Engine Controls - Basic Diagnostic Procedures - Diesel Chevrolet Suburban IX

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 comfcplaint 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.

The 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 HOW TO USE THE ENGINE PERFORMANCE SECTION in this section.

GENERAL MOTORS 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 VACUUM DIAGRAMS article 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) 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 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.
2. Diagnosis 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 ). 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.

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

Ensure proper starting procedure is being used. Visually check vacuum hoses for splits, kinks and proper connections, as shown on Vehicle Emission Control Information label. In very cold temperatures, ensure oil is proper viscosity and not contaminated.

Ignition System

1. Perform «ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__on-board-diagnostic-obd-system-check). After performing OBD system check, go to next step.
2. Check battery condition. If battery is okay, go to next step. If battery condition is not okay, go to step 23).
3. Check fuel level in tank. If fuel level is okay, go to next step. If fuel level is not okay, go to step 23).
4. Check quality of fuel. If fuel quality is okay, go to next step. If fuel quality is not okay, go to step 23).
5. Check glow plug operation. If glow plug operation is okay, go to next step. If glow plug operation is not okay, go to step 23).
6. Check for proper cranking speed. If cranking speed is okay, go to next step. If cranking speed is not okay, go to step 23).
7. Check for restriction in fuel return system. If restriction is not present, go to next step. If return line is restricted, go to step 23).
8. Check injection pump ground wire. If ground is okay, go to next step. If ground is not okay, go to step 23).
9. Turn ignition on. Observe Malfunction Indicator Light (MIL). If MIL illuminates, go to step 10). If MIL does not illuminate, see «A-1, MALFUNCTION INDICATOR LIGHT (MIL)»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__a-1-malfunction-indicator-light-mil).
10. Install Tech 1 scan tool. Using scan tool, check for any data display. If data is displayed, go to next step. If data is not displayed, see «ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__on-board-diagnostic-obd-system-check).
11. Loosen injector line at injector. Crank engine. If fuel comes out of fuel line, go to step 17). If fuel is not coming out of fuel line, go to next step.
12. Disconnect optical/fuel temperature sensor. (Scheme 110) Attempt to start engine. If engine starts, go to next step. If engine does not start, go to step 16).
13. Reconnect optical/fuel temperature sensor. Disconnect fuel solenoid driver. (Scheme 110) Crank engine and check voltage between ground and fuel injector control circuit at harness terminal. Voltage should be 1.2 volts or greater. If voltage is as specified, go to step 16). If voltage is not as specified, go to step 18).
14. With fuel solenoid driver still disconnected, probe solenoid ground circuit with test light connected to battery voltage at harness connector. (Scheme 110) If test light illuminates, go to next step. If test light does not illuminate, go to step 21).
15. Turn ignition on with engine off. Using test light connected to ground, probe ignition feed circuit at fuel solenoid harness connector. (Scheme 110) If test light illuminates, go to next step. If test light does not illuminate, go to step 21).
16. Replace fuel injection pump. After repairs, go to step 25).
17. Injection system is okay. See TESTS W/O CODES article.
18. Check for open or short in circuit between fuel solenoid driver and PCM. (Scheme 110) Repair as necessary. After repairs, go to step 22). If circuit is okay, go to step 20).
19. Check closure signal ground circuit for open between fuel solenoid driver and PCM. (Scheme 110) Repair as necessary. After repairs, go to step 22). If circuit is okay, go to next step.
20. Check for faulty solenoid driver and PCM connectors. Repair as necessary. After repairs, go to step 22). If connectors are okay, go to step 24).
21. Repair open in ignition feed circuit (Pink wire). After repairs, go to step 25).
22. Repair circuit as necessary. After repairs, go to step 25).
23. Repair as necessary. After repairs, go to step 25).
24. Replace PCM. Perform PCM relearn procedures. After repairs, go to step 25).
25. Using scan tool, select DTC, CLEAR INFO function. Attempt to start engine. If engine starts and continues to run, go to next step. If engine does not start or starts and stalls/dies, go to step 2).
26. Warm engine to normal operating temperature. Using scan tool, select DTC, FAIL THIS IGN function. If any DTC(s) are present, go to next step.
27. Select CAPTURE INFO, REVIEW INFO function. If any other DTC(s) are displayed that have not been diagnosed, see TESTS W/CODES article.

