Engine Controls - System/component Tests - 6.5l Chevrolet Chevy Van G3500

MODEL IDENTIFICATION

Vehicle model is identified by fifth character of Vehicle Identification Number (VIN), stamped on metal pad on top of left end of instrument panel, near windshield. See MODEL IDENTIFICATION .

MODEL IDENTIFICATION

TERMINOLOGY

Due to Federal government requirements, manufacturers may use names and acronyms for systems and components different than those used in previous years. The following table will help eliminate confusion when dealing with these components and systems. Only relevant components and systems whose names have changed from current General Motors Corp. terminology have been listed.

SAE TERMINOLOGY

INTRODUCTION

Before testing separate components or systems, perform procedures in BASIC TESTING - 6.5L DIESEL article. Since many computer-controlled and monitored components set a trouble code if they malfunction, also perform procedures in appropriate TESTS W/CODES article below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

Note. Testing individual components does not isolate shorts or opens. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter and refer to the WIRING DIAGRAMS at the end of this article to isolate wiring harness shorts or opens.

Note. The following table provides the location of commonly used diagnostic information. These former "A" and "C" charts are now written in text and inserted into the appropriate location in the new Engine Performance workflow. To familiarize yourself with the Engine Performance workflow, see HOW TO USE THE ENGINE PERFORMANCE SECTION in GENERAL INFORMATION section.

GENERAL MOTORS "A" & "C" CHART REFERENCE

TURBOCHARGER

Note. No turbocharger testing information is available from manufacturer. For symptom diagnosis see the TESTS W/O CODES - 6.5L DIESEL article or appropriate TESTS W/CODES - DIESEL article below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

CONTROL UNIT

Note. To perform the following ground and power tests, use appropriate wiring diagram in the WIRING DIAGRAMS section at the end of this article.

Ground Circuits

1. Using an ohmmeter, check for continuity to ground on ECM/PCM/VCM ground terminals. Resistance should be zero ohms. If not, repair open to ground.
2. Using a DVOM, touch negative lead of voltmeter to a good ground. Touch positive lead of voltmeter to each ground terminal. With vehicle running, voltmeter should indicate less than one volt. If voltmeter reading is greater than one volt, check for open, corrosion or loose connection on ground circuit.

Power Circuits

1. Using a voltmeter, check for battery voltage between ECM/PCM/VCM continuous power terminal(s) and ground. If battery voltage is not present, check for blown fuse or open fusible link. If okay, check for open in wire between ECM/PCM/VCM terminal and power source.
2. Turn ignition on. Using a voltmeter, check for battery voltage between ECM/PCM/VCM ignition power terminals and ground. If battery voltage is not present, check IGN fuse. If fuse is okay, check for an open in wire between battery and ignition switch, and between ignition switch and ECM/PCM/VCM terminal. If okay, check for a defective ignition switch.
3. Connect voltmeter between ground and ECM/PCM/VCM starter (crank) signal terminal. On vehicles with manual transmission/transaxle, depress clutch pedal. Turn ignition switch to START position. Battery voltage should be present ONLY when ignition switch is in START position.
4. If voltage is not present, check CRANK fuse or fusible link between ignition switch and ECM/PCM/VCM terminal. If fuse or fusible link is okay, check for an open in wire between ignition switch and ECM/PCM/VCM terminal, or check for a defective ignition switch.

A/C ON SWITCH/SYSTEM TEST

1. Turn ignition switch to RUN position. Move mode selector switch to OFF position. With A/C control assembly connected, measure voltage between mode selector switch Dark Green wire and ground. For wiring schematics, see mini-schematics in «A/C CLUTCH»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l__ac-clutch-relay) under MISCELLANEOUS ECM/PCM/VCM CONTROLS.
2. Battery voltage should be present. If battery voltage is present, mode selector switch is operating normally. If battery voltage is not present, check wire from selector switch to fuse for an open circuit. Also check A/C high and low pressure switches for open.
3. Check voltage between mode selector Dark Green or Dark Green/White wire and ground. Voltage should not be present. If voltage is present, replace mode selector switch.

