Hard Failures
Hard failures cause MIL to glow and remain on until the malfunction is repaired. If light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be determined using self-diagnostic tests. If a sensor fails, PCM will use a substitute value in its calculations, allowing engine to operate in limp-in mode. In this condition, vehicle will run, but driveability may be poor.
Intermittent Failures
Intermittent failures may cause MIL to flicker or stay on until the intermittent trouble code goes away. However, the corresponding trouble code will be retained in PCM memory. If related trouble code does not reoccur within a certain time frame, related trouble code will be erased from PCM memory. Intermittent failures can be caused by a faulty sensor, bad connector or wiring related problems.
SERVICE PRECAUTIONS
Before proceeding with diagnosis, the following precautions must be followed
- Always check if any Technical Service Bulletins (TSBs) apply to vehicle.
- ALWAYS relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. See «FUEL PRESSURE RELEASE»(ref-11020-S12805262302000111000000) .
- When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See «COMPUTER RELEARN PROCEDURES»(ref-10979) article in GENERAL INFORMATION before disconnecting battery.
- Vehicle must have a fully charged battery and functional charging system.
- Probe PCM 60-pin connector from pin side. DO NOT backprobe PCM connector.
- DO NOT cause short circuits when performing electrical tests. This will set additional trouble codes, making diagnosis of original problem more difficult.
- DO NOT use a test light instead of a voltmeter.
- When checking for spark, ensure coil wire is NO more than 1/4" from ground. If coil wire is more than 1/4" from ground, damage to vehicle electronics and/or PCM may result.
- DO NOT prolong testing of fuel injectors, or engine may hydrostatically (liquid) lock.
- Always repair lowest trouble code number (MIL) or first trouble code message displayed (scan tool) first.
- Always perform verification procedure test after repairs are made.
- Always disconnect scan tool after use.
- Always disconnect scan tool before charging battery.
Malfunction Indicator Light (MIL) Mode
- Start engine (if possible). Move transmission shift lever through all positions, ending in Park. Turn A/C switch on and then off (if equipped).
- Turn engine off. Without starting engine again, turn ignition on, off, on, off and on within 5 seconds. Record 2-digit trouble codes as displayed by flashing MIL.
- For example, Trouble Code 23 is displayed as flash, flash, 4-second pause, flash, flash, flash. After a slightly longer pause, other codes stored are displayed in numerical order.
- When MIL begins to flash trouble codes, it cannot be stopped. Start over if count is lost. Code 55 indicates end of trouble code display.
- Refer to «TROUBLE CODES»(ref-11020-S17560205302000111000000) to translate trouble code number to a scan tool trouble code message. Once trouble area is identified, refer to «TEST TC-1A»(ref-11020-S30687321432000111000000) . Use scan tool trouble codes to find appropriate test.
- When scan tool trouble code message is obtained, refer to appropriate test number. To clear trouble codes, see «CLEARING TROUBLE CODES»(ref-11020-S00742261612000111000000) .
FUEL PRESSURE RELEASE
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Multipoint Fuel Injection (MFI)
- Turn ignition off. Disconnect negative battery cable. Slowly open fuel tank cap to release pressure in tank. Remove fuel rail pressure test port cap. Place open end of Fuel Pressure Release Hose (C-4799-1) in approved gasoline container. NOTE: Fuel Pressure Gauge (C-4799-A) contains Hose (C-4799-1).
- Connect other end of pressure release hose to test port. As fuel pressure release hose is tightened onto fuel rail pressure test port, fuel pressure will bleed-off into container.
Throttle Body Injection (TBI)
- Slowly open fuel tank cap to release pressure in tank. Disconnect 2-pin injector connector at edge of throttle body. Connect a jumper wire between injector connector (injector side) Dark Green/Orange wire and battery positive terminal.
- Connect another jumper wire to injector connector (injector side) White/Dark Blue wire (AA, AJ and AN bodies) or Light Blue wire (AS body). Momentarily ground jumper wire connected to White/Dark Blue wire (AA, AJ and AN bodies) or Light Blue wire (AS body) for no more than 5 seconds. Injector will energize open, relieving fuel pressure. Remove jumper wires. Fuel pressure is now released.
Code 11
DRB displays NO CRANK REFERENCE SIGNAL AT PCM. Condition is: no distributor, crankshaft, or camshaft reference signal picked up during cranking.
Code 12
DRB displays BATTERY DISCONNECT. Condition is: direct battery voltage to PCM was disconnected within the last 50 key-on cycles.
Code 13
DRB displays NO CHANGE IN MAP FROM START TO RUN. Condition is: no difference recognized between Manifold Absolute Pressure (MAP) reading and barometric (atmospheric) pressure reading at start-up.
Code 14
DRB displays MAP VOLTAGE TOO LOW. Condition is: Manifold Absolute Pressure (MAP) sensor input less than minimum acceptable voltage.
DRB displays MAP VOLTAGE TOO HIGH. Condition is: Manifold Absolute Pressure (MAP) sensor input more than maximum acceptable voltage.
Code 15
DRB displays NO VEHICLE SPEED SENSOR SIGNAL. Condition is: no Vehicle Speed Sensor (VSS) signal detected from Transmission Control Module (TCM) with road load conditions.
Code 16
DRB displays KNOCK SENSOR #1 CIRCUIT or KNOCK SENSOR #2 CIRCUIT. Condition is: open or shorted condition detected in knock sensor circuit.
Code 17
DRB displays ENGINE IS COLD TOO LONG. Condition is: coolant temperature stays less than normal operating temperature during vehicle operation.
Code 21
DRB displays LEFT O2S SHORTED TO VOLTAGE or RIGHT O2S SHORTED TO VOLTAGE. Condition is: oxygen sensor input voltage maintained at more than normal operating range.
Code 22
DRB displays ECT SENSOR VOLTAGE TOO LOW. Condition is: Engine Coolant Temperature (ECT) sensor input less than minimum acceptable voltage.
DRB displays ECT SENSOR VOLTAGE TOO HIGH. Condition is: Engine Coolant Temperature (ECT) sensor input more than maximum acceptable voltage.
Code 23
DRB displays INTAKE AIR TEMPERATURE SENSOR VOLTAGE LOW. Condition is: Intake Air Temperature (IAT) sensor input less than minimum acceptable voltage.
DRB displays INTAKE AIR TEMPERATURE SENSOR VOLTAGE HIGH. Condition is: Intake Air Temperature (IAT) sensor input more than maximum acceptable voltage.
Code 24
DRB displays THROTTLE POSITION SENSOR VOLTAGE LOW. Condition is: Throttle Position Sensor (TPS) input less than minimum acceptable voltage.
DRB displays THROTTLE POSITION SENSOR VOLTAGE HIGH. Condition is: Throttle Position Sensor (TPS) input more than maximum acceptable voltage.
Code 25
DRB displays IDLE AIR CONTROL MOTOR CIRCUITS. Condition is: shorted condition detected in one or more Idle Air Control (IAC) motor circuits.
