Connector End Views . ... ... .. .. ... .. .. .. .. . .. . .. ... ... . 8-243
Description
System Operation . .. ... .. .. . .. .. .. . .. .. .... .. .. .. .... . 8-270
Windshield Wipers/Washer System ........... 8-270
Diagnosis
System Check ... . .. .. .. .... .. . .. ... ... .. .. .. ... .. . .... . 8-244
Washers Inoperative ................................. 8-249
Wiper Arm Tip Pressure Check,
Blade Element Check .. .. .. . .. .. .. .. .. .. .. 8-251
Wiper Blade Do Not Park with
Switch Off .. . .. .. .. ... .. .. . .. .. .. . .. .. .. . . .. .. . .. 8-248
Wiper High Mode Inoperative,
Low Mode Operates ....................... 8-246
Wipers Always On .................................... 8-247
Wipers Delay Mode Inoperative ................ 8-245
Wipers Inoperative .................................... 8-244
All Modes .. . .. . .. . .. . .. .. .. .. . .. ... .. .. .. . . .. . .. .. .. .. . 8-244
Wipers Mist, Delay, and Low Modes
Inoperative ...................................... 8-246
Schematics
Pulse . .. .. .. .. . .... .. .. . .. .. . .. .... . .. .. ... ... .. . .. . . .. .. .. .. 8-240
Special Tools ............................................... 8-271
Specifications
INDEX
34
Wiring Systems
Description
Harness Routing Views .............................
lnline Harness Connector End Views ........
Diagnosis
Checking Aftermarket Accessories ,...........
Circuit Protection ......................................
Circuit Breakers .....................................
Fuses .................................. : .................
Fusible Links .........................................
Circuit Testing ..........................................
Connector Position Assurance Locks .; ... , ..
Connector Repairs ......... , ..........................
Electrical Symbols ....................................
Flat Wire Repairs .....................................
General Electrical Diagnosis Procedures ...
H02S Wiring Repairs ...................... , ........
Inducing Intermittent Fault Condition .........
Measuring Frequency ...............................
Measuring Voltage ....................................
Measuring Voltage Drop ...........................
Passenger Car Zoning ..............................
Probing Electrical Connectors ...................
Pull to Seat Connectors ............................
Push to Seat Connectors ..........................
Repairing Connector Terminals .................
Repairing Damaged Wire Insulation ..........
Scan Tool Snapshot Procedure ................
SIR Wiring Repairs ........................... ,.......
8-481
8-461
8-384
8-390
8-390
8-390
8-391
8-384
8~398
8-398
8-380
8:398
8,384
8-395
8-388
8-386
8-386
8:.386
8~379
8-384
8-399
8~398
8-401
8-391
8-389
8-396
Wiring Systems (cont.)

Diagnosis (cont.)
Splicing Copper Wire Using Splice Clips ... 8-384
Splicing Copper Wire Using Splice
Sleeves .............................. ,........... 8-393
Splicing In line Harness Diodes .................. 8-395
Splicing Twisted or Shielded Cable ........... 8-394
Terminal Position Assurance Locks ........... 8-398
Testing for Continuity ............................. ,.. 8-386
Testing for Electrical lntermittents ............. 8-389
Testing for Poor Connections .................... 8-387
Testing for Short to Ground ...................... 8-387
Testing for Short to Voltage ...................... 8-387
Troubleshooting with a Digital
Multimeter ....................................... 8-385
Troubleshooting with a Test Light ............. 8-385
Using Connector Test Adapters ................ 8-384
Using Fused Jumper Wires ....................... 8-385
Weather Pack Connectors ........................ 8-400
Where to Find Electrical Schematics ......... 8-376
Wiring Repairs .......................................... 8-390
Electrical Center Identification ...................... 8-454
Power and Grounding Component Views ..... 8-449
Power and Grounding Components .............. 8-436
Power and Grounding
Schematics
Ground Distribution ................................... 8-421
Power Distribution .. .. .. .. .. ... .. .. ... . .. .. .. .. .. .. .. .. 8-402
Work Sheets, Diagnostic .............. ,...................... 0-5

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6-2 Table of Contents

Balance Shaft Removal .............................. 6-183

Engine Mechanical - 5.7L ....... ,...................6-249

Sealers, Adhesives, and Lubricants ............ 6-256

Replacement (Right) ............................... 6-332

Oil Pump, Pump Screen and Deflector

Piston and Connecting Rod Assemble ........ 6-476

Radiator Hos.e Replacement Inlet (5.7 L) ........ , ................................... 6-617

Engine Electrical ..........................................6-674

Spark Plug Wires Not Operating

Battery Cable Replacement

Replacement (5.7 L) ................................ 6-773

Engine Controls - 3.8L ................................6-786

Diagnostic (OBD) System Check ............. 6827

Inoperative .................. : .......................... :6-843

DTC P0152 H02S Circuit High Voltage

DTC P0452 Fuel Tank Pressure Sensor

(Table 1) ............................................... 6-1199

Fuel Tank Leak Check ............................. 6-1226

Crankshaft Position (CKP) Sensor

Electronic Ignition (El) System

Scan Tool Data List ................................. 6-1383

OTC P0358 Ignition Coil 8 Control

DTC P0602 Control Module Not

OTC P1539 Air Conditioning (A/C)

Secondary Air Injection Pump Relay

Engine Exhaust ..........................................6-1972

Engine Mechanical - 3.8L

Engine Mechanical - 3.8L

Accelerator Control Cable Bracket Bolt

Balance Shaft Retainer Bolt

Camshaft Position Sensor Bolt

Camshaft Sprocket Bolt

Crankshaft Balancer Bolt

Crankshaft Main Bearing Cap Bolt

EGR Valve Wiring Harness Heat Shield Bolt/Nut

Engine Block Coolant Drain Plug

Crankshaft Position Sensor Stud

EGR Valve Outlet Pipe Bolt/Nut (Except Upper Intake Manifold)

Engine Flywheel Bolt (New)

Engine Front Cover Bolt/Stud

Engine Coolant Temperature Sensor

Engine Lift Bracket Bolt/Nut/Stud

Engine Mount Bracket Bolt

Engine Mount Nut, Lower

Engine Mount Nut, Upper

Engine Mount Strut Bolt

Engine Mount Strut Bracket Bolt at Engine, Left

Engine Mount Strut Bracket Bolt at Engine, Right

Engine Mount Strut Bracket Bolt at Upper Radiator Support

Engine Mount Strut Nut

Engine Oil Gallery Plug

Exhaust Manifold Nut

Exhaust Manifold Bolt/Stud

Fuel Injector Rail Stud

Fuel Injector Sight Shield Bracket Nut

Generator Brace Bracket Bolt

Fuel Injector Rail Assembly Nut

Heated Oxygen Sensor

ICM Bracket Stud

ICM Assembly Bolt/Nut

Lower Intake Manifold Bolt

MAP Sensor Bracket Bolt

Engine Mechanical - 3.8l

2000 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

2000 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2