Engine Controls - Basic Testing - Gasoline Chevrolet Cab & Chassis K3500

MODEL IDENTIFICATION

MODEL IDENTIFICATION

INTRODUCTION

The following diagnostic steps help prevent overlooking simple problems. This is also where to begin diagnosis for no-start condition.

The first step in diagnosing any driveability problem is verifying the customer's complaint by test driving vehicle under the conditions in which the problem reportedly occurred.

Before entering self-diagnostics, perform a careful and complete visual inspection. Most engine control problems result from mechanical breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test listed in this article.

Note. Unless otherwise instructed in test procedures, perform all voltage tests using a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance.

Note. Following table provides location of commonly used diagnostic information. These former "A" and "C" charts are now written in text and inserted into appropriate location of engine performance workflow. To learn about engine performance workflow, see the AA - USING THIS SECTION (GENERAL HELP INFORMATION) article in GENERAL INFORMATION section.

A & C CHART REFERENCE

VISUAL INSPECTION

Visually inspect all electrical wiring. Look for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and not pinched or cut. If necessary, see the VACUUM DIAGRAMS article in this section to verify routing and connections. Inspect air induction system for possible vacuum leaks.

Compression

Check engine mechanical condition using a compression gauge, vacuum gauge or engine analyzer capable of performing a relative compression test. If using engine analyzer, see engine analyzer instruction manual for availability and description of relative compression feature.

Exhaust System Backpressure

Before replacing any components, check exhaust system for restrictions. Use a vacuum gauge or a low-pressure (1-5 psi) pressure gauge to check exhaust system.

If using a vacuum gauge, connect gauge to intake manifold vacuum, and start engine. Observe gauge while holding throttle steady at 2000-2500 RPM. If vacuum gauge reading slowly drops after stabilizing, exhaust system may be restricted.

1. Check At AIR Pipe

Remove rubber hose at exhaust manifold AIR pipe check valve, and remove check valve. Install pressure gauge to hose and nipple via Propane Enrichment Device (J26911). Nipple should be inserted into exhaust manifold AIR pipe.

1. Check At Oxygen Sensor

Remove oxygen sensor. Install backpressure tester in place of oxygen sensor. After test is completed, coat oxygen sensor threads with anti-seize compound before installation.

Diagnosis

1. Start engine and bring to operating temperature. Increase engine speed to 2000-2500 RPM. Note gauge. Exhaust system is restricted if reading exceeds 1.25 psi (.09 kg/cm 2 ).
2. Check exhaust system for collapsed pipe, heat distress and possible internal muffler failure. If none of these conditions exists, check for restricted catalytic converter. Replace as required.

A-3, NO-START DIAGNOSIS

Note. For diesel information, see TESTS W/CODES - 6.5L DIESEL and TESTS W/O CODES - 6.5L DIESEL articles in the ENGINE PERFORMANCE section.

Definition

No-start is defined as engine cranks okay but does not start. Engine may fire a few times.

Note. Before performing following tests, check battery condition, engine cranking speed and fuel supply.

General Inspection

1. Ensure proper starting procedure is being used.
2. Visually check vacuum hoses for splits, kinks and improper connections. See underhood emission control information label. Check ignition wires for cracks, hardness and improper connections at distributor cap and spark plugs.
3. Remove spark plugs. Check and replace if necessary.
4. Remove distributor cap and check for moisture, dust, cracks, burns, and arcing to ground through coil mounting screws or rotor.
5. Try to turn distributor shaft by hand. Drive gear pin may be broken.
6. If vehicle has been exposed to very cold temperatures, ensure oil is of proper viscosity and not contaminated with gasoline.