Scheme 110

Fuel System

1. Perform «ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__on-board-diagnostic-obd-system-check). After performing OBD system check, go to next step.
2. Turn ignition off for about 10 seconds. Turn ignition on. Fuel pump should operate during glow plug cycle. If fuel pump operates, go to IGNITION SYSTEM check. If fuel pump does not operate, go to next step.
3. Connect a fused jumper wire between battery positive and fuel pump test terminal. If fuel pump operates, go to next step. If fuel pump does not operate, go to step 12).
4. Disconnect jumper wire from test terminal. Turn ignition off for 10 seconds. Turn ignition on. Fuel pump should operate during glow plug cycle. If fuel pump operates, go to step 25). If fuel pump does not operate, go to next step.
5. Remove fuel pump relay. Turn ignition on with engine off. Using a test light connected to ground, probe fuel pump relay harness connector battery feed terminal (Orange wire). (Scheme 111) If test light illuminates, go to next step. If test light does not illuminate, go to step 14).
6. Connect test light between ground and fuel pump relay harness connector battery feed circuit. If test light illuminates, go to next step. If test light does not illuminate, go to step 15).
7. Connect test light between ground and fuel pump relay terminal. Turn ignition off for 20 seconds. Turn ignition on. Test light should illuminate during glow plug cycle and then turn off. If test light illuminates as specified, go to next step. If test light does not illuminate as specified, go to step 16).
8. Check for faulty fuel pump relay harness connector. Repair as necessary. After repairs, go to step 11). If connector is okay, go to next step.
9. Replace fuel pump relay. After repairs, go to step 25). If fuel pump relay is okay, go to next step.
10. Start and warm engine to normal operating temperature. Ensure oil pressure is within normal range. Disconnect fuel pump relay. If engine continues to run, go to next step. If engine stalls/dies, go to step 17).
11. Reinstall fuel pump relay. Turn ignition off. Using a test light connected to ground, probe fuel pump test connector. If test light illuminates, go to step 18). If test light does not illuminate, go to step 25).
12. Disconnect fuel pump harness connector. Using a fused jumper wire connected to battery voltage, jumper fuel pump test terminal. Using a test light connected to ground, probe fuel pump feed circuit. If test light illuminates, go to next step. If test light does not illuminate, go to step 20).
13. Connect test light to fuel pump ground terminal on harness connector. (Scheme 111) If test light illuminates, go to step 19). If test light does not illuminate, go to step 21).
14. Repair open in battery feed circuit to fuel pump relay harness connector terminal. After repairs, go to step 25).
15. Repair open in fuel pump relay ground circuit. After repairs, go to step 25).
16. Check for faulty connection at PCM fuel pump relay control circuit. Check for open or short to ground in harness between fuel pump relay control connector terminal and fuel pump relay control circuit. (Scheme 111) Repair as necessary. After repairs, go to step 22). If circuits are okay, go to step 24).
17. Check for faulty oil pressure switch connector terminals. Repair as necessary. After repairs, go to step 22). If connector terminals are okay, go to next step.
18. Replace oil pressure switch. After repairs, go to step 25).
19. Replace fuel pump. After repairs, go to step 25).
20. Repair open between fuel pump test terminal and fuel pump feed circuit at fuel pump harness connector. After repairs, go to step 25).
21. Repair open in fuel pump harness ground circuit. After repairs, go to step 25).
22. Repair affected circuit as necessary. After repairs, go to step 25).
23. Repair connectors as necessary. After repairs, go to step 25).
24. Replace PCM. Perform PCM relearn procedures. After repairs, go to next step.
25. Clear DTC(s) using scan tool. Attempt to start engine. If engine starts and continues to run, go to next step. If engine does not start or starts and stalls/dies, go to step 2).
26. Warm engine to normal operating temperature. Using scan tool, select DTC, FAILED THIS IGN function. If any DTC(s) are present, diagnose DTC. See TESTS W/CODES article. If DTC(s) are not present, go to next step.
27. Select CAPTURE INFO, REVIEW INFO function. If additional DTC(s) are displayed, diagnose DTC(s). See TESTS W/CODES article.

Scheme 111

FUEL PUMP FLOW TEST

1. Disconnect fuel line at fuel filter inlet. Disconnect fuel injection pump electric shut-off solenoid wire (Pink).
2. Crank engine for 15 seconds. If fuel pump does not supply about 1/2 pint of fuel in 15 seconds, go to «FUEL SYSTEM PRESSURE TEST»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__fuel-system-pressure-test) .

FUEL SYSTEM PRESSURE TEST

Note. For fuel pump circuit testing, see appropriate FUEL SYSTEM test in A-3, NO-START DIAGNOSIS .

1. Turn engine off. Disconnect fuel line at inlet to fuel filter assembly. Install low pressure fuel gauge to fuel line.
2. Crank or run engine 10-15 seconds. If fuel pressure is not 5.8-8.7 psi (.41-.61 kg/cm 2 ), check fuel lines and fuel tank sending unit for restriction. If fuel lines and sending unit are okay, replace fuel pump.

ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

Note. Use of Tech 1 scan tool is required to perform ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK.

THE OBD SYSTEM CHECK DETERMINES

1. If Malfunction Indicator Light (MIL) works.
2. If PCM/VCM is operating and can recognize a fault.
3. If any Diagnostic Trouble Codes (DTCs) are stored.

After performing procedures in PRELIMINARY INSPECTION & ADJUSTMENTS, BASIC FUEL SYSTEM CHECKS and BASIC IGNITION SYSTEM CHECKS, this is the starting point for utilizing the self-diagnostic system for determining computer-related problems. After performing necessary tests as described in the OBD system circuit check, if no codes are indicated and driveability problems still exist, see TESTS W/O CODES article and SCAN TESTER usage in TESTS W/CODES article.