Code 27
DRB displays INJECTOR #1-6 CONTROL CIRCUIT. Condition is: injector output driver does not respond properly to Powertrain Control Module (PCM) control signal.
Code 31
DRB displays EVAP SOLENOID CIRCUIT. Condition is: open or shorted condition detected in purge solenoid circuit.
Code 33
DRB displays A/C CLUTCH RELAY CIRCUIT. Condition is: open or shorted condition detected in A/C clutch relay circuit.
DRB displays A/C PRESSURE SENSOR VOLTAGE TOO LOW. Condition is: A/C pressure transducer input less than minimum acceptable voltage.
DRB displays A/C PRESSURE SENSOR VOLTAGE TOO HIGH. Condition is: A/C pressure transducer input more than maximum acceptable voltage.
Code 34
DRB displays SPEED CONTROL SOLENOID CIRCUITS. Condition is: open or shorted condition detected in Speed Control (S/C) vacuum or vent solenoid circuits.
DRB displays SPEED CONTROL SWITCH ALWAYS LOW. Condition is: speed control switch input less than minimum acceptable voltage.
DRB displays SPEED CONTROL SWITCH ALWAYS HIGH. Condition is: speed control switch input more than maximum acceptable voltage.
Code 35
DRB displays LOW SPEED FAN CTRL RELAY CIRCUIT. Condition is: open or shorted condition detected in low speed radiator fan relay circuit.
DRB displays HIGH SPEED FAN RELAY CTRL CIRCUIT. Condition is: open or shorted condition detected in high speed radiator fan relay circuit.
Code 41
DRB displays GENERATOR FIELD NOT SWITCHING PROPERLY. Condition is: open or shorted condition detected in generator field control circuit.
Code 42
DRB displays AUTO SHUTDOWN RELAY CONTROL CIRCUIT. Condition is: open or shorted condition detected in Auto Shutdown (ASD) relay circuit.
Code 43
DRB displays IGNITION COIL #1-3 PRIMARY CIRCUIT. Condition is: peak primary circuit current not achieved with maximum dwell time.
Code 44
DRB displays BATTERY TEMP SENSOR VOLTS OUT OF LIMIT. Condition is: open or shorted condition exists in battery temperature sensor circuit or a problem is present in Powertrain Control Module (PCM) battery temperature voltage circuit.
Code 46
DRB displays CHARGING SYSTEM VOLTAGE TOO HIGH. Condition is: battery voltage sense input more than target charging voltage during engine operation.
Code 47
DRB displays CHARGING SYSTEM VOLTAGE TOO LOW. Condition is: battery voltage sense input less than target charging voltage during engine operation or no significant change detected in battery voltage during active test of generator output.
Code 51
DRB displays LEFT O2S SIGNAL STAYS BELOW CENTER (LEAN) or RIGHT O2S SIGNAL STAYS BELOW CENTER (LEAN). Condition is: oxygen sensor input indicates lean air/fuel ratio condition during engine operation.
Code 52
DRB displays LEFT O2S SIGNAL STAYS ABOVE CENTER (RICH) or RIGHT O2S SIGNAL STAYS ABOVE CENTER (RICH). Condition is: oxygen sensor input indicates rich air/fuel ratio condition during engine operation.
Code 53
DRB displays INTERNAL CONTROLLER FAILURE or PCM FAILURE SPI COMMUNICATIONS. Condition is: Powertrain Control Module (PCM) detects internal failure.
Code 54
DRB displays NO CAM SYNC SIGNAL AT PCM. Condition is: no fuel sync signal (camshaft signal) detected during engine cranking.
Code 55
DRB display will be blank. Completion of trouble code display by Malfunction Indicator Light (MIL), (CHECK ENGINE) light.
Code 62
DRB displays PCM FAILURE SPI MILES NOT STORED. Condition is: unsuccessful attempt to update SPI mileage.
Code 63
DRB displays PCM FAILURE EEPROM WRITE DENIED. Condition is: unsuccessful attempt to write to an EEPROM location by PCM.
Code 65
DRB displays MANIFOLD TUNING VALVE SOLENOID CIRCUIT. Condition is: open or shorted condition detected in Manifold Tuning Valve (MTV) solenoid circuit.
Code 66
DRB displays NO CCD MESSAGES FROM TCM. Condition is: Powertrain Control Module (PCM) did not receive CCD BUS messages from Transmission Control Module (TCM).
DRB displays NO CCD MESSAGES FROM BODY CONTROL MODULE. Condition is: Powertrain Control Module (PCM) did not receive CCD BUS messages from Body Control Module (BCM).
Code 77
DRB displays SPEED CONTROL POWER RELAY CKT. Condition is: open or shorted condition detected in speed control relay circuit.
| CAUTION | When battery is disconnected, vehicle computer and energy systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
NO CRANK REFERENCE SIGNAL AT PCM
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect Crankshaft Position (CKP) sensor connector. Inspect CKP sensor connector. Clean and repair wiring and connectors as required. If CKP connector is okay, go to next step.
- Using scan tool in voltmeter mode, check voltage on CKP sensor terminal No. 1 (Orange wire). If voltage is more than 7 volts, replace CKP sensor. If voltage is less than 7 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Inspect PCM connector. Clean and repair wiring and connectors as required. If PCM connector is okay, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 7 (Orange wire). If resistance is less than 5 ohms, repair short to ground in Orange wire. If resistance is more than 5 ohms, go to next step.
- Using an external ohmmeter, check resistance of Orange wire between CKP sensor connector terminal No. 1 and PCM connector terminal No. 7. If resistance is more than 5 ohms, repair open Orange wire. If resistance is less than 5 ohms, replace PCM.
NO VEHICLE SPEED SENSOR SIGNAL
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Using scan tool in ohmmeter mode, check resistance of Powertrain Control Module (PCM) connector terminal No. 47 (White/Orange wire). PCM is located under air cleaner. If resistance is more than 5 ohms, go to step 3). If resistance is less than 5 ohms, go to next step.
- Disconnect Speed Proportional Steering (SPS) Module. SPS module is located on end of steering gear. Check resistance of PCM connector terminal No. 47 (White/Orange wire). If resistance is more than 5 ohms, replace SPS module. If resistance is less than 5 ohms, repair short to ground in White/Orange wire.
- If resistance is more than 5 ohms in step 1), use an external ohmmeter to check resistance of White/Orange wire between Powertrain Control Module (PCM) connector terminal No. 47 and Transmission Control Module (TCM) connector terminal No. 58. TCM is located in engine compartment between left front fender and battery. If resistance is more than 5 ohms, repair open White/Orange wire. If resistance is less than 5 ohms, replace PCM.
