MODEL IDENTIFICATION
Vehicle model is identified by fourth character of Vehicle Identification Number (VIN). VIN is stamped on metal pad on top of left end of instrument panel, near windshield. See MODEL IDENTIFICATION table.
| Series (1) | Model |
|---|---|
| "C" | 2WD Pickup, Sierra, Silverado, Suburban, Tahoe & Yukon |
| "G" | Cutaway, Express, RV Cutawy & Savana |
| "K" | 4WD Pickup, Sierra, Silverado, Suburban, Tahoe & Yukon, & AWD Escalade |
| "L" | AWD Astro & Safari |
| "M" | 2WD Astro & Safari |
| "P" | Forward Control (P42) & Motorhome (P32) |
| "S" | 2WD Blazer, Envoy, Jimmy, Sonoma & S10 Pickup |
| "T" | 4WD Blazer, Bravada, Envoy, Jimmy, Sonoma & S10 Pickup |
| "U" | Montana, Silhouette & Venture |
| (1) Vehicle series is fifth character of VIN. | |
| (1) | Vehicle series is fifth character of VIN. |
MODEL IDENTIFICATION
INTRODUCTION
Before testing separate components or systems, perform all procedures listed in appropriate BASIC DIAGNOSTIC PROCEDURES article. Since many computer-controlled and monitored components will set a Diagnostic Trouble Code (DTC) if they malfunction, it is also recommended self-diagnostics be performed. See appropriate SELF-DIAGNOSTICS article.
Note. Testing individual components does not isolate shorts or opens. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.
AIR INDUCTION SYSTEMS
Note. Manufacturer does not provide testing procedures for many individual systems and components. For system and component testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
TURBOCHARGER (6.5L DIESEL)
A malfunction in turbocharger boost system can set a related Diagnostic Trouble Code (DTC). For testing procedures, see appropriate SELF-DIAGNOSTICS article.
PCM OUTPUT DIAGNOSIS (2.2L)
- Perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article. After performing OBD system check, go to next step.
- Turn ignition on with engine off. Connect scan tool to Data Link connector (DLC). If a No. 1 is displayed below any of the number output drivers, go to next step. If a No. 1 is not displayed below any of the number output drivers, go to step 4 .
- Disconnect electrical connector from component related to malfunctioning circuit. If a No. 1 is still displayed below corresponding output driver, go to step 6 . If a No. 1 is not displayed below any of the number output drivers, go to step 9 .
- Using scan tool, command output being checked while watching corresponding position for that circuit. If that circuits position does not change to a No. 1, go to next step. If that circuits position changes to a No. 1, go to step 7 .
- If component or function does not operate when commanded, go to step 9 . If component or function operates when commanded, go to step 11 .
- Turn ignition off. Check for an open, short to voltage or short to ground in any corresponding circuit that indicated a No. 1 below output driver. Repair component or component circuit as necessary and go to step 11 . If circuits are okay, go to step 10 .
- Disconnect electrical connector from component related to malfunctioning circuit. Using scan tool, command output being checked while watching corresponding position for that circuit. If a No. 1 is still displayed below corresponding output driver, go to next step. If a No. 1 is not displayed below any of the number output drivers, go to step 9 .
- Turn ignition off. Check for an open, short to voltage or short to ground in any corresponding circuit that indicated a No. 1 below output driver. Repair component or component circuit as necessary and go to step 11 . If circuits are okay, go to step 10 .
- Diagnose and repair any component that malfunctioned when commanded with scan tool. After repairs, go to step 11 .
- Replace PCM. Program replacement PCM using required equipment. After repairs, go to next step.
- Start engine and operate vehicle under condition under which original symptom was noted. If system does not operate properly, go to step 2 . If system operates properly, go to «DIAGNOSTIC AIDS»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__diagnostic-aids) .
Diagnostic Aids
Scan tool has the ability to command certain components and functions ON and OFF. If a component or function does not have this capability, operate vehicle during normal function criteria to check for an open or shorted circuit. An open or short to ground will appear in the open positions of the scan tool only when it is not commanded by the PCM or scan tool. A short to voltage will appear in the short positions on the scan tool only while the component is being commanded by the PCM or scan tool.
PCM POWER & GROUND CHECK
Note. To identify circuits referenced in the following ground and power tests, see appropriate wiring diagram in WIRING DIAGRAMS article.
Ground Circuits
- Using an ohmmeter, check for continuity to ground at PCM/VCM ground terminals. See «POWERTRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests). (Scheme 18)- (Scheme 21). Resistance should be zero ohms. If not, repair open to ground.
- Using a voltmeter, connect negative lead of a voltmeter to a good ground. Backprobe positive lead of voltmeter to each ground terminal. With vehicle running, voltmeter should indicate less than one volt. If voltmeter reading is more than one volt, check for open, short to voltage, corrosion or loose connection on ground circuit.
Power Circuits
- Using a voltmeter, check for battery voltage between PCM/VCM continuous power terminal(s) and ground. See «POWERTRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests). (Scheme 18)- (Scheme 21). If battery voltage is not present, check for blown fuse or open fusible link. If okay, check for open in wire between PCM/VCM terminal and power source.
- Turn ignition switch to RUN position. Using a voltmeter, check for battery voltage between PCM/VCM ignition power terminals and ground. If battery voltage is not present, check IGN fuse. If fuse is okay, check for an open in wire between battery and ignition switch, and between ignition switch and PCM/VCM terminal. If wiring is okay, check for a defective ignition switch.
- Connect voltmeter between ground and PCM/VCM starter (crank) signal terminal. On vehicles with manual transmission/transaxle, depress clutch pedal. On vehicles with automatic transmission/transaxle, position gear shift lever in Park. On all vehicles, turn ignition switch to START position. Battery voltage should be present ONLY when ignition switch is in START position.
- If voltage is not present, check CRANK fuse or fusible link between ignition switch and PCM/VCM terminal. If fuse or fusible link is okay, check for an open in wire between ignition switch and PCM/VCM terminal, or check for a defective ignition switch.
PCM Harness Resistance
Turn ignition switch to LOCK position. Disconnect PCM and appropriate component harness connectors. Check for open or short circuits between appropriate PCM harness connector terminal and appropriate component harness connector terminal. See POWERTRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL IDENTIFICATION. (Scheme 18)- (Scheme 21). See appropriate wiring diagram in WIRING DIAGRAMS article. If harness is open or shorted, repair as necessary.
Scheme 18
Scheme 19
Scheme 20
Scheme 21
POWERTRAIN CONTROL MODULE (PCM) - 2.2L
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1-5 | — | Not Used |
| C1 (Blue) | 6 | ORG/BLK | (2) Ground |
| C1 (Blue) | 7 | BRN/WHT | CMP Sensor Signal |
| C1 (Blue) | 8 | PPL/WHT | CKP 7x Reference Signal |
| C1 (Blue) | 9 | — | Not Used |
| C1 (Blue) | 10 | GRY | Fuel Tank Pressure Sensor Reference Voltage |
| C1 (Blue) | 11-17 | — | Not Used |
| C1 (Blue) | 180 | BLK/WHT | PCM Ground |
| C1 (Blue) | 19 | PNK | Ignition Voltage |
| C1 (Blue) | 20 | ORN | Battery Voltage |
| C1 (Blue) | 21 | DK BLU | TP Sensor Signal |
| C1 (Blue) | 22-24 | — | Not Used |
| C1 (Blue) | 25 | ORN | Ignition Control B |
| C1 (Blue) | 26 | WHT | Ignition Control A |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | RED | Transmission Range C Input |
| C1 (Blue) | 29 | BLK/WHT | PRNDL A Input |
| C1 (Blue) | 30-32 | — | Not Used |
| C1 (Blue) | 33 | DK BLU | KS Signal |
| C1 (Blue) | 34 | — | Not Used |
| C1 (Blue) | 35 | PPL | TCC Brake Switch Input |
| C1 (Blue) | 36 | LT BLU | A/C Request Signal |
| C1 (Blue) | 37-44 | — | Not Used |
| C1 (Blue) | 45 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C1 (Blue) | 46 | YEL/BLK | TFT Sensor Signal |
| C1 (Blue) | 47 & 48 | — | Not Used |
| C1 (Blue) | 49 | RED/BLK | A/C Refrigerant Pressure Sensor Signal |
| C1 (Blue) | 50 & 51 | — | Not Used |
| C1 (Blue) | 52 | BLK | A/C Refrigerant Pressure Sensor Ground |
| C1 (Blue) | 53 | — | Not Used |
| C1 (Blue) | 54 | YEL | ECT Sensor Signal |
| C1 (Blue) | 55 | PPL | Fuel Level Sensor Input |
| C1 (Blue) | 56 | — | Not Used |
| C1 (Blue) | 57 | BLK | TP Sensor Ground |
| C1 (Blue) | 58 | YEL | Serial Data (Class II) |
| C1 (Blue) | 59 | DK GRN | Serial Data (Class II) |
| C1 (Blue) | 60 | BLK/WHT | PCM Ground |
| C1 (Blue) | 61 | PNK | IGN 2 |
| C1 (Blue) | 62 | LT GRN | MAP Sensor Signal |
| C1 (Blue) | 63 | PPL/WHT | VSS High |
| C1 (Blue) | 64-66 | — | Not Used |
| C1 (Blue) | 67 | DK BLU | Transmission Range B Input |
| C1 (Blue) | 68 | PNK | Transmission Range A Input |
| C1 (Blue) | 69 | YEL | PRNDL B |
| C1 (Blue) | 70 | YEL/BLK | High Resolution Vehicle Speed Output |
| C1 (Blue) | 71 | — | Not Used |
| C1 (Blue) | 72 | GRY | PRNDL C |
| C1 (Blue) | 73 | WHT | PRNDL P |
| C1 (Blue) | 74 | RED | Generator Terminal L |
| C1 (Blue) | 75 | BLK | Fuel Injector No. 1 Control |
| C1 (Blue) | 76 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C1 (Blue) | 77-80 | — | Not Used |
| C2 (Red) | 1-5 | — | Not Used |
| C2 (Red) | 6 | RED/BLK | Pressure Control Solenoid High Control |
| C2 (Red) | 7 | — | Not Used |
| C2 (Red) | 8 | DK GRN/WHT | Fuel Pump Relay Control |
| C2 (Red) | 9 | LT BLU/WHT | Pressure Control Solenoid Low Control |
| C2 (Red) | 10 | WHT | Tachometer Output |
| C2 (Red) | 11-13 | — | Not Used |
| C2 (Red) | 14 | BLK/WHT | MAP Sensor Ground |
| C2 (Red) | 15 | — | Not Used |
| C2 (Red) | 16 | DK GRN/WHT | VSS Output (Cruise) |
| C2 (Red) | 17 | DK GRN | VSS Output (Cluster) |
| C2 (Red) | 18 & 19 | — | Not Used |
| C2 (Red) | 20 | TAN | IAT Sensor Signal |
| C2 (Red) | 21 | TAN | HO2S 1 Low |
| C2 (Red) | 22 | PPL | HO2S 1 Signal |
| C2 (Red) | 23 | TAN/WHT | HO2S 2 Low |
| C2 (Red) | 24 | PPL/WHT | HO2S 2 Signal |
| C2 (Red) | 25 & 26 | — | Not Used |
| C2 (Red) | 27 | BRN | ECT Sensor Ground |
| C2 (Red) | 28 | GRY | IAT Sensor Ground |
| C2 (Red) | 29 | BLK | TFT Sensor Ground |
| C2 (Red) | 30 | — | Not Used |
| C2 (Red) | 31 | RED/BLK | ICM Reference Low |
| C2 (Red) | 32 | — | Not Used |
| C2 (Red) | 33 | GRY | TP Sensor Reference Voltage |
| C2 (Red) | 34 | GRY | A/C Refrigerant Pressure Sensor Reference Voltage |
| C2 (Red) | 35 | GRY | MAP Sensor Reference Voltage |
| C2 (Red) | 36 | RED | CMP Sensor Battery Voltage Supply |
| C2 (Red) | 37-45 | — | Not Used |
| C2 (Red) | 46 | BRN/WHT | MIL Control |
| C2 (Red) | 47 | — | Not Used |
| C2 (Red) | 48 | LT BLU/BLK | Cruise Engaged Input |
| C2 (Red) | 49 | — | Not Used |
| C2 (Red) | 50 | TAN/BLK | TCC Solenoid Control |
| C2 (Red) | 51 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 52 | WHT | 3-2 Shift Solenoid Control |
| C2 (Red) | 53 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 54 | — | Not Used |
| C2 (Red) | 55 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C2 (Red) | 56 | DK GRN/WHT | EVAP Canister Purge Valve Control |
| C2 (Red) | 57 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 58 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 59-61 | — | Not Used |
| C2 (Red) | 62 | LT GRN/BLK | VSS Low |
| C2 (Red) | 63 | PNK/BLK | CMP Sensor Ground |
| C2 (Red) | 64 | BLK/WHT | PCM Ground |
| C2 (Red) | 65-70 | — | Not Used |
| C2 (Red) | 71 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 72 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 73 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 74 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 75 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 76 | PNK/BLK | Fuel Injector No. 3 Control |
| C2 (Red) | 77-80 | — | Not Used |
| (1) (Scheme 18) (2) Fuel tank pressure sensor, fuel level sensor and fuel pump grounds. | |||
| (1) | (Scheme 18) |
| (2) | Fuel tank pressure sensor, fuel level sensor and fuel pump grounds. |
POWERTRAIN CONTROL MODULE (PCM) - 2.2L (1)
POWERTRAIN CONTROL MODULE (PCM) - 3.4L
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | ORG | Fuel Level Output |
| C1 (Blue) | 4 | LT GRN | Shift Solenoid A Control |
| C1 (Blue) | 5 | DK BLU | Cooling Fan High Speed Control |
| C1 (Blue) | 6 | DK GRN | Cooling Fan Low Speed Control |
| C1 (Blue) | 7 | BLK | Camshaft Position PCM Input |
| C1 (Blue) | 8 | PPL/WHT | CKP 3x Reference Signal |
| C1 (Blue) | 9 | LT BLU/BLK | CKP 24x Reference Signal |
| C1 (Blue) | 10 & 11 | — | Not Used |
| C1 (Blue) | 12 | BLK | Engine Coolant Temperature Sensor Ground |
| C1 (Blue) | 13 | ORG/BLK | Manifold Absolute Pressure Sensor Ground |
| C1 (Blue) | 14 | — | Not Used |
| C1 (Blue) | 15 | TAN | Serial Data |
| C1 (Blue) | 16 | BLK/WHT | PCM Ground |
| C1 (Blue) | 17 | YEL | Intake Air Temperature Sensor Ground |
| C1 (Blue) | 18 | — | Not Used |
| C1 (Blue) | 19 | PNK | Ignition Voltage |
| C1 (Blue) | 20 | ORG | Battery Voltage |
| C1 (Blue) | 21-27 | — | Not Used |
| C1 (Blue) | 28 | TAN/WHT | HO2S Sensor 2 Signal Low |
| C1 (Blue) | 29 | TAN | HO2S Sensor 1 Signal Low |
| C1 (Blue) | 30 | PPL | TCC Brake Switch |
| C1 (Blue) | 31 | BLK | EGR Valve Ground |
| C1 (Blue) | 32 | GRY | EGR Valve Ground |
| C1 (Blue) | 33 | DK BLU | Knock Sensor Signal |
| C1 (Blue) | 34 & 35 | — | Not Used |
| C1 (Blue) | 36 | BRN | Generator Light Signal |
| C1 (Blue) | 37 | — | Not Used |
| C1 (Blue) | 38 | LT GRN/WHT | Idle Air Control B High |
| C1 (Blue) | 39-42 | — | Not Used |
| C1 (Blue) | 43 | BLK | Fuel Injector No. 1 Control |
| C1 (Blue) | 44 | YEL/BLK | Shift Solenoid B Control |
| C1 (Blue) | 45 | — | Not Used |
| C1 (Blue) | 46 | PNK/BLK | Fuel Injector No. 3 Control |
| C1 (Blue) | 47 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C1 (Blue) | 48 | RED/BLK | Reference Low |
| C1 (Blue) | 49-52 | — | Not Used |
| C1 (Blue) | 53 | TAN/BLK | By-Pass |
| C1 (Blue) | 54 | WHT | Ignition Control |
| C1 (Blue) | 55 | DK GRN | 4k Pulse Per Mile |
| C1 (Blue) | 56 | BLK/WHT | PCM Ground |
| C1 (Blue) | 57 | BLK/WHT | PCM Ground |
| C1 (Blue) | 58 | — | Not Used |
| C1 (Blue) | 59 | PPL | Serial Data (Class 2) |
| C1 (Blue) | 60 | BLK/WHT | PCM Ground |
| C1 (Blue) | 61 | PPL | TP Sensor Ground |
| C1 (Blue) | 62 & 63 | — | Not Used |
| C1 (Blue) | 64 | YEL | Vehicle Speed Sensor High |
| C1 (Blue) | 65 | PPL | Vehicle Speed Sensor Low |
| C1 (Blue) | 66 & 67 | — | Not Used |
| C1 (Blue) | 68 | YEL | Transaxle Range Switch Input B |
| C1 (Blue) | 69 | YEL | Mass Airflow Signal |
| C1 (Blue) | 70 | DK BLU | Theft Deterrent Input |
| C1 (Blue) | 71 | ORG/BLK | Required Torque |
| C1 (Blue) | 72 | DK GRN | Cruise Control Inhibit |
| C1 (Blue) | 73 | BLK/WHT | Fuel Injector No. 5 Control |
| C1 (Blue) | 74 | — | Not Used |
| C1 (Blue) | 75 | DK GRN | Engine Hot Light Control |
| C1 (Blue) | 76 | DK GRN/WHT | EVAP Canister Purge Control |
| C1 (Blue) | 77 & 78 | — | Not Used |
| C1 (Blue) | 79 | YEL/BLK | Fuel Injector No. 6 Control |
| C1 (Blue) | 80 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Valve Control |
| C2 (Red) | 3 | DK GRN/WHT | Fuel Pump Relay Control |
| C2 (Red) | 4 | RED | EGR Valve Control |
| C2 (Red) | 5 | BRN/WHT | MIL Control |
| C2 (Red) | 6 | BRN/WHT | Low Oil Level Light Control |
| C2 (Red) | 7 | LT BLU/WHT | Intake Air Control A High |
| C2 (Red) | 8 | WHT | Tachometer Output |
| C2 (Red) | 9 | TAN/BLK | Delivered Torque |
| C2 (Red) | 10 | PPL | HO2S Sensor 1 Signal High |
| C2 (Red) | 11 | PPL/WHT | HO2S Sensor 2 Signal High |
| C2 (Red) | 12-15 | — | Not Used |
| C2 (Red) | 16 | WHT | Transaxle Range P |
| C2 (Red) | 17 | — | Not Used |
| C2 (Red) | 18 | BLK/WHT | Transaxle Range D |
| C2 (Red) | 19-21 | — | Not Used |
| C2 (Red) | 22 | DK GRN/WHT | A/C Request Signal |
| C2 (Red) | 23 & 24 | — | Not Used |
| C2 (Red) | 25 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 26 | YEL | ECT Sensor Signal |
| C2 (Red) | 27 | RED/BLK | A/C Refrigerant Pressure Sensor Signal |
| C2 (Red) | 28 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 29-32 | — | Not Used |
| C2 (Red) | 33 | GRY | Reference Voltage A |
| C2 (Red) | 34 | GRY | Reference Voltage B |
| C2 (Red) | 35 | ORG | Sensor Ground |
| C2 (Red) | 36-38 | — | Not Used |
| C2 (Red) | 39 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C2 (Red) | 40 & 41 | — | Not Used |
| C2 (Red) | 42 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 43 | — | Not Used |
| C2 (Red) | 44 | LT BLU/BLK | Intake Air Control Valve A Low |
| C2 (Red) | 45-48 | — | Not Used |
| C2 (Red) | 49 | LT GRN/BLK | Intake Air Control Valve B Low |
| C2 (Red) | 50 | TAN | Intake Air Temperature Sensor Signal |
| C2 (Red) | 51-54 | — | Not Used |
| C2 (Red) | 55 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 56 | GRY | Transaxle Range C |
| C2 (Red) | 57 | — | Not Used |
| C2 (Red) | 58 | BRN | Engine Oil Level Sensor Signal |
| C2 (Red) | 59 | WHT | Cruise Status |
| C2 (Red) | 60 | — | Not Used |
| C2 (Red) | 61 | RED | Generator Control |
| C2 (Red) | 62-65 | — | Not Used |
| C2 (Red) | 66 | DK BLU | Throttle Position Sensor Signal |
| C2 (Red) | 67 | — | Not Used |
| C2 (Red) | 68 | YEL/BLK | Transaxle Fluid Temperature Sensor |
| C2 (Red) | 69 | PPL | Fuel Level Input |
| C2 (Red) | 70 & 71 | — | Not Used |
| C2 (Red) | 72 | RED/WHT | CMP Sensor Ignition Voltage |
| C2 (Red) | 73 | BLK | CMP Sensor Ground |
| C2 (Red) | 74-77 | — | Not Used |
| C2 (Red) | 78 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 79 | TAN/BLK | TCC Enable Solenoid |
| C2 (Red) | 80 | — | Not Used |
| (1) (Scheme 19) | |||
| (1) | (Scheme 19) |
POWERTRAIN CONTROL MODULE (PCM) - 3.4L (1)
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("G" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Output |
| C1 (Blue) | 10 | TAN/BLK | TCC Solenoid Control |
| C1 (Blue) | 11 & 12 | — | Not Used |
| C1 (Blue) | 13 | WHT | 3-2 Shift Solenoid Valve Control |
| C1 (Blue) | 14 | — | Not Used |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | — | Not Used |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 1 Sensor 3 High |
| C1 (Blue) | 23 & 24 | — | Not Used |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 1 Sensor 3 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 3x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Valve Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Valve Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Valve Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 & 12 | — | Not Used |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 16 | PNK/BLK | Fuel Injector No. 3 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 32 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid Valve High |
| C3 (Clear) | 7 & 8 | — | Not Used |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL | Fuel Level Sensor Signal |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Valve Low |
| C3 (Clear) | 17 | TAN/WHT | VCM Ground |
| C3 (Clear) | 18 | TAN/WHT | VCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | WHT | PRNDL P |
| C3 (Clear) | 27 | GRY | Reference Voltage |
| C3 (Clear) | 28 | GRY | PRNDL C |
| C3 (Clear) | 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Cycling Switch Signal |
| C3 (Clear) | 31 | BLK/WHT | PRNDL A |
| C3 (Clear) | 32 | YEL | PRNDL B |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output |
| C4 (Black) | 4 | DK GRN | VSS Output |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Switch Input |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21-23 | — | Not Used |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Input |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("G" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("L" & "M" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Output |
| C1 (Blue) | 10 | TAN/BLK | TCC Solenoid Control |
| C1 (Blue) | 11 & 12 | — | Not Used |
| C1 (Blue) | 13 | WHT | 3-2 Shift Solenoid Valve Control |
| C1 (Blue) | 14 | — | Not Used |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | — | Not Used |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 1 Sensor 3 High |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN/WHT | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 1 Sensor 3 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 3x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Valve Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Valve Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 & 12 | — | Not Used |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 16 | PNK/BLK | Fuel Injector No. 3 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 32 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 & 8 | — | Not Used |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Sensor Signal |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | VCM Ground |