Ignition System

1. Disconnect tachometer wire at distributor tachometer terminal (if equipped). A shorted tachometer or tachometer circuit prevents vehicle from starting. Ensure TP sensor and coolant sensor codes are not present and sensors are not out of calibration.
2. Check for battery voltage at "+" terminal of ignition coil with ignition on. (Scheme 143)- (Scheme 146). Repair as necessary.
3. Connect Spark Tester (ST-125) to end of one plug wire. Crank engine. If spark is present, check fuel delivery.
4. If spark does not occur, disconnect 4-wire EST connector at distributor and check for spark at ignition coil tower using Spark Tester (ST-125). If spark now occurs, check cap and rotor for damage or wear. Check for open in coil wires.
5. If spark does not occur, reconnect EST connector. Leave spark tester connected to coil tower for remainder of test. Disconnect ignition coil Black 2-wire connector, and check voltage on "C" and "+" terminals with ignition on.
6. If voltage on both terminals is 10 volts or greater, go to next step. If voltage on both terminals is less than 10 volts, repair wire from "+" terminal on module to "B" terminal on coil Black 2-wire connector. If voltage is less than 10 volts on "C" terminal only, check for open or short to ground in circuit from "C" terminal of ignition module to ignition coil. If circuit is okay, problem is faulty coil or coil connections.
7. Connect voltmeter between ground and tachometer terminal at coil with ignition on. Tachometer terminal may be taped back against harness. If voltage is greater than 10 volts, go to step 9).
8. If voltage is 1-10 volts, replace ignition module and check for spark at coil tower using Spark Tester (ST-125). If voltage is less than one volt, repair open in tachometer lead or tachometer connector. After repairs, recheck voltage at tachometer terminal.
9. Connect test light between ground and tachometer terminal. Crank engine. If test light remains on (steady), go to next step. If test light flashes, replace ignition coil with a known-good unit and recheck for spark. If spark does not occur, reinstall original ignition coil and replace ignition module.
10. Remove distributor cap. Unplug ignition module pick-up coil connector. Connect voltmeter between ground and tachometer terminal. Turn ignition on. Using jumper wires, connect positive end of a known-good 1.5-volt battery to terminal "P" of module. Observe voltmeter at tachometer terminal as negative end of test battery is momentarily grounded to distributor housing.
11. If voltage at tachometer terminal does not drop, check ignition module ground. Check for open in wires from ignition coil to module. If all is okay, replace ignition module.
12. If voltage at tachometer terminal drops, check for spark at spark tester as jumper is removed from terminal "P". If spark does not occur, go to next step. If spark occurs, check pick-up coil connections. Check for 500-1500 ohms resistance at pick-up coil leads. Ensure leads are not shorted to ground. Repair as necessary.
13. Test ignition module with module tester. If module tests okay, check ignition coil wire. If module tester is not available, replace ignition coil, and touch terminal "P" again. If spark occurs, system is okay. If spark does not occur, reinstall original ignition coil, and check coil wire from distributor cap. If no problem is found, replace ignition module.

Fuel System (TBI)

1. Before checking fuel system for a no-start condition, check ignition for adequate spark. Check for proper fuel pump pressure (9-13 psi) and capacity (one pint in 30 seconds). See «A-7, BASIC FUEL SYSTEM CHECKS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline) .
2. Crank engine, and watch for injector spray. If injector spray occurs, go to step 5). If no spray occurs, disconnect injector harness. Check for battery voltage at harness with ignition on. Battery voltage should be present on one injector terminal. If battery voltage is not present, check for blown injector power fuse. If battery voltage is present on both terminals, check for wires shorted together.
3. If battery voltage is present on only one terminal, connect injector test light to injector harness. Crank engine, and note light. If light flashes, check for stored ECM codes. See DIAGNOSTIC CIRCUIT CHECK. If no codes are present, refer to HARD START symptom in TESTS W/O CODES - GASOLINE article in this section. If light does not flash, momentarily touch test light from battery voltage to ECM RPM reference terminal (circuit No. 430 - Purple/White wire).
4. Each time test light is removed from ECM RPM reference terminal, injector test light should flash. If test light does not flash, check for open in RPM reference wire or injector drive (ground) circuit. If wiring is okay, replace faulty ECM. Before replacing ECM, check ECM power and ground circuits.
5. Disconnect injector harness, and crank engine. If injector spray or leakage occurs, a no-start condition may be caused by excessive fuel being delivered during cranking. Repair faulty injector or injector seal. If no spray or leakage occurs, refer to HARD START symptom in TESTS W/O CODES - GASOLINE article in this section.