BRAKE SWITCH

Disconnect brake switch harness connector. Using an ohmmeter, check continuity between brake switch terminals. Continuity should be present. Depress brake pedal or activate brake switch, continuity should not be present.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

If a coolant sensor-related code is present, see appropriate TESTS W/CODES article below. An out-of-calibration sensor may not set a trouble code. Use following procedure to test sensor calibration. Disconnect ECT sensor connector. Measure resistance between sensor terminals. Resistance should be high when engine is cold and drop as engine warms. See ECT SENSOR RESISTANCE VALUES .

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

ECT SENSOR RESISTANCE VALUES

Note. Intake Air Temperature (IAT) sensor is also referred to as Manifold Air Temperature (MAT) sensor.

INTAKE AIR TEMPERATURE (IAT) SENSOR

If an IAT sensor-related code is present, see appropriate TESTS W/CODES article below. An out-of-calibration sensor may not set a trouble code. Use following procedure to test calibration. Disconnect IAT sensor harness connector. Connect ohmmeter between sensor terminals. Sensor resistance should be as specified. See IAT SENSOR RESISTANCE . With vehicle sitting overnight, IAT sensor and coolant sensor should have close to the same resistance reading.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

IAT SENSOR RESISTANCE

KNOCK SENSOR

1. Disconnect knock sensor harness connector. Using an ohmmeter, measure knock sensor resistance between sensor terminal and engine block. Resistance should be 3300-4500 ohms. Connect voltmeter between sensor terminal and ground. Set voltmeter to 2-volt AC scale.
2. Start and idle engine. Tap on engine block near sensor. A signal should be indicated on voltmeter. If no signal is indicated, replace knock sensor. Also see «TIMING CONTROL SYSTEMS»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l) under IGNITION SYSTEM and appropriate TESTS W/CODES article. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon) «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

1. MAP sensor circuit malfunction should set a related code in ECM/PCM/VCM memory. If a code is present, see appropriate TESTS W/CODES article listed above. An out-of-calibration sensor may not set a trouble code. Use following procedure to test sensor calibration. If driveability problems exist, MAP sensor failure is suspected and no MAP code is present, disconnect MAP sensor connector. If driveability condition improves, check MAP vacuum hose for splits, kinks, proper routing and blockage. If no problems are found, replace MAP sensor.
2. With ignition on and engine off, check MAP sensor parameter using a scan tester connected to Data Link Connector (DLC). Voltage should be as specified in «MAP SENSOR VOLTAGE RANGE»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l) .
3. If MAP sensor voltage is as specified, go to next step. If voltage is not as specified, check for 5-volt reference supplied to sensor. Check harness integrity. If no problems are evident, replace MAP sensor.
4. Using a hand-held vacuum pump, apply 10 in. Hg to MAP sensor and note voltage change. Voltage should drop to about 1.0-2.5 volts less than specified in table. If voltage is not as specified or voltage reading does not immediately follow vacuum change, MAP sensor is faulty.

MAP SENSOR VOLTAGE RANGE

OXYGEN SENSOR (O2S)

1. Start engine and warm to operating temperature. Disconnect oxygen sensor. Connect DVOM between Purple lead of oxygen sensor and ground. Place DVOM on 2-volt scale.
2. Using another DVOM on 20-volt scale, connect DVOM in series between Purple wire from ECM/PCM/VCM and positive post of battery. This will simulate a rich condition, causing ECM/PCM/VCM to respond by leaning mixture. Reading on DVOM connected to oxygen sensor should decrease to less than .3 volt.
3. Move DVOM lead from positive battery post to negative battery post. This will simulate a lean condition, causing ECM/PCM/VCM to respond by richening mixture. Reading on DVOM connected to oxygen sensor should increase to greater than .8 volt. If reading does not change as specified, replace oxygen sensor.
4. If a second DVOM is not available, connect a jumper in Purple wire from ECM/PCM/VCM. Hold jumper in one hand and touch positive post of battery with other hand to simulate a rich condition. Touch negative post of battery to simulate a lean condition. For additional testing procedures, see appropriate TESTS W/CODES article as listed below. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon) «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

OXYGEN SENSOR HEATING ELEMENT

On models with oxygen sensor heating elements, disconnect 3-wire connector at oxygen sensor. Measure resistance between White wire terminals on sensor side of connector. Resistance should be 3.5-14 ohms at 68°F (20°C). If resistance is not 3.5-14 ohms, replace oxygen sensor.