IDLE AIR CONTROL MOTOR CIRCUITS
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect and inspect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. If any terminals are damaged, pushed out or miswired, repair as necessary. If PCM connector is okay, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 39 (Gray/Red wire). If resistance is less than 5 ohms, repair short to ground in Gray/Red wire. If resistance is more than 5 ohms, replace PCM.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect and inspect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. If any terminals are damaged, pushed out or miswired, repair as necessary. If PCM connector is okay, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 60 (Yellow/Black wire). If resistance is less than 5 ohms, repair short to ground in Yellow/Black wire. If resistance is more than 5 ohms, replace PCM.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect and inspect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. If any terminals are damaged, pushed out or miswired, repair as necessary. If PCM connector is okay, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 40 (Brown/White wire). If resistance is less than 5 ohms, repair short to ground in Brown/White wire. If resistance is more than 5 ohms, replace PCM.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect and inspect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. If any terminals are damaged, pushed out or miswired, repair as necessary. If PCM connector is okay, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 59 (Violet/Black wire). If resistance is less than 5 ohms, repair short to ground in Violet/Black wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #1 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Scheme 13
- Turn ignition off. Disconnect junction block connectors No. 1 and 3. Junction block is located next to right shock tower. (Scheme 13) Go to next step. (Scheme 13): Identifying Junction Block Connectors
- Using an external ohmmeter, check resistance between junction block No. 1 (White/Dark Blue wire) and junction block No. 3 (Dark Green/Orange wire). If resistance is not 10-15 ohms, go to TEST TC-29C. If resistance is 10-15 ohms, go to next step.
- Move external ohmmeter lead from junction block No. 3 (Dark Green/Orange wire) to chassis ground. If resistance is less than 5 ohms, repair short to ground in White/Dark Blue wire. If resistance is more than 5 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Using scan tool in voltmeter mode, check voltage on junction block connector No. 3 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 16 (White/Dark Blue wire). If resistance is less than 5 ohms, repair short to ground in White/Dark Blue wire. If resistance is more than 5 ohms, go to next step.
- Using an external ohmmeter, check resistance of White/Dark Blue wire between junction block No. 1 and PCM connector terminal No. 16. If resistance is more than 5 ohms, repair open White/Dark Blue wire. If resistance is less than 5 ohms, replace PCM.
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 1 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 1 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of White/Dark Blue wire between junction block No. 1 and injector No. 1 connector. If resistance is more than 5 ohms, repair open White/Dark Blue wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 1 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 1. Using scan tool in voltmeter mode, check voltage on injector No. 1 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of White/Dark Blue wire between injector No. 1 connector terminal No. 1 and PCM connector terminal No. 16. If resistance is more than 5 ohms, repair open White/Dark Blue wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 16 (White/Dark Blue wire). If resistance is less than 5 ohms, repair short to ground in White/Dark Blue wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #2 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 2 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 2 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of Tan wire between junction block No. 1 and injector No. 2 connector. If resistance is more than 5 ohms, repair open Tan wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 2 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 2. Using scan tool in voltmeter mode, check voltage on injector No. 2 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of Tan wire between injector No. 2 connector terminal No. 1 and PCM connector terminal No. 15. If resistance is more than 5 ohms, repair open Tan wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 15 (Tan wire). If resistance is less than 5 ohms, repair short to ground in Tan wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #3 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 3 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 3 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of Yellow/White wire between junction block No. 1 and injector No. 3 connector. If resistance is more than 5 ohms, repair open Yellow/White wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 3 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 3. Using scan tool in voltmeter mode, check voltage on injector No. 3 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of Yellow/White wire between injector No. 3 connector terminal No. 1 and PCM connector terminal No. 14. If resistance is more than 5 ohms, repair open Yellow/White wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 14 (Yellow/White wire). If resistance is less than 5 ohms, repair short to ground in Yellow/White wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #4 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 4 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 4 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of Light Blue/Brown wire between junction block No. 1 and injector No. 4 connector. If resistance is more than 5 ohms, repair open Light Blue/Brown wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 4 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 4. Using scan tool in voltmeter mode, check voltage on injector No. 4 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of Light Blue/Brown wire between injector No. 4 connector terminal No. 1 and PCM connector terminal No. 13. If resistance is more than 5 ohms, repair open Light Blue/Brown wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 13 (Light Blue/Brown wire). If resistance is less than 5 ohms, repair short to ground in Light Blue/Brown wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #5 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 5 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 5 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of Brown/Red wire between junction block No. 1 and injector No. 5 connector. If resistance is more than 5 ohms, repair open Brown/Red wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 5 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 5. Using scan tool in voltmeter mode, check voltage on injector No. 5 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of Brown/Red wire between injector No. 5 connector terminal No. 1 and PCM connector terminal No. 38. If resistance is more than 5 ohms, repair open Brown/Red wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 38 (Brown/Red wire). If resistance is less than 5 ohms, repair short to ground in Brown/Red wire. If resistance is more than 5 ohms, replace PCM.
INJECTOR #6 CONTROL CIRCUIT
Note. When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested. (Scheme 13) For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2.
Note. It may be necessary to remove intake plenum in the following steps.
- Reconnect junction block connector No. 3. Disconnect injector No. 6 connector. Turn ignition on. Using scan tool, actuate Auto Shutdown (ASD) relay. Go to next step.
- Using scan tool in voltmeter mode check voltage on injector No. 6 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Using an external ohmmeter, check resistance of Brown/Black wire between junction block No. 1 and injector No. 6 connector. If resistance is more than 5 ohms, repair open Brown/Black wire. If resistance is less than 5 ohms, replace injector.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Disconnect and inspect injector No. 6 connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Using an external ohmmeter, check resistance across injector terminals. If resistance is not 10-15 ohms, replace injector. If resistance is 10-15 ohms, go to next step.
- Turn ignition on. Using scan tool, actuate injector No. 6. Using scan tool in voltmeter mode, check voltage on injector No. 6 connector terminal No. 2 (Dark Green/Orange wire). If voltage is less than 10 volts, repair open Dark Green/Orange wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance of Brown/Black wire between injector No. 6 connector terminal No. 1 and PCM connector terminal No. 58. If resistance is more than 5 ohms, repair open Brown/Black wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 58 (Brown/Black wire). If resistance is less than 5 ohms, repair short to ground in Brown/Black wire. If resistance is more than 5 ohms, replace PCM.
IGNITION COIL #1 PRIMARY CIRCUIT
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- If scan tool displays IGNITION COIL #1 PRIMARY CIRCUIT in «TEST TC-35A»(ref-11020-S12146495162000111000000) and ASD RELAY CONTROL CIRCUIT trouble code is also present, go to «TEST TC-44A»(ref-11020-S18558958442000111000000) . If ASD RELAY CONTROL CIRCUIT trouble code is not present, go to next step.
- Turn ignition off. Disconnect and inspect ignition coil connector. If any terminal is damaged, pushed out or miswired, repair as necessary. If connector is okay, go to next step.