Fuel System (4.3L CPI)

Before checking fuel system for a no-start condition, check ignition for adequate spark. For fuel system testing, see FUEL SYSTEM PRESSURE TEST under A-7, BASIC FUEL SYSTEM CHECKS.

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Model 220 TBI Unit

Fuel pressure is relieved and drops to zero when ignition is turned off. To minimize risk of fire and personal injury, cover area to be disconnected with a shop rag.

CPI (4.3L)

Fuel system is under pressure, which must be relieved before servicing fuel system. Fuel pressure may be relieved by one of following methods.

1. Disconnect fuel pump at rear body connector. Start engine and allow it to run until it stalls. Crank starter 3 seconds to remove remaining fuel from fuel lines. Reconnect rear body connector.
2. Install Fuel Pressure Gauge (J-34730-1) on fuel pressure connector of fuel rail. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb fuel leakage. Place gauge bleed hose in container. Open bleed valve to relieve fuel pressure.

FUEL SYSTEM PRESSURE TEST

Note. Fuel pressure specification on 7.4L engines should be 26-32 psi (1.8-2.2 kg/cm 2 ), and on all others is 9-13 psi (.63-.91 kg/cm 2 ).

TBI

1. Turn ignition off for 10 seconds. Turn ignition on, and listen at fuel tank for fuel pump operation. Pump should run 2 seconds (20 seconds on models with fuel module). If fuel pump runs, go to next step. If fuel pump does not run, go to step 7).
2. If fuel pump runs, turn ignition off. Verify fuel tank has fuel. Relieve fuel pressure. See «FUEL SYSTEM PRESSURE RELIEF»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline) . Remove air cleaner, and plug air cleaner vacuum ports (if equipped). Disconnect fuel line between throttle body and fuel filter. Install Fuel Pressure Gauge (J-29658A) and Adapter (J-2968A-85) between steel fuel line and flexible hose, ahead of in-line fuel filter.
3. Turn ignition on, and note reading on pressure gauge. If fuel pressure is 26-32 psi (1.8-2.2 kg/cm 2 ) on 7.4L and 9-13 psi (.63-.91 kg/cm 2 ) on all other, no problems exist. If pressure is less than than 26 psi (1.8 kg/cm 2 ) on 7.4L or less than 9 psi (.63 kg/cm 2 ) on all others, go to step 5). If pressure is greater than 32 psi (2.2 kg/cm 2 ) on 7.4L or greater than 13 psi (.91 kg/cm 2 ) on all others, turn ignition off, and bleed fuel pressure. Disconnect fuel return line downstream of pressure gauge. Insert return line into a gasoline container.
4. Turn ignition on. If pressure is now 26-32 psi (1.8-2.2 kg/cm 2 ) on 7.4L or 9-13 psi (.63-.91 kg/cm 2 ) on all others, correct restriction in fuel return line between disconnected point and fuel tank. If fuel pressure is greater than 32 psi (2.2 kg/cm 2 ) on 7.4L or greater than 13 psi (.91 kg/cm 2 ) on all others, check for restricted return line (including fuel filter) downstream of pressure gauge. If no restrictions are present, replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220).
5. Check for restricted line between in-tank fuel pump and pressure regulator. If fuel line is okay, disconnect injector connector. Turn ignition on. Gradually pinch fuel pressure gauge outlet hose. Note pressure. CAUTION: DO NOT pinch off fuel return line completely. DO NOT allow fuel pressure build-up to exceed specification, as damage to fuel pressure regulator may occur.
6. If pressure is greater than 32 psi (2.2 kg/cm 2 ) on 7.4L or greater than 13 psi (.91 kg/cm 2 ) on all others, replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220). If pressure is less than than 26 psi (1.8 kg/cm 2 ) on 7.4L or less than 9 psi (.63 kg/cm 2 ) on all others, check for faulty fuel pump or incorrect part. Check fuel pump coupling hose and pump inlet filter in fuel tank. On models with dual fuel tanks, check for faulty fuel tank selector valve and meter switch.
7. Apply 12 volts to fuel pump test connector. For fuel pump test connector location, see underhood engine component views under COMPONENT LOCATIONS in SYSTEM/COMPONENT TESTS - GASOLINE article in this section. If fuel pump now runs, repair open in fuel pump relay drive or power circuit or repair faulty fuel pump relay. To test relay, see SYSTEM/COMPONENT TESTS - GASOLINE article in this section.
8. If fuel pump does not run with 12 volts applied to fuel pump test connector, repair open in fuel pump power or ground circuit, or repair faulty fuel pump.