THROTTLE POSITION (TP) SENSOR

1. Install jumper wires to enable connection of a DVOM in parallel between TP sensor harness connectors. Connect DVOM positive lead to Dark Blue wire terminal. Connect negative lead to Black wire terminal. (Scheme 575)
2. Turn ignition on, engine off. Slowly depress accelerator pedal. Signal voltage should gradually change from less than one volt at closed throttle to about 5.0 volts at wide open throttle position. If reading is not as specified, replace TP sensor.
3. TP sensor circuit malfunction should set a related trouble code. For further information, see appropriate TESTS W/CODES article as listed below. Also, refer to TP SSENSOT under ADJUSTMENTS in the «ADJUSTMENTS - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/adjustments/#engine-controls-adjustments-65l-diesel) article. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon) «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

Scheme 575

TRANSMISSION RANGE SWITCH

A problem in transmission range switch circuit will set related diagnostic trouble code. See appropriate TESTS W/CODES article below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

VEHICLE SPEED SENSOR (PM GENERATOR)

Disconnect vehicle speed sensor harness connector (located in transmission/transaxle). Place gear selector in Neutral. Raise vehicle drive wheels off the ground. Turn drive wheels by hand (greater than 3 MPH). Measure AC signal voltage between sensor terminals. Voltage reading should vary from 0.1 to 0.5 volt AC as wheel is turned. If reading is not as specified, replace vehicle speed sensor. If a code is set, refer to appropriate TESTS W/CODES article.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

A/C Relays

See MISCELLANEOUS ECM/PCM/VCM CONTROLS .

Fuel Pump Relay

1. If a prolonged crank is required to start vehicle, fuel pump relay may be faulty. To verify, start engine. With engine running, disconnect oil pressure switch (fuel pump back-up circuit). If engine stalls, fuel pump relay is faulty. If vehicle continues to run, relay is okay. Check for other causes of prolonged crank.
2. To test fuel pump relay, disconnect fuel pump relay. Refer to «COMPONENT LOCATIONS»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l) . Apply battery voltage and ground to fuel pump relay winding terminals (control and ground).
3. Using an ohmmeter, check continuity between fuel pump relay control and ground terminals. Continuity should exist. If continuity does not exist, fuel pump relay is defective.
4. To by-pass fuel pump relay on vehicle (fuel pump not operating), turn ignition off. Disconnect fuel pump relay connector. Using a fused jumper wire, connect fuel pump test connector to positive side of battery. Fuel pump should run.
5. If fuel pump runs, check for faulty connections to relay or replace defective relay. To locate fuel pump test connector, refer to «COMPONENT LOCATIONS»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l) .

SOLENOIDS

Note. All ECM/PCM/VCM-controlled solenoids should have at least 20 ohms of resistance (except fuel injectors).

Electronic Air Control (EAC) Solenoid

See EMISSION SYSTEMS & SUB-SYSTEMS .

EGR Control Solenoid

See EMISSION SYSTEMS & SUB-SYSTEMS .

Torque Converter Clutch (TCC) Solenoid

See MISCELLANEOUS ECM/PCM/VCM CONTROLS .

FUEL SYSTEM

Note. For complete system testing and diagnosis, see appropriate TESTS W/CODES - DIESEL article. TESTS W/CODES - 6.5L DIESEL (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon) TESTS W/CODES - 6.5L DIESEL (for "P" & "G" Series Van) For symptom testing, see SYMPTOMS in TESTS W/O CODES - 6.5L DIESEL article.

A normal functioning system should operate as follows

1. With ignition switch in ON position, engine not running and at room temperature, glow plugs are on for 4-6 seconds, then off for about 4.5 seconds. Following this on-and-off cycle, glow plugs are on for about 1.5 seconds and off for about 4.5 seconds. The glow plugs continue to cycle on and off in this time sequence for about 20 seconds.
2. If engine is cranked during or after the above sequence, glow plugs will cycle on and off for a total duration of 25 seconds after ignition switch is returned from crank position, whether engine starts or not. Engine does not have to be running to terminate glow plug cycling.

Note. Glow plug on-and-off times vary with engine temperature, system voltage and/or ambient temperature. Lower temperatures cause longer duration of cycling.