| C3 (Clear) | 18 | BLK/WHT | VCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | WHT | PRNDL P |
| C3 (Clear) | 27 | GRY | Reference Voltage |
| C3 (Clear) | 28 | GRY | PRNDL C |
| C3 (Clear) | 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Cycling Switch Signal |
| C3 (Clear) | 31 | BLK/WHT | PRNDL A |
| C3 (Clear) | 32 | YEL | PRNDL B |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output |
| C4 (Black) | 4 | DK GRN | VSS Output |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Switch Input |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | TAN/WHT | HO2S Bank 1 Sensor 3 Low |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 | YEL | Serial Data (Class II) |
| C4 (Black) | 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | PNK | Ignition Voltage |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21-23 | — | Not Used |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Input |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("L" & "M" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("P" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4 | PNK | Ignition Voltage |
| C1 (Blue) | 5 & 6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Signal |
| C1 (Blue) | 10-14 | — | Not Used |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | — | Not Used |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 1 Sensor 3 High |
| C1 (Blue) | 23 & 24 | — | Not Used |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 1 Sensor 3 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 & 12 | — | Not Used |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 16 | PNK/BLK | Fuel Injector No. 3 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 32 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | ECT/TP Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | BLU/WHT | Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Signal |
| C3 (Clear) | 12 | GRY | TP Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL | Fuel Level Input Signal |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Signal |
| C3 (Clear) | 23 | PNK | Transmission Range A Signal |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Reference Voltage (EGR/MAP) |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 & 3 | — | Not Used |
| C4 (Black) | 4 | DK GRN | VSS Output (Speedometer) |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Signal |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21-24 | — | Not Used |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("P" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("S" & "T" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | — | Not Used |
| C1 (Blue) | 10 | TAN/BLK | TCC Solenoid Control |
| C1 (Blue) | 11 & 12 | — | Not Used |
| C1 (Blue) | 13 | WHT | 3-2 Shift Solenoid Control |
| C1 (Blue) | 14 | BRN | AIR Pump Relay Control |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | — | Not Used |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 1 Sensor 2 High |
| C1 (Blue) | 23 & 24 | — | Not Used |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 1 Sensor 2 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 3x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 & 12 | — | Not Used |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 16 | PNK/BLK | Fuel Injector No. 3 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | WHT | Tachometer Output |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 32 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | Sensor Ground |
| C3 (Clear) | 5 | BRN | Generator Terminal L Control/Monitoring |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 & 8 | — | Not Used |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL | Fuel Level Sensor Signal |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | VCM Ground |
| C3 (Clear) | 18 | BLK/WHT | VCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | WHT | PRNDL P |
| C3 (Clear) | 27 | GRY | Reference Voltage |
| C3 (Clear) | 28 | GRY | PRNDL C |
| C3 (Clear) | 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Cycling Switch Signal |
| C3 (Clear) | 31 | BLK/WHT | PRNDL A |
| C3 (Clear) | 32 | YEL | PRNDL B |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output |
| C4 (Black) | 4 | DK GRN | VSS Output |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Switch Input |
| C4 (Black) | 11 | DK GRN | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 | YEL | Serial Data (Class II) |
| C4 (Black) | 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | PNK | Ignition Voltage |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | BLK/WHT | 4WD Front Wheel Lock Input |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21 | — | Not Used |
| C4 (Black) | 22 | GRY | CPP Switch Signal |
| C4 (Black) | 23 | GRY/BLK | 4WD Indicator Signal Input |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Input |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 4.3L ("S" & "T" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 4.8L, 5.3L & 6.0L
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 | BLK | PCM Ground |
| C1 (Blue) | 2 | LT GRN | CKP Sensor Voltage Supply |
| C1 (Blue) | 3 | PNK/BLK | Fuel Injector No. 3 Control |
| C1 (Blue) | 4 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C1 (Blue) | 5-10 | — | Not Used |
| C1 (Blue) | 11 | LT BLU | KS Signal Rear |
| C1 (Blue) | 12 | DK BLU/WHT | CKP Sensor Signal |
| C1 (Blue) | 13-16 | — | Not Used |
| C1 (Blue) | 17 | DK BLU | Transmission Range Signal B |
| C1 (Blue) | 18 | RED | Transmission Range Signal C |
| C1 (Blue) | 19 | PNK | PCM Ignition Supply |
| C1 (Blue) | 20 | ORG | PCM Battery Supply |
| C1 (Blue) | 21 | YEL/BLK | CKP Sensor Ground |
| C1 (Blue) | 22 | — | Not Used |
| C1 (Blue) | 23 | PPL | Sensor Ground |
| C1 (Blue) | 24 | — | Not Used |
| C1 (Blue) | 25 | TAN | HO2S Bank 2 Sensor 2 Signal Low |
| C1 (Blue) | 26 | TAN | HO2S Bank 2 Sensor 1 Signal Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | TAN/WHT | HO2S Bank 1 Sensor 2 Signal Low |
| C1 (Blue) | 29 | TAN/WHT | HO2S Bank 1 Sensor 1 Signal Low |
| C1 (Blue) | 30 | LT GRN | Engine Coolant Level Switch |
| C1 (Blue) | 31 | — | Not Used |
| C1 (Blue) | 32 | BLK/WHT | PRND A |
| C1 (Blue) | 33 | PPL | TCC Brake Switch |
| C1 (Blue) | 34 | WHT | PRND P |
| C1 (Blue) | 35 | GRY | Clutch Switch Signal |
| C1 (Blue) | 36 | BLK | Fuel Injector No. 1 Control |
| C1 (Blue) | 37 | YEL/BLK | Fuel Injector No. 6 Control |
| C1 (Blue) | 38 & 39 | — | Not Used |
| C1 (Blue) | 40 | BLK/WHT | PCM Ground |
| C1 (Blue) | 41 | BLK | Sensor Ground |
| C1 (Blue) | 42 | — | Not Used |
| C1 (Blue) | 43 | RED/BLK | Fuel Injector No. 7 Control |
| C1 (Blue) | 44 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C1 (Blue) | 45 | GRY | Fuel Tank Pressure Sensor Reference Voltage |
| C1 (Blue) | 46 | GRY | TP Sensor Reference Voltage |
| C1 (Blue) | 47 | GRY | MAP Sensor Reference Voltage |
| C1 (Blue) | 48 | GRY | EGR Pintle Position Sensor Reference Voltage |
| C1 (Blue) | 49 & 50 | — | Not Used |
| C1 (Blue) | 51 | DK BLU | KS Signal Front |
| C1 (Blue) | 52 | — | Not Used |
| C1 (Blue) | 53 | BLK | Fuel Tank Pressure Sensor Ground |
| C1 (Blue) | 54 | BLK | TP Sensor Ground |
| C1 (Blue) | 55 | BRN | EGR Pintle Position Sensor Signal |
| C1 (Blue) | 56 | — | Not Used |
| C1 (Blue) | 57 | ORG | PCM Battery Supply |
| C1 (Blue) | 58 | DK GRN | Serial Data |
| C1 (Blue) | 59 | YEL | Serial Data |
| C1 (Blue) | 60 | ORG/BLK | MAP Sensor Ground |
| C1 (Blue) | 61 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 62 | — | Not Used |
| C1 (Blue) | 63 | GRY | ECT Sensor Ground |
| C1 (Blue) | 64 | — | Not Used |
| C1 (Blue) | 65 | PPL | HO2S Bank 2 Sensor 2 Signal High |
| C1 (Blue) | 66 | PPL | HO2S Bank 2 Sensor 1 Signal High |
| C1 (Blue) | 67 | — | Not Used |
| C1 (Blue) | 68 | PPL/WHT | HO2S Bank 1 Sensor 2 Signal High |
| C1 (Blue) | 69 | PPL/WHT | HO2S Bank 1 Sensor 1 Signal High |
| C1 (Blue) | 70 | BRN | Low Oil Level Switch |
| C1 (Blue) | 71 | — | Not Used |
| C1 (Blue) | 72 | YEL | PRND B |
| C1 (Blue) | 73 | BRN/WHT | CMP Sensor Signal |
| C1 (Blue) | 74 | YEL | ECT Sensor Signal |
| C1 (Blue) | 75 | PNK | PCM Ignition Supply |
| C1 (Blue) | 76 | BLK/WHT | Fuel Injector No. 5 Control |
| C1 (Blue) | 77 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C1 (Blue) | 78 | — | Not Used |
| C1 (Blue) | 79 | WHT | 3-2 Shift Solenoid Control |
| C1 (Blue) | 80 | ORG/BLK | Fuel Level Sensor Ground |
| C2 (Red) | 1 | BLK/WHT | PCM Ground |
| C2 (Red) | 2 | BRN | TCC Control Solenoid |
| C2 (Red) | 3-5 | — | Not Used |
| C2 (Red) | 6 | RED/BLK | Trans Fluid Pressure Control Solenoid High |
| C2 (Red) | 7 | RED | EGR Solenoid Supply |
| C2 (Red) | 8 | LT BLU/WHT | Trans Fluid Pressure Control Solenoid Low |
| C2 (Red) | 9 | DK GRN/WHT | Fuel Pump Relay Control |
| C2 (Red) | 10 | WHT | Engine Speed (Tach) Output Signal |
| C2 (Red) | 11 | DK BLU | Secondary A/C High Pressure Switch |
| C2 (Red) | 12 | — | Not Used |
| C2 (Red) | 13 | LT BLU/BLK | Cruise Control Engage Signal |
| C2 (Red) | 14 | — | Not Used |
| C2 (Red) | 15 | BRN | Generator L Terminal |
| C2 (Red) | 16 | GRY/BLK | 4WD Switch Signal Low |
| C2 (Red) | 17 | DK GRN/WHT | A/C Request Signal |
| C2 (Red) | 18 | — | Not Used |
| C2 (Red) | 19 | BLK/WHT | 4WD Front Axle Switch |
| C2 (Red) | 20 | LT GRN/BLK | VSS Reference Low |
| C2 (Red) | 21 | PPL/WHT | VSS Signal |
| C2 (Red) | 22 | RED/BLK | VSS Signal (6.0L) |
| C2 (Red) | 23 | DK BLU/WHT | VSS Reference Low (6.0L) |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | TAN | IAT Sensor Signal |
| C2 (Red) | 26 | PPL | Ignition Control No. 1 |
| C2 (Red) | 27 | RED | Ignition Control No. 7 |
| C2 (Red) | 28 | LT BLU/WHT | Ignition Control No. 6 |
| C2 (Red) | 29 | DK GRN/WHT | Ignition Control No. 4 |
| C2 (Red) | 30 | — | Not Used |
| C2 (Red) | 31 | YEL | MAF Sensor Signal |
| C2 (Red) | 32 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 33 | DK GRN | HVAC Recirculation Door Control |
| C2 (Red) | 34 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C2 (Red) | 35 | — | Not Used |
| C2 (Red) | 36 | BRN | AIR Pump Relay Control |
| C2 (Red) | 37 & 38 | — | Not Used |
| C2 (Red) | 39 | RED | CMP Sensor Voltage Supply |
| C2 (Red) | 40 | BLK/WHT | PCM Ground |
| C2 (Red) | 41 | WHT | EGR Solenoid Ground |
| C2 (Red) | 42 | TAN/BLK | TCC Enable Circuit |
| C2 (Red) | 43 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C2 (Red) | 44 | — | Not Used |
| C2 (Red) | 45 | WHT | EVAP Canister Vent Valve Control |
| C2 (Red) | 46 | BRN/WHT | MIL Control |
| C2 (Red) | 47 | YEL/BLK | Transmission Shift Solenoid B |
| C2 (Red) | 48 | LT GRN | Transmission Shift Solenoid A |
| C2 (Red) | 49 | YEL/BLK | Vehicle Speed Output Circuit 128K |
| C2 (Red) | 50 | DK GRN/WHT | Vehicle Speed Output Circuit 4K |
| C2 (Red) | 51 | YEL/BLK | Transmission Temperature Sensor Signal |
| C2 (Red) | 52 & 53 | — | Not Used |
| C2 (Red) | 54 | PPL | Fuel Level Sensor Signal |
| C2 (Red) | 55 | DK GRN | A/C Compressor Cycling Switch Signal |
| C2 (Red) | 56 | — | Not Used |
| C2 (Red) | 57 | BLK | IAT Sensor Ground |
| C2 (Red) | 58 & 59 | — | Not Used |
| C2 (Red) | 60 | BRN | IC Reference Low Bank 1 |
| C2 (Red) | 61 | BRN/WHT | IC Reference Low Bank 2 |
| C2 (Red) | 62 | GRY | PRND C |
| C2 (Red) | 63 | PNK | Transmission Range Signal A |
| C2 (Red) | 64 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 65 | — | Not Used |
| C2 (Red) | 66 | PPL/WHT | Ignition Control No. 8 |
| C2 (Red) | 67 | RED/WHT | Ignition Control No. 2 |
| C2 (Red) | 68 | DK GRN | Ignition Control No. 5 |
| C2 (Red) | 69 | LT BLU | Ignition Control No. 3 |
| C2 (Red) | 70-75 | — | Not Used |
| C2 (Red) | 76 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 77 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 78 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 79 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 80 | — | Not Used |
| (1) (Scheme 19) | |||
| (1) | (Scheme 19) |
POWERTRAIN CONTROL MODULE (PCM) - 4.8L, 5.3L & 6.0L (1)
POWERTRAIN CONTROL MODULE (PCM) - 5.0L & 5.7L ("C" & "K" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Output |
| C1 (Blue) | 10 | TAN/BLK | TCC Solenoid Control |
| C1 (Blue) | 11 & 12 | — | Not Used |
| C1 (Blue) | 13 | WHT | 3-2 Shift Solenoid Control |
| C1 (Blue) | 14 | BRN | AIR Pump Relay Control |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL | HO2S Bank 2 Sensor 2 High (Under 8600 GVW); HO2S Bank 1 Sensor 2 High (Over 8600 GVW) |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 2 Sensor 2 High (Over 8600 GVW); HO2S Bank 1 Sensor 2 High (Under 8600 GVW) |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN | HO2S Bank 2 Sensor 2 Low (Under 8600 GVW); HO2S Bank 1 Sensor 2 Low (Over 8600 GVW) |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 2 Sensor 2 Low (Over 8600 GVW); HO2S Bank 1 Sensor 2 Low (Under 8600 GVW) |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Input |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Transmission Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Transmission Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Sensor Signal |
| C3 (Clear) | 14 | DK BLU | A/C Recirculation Signal |
| C3 (Clear) | 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output |
| C4 (Black) | 4 | DK GRN | VSS Output |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6 | — | Not Used |
| C4 (Black) | 7 | DK GRN | Recirculation Door Motor Control |
| C4 (Black) | 8 | — | Not Used |
| C4 (Black) | 9 | DK BLU | Auxiliary Fan |
| C4 (Black) | 10 | PPL | Brake Switch Input |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | BLK | Dual Fuel Module Return |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 | — | Not Used |
| C4 (Black) | 15 | TAN/BLK | Shift Light (M/T) |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | BLK/WHT | 4WD Wheel Lock Input |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21 | — | Not Used |
| C4 (Black) | 22 | BRN/WHT | Clutch Pedal Position Switch Signal (M/T) |
| C4 (Black) | 23 | GRY/BLK | 4WD Indicator Signal Input |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Input |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 5.0L & 5.7L ("C" & "K" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 5.0L & 5.7L ("G" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Output |
| C1 (Blue) | 10 | TAN/BLK | TCC Solenoid Control |
| C1 (Blue) | 11 & 12 | — | Not Used |
| C1 (Blue) | 13 | WHT | 3-2 Shift Solenoid Control |
| C1 (Blue) | 14 | — | Not Used |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL | HO2S Bank 1 Sensor 3 High (5.0L); HO2S Bank 1 Sensor 2 High (5.7L) |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 2 Sensor 2 High (5.7L) |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN | HO2S Bank 1 Sensor 3 Low (5.0L); HO2S Bank 1 Sensor 2 Low (5.7L) |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 2 Sensor 2 Low (5.7L) |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Input |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Pressure Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Transmission Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Transmission Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Sensor Signal |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Sensor Reference Voltage |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output |
| C4 (Black) | 4 | DK GRN | VSS Output |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Switch Input |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Control |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Ground |
| C4 (Black) | 21-23 | — | Not Used |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Input |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 5.0L & 5.7L ("G" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 5.7L ("P" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4 | PNK | Ignition Voltage |
| C1 (Blue) | 5 & 6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Sensor Ground |
| C1 (Blue) | 9 | PPL | Fuel Level Signal Output |
| C1 (Blue) | 10-13 | — | Not Used |
| C1 (Blue) | 14 | BRN | AIR Relay Control (Calif. Only) |
| C1 (Blue) | 15 | YEL/BLK | VSS Output |
| C1 (Blue) | 16-18 | — | Not Used |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL | HO2S Bank 1 Sensor 2 High |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 2 Sensor 2 High |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN | HO2S Bank 1 Sensor 2 Low |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 2 Sensor 2 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Sensor Ground |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS High |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 6 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Vacuum Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC Coil B Low |
| C2 (Red) | 30 | LT BLU/BLK | IAC Coil A Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | ECT/TP Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/WHT | Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | TP Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL | Fuel Level Module (Single Tank) |
| C3 (Clear) | 14 & 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | VCM Ground |
| C3 (Clear) | 18 | BLK/WHT | VCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground (EGR/IAT/MAP) |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Reference Voltage (EGR/MAP) |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Compressor Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 & 3 | — | Not Used |
| C4 (Black) | 4 | DK GRN | VSS Output Signal (Speedometer) |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Signal |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Feed |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Control |
| C4 (Black) | 21-24 | — | Not Used |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 5.7L ("P" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("C" & "K" SERIES)
| Connector | Terminal | Wire Color | Function |
|---|---|---|---|
| C1 (Brown) | C1 | — | Not Used |
| C1 (Brown) | C2 | DK GRN/WHT | A/C Request Signal |
| C1 (Brown) | C3 | YEL | Mass Airflow Signal |
| C1 (Brown) | C4 | TAN | Intake Air Temperature Signal |
| C1 (Brown) | C5 | LT BLU | Accelerator Pedal Position 2 Signal |
| C1 (Brown) | C6 | YEL | Glow Plug Relay Control |
| C1 (Brown) | C7 | RED/BLK | Pressure Control Solenoid Valve High |
| C1 (Brown) | C8 | YEL | Fuel Temperature Signal |
| C1 (Brown) | C9 | YEL/BLK | Transmission Fluid Temperature Sensor |
| C1 (Brown) | C10 | — | Not Used |
| C1 (Brown) | C11 | YEL | Engine Coolant Temperature Signal |
| C1 (Brown) | C12 | GRY/BLK | EGR Control Pressure/BARO Signal |
| C1 (Brown) | C13 | RED | Closure Signal |
| C1 (Brown) | C14 | LT GRN | Boost Sensor Signal |
| C1 (Brown) | C15 | LT BLU/WHT | Pressure Control Solenoid Valve Low |
| C1 (Brown) | C16 | — | Not Used |
| C1 (Brown) | D1 | BLU/WHT | Transmission Input Speed Signal Low |
| C1 (Brown) | D2 | GRY/BLK | 4WD Front Wheel Lock Signal |
| C1 (Brown) | D3 | YEL/BLK | Accelerator Pedal Position 3 Reference Voltage |
| C1 (Brown) | D4 | DK GRN | Accelerator Pedal Position 3 Signal |
| C1 (Brown) | D5 | GRY | Fuel Lift Pump Signal |
| C1 (Brown) | D6 | GRY | Accelerator Pedal Position 3 Ground |
| C1 (Brown) | D7 | BRN | Glow Plug Signal |
| C1 (Brown) | D8 | DK GRN/WHT | Fuel Lift Pump Control |
| C1 (Brown) | D9 | PNK/BLK | Sensor Ground (Pump CAM, High Res. & Fuel Temp.) |
| C1 (Brown) | D10 | GRY/BLK | Cruise Resume/Accel Signal |
| C1 (Brown) | D11 | RED/BLK | Transmission Input Speed Signal High |
| C1 (Brown) | D12 | WHT/BLK | Accelerator Pedal Position 1 Reference Voltage |
| C1 (Brown) | D13 | GRY | Sensor Reference Voltage (Boost, CKP & EGR) |
| C1 (Brown) | D14 | GRY | Sensor Reference Voltage (Pump CAM & High Res.) |
| C1 (Brown) | D15 & D16 | — | Not Used |
| C2 (Brown) | A1 | BLK | Closure Ground |
| C2 (Brown) | A2 | ORG | High Res. Signal |
| C2 (Brown) | A3 | BRN | Transmission Input Speed Signal |
| C2 (Brown) | A4 | BRN/WHT | Pump CAM Sensor Signal |
| C2 (Brown) | A5 | YEL | CKP Sensor Signal |
| C2 (Brown) | A6 | DK GRN | Vehicle Speed Sensor Signal |
| C2 (Brown) | A7 | RED/BLK | Injection Timing Stepper Motor High Coil 1 |
| C2 (Brown) | A8 | TAN/BLK | Injection Timing Stepper Motor Low Coil 1 |
| C2 (Brown) | A9 | ORG/BLK | Injection Timing Stepper Motor Low Coil 2 |
| C2 (Brown) | A10 | YEL/BLK | Injection Timing Stepper Motor High Coil 2 |
| C2 (Brown) | A11 | GRY | Cruise Control On/Off Signal |
| C2 (Brown) | A12 | PPL | Accelerator Pedal Position 2 Ground |
| C2 (Brown) | B1 | BRN | Accelerator Pedal Position 1 Ground |
| C2 (Brown) | B2 | DK BLU | Accelerator Pedal Position 1 Signal |
| C2 (Brown) | B3 | BLK/WHT | 4WD Low Indicator Signal |
| C2 (Brown) | B4 | RED | Transmission Range Switch C Input |
| C2 (Brown) | B5 | DK BLU | Transmission Range Switch B Input |