FIELD SERVICE MODE CHECK

Note. Assembly Line Data Link (ALDL) connector may also be referred to as Data Link Connector (DLC). SERVICE ENGINE SOON (SES) light may also be referred to as Malfunction Indicator Light (MIL).

Note. Oxygen sensor may cool off while engine idles, causing system to enter open loop. To restore closed loop mode, run engine at part throttle several minutes and accelerate from idle to part throttle several times.

This test confirms proper fuel system operation and verifies closed loop operation. Clear codes and perform this test after any repair is completed. When performing this test, always engage parking brake and block drive wheels. Parking brake on FWD models does not hold drive wheels.

1. Start engine. With engine running, ground diagnostic test terminal "B" of DLC. (Scheme 149)- (Scheme 151). In closed loop mode, Malfunction Indicator Light (MIL) flashes once per second.
2. In open loop, light flashes 2.5 times per second. A lean exhaust is indicated if light is usually off. A rich exhaust is indicated if light is usually on.

HEI-EST DISTRIBUTOR

Note. Only basic ignition timing is adjustable in HEI/EST ignition system.

Spark

1. If factory tachometer is connected to ignition coil tachometer terminal, disconnect it before performing tests. When removing spark plug wire from spark plug, twist and pull on boot. DO NOT pull on wire.
2. Using Spark Tester (ST-125), check for spark at coil wire (if applicable) and at each spark plug wire. Check spark plug wire resistance on suspect wires. Resistance should not be greater than 30,000 ohms.

Ignition Coil Power Source

Turn ignition on. Use voltmeter to check voltage between terminal "B" of ignition coil and ground. If battery voltage does not exist, check for open circuit, blown ignition fuse or defective ignition switch.

Ignition Coil Resistance

1. Remove coil connectors and secondary coil wire. In test "A", use high ohmmeter scale. (Scheme 147) Resistance value should be very high (infinite). If reading is not infinite, replace coil.
2. In test "B", use low ohmmeter scale. Reading should be very low (near zero ohms). If reading is not near zero ohms, replace coil. In test "C", use high ohmmeter scale. Continuity should exist. If no continuity exists, replace coil.

Scheme 147

Distributor Pick-Up Coil Short & Resistance Checks

1. Disconnect pick-up coil leads from module. Using ohmmeter, check pick-up coil resistance. Connect ohmmeter to distributor housing and either pick-up coil lead (step 1 in illustration). (Scheme 148) Flex pick-up coil leads by hand to check for intermittent short to ground. If reading is not always infinite, replace pick-up coil.
2. Connect ohmmeter between pick-up coil leads (step 2 in illustration). (Scheme 148) Check for intermittent open by flexing wires and connectors. If resistance is not 500-1500 ohms, replace pick-up coil.

Scheme 148

Tach Pulse (RPM) Signal

Connect scan tester to DLC. RPM should be indicated on tester when engine is cranked or running. Tach pulse (RPM reference) will be indicated as a voltage signal when a DVOM connected to battery voltage is used to backprobe circuit No. 430, ECM terminal. (Scheme 143)- (Scheme 146). If tach pulse signal is not present, vehicle will not run.