PRELIMINARY GLOW PLUG DIAGNOSIS

1. If system does not operate as described in NORMAL GLOW PLUG CIRCUIT OPERATION, ensure glow plug system is correctly installed. Ensure all connectors are properly attached, clean and tight. Inspect engine harness ground connection. Ensure nut securing 4-wire connector at controller is tightened to 96 INCH lbs. (11 N.m), with connector fully seated and latched.
2. Ensure controller copper stud upper nuts are tightened to 96 INCH lbs (11 N.m). DO NOT tighten lower nuts. Ensure temperature switch connector in water crossover near front of engine is tightened to 48 INCH lbs. (5.4 N.m). Inspect WAIT light on instrument panel for tight connection and operation.

INHIBIT SWITCH (BLACK CAP)

1. Remove connector from inhibit switch when engine temperature is less than 100°F (38°C). Inhibit switch is located in water crossover near front of engine. Set ohmmeter on low range. Test continuity across switch terminals. Switch should be closed (a reading of less than one ohm on meter.)
2. Test terminals for continuity to ground with a test light to batter voltage or ohmmeter on high scale. Light should be off. Meter should show greater than one megohm resistance. Replace switch if results are not as specified.
3. Disconnect plug from switch terminals when engine temperature is greater than 125°F (52°C). Change ohmmeter setting to highest scale or use a self-powered test light. Test continuity across switch terminals. Test continuity from each terminal to ground. Switch should be open (test light off or high ohm reading of greater than one megohm on meter) and resistance to ground should be infinite. Replace switch if it is closed or if shorted to ground. When installing replacement switch, tighten to 17 ft. lbs. (23 N.m).

Electrical Check

Turn ignition off. Disconnect all glow plug connectors. Using an ohmmeter, check resistance between each glow plug terminal and ground. Glow plug resistance should be greater than 2 ohms. Replace glow plug if resistance is not as specified.

Scheme 576

1. Ensure coolant temperature is less than 80°F (27°C) before beginning test. Place ignition switch in RUN position and allow glow plugs to cycle. After 2 minutes, crank engine for one second. It is NOT important that engine starts. Return ignition switch to RUN position. Glow plugs should cycle on at least once.
2. If glow plugs do not cycle, disconnect controller (controller is located on top rear of valve cover). Connect a 12-volt test light between Pink/Black wire terminal of harness connector (terminal "A") and ground. (Scheme 576) With ignition switch in RUN position, test light should be off. Test light should illuminate when engine is cranked.
3. If test light does not illuminate as specified, repair short or open in engine harness Pink/Black wire. If test light illuminates as specified but glow plugs do not cycle, replace controller.

INJECTION PUMP HOUSING LEAKAGE TEST

1. Remove injection pump and drain all fuel. Connect an air supply line to fuel inlet fitting. Ensure air supply is clean and dry. Seal off return line fitting. Completely immerse pump assembly in a container of clean test oil.
2. Apply 20 psi (1.4 kg/cm 2 ) to pump. Leave pump immersed for 10 minutes to allow trapped air to escape. Watch for leaks after 10 minutes. If no leaks are observed after 10 minutes, reduce air pressure to 2 psi (.14 kg/cm 2 ) for 30 seconds.
3. If there are still no leaks, increase pressure to 20 psi (1.4 kg/cm 2 ) again. If no leaks are observed, pump is ready for use. If leaks are noticed, replace pump.

Test Preparation

1. Remove injector nozzles from engine. Clean carbon from tip area of nozzle with soft brass wire brush. DO NOT use steel brush or motorized brush to clean nozzle tip. Damage to nozzle tip may result. CAUTION: Use Nozzle Socket (J-36142) to remove and replace injection nozzle. Attach socket to 30-mm hex portion of nozzle. Failure to do so will result in damage to injector nozzle.
2. Connect injector nozzle to injection nozzle tester. Place clear plastic tubing on both fuel return fittings to prevent bleed-off from being confused with leaks. Close tester shutoff valve to pressure gauge.
3. Fill tester with test fluid. Fill and flush nozzle assembly with test fluid by operating tester lever briskly and repeatedly. This purges air from injector nozzle and coats all parts with test fluid.

Opening Pressure Test

1. Open tester shutoff valve 1/4 turn from closed position. Slowly depress tester lever and observe gauge. Note pressure at which needle of pressure gauge stops. Some injector nozzles may pop while other injector nozzles may drip (this is not a leak).
2. Injector opening pressure should not fall to less than 1500 psi (105 kg/cm 2 ). Replace any injector nozzle that does not meet lowest acceptable pressure. Release tester pressure.