- Turn ignition on. Using scan tool, actuate ignition coil No. 1. Using scan tool in voltmeter mode, check voltage on ignition coil connector terminal No. 4 (Dark Green/Orange wire). If voltage is less than 10 volts, go to «TEST TC-37B»(ref-11020-S14805407502000111000000) . If voltage is more than 10 volts, go to next step.
- Using an external ohmmeter, check resistance between ignition coil terminals No. 2 (Black wire) and No. 4 (Dark Green/Orange wire). If resistance is more than 2 ohms, replace ignition coil. If resistance is less than 2 ohms, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 19 (Black wire). If resistance is less than 5 ohms, repair short to ground in Black wire. If resistance is more than 5 ohms, go to next step.
- Using an external ohmmeter, check resistance of Black wire between PCM connector terminal No. 19 and ignition coil connector terminal No. 2. If resistance is more than 5 ohms, repair open Black wire. If resistance is less than 5 ohms, replace PCM.
IGNITION COIL PRIMARY CIRCUITS
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect Auto Shutdown (ASD) relay. Using an external ohmmeter, check resistance of Dark Green/Orange wire between ASD relay connector terminal "D" and ignition coil connector terminal No. 4. If resistance is more than 5 ohms, repair open Dark Green/Orange wire. If resistance is less than 5 ohms, go to next step.
- Turn ignition on. Using scan tool in voltmeter mode, check voltage on ASD relay connector terminal "B" (Red/White wire). If voltage is less than 10 volts, repair open Red/White wire. If voltage is more than 10 volts, go to next step.
- Check voltage ASD relay connector terminal "A" (Dark Blue/White wire). If voltage is less than 10 volts, repair open Dark Blue/White wire. If voltage is more than 10 volts, go to next step.
- Turn ignition off. Disconnect fuel pump relay. Using an external ohmmeter, check resistance of Dark Blue/Yellow wire between ASD relay connector terminal "C" and fuel pump relay terminal "C". If resistance is more than 5 ohms, repair open Dark Blue/Yellow wire. If resistance is less than 5 ohms, replace ASD relay.
EGR SOLENOID CIRCUIT
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
Using an external ohmmeter, check resistance across EGR solenoid terminals. If resistance is more than 5 ohms, repair open Light Green/Black wire. If resistance is less than 5 ohms, replace EGR solenoid, and replace fuse No. 20.
EVAP SOLENOID CONTROL CIRCUIT
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
Using an external ohmmeter, check resistance across EVAP solenoid terminals. If resistance is more than 5 ohms, repair open Light Green/Black wire. If resistance is less than 5 ohms, replace EVAP solenoid and fuse No. 20.
MANIFOLD TUNE VALVE SOLENOID CIRCUIT
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
Using an external ohmmeter, check resistance across Manifold Tuning Valve (MTV) solenoid terminals. MTV solenoid is located on right front strut tower. If resistance is more than 5 ohms, repair open Light Green/Black wire. If resistance is less than 5 ohms, replace MTV solenoid and fuse No. 20.
CHECKING SECONDARY IGNITION & TIMING
Note. After each repair, perform TEST VER-2 .
- Turn engine off. Connect engine analyzer to engine. Start engine, and let it idle. Set scope to read display or parade pattern. Follow equipment manufacturer's procedure for pattern analysis. If secondary ignition pattern is not okay, repair indicated component in secondary ignition system. If secondary ignition pattern is okay, go to next step.
- Remove all lower spark plug wires one at a time from ignition coil. Observe secondary kilovolt line. If open circuit secondary voltage is not at least 25 kV, replace electronic ignition coil. If open circuit secondary voltage is at least 25 kV, reinstall spark plug wires. Go to next step.
- Ensure engine temperature is more than 180°F (82°C) before proceeding. Using scan tool, read spark advance. Increase engine speed to 2000 RPM. If spark advance does not change with increase in RPM, replace Powertrain Control Module (PCM). PCM is located under air cleaner. If spark advance changes with increase in RPM, test is complete.
CHECKING FUEL PRESSURE
| WARNING | High fuel pressure may be present in fuel lines. Open fuel system with caution. See FUEL PRESSURE RELEASE . |
Note. After each repair, perform TEST VER-2 .
- Release fuel pressure. Connect fuel pressure gauge to fuel rail. Turn ignition on. Using scan tool, actuate fuel system test. If fuel pressure is 50-60 psi (3.3L) or 43-53 psi (3.5L), test is complete. If fuel pressure is not 50-60 psi (3.3L) or 43-53 psi (3.5L), go to next step.
- Record fuel pressure reading. If pressure is more than 60 psi (3.3L) or 53 psi (3.5L), go to TEST NTC-3B. If fuel pressure is less than 60 psi (3.3L) or 53 psi (3.5L), stop fuel system actuation test. Go to next step.
- Turn ignition off. Inspect fuel lines for kinked or restricted lines. Repair fuel lines as necessary. If no kinked or restricted lines exist, go to next step.
- Release fuel pressure. Remove fuel pressure gauge from fuel rail. Install fuel pressure gauge between fuel tank and fuel filter at rear of vehicle. Turn ignition on. Using scan tool, actuate ASD relay. If fuel pressure is at least 5 psi more than previously recorded pressure, replace fuel filter. If fuel pressure is not at least 5 psi more than previously recorded, go to next step. CAUTION: DO NOT allow fuel pressure to exceed 70 psi (3.3L) or 60 psi (3.5L) when squeezing fuel return hose.
- Gently squeeze fuel return hose while observing fuel pressure gauge, ensuring fuel pressure does not exceed 70 psi (3.3L) or 60 psi (3.5L). If fuel pressure increases, replace fuel pressure regulator. If fuel pressure does not increase, replace fuel pump and sock assembly.
| WARNING | High fuel pressure may be present in fuel lines. Open fuel system with caution. See FUEL PRESSURE RELEASE . |
Note. After each repair, perform TEST VER-2 .
- Using scan tool, stop fuel system actuation test. Release fuel pressure. Ensure fuel tank is at least 1/4 full before performing following test. Install fuel pressure gauge and adapter between fuel tank and fuel filter at rear of vehicle. Go to next step.
- Remove fuel return line from fuel pump at fuel tank. Connect Fuel Pressure Test Adapter (6541) to fuel return line. Place other end of adapter hose into an approved 2-gallon gasoline can. Turn ignition on. Go to next step.
- Using scan tool, actuate fuel system test. Observe fuel pressure gauge. If fuel pressure is 50-60 psi (3.3L) or 43-53 psi (3.5L), repair fuel return line for a restriction at fuel tank. If fuel pressure is not 50-60 psi (3.3L) or 43-53 psi (3.5L), go to next step.
- Stop fuel system actuation test. Release fuel pressure. Reconnect fuel return line to fuel tank. Disconnect fuel return line from fuel rail. Attach Fuel Pressure Test Adapter (6541) to fuel return line nipple at fuel rail. Place other end of adapter hose into an approved 2-gallon gasoline can. Turn ignition on. Go to next step.
