POWERTRAIN CONTROL MODULE (PCM)
Note. All vehicles are equipped with either an Electronic Control Module (ECM), Powertrain Control Module (PCM) or Vehicle Control Module (VCM). Unless specifically stated, references to PCM also apply to ECM and VCM equipped vehicles.
CONTROL UNIT
| CAUTION | When certain materials rub together, a transfer of electrons from one material to another may occur under special conditions. This causes electrostatic charge (static electricity) build-up in one of the materials. When any conducting material comes in contact with the charged material, electrostatic discharge occurs, transferring electrons to the third material. Electronic components used in control systems are designed to carry very low voltages; a 30-volt charge created by static electricity can cause a total or degrading failure in PCM or other electronic components containing integrated circuits. Before servicing PCM, ground yourself, and ground the work area to discharge stored electricity. |
| Movement/Action | Relative Humidity 10-20% | Relative Humidity 65-90% |
|---|---|---|
| Handling Clear Plastic Bag | 20,000 | 1200 |
| Handling Vinyl Envelope | 7000 | 600 |
| Sliding On Velour Seat | 15,000 | 400 |
| Walking On Carpet | 35,000 | 1500 |
| Walking On Tile/Vinyl | 12,000 | 50 |
STATIC CHARGE (VOLTS)
| CAUTION | DO NOT remove PCM from packaging until ready to install. Ground static-proof package BEFORE opening. DO NOT touch electrical terminals of components unless properly grounded. DO NOT lay electrical components on car seat, carpeting or dashboard. Use electrostatic protection mat and ground strap whenever possible. (Scheme 9) |
Servicing PCM While Using 3M Anti-Static Mat. Scheme 9
Note. Before replacing PCM, carefully inspect all wiring and control components. Ensure ignition switch is in OFF position when connecting or disconnecting PCM connector.
ELECTRONIC SPARK CONTROL (ESC) MODULE
Note. On models equipped with external ESC module, ESC is located on bracket behind distributor, mounted to firewall.
FUEL SYSTEM PRESSURE RELIEF (TBI)
Disconnect battery. Set parking brake and block drive wheels. 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.
FUEL PUMP
Note. When installing sending unit, DO NOT fold or twist strainer. This will restrict fuel flow.
THROTTLE BODY (TBI)
Note. Identification number is stamped on throttle body near throttle shaft. Identification number must be used for ordering replacement components.
Left Side
- Disconnect negative battery cables.
- Using Glow Plug Remover & Installer (J-39083), disconnect glow plug lead wires.
- Remove glow plug from cylinders No. 1, 3, 5 and 7.
Right Side
- Raise and support vehicle.
- Remove right wheel.
- Remove splash shield from right front wheelwell.
- Remove lead wire from glow plug in cylinder No. 2.
- Remove lead wires for glow plugs in cylinders No. 4 and 6 at harness connectors.
- Remove heat shroud from glow plug in cylinder No. 4.
- Remove heat shroud from cylinder No. 6. Slide shrouds back far enough to allow access for unplugging the wires at cylinders No. 4 and 6 glow plugs. Use Glow Plug Remover & Installer (J-39083) to disconnect glow plug wires.
- Remove glow plugs from cylinders No. 2, 4 and 6.
- Disconnect lead wire at glow plug from cylinder No. 8 by reaching from underneath the vehicle.
- Remove glow plug from cylinder No. 8.
PURGING FUEL SYSTEM
- Park vehicle on a level surface. Place drain pan under drain hose to collect fuel. Open drain valve 3-4 turns. With fuel tank cap installed, use air nozzle and apply 3-5 psi (.21-.35 kg/cm 2 ) through fuel return hose at injection pump.
- Contaminated fuel will be forced out of tank via filter drain hose. Continue to drain fuel until clear fuel is observed. Entire fuel tank may have to be drained. Close drain valve. Install fuel return hose.
Note. If vehicle is equipped with dual tanks, perform purging procedure on each tank.
WATER-IN-FUEL WARNING LIGHT
- Fuel filter should be drained every 5000 miles, or when WATER-IN-FUEL warning light comes on. Diesel fuel can damage asphalt and painted surfaces. Always place a drain pan under drain hose to collect fuel.
- Stop vehicle and turn engine off. Apply parking brake. Remove fuel tank cap. Open water drain valve 2-3 turns. Start and allow engine to idle for 2 minutes or until clear fuel is observed. Turn engine off and close water drain valve.
- Install fuel tank cap. If WATER-IN-FUEL warning light comes on after driving a short distance, or if engine runs rough or stalls, a large amount of water may be present in fuel tank. Purge fuel system. See «PURGING FUEL SYSTEM»(ref-19770-S39076754082001010200000) under FUEL SYSTEM (DIESEL).
OXYGEN SENSOR
| CAUTION | Oxygen sensor is equipped with a permanent pigtail, which must be protected to prevent damage when removing sensor. |
TURBOCHARGER
Note. Turbocharger overhaul information is not available from manufacturer.