Leakage Test

1. Open tester shutoff valve 3/4 to 1 3/4 turns from closed position. Blow dry injector nozzle tip. Slowly depress tester lever until pressure gauge reads 1400 psi (98 kg/cm 2 ). Maintain pressure for 10 seconds and observe injector nozzle tip.
2. A drop may form on end of injector nozzle, but should not fall off within a 10 second period. Replace injector nozzle if a drop of test fluid falls from tip during 10 second period. (Scheme 577) Release tester pressure.

Scheme 577

Chatter Test

Chatter for new and used injector nozzles may vary. With some used injector nozzles, chatter is difficult to detect during slow actuation of tester lever. Some injector nozzles may chatter louder than others. As long as there is chatter, injector nozzle is acceptable.

1. Close tester shutoff lever at pressure gauge. Slowly depress lever and note whether chatter is heard. If no chatter is heard, increase speed of lever movement until it reaches a point at which injector nozzle chatters.
2. At fast lever movement, injector nozzle may emit a "hissing" or "squealing" sound rather than normal chatter. This is acceptable. These sounds indicate that injector nozzle needle moves freely and injector nozzle seat, guide and pintle have no mechanical defects. Replace any injector nozzle assembly that does not chatter.

Spray Pattern Test

The injector nozzles used with this system have several features that make pattern testing difficult. These features include longer nozzle overlap, greater pintle-to-body clearances and an internal wave washer between injector nozzle nut and injector. Typical injector nozzle tester cannot deliver fuel with sufficient velocity to obtain proper spray patterns. DO NOT replace injector nozzle(s) based on spray pattern.

IGNITION SYSTEM

Note. For basic ignition system checks, see the BASIC TESTING - 6.5L DIESEL article.

C-5, Knock Sensor Circuit (Models Using External Spark Controller Module)

1. An open or short circuit on ESC wire to ECM/PCM/VCM will cause a loss of 12-volt ESC controller signal. This will cause ECM/PCM/VCM to fully retard ignition timing.
2. If a scan tester is available, connect tester to Data Link Connector (DLC). Using a metal object, tap on engine next to knock sensor and note knock parameter. Knock should be indicated on scan tester.
3. If a scan tester is not available, backprobe ECM/PCM/VCM knock sensor signal terminal with a DVOM. With engine idling, 8-12 volts should be present at this terminal. Using a metal object, tap on engine close to knock sensor. Voltage signal at ECM/PCM/VCM terminal should drop to zero volts, and return when knock signal ceases.
4. If signal does not respond as described, check knock sensor-to-controller-signal. On vehicles equipped with automatic transmission, it may be necessary to place transmission in Drive for timing change to occur. See «KNOCK SENSOR»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l__knock-sensor) under ENGINE SENSORS & SWITCHES.

C-5, Knock Sensor Circuit (Models Using Knock Sensor With Internal Spark Controller Module)

1. An open or short circuit on knock sensor wire to ECM/PCM/VCM will set a related trouble code. A false detonation signal will not cause ECM/PCM/VCM to set a code.
2. If a scan tester is available, connect it to Data Link Connector (DLC). Tap on engine next to knock sensor and note "knock" parameter. Knock should be indicated on scan tester.
3. If a scan tester is not available, connect tachometer to engine. Start engine and hold RPM above idle. Using a metal object, tap on engine close to knock sensor. A noticeable decrease in engine RPM should occur. If no RPM decrease occurred, check knock sensor to ECM/PCM/VCM circuit.
4. On vehicles equipped with automatic transmission, it may be necessary to place transmission in Drive for timing change to occur. See «KNOCK SENSOR»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-65l__knock-sensor) under ENGINE SENSORS & SWITCHES.

Crankcase Depression Regulator (CDR)

To test CDR valve, connect one hose of a water manometer to engine oil dipstick tube. Leave other hose of manometer open to atmosphere. Install air cleaner and run engine. CDR valve specification is one inch of water pressure at idle to 3-4 inches at full load. Add amount of distance water travels down one side of gauge to distance water travels up other side of gauge to obtain reading.

EGR Valve Check

With engine off, disconnect vacuum hose to EGR valve. Connect vacuum pump to EGR and apply 10 in. Hg. EGR diaphragm should move up and stay up for at least 20 seconds. If not, replace EGR valve.