IDLE SPEED & IGNITION TIMING

Ensure idle speed and ignition timing are set to specifications. For specifications, see SPECIFICATIONS - GASOLINE article in this section. For adjustment procedures, see ADJUSTMENTS - GASOLINE article in this section.

DIAGNOSTIC CIRCUIT CHECK

There are different/unique types of control modules, and various systems are used to control their operation depending on engine and/or vehicle type. For easier referencing, engines and models are identified or divided into system groups. See SYSTEM GROUPING CHART .

SYSTEM GROUPING CHART

Diagnostic circuit check determines following

1. Whether Malfunction Indicator Light (MIL) works.
2. Whether ECM is operating and can recognize a fault.
3. Whether any codes are stored.

After performing basic diagnostic procedures listed under PRELIMINARY INSPECTION & ADJUSTMENTS; A-7, BASIC FUEL SYSTEM CHECKS and C-4, BASIC IGNITION SYSTEM CHECKS, use self-diagnostic system for determining computer-related problems. (Scheme 152)

If codes are NOT indicated and driveability problems still exist after performing necessary tests in diagnostic circuit check, see TESTS W/O CODES - GASOLINE article and SCAN TESTER USAGE under SELF-DIAGNOSTIC SYSTEM in appropriate G - GASOLINE TESTS W/ CODES article in this section below.

1. G - TESTS W/CODES - 4.3L
2. G - TESTS W/CODES - 5.0L
3. G - TESTS W/CODES - 5.7L
4. G - TESTS W/CODES - 7.4L

1. Check MIL operation. Turn ignition on with scan tester not connected, DLC terminal not grounded and engine not running. MIL should be on steadily. If light glows and stays on steadily, go to next step. If light does not glow, go to «A-1, MALFUNCTION INDICATOR LIGHT (MIL) INOPERATIVE»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline__a-1-malfunction-indicator-light-mil-inoperative). If light flashes, go to step 3).
2. Ground DLC test terminal "B". MIL should flash Code 12, followed by any codes stored in ECM memory. If light goes from bright to dim or if light remains on and does not flash Code 12, see «A-2, MIL ALWAYS ON OR WON'T FLASH CODE 12»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline__a-2-mil-always-on-or-wont).
3. Check for short to ground in diagnostic test terminal wire between DLC terminal "B" and ECM terminal. (Scheme 149)- (Scheme 151). If circuit is okay, replace ECM.

Scheme 149

Scheme 150

Scheme 151

A-1, MALFUNCTION INDICATOR LIGHT (MIL) INOPERATIVE

1. If MIL does not illuminate with ignition on and engine off, attempt to start engine. If engine starts, go to step 3). If engine does not start, check fusible links at battery. Also check ECM fuse. If fusible links or ECM fuse are blown, repair short to ground.
2. If fusible links and ECM fuse are okay, turn ignition on and check power circuits to ECM, including keep-alive memory and ignition feed. See «WIRING DIAGRAMS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline) at the end of this article for power terminal identification. If power to ECM power terminals is not available, check for open in power circuits. If power to ECM power terminals is available, check for poor ECM ground circuits. If circuits are okay, replace faulty ECM.
3. Turn ignition off. Disconnect ECM connectors. Turn ignition on, and connect ECM MIL driver terminal to ground using a test light. See «WIRING DIAGRAMS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline) at the end of this article for power terminal identification.
4. If MIL is now on, repair MIL driver terminal connections at ECM, or replace faulty ECM. If MIL stays off when test light is used to ground MIL driver terminal, check for blown instrument panel fuse, faulty bulb, open in MIL driver circuit between ECM and bulb, short in driver circuit to voltage or open in ignition feed to MIL.