- Using scan tool, actuate fuel system test. Observe fuel pressure gauge. If fuel pressure is 50-60 psi (3.3L) or 43-53 psi (3.5L), repair restricted fuel return line to fuel tank. If fuel pressure is not 50-60 psi (3.3L) or 43-53 psi (3.5L), go to next step.
- Inspect fuel pressure damper line for restrictions. If restrictions exist, replace fuel pressure damper line. If no restrictions exist, replace fuel pressure regulator.
CHECKING OXYGEN SENSOR (O2S) SWITCHING
Note. Scan tool displays left oxygen sensor as O2 and right oxygen sensor as O2R. After each repair, perform TEST VER-2 .
- Allow engine to reach normal operating temperature. Using scan tool, read O2S states (left and right). Increase engine speed to more than 1500 RPM. If O2S states are switching, system is functioning okay. Test is complete. If O2S states are not switching, check if O2S is locked on lean. If O2S is locked on lean, go to TEST NTC-7B. If O2S is not locked on lean, go to next step. WARNING: High fuel pressure may be present in fuel lines. Open fuel system with caution. See «FUEL PRESSURE RELEASE»(ref-11020-S12805262302000111000000) .
- Turn engine off. Release fuel pressure. Install fuel pressure gauge in fuel supply line. Turn ignition on. Using scan tool, actuate fuel system test. Allow fuel pressure gauge to stabilize to normal fuel pressure. Stop fuel system actuation test. Go to next step.
- Monitor fuel pressure gauge for one minute. If fuel pressure gauge reading drops more than 10 psi, replace leaking injector(s) or "O" rings as needed. If fuel pressure gauge reading does not drop more than 10 psi, go to next step.
- Inspect air cleaner and inlet ducts for restriction(s). Repair as required. If no restrictions are observed, go to «TEST NTC-16A»(ref-11020-S35954584912000111000000) .
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Allow engine to idle. Inspect engine for vacuum leaks. Repair vacuum leaks as necessary. If no vacuum leaks exist, go to next step. NOTE: Scan tool displays left oxygen sensor as O2 and right oxygen sensor as O2R.
- Using scan tool, read both O2S signal voltages. If voltage for either or both O2S is more than 0.1 volt, go to step 5). If voltage is less than 0.1 volt for either or both O2S, go to next step.
- Turn ignition off. Disconnect faulty O2S connector(s) (left and/or right). Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Go to next step.
- Using scan tool in ohmmeter mode, check resistance of left O2S connector terminal No. 2 (Black/Dark Green wire) and/or right O2S connector terminal No. 2 (Tan/White wire). If resistance at either or both O2S is less than 10 ohms, repair short to ground in Black/Dark Green wire or Tan/White wire. If resistance is more than 10 ohms, replace O2S. Test is complete.
- If voltage for either or both O2S is more than 0.1 volt in step 2), turn engine off. Replace O2S. Turn ignition on. Using scan tool, reset adaptive fuel memory. Start engine, and allow it to reach normal operating temperature. Go to next step.
- Using scan tool, read right and left O2S states. If both O2S states are switching, repair is complete. If both O2S states are not switching, go to «TEST NTC-16A»(ref-11020-S35954584912000111000000) .
CHECKING OXYGEN SENSOR (O2S) HEATER
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
Note. Scan tool displays left oxygen sensor as O2 and right oxygen sensor as O2R.
- Turn ignition on. Wait 2 minutes for Oxygen Sensor (O2S) voltage to stabilize. Using scan tool, read left O2S voltage. If voltage is not 0.4-0.6 volt, go to step 4). If voltage is 0.4-0.6 volt, go to next step.
- Disconnect left O2S connector. Using scan tool in voltmeter mode, check voltage on left O2S connector terminal No. 4 (Light Green/Black wire). If voltage is less than 10 volts, repair open Light Green/Black wire. If voltage is more than 10 volts, go to next step.
- Using scan tool in ohmmeter mode, check resistance of left O2S connector terminal No. 3 (Black wire). If resistance is more than 5 ohms, repair open Black wire. If resistance is less than 5 ohms replace left O2S.
- If voltage is not 0.4-0.6 volt in step 1), read right O2S voltage. If voltage is not 0.4-0.6 volt, test passed. if voltage is 0.4-0.6 volt, go to next step.
- Disconnect right O2S connector. Using scan tool in voltmeter mode, check voltage on right O2S connector terminal No. 4 (Light Green/Black wire). If voltage is less than 10 volts, repair open Light Green/Black wire. If voltage is more than 10 volts, go to next step.
- Using scan tool in ohmmeter mode, check resistance of right O2S connector terminal No. 3 (Black wire). If resistance is more than 5 ohms, repair open Black wire. If resistance is less than 5 ohms replace right O2S.
CHECKING IDLE AIR CONTROL MOTOR
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Using scan tool, set engine speed to 1100 RPM. If engine speed set at 1050-1150 RPM, idle speed motor is operating properly. Test is complete. If engine speed does not set at 1050-1150 RPM, go to next step.
- Return engine to normal idle speed. Disconnect Idle Air Control (IAC) motor connector. Using scan tool in voltmeter mode, check voltage on IAC motor connector terminal No. 1 (Gray/Red wire) while momentarily opening and closing throttle. If voltage is less than one volt, go to TEST NTC-9B. If voltage is more than one volt, go to next step.
- Using scan tool, check voltage on IAC motor connector terminal No. 2 (Yellow/Black wire). If voltage is less than one volt, go to TEST NTC-9B. If voltage is more than one volt, go to next step.
- Using scan tool, check voltage on IAC motor connector terminal No. 3 (Brown/White wire). If voltage is less than one volt, go to TEST NTC-9B. If voltage is more than one volt, go to next step.
- Using scan tool, check voltage on IAC motor connector terminal No. 4 (Violet/Black wire). If voltage is less than one volt, go to TEST NTC-9B. If voltage is more than one volt, go to next step.
- Check engine for vacuum leaks. Repair as required. If no vacuum leaks are observed, turn ignition off. Remove IAC motor. Turn ignition on. Using scan tool, actuate IAC motor. If IAC motor tip does not extend and retract, replace IAC motor. If IAC motor tip extends and retracts, test is complete.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
Turn engine off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance on each wire between Idle Air Control (IAC) motor connector and PCM connector. See PCM TERMINAL IDENTIFICATION table. If resistance for any wire is more than 10 ohms, repair open as necessary. If resistance for all wire is less than 10 ohms, replace PCM.
| Wire Color | Terminal No. |
|---|---|
| Gray/Red | 39 |
| Brown/White | 40 |
| Violet/Black | 59 |
| Yellow/Black | 60 |
PCM TERMINAL IDENTIFICATION
CHECKING MANUAL VALVE LEVER POSITION SWITCH (MVLPS)
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Using scan tool, read park/neutral switch input state. While observing scan tool display, move gear selector in and out of Park and Reverse. If display shows P/N and D/R, system is functioning correctly. If display does not show P/N and D/R, go to next step.