| C2 (Brown) | B6 | PNK | Transmission Range Switch A Input |
| C2 (Brown) | B7 & B8 | — | Not Used |
| C2 (Brown) | B9 | PPL (A/T) | Cruise Control Brake Switch Signal (A/T) |
| C2 (Brown) | B9 | BRN/WHT (M/T) | Brake/Clutch Pedal Position Switch Signal (M/T) |
| C2 (Brown) | B10 | WHT | Brake Switch Signal |
| C2 (Brown) | B11 | DK BLU | Cruise Set/Coast Signal |
| C2 (Brown) | B12 | BLK | Sensor Ground (Boost, EGR, ECT, IAT, Fuel Temp., TFT & CKP) |
| C3 (Blue) | C1 | — | Not Used |
| C3 (Blue) | C2 | TAN | Accelerator Pedal Position 2 Reference Voltage |
| C3 (Blue) | C3 | LT GRN | Fuel Injection Control |
| C3 (Blue) | C4 | LT GRN | 1-2 Shift Solenoid Signal |
| C3 (Blue) | C5 | BRN | TCC PWM Solenoid Signal |
| C3 (Blue) | C6 | YEL/BLK | 2-3 Shift Solenoid Signal |
| C3 (Blue) | C7 | DK BLU | Wait To Start Light Control |
| C3 (Blue) | C8 | PPL | Class II Communication |
| C3 (Blue) | C9 & C10 | — | Not Used |
| C3 (Blue) | C11 | PNK | Ignition Voltage |
| C3 (Blue) | C12 | PNK | Ignition Voltage |
| C3 (Blue) | C13 | ORG | Battery Voltage |
| C3 (Blue) | C14 | BRN/WHT | MIL Control |
| C3 (Blue) | C15 | DK BLU/WHT | Engine Shutoff Control |
| C3 (Blue) | C16 | GRY | EGR Solenoid Control |
| C3 (Blue) | D1 & D2 | — | Not Used |
| C3 (Blue) | D3 | LT GRN/BLK | Fuel Injection Control |
| C3 (Blue) | D4 | — | Not Used |
| C3 (Blue) | D5 | DK GRN/WHT | A/C Enable Signal |
| C3 (Blue) | D6 | BLK/WHT | PCM Ground |
| C3 (Blue) | D7 | TAN/WHT | PCM Ground |
| C3 (Blue) | D8-D10 | — | Not Used |
| C3 (Blue) | D11 | WHT/BLK | Service Throttle Soon Light Control |
| C3 (Blue) | D12 | WHT | EGR Vent Control |
| C3 (Blue) | D13 | ORG | Battery Voltage |
| C3 (Blue) | D14 | YEL | Wastegate Solenoid Control |
| C3 (Blue) | D15 | DK BLU/WHT | Engine Shutoff Solenoid Control |
| C3 (Blue) | D16 | — | Not Used |
| (1) (Scheme 21) | |||
| (1) | (Scheme 21) |
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("C" & "K" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("G" SERIES)
| Connector | Terminal | Wire Color | Function |
|---|---|---|---|
| C1 (Brown) | C1 | — | Not Used |
| C1 (Brown) | C2 | DK GRN/WHT | A/C Request Signal |
| C1 (Brown) | C3 | YEL | Mass Airflow Signal |
| C1 (Brown) | C4 | TAN | Intake Air Temperature Signal |
| C1 (Brown) | C5 | LT BLU | Accelerator Pedal Position 2 Signal |
| C1 (Brown) | C6 | YEL | Glow Plug Relay Control |
| C1 (Brown) | C7 | RED/BLK | Pressure Control Solenoid Valve High |
| C1 (Brown) | C8 | YEL | Fuel Temperature Signal |
| C1 (Brown) | C9 | YEL/BLK | Transmission Fluid Temperature Sensor |
| C1 (Brown) | C10 | — | Not Used |
| C1 (Brown) | C11 | YEL | Engine Coolant Temperature Signal |
| C1 (Brown) | C12 | GRY/BLK | EGR Control Pressure/BARO Signal |
| C1 (Brown) | C13 | RED | Closure Signal |
| C1 (Brown) | C14 | LT GRN | Boost Sensor Signal |
| C1 (Brown) | C15 | LT BLU/WHT | Pressure Control Solenoid Valve Low |
| C1 (Brown) | C16 | — | Not Used |
| C1 (Brown) | D1 | BLU/WHT | Transmission Input Speed Signal Low |
| C1 (Brown) | D2 | GRY/BLK | 4WD Low Indicator Signal |
| C1 (Brown) | D3 | YEL/BLK | Accelerator Pedal Position 3 Reference Voltage |
| C1 (Brown) | D4 | DK GRN | Accelerator Pedal Position 3 Signal |
| C1 (Brown) | D5 | GRY | Fuel Lift Pump Signal |
| C1 (Brown) | D6 | GRY | Accelerator Pedal Position 3 Ground |
| C1 (Brown) | D7 | LT BLU | Glow Plug Signal |
| C1 (Brown) | D8 | DK GRN/WHT | Fuel Lift Pump Control |
| C1 (Brown) | D9 | PNK/BLK | Sensor Ground (Pump CAM, High Res. & Fuel Temp.) |
| C1 (Brown) | D10 | GRY/BLK | Cruise Resume/Accel Signal |
| C1 (Brown) | D11 | RED/BLK | Transmission Input Speed Signal High |
| C1 (Brown) | D12 | WHT/BLK | Accelerator Pedal Position 1 Reference Voltage |
| C1 (Brown) | D13 | GRY | Sensor Reference Voltage (Boost & CKP) |
| C1 (Brown) | D14 | GRY | Sensor Reference Voltage (Pump CAM & High Res.) |
| C1 (Brown) | D15 & D16 | — | Not Used |
| C2 (Brown) | A1 | BLK | Closure Ground |
| C2 (Brown) | A2 | ORG | High Res. Signal |
| C2 (Brown) | A3 | BRN | Transmission Output Speed Signal |
| C2 (Brown) | A4 | BRN/WHT | Pump CAM Sensor Signal |
| C2 (Brown) | A5 | YEL | CKP Sensor Signal |
| C2 (Brown) | A6 | DK GRN | Vehicle Speed Sensor Signal |
| C2 (Brown) | A7 | RED/BLK | Injection Timing Stepper Motor High |
| C2 (Brown) | A8 | TAN/BLK | Injection Timing Stepper Motor Low |
| C2 (Brown) | A9 | ORG/BLK | Injection Timing Stepper Motor Low |
| C2 (Brown) | A10 | YEL/BLK | Injection Timing Stepper Motor High |
| C2 (Brown) | A11 | GRY | Cruise Control On/Off Signal |
| C2 (Brown) | A12 | PPL | Accelerator Pedal Position 2 Ground |
| C2 (Brown) | B1 | BRN | Accelerator Pedal Position 1 Ground |
| C2 (Brown) | B2 | DK BLU | Accelerator Pedal Position 1 Signal |
| C2 (Brown) | B3 | BLK/WHT | Front Axle Switch Signal |
| C2 (Brown) | B4 | RED | Transmission Range Switch C Input |
| C2 (Brown) | B5 | DK BLU | Transmission Range Switch B Input |
| C2 (Brown) | B6 | PNK | Transmission Range Switch A Input |
| C2 (Brown) | B7 & B8 | — | Not Used |
| C2 (Brown) | B9 | PPL | Brake Switch Signal |
| C2 (Brown) | B10 | WHT | Brake Switch Signal |
| C2 (Brown) | B11 | DK BLU | Cruise Set/Coast Signal |
| C2 (Brown) | B12 | BLK | Sensor Ground (Boost, ECT, IAT & TFT) |
| C3 (Blue) | C1 | — | Not Used |
| C3 (Blue) | C2 | TAN | Accelerator Pedal Position 2 Signal |
| C3 (Blue) | C3 | LT GRN | Fuel Injection Control |
| C3 (Blue) | C4 | LT GRN | 1-2 Shift Solenoid Signal |
| C3 (Blue) | C5 | BRN | TCC PWM Solenoid Signal |
| C3 (Blue) | C6 | YEL/BLK | 1-2 Shift Solenoid Signal |
| C3 (Blue) | C7 | DK BLU | Wait To Start Light Control |
| C3 (Blue) | C8 | PPL | Class 2 Communication |
| C3 (Blue) | C9 & C10 | — | Not Used |
| C3 (Blue) | C11 | PNK | Ignition Voltage |
| C3 (Blue) | C12 | PNK | Ignition Voltage |
| C3 (Blue) | C13 | ORG | Battery Voltage |
| C3 (Blue) | C14 | BRN/WHT | MIL Control |
| C3 (Blue) | C15 | DK BLU/WHT | Engine Shutoff Control |
| C3 (Blue) | C16 | — | Not Used |
| C3 (Blue) | D1 & D2 | — | Not Used |
| C3 (Blue) | D3 | LT GRN | Fuel Injection Control |
| C3 (Blue) | D4 | — | Not Used |
| C3 (Blue) | D5 | DK GRN/WHT | A/C Enable Signal |
| C3 (Blue) | D6 | BLK/WHT | PCM Ground |
| C3 (Blue) | D7 | TAN/WHT | PCM Ground |
| C3 (Blue) | D8-D10 | — | Not Used |
| C3 (Blue) | D11 | WHT/BLK | Service Throttle Soon Light Control |
| C3 (Blue) | D12 | — | Not Used |
| C3 (Blue) | D13 | ORG | Battery Voltage |
| C3 (Blue) | D14 | YEL | Wastegate Solenoid Control |
| C3 (Blue) | D15 | DK BLU/WHT | Engine Shutoff Solenoid Control |
| C3 (Blue) | D16 | — | Not Used |
| (1) (Scheme 21) | |||
| (1) | (Scheme 21) |
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("G" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("P" SERIES)
| Connector | Terminal | Wire Color | Function |
|---|---|---|---|
| C1 (Brown) | C1 | PPL | Crankshaft Position Sensor Ground |
| C1 (Brown) | C2 | DK GRN/WHT | A/C Request Signal |
| C1 (Brown) | C3 | — | Not Used |
| C1 (Brown) | C4 | TAN | Intake Air Temperature Signal |
| C1 (Brown) | C5 | LT BLU | Accelerator Pedal Position 2 Signal |
| C1 (Brown) | C6 | YEL | Glow Plug Relay Control |
| C1 (Brown) | C7 | RED/BLK | Pressure Control Solenoid Valve High |
| C1 (Brown) | C8 | YEL | Fuel Temperature Signal |
| C1 (Brown) | C9 | YEL/BLK | Transmission Fluid Temperature Sensor Signal |
| C1 (Brown) | C10 | — | Not Used |
| C1 (Brown) | C11 | YEL | Engine Coolant Temperature Signal |
| C1 (Brown) | C12 | — | Not Used |
| C1 (Brown) | C13 | RED | Closure Signal |
| C1 (Brown) | C14 | LT GRN | Boost Sensor Signal |
| C1 (Brown) | C15 | LT BLU/WHT | Pressure Control Solenoid Valve Low |
| C1 (Brown) | C16 | — | Not Used |
| C1 (Brown) | D1 | BLU/WHT | Transmission Input Speed Signal Low |
| C1 (Brown) | D2 | — | Not Used |
| C1 (Brown) | D3 | YEL/BLK | Accelerator Pedal Position 3 Reference Voltage |
| C1 (Brown) | D4 | DK GRN | Accelerator Pedal Position 3 Signal |
| C1 (Brown) | D5 | GRY | Fuel Lift Pump Signal |
| C1 (Brown) | D6 | GRY | Accelerator Pedal Position 3 Ground |
| C1 (Brown) | D7 | BRN | Glow Plug Signal |
| C1 (Brown) | D8 | DK GRN/WHT | Fuel Pump Relay Control |
| C1 (Brown) | D9 | PNK/BLK | Sensor Ground (Pump CAM, High Res. & Fuel Temp.) |
| C1 (Brown) | D10 | GRY/BLK | Cruise Control Resume/Accel Signal |
| C1 (Brown) | D11 | RED/BLK | Transmission Input Speed Signal High |
| C1 (Brown) | D12 | WHT/BLK | Accelerator Pedal Position 1 Reference Voltage |
| C1 (Brown) | D13 | GRY | Sensor Reference Voltage (Boost & CKP) |
| C1 (Brown) | D14 | GRY | Sensor Reference Voltage (Pump CAM & High Res.) |
| C1 (Brown) | D15 & D16 | — | Not Used |
| C2 (Brown) | A1 | BLK | Closure Ground |
| C2 (Brown) | A2 | ORG | High Res. Signal |
| C2 (Brown) | A3 | BRN | Transmission Output Speed Signal |
| C2 (Brown) | A4 | BRN/WHT | Pump CAM Sensor Signal |
| C2 (Brown) | A5 | YEL | CKP Sensor Signal |
| C2 (Brown) | A6 | DK GRN/WHT | Vehicle Speed Sensor Signal |
| C2 (Brown) | A7 | RED/BLK | Injection Timing Stepper Motor High Coil 1 |
| C2 (Brown) | A8 | TAN/BLK | Injection Timing Stepper Motor Low Coil 1 |
| C2 (Brown) | A9 | ORG/BLK | Injection Timing Stepper Motor Low Coil 2 |
| C2 (Brown) | A10 | YEL/BLK | Injection Timing Stepper Motor High Coil 2 |
| C2 (Brown) | A11 | GRY | Cruise Control On/Off Signal |
| C2 (Brown) | A12 | PPL | Accelerator Pedal Position 2 Ground |
| C2 (Brown) | B1 | BRN | Accelerator Pedal Position 1 Ground |
| C2 (Brown) | B2 | DK BLU | Accelerator Pedal Position 1 Signal |
| C2 (Brown) | B3 | — | Not Used |
| C2 (Brown) | B4 | RED | Transmission Range Switch C Input |
| C2 (Brown) | B5 | DK BLU | Transmission Range Switch B Input |
| C2 (Brown) | B6 | PNK | Transmission Range Switch A Input |
| C2 (Brown) | B7 & B8 | — | Not Used |
| C2 (Brown) | B9 | PPL | TCC/ABS Brake Switch Signal |
| C2 (Brown) | B10 | LT BLU | Brakelight Switch Signal |
| C2 (Brown) | B11 | DK BLU | Cruise Set/Coast Signal |
| C2 (Brown) | B12 | BLK | Sensor Ground (Boost, ECT, IAT & TFT) |
| C3 (Blue) | C1 | — | Not Used |
| C3 (Blue) | C2 | TAN | Accelerator Pedal Position 2 Reference Voltage |
| C3 (Blue) | C3 | LT GRN | Fuel Injection Control |
| C3 (Blue) | C4 | LT GRN | 1-2 Shift Solenoid Signal |
| C3 (Blue) | C5 | BRN | TCC PWM Solenoid |
| C3 (Blue) | C6 | YEL/BLK | 2-3 Shift Solenoid Signal |
| C3 (Blue) | C7 | DK BLU | Wait To Start Light Control |
| C3 (Blue) | C8 | PPL | Class II Communication |
| C3 (Blue) | C9 & C10 | — | Not Used |
| C3 (Blue) | C11 | PNK | Ignition Voltage |
| C3 (Blue) | C12 | PNK | Ignition Voltage |
| C3 (Blue) | C13 | ORG | Battery Voltage |
| C3 (Blue) | C14 | BRN/WHT | MIL Control |
| C3 (Blue) | C15 | DK BLU/WHT | Engine Shutoff Control |
| C3 (Blue) | C16 | — | Not Used |
| C3 (Blue) | D1-D4 | — | Not Used |
| C3 (Blue) | D5 | DK GRN/WHT | A/C Enable Signal |
| C3 (Blue) | D6 | BLK/WHT | PCM Ground |
| C3 (Blue) | D7 | BLK/WHT | PCM Ground |
| C3 (Blue) | D8-D10 | — | Not Used |
| C3 (Blue) | D11 | WHT/BLK | Service Throttle Soon Light Control |
| C3 (Blue) | D12 | — | Not Used |
| C3 (Blue) | D13 | ORG | Battery Voltage |
| C3 (Blue) | D14 | YEL | Wastegate Solenoid Control |
| C3 (Blue) | D15 & D16 | — | Not Used |
| (1) (Scheme 21) | |||
| (1) | (Scheme 21) |
POWERTRAIN CONTROL MODULE (PCM) - 6.5L ("P" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("C" & "K" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Low |
| C1 (Blue) | 9 | PPL | Fuel Gauge |
| C1 (Blue) | 10-13 | — | Not Used |
| C1 (Blue) | 14 | BRN | AIR Relay Control (Calif. Only) |
| C1 (Blue) | 15 | YEL/BLK | VSS Signal |
| C1 (Blue) | 16 & 17 | — | Not Used |
| C1 (Blue) | 18 | PPL/WHT | Dual Tank Fuel Module |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL | HO2S Bank 1 Sensor 2 High |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 2 Sensor 2 High |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN | HO2S Bank 1 Sensor 2 Low |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 2 Sensor 2 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Low |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS Signal |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Vacuum Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC High |
| C2 (Red) | 30 | LT BLU/BLK | IAC Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | ECT/TP Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | TP Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Signal |
| C3 (Clear) | 14 | DK BLU | A/C Recirculation |
| C3 (Clear) | 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground (IAT/MAP/EGR) |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Reference Voltage (EGR/MAP) |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Compressor Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output Signal (TCC/Radio/Cruise Control) |
| C4 (Black) | 4 | DK GRN | VSS Output Signal (Speedometer) |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-9 | — | Not Used |
| C4 (Black) | 10 | PPL | Brake Signal |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | BLK | Dual Fuel Module Return |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Feed |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Control |
| C4 (Black) | 21 & 23 | — | Not Used |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Signal |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("C" & "K" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("G" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Low |
| C1 (Blue) | 9 | PPL | Fuel Gauge |
| C1 (Blue) | 10-13 | — | Not Used |
| C1 (Blue) | 14 | BRN | AIR Relay Control (Calif. Only) |
| C1 (Blue) | 15 | YEL/BLK | VSS Signal |
| C1 (Blue) | 16 & 17 | — | Not Used |
| C1 (Blue) | 18 | PPL/WHT | Dual Tank Fuel Module |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL/WHT | HO2S Bank 2 Sensor 2 High |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 1 Sensor 2 High |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN/WHT | HO2S Bank 2 Sensor 2 Low |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN | HO2S Bank 1 Sensor 2 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Low |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS Signal |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1 | — | Not Used |
| C2 (Red) | 2 | WHT | EVAP Canister Vent Solenoid Control |
| C2 (Red) | 3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 | DK GRN | Fuel Tank Vacuum Sensor Signal |
| C2 (Red) | 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC High |
| C2 (Red) | 30 | LT BLU/BLK | IAC Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | ECT/TP Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | TP Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Module (Single Tank) |
| C3 (Clear) | 14 | DK BLU | A/C Recirculation |
| C3 (Clear) | 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground (IAT/MAP/EGR) |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | Reference Voltage (EGR/MAP) |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Compressor Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output Signal (TCC/Radio/Cruise Control) |
| C4 (Black) | 4 | DK GRN | VSS Output Signal (Speedometer) |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6 | — | Not Used |
| C4 (Black) | 7 | DL GRN | Inlet Air Actuator |
| C4 (Black) | 8 | — | Not Used |
| C4 (Black) | 9 | DL BLU | Auxiliary Electric Cooling Fan |
| C4 (Black) | 10 | PPL | Brake Signal |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | BLK | Dual Fuel Module Return |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Feed |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | BLK/WHT | 4WD Engaged Signal |
| C4 (Black) | 20 | WHT | EGR Valve Control |
| C4 (Black) | 21 & 22 | — | Not Used |
| C4 (Black) | 23 | GRY/BLK | Transfer Case High Low Switch |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Signal |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("G" SERIES) (1)
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("P" SERIES)
| Connector | Terminal No. | Wire Color | Function |
|---|---|---|---|
| C1 (Blue) | 1 & 2 | — | Not Used |
| C1 (Blue) | 3 | BRN/WHT | CMP Sensor 1x Signal |
| C1 (Blue) | 4-6 | — | Not Used |
| C1 (Blue) | 7 | TAN | HO2S Bank 2 Sensor 1 Low |
| C1 (Blue) | 8 | PNK/BLK | CMP Low |
| C1 (Blue) | 9 | PPL | Fuel Gauge |
| C1 (Blue) | 10-13 | — | Not Used |
| C1 (Blue) | 14 | BRN | AIR Relay Control (Calif. Only) |
| C1 (Blue) | 15 | YEL/BLK | VSS Signal |
| C1 (Blue) | 16 & 17 | — | Not Used |
| C1 (Blue) | 18 | PPL/WHT | Dual Tank Fuel Module |
| C1 (Blue) | 19 | PPL/WHT | HO2S Bank 1 Sensor 1 High |
| C1 (Blue) | 20 | PPL | HO2S Bank 1 Sensor 2 High |
| C1 (Blue) | 21 | PPL | HO2S Bank 2 Sensor 1 High |
| C1 (Blue) | 22 | PPL/WHT | HO2S Bank 2 Sensor 2 High |
| C1 (Blue) | 23 | — | Not Used |
| C1 (Blue) | 24 | TAN | HO2S Bank 1 Sensor 2 Low |
| C1 (Blue) | 25 | TAN/WHT | HO2S Bank 1 Sensor 1 Low |
| C1 (Blue) | 26 | TAN/WHT | HO2S Bank 2 Sensor 2 Low |
| C1 (Blue) | 27 | — | Not Used |
| C1 (Blue) | 28 | PPL | CKP Low |
| C1 (Blue) | 29 | LT GRN/BLK | VSS Low |
| C1 (Blue) | 30 | PPL/WHT | VSS Signal |
| C1 (Blue) | 31 | YEL | CKP Sensor 4x Signal |
| C1 (Blue) | 32 | — | Not Used |
| C2 (Red) | 1-3 | — | Not Used |
| C2 (Red) | 4 | YEL/BLK | 2-3 Shift Solenoid Control |
| C2 (Red) | 5 | — | Not Used |
| C2 (Red) | 6 | LT GRN | 1-2 Shift Solenoid Control |
| C2 (Red) | 7 | BRN | TCC PWM Solenoid Control |
| C2 (Red) | 8 | BLK | Fuel Injector No. 1 Control |
| C2 (Red) | 9 | DK BLU/WHT | Fuel Injector No. 8 Control |
| C2 (Red) | 10 | BRN | EGR Pintle Position Signal |
| C2 (Red) | 11 | LT GRN/BLK | Fuel Injector No. 2 Control |
| C2 (Red) | 12 | RED/BLK | Fuel Injector No. 7 Control |
| C2 (Red) | 13 | LT GRN/WHT | IAC Coil B High |
| C2 (Red) | 14 | LT BLU/WHT | IAC Coil A High |
| C2 (Red) | 15 | BLK/WHT | Fuel Injector No. 5 Control |
| C2 (Red) | 16 | YEL/BLK | Fuel Injector No. 6 Control |
| C2 (Red) | 17 & 18 | — | Not Used |
| C2 (Red) | 19 | DK BLU | KS Signal |
| C2 (Red) | 20 | — | Not Used |
| C2 (Red) | 21 | LT GRN | MAP Sensor Signal |
| C2 (Red) | 22 | TAN | IAT Sensor Signal |
| C2 (Red) | 23 | YEL | ECT Sensor Signal |
| C2 (Red) | 24 | DK BLU | TP Sensor Signal |
| C2 (Red) | 25 & 26 | — | Not Used |
| C2 (Red) | 27 | YEL/BLK | TFT Sensor Signal |
| C2 (Red) | 28 | YEL | MAF Sensor Signal |
| C2 (Red) | 29 | LT GRN/BLK | IAC High |
| C2 (Red) | 30 | LT BLU/BLK | IAC Low |
| C2 (Red) | 31 | LT BLU/BLK | Fuel Injector No. 4 Control |
| C2 (Red) | 32 | PNK/BLK | Fuel Injector No. 3 Control |
| C3 (Clear) | 1 | DK GRN/WHT | A/C Compressor Clutch Relay Control |
| C3 (Clear) | 2 | DK GRN/WHT | EVAP Canister Purge Solenoid Control |
| C3 (Clear) | 3 | — | Not Used |
| C3 (Clear) | 4 | BLK | ECT/TP Sensor Ground |
| C3 (Clear) | 5 | — | Not Used |
| C3 (Clear) | 6 | RED/BLK | Pressure Control Solenoid High |
| C3 (Clear) | 7 | DK BLU/WHT | Input Shaft Speed Sensor Low |
| C3 (Clear) | 8 | RED/BLK | Input Shaft Speed Sensor High |
| C3 (Clear) | 9 | WHT | IC Control |
| C3 (Clear) | 10 | — | Not Used |
| C3 (Clear) | 11 | RED | Transmission Range C Input |
| C3 (Clear) | 12 | GRY | TP Sensor Reference Voltage |
| C3 (Clear) | 13 | PPL/WHT | Fuel Level Module (Single Tank) |
| C3 (Clear) | 14 | DK BLU | A/C Recirculation |
| C3 (Clear) | 15 | — | Not Used |
| C3 (Clear) | 16 | LT BLU/WHT | Pressure Control Solenoid Low |
| C3 (Clear) | 17 | BLK/WHT | PCM Ground |
| C3 (Clear) | 18 | BLK/WHT | PCM Ground |
| C3 (Clear) | 19 | BLK | Sensor Ground (EGR/IAT/MAP) |
| C3 (Clear) | 20 | — | Not Used |
| C3 (Clear) | 21 | ORG | Battery Voltage |
| C3 (Clear) | 22 | DK BLU | Transmission Range B Input |
| C3 (Clear) | 23 | PNK | Transmission Range A Input |
| C3 (Clear) | 24 | — | Not Used |
| C3 (Clear) | 25 | DK GRN/WHT | A/C Request Signal |
| C3 (Clear) | 26 | — | Not Used |
| C3 (Clear) | 27 | GRY | EGR/MAP Reference Voltage |
| C3 (Clear) | 28 & 29 | — | Not Used |
| C3 (Clear) | 30 | DK GRN | A/C Compressor Cycling Switch Signal |
| C3 (Clear) | 31 & 32 | — | Not Used |
| C4 (Black) | 1 | DK GRN/WHT | Fuel Pump Relay Control |
| C4 (Black) | 2 | — | Not Used |
| C4 (Black) | 3 | DK GRN/WHT | VSS Output Signal (TCC/Radio/Cruise Control) |
| C4 (Black) | 4 | DK GRN | VSS Output Signal (Speedometer) |
| C4 (Black) | 5 | BRN/WHT | MIL Control |
| C4 (Black) | 6-8 | — | Not Used |
| C4 (Black) | 9 | DK BLU | Auxiliary Elactric Cooling Fan |
| C4 (Black) | 10 | PPL | Brake Signal |
| C4 (Black) | 11 | PPL | Serial Data (Class II) |
| C4 (Black) | 12 | — | Not Used |
| C4 (Black) | 13 | BRN | Ignition Voltage |
| C4 (Black) | 14 & 15 | — | Not Used |
| C4 (Black) | 16 | RED | EGR Valve Feed |
| C4 (Black) | 17 | — | Not Used |
| C4 (Black) | 18 | PNK | Ignition Voltage |
| C4 (Black) | 19 | — | Not Used |
| C4 (Black) | 20 | WHT | EGR Valve Control |
| C4 (Black) | 21-23 | — | Not Used |
| C4 (Black) | 24 | LT BLU/BLK | Cruise Engaged Signal |
| (1) (Scheme 20) | |||
| (1) | (Scheme 20) |
POWERTRAIN CONTROL MODULE (PCM) - 7.4L ("P" SERIES) (1)
ENGINE SENSORS & SWITCHES
Note. For additional sensor testing specifications, see appropriate SENSOR OPERATING RANGE CHARTS article.