1. Turn ignition on with engine off. Observe Malfunction Indicator Light (MIL). If MIL illuminates, go to next step. If MIL does not illuminate, go to «A-1, MALFUNCTION INDICATOR LIGHT (MIL)»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__a-1-malfunction-indicator-light-mil) .
2. Turn ignition off. Install Tech 1 scan tool, follow scan tool manufacturer's instructions to proceed with test. Turn ignition on. If scan tool displays PCM data, go to next step. If scan tool does not display PCM data, go to «ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__on-board-diagnostic-obd-system-check) .
3. If DTC(s) are present, diagnose DTC(s) using appropriate self-diagnostic test. See TESTS W/CODES article. If DTC(s) are not present, go to next step.
4. Turn ignition off for 20 seconds. Turn ignition on and wait for glow plug cycle. Crank engine for about 10 seconds. If engine start and runs, go to next step. If engine does not start or starts and dies, go to «A-3, NO-START DIAGNOSIS»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel) .
5. Compare scan tool engine data with actual control system data values. If parameter is within limits, go TESTS W/O CODES article. If parameter is not within limits, go to next step.
6. Go to SYSTEM/COMPONENT TESTS article. Replace components that are out of range.

Scheme 112

A-1, MALFUNCTION INDICATOR LIGHT (MIL)

1. Perform «ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK»(/chevrolet/suburban/ix-1991-2001/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-diesel__on-board-diagnostic-obd-system-check). After performing OBD system check, go to next step.
2. Attempt to start engine. If engine starts, go to next step. If engine does not start, go to step 6).
3. Check fuse No. 4 (Gauges). If fuse if faulty, go to step 14). If fuse is okay, go to next step.
4. Turn ignition on. Using a test light connected to ground, probe ignition feed terminal at PCM connector. (Scheme 112) If test light illuminates, go to step 5). If test light does not illuminate, go to step 14).
5. Turn ignition off. Disconnect Black PCM harness connector. Turn ignition on. Using a fused jumper wire, jumper MIL control circuit at PCM connector terminal (Brown/White wire). (Scheme 112) If MIL illuminates, go to step 9). If test light does not illuminate, go to step 10).
6. Check fuses to PCM ignition and battery feed circuit. (Scheme 112) If fuses are okay, go to next step. If fuse(s) are faulty, go to step 13).
7. Turn ignition off. Disconnect PCM connectors. Turn ignition on. Using a test light connected to ground, probe PCM harness connector ignition and battery feed circuits. (Scheme 112) If test light illuminates on both circuits, go to next step. If test light does not illuminate on both circuits, go to step 12).
8. Check for faulty or poor PCM ground connections. Repair as necessary. After repairs, go to step 20). If ground connections are okay, go to next step.
9. Check for poor connection at PCM harness connector. Repair as necessary. After repairs, go to step 20). If connector is okay, go to step 15).
10. Check for open MIL control circuit. Repair as necessary. After repairs, go to step 20).
11. Repair open in ignition feed circuit to instrument cluster. (Scheme 112) After repairs, go to step 20).
12. Locate and repair open in PCM battery feed or ignition circuit. Repair as necessary. After repairs, go to step 20).
13. Locate and repair short to ground in PCM ignition feed circuit or PCM battery feed circuit. Repair as necessary. After repairs, go to step 20).
14. Locate and repair short to ground in instrument cluster ignition feed circuit. After repairs, go to step 20).
15. Replace PCM. Perform PCM relearn procedures. After repairs, go to step 20).
16. Check for poor connection at MIL control circuit to instrument cluster connector. Repair as necessary. After repairs, go to step 20). If circuit is okay, go to next step.
17. Remove instrument panel assembly. Inspect MIL bulb. If bulb is okay, go to step 19). If bulb is faulty, go to next step.
18. Replace MIL bulb. After replacing bulb, go to step 20).
19. Replace instrument cluster. After repairs, go to step 20).
20. Using scan tool, select DTC, CLEAR INFO function. Attempt to start engine. If engine starts and continues to run, go to next step. If engine does not start or starts and dies/stalls, go to step 2).
21. Warm engine to normal operating temperature. Using scan tool, select DTC, FAILED THIS IGN function. Diagnose any DTC present. See TESTS W/CODES article. If DTC(s) are not present, go to next step.
22. Select CAPTURE INFO, REVIEW INFO function. If DTC(s) are present. Diagnose any DTC present. See TESTS W/CODES article.

SUMMARY

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, no trouble codes (or only intermittent ones) were found while performing ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK and driveability problems exist, proceed to TESTS W/O CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO-START, etc.) or intermittent diagnostic procedures.

See also:
• ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
• A-3
• A-1, MALFUNCTION INDICATOR LIGHT (MIL)
• FUEL SYSTEM PRESSURE TEST