VACUUM PUMP

Connect vacuum gauge to vacuum pump inlet (small fitting). DO NOT plug or disconnect outlet fitting. With engine idling, vacuum should be 18 in. Hg one minute after start. If not, check for belt slippage, vacuum leaks or other obvious defects. If no defects are present, replace vacuum pump.

MISCELLANEOUS ECM/PCM/VCM CONTROLS

Note. Although not considered true engine performance-related systems, some controlled devices may affect driveability if they malfunction.

Disconnect harness connector to TCC solenoid. Measure resistance between TCC solenoid terminals. (Scheme 578)- (Scheme 580). Solenoid resistance should be greater than 20 ohms.

Scheme 578

Scheme 579

Scheme 580

Note. Some solenoids have an internal pressure switch in series with solenoid winding and will not show continuity until transmission hydraulic pressure is applied.

Converter Lock-Up Signal At Transmission

1. Warm engine to operating temperature. Raise vehicle and support drive wheels. Support suspension where necessary to prevent damage to drive axles.
2. Disconnect converter clutch connector at transmission. Connect a test light across converter clutch harness terminals. (Scheme 578)- (Scheme 580). Start engine and place transmission in Drive. Accelerate vehicle to 45 MPH and note test light.
3. If test light is not on, check solenoid power supply wire of harness for open or short to ground. Check ground circuit for open between harness connector and ECM/PCM/VCM. If harness is okay, see CONVERTER LOCK-UP SIGNAL FROM ECM/PCM/VCM below.

Converter Lock-Up Signal From ECM/PCM/VCM

1. Warm engine to operating temperature. Raise vehicle and support drive wheels. Support suspension where necessary to prevent damage to drive axles.
2. Connect a test light to battery voltage. Touch TCC control driver terminal with test light. (Scheme 578)- (Scheme 580). Accelerate vehicle to 45 MPH and note test light. If test light does not illuminate, problem is a faulty ECM/PCM/VCM connector or ECM/PCM/VCM. On some models, lock-up signal may be checked at Data Link Connector (DLC) terminal "F" instead of at ECM/PCM/VCM terminal.

Shift Light (Manual Transmission)

1. These tests assume a shift light problem exists. Use this procedure only if the light will not illuminate, or illuminates all the time.
2. Turn ignition on, with engine off. Note shift light. Shift light should not be on. If shift light is on, check for a short to ground between bulb and ECM/PCM/VCM or for bad ECM/PCM/VCM.
3. With ignition on and engine off, ground test terminal "B" of Data Link Connector (DLC). Malfunction Indicator Light (MIL) should start to flash and shift light should come on. If MIL comes on, go to next step. If MIL does not flash, perform DIAGNOSTIC CIRCUIT CHECK as described in «BASIC TESTING - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-basic-testing-65l-diesel) article.
4. If shift light does not come on, ground Tan/Black light driver wire at ECM/PCM/VCM terminal using a jumper wire. For circuit identification, see SHIFT LIGHT CIRCUIT IDENTIFICATION below, and (Scheme 581).
5. If shift light still does not come on, check for blown GAGES fuse, blown bulb or open circuit between fuse and ECM/PCM/VCM. If shift light comes on when grounding ECM/PCM/VCM terminal with a jumper wire, problem is a bad ECM/PCM/VCM connection or bad ECM/PCM/VCM.

SHIFT LIGHT CIRCUIT IDENTIFICATION

Scheme 581

A/C CLUTCH (C-10) & ELECTRIC COOLING FAN (C-12)

Note. For additional information on electric cooling fans, see appropriate ENGINE COOLING FAN article in ENGINE COOLING section below.

1. «ENGINE COOLING FAN»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-fan/#engine-cooling-fan) (for "C" & "K" Series Pickup, Commercial Van, Sierra Pickup & Van)
2. «ENGINE COOLING FAN»(ref-20108) (for Suburban, Tahoe & Yukon)

A/C Clutch Relay

1. Disconnect A/C clutch relay harness connector. Using proper mini-schematic and an ohmmeter, check continuity between A/C clutch relay winding terminals. (Scheme 582) Continuity should exist. Check continuity between clutch drive circuit terminals of relay. Continuity should not exist.
2. Using jumper wires, apply ground and battery voltage to relay winding. Continuity should now exist between clutch drive circuit terminals of relay. Replace A/C clutch relay if continuity does not exist.