Manufacturer does not provide testing procedures for many individual systems and components. For sensor and switch testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
- Engine Coolant Temperature (ECT) Sensor A malfunction in ECT sensor circuit can set a related Diagnostic Trouble Code (DTC). For testing procedure, see appropriate SELF-DIAGNOSTICS article. An out-of-calibration ECT sensor may not set a DTC. Use the following procedure to test sensor calibration. Disconnect ECT sensor harness connector. Using an ohmmeter, measure resistance of ECT sensor at specified temperatures. See «ECT SENSOR RESISTANCE VALUES»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) table. Resistance should be high when engine is cold and drop as engine warms. With vehicle sitting overnight, IAT sensor and ECT sensor should have close to the same resistance reading. If resistance is not within specification, replace ECT sensor. ECT SENSOR RESISTANCE VALUES Temperature °F (°C) Ohms 212 (100) 177 158 (70) 467 104 (40) 1459 68 (20) 3520 32 (0) 9420 5 (-15) 21,450 -40 (-40) 100,700
- Intake Air Temperature (IAT) Sensor A malfunction in IAT sensor circuit can set a related Diagnostic Trouble Code (DTC). For testing procedure, see appropriate SELF-DIAGNOSTICS article. An out-of-calibration IAT sensor may not set a DTC. Use the following procedure to test sensor calibration. Disconnect IAT sensor harness connector. Using an ohmmeter, measure resistance of IAT sensor at specified temperatures. See «IAT SENSOR RESISTANCE VALUES»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) table. Resistance should be high when air temperature is cold and drop as air temperature warms. With vehicle sitting overnight, ECT sensor and IAT sensor should have close to the same resistance reading. If resistance is not within specification, replace IAT sensor. IAT SENSOR RESISTANCE VALUES Temperature °F (°C) Ohms 212 (100) 177 158 (70) 467 104 (40) 1459 68 (20) 3520 32 (0) 9420 5 (-15) 21,450 -40 (-40) 100,700
Note. MAP sensor circuit diagnosis is only available from manufacturer for 2.2L and 3.4L engines.
- MAP Sensor Circuit Diagnosis (2.2L) If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool and retrieve DTCs. If no MAP sensor related DTCs are set, go to next step. If any MAP sensor related DTCs are set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
- Turn ignition on with engine off. Compare MAP sensor reading with that of a known-good vehicle. If voltage readings are within 0.4 volt of each other, go to next step. If voltage readings are not within 0.4 volt of each other, go to step 5 .
- Disconnect and plug vacuum source to MAP sensor. Connect a hand-held vacuum pump to vacuum source port on MAP sensor. Apply 10 in. Hg of vacuum to MAP sensor while observing MAP sensor reading on scan tool. Subtract this reading from the reading obtained in step 3) . If difference is greater than 1.5 volts, go to step 6 . If difference is not greater than 1.5 volts, go to step 7 .
- Replace MAP sensor. After repairs, go to step 9 .
- Check MAP sensor vacuum source for leakage or restriction, and that vacuum source only supplies MAP sensor. If problem exists, go to step 8 . If problem does not exist, go to step 9 .
- Check for poor connection at MAP sensor. If poor connection does not exist, go to step 5 . If poor connection exists, repair as necessary and go to step 9 .
- Repair leak or restriction in MAP sensor vacuum source as necessary. After repairs, go to next step.
- Operate vehicle under conditions which original symptom was noted. If system operates properly, system is okay at this time. If system does not operate properly, go to step 2 .
- MAP Sensor Circuit Diagnosis (3.4L) If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Check for the following: Missing or damaged MAP sensor seal. Damage, disconnected or misrouted vacuum hoses. Intake manifold vacuum leaks. Vacuum leaks at throttle body. Vacuum leaks in EGR system. Faulty, missing or incorrectly installed PCV valve. If a problem does not exist, go to next step. If a problem exists, repair as necessary and go to step 14 .
- Disconnect MAP sensor harness connector. Using scan tool, observe MAP sensor parameter. If zero volts is displayed, go to next step. If zero volts is not displayed, go to step 12 .
- Using a test light connected to battery voltage, probe MAP sensor signal circuit (Light Green wire) at MAP sensor harness connector. See appropriate wiring diagram in WIRING DIAGRAMS article. Observe MAP sensor parameter on scan tool. If 4.95 volts is displayed, go to next step. If 4.95 volts is not displayed, go to step 8 .
- Using a fused jumper wire, connect MAP sensor signal circuit (Light Green wire) and MAP sensor reference voltage circuit (Gray wire) at MAP sensor harness connector. See appropriate wiring diagram in WIRING DIAGRAMS article. Observe MAP sensor parameter on scan tool. If scan tool displays 4.95 volts, go to next step. If scan tool does not display 4.95 volts, go to step 7 .
- Turn ignition off. Disconnect PCM harness connectors. Check MAP sensor ground circuit (Orange/Black wire) for open, high resistance or poor connection at PCMs. If problem does not exist, go to step 10 . If problem exists, repair as necessary and go to step 14 .
- Check MAP sensor reference voltage circuit (Gray wire) for open, high resistance or poor connection at PCM. If problem does not exist, go to step 9 . If problem exists, repair as necessary and go to step 14 .
- Turn ignition off. Disconnect PCM harness connectors. Check MAP sensor signal circuit (Light Green wire) for open, high resistance, short to ground or short to sensor. If problem does not exist, go to next step. If problem exists, repair as necessary and go to step 14 .
- Check MAP sensor signal circuit (Light Green wire) for poor connection at PCM. If problem does not exist, go to step 13 . If problem exists, repair as necessary and go to step 14 .
- Check for poor connection at MAP sensor. If problem does not exist, go to next step. If problem exists, repair as necessary and go to step 14 .
- Replace MAP sensor. After repairs, go to step 14 .
- Turn ignition off. Disconnect PCM harness connector. Turn ignition on. Check MAP sensor signal circuit (Light Green) for a short to voltage or short to MAP sensor reference voltage circuit (Gray wire). If problem does not exist, go to next step. If problem exists, repair as necessary and go to step 14 .
- Replace PCM. Program PCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Start engine and let idle. While observing MAP sensor parameter on scan tool, increase engine RPM. If MAP sensor value changes, system is okay. If MAP sensor value does not change, go to step 2 .
- Engine Oil Level Switch Diagnosis If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Using scan tool, observe engine oil level display. If scan tool does not display OK, go to next step. If scan tool displays OK, check for poor connections at engine oil level switch and PCM. If poor connection exists, repair as necessary. If poor connection does not exist, perform warning light diagnosis. See «PCM CONTROLLED WARNING LIGHTS & GAUGES»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) under MISCELLANEOUS CONTROLS.
- Turn ignition off. Disconnect PCM harness connectors. Using a test light connected to battery voltage, probe engine oil level switch signal circuit (Brown wire) at PCM harness connector. If test light does not illuminate, go to next step. If test light illuminates, go to step 7 .
- Ensure ignition is off. Reconnect PCM harness connectors. Turn ignition on. Raise and support vehicle. Disconnect engine oil level switch harness connector. Using DVOM, measure voltage between engine oil level switch harness connector terminals. If battery voltage does not exist, go to next step. If battery voltage exists, go to step 8 .
- Using DVOM, measure voltage between chassis ground and engine oil level switch signal circuit (Brown wire) at engine oil level switch harness connector. If battery voltage does not exist, go to next step. If battery voltage exists, go to step 9 .
- Check for open in engine oil level switch signal circuit (Brown wire) between engine oil level switch and PCM. If open exists, repair as necessary and go to step 12 . If open does not exist, check for poor connections at engine oil level switch and PCM. If poor connection exists, repair as necessary. If poor connection does not exist, perform warning light diagnosis. See «PCM CONTROLLED WARNING LIGHTS & GAUGES»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) under MISCELLANEOUS CONTROLS.
- Check for poor connections at PCM. If poor connection exists, repair as necessary and go to step 12 . If poor connection does not exist, go to step 11 .
- Check for poor connections at engine oil level switch. If poor connection exists, repair as necessary and go to step 12 . If poor connection does not exist, go to step 10 .
- Locate and repair open in engine oil level switch ground circuit (Black/White wire). After repairs, go to step 12 .
- Replace engine oil level switch. After repairs, go to step 12 .
- Replace PCM. Program PCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Start engine and allow to warm to normal operating temperature. Turn ignition off. Allow engine to cool for 15 minutes. Turn ignition on. Using scan tool, observe engine oil level display. If scan tool displays OK, system is okay. If scan tool does not display OK, go to step 3 .
MODULES, MOTORS, RELAYS & SOLENOIDS
Note. Manufacturer does not provide testing procedures for many individual systems and components. For module, motor, relay and solenoid testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
A/C Compressor Clutch Relay
See appropriate MANUAL A/C-HEATER SYSTEMS or AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING.
Fuel Pump Relay
Fuel pump relay is located in underhood fuse/relay block. To test fuel pump relay, see FUEL SYSTEM ELECTRICAL CIRCUIT under appropriate NO START - ENGINE CRANKS OKAY in appropriate BASIC DIAGNOSTIC PROCEDURES article.
EVAP Canister Purge Solenoid
See FUEL EVAPORATION under EMISSION SYSTEMS & SUB-SYSTEMS (GASOLINE).
Idle Air Control (IAC) Valve
See IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS under IDLE CONTROL SYSTEM.
Torque Converter Clutch (TCC) Solenoid
See TRANSMISSION under MISCELLANEOUS CONTROLS.
FUEL SYSTEM (GASOLINE)
Note. For fuel system pressure testing, see appropriate BASIC DIAGNOSTIC PROCEDURES article.
Manufacturer does not provide testing procedures for many individual systems and component. For fuel system testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Fuel Pressure Regulator (CSI)
Fuel pressure regulator is a vacuum-controlled diaphragm type, which uses manifold vacuum to modify fuel pressure to compensate for engine load fuel requirements. Connect fuel pressure gauge to fuel pressure service port. Start engine and note fuel pressure. Disconnect vacuum hose from fuel pressure regulator. Fuel pressure should increase 4-10 psi (.28-.70 kg/cm 2 ). If pressure does not increase 4-10 psi (.28-.70 kg/cm 2 ), check for presence of manifold vacuum at signal line. If vacuum is not present, check for kinked, cut or split vacuum hose or plugged throttle body vacuum port. If vacuum is present and no pressure change occurs, replace fuel pressure regulator.
Fuel Pressure Regulator (SFI)
Fuel pressure regulator is mechanically controlled by internal spring pressure. Regulator is adjusted at factory and is not serviceable. If fuel pressure is too low, check for restricted delivery line. Also, check fuel pump pressure and volume. If fuel pressure is too high, check for restricted fuel tank return line or fuel filter. If no faults are found and pressure is too high or too low, replace fuel pressure regulator.
Fuel Pump Oil Pressure Switch (Back-Up Circuit)
To test fuel pump oil pressure switch (fuel pump back-up circuit), start engine. With engine running, disconnect fuel pump relay. If engine stalls, fuel pump oil pressure switch is faulty. If vehicle continues to run, switch is okay.
FUEL CONTROL
Note. Retrieve DTCs and perform appropriate DTC test before performing FUEL INJECTOR CIRCUIT DIAGNOSIS. See appropriate SELF-DIAGNOSTICS article. Also, ensure all mechanical and ignition coil/module circuit malfunctions are repaired before performing fuel injector circuit diagnosis.
Fuel Injector Circuit Diagnosis (Except 2.2L & 3.4L)
Note. Fuel injector circuit diagnosis test information for 2.2L and 3.4L engines is not available from manufacturer.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Disconnect fuel injector harness connectors at intake manifold. Using a test light connected to ground, probe appropriate injector ignition feed circuits at fuel injector harness connector. Turn ignition on with engine off. If test light illuminates on both circuits, go to step 6 . If test light does not illuminate on both circuits, go to next step.
- If test light illuminates on only one injector ignition feed circuit, go to step 5 . If test light does not illuminate on only one injector ignition feed circuit, go to next step.
- Check injector fuse. If fuse is blown, go to step 10 . If fuse is okay, go to step 11 .
- Check for an open in appropriate injector feed circuit between PCM/VCM and injector harness connector. If open exists, go to step 12 .
- Connect Fuel Injector Test Light (J-34730-380) to fuel injector harness connectors (PCM/VCM side) one at a time. Crank engine while observing test light. If test light does not flash at each injector, go to next step. If test light flashes at each injector, perform injector coil test. See «INJECTOR COIL TEST (EXCEPT 2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-except-22l) .
- If fuel injector test light illuminates constantly while engine is being cranked, go to next step. If fuel injector test light does not illuminate constantly while engine is being cranked, go to step 9 .
- Install fuel injector test light on affected circuit. Turn ignition off. Disconnect PCM/VCM harness connectors. Turn ignition on with engine off. If test light illuminates, go to step 13 . If test light does not illuminate, go to step 16 .
- Check for an open in injector control circuit between PCM/VCM and injector harness connectors. If open exists, go to step 12 . If an open does not exist, go to step 14 .
- Check for a short to ground in injector ignition feed circuit between PCM/VCM and injector harness connectors. If a short to ground exists, go to step 12 .
- Repair open or short to ground on both injector ignition feed circuits. After repairs, go to step 17 .
- Repair circuit as necessary. After repairs, go to step 17 .
- Repair short to ground in injector control circuit between PCM/VCM and injector harness connectors. After repairs, go to step 17 .
- Check PCM/VCM harness connectors for poor connections. If poor connection exists, go to next step. If poor connection does not exist, go to step 16 .
- Repair terminal contact as necessary. After repairs, go to step 17 .
- Replace PCM/VCM. Program PCM/VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to step 17 .
- Using scan tool, clear DTCs. Attempt to start engine. If engine starts and continues to run, go to next step. If engine does not start and continue to run, go to step 2 .
- Let engine idle until normal operating temperature is reached. Retrieve DTCs. If no DTCs are set, system is okay. If any DTCs are set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
Injector Balance Test (Except 2.2L & 3.4L)
Note. Allow engine to cool down to avoid irregular reading due to "hot soak" fuel boiling. To prevent flooding, the fuel injector balance test should not be performed more than once without starting and running engine.
Note. If injectors are dirty, they should be cleaned using approved injector cleaning procedure before performing fuel injector balance test.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- If engine coolant temperature is greater than 201°F (94°C), go to next step. If engine coolant temperature is less than 201°F (94°C), go to step 4 .
- Allow engine to cool to less than 201°F (94°C). After engine cools to less than 201°F (94°C), go to next step.
- Turn ignition off. Relieve fuel pressure. Install fuel pressure gauge. Turn ignition on with engine off. Install scan tool. Using scan tool, energize fuel pump. Place fuel pressure gauge bleed hose into container. Bleed air out of fuel pressure gauge. Using scan tool, energize fuel pump again. Wait for fuel pressure to build. Observe fuel pressure while fuel pump is running. If fuel pressure reading is 60-66 psi (4.2-4.6 kg/cm 2 ) on 4.3L, 5.0L and 5.7L, or 55-62 psi (4.0-4.4 kg/cm 2 ) on 4.8L, 5.3L, 6.0L and 7.4L, go to next step. If fuel pressure reading is not within specification, perform fuel system diagnosis. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
- After fuel pump stops, fuel pressure should slightly decrease. If fuel pressure remains constant within 55-60 psi (4.0-4.2 kg/cm 2 ) on 4.3L, 5.0L and 5.7L, or 48-52 psi (3.4-3.7 kg/cm 2 ) on 4.8L, 5.3L, 6.0L and 7.4L, go to next step. If fuel pressure reading is not within specification, perform fuel system diagnosis. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
- Turn ignition off. Turn ignition on with engine off. Using scan tool, select SPECIAL FUNCTIONS. Select FUEL SYSTEMS, and then INJECTOR BALANCE TEST. Select injector to be tested. Press enter, this will prime fuel pump. After fuel pressure stabilizes, record fuel pressure reading on fuel pressure gauge (first reading). Energize injector by depressing PULSE INJECTOR button on scan tool. Injector will be energized and fuel pressure will decrease. Record fuel pressure reading after fuel pressure stabilizes (second reading). Press enter on scan tool to return to SELECT INJECTOR. Repeat procedure for each injector. Subtract first reading from second reading for each injector (this result is pressure drop value). Add pressure drop value for each injector together and divide total by total number of injectors. If any injector's drop value is greater or less than average drop value by 1.5 psi, replace faulty injector(s) as necessary. If no injector's drop value is greater or less than average drop value by 1.5 psi, perform injector coil test. See «INJECTOR COIL TEST (EXCEPT 2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-except-22l) .