- Turn ignition off. Place gear selector in Park. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Place scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 30 (Black/Light Green wire). Go to next step.
- Observe scan tool display while moving gear selector in and out of Park and Reverse. If display switches from less than 5 ohms to more than 5 ohms, replace PCM. If display does not switch from less than 5 ohms to more than 5 ohms, check if display always stays less than 5 ohms. If display always stays less than 5 ohms, repair short to ground in park/neutral switch sense wire. If display does not always stay less than 5 ohms, go to next step.
- Disconnect Manual Valve Lever Position Switch (MVLPS) connector. MVLPS is located on transmission. Using external ohmmeter, check resistance between MVLPS connector terminal No. 1 (Black/Light Green wire) and PCM connector terminal No. 30. If resistance is less than 10 ohms, replace MVLPS. If resistance is more than 10 ohms, repair open Black/Light Green wire.
CHECKING PCM GROUND & POWER CIRCUITS
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 5 (Black/White wire). If resistance is more than 5 ohms, repair open in Black/White wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool, check resistance of PCM connector terminal No. 11 (Black/Tan wire). If resistance is more than 5 ohms, repair open in Black/Tan wire. If resistance is less than 5 ohms, go to next step.
- Using scan tool, check resistance of PCM connector terminal No. 12 (Black/Tan wire). If resistance is more than 5 ohms, repair open in Black/Tan wire. If resistance is less than 5 ohms, go to next step.
- Turn ignition on. Using scan tool in voltmeter mode, check voltage on PCM connector terminal No. 9 (Dark Blue/White wire). If voltage is less than 10 volts, repair open Dark Blue/White wire. If voltage is more than 10 volts, turn ignition off. Reconnect PCM connector. PCM ground and power circuits are okay. Test is complete.
CHECKING EGR SYSTEM
Note. After each repair, perform TEST VER-2 .
- Disconnect vacuum hose from EGR solenoid. Connect vacuum gauge to disconnected vacuum hose. Start engine. If vacuum is more than 10 in. Hg at idle, go to step 3). If vacuum is less than 10 in. Hg at idle, go to next step.
- Turn engine off. Disconnect EGR vacuum signal hose at intake manifold. Connect a vacuum gauge to intake manifold nipple. Start engine. Read vacuum gauge at idle. If vacuum is more than 10 in. Hg at idle, repair restriction or leak in vacuum line to EGR solenoid. If vacuum is less than 10 in. Hg at idle, repair plugged vacuum nipple at throttle body.
- If vacuum is more than 10 in. Hg at idle in step 1), stop engine. Disconnect vacuum gauge, and reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve, and connect vacuum gauge to disconnected hose. Go to next step.
- Start engine. While observing gauge vacuum gauge, disconnect EGR solenoid 2-way connector. If vacuum is more than one in. Hg at any time, replace EGR valve assembly. If vacuum is not more than one in. Hg at any time, go to next step.
- Turn ignition off. Disconnect hose to EGR valve backpressure signal tube. Adjust a shop air hose to 20 psi. Connect shop air to nipple on base of EGR valve. Listen for a tone change while opening and closing throttle. If tone changes, replace EGR valve assembly. If tone does not change, go to next step.
- Remove vacuum gauge. Cap open nipple at EGR valve base. Connect hand vacuum pump to EGR valve. Start engine. While slowly applying vacuum to EGR valve, listen for engine RPM change. If engine RPM does not change, replace EGR valve assembly. If engine RPM changes, go to next step.
- Turn ignition off. Apply 10 in. Hg and hold for 30 seconds. If vacuum does not hold for 30 seconds, replace EGR valve assembly. If vacuum holds for 30 seconds, test is complete.
CHECKING ENGINE VACUUM
Note. After each repair, perform TEST VER-2 .
Connect a vacuum gauge to engine. Start engine, and let it idle. Normal vacuum reading will vary depending on altitude. Observe vacuum gauge at idle. If vacuum gauge reading is not steady 13-22 in. Hg, go to TEST NTC-16A . If vacuum gauge reading is steady and within specification, test is complete.
CHECKING MINIMUM IDLE AIRFLOW
Note. After each repair, perform TEST VER-2 .
- Turn ignition off. Disconnect PCV valve hose from vacuum nipple. Cap PCV valve nipple. On 3.3L engine, disconnect 3/16" idle purge hose from throttle body. Install Vacuum Fitting (6457) to intake manifold PCV nipple. On 3.5L, disconnect 3/16" idle purge hoses on both throttle bodies. Install Vacuum Fitting (C-6457) to each purge nipple on both throttle bodies. Go to next step.
- On all engines, start engine. Allow engine to reach normal operating temperature. Using scan tool, actuate minimum airflow. If vehicle odometer indicates more than 1000 miles, go to step 4). If vehicle odometer indicates less than 1000 miles, go to next step.
- On 3.3L, if vehicle odometer indicates less than 1000 miles, and engine speed is not 540-840 RPM, replace throttle body. On 3.5L, if vehicle odometer indicates less than 1000 miles, and engine speed is not 700-1000 RPM, inspect throttle body and check throttle body adjustments. Repair as required. On all engines, if engine speed is 540-840 RPM (3.3L) or 700-1000 RPM (3.5L), minimum airflow is normal. Test is complete.
- If vehicle odometer indicates more than 1000 miles in step 2) and engine speed is 600-840 RPM (3.3L) or 750-1100 RPM (3.5L), minimum airflow is normal. Test is complete. If vehicle odometer indicates more than 1000 miles in step 2) and engine speed is not 600-840 RPM (3.3L) or 750-1100 RPM (3.5L), go to next step.
- On 3.3L, replace throttle body. On 3.5L, inspect throttle body and check throttle body adjustments. Repair as required.
QUALIFYING NO START CONDITION
Note. After each repair, perform TEST VER-1 .
| CAUTION | When checking for spark, powertrain control module damage may occur if spark plug cable is held more than 1/4" away from a good ground. |
- Attempt to crank engine. If engine will not crank, go to «TEST NS-9A»(ref-11020-S00499119542000111000000). If engine cranks, turn ignition off. Disconnect any spark plug cable at spark plug. Insert an insulated screwdriver in spark plug cable terminal. Hold screwdriver within 1/4" of good ground. Go to next step. NOTE: When checking for spark, consider 1-2 sparks as a no-spark condition.
- While cranking engine for 10 seconds, observe for spark. If a good spark occurs, go to TEST NS-2A. If a good spark does not occur, reconnect spark plug cable. Disconnect another spark plug cable at spark plug, and repeat test. Go to next step.
- If a good spark occurs, replace spark plug cable that is initially used to test for spark. Go to TEST NS-2A. If a good spark does not occur, disconnect ignition coil connector. Inspect all terminals. Repair as required. If terminals are okay, go to next step.