COOLING FAN (C-12)

Note. For additional information on electric cooling fans, see appropriate ENGINE COOLING FAN article in the ENGINE COOLING section below.

1. «ENGINE COOLING FAN»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-fan/#engine-cooling-fan) (for "C" & "K" Series Pickup, Commercial Van, Sierra Pickup & Van)
2. «ENGINE COOLING FAN»(ref-20108) (for Suburban, Tahoe & Yukon)

Cooling Fan Relay

1. Disconnect cooling fan relay harness connector. Using an ohmmeter, check continuity of relay winding. (Scheme 584) Continuity should exist. Check continuity across power delivery terminals of relay. With relay not energized, continuity should not exist.
2. With ohmmeter still attached to power delivery terminals of relay, apply battery voltage and ground to energize relay winding. Continuity should now exist between cooling fan relay power delivery terminals. Replace cooling fan relay if continuity does not exist.

Cooling Fan Motor

Disconnect cooling fan motor harness connector. Apply battery voltage to one of the fan motor terminals and jumper the other terminal to ground. Fan motor should activate. If fan motor does not activate, replace faulty fan motor.

Note. For a more specific system testing, refer to the following C-10 or C-12 diagnostic charts. If any chart other than a C-10 or C-12 chart is referenced, see appropriate TESTS W/CODES article below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-20088) (for C/K Pickup, Sierra Pickup, Suburban, Tahoe & Yukon)
2. «TESTS W/CODES - 6.5L DIESEL»(/chevrolet/chevy-van-g3500/1985-1999/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel) (for "P" & "G" Series Van)

DIAGNOSTIC CHARTS

Note. In the following diagnostic tests, illustrations, schematics and flow charts are courtesy of General Motors Corp.

A/C REQUEST SIGNAL CIRCUIT DIAGNOSIS

Turning on A/C system supplies battery voltage to A/C compressor clutch and Powertrain Control Module (PCM) terminal PB4 through circuit No. 59, increasing idle speed. PCM does not control A/C compressor clutch. If A/C compressor clutch is malfunctioning, repair basic A/C system problem. If A/C system is operating properly and idle speed drops too low when A/C compressor turns on or flares too high when A/C compressor turns off, check for an open A/C signal circuit to PCM. If circuit is okay, repair faulty PCM connection or replace faulty PCM.

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Wiring Diagram ("C" & "K" Series Pickup, & Sierra - Diesel VIN F & P With M/T - 1 Of 2). Scheme 589

Wiring Diagram ("C" & "K" Series Pickup, & Sierra - Diesel VIN F & P With M/T - 2 Of 2). Scheme 590

Wiring Diagram ("C" & "K" Series Pickup, & Sierra - Diesel VIN P With 4L60-E - 1 Of 2). Scheme 591

Wiring Diagram ("C" & "K" Series Pickup, & Sierra - Diesel VIN P With 4L60-E - 2 Of 2). Scheme 592

Wiring Diagram ("C" & "K" Series Pickup, Sierra, Suburban, Tahoe & Yukon - Diesel VIN F & S With 4L80-E - 1 Of 2). Scheme 593

Wiring Diagram ("C" & "K" Series Pickup, Sierra, Suburban, Tahoe & Yukon - Diesel VIN F & S With 4L80-E - 2 Of 2). Scheme 594

Wiring Diagram ("P" Series - 6.5L Diesel VIN F - 1 Of 2). Scheme 595

Wiring Diagram ("P" Series - 6.5L Diesel VIN F - 2 Of 2). Scheme 596

Wiring Diagram ("P" Series - 6.5L Diesel VIN Y A/T). Scheme 597

Wiring Diagram ("P" Series - 6.5L Diesel VIN Y M/T). Scheme 598

Wiring Diagram (Van - 6.5L Diesel VIN P - 1 Of 2). Scheme 599

Wiring Diagram (Van - 6.5L Diesel VIN P - 2 Of 2). Scheme 600

See also:
• BASIC TESTING - 6.5L DIESEL
• TESTS W/CODES - 6.5L DIESEL
• TESTS W/O CODES - 6.5L DIESEL
• ADJUSTMENTS - 6.5L DIESEL
• SYMPTOMS
• ENGINE COOLING FAN
• MODEL IDENTIFICATION
• A/C CLUTCH
• MISCELLANEOUS ECM/PCM/VCM CONTROLS
• KNOCK SENSOR