Injector Balance Test (2.2L & 3.4L)
Note. Allow engine to cool down to avoid irregular reading due to "hot soak" fuel boiling. To prevent flooding, the fuel injector balance test should not be performed more than once without starting and running engine.
Note. If injectors are dirty, they should be cleaned using approved injector cleaning procedure before performing fuel injector balance test.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- If injector coil test has been performed, go to next step. If injector coil test has not been performed, go to appropriate INJECTOR COIL TEST - ECT BETWEEN 50-95°F.
- If engine coolant temperature is greater than 201°F (94°C), go to next step. If engine coolant temperature is less than 201°F (94°C), go to step 5 .
- Allow engine to cool to less than 201°F (94°C). After engine cools to less than 201°F (94°C), go to next step.
- Install fuel pressure gauge. Using scan tool, energize fuel pump. Place fuel pressure gauge bleed hose into container. Bleed air out of fuel pressure gauge. Using scan tool, energize fuel pump again. Wait for fuel pressure to build. Observe fuel pressure. If fuel pressure reading is 41-47 psi (2.9-3.3 kg/cm 2 ), go to next step. If fuel pressure reading is not within specification, perform fuel system diagnosis. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
- Turn fuel pump off. Observe fuel pressure gauge. If fuel pressure remains constant, go to next step. If fuel system does not remain constant, perform fuel system diagnosis. See appropriate BASIC DIAGNOSTIC PROCEDURES article.
- Disconnect fuel injectors harness connector. Using appropriate fuel injector adapter, connect Fuel Injector Tester (J-39021) to fuel injector. Connect fuel injector tester power leads to appropriate battery terminals. Set amperage supply selector switch on fuel injector tester to Balance Test 0.5-2.5-amp position. Turn ignition on, and then off to pressurize system. Record fuel pressure reading after fuel pressure stabilizes (first reading). Energize injector by depressing PUSH TO START TEST button on injector tester and hold until fuel pressure gauge stabilizes. Record fuel pressure reading (second reading). Subtract first reading from second reading (this result is pressure drop value). Repeat procedure for each injector. Add pressure drop value for each injector together and divide total by total number of injectors. If any injector's drop value is greater or less than average drop value by 1.5 psi, replace faulty injector(s) as necessary. If no injector's drop value is greater or less than average drop value by 1.5 psi, repair by symptom. See appropriate TROUBLE SHOOTING - NO CODES article.
Injector Coil Test (Except 2.2L & 3.4L)
| WARNING | In order to prevent flooding of cylinder and possible engine damage, relieve fuel pressure before performing injector coil test procedure. |
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Turn ignition off. Relieve fuel pressure. Connect Fuel Injector Tester (J-39021) to battery voltage. Connect Injector Switch Box (J-39021-210). Set amperage on fuel injector tester to 0.5 amp. Connect DVOM to fuel injector tester. Install scan tool and monitor engine coolant temperature. If coolant temperature is 50-95°F (10-35°C), go to step 4 . If coolant temperature is not as specified, go to next step.
- Allow engine to warm or cool as necessary. If engine coolant temperature is now 50-95°F (10-35°C), go to next step.
- Using fuel injector tester, press PUSH TO START TEST button and monitor DVOM reading. Repeat procedure for each injector. Voltage reading should be 5.44-7.53 volts. If voltage reading is as specified, go to next step. If voltage reading is not as specified, perform injector balance test. See «INJECTOR BALANCE TEST (EXCEPT 2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-except-22l) .
- Replace faulty injector nozzle and poppet assembly. After repairs, go to next step.
- Using scan tool, clear DTCs. Start engine. If engine starts and continues to run, go to next step. If engine does not start, or starts and dies, go to step 2 .
- Warm engine to normal operating temperature. Using scan tool, retrieve DTCs. If no DTC(s) are set, system is okay. If any DTC(s) are set, perform appropriate DTC(s) test. See appropriate SELF-DIAGNOSTICS article.
Injector Coil Test - ECT Between 50-95°F (2.2L)
| WARNING | In order to prevent flooding of cylinder and possible engine damage, relieve fuel pressure before performing injector coil test procedure. |
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Using scan tool, check engine coolant temperature. If coolant temperature is 50-95°F (10-35°C), go to next step. If coolant temperature is not 50-95°F (10-35°C), perform injector coil test. See «INJECTOR COIL TEST - ECT NOT BETWEEN 50-95°F (2.2L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-ect-not) .
- Turn ignition off. Relieve fuel pressure. Disconnect fuel injectors harness connector. Using appropriate fuel injector adapter, connect Fuel Injector Tester (J-39021) to fuel injector. Connect fuel injector tester power leads to appropriate battery terminals. Set amperage supply selector switch on fuel injector tester to Coil Test 2.5-amp position. Connect DVOM to injector tester. Depress PUSH TO START TEST button. Record lowest voltage reading within first second of test. Repeat procedure for each injector. If any injector has erratic voltage reading or reading not within 4.7-5.8 volts, go to next step. If no injector has erratic voltage reading or reading not within 4.7-5.8 volts, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
- Replace faulty injector(s). After repairs, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
Injector Coil Test - ECT Between 50-95°F (3.4L)
| WARNING | In order to prevent flooding of cylinder and possible engine damage, relieve fuel pressure before performing injector coil test procedure. |
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Using scan tool, check engine coolant temperature. If coolant temperature is 50-95°F (10-35°C), go to next step. If coolant temperature is not 50-95°F (10-35°C), perform injector coil test. See «INJECTOR COIL TEST - ECT NOT BETWEEN 50-95°F (3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-ect-not) .
- Turn ignition off. Relieve fuel pressure. Connect Fuel Injector Tester (J-39021), Injector Switch Box (J-39021-210) and Fuel Injector Test Harness (J-39021-306) to fuel injector connector. Set amperage on fuel injector tester to Coil Test 0.5 amp position. Connect DVOM to fuel injector tester. Select fuel injector using injector switch box. Depress PUSH TO START TEST button. Record lowest voltage reading within first second of test. Repeat procedure for each injector. If any injector has erratic voltage reading or reading not within 5.7-6.6 volts, go to next step. If no injector has erratic voltage reading or reading not within 5.7-6.6 volts, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
- Replace faulty injector(s). After repairs, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
Injector Coil Test - ECT Not Between 50-95°F (2.2L)
| WARNING | In order to prevent flooding of cylinder and possible engine damage, relieve fuel pressure before performing injector coil test procedure. |
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Using scan tool, check engine coolant temperature. If coolant temperature is not 50-95°F (10-35°C), go to next step. If coolant temperature is 50-95°F (10-35°C), perform injector coil test. See «INJECTOR COIL TEST - ECT BETWEEN 50-95°F (2.2L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-ect-between) .
- Turn ignition off. Relieve fuel pressure. Disconnect fuel injectors harness connector. Using appropriate fuel injector adapter, connect Fuel Injector Tester (J-39021) to fuel injector. Connect fuel injector tester power leads to appropriate battery terminals. Set amperage supply selector switch on fuel injector tester to Coil Test 2.5-amp position. Connect DVOM to injector tester. Depress PUSH TO START TEST button. Record lowest voltage reading within first second of test. Record highest voltage reading other than those above 9.5 volts. Subtract any other voltage reading observed from highest voltage reading. Repeat procedure for each injector. If difference is greater than 4.7-5.8 volts, go to next step. If difference is less than 4.7-5.8 volts, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
- Replace any injector(s) that had any of the following results: initial reading greater than 9.5 volts, erratic reading or difference is greater than 0.6 volt. After repairs, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
Injector Coil Test - ECT Not Between 50-95°F (3.4L)
| WARNING | In order to prevent flooding of cylinder and possible engine damage, relieve fuel pressure before performing injector coil test procedure. |
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Using scan tool, check engine coolant temperature. If coolant temperature is not 50-95°F (10-35°C), go to next step. If coolant temperature is 50-95°F (10-35°C), perform injector coil test. See «INJECTOR COIL TEST - ECT BETWEEN 50-95°F (3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-coil-test-ect-between) .
- Turn ignition off. Relieve fuel pressure. Connect Fuel Injector Tester (J-39021), Injector Switch Box (J-39021-210) and Fuel Injector Test Harness (J-39021-306) to fuel injector connector. Set amperage on fuel injector tester to Coil Test 0.5 amp position. Connect DVOM to fuel injector tester. Select fuel injector using injector switch box. Depress PUSH TO START TEST button. Record lowest voltage reading within first second of test. Record highest voltage reading other than those above 9.5 volts. Subtract any other voltage reading observed from highest voltage reading. Repeat procedure for each injector. If difference is greater than 0.6 volt, go to next step. If difference is less than 0.6 volt, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
- Replace any injector(s) that had any of the following results: initial reading greater than 9.5 volts, erratic reading or difference is greater than 0.6 volt. After repairs, perform injector balance test. See «INJECTOR BALANCE TEST (2.2L & 3.4L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__injector-balance-test-22l-34l) .
See RELAYS under MODULES, MOTORS, RELAYS & SOLENOIDS.
FUEL SYSTEM (DIESEL)
Note. Manufacturer does not provide testing procedures for many individual systems and component. For fuel system testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Note. For complete system testing and diagnosis, see SELF-DIAGNOSTICS - DIESEL article.
Function Check
- With ignition on, engine not running and at room temperature, glow plugs are on for 4-6 seconds, and then off for about 4.5 seconds. Following this on-and-off cycle, glow plugs are on for about one second and off for about 3 seconds. The glow plugs continue to cycle on and off in this time sequence for about 16 seconds.
- If engine is cranked during or after the above sequence, glow plugs will cycle on and off for a total duration of 25 seconds after ignition switch is returned from crank position, whether engine starts or not. Engine does not have to be running to terminate glow plug cycling.
PRELIMINARY GLOW PLUG DIAGNOSIS
Note. Glow plug on-and-off times vary with engine temperature, system voltage and/or ambient temperature. Lower temperatures cause longer duration of cycling.
- If system does not operate as described in «NORMAL GLOW PLUG CIRCUIT OPERATION»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__function-check) , ensure glow plug system is correctly installed. Ensure all connectors are properly attached, clean and tight. Inspect engine harness ground connection. Ensure nuts securing glow plug relay to engine are tightened to 31 ft. lbs. (42 N.m). Ensure connector is fully seated in relay.
- Ensure glow plug relay copper stud upper nuts are tightened to 44 INCH lbs. (5 N.m). DO NOT overtighten nuts. Inspect WAIT TO START light on instrument cluster for tight connection and proper operation.
FUEL HEATER DIAGNOSIS
- If water in fuel light is operating properly, go to next step. If water in fuel light is not operating properly, perform water in fuel light diagnosis. See «WATER-IN-FUEL LIGHT DIAGNOSIS»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__water-in-fuel-light-diagnosis) .
- Disconnect fuel heater harness connector and remove heater from filter housing. With fuel heater temperature greater than 50°F (10°C), apply battery voltage to fuel heater terminal "C" (Pink wire) and ground fuel heater terminal "A" (Black wire). Observe heater element. If heat does not exist, go to next step. If heat exists, go to step 4 .
- Cool fuel heater to less than 46°F (8°C) and wet heating element with fuel. Connect fuel heater to battery voltage and ground as in step 2) . Observe heater element. If heat does not exist, go to next step. If heat exists, go to step 5 .
- Replace fuel heater. After repairs, go to next step.
- Operate vehicle under conditions when problem was noted. If system does not operate properly, go to step 1 .
WATER-IN-FUEL LIGHT DIAGNOSIS
- Turn ignition on with engine off. If WATER IN FUEL light does not illuminate, go to next step. If WATER IN FUEL light illuminates briefly, go to step 5.
- Disconnect water-in-fuel sensor harness connector. Ensure ignition is on with engine off. Using an unpowered test light connected to ground, probe ignition feed circuit (Pink wire) at water-in-fuel sensor harness connector. (Scheme 22) If test light illuminates, go to next step. If test light does not illuminate, go to step 6.
- Connect test light between ignition feed circuit (Pink wire) and ground circuit (Black wire) at water-in-fuel sensor harness connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 8.
- Using test light connected to ground, probe indicator light control circuit (Yellow/Black wire) at water-in-fuel sensor harness connector. (Scheme 22) If test light illuminates, go to step 11. If test light does not illuminate, go to step 10.
- Operate vehicle under conditions when problem was noted. If system does not operate properly, go to step 2.
- Check for open in ignition feed circuit (Pink wire) between underhood fuse/relay center and water-in-fuel sensor. If problem exists, repair as necessary and go to step 12. If problem does not exist, go to next step.
- Check ignition feed circuit (Pink wire) for poor connection at water-in-fuel sensor. If problem exists, repair as necessary and go to step 12. If problem does not exist, go to step 11.
- Check for open in ground circuit (Black wire) between water-in-fuel sensor and ground connection. If problem exists, repair as necessary and go to step 12. If problem does not exist, go to next step.
- Check ground circuit (Black wire) for poor connection at water-in-fuel sensor. If problem exists, repair as necessary and go to step 12. If problem does not exist, go to step 11.
- Repair open in indicator light control circuit (Yellow/Black wire) between instrument cluster and water-in-fuel sensor. After repairs, go to step 12.
- Replace water-in-fuel sensor. After repairs, go to next step.
- Operate vehicle under conditions when problem was noted. If system does not operate properly, go to step 1.
Scheme 22
GLOW PLUG SYSTEM DIAGNOSIS
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Retrieve DTCs. If DTC P0117, P0118 and/or P0380 is not set, go to next step. If DTC P0117, P0118 and/or P0380 is set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
- Turn ignition off. Disconnect all glow plug harness connectors. Using a test light connected to battery voltage, probe each glow plug spade terminal at glow plugs. If test light illuminates at each glow plug, go to next step. If test light does not illuminate at each glow plug, go to step 9 .
- Ensure all glow plug harness connectors are still disconnected. Turn ignition on with engine off. Using scan tool, command glow plugs on. Using a test light connected to ground, probe each glow plug harness connector terminal. If test light illuminates at each glow plug harness connector, go to next step. If test light does not illuminate at each glow plug harness connector, go to step 10 .
- Using scan tool, command glow plugs off. Using a test light connected to ground, probe each glow plug harness connector terminal. If test light illuminates at any glow plug harness connector, go to next step. If test light does not illuminate at any glow plug harness connector, go to step 11 .
- Remove glow plug relay. Using scan tool, command glow plugs off. Using a test light connected to ground, probe each glow plug harness connector terminal. If test light illuminates at any glow plug harness connector, go to next step. If test light does not illuminate at any glow plug harness connector, go to step 8 .
- Repair short to voltage in glow plug output circuit or glow plug signal circuit. After repairs, go to step 11 .
- Replace glow plug relay. After repairs, go to step 11 .
- Replace glow plugs that did not illuminate test light. After repairs, go to step 11 .
- Repair open in glow plug circuit(s) that did not illuminate test light. After repairs, go to next step.
- Operate vehicle under conditions when problem was noted. If system does not operate properly, go to step 1 .
GLOW PLUG RELAY
- Ensure coolant temperature is less than 80°F (27°C) before beginning test. Place ignition switch in RUN position and allow glow plugs to cycle. After 2 minutes, crank engine for one second. It is NOT important that engine starts. Return ignition switch to RUN position. Glow plugs should cycle on at least once.
- If glow plugs do not cycle, disconnect glow plug relay (relay is located on top rear of engine). Connect test light between Pink wire terminal of harness connector and ground. With ignition switch in RUN position, test light should be off. Test light should illuminate when engine is cranked.
- If test light does not illuminate as specified, repair short or open in engine harness Pink wire. If test light illuminates as specified but glow plugs do not cycle, replace glow plug relay.
INJECTION PUMP HOUSING LEAKAGE TEST
- Remove injection pump and drain all fuel. Connect an air supply line to fuel inlet fitting. Ensure air supply is clean and dry. Seal off return line fitting. Completely immerse pump assembly in a container of clean test oil.
- Apply 20 psi (1.4 kg/cm 2 ) to pump. Leave pump immersed for 10 minutes to allow trapped air to escape. Watch for leaks after 10 minutes. If no leaks are observed after 10 minutes, reduce air pressure to 2 psi (.14 kg/cm 2 ) for 30 seconds.
- If there are still no leaks, increase pressure to 20 psi (1.4 kg/cm 2 ) again. If no leaks are observed, pump is okay. If leaks are noticed, replace pump.
Test Preparation
| CAUTION | Use Nozzle Socket (J-29873) to remove and replace injection nozzle. Attach socket to 30-mm hex portion of nozzle. Failure to do so will result in damage to injector nozzle. |
- Remove injector nozzles from engine. Clean carbon from tip area of nozzle with soft brass wire brush. DO NOT use steel brush or motorized brush to clean nozzle tip. Damage to nozzle tip may result.
- Connect injector nozzle to injection nozzle tester. Place clear plastic tubing on both fuel return fittings to prevent bleed-off from being confused with leaks. Close tester shutoff valve to pressure gauge.
- Fill tester with test fluid. Fill and flush nozzle assembly with test fluid by operating tester lever briskly and repeatedly. This purges air from injector nozzle and coats all parts with test fluid.
Opening Pressure Test
| WARNING | When testing injectors, keep spray contained to avoid serious injury. DO NOT allow injector to release line pressure on hands, arms or any part of body. Pressure of atomized test spray has sufficient penetrating power to puncture flesh. |
- Open tester shutoff valve 1/4 turn from closed position. Slowly depress tester lever and observe gauge. Note pressure at which needle of pressure gauge stops. Some injector nozzles may pop while other injector nozzles may drip (this is not a leak).
- Injector opening pressure should not fall to less than 1500 psi (105 kg/cm 2 ). Replace any injector nozzle where measurement does not meet lowest acceptable pressure. Release tester pressure.
Leakage Test
- Open tester shutoff valve 3/4 to 1 3/4 turns from closed position. Blow dry injector nozzle tip. Slowly depress tester lever until pressure gauge reads 1400 psi (98 kg/cm 2 ). Maintain pressure for 10 seconds and observe injector nozzle tip.
- A drop may form on end of injector nozzle, but should not fall off within a 10 second period. Replace injector nozzle if a drop of test fluid falls from tip during 10 second period. (Scheme 23) Release tester pressure.
Scheme 23
Chatter Test
Chatter for new and used injector nozzles may vary. With some used injector nozzles, chatter is difficult to detect during slow actuation of tester lever. Some injector nozzles may chatter louder than others. As long as there is audible chatter, injector nozzle is acceptable.
- Close tester shutoff lever at pressure gauge. Slowly depress lever and note whether chatter is heard. If no chatter is heard, increase speed of lever movement until it reaches a point at which injector nozzle chatters.
- At fast lever movement, injector nozzle may emit a "hissing" or "squealing" sound rather than normal chatter. This is acceptable. These sounds indicate that injector nozzle needle moves freely and injector nozzle seat, guide and pintle have no mechanical defects. Replace any injector nozzle assembly that does not chatter.
Spray Pattern Test
The injector nozzles used with this system have several features that make pattern testing difficult. These features include longer nozzle overlap, greater pintle-to-body clearances and an internal wave washer between injector nozzle nut and injector. Typical injector nozzle tester cannot deliver fuel with sufficient velocity to obtain proper spray patterns. DO NOT replace injector nozzle(s) based on spray pattern.
IDLE CONTROL SYSTEM
Note. For idle control system testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Idle Air Control (IAC) System Diagnosis
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Set parking brake and block wheels. Turn A/C off. Start engine and let idle. Install scan tool and select SPECIAL FUNCTIONS. Select IAC SYSTEM TEST, and then RPM CONTROL. Using scan tool, command engine speed to 500 RPM. If actual engine RPM is within 100 RPM of scan tool display, go to next step. If actual engine RPM is not within 100 RPM of scan tool display, go to step 4.
- Using scan tool, command engine speed to 1200 RPM. If actual engine RPM is within 100 RPM of scan tool display, check for a non-IAC system problem (i.e., vacuum leak, sticking throttle cable, fuel system lean or rich, throttle body, poor electrical connections, faulty PCV valve, A/C compressor circuits). If actual engine RPM is not within 100 RPM of scan tool display, go to step 5.
- Check for vacuum leaks, sticking throttle plates, faulty PCV valve, or restriction in air induction system. If problem exists, go to step 20. If problem does not exist, go to step 6.
- Check for obstruction or excessive carbon deposit in throttle body IAC passages. If problem exists, go to step 21. If problem does not exist, go to next step.
- Turn ignition off. Disconnect IAC valve harness connector. Check for poor connection at IAC valve. If problem exists, go to step 19. If problem does not exist, go to next step.
- Connect IAC Driver (J-37027-A) to IAC valve. Set parking brake and block wheels. Turn A/C off. Start engine and let idle. Install scan tool and monitor engine RPM. Using IAC driver, extend and retract IAC valve. If engine RPM decreases and increases as IAC valve is cycled, go to next step. If engine RPM does not decrease and increase as IAC valve is cycled, go to step 22.
- If RPM changes smoothly with each flash of IAC valve cycle, go to next step. If RPM does not change smoothly with each flash of IAC valve cycle, go to step 22.
- Install appropriate IAC node light onto IAC valve harness connector. Cycle IAC driver and observe lights. Both lights should cycle Green to Red, but never off as RPM changed over its range. If lights flash as specified, go to next step. If lights do not flash as specified, go to step 12.
- Remove IAC driver from IAC valve. Using DVOM, measure resistance between IAC valve terminals "A" and "B". (Scheme 24) Also, measure resistance between IAC valve terminals "C" and "D". If resistance is 40-80 ohms on both measurements, go to next step. If resistance is not 40-80 ohms on both measurements, go to step 22.