- Using scan tool, actuate fuel system. Using scan tool in voltmeter mode, check voltage on ignition coil connector terminal No. 4 (Dark Green/Orange wire). If voltage is more than 10 volts, turn ignition off and replace ignition coil. If voltage is less than 10 volts, go to next step.
- Using scan tool, stop fuel system actuation. Using scan tool, actuate Auto Shutdown (ASD) relay. If ASD relay does not click, go to step 7). If ASD relay clicks, stop ASD relay actuation. Go to next step.
- Remove ASD relay. Using an external ohmmeter, check resistance of Dark Green/Orange wire between ignition coil connector terminal No. 4 and ASD relay connector terminal "D". If resistance is less than 5 ohms, replace ASD relay. If resistance is more than 5 ohms, repair open Dark Green/Orange wire.
- If ASD relay does not click in step 5), remove ASD relay. Using scan tool in voltmeter mode, check voltage of ASD relay connector terminal "A" (Dark Blue/White wire). If voltage is less than 10 volts, repair open Dark Blue/White wire. If voltage is more than 10 volts, go to next step.
- Using an external ohmmeter, check resistance between ASD relay terminals No. 85 and No. 86. see scheme 9 If resistance is more than 100 ohms, replace ASD relay. If resistance is less than 100 ohms, repair open Dark Blue/Yellow wire.
CORRECTING FUEL DELIVERY
| WARNING | High fuel pressure may be present in fuel lines. Open fuel system with caution. See FUEL PRESSURE RELEASE . |
Note. After each repair, perform TEST VER-1 .
- Record fuel pressure gauge reading. Turn ignition off. Release fuel pressure. Remove fuel pressure gauge. Install fuel pressure gauge between fuel tank and fuel filter. Turn ignition on. Go to next step.
- Using scan tool, actuate Auto Shutdown (ASD) fuel system. Record fuel pressure gauge reading. Compare fuel pressure gauge reading with previous reading. If fuel pressure gauge reading is not at least 10 psi more than previous reading, go to step 4). If fuel pressure gauge reading is at least 10 psi more than previous reading, go to next step.
- Turn ignition off. Inspect fuel lines between fuel filter and fuel rail for restriction. Repair as required. If no restrictions are observed, replace fuel filter.
- If fuel pressure gauge reading is not at least 10 psi more than previous reading in step 2), turn ignition off. Release fuel pressure. Disconnect fuel return hose at fuel rail tube. Connect a 6-foot fuel hose to fuel rail return tube. Put other end of 6-foot fuel hose into an approved 2-gallon or more capacity fuel container. Go to next step. CAUTION: DO NOT allow fuel pressure to exceed 70 psi when squeezing fuel hose.
- Turn ignition on. Using scan tool, actuate fuel system. Gently squeeze 6-foot fuel hose. Read fuel pressure gauge reading. Using scan tool, stop fuel system actuation test. If fuel pressure exceeds 50 psi (3.3L) or 43 psi (3.5L), replace fuel pressure regulator. If fuel pressure does not exceed 50 psi (3.3L) or 43 psi (3.5L), replace fuel pump and sock filter.
| WARNING | High fuel pressure may be present in fuel lines. Open fuel system with caution. See FUEL PRESSURE RELEASE . After each repair, perform TEST VER-1 . |
- Ensure fuel tank is at least 1/4 full, and release fuel pressure. Turn ignition off. Remove fuel return hose from fuel rail tube. Connect a 6-foot fuel hose to fuel rail return tube. Put other end of 6-foot hose into an approved 2-gallon or more capacity gasoline container. Go to next step.
- Turn ignition on. Using DRB, actuate fuel system. Read fuel pressure gauge reading. If fuel pressure is more than 60 psi (3.3L) or 53 psi (3.5L), replace fuel pressure regulator. If fuel pressure is less than 60 psi (3.3L) or 53 psi (3.5L), go to next step.
- Turn ignition off. Reconnect fuel return hose. Remove fuel return hose from fuel tank. Connect Fuel Pressure Test Adapter (C-6541) to disconnected return hose. Put other end of hose into an approved 2-gallon or more capacity gasoline container. Go to next step.
- Turn ignition on. Using DRB, actuate fuel system. Read fuel pressure gauge. Using DRB, stop actuation test. If fuel pressure is less than 60 psi (3.3L) or 53 psi (3.5L), repair or replace restricted fuel pump module. If fuel pressure is more than 60 psi (3.3L) or 53 psi (3.5L), repair restricted fuel return line between fuel rail and fuel tank.
CORRECTING NO RESPONSE CONDITION
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-1 .
- If vehicle starts, go to TEST NS-6B. If vehicle does not start, turn ignition off. Disconnect Throttle Position Sensor (TPS) connector. Turn ignition on. Go to next step.
- Using scan tool in voltmeter mode, check voltage on TPS connector terminal No. 3 (Violet/White wire). If voltage is more than 6 volts, repair open ground(s) at Powertrain Control Module (PCM) connector terminals No. 5 (Black/White wire), No. 11 (Black/Tan wire) or No. 12 (Black/Tan wire). If voltage is less than 6 volts, go to next step.
- If voltage is less than 4.4 volts, go to next step. If voltage is more than 4.4 volts, reconnect TPS connector. Disconnect Manifold Absolute Pressure (MAP) sensor connector. Using scan tool in voltmeter mode, check voltage on MAP sensor connector terminal No. 3 (Violet/White wire). If voltage is more than 4.4 volts, go to TEST NS-6B. If voltage is less than 4.4 volts, replace TPS.
- Disconnect MAP sensor connector. Using scan tool in voltmeter mode, check voltage on TPS connector terminal No. 3 (Violet/White wire). If voltage is more than 4.4 volts, replace MAP sensor. If voltage is less than 4.4 volts, go to next step.
- Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 6 (Violet/White wire). If resistance is less than 5 ohms, repair short to ground in Violet/White wire. If resistance is more than 5 ohms, go to next step.
- Turn ignition on. Using scan tool in voltmeter mode, check voltage on PCM connector terminal No. 9 (Dark Blue/White wire). If voltage is less than 10 volts, repair open Dark Blue/White wire. If voltage is more than 10 volts, go to next step.
- Check voltage on PCM connector terminal No. 3 (Red/White wire). If voltage is more than 10 volts, replace PCM. If voltage is less than 10 volts, go to next step.
- Remove and inspect PCM fuse from power distribution center. If fuse is blown, go to step 10). If fuse is okay, go to next step.
- Using scan tool in voltmeter mode, check voltage at PCM fuse socket (Red/White wire). If voltage is more than 10 volts, repair open Red/White wire from PCM to PCM fuse connector. If voltage is less than 10 volts, repair open Red/White wire from PCM fuse connector to battery.
- If fuse is blown in step 8), turn ignition off. Disconnect Auto Shutdown (ASD) relay. Disconnect fuel pump relay. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 3 (Red/White wire). If resistance is less than 5 ohms, repair short to ground in Red/White wire. If resistance is more than 5 ohms, go to next step.
