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Engine Controls - System & Component Testing - 6.6L: Other Chevrolet Silverado 1500 HD

Testing & Diagnostics ~1683 words

COMPUTERIZED ENGINE CONTROLS

Note. For component locations, see COMPONENT LOCATIONS .

ENGINE CONTROL MODULE & FUEL INJECTOR CONTROL MODULE

Note. To identify circuits referenced in the following ground and power tests, see WIRING DIAGRAMS or (Схема №11) - (Схема №18).

Ground Circuits

Check ECM/FICM connectors for corroded or loose connections. Repair as necessary. Disconnect ECM/FICM connectors. Using a DVOM, measure resistance between negative battery terminal and ground terminals at ECM/FICM harness connector. If resistance is more than 5 ohms, repair open in affected ground circuit. If resistance is 5 ohms or less, ground circuits are okay.

Power Circuits

  1. Check ECM/FICM connectors for corroded or loose connections. Repair as necessary. Disconnect ECM/FICM connectors. Using a DVOM, check for battery voltage between chassis ground and continuous power terminal(s) at ECM/FICM harness connector(s). If battery voltage is present, go to next step. If battery voltage is not present, check for open fuse or fusible link. If fuse or fusible link is okay, check for open in wire between ECM/FICM terminal and power source.
  2. Turn ignition switch to RUN position. Using DVOM, check for battery voltage between chassis ground and ignition power terminals at ECM/FICM harness connector(s). If battery voltage is present, power circuits are okay. If battery voltage is not present, check related fuse. If fuse is okay, check for an open in wire between battery and ignition switch, and between ignition switch and ECM/FICM terminal. If wiring is okay, check for a defective ignition switch.

SENSORS & SWITCHES

Note. For circuit reference, see WIRING DIAGRAMS . For component locations, see COMPONENT LOCATIONS .

Note. For additional sensor testing specifications, see SENSOR OPERATING RANGE CHARTS - TRUCKS article.

Manufacturer does not provide testing procedures for many individual systems and components. For sensor and switch testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

ACCELERATOR PEDAL POSITION SENSOR

A malfunction in Accelerator Pedal Position (APP) sensor circuit can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

BOOST SENSOR

A malfunction in boost sensor circuit can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

CAMSHAFT POSITION SENSOR

A malfunction in Camshaft Position (CMP) sensor can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

CRANKSHAFT POSITION SENSOR

A malfunction in Crankshaft Position (CKP) sensor can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

ENGINE COOLANT TEMPERATURE SENSOR

A malfunction in Engine Coolant Temperature (ECT) sensor circuit can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article. An out-of-calibration ECT sensor may not set a DTC. Use the following procedure to test sensor calibration.

Disconnect ECT sensor harness connector. See COMPONENT LOCATIONS . Using DVOM, measure resistance of ECT sensor at specified temperatures. See SENSOR TEMPERATURE VS RESISTANCE table. Resistance should be high when engine is cold and drop as engine warms. With vehicle sitting overnight, IAT sensor and ECT sensor should have close to the same resistance reading. If resistance is not within specification, replace ECT sensor.

Temperature - °F (°C)(1) Ohms
302 (150)47
284 (140)60
266 (130)77
248 (120)100
230 (110)132
212 (100)177
194 (90)241
176 (80)332
158 (70)467
140 (60)667
122 (50)973
113 (45)1188
104 (40)1459
95 (35)1802
86 (30)2238
77 (25)2796
68 (20)3520
59 (15)4450
50 (10)5670
41 (5)7280
32 (0)9420
23 (-5)12,300
14 (-10)16,180
5 (-15)21,450
4 (-20)28,680
22 (-30)52,700
40 (-40)100,700
(1) Measure resistance across sensor terminals.
(1)Measure resistance across sensor terminals.

SENSOR TEMPERATURE VS RESISTANCE

FUEL RAIL PRESSURE SENSOR

A malfunction in the fuel rail pressure sensor circuit can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

INTAKE AIR TEMPERATURE SENSOR

A malfunction in IAT sensor circuit can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article. An out-of-calibration IAT sensor may not set a DTC. Use the following procedure to test sensor calibration.

Disconnect IAT sensor harness connector. See COMPONENT LOCATIONS . Using DVOM, measure resistance of IAT sensor at specified temperatures. See SENSOR TEMPERATURE VS RESISTANCE table. Resistance should be high when air temperature is cold and drop as air temperature warms. With vehicle sitting overnight, ECT sensor and IAT sensor should have close to the same resistance reading. If resistance is not within specification, replace IAT sensor.