- Using DVOM, measure resistance between IAC valve terminals "B" and "C". (Scheme 24) Also, measure resistance between IAC valve terminals "A" and "D". If resistance is infinite on both measurements, check for a non-IAC system problem (i.e. vacuum leak, sticking throttle cable, fuel system lean or rich, throttle body, poor electrical connections, faulty PCV valve, A/C compressor circuits). If resistance is not infinite on both measurements, go to step 22.
- Turn ignition off. Disconnect PCM/VCM harness connectors. Check for poor connections at PCM/VCM. If problem exists, go to step 19. If problem does not exist, go to next step.
- Remove IAC node light. Check for an open in IAC driver circuits between IAC valve harness connector and PCM/VCM harness connector. If problem exists, go to step 19. If problem does not exist, go to next step.
- Using a test light connected to battery voltage, probe IAC valve harness connector terminals. If test light illuminates at any terminal, go to step 17. If test light does not illuminate at any terminal, go to next step.
- Turn ignition on with engine off. Using a test light connected to ground, probe IAC valve harness connector terminals. If test light illuminates at any terminal, go to step 18. If test light does not illuminate at any terminal, go to next step.
- Check for a short between IAC valve circuits. If problem exists, go to step 19. If problem does not exist, go to step 23.
- Repair short to ground in IAC circuit. After repairs, go to step 24.
- Repair short to voltage in IAC circuit. After repairs, go to step 24.
- Repair circuit as necessary. After repairs, go to step 24.
- Repair condition as necessary. After repairs, go to step 24.
- Clean IAC passages. After repairs, go to step 24.
- Replace IAC valve. After repairs, go to step 24.
- Replace PCM/VCM. Program PCM/VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Install scan tool. Start engine and let idle. Turn off all accessories. Using scan tool, command engine speed to 1200 RPM, and then down to 500 RPM. Again, using scan tool, command engine speed as specified. If actual RPM is close to commanded RPM, system is okay. If actual RPM is not close to commanded RPM, go to step 2.
Scheme 24
IGNITION SYSTEM
Note. For basic ignition system checks, see appropriate BASIC DIAGNOSTIC PROCEDURES article.
For ignition system testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Ignition Control Circuit (Gasoline Engines)
An open or short to ground in Ignition Control (IC) or by-pass circuit will cause PCM/VCM to turn on Malfunction Indicator Light (MIL) and confirm fault by setting a related DTC. See appropriate SELF-DIAGNOSTICS article.
Knock Sensor Circuit (Models Using External Spark Controller Module)
- An open or short circuit on IC module control wire to PCM/VCM will cause a loss of 12-volt IC module signal. This will cause PCM/VCM to fully retard ignition timing.
- Install scan tool. Using a metal object, tap on engine next to knock sensor and note knock parameter. Knock should be indicated on scan tool.
- If a scan tool is not available, backprobe PCM/VCM knock sensor signal terminal with a DVOM. With engine idling, 8-12 volts should be present at this terminal. Using a metal object, tap on engine close to knock sensor. Voltage signal at PCM/VCM terminal should drop to zero volts, and then return to original voltage when knock signal ceases.
- If voltage signal does not respond as described, check knock sensor-to-module signal. On vehicles equipped with automatic transmission, it may be necessary to place transmission in Drive for timing change to occur.
Knock Sensor Circuit (Models Using Knock Sensor With Internal Spark Controller Module)
- An open or short circuit on knock sensor wire to PCM/VCM will set a related DTC. A false detonation signal will not cause PCM/VCM to set a DTC.
- Install scan tool. Using a metal object, tap on engine next to knock sensor and note knock parameter. Knock should be indicated on scan tool.
- If a scan tool is not available, connect tachometer to engine. Start engine and hold RPM above idle. Using a metal object, tap on engine close to knock sensor. A noticeable decrease in engine RPM should occur. If no RPM decrease occurred, check knock sensor-to-PCM/VCM circuit.
- On vehicles equipped with automatic transmission, it may be necessary to place transmission in Drive for timing change to occur.
EMISSION SYSTEMS & SUB-SYSTEMS (GASOLINE)
Note. For emission and subsystem testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Secondary Air Injection System Diagnosis (5.0L & 5.7L "C" & "K" Series)
Note. For circuit and connector terminal identification, see appropriate wiring diagram in WIRING DIAGRAMS article.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, verify engine is at normal operating temperature and operating in closed loop. Using scan tool, command air pump on. If short term fuel trim indicates 16 percent within 30 seconds, go to next step. If short term fuel trim does not indicate 16 percent within 30 seconds, go to step 4 .
- If any DTCs exist, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article. If no DTCs exist, check the following and repair as necessary. Loose air pump belt. Poor connection at PCM or any secondary air injection system component. Damaged wiring harness. Pinched, kinked or restricted air pipes, line or fittings.
- Turn ignition on with engine off. Using scan tool, command air pump on. If air pump runs, go to next step. If air pump does not run, go to step 9 .
- Using scan tool, command air pump off. If air pump continues to run, go to next step. If air pump turns off, go to step 20 .
- Turn ignition off. Remove air pump relay. Turn ignition on with engine off. If air pump continues to run, go to step 35 . If air pump turns off, go to next step.
- Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 43 .
- Turn ignition off. Disconnect VCM harness connectors. Turn ignition on with engine off. Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. If test light illuminates, go to step 41 . If test light does not illuminate, go to step 47 .
- Turn ignition off. Disconnect air pump connector. Check for poor connection at air pump. If problem exists, go to step 33 . If problem does not exist, go to next step.
- Turn ignition on with engine off. Using a test light connected to ground, probe air pump feed circuit (Red wire) at air pump connector (engine side). Using scan tool, command air pump on. If test light illuminates, go to next step. If test light does not illuminate, go to step 12 .
- Using a test light connected to ground, probe air pump ground circuit (Black wire) at air pump connector (engine side). If test light illuminates, go to step 46 . If test light does not illuminate, go to step 34 .
- Turn ignition off. Disconnect air pump relay connector. Check for poor connection at air pump relay. If problem exists, go to step 33 . If problem does not exist, go to next step.
- Check for open in air pump feed circuit (Red wire) between air pump relay and air pump. If problem does not exist, go to next step. If problem exist, go to step 33 .
- Using a test light connected to ground, probe battery feed circuit (Red wire) at air pump relay connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 36 .
- Turn ignition on. Using a test light connected to ground, probe ignition feed circuit (Pink wire) at air pump relay connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 37 .
- Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. Using scan tool, command air pump on. If test light illuminates, go to step 43 . If test light does not illuminate, go to next step.
- Turn ignition off. Disconnect VCM harness connectors. Check for poor connections at VCM. If problem does not exist, go to next step. If problem exist, go to step 33 .
- Check for open in air pump relay control circuit (Brown wire) between air pump relay and VCM. If problem does not exist, go to next step. If problem exist, go to step 33 .
- Turn ignition on. Using a test light connected to ground, probe air pump relay control circuit (Brown wire) at air pump relay connector. If test light illuminates, go to step 38 . If test light does not illuminate, go to step 47 .
- Disconnect air pump output hose at air shutoff valve. Start engine and let idle. Using scan tool, command air pump on. If air flows from air shutoff valve, go to next step. If air does not flow from air shutoff valve, go to step 23 .
- Disconnect vacuum hose from air shutoff valve. Install a vacuum gauge on air shutoff valve vacuum hose. Using scan tool, command air pump off. If vacuum is present at vacuum hose, go to step 45 . If vacuum is not present at vacuum hose, go to next step.
- Turn ignition off. Turn ignition on with engine off. Using scan tool, command air pump on. If air flows from air shutoff valve, go to step 44 . If air does not flow from air shutoff valve, go to step 30 .
- Turn ignition off. Disconnect air pump output hose from air shutoff valve. Turn ignition on with engine off. Using scan tool, command air pump on. If air flows from output hose, go to next step. If air does not flow from output hose, go to step 31 .
- Disconnect vacuum hose from air shutoff valve. Install a vacuum gauge on air shutoff valve vacuum hose. Start engine and let idle. Using scan tool, command air pump on. If vacuum is greater than 10 in. Hg while air pump is running, go to step 44 . If vacuum is less than 10 in. Hg while air pump is running, go to next step.
- Check for leak or restriction in vacuum hose between air solenoid and air shutoff valve. If problem exists, go to step 42 . If problem does not exist, go to next step.
- Remove vacuum connector from air solenoid. Install a vacuum gauge on source hose coming from engine. Measure vacuum with engine running. If vacuum is greater than 10 in. Hg, go to next step. If vacuum is less than 10 in. Hg, go to step 32 .
- Turn ignition off. Disconnect air solenoid connector. Check for poor connection at air solenoid. If problem exists, go to step 33 . If problem does not exist, go to next step.
- Turn ignition on with engine off. Using a test light connected to ground, probe air solenoid feed circuit (Red wire) at air solenoid connector. Using scan tool, command air pump on. If test light illuminates, go to next step. If test light does not illuminate, go to step 40 .
- Turn ignition off. Using a test light connected to battery voltage, probe air solenoid ground circuit (Black wire) at air solenoid connector. If test light illuminates, go to step 45 . If test light does not illuminate, go to step 39 .
- Check for leaks or restrictions in air shutoff valve, hoses, check valves, fittings, air pipes, and/or exhaust manifolds. If problem exists, go to step 42 . If problem does not exist, check the following and repair as necessary. Loose air pump belt. Poor connection at PCM or any secondary air injection system component. Damaged wiring harness. Pinched, kinked or restricted air pipes, line or fittings.
- Check for restriction or obstruction in air pump inlet hose. If problem exists, go to step 42 . If problem does not exist, go to step 46 .
- Repair leak or restriction in air solenoid vacuum supply hose. After repairs, go to step 48 .
- Repair circuit as necessary. After repairs, go to step 48 .
- Repair open in air pump ground circuit. After repairs, go to step 48 .
- Repair short to voltage in air pump feed circuit. After repairs, go to step 48 .
- Repair open or short to ground in air pump relay battery feed circuit. After repairs, go to step 48 .
- Repair open or short to ground in air pump relay ignition feed circuit. After repairs, go to step 48 .
- Repair short to voltage in air pump relay control circuit. After repairs, go to step 48 .
- Repair open in air solenoid ground circuit. After repairs, go to step 48 .
- Repair open in air solenoid feed circuit. After repairs, go to step 48 .
- Repair short to ground in air pump relay control circuit. After repairs, go to step 48 .
- Repair as necessary. After repairs, go to step 48 .
- Replace air pump relay. After repairs, go to step 48 .
- Replace air shutoff valve. After repairs, go to step 48 .
- Replace air solenoid. After repairs, go to step 48 .
- Replace air pump. After repairs, go to step 48 .
- Replace VCM. Program VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, verify engine is at normal operating temperature and operating in closed loop. Using scan tool, command air pump on. If short term fuel trim indicates 16 percent within 30 seconds, system is okay. If short term fuel trim does not indicate 16 percent within 30 seconds, go to step 4 .
Secondary Air Injection System Diagnosis (7.4L)
Note. For circuit and connector terminal identification, see appropriate wiring diagram in WIRING DIAGRAMS article.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, verify engine is at normal operating temperature and operating in closed loop. Using scan tool, command air pump on. If short term fuel trim indicates 16 percent within 30 seconds, go to next step. If short term fuel trim does not indicate 16 percent within 30 seconds, go to step 4 .
- If any DTCs exist, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article. If no DTCs exist, check the following and repair as necessary. Loose air pump belt. Poor connection at PCM or any secondary air injection system component. Damaged wiring harness. Pinched, kinked or restricted air pipes, line or fittings.
- Ensure engine is still running. Using scan tool, command air pump on. If air pump clutch is engaged, go to next step. If air pump clutch is not engaged, go to step 9 .
- Ensure engine is still running. Using scan tool, command air pump off. If air pump clutch is engaged, go to next step. If air pump clutch is not engaged, go to step 19 .
- Turn ignition off. Remove air pump relay. Turn ignition switch on. Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 8 .
- Turn ignition off. Disconnect VCM harness connectors. Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. If test light illuminates, go to step 30 . If test light does not illuminate, go to step 36 .
- Turn ignition on. Using a test light connected to ground, probe air pump feed circuit (Red wire) at air pump relay connector. If test light illuminates, go to step 31 . If test light does not illuminate, go to step 33 .
- Turn ignition off. Disconnect air pump clutch connector. Check for poor connection at air pump clutch. If problem exists, go to step 26 . If problem does not exist, go to next step.
- Turn ignition on with engine off. Using a test light connected to ground, probe air pump clutch feed circuit (Red wire) at air pump clutch connector. Using scan tool, command air pump on. If test light illuminates, go to next step. If test light does not illuminate, go to step 12 .
- Using a test light connected to ground, probe air pump clutch ground circuit (Black wire) at air pump clutch connector. If test light illuminates, go to step 35 . If test light does not illuminate, go to step 27 .
- Turn ignition off. Disconnect air pump relay connector. Check for poor connection at air pump relay. If problem exists, go to step 26 . If problem does not exist, go to next step.
- Check for open in air pump clutch feed circuit. If problem exists, go to step 26 . If problem does not exist, go to next step.
- Turn ignition on. Using a test light connected to ground, probe both ignition feed circuits (Pink wires) at air pump relay socket. If test light illuminates on both terminals, go to next step. If test light does not illuminate on both terminals, go to step 28 .
- Using a test light connected to battery voltage, probe air pump relay control circuit (Brown wire) at air pump relay connector. Using scan tool, command air pump on. If test light illuminates, go to step 33 . If test light does not illuminate, go to next step.
- Turn ignition off. Disconnect VCM harness connector. Check for poor connection at VCM. If problem exists, go to step 26 . If problem does not exist, go to next step.
- Check for open in air pump relay control circuit. If problem exists, go to step 26 . If problem does not exist, go to next step.
- Turn ignition on. Using a test light connected to ground, probe air pump relay control circuit (Brown wire) at VCM harness connector. If test light illuminates, go to step 29 . If test light does not illuminate, go to step 36 .
- Turn ignition off. Disconnect air output hose at output of air shutoff valve. Start engine and let idle. Using scan tool, command air pump on. If air flows from air shutoff valve, go to step 24 . If air does not flow from air shutoff valve, go to next step.
- Turn ignition off. Disconnect air output hose at inlet of air shutoff valve. Start engine and let idle. Using scan tool, command air pump on. If air flows from output hose, go to next step. If air does not flow from output hose, go to step 23 .
- Using scan tool, command air pump on. Accelerate engine to about 1500 RPM. If airflow increases as engine is accelerated, go to next step. If airflow does not increase as engine is accelerated, go to step 25 .
- Check for leaks or loose connections in hose between air pump and air shutoff valve. If problem exists, go to step 32 . If problem does not exist, go to step 34 .
- Check for leaks or obstructions in hose between air pump and air shutoff valve. If problem exists, go to step 32 . If problem does not exist, go to step 25 .
- Check for leaks or restrictions in air shutoff valve, hoses, check valves, fittings, air pipes, and/or exhaust manifolds. If problem exists, go to step 32 . If problem does not exist, check the following and repair as necessary. Loose air pump belt. Poor connection at PCM or any secondary air injection system component. Damaged wiring harness. Pinched, kinked or restricted air pipes, line or fittings.
- Check for restriction or obstruction in air pump inlet hose. If problem exists, go to step 32 . If problem does not exist, go to step 35 .
- Repair circuit as necessary. After repairs, go to step 37 .
- Repair open in air pump clutch ground circuit. After repairs, go to step 37 .
- Repair open or short to ground in ignition feed circuits. After repairs, go to step 37 .
- Repair short to voltage in air pump relay control circuit. After repairs, go to step 37 .
- Repair short to ground in air pump relay control circuit. After repairs, go to step 37 .
- Repair short to voltage in air pump clutch feed circuit. After repairs, go to step 37 .
- Repair as necessary. After repairs, go to step 37 .
- Replace air pump relay. After repairs, go to step 37 .
- Replace air shutoff valve. After repairs, go to step 37 .
- Replace air pump. After repairs, go to step 37 .
- Replace VCM. Program VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, verify engine is at normal operating temperature and operating in closed loop. Using scan tool, command air pump on. If short term fuel trim indicates 16 percent within 30 seconds, system is okay. If short term fuel trim does not indicate 16 percent within 30 seconds, go to step 4 .
EGR System Diagnosis
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Set parking brake and block wheels. Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, check actual EGR position. If scan tool indicates greater than zero percent, go to step 4. If scan tool indicates zero percent, go to next step.
- Turn ignition on with engine off. Using scan tool, command EGR position to 100 percent. If actual EGR position follows the commanded EGR position, go to step 17. If the actual EGR position does not follow commanded EGR position, go to step 6.
- Disconnect EGR valve harness connector. If scan tool indicates greater than zero percent, go to step 16. If scan tool indicates zero percent, go to next step.
- Turn ignition off. Connect a test light between EGR valve feed circuit (Red wire) and EGR valve control circuit (White wire) at EGR valve harness connector. (Scheme 25) Turn ignition on with engine off. If test light illuminates, go to step 15. If test light does not illuminate, go to step 10.
- Turn ignition on with engine off. Connect a test light between EGR valve feed circuit (Red wire) and EGR valve control circuit (White wire) at EGR valve harness connector. (Scheme 25) Using scan tool, command EGR position to 100 percent. If test light illuminates, go to step 13. If test light does not illuminate, go to next step.
- Turn ignition off. Using a test light connected to battery voltage, probe EGR valve control circuit (White wire) at EGR valve harness connector. (Scheme 25) If test light illuminates, go to next step. If test light does not illuminate, go to step 9.
- Check for an open in EGR valve feed circuit. If problem exists, go to step 22. If problem does not exist, go to step 21.
- Check for open, high resistance or short to voltage in EGR valve control circuit. If problem exists, go to step 22. If problem does not exist, go to step 21.
- Turn ignition on with engine off. Using a DVOM connected to ground, probe EGR reference voltage circuit (Gray wire) at EGR valve harness connector. (Scheme 25) If voltage is greater than 5.2 volts, go to step 22. If voltage is 5.2 volts or less, go to next step.
- Turn ignition off. Using a test light connected to battery voltage, probe EGR sensor ground circuit (Black wire) at EGR valve harness connector. (Scheme 25) If test light illuminates, go to step 19. If test light does not illuminate, go to next step.
- Turn ignition off. Disconnect VCM harness connectors. Check for open in EGR sensor ground circuit. If problem exists, go to step 22. If problem does not exist, go to step 21.
- Turn ignition on with engine off. Using a DVOM connected to ground, probe EGR reference voltage circuit (Gray wire) at EGR valve harness connector. (Scheme 25) If voltage is near 5.2 volts, go to next step. If voltage is not near 5.2 volts, go to step 22.
- Disconnect EGR valve harness connector. Install jumper wire between EGR reference voltage circuit (Gray wire) and EGR pintle position signal circuit (Brown wire) at EGR valve harness connector. (Scheme 25) Turn ignition on with engine off. If actual EGR position is near 100 percent, go to step 19. If actual EGR position is not near 100 percent, go to step 20.
- Disconnect VCM harness connector. Turn ignition on with engine off. Check for short to voltage in EGR valve feed circuit. If problem exists, go to step 22. If problem does not exist, go to step 23.
- Disconnect VCM harness connectors. Turn ignition on with engine off. Check for short to voltage in EGR pintle position signal circuit. If problem exists, go to step 22. If problem does not exist, go to step 23.
- Start engine. Observe MAP sensor reading. Using scan tool, command EGR position to 30 percent. Observe MAP sensor reading again. If MAP sensor reading increases, go to step 24. If MAP sensor reading does not increase, go to next step.
- Repair blockage in EGR valve passages. After repairs, go to step 24.
- Replace EGR valve. After repairs, go to step 24.
- Check for short to ground in EGR pintle position signal circuit. If problem exists, go to step 22. If problem does not exist, go to next step.
- Check for poor connections at VCM. If problem exists, go to step 22. If problem does not exist, go to step 23.
- Repair circuit as necessary. After repairs, go to step 24.
- Replace VCM. Program VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Set parking brake and block wheels. Install scan tool. Start engine and let idle until normal operating temperature is obtained. Using scan tool, command EGR on and off. If actual EGR position follows the commanded EGR position, system is okay. If the actual EGR position does not follow commanded EGR position, go to step 2.
Scheme 25
FUEL EVAPORATION
Note. Ensure all vacuum line and EVAP system components are not damaged or missing before proceeding with this test.
EVAP Control System Diagnosis (Except 2.2L & 3.4L)
Note. For circuit and connector terminal identification, see appropriate wiring diagram in WIRING DIAGRAMS article.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Retrieve DTCs. If DTC P0440, P0442, P0446, P0452, P0453, P0461, P0462, P0463 or P1441 is not set, go to next step. If DTC P0440, P0442, P0446, P0452, P0453, P0461, P0462, P0463 or P1441 is set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
- Inspect EVAP system for the following: Loose, incorrect, defective or missing fuel filler cap. Improperly routed, kinked, or damaged EVAP system purge lines. Damaged EVAP system components. Loose, missing or damaged service port dust cap and/or schrader valve. If problem exists, repair as necessary and go to step 25 . If problem does not exist, go to next step.
- Before proceeding with service bay test, ensure DTCs are cleared, battery voltage is 10.5-17.5 volts, fuel level is 15-85 percent, and with ignition on engine temperature is less than 176°F (80°C). Scan tool will display TEST ABORTED when service bay test is activated if the listed criteria are not met. Using scan tool, capture and save freeze frame records. Clear DTCs. Using scan tool, perform service bay test for EVAP system. If vehicle does not pass service bay test, go to next step. If vehicle passes service bay test, inspect EVAP system for the following: Loose, incorrect, defective or missing fuel filler cap. Missing or damaged EVAP canister fuel vapor and purge line fitting "O" rings. Cracked or punctured EVAP canister. Improperly routed, kinked, or damaged EVAP system purge and vapor lines. Disconnected or damaged EVAP purge line, vent hose or fuel tank vapor line. Poor connection at VCM, backed-out terminals, broken locks, improperly formed or damaged terminals, or poor terminal-to-wire connection Damaged EVAP purge solenoid valve, EVAP canister vent solenoid valve of fuel tank pressure sensor wiring harnesses. Kinked, pinched, plugged or restricted EVAP purge or fuel tank vapor line.