A-2, MIL ALWAYS ON OR WON'T FLASH CODE 12

1. Turn ignition on, engine off. If MIL does not illuminate, see «A-1, MALFUNCTION INDICATOR LIGHT (MIL) INOPERATIVE»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline__a-1-malfunction-indicator-light-mil-inoperative). If MIL is on, ground DLC test terminals "A" and "B". Code 12 should flash. If Code 12 does not flash, go to step 2). If Code 12 now flashes, problem is no serial data. Check serial data circuit for open or short to ground, or short to voltage between ECM and DLC terminal. If circuits are okay, replace faulty ECM or PROM (MEM-CAL).
2. Turn ignition off. Disconnect ECM connectors. Turn ignition on. If MIL is on, check for short to ground in MIL driver circuit between MIL and ECM driver terminal. (Scheme 149)- (Scheme 151). Also, see «WIRING DIAGRAMS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/testing-diagnostics/#engine-controls-basic-testing-gasoline) at the end of this article for terminal identification.
3. If light is off with ECM connectors disconnected, turn ignition off. Reconnect ECM connectors. Turn ignition on with engine off and diagnostic terminal not grounded. Using a test light connected to ground, backprobe ECM terminal circuit to DLC terminal "B". (Scheme 149)- (Scheme 151). If MIL does not flash Code 12, go to step 4). If MIL flashes Code 12, check for open in DLC test terminal "B" circuit to ECM. If circuit is okay, check for open in DLC terminal "A" circuit to ECM and ECM ground. (Scheme 149)- (Scheme 151).
4. Check PROM (MEM-CAL) for proper installation. If installation is okay, replace ECM using original PROM (MEM-CAL). Recheck for Code 12. If Code 12 is not present, replace PROM (MEM-CAL). If Code 12 is present, system is okay.

Diagnostic Circuit Check & Work Flow (Gasoline). Scheme 152

SUMMARY

If faults were not found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to appropriate G - GASOLINE TESTS W/ CODES article in this section below. If no hard codes are found in self-diagnostics, or vehicle does not have a self-diagnostic system, proceed to TESTS W/O CODES - GASOLINE article in this section for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.

1. G - TESTS W/CODES - 4.3L
2. G - TESTS W/CODES - 5.0L
3. G - TESTS W/CODES - 5.7L
4. G - TESTS W/CODES - 7.4L

Schematic (Blazer, Pickup, Sierra, Suburban & Yukon - 4.3L, 5.0L & 5.7L With A/T - 1 Of 3). Scheme 153

Schematic (Blazer, Pickup, Sierra, Suburban & Yukon - 4.3L, 5.0L & 5.7L With A/T - 2 Of 3). Scheme 154

Schematic (Blazer, Pickup, Sierra, Suburban & Yukon - 4.3L, 5.0L & 5.7L With A/T - 3 Of 3). Scheme 155

Schematic (Pickup, Sierra, Suburban - 4.3L & 7.4L With M/T - 1 Of 3). Scheme 156

Schematic (Pickup, Sierra, Suburban - 4.3L & 7.4L With M/T - 2 Of 3). Scheme 157

Schematic (Pickup, Sierra, Suburban - 4.3L & 7.4L With M/T - 3 Of 3). Scheme 158

Schematic (Blazer, Pickup, Sierra, Suburban & Yukon - 5.0L & 5.7L With M/T - 1 Of 2). Scheme 159

Schematic (Blazer, Pickup, Sierra, Suburban & Yukon - 5.0L & 5.7L With M/T - 2 Of 2). Scheme 160

Schematic (Pickup, Sierra, Suburban - 7.4L With A/T - 1 Of 3). Scheme 161

Schematic (Pickup, Sierra, Suburban - 7.4L With A/T - 2 Of 3). Scheme 162

Schematic (Pickup, Sierra, Suburban - 7.4L With A/T - 3 Of 3). Scheme 163

See also:
• I - SYSTEM/COMPONENT TESTS - GASOLINE
• A-7, BASIC FUEL SYSTEM CHECKS
• FUEL SYSTEM PRESSURE TEST
• A-1, MALFUNCTION INDICATOR LIGHT (MIL) INOPERATIVE
• A-2, MIL ALWAYS ON OR WON'T FLASH CODE 12