TRANSMISSION RANGE SWITCH

See appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

VEHICLE SPEED SENSOR

See appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

MODULES, MOTORS, RELAYS & SOLENOIDS

Note. For component locations, see COMPONENT LOCATIONS . For circuit reference, see WIRING DIAGRAMS .

Note. Manufacturer does not provide testing procedures for many individual systems and components. For module, motor, relay and solenoid testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

A/C COMPRESSOR CLUTCH RELAY

See appropriate AUTOMATIC A/C-HEATER SYSTEMS or MANUAL A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING.

IGNITION RELAY

Note. For circuit reference, see WIRING DIAGRAMS .

FUEL HEATER INOPERATIVE

Note. For component locations, see COMPONENT LOCATIONS . For circuit reference, see WIRING DIAGRAMS .

FUEL HEATER ALWAYS ON

Note. For component locations, see COMPONENT LOCATIONS . For circuit reference, see WIRING DIAGRAMS .

Cleaning Water From Fuel System

  1. Disconnect negative battery terminal.
  2. Drain fuel tank.
  3. Remove fuel tank.
  4. Remove fuel sending unit.
  5. Inspect fuel tank and fuel sender for rust, fungi or bacteria. If there is rust, replace rusted components.
  6. Clean inside of fuel tank and fuel sender with hot water.
  7. Use compressed air to dry fuel tank and fuel sender.
  8. Disconnect the ends of the fuel filter inlet line (both ends), transfer pump pressure line and suction line (if applicable), fuel filter outlet line (both ends), fuel filter drain and fuel return line (both ends).
  9. Inspect each of the pipes and lines.
  10. Replace any rusted pipes.
  11. Clean inside of fuel filter housing.
  12. Dry fuel filter housing with compressed air.
  13. Dry inside of each line with low pressure air.
  14. Remove ignition 1 relay from the underhood fuse/relay center.
  15. Install a new fuel filter.
  16. Install sending unit and fuel tank.
  17. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
  18. Reconnect fuel filter inlet line, fuel filter outlet line, transfer pump pressure and suction (both ends) lines and fuel return line (tank end).
  19. Connect fuel filter drain to a line that flows into a clean metal container.
  20. Reconnect battery terminals.
  21. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into a metal container.
  22. Close fuel filter drain and remove bleeder hose.
  23. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 2-gallon metal container.
  24. Crank engine for 30 second time intervals, with one minute cool down periods. Continue until one gallon of fuel has passed into the container.
  25. Connect fuel return line.
  26. Install ignition 1 relay in the underhood fuse/relay center.
  27. Start and operate engine.
  28. Turn engine off.
  29. Clean any fuel spillage from engine.
  30. Fill fuel tank and add a biocide, if needed.

Cleaning Gasoline From Fuel System

  1. Drain fuel tank.
  2. Fill fuel tank to 1/4 full.
  3. Remove ignition 1 relay from the underhood fuse/relay center.
  4. Loosen fuel filter drain and connect filter to a hose that flows into a metal container.
  5. Operate fuel system hand primer at fuel filter until clean fuel flows from fuel filter drain into metal container.
  6. Hand tighten fuel filter drain and disconnect the hose.
  7. Install a hose on the fuel return line near the glow plug relay and insert other end into a 2 gallon metal container.
  8. Crank engine for 30 second time intervals with one minute cool down periods. Continue until one gallon of fuel has passed into the container.
  9. Reconnect fuel return line.
  10. Install ignition 1 relay into the underhood fuse/relay center.
  11. Attempt to start and operate engine for 15 minutes (if engine does not start, operate the hand primer for 30 strokes or until firm).
  12. Turn engine off.
  13. Clean any fuel spillage from engine.
  14. Clear any DTCs.

IDLE CONTROL SYSTEM

Note. For idle control system testing, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

EMISSION SYSTEMS & SUB-SYSTEMS

Note. For component locations, see COMPONENT LOCATIONS .

Note. For emission and sub-system testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

EXHAUST GAS RECIRCULATION

A malfunction in Exhaust Gas Recirculation (EGR) sensor can set a DTC. For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

MISCELLANEOUS CONTROLS

Note. For component locations, see COMPONENT LOCATIONS .

Note. Although some of the controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.

Manufacturer does not provide testing procedures for many individual systems and components. For system and component testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO - DIESEL article.

A/C COMPRESSOR CLUTCH CONTROLS

Note. For A/C compressor clutch circuit testing, see appropriate AUTOMATIC A/C-HEATER SYSTEMS or MANUAL A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING. See appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL for terminal and wire color identification.

TRANSMISSION

Note. For transmission electronic controls and component testing, see appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS. For component circuit identification, see appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

SIERRA 2500HD

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

SIERRA 3500

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

SILVERADO 2500HD

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

SILVERADO 3500

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

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