- Turn ignition off. Connect a vacuum gauge directly to purge connection of EVAP purge solenoid valve. Start engine and let idle. Using scan tool, command EVAP purge solenoid valve to 100 percent purge. If vacuum is 12 in. Hg or more, go to next step. If vacuum is less than 12 in. Hg, go to step 11 .
- Turn ignition off. Disconnect fuel tank vapor line and EVAP purge line from EVAP canister. Plug EVAP canister fuel tank vapor port. Connect a hand-held vacuum pump to EVAP canister purge port. With ignition on, using scan tool, command EVAP vent solenoid valve on. Attempt to apply 5 in. Hg to EVAP canister. If 5 in. Hg can be obtained and held, go to step 9 . If 5 in. Hg cannot be obtained or held, go to next step.
- Leave system connected as described in step 6) . Disconnect vent line at EVAP canister vent solenoid valve. Plug disconnected vent line. Attempt to apply 5 in. Hg to EVAP canister. If 5 in. Hg can be obtained and held, go to step 15 . If 5 in. Hg cannot be obtained or held, go to next step.
- Inspect for leaks in EVAP vent line from EVAP canister to EVAP vent solenoid valve. Replace as necessary. If problem exists, go to step 25 . If problem does not exist, go to step 21 .
- Turn ignition off. Remove plug and hand-held vacuum pump. Reconnect EVAP canister purge and fuel tank vapor lines. Connect EVAP Pressure/Purge Diagnostic Station (J-41413) to EVAP system service port. Using scan tool, command EVAP vent solenoid valve on. Attempt to pressurize EVAP system to 15 in. H 2 O. DO NOT pressurize EVAP system to more than 15 in. H 2 O. Using Ultrasonic Leak Detector (J-41416), locate and repair EVAP system leak. If problem exists, go to step 25 . If problem does not exist, go to next step.
- Check EVAP system for restrictions. Repair as necessary. If problem exists, go to step 25 . If problem does not exist, go to step 22 .
- Turn ignition on with engine off. Disconnect EVAP purge solenoid valve connector. Connect a test light between ground and ignition feed circuit of EVAP purge solenoid valve connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 13 .
- Connect a test light between ignition feed circuit and control circuit of EVAP purge solenoid valve connector. Using scan tool, command EVAP purge solenoid valve on. If test light illuminates, go to step 19 . If test light does not illuminate, go to step 14 .
- Check for and repair cause of no power to EVAP purge solenoid valve ignition feed circuit. Possible causes may be: Open ignition feed circuit. Shorted ignition feed circuit (open fuse). Shorted EVAP purge solenoid valve (open fuse). No power to EVAP purge solenoid valve fuse (open maxi fuse, fuse link, etc.). After repairs, go to step 25 .
- Check for open in EVAP purge solenoid valve control circuit. Repair as necessary. If problem exists, go to step 25 . If problem does not exist, go to step 24 .
- Turn ignition on with engine off. Disconnect EVAP canister vent solenoid valve connector. Connect a test light between ground and ignition feed circuit of EVAP canister vent solenoid valve connector. If test light illuminates, go to next step. If test light does not illuminate, go to step 17 .
- Connect a test light between ignition feed circuit and control circuit of EVAP canister vent solenoid valve connector. Using scan tool, command EVAP canister vent solenoid valve on. If test light illuminates, go to step 20 . If test light does not illuminate, go to step 18 .
- Check for and repair cause of no power to EVAP canister vent solenoid valve ignition feed circuit. Possible causes may be: Open ignition feed circuit. Shorted ignition feed circuit (open fuse). Shorted EVAP canister vent solenoid valve (open fuse). No power to EVAP canister vent solenoid valve fuse (open maxi fuse, fuse link, etc.). After repairs, go to step 25 .
- Check for open in EVAP canister vent solenoid valve control circuit. Repair as necessary. If problem exists, go to step 25 . If problem does not exist, go to step 24 .
- Check EVAP purge solenoid valve and purge line for carbon contamination. Replace EVAP purge solenoid valve. After repairs, go to step 25 .
- Replace EVAP canister vent solenoid valve. After repairs, go to step 25 .
- Replace EVAP vapor canister. After repairs, go to step 25 .
- Relieve all system pressure. Using scan tool, select PURGE/SEAL. Turn EVAP purge solenoid valve on to varying vacuum levels with engine running and quickly SEAL system using scan tool. Leaving EVAP purge solenoid valve on for higher percents or longer times will develope a higher level of vacuum. Maximum of 8.5 in. H 2 O of vacuum can be applied to EVAP system using scan tool. While system is sealed, compare EVAP pressure/purge diagnostic station vacuum gauge (H 2 O) to vacuum indicated on scan tool from EVAP fuel tank pressure sensor. Allow system to stabilize for a few seconds. If values indicate the same amount of vacuum in EVAP system within 2 in. H 2 O, go to step 3 . If values do not indicate the same amount of vacuum in EVAP system within 2 in. H 2 O, go to next step.
- Replace fuel tank pressure sensor. After repairs, go to step 25 .
- Replace VCM. Program VCM. Perform VTD password relearn procedure and crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
- Using scan tool, clear DTCs. Start engine and let idle until normal operating temperature is obtained. Using scan tool, select DTC, and then SPECIFIC DTC. Enter the DTC number which was set. Operate vehicle under conditions for setting DTC until scan tool indicates the diagnostic ran. If scan tool indicates the diagnostic passed, go to next step. If scan tool does not indicate the diagnostic passed, go to step 2 .
- If scan tool displays any additional undiagnosed DTCs, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article. If scan tool does not display any additional undiagnosed DTCs, system is okay.
EVAP Control System Diagnosis (2.2L)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Turn ignition on with engine off. Retrieve DTCs. If no DTCs are set, go to next step. If any DTCs are set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
- Using scan tool, command EVAP purge solenoid valve and EVAP canister vent solenoid valve on and off. If both purge solenoid valve and canister vent solenoid valve click when toggled on and off, go to next step. If either purge solenoid valve or vent solenoid valve do not click when toggled on and off, perform PCM output diagnosis. See «PCM OUTPUT DIAGNOSIS (2.2L)»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__pcm-output-diagnosis-22l) under COMPUTERIZED ENGINE CONTROLS.
- Remove fuel cap. Using scan tool, observe fuel tank pressure. If scan tool displays -1.28-1.28 in. H 2 O, go to next step. If scan tool does not display -1.28-1.28 H 2 O, perform DTC P0452 or DTC P0453 test. See appropriate SELF-DIAGNOSTICS article.
- Reinstall fuel cap. Install EVAP Pressure/Purge Diagnostic Station (J-41413) to EVAP service port and zero gauges. Using scan tool, command EVAP canister vent solenoid valve on. Using diagnostic station, pressurize EVAP system to 5 in. H 2 O. Using scan tool, observe fuel tank pressure. If scan tool displays 3.85-8.99 in. H 2 O, go to next step. If scan tool does not display 3.85-8.99 in. H 2 O, perform DTC P0452 or DTC P0453 test. See appropriate SELF-DIAGNOSTICS article.
- Observe EVAP system pressure on diagnostic station. Using scan tool, command EVAP canister vent solenoid valve off. If EVAP system pressure decreases to zero in. H 2 O within 5 seconds, go to next step. If EVAP system pressure does not decrease to zero in. H 2 O within 5 seconds, perform DTC P0446 test. See appropriate SELF-DIAGNOSTICS article.
- Start engine. Remove fuel cap. Using scan tool, select EVAP PURGE/SEAL and seal EVAP system. Using diagnostic station, attempt to pressurize EVAP system to 5 in. H 2 O. If fuel tank pressure does not decrease, go to next step. If fuel tank pressure is decreasing, perform DTC P1441 test. See appropriate SELF-DIAGNOSTICS article.
- Using scan tool, command EVAP canister vent solenoid valve and EVAP purge solenoid valve on. Increase engine speed to 1500 RPM. Using scan tool, observe fuel tank pressure. If fuel tank pressure is decreasing, system is okay. If fuel tank pressure does not decrease, perform DTC P0440 test. See appropriate SELF-DIAGNOSTICS article.
EVAP Control System Diagnosis (3.4L)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Ensure vacuum and purge lines are connected. Check for loose or missing fuel filler cap. Install scan tool. Turn ignition on with engine off. Retrieve DTCs. If no DTCs are set, go to next step. If any DTCs are set, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
- Turn ignition off. Remove fuel filler cap to relieve fuel pressure. Turn ignition on with engine off. Using scan tool, observe fuel tank pressure. If fuel tank pressure is zero in. H 2 O, go to next step. If fuel tank pressure is not zero in. H 2 O, perform DTC P0453 test. See appropriate SELF-DIAGNOSTICS article.
- Turn ignition off. Reinstall fuel cap. Install EVAP Pressure/Purge Diagnostic Station (J-41413) to EVAP service port and zero gauges. Turn ignition on with engine off. Using scan tool, capture and save freeze frame record for DTC 0440. Clear DTCs. Using scan tool, select EVAP PURGE/SEAL and seal EVAP system. Attempt to pressurize EVAP system to 5 in. H 2 O by slowly turning diagnostic station rotary switch to PRESSURE position. Monitor pressure with switch in OFF/HOLD position. If fuel tank pressure is 5 in. H 2 O, go to next step. If fuel tank pressure is not 5 in. H 2 O, perform DTC P0440 test. See appropriate SELF-DIAGNOSTICS article.
- Maintain fuel tank pressure at 5 in. H 2 O. Monitor pressure with switch in OFF/HOLD position. Using scan tool, observe fuel tank pressure. If fuel tank pressure is 5 in. H 2 O, go to next step. If fuel tank pressure is not 5 in. H 2 O, go to step 10 .
- Command EVAP canister vent solenoid valve off to relieve pressure through vent solenoid valve. If EVAP pressure gauge decreases to about -5 in. H 2 O within 2 minutes with rotary switch in OFF/HOLD position, go to next step. If EVAP pressure gauge does not decrease to about -5 in. H 2 O within 2 minutes with rotary switch in OFF/HOLD position, perform DTC P0446 test. See appropriate SELF-DIAGNOSTICS article.
- Connect the in. Hg vacuum gauge of diagnostic station to EVAP purge solenoid valve (canister side). Turn ignition on with engine off. Using scan tool, select EVAP PURGE/SEAL and seal EVAP system. Start engine and let idle. Run engine from 1200-1500 RPM and observe vacuum level. If vacuum is near zero in. Hg, go to next step. If vacuum is not near zero in. Hg, go to step 11 .
- Using scan tool, increase purge to 100 percent. Run engine from 1200-1500 RPM and observe vacuum level. If vacuum level is greater than 15 in. Hg, go to next step. If vacuum level is 15 in. Hg or less, go to step 12 .
- Check for kinked or restricted canister purge line between EVAP purge solenoid valve and EVAP canister. Repair as necessary. After repairs, go to step 13 .
- Check for restricted fuel tank vapor line or EVAP purge line. If problem exists, repair as necessary and go to step 13 . If problem does not exist, perform DTC P0452 test. See appropriate SELF-DIAGNOSTICS article.
- Check EVAP purge solenoid valve and purge line for carbon contamination. Replace EVAP purge solenoid valve. After repairs, go to step 13 .
- Check for no source vacuum to EVAP purge solenoid valve. If problem exists, repair as necessary and go to step 2 . If problem does not exist, go to next step.
- Reconnect all previously disconnect EVAP system components and hardware. Turn ignition on with engine off. Using scan tool, select EVAP PURGE/SEAL and seal EVAP system. Pressurize EVAP system to 15 in. H 2 O by slowly turning diagnostic station rotary switch to PRESSURE position. Monitor pressure with switch in OFF/HOLD position. If EVAP pressure gauge decreases to less than 10 in. H 2 O within 2 minutes with rotary switch in OFF/HOLD position, perform DTC P0442 test. See appropriate SELF-DIAGNOSTICS article. If EVAP pressure gauge does not decrease to less than 10 in. H 2 O within 2 minutes with rotary switch in OFF/HOLD position, system is okay.
Fuel Tank Pressure Sensor Diagnosis (3.4L)
Note. For fuel tank pressure sensor testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Note. For component circuit identification, see appropriate wiring diagram in WIRING DIAGRAMS article.
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Disconnect fuel tank pressure sensor harness connector. Using DVOM, measure voltage between reference voltage circuit (Gray wire) and sensor ground circuit (Orange/Black wire) at fuel tank pressure sensor harness connector. If voltage is about 5 volts, go to step 5 . If voltage is not about 5 volts, go to next step.
- Check reference voltage circuit (Gray wire) for poor connection at PCM. If problem exists, go to step 11 . If problem does not exist, go to next step.
- Check for open or poor connection in reference voltage circuit (Gray wire) to fuel tank pressure sensor harness connector. If problem exists, go to step 12 . If problem does not exist, go to step 8 .
- Remove fuel cap. Disconnect fuel tank pressure sensor harness connector. Using 2 fused jumper wires, connect reference voltage circuit (Gray wire) and sensor signal circuit (Dark Green wire) between fuel tank pressure sensor and fuel tank pressure sensor harness connector. Using DVOM, measure voltage at sensor signal circuit terminal of fuel tank pressure sensor pigtail. If voltage is 1.3-1.7 volts, go to next step. If voltage is not 1.3-1.7, go to step 13 .
- Check sensor signal circuit (Dark Green wire) for poor connection at PCM. If problem exists, go to step 11 . If problem does not exist, go to next step.
- Check for open, short to ground or short to voltage in sensor signal circuit (Dark Green wire) between fuel tank pressure sensor and PCM. If problem exists, go to step 12 . If problem does not exist, go to step 14 .
- Check sensor ground circuit (Orange/Black wire) for poor terminal connection at PCM. If problem exists, go to step 11 . If problem does not exist, go to next step.
- Check for open or faulty splice in sensor ground circuit (Orange/Black wire). If problem exists, go to step 12 . If problem does not exist, go to step 14 .
- Check for poor terminal connection at fuel tank pressure sensor connector. If problem exists, go to next step. If problem does not exist, go to step 13 .
- Replace faulty harness connector terminals as necessary. After repairs, go to step 15 .
- Locate and repair open or short circuit in wiring harness as necessary. After repairs, go to step 15 .
- Replace fuel tank pressure sensor. After repairs, go to step 15 .
- Replace PCM. Program PCM, perform VTD password relearn procedure and perform crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION. After repairs, go to next step.
- Turn ignition off. Remove fuel cap. Turn ignition on. Using scan tool, observe fuel tank pressure. If fuel tank pressure is zero in. H 2 O, go to next step. If fuel tank pressure is not zero in. H 2 O, go to step 2 .
- Connect EVAP Pressure/Purge Diagnostic Station (J-41413) to EVAP system service port. Using scan tool, command EVAP vent solenoid valve on. Pressurize EVAP system to 5 in. H 2 O. Using scan tool, observe fuel tank pressure. If problem exists, system is okay. If problem does not exist, go to step 2 .
Required Service
The PCV system may require service for obstructions if any of the following conditions exist
- Rough idle.
- Stalling or low idle speed.
- Oil leaks.
- Oil in air cleaner.
- Sludge in engine.
A leaking PCV valve or hose could cause
- Rough idle.
- Stalling.
- High idle speed.
If engine idles rough, check for clogged PCV valve, or for plugged or broken PCV hoses BEFORE adjusting idle. Check PCV valve application to ensure valve is fitted. Replace PCV valve if required.
Checking PCV Valve Function
- Disconnect PCV valve vacuum hose from cylinder head cover. Run engine at idle. Place thumb over open end of PCV valve vacuum hose to check for vacuum. If vacuum does not exist, check for obstruction in source vacuum supply. If source vacuum supply is okay, replace PCV valve.
- Turn ignition off. Remove PCV valve. Shake valve and listen for rattle of check valve inside PCV valve. If a clear rattle is not heard, replace PCV valve.
- Visually inspect valve for varnish or deposits that may make PCV valve operation sticky or restricted, or cause incomplete seating of valve. Replace as necessary.
- Engine must be sealed for PCV system to function as designed. If leakage, sludging or dilution of oil is noted and PCV system is functioning properly, check engine for cause and repair as required to ensure PCV system will continue to function properly.
- An engine operating without any crankcase ventilation can be damaged, so it is important to replace PCV valve and air cleaner breather (if equipped) at regular intervals (at least every 30,000 miles). Check all hoses and clamps for failure or deterioration.
EMISSION SYSTEMS & SUB-SYSTEMS (DIESEL)
Note. For emission and subsystem testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
Crankcase Depression Regulator (CDR) Valve
To test CDR valve, connect one end of a water manometer to engine oil dipstick tube. Leave other end of manometer open to atmosphere. Unplug rubber vent tube from turbo inlet elbow. Install air cleaner and run engine. CDR valve specification is one in. H 2 O at idle to 3-4 in. H 2 O at full load. Add amount of distance water travels down one side of gauge to distance water travels up other side of gauge to obtain reading.
EGR Valve Check
With engine off, disconnect vacuum hose to EGR valve. Connect vacuum pump to EGR and apply 10 in. Hg. EGR diaphragm should move up and stay up for at least 20 seconds. If EGR does not operate as specified, replace EGR valve.
VACUUM PUMP
Connect vacuum gauge to vacuum pump inlet (small fitting). DO NOT plug or disconnect outlet fitting. With engine idling, vacuum should be 18 in. Hg one minute after start. If vacuum is not as specified, check for belt slippage, vacuum leaks or other obvious defects. If no defects are present, replace vacuum pump.
MISCELLANEOUS CONTROLS
Note. Although some of the controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.
Manufacturer does not provide testing procedures for many individual systems and components. For system and component testing not listed, perform related DTC testing procedure. See appropriate SELF-DIAGNOSTICS article.
A/C COMPRESSOR CLUTCH CONTROLS
Note. For A/C compressor clutch circuit testing, see appropriate MANUAL A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING. See appropriate wiring diagram in WIRING DIAGRAMS article for terminal and wire color identification.
FWD Vans
To provide improved idle quality, maintain Wide Open Throttle (WOT) performance and provide A/C system protection, compressor clutch is controlled by PCM.
The A/C compressor clutch relay is controlled by PCM according to information received from A/C refrigerant pressure sensor and various other sensors. This allows PCM to increase idle speed before engaging compressor clutch. PCM will disable compressor clutch during WOT, when refrigerant pressure is incorrect or if coolant temperature exceeds a predetermined value. PCM inhibits compressor clutch operation when engine speed is greater than 4500 RPM for 5 seconds, or when throttle angle exceeds 90 percent.
Trucks & RWD Vans
The A/C compressor clutch relay is controlled by PCM. The PCM improves idle quality by delaying compressor clutch engagement until idle speed is increased, or disengages compressor clutch when idle speed is too low. Compressor clutch is cycled by PCM. The PCM smooths cycling of compressor clutch by adding fuel the instant compressor clutch is applied.
ELECTRIC COOLING FAN CONTROL
Note. For electric cooling fan circuit testing, see ELECTRIC COOLING FANS article in AIR CONDITIONING & HEATING. See appropriate wiring diagram in WIRING DIAGRAMS article for terminal and wire color identification.
All FWD and some RWD vehicles use an electric cooling fan. The electric cooling fan is used for radiator and A/C condenser cooling. Cooling fan operates when A/C is on and when engine coolant temperature exceeds a specific value. One or more cooling fan relays may be used. Some RWD trucks, vans and motorhomes are equipped with an auxiliary electric cooling fan.
Generator Circuit Diagnosis (2.2L)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Turn ignition on with engine off. If charging system light illuminates, go to next step. If charging system light does not illuminate, go to step 4 .
- Start engine. If charging system light goes out, go to step 17 . If charging system light remains illuminated, go to step 5 .
- Turn ignition off. Disconnect generator connector. Turn ignition on with ignition off. If charging system light illuminates, go to step 6 . If charging system light does not illuminate, go to step 7 .
- Turn all accessories off. Install scan tool. If voltage is greater than 12 volts, go to step 7 . If voltage is 12 volts or less, go to step 8 .
- With test light connected to ground, probe light driver output circuit at generator connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If test light illuminates, go to step 9 . If test light does not illuminate, go to step 10 .
- Replace instrument cluster. After repairs, go to step 17 .
- Turn ignition off. Disconnect generator connector. Turn ignition on with engine off. Using a test light connected to ground, probe light driver output circuit at generator connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If test light illuminates, go to step 11 . If test light does not illuminate, go to step 12 .
- Repair short to voltage in light driver output circuit. After repairs, go to step 17 .
- Replace generator. After repairs, go to step 17 .
- Repair short to ground in light driver output circuit. After repairs, go to step 17 .
- Using DVOM connected to ground, probe light driver output circuit at generator connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If voltage is greater than 4.5 volts, go to next step. If voltage is 4.5 volts or less, go to step 14 .
- Using DVOM connected to ground, probe battery circuit at generator connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If battery voltage exists, go to step 10 . If battery voltage does not exist, go to step 15 .
- Check for poor connection or open in light driver output circuit. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 16 .
- Check for poor connection or open in battery circuit. Repair as necessary. After repairs, go to step 17 .
- Replace PCM. Program PCM, perform VTD password relearn procedure and perform crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION article. After repairs, go to next step.
- Start engine and operate vehicle under condition under which original symptom was noted. If system does not operate properly, go to step 2 . If system operates properly, check for poor connection at PCM, backed-out terminals, broken locks, improperly formed or damaged terminals, or poor terminal-to-wire connection.
Shift Light Circuit Diagnosis (Manual Transmission)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Turn ignition off. Install scan tool. Turn ignition on. Using scan tool, command shift light on. If shift light illuminates, go to step 4 . If shift light does not illuminate, go to next step.
- Turn ignition off. Disconnect PCM/VCM harness connector that contains shift light circuit. Turn ignition on. Connect a fused jumper wire between ground and shift light control circuit (Tan/Black wire) at PCM/VCM harness connector. If shift light illuminates, go to step 5 . If shift light does not illuminate, go to step 6 .
- Using scan tool, command shift light off, and then on. If shift light operates as commanded, system is okay. If shift light does not operate as commanded, go to step 8 .
- Check shift light control circuit (Tan/Black wire) for poor connection at PCM/VCM. If problem exists, go to step 7 . If problem does not exist, go to step 10 .
- Repair open in shift light control circuit between PCM/VCM and instrument cluster. After repairs, go to step 11 .