- Check resistance of ASD relay connector terminal "D" (Dark Green/Orange wire). If resistance is less than 5 ohms, go to step 13). If resistance is more than 5 ohms, go to next step.
- Disconnect fuel pump connector. Using scan tool, check resistance of fuel pump relay terminal "D" (Dark Green/Black wire). If resistance is less than 5 ohms, repair short to ground in Dark Green/Black wire. If resistance is more than 5 ohms, replace fuel pump.
- If resistance is less than 5 ohms in step 11), disconnect ignition coil connector. Using scan tool in ohmmeter mode, check resistance of ASD relay connector terminal "D" (Dark Green/Orange wire). If resistance is more than 5 ohms, replace ignition coil. If resistance is less than 5 ohms, go to next step.
- Disconnect generator field connector. Using scan tool in ohmmeter mode, check resistance of ASD relay connector terminal "D" (Dark Green/Orange wire). If resistance is more than 5 ohms, repair generator for short to ground. If resistance is less than 5 ohms, go to next step. NOTE: When testing on junction block terminals, it may be necessary to unbolt junction block from vehicle to identify wire color for terminal being tested.
- Disconnect junction block No. 3 connector. see scheme 9 Using scan tool in ohmmeter mode, check resistance of ASD relay connector terminal "D" (Dark Green/Orange wire). If resistance is more than 5 ohms, repair short to ground in Dark Green/Orange wire. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 1 connector. Using scan tool in ohmmeter mode, check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 1. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 2 connector. Check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 2. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 3 connector. Check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 3. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 4. Check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 4. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 5. Check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 5. If resistance is less than 5 ohms, go to next step.
- Disconnect fuel injector No. 6. Check resistance of junction block connector No. 3 (Dark Green/Orange wire). If resistance is more than 5 ohms, replace fuel injector No. 6. If resistance is less than 5 ohms, repair short to ground in Dark Green/Orange wire.
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-1 .
- If ignition is not on when NO RESPONSE message is displayed, turn ignition on to get a response. If ignition is on when NO RESPONSE message is displayed, turn ignition off. Go to next step.
- Disconnect scan tool from Data Link Connector (DLC). Disconnect Powertrain Control Module (PCM) connector. PCM is located under air cleaner. Using an external ohmmeter, check resistance between DLC terminal No. 5 (Pink wire) and chassis ground. If resistance is less than 5 ohms, repair short to ground in Pink wire. If resistance is more than 5 ohms, go to next step.
- Check resistance between DLC terminal No. 1 (Light Green wire) and chassis ground. If resistance is less than 5 ohms, repair short to ground in Light Green wire. If resistance is more than 5 ohms, go to next step.
- Connect a jumper wire between DLC terminal No. 5 (Pink wire) and chassis ground. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 25 (Pink wire). If resistance is more than 5 ohms, repair open Pink wire. If resistance is less than 5 ohms, go to next step.
- Disconnect jumper wire. Connect jumper wire between DLC connector terminal No. 1 (Light Green wire) and ground. Using scan tool, check resistance of PCM connector terminal No. 45 (Light Green wire). If resistance is more than 5 ohms, repair open Light Green wire. If resistance is less than 5 ohms, go to next step.
- Connect scan tool to a functional DLC on another vehicle. Turn ignition on. Using scan tool, attempt to read trouble codes. If scan tool does not display NO RESPONSE, replace initial vehicle's PCM. If scan tool displays NO RESPONSE, substitute another scan tool cartridge. Go to next step.
- Using scan tool, attempt to read trouble codes. If scan tool does not display NO RESPONSE, replace scan tool cartridge. If scan tool displays NO RESPONSE, substitute another scan tool adapter cable. Using scan tool, attempt to read trouble codes. If scan tool does not display NO RESPONSE, replace scan tool adapter cable. If scan tool displays NO RESPONSE, repair or replace scan tool.
CORRECTING START & STALL CONDITION
Note. If coming to this test from oxygen sensor test and rich or lean condition is not corrected after checking items listed below, replace Powertrain Control Module (PCM). PCM is located under air cleaner.
At this point in diagnostic test procedure, all engine control systems have been determined to be operating as designed and not causing a start and stall problem. Following additional items should be checked as possible causes
- Check if any Technical Service Bulletins (TSBs) apply to vehicle.
- Check valve timing.
- Check engine compression.
- Check for exhaust system restriction.
- Ensure PCV system is functioning properly.
- Check camshaft and crankshaft sprockets.
- Check torque converter stall speed.
- Check for fuel contamination.
- Check secondary ignition system.
REPAIRING NO CRANK CONDITION
Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.5L article in ENGINE PERFORMANCE. After each repair, perform TEST VER-1 .
- Ensure transmission is in Park position. Using scan tool, read park/neutral position switch sense. If scan tool does not display PARK, repair open Black/Dark Green wire. If scan tool displays PARK, go to next step.
- Remove starter relay. Using scan tool in voltmeter mode, check voltage on starter relay connector terminal "B" (Red wire). If voltage is less than 10 volts, repair open Red wire. If voltage is more than 10 volts, go to next step.
- Check voltage on starter relay connector terminal "A" (Yellow wire). If voltage is less than 10 volts, repair open Yellow wire. If voltage is more than 10 volts, go to next step. WARNING: Engine may crank in following step. Keep away from moving engine parts.
- Ensure transmission is in Park position and parking brake is set. Briefly connect a jumper wire between starter relay connector terminals "B" (Red wire) and "D" (Light Green wire). If starter motor cranks, replace starter relay. If starter motor does not crank, and solenoid does not click, replace starter solenoid. If starter motor does not crank and solenoid clicks, go to next step.
- Disconnect jumper wire. Disconnect starter solenoid connector (Light Green wire). Using an external ohmmeter, check resistance of Light Green wire between starter solenoid connector terminal No. 1 and starter relay connector terminal "D". If resistance is more than 5 ohms, repair open Light Green wire. If resistance is less than 5 ohms, go to next step.
- Reinstall starter relay. Check battery cables. Repair cables as necessary. If cables are okay, repair starter motor as necessary.
VERIFICATION PROCEDURE
- Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. Inspect engine oil for fuel contamination. Change oil and filter if necessary. Attempt to start engine.
- If engine does not start, check if any Technical Service Bulletins (TSBs) apply to vehicle and return to «TEST TC-1A»(ref-11020-S30687321432000111000000) , if necessary.
- If engine starts and Powertrain Control Module (PCM) is changed, repair is complete.
- If engine starts and PCM is not changed, connect scan tool to data link connector and erase trouble codes. Repair is complete.
Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If another trouble code was read previously and not corrected, return to TEST TC-1A and follow path specified by other trouble code. If powertrain control module has not been replaced, perform the following
- Connect scan tool to Data Link Connector (DLC), and erase trouble codes.
- Using scan tool, reset all values in adaptive memory.
- Disconnect scan tool.