- Repair poor connection as necessary. After repairs, go to step 11 .
- Turn ignition off. Disconnect PCM/VCM harness connector that contains shift light circuit. Turn ignition on. If shift light illuminates, go to next step. If shift light does not illuminate, go to step 10 .
- Repair short to ground in shift light control circuit (Tan/Black wire) between PCM/VCM and instrument cluster. After repairs, go to step 11 .
- Replace PCM/VCM. Program PCM/VCM, perform VTD password relearn procedure and perform crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION article. After repairs, go to next step.
- Using scan tool, clear DTCs. Start engine and let idle until normal operating temperature is obtained. Using scan tool, select DTC, and then SPECIFIC DTC. Enter the DTC number which was set. Operate vehicle under conditions for setting DTC until scan tool indicates the diagnostic ran. If scan tool indicates the diagnostic passed, go to next step. If scan tool does not indicate the diagnostic passed, go to step 2
- If scan tool does not display any DTCs, system is okay. If scan tool displays any DTCs, perform appropriate DTC test. See appropriate SELF-DIAGNOSTICS article.
Tachometer Control Circuit Diagnosis (4.3L)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Install scan tool. Using scan tool, select BODY (IPC) diagnosis tachometer sweep test function. Sweep tachometer needle on and off. If tachometer needle sweeps when commanded, go to next step. If tachometer needle does not sweep when commanded, diagnose instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
- Using scan tool, select POWERTRAIN tachometer control. Start engine and let idle. Using scan tool, command tachometer output to 600 RPM, and then to 6000 RPM. Compare scan tool display to actual tachometer value displayed on instrument cluster. If scan tool display matches instrument cluster display, system is okay. If scan tool display does not match instrument cluster display, go to next step.
- Disconnect instrument cluster connector that contains tachometer output circuit. Using scan tool, select POWERTRAIN tachometer control. Connect DVOM between ground and tachometer circuit of instrument cluster connector (harness side) and measure AC frequency (press Hz button) of tachometer circuit. Start engine and let idle. Using scan tool, command tachometer output to 600 RPM, and then to 6000 RPM. Compare DVOM display to specifications in table. See «FREQUENCY VS. RPM»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) table. If DVOM display matches table specifications, diagnose instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If DVOM display does not match table specifications, go to next step.
- Check for open, short to ground or short to voltage in tachometer output circuit. See appropriate wiring diagram in WIRING DIAGRAMS article. If problem exists, go to next step. If problem does not exist, go to step 7 .
- Repair circuit as necessary. After repairs, go to step 3 .
- Check for poor connection at VCM. If problem exists, repair as necessary and go to step 3 . If problem does not exist, go to next step.
- Replace VCM. Program VCM, perform VTD password relearn procedure and perform crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION article. After repairs, go to step 3 .
| Commanded Output (RPM) | VCM PWM Signal (Hz) |
|---|---|
| 500 | 16.4 |
| 1000 | 32.9 |
| 1500 | 49.4 |
| 2000 | 66.7 |
| 2500 | 83.1 |
| 3000 | 99.7 |
| 3500 | 116.1 |
| 4000 | 133.6 |
| 4500 | 150.1 |
| 5000 | 166.6 |
| 5500 | 183.1 |
| 6000 | 200.4 |
FREQUENCY VS. RPM
Warning Light Circuit Diagnosis (3.4L)
- If On-Board Diagnostic (OBD) system check has been performed, go to next step. If On-Board Diagnostic (OBD) system check has not been performed, perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article.
- Diagnose instrument cluster. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. After diagnosis, go to next step.
- Turn ignition off. Disconnect PCM harness connectors. Turn ignition on. Using DVOM, measure voltage between ground and affected PCM output circuit at PCM harness connector. See «POWERTRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) . See appropriate wiring diagram in WIRING DIAGRAMS article. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 7 .
- Set DVOM to 10-amp scale. Using DVOM, measure current between ground and affected PCM output circuit at PCM harness connector. See «POWERTRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests) . See appropriate wiring diagram in WIRING DIAGRAMS article. Monitor current reading for about 2 minutes. If current is .05-1.5 amps, go to step 12 . If current is not .05-1.5 amps, go to next step.
- Disconnect instrument cluster connector. Leave PCM harness connectors disconnected. Using DVOM, measure voltage between ground and affected PCM output circuit at instrument cluster connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If voltage is zero volts, go to step 15 . If voltage is not zero volts, go to next step.
- Locate and repair short to voltage in affected PCM output circuit. After repairs, go to step 17 .
- Check ignition feed fuse for instrument cluster indicator lights. If fuse is blown, go to next step. If fuse is okay, go to step 9 .
- Locate and repair short to ground in ignition feed circuit for instrument cluster indicator lights. Replace fuse and go to step 17 .
- Disconnect instrument cluster connector. Turn ignition on. Using DVOM, measure voltage between ground and ignition feed circuit at instrument cluster connector. See appropriate wiring diagram in WIRING DIAGRAMS article. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 14 .
- Check for an open or short to ground in affected PCM output circuit. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to next step.
- Check affected PCM output circuit and ignition feed circuit for poor connection at instrument cluster and at PCM. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 15 .
- Turn ignition off. Reconnect PCM harness connector. Disconnect instrument cluster connector. Turn ignition on. Connect a test light between affected PCM output circuit and ignition feed circuit at instrument cluster connector. See appropriate wiring diagram in WIRING DIAGRAMS article. Using scan tool, select OUTPUTS TEST, and cycle affected warning light on and off. If test light flashes on and off, check for shorted component or circuit in the output driver circuit. Check for faulty instrument cluster. If test light does not flash on and off, go to next step.
- Check affected PCM output circuit for poor connection at PCM. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 16 .
- Locate and repair open in ignition feed circuit to instrument cluster indicator lights. After repairs, go to step 17 .
- Replace instrument cluster. After repair, go to step 17 .
- Replace PCM. Program PCM, perform VTD password relearn procedure and perform crankshaft variation learn procedure. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION article. After repairs, go to next step.
- Using scan tool, operate affected warning light. If warning light operates properly, system is okay. If warning light does not operate properly, go to step 2 .
TRANSMISSION
Note. Computerized transmission controls are also covered in greater detail in appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. For component circuit identification, see appropriate wiring diagram in WIRING DIAGRAMS article.
Note. Some TCC solenoids have an internal pressure switch in series with solenoid winding and will not show continuity until transmission hydraulic pressure is applied.
Disconnect Torque Converter Clutch (TCC) solenoid harness connector. Using DVOM, measure resistance between appropriate TCC solenoid terminals. Solenoid resistance should be greater than 20 ohms.
Torque Converter Lock-Up Signal At Transmission
- Warm engine to operating temperature. Raise vehicle and support drive wheels. Support suspension where necessary to prevent damage to drive axles.
- Disconnect torque converter clutch harness connector at transmission. Connect a test light between appropriate torque converter clutch harness connector terminals. Start engine and place transmission in Drive. Accelerate vehicle to 45 MPH and note test light.
- If test light does not illuminate, check for open or short to ground in solenoid power supply circuit of torque converter clutch harness connector. Also, check for open in ground circuit between torque converter clutch harness connector and PCM/VCM. If circuit is okay, see «TORQUE CONVERTER LOCK-UP SIGNAL FROM PCM/VCM»(/gmc/savana/i-1996-2002/remont/testing-diagnostics/#engine-control-system-component-tests__torque-converter-lock-up-signal-from-pcmvcm) .
Torque Converter Lock-Up Signal From PCM/VCM
- Warm engine to operating temperature. Raise vehicle and support drive wheels. Support suspension where necessary to prevent damage to drive axles.
- Connect a test light to battery voltage. Touch TCC control driver terminal with test light. Accelerate vehicle to 45 MPH and note test light. If test light does not illuminate, problem is a faulty PCM/VCM connector or PCM/VCM.
COMPONENT LOCATIONS 2.2L (VIN 4) "S" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C Refrigerant Pressure Sensor | On A/C Evaporator Tube | |
| Body Control Module (BCM) | Below Right Side Of Instrument Panel, On Heater | |
| Camshaft Position (CMP) Sensor | Right Side Of Engine, Forward Of Coil Packs | |
| Crankshaft Position (CKP) Sensor | Right Side Of Engine, Below Coil Packs | |
| Cruise Control Module | Left Rear Of Engine Compartment, On Cowl | |
| Data Link Connector (DLC) | Lower Left Side Of Instrument Panel | |
| Engine Coolant Temperature (ECT) Sensor | Front Of Engine, In Coolant Piping | |
| EVAP Canister Purge Solenoid | Right Side Of Engine, Above Coil Packs | |
| EVAP Canister Vent Solenoid | Crossmember Area Of Fuel Tank | |
| Fuel Injectors | On Lower Manifold Assembly | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | Top Of Fuel Tank | |
| Idle Air Control (IAC) Valve | Top Of Engine, On Throttle Body | |
| Ignition Control Module | Right Rear Of Engine, Near Grounding Strap | |
| Intake Air Temperature (IAT) Sensor | Left Front Of Engine Compartment, On Air Intake Duct | |
| Knock Sensor | Lower Right Of Engine, Below Coil Packs | |
| Manifold Absolute Pressure (MAP) Sensor | Top Right Side Of Engine, On Intake Manifold | |
| Oxygen Sensor (O2S) | ||
| Pre-Converter | In Left Exhaust Manifold | |
| Post-Converter (Heated) | Rear Of Catalytic Converter | |
| Powertrain Control Module (PCM) | Right Side Of Engine Compartment | |
| Throttle Position (TP) Sensor | Top Of Engine, Forward of Throttle Body | |
| Underhood Fuse/Relay Block | On Top Of Left Inner Wheelwell | |
| Vehicle Speed Sensor | ||
| A/T | Right Rear Of Transmission | |
| M/T | Left Rear Of Transmission | |
COMPONENT LOCATIONS 2.2L (VIN 4) "S" SERIES
COMPONENT LOCATIONS 3.4L (VIN E) "U" SERIES
| Component | Location | |
|---|---|---|
| A/C Refrigerant Pressure Sensor | Left Side Of Engine Compartment, Below Accumulator | |
| Body Control Module (BCM) | Below Right Side Of Instrument Panel, Right Of Glove Box | |
| Camshaft Position (CMP) Sensor | Right Side Of Engine, Above A/C Compressor Clutch | |
| Crankshaft Position (CKP) Sensor | ||
| 7X | Lower Rear Of Engine | |
| 24X | Right Side Of Engine, Behind Harmonic Balancer | |
| Cruise Control Module | In Engine Compartment, Near Left Strut Tower | |
| Data Link Connector (DLC) | Below Steering Column, At Bottom Of Knee Bolster | |
| EGR Valve | Top Left Side Of Engine | |
| Engine Coolant Temperature (ECT) Sensor | Top Left Side Of Engine | |
| Engine Oil Level Indicator Switch | Center Of Engine Oil Pan | |
| Engine Oil Pressure Indicator Switch | Front Of Engine, Above Starter | |
| EVAP Canister Purge Solenoid | Top Rear Of Engine, Below Ignition Control Module | |
| EVAP Canister Vent Solenoid | Below Center Of Vehicle, Forward Of Fuel Tank | |
| Fuel Injectors | In Intake Manifold | |
| Fuel Pump Prime Connector | One-Cavity Connector Branching Out Of Engine Wiring Harness, Near Battery | |
| Fuel Pump Relay | In Underhood Junction Block | |
| Heated Oxygen Sensors (HO2S) | ||
| Pre-Converter | In Exhaust Manifold | |
| Post-Converter | Rear Of Catalytic Converter | |
| Idle Air Control (IAC) Valve | Top Of Engine, Front Of Throttle Body | |
| Ignition Control Module | Top Center Rear Of Engine | |
| Intake Air Temperature (IAT) Sensor | On Air Intake Duct, Near Throttle Body | |
| Knock Sensor | Front Of Engine, Above Starter | |
| Manifold Absolute Pressure (MAP) Sensor | Right Top Of Engine | |
| Mass Airflow (MAF) Sensor | Left Front Of Engine Compartment, In Air Cleaner Duct | |
| Powertrain Control Module (PCM) | In Engine Compartment, Secured In Air Cleaner Assembly | |
| Throttle Position (TP) Sensor | Top Of Engine, On Throttle Assembly | |
| Underhood Junction Block | In Engine Compartment, At Front Of Right Wheelwell, Above Battery | |
| Vehicle Speed Sensor | Lower Right Rear Of Engine Compartment, Mounted To Right Side Of Transaxle | |
COMPONENT LOCATIONS 3.4L (VIN E) "U" SERIES
COMPONENT LOCATIONS 4.3L (VIN W) "G" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Out Switch | In Low Pressure Refrigerant Line | |
| Camshaft Position (CMP) Sensor | Part Of Distributor, Rear Top Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Front Of Engine, Near Crankshaft | |
| Cruise Control Module | Front Of Engine Compartment, Near Left Wheelwell | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| EGR Valve | Top Front Of Engine | |
| Engine Coolant Temperature (ECT) Sensor | Left Side Of Engine | |
| Engine Oil Pressure Gauge Sensor | Top Rear Of Engine | |
| EVAP Canister Purge Solenoid | Right Side Of Engine | |
| EVAP Canister Vent Solenoid | Right Side Of Engine | |
| Fuel Injectors | On Intake Manifold | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | In Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Exhaust Pipe, In Front Of Catalytic Converter | |
| Bank 1, Sensor 3 | In Exhaust Pipe, In Rear Of Catalytic Converter | |
| Bank 2, Sensor 1 | In Exhaust Pipe, In Front Of Catalytic Converter | |
| Idle Air Control (IAC) Valve | Top Left Side Of Engine | |
| Ignition Coil | Top Right Of Engine | |
| Ignition Control Module | Top Right Side Of Engine | |
| Intake Air Temperature (IAT) Sensor | Front Of Engine Compartment, Part Of Air Intake Duct | |
| Knock Sensor | Top Rear Of Engine | |
| Manifold Absolute Pressure (MAP) Sensor | Top Right Side Of Engine | |
| Mass Airflow (MAF) Sensor | Front Top Of Engine, Part Of Air Intake Duct | |
| Throttle Position (TP) Sensor | Left Top Of Engine | |
| Underhood Fuse/Relay Block | Left Rear Of Engine Compartment, On Wheelwell | |
| Vehicle Control Module (VCM) | In Engine Compartment, Near Master Cylinder, At Left Front Wheelwell | |
| Vehicle Speed Sensor | Behind Left Side Of Instrument Panel, Near Steering Column | |
COMPONENT LOCATIONS 4.3L (VIN W) "G" SERIES
COMPONENT LOCATIONS 4.3L (VIN W) "L" & "M" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Out Switch | On Top Of A/C Receiver Dryer | |
| Camshaft Position (CMP) Sensor | Side of Distributor | |
| Crankshaft Position (CKP) Sensor | Behind & To Right Of Crankshaft Pulley | |
| Cruise Control Module | Center Of Dash, Left Of Windshield Wiper Module | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| Distributor | To Rear Of Engine | |
| EGR Valve Solenoid | Top Of Engine, Left Of Generator | |
| Engine Coolant Temperature (ECT) Sensor | Side Of Linear EGR Valve Solenoid | |
| EVAP Canister Purge Solenoid | Top Of Engine, Near MAP Sensor | |
| EVAP Canister Vent Solenoid | At Undercarriage, Left Of EVAP Canister | |
| Fuel Injectors | On Intake Manifold, Under Manifold Cover | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | Left Front Exhaust Pipe | |
| Bank 1, Sensor 3 | Rear Of Catalytic Converter | |
| Bank 2, Sensor 1 | Right Front Exhaust Pipe | |
| Heater & A/C Control Module | Center Of Instrument Panel, At Heater Control | |
| Idle Air Control (IAC) Valve | Left Rear Of Throttle Body | |
| Ignition Coil | Top Of Engine, Behind Generator | |
| Ignition Control Module | Top Of Engine, In Front Of Coil | |
| Intake Air Temperature (IAT) Sensor | Top Of Air Intake Duct | |
| Knock Sensor | Left Rear Of Distributor, On Engine Block | |
| Manifold Absolute Pressure (MAP) Sensor | Top Of Engine, Near Ignition Coil | |
| Mass Airflow (MAF) Sensor | Front Of Air Intake Duct | |
| Oil Pressure Switch | Rear Of Engine, Left Of Distributor | |
| Throttle Position (TP) Sensor | On Left Side Of Throttle Body | |
| Underhood Fuse/Relay Block | Left Side Front Of Dash, Near Battery | |
| Vehicle Control Module (VCM) | At Left Side Of Engine Compartment, Near Battery | |
| Vehicle Speed Sensor | Rear Of Transmission | |
COMPONENT LOCATIONS 4.3L (VIN W) "L" & "M" SERIES
COMPONENT LOCATIONS 4.3L (VIN W) & 5.7L (VIN R) "P" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Compressor Refrigerant Pressure Switch | Located By Body Builder | |
| A/C Compressor Relay | In Engine Compartment, On Bulkhead, Under Battery Junction Block | |
| Camshaft Position (CMP) Sensor | In Distributor | |
| Crankshaft Position (CKP) Sensor | At Lower Right Front Of Engine, Near Harmonic Balancer | |
| Data Link Connector (DLC) | Lower Left Side Of Instrument Panel | |
| Distributor | At Top Rear Of Engine | |
| EGR Valve | At Top Front Left Of Intake Manifold | |
| Engine Coolant Temperature (ECT) Sensor | At Top Front Of Engine, Near Thermostat Housing | |
| EVAP Canister Purge Solenoid | At Right Center Of Intake Manifold | |
| EVAP Canister Vent Solenoid (CA Only) | Along Right Frame Rail, In Front Of Fuel Tank, Near EVAP Canister | |
| Fuel Control Relay | On Top Of Steering Column Support, Behind Steering Column | |
| Fuel Pump Module | At Top Center Of Fuel Tank | |
| Fuel Pump Prime Connector | Taped To Fuel Pump Relay Breakout | |
| Fuel Pump Relay | In Engine Compartment, On Bulkhead, Under Battery Junction Block | |
| Fuel Tank Pressure Sensor (4.3L CA Only) | At Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Left Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 1, Sensor 3 | In Left Exhaust Pipe, Behind Catalytic Converter | |
| Bank 2, Sensor 1 | In Right Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 2, Sensor 2 (5.7L) | In Right Exhaust Pipe, Behind Catalytic Converter | |
| Idle Air Control (IAC) Valve | At Left Center Of Intake Manifold | |
| Ignition Coil | Mounted On Bracket, Above Top Edge Of Right Cylinder Head | |
| Ignition Control Module | Mounted On Bracket, Above Top Edge Of Right Cylinder Head | |
| Intake Air Temperature (IAT) Sensor | At Right Front Side, In Engine Air Induction System Elbow, Near Remote Air Cleaner | |
| Knock Sensor | ||
| 4.3L | At Rear Of Engine, Top Center | |
| 5.7L | At Lower Right Side Of Engine Block, In Front Of Starter | |
| Manifold Absolute Pressure (MAP) Sensor | Near Center Of Intake Manifold, Behind Air Intake | |
| Mass Airflow (MAF) Sensor | At Right Front Side, In Engine Air Induction System Elbow, Near Remote Air Cleaner | |
| Throttle Position (TP) Sensor | At Left Center Of Intake Manifold, Near IAC Valve | |
| Vehicle Control Module (VCM) | At Left Side Of Radiator Support | |
| Vehicle Speed Sensor (5.7L M/T) | At Left Side Of Transmission, Near Middle | |
COMPONENT LOCATIONS 4.3L (VIN W) & 5.7L (VIN R) "P" SERIES
COMPONENT LOCATIONS 4.3L (VIN W & X) "S" & "T" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C Compressor High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Compressor Cycling Switch | On Accumulator | |
| Body Control Module (BCM) | Lower Rear Of Instrument Panel, On Heater | |
| Camshaft Position (CMP) Sensor | Rear Of Distributor | |
| Crankshaft Position (CKP) Sensor | Below Right Front Of Engine, Near Harmonic Balancer | |
| Cruise Control Module | Left Rear Of Engine Compartment, On Cowl | |
| Data Link Connector (DLC) | Lower Left Side Of Instrument Panel | |
| EGR Valve | Top Front Of Engine, Near Drive Belt | |
| Engine Coolant Temperature (ECT) Sensor | Left Side Of Engine, At Spark Plugs | |
| EVAP Canister Purge Solenoid | Top Right Center Of Engine, Near Fuel Injector Connector | |
| EVAP Canister Vent Solenoid | On Crossmember, Behind Fuel Tank | |
| Fuel Injector | Top Center Of Engine | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | Top Of Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | Left Rear Of Exhaust Pipe, Left Of Transmission | |
| Bank 1, Sensor 3 | Rear Of Catalytic Converter | |
| Bank 2, Sensor 1 | Right Rear Of Engine, In Exhaust Pipe | |
| Idle Air Control (IAC) Valve | Top Of Engine, On Throttle Body | |
| Ignition Coil | Top Right Of Engine | |
| Ignition Control Module | Top Right Side Of Engine | |
| Intake Air Temperature (IAT) Sensor | Left Front Of Engine Compartment, In Air Intake Duct | |
| Knock Sensor | Top Rear Of Engine, Above Transmission Bellhousing | |
| Manifold Absolute Pressure (MAP) Sensor | Top Center Of Engine | |
| Mass Airflow (MAF) Sensor | Left Front Of Engine Compartment, In Air Intake Duct | |
| Relay Block | Behind Left Side Of Instrument Panel, Right Of Fuse Block | |
| Throttle Position (TP) Sensor | Top Left Side Of Engine, On Throttle Body | |
| Underhood Fuse/Relay Block | In Left Side Of Engine Compartment, On Wheelwell | |
| Vehicle Control Module (VCM) | Right Side Of Engine Compartment | |
| Vehicle Speed Sensor | ||
| A/T With 2WD | Right Rear Of Transmission | |
| A/T With 4WD | Right Rear Of Transfer Case | |
| M/T With 2WD | Left Rear Of Transmission | |
COMPONENT LOCATIONS 4.3L (VIN W & X) "S" & "T" SERIES
COMPONENT LOCATIONS 4.8L (VIN V), 5.3L (VIN T) & 6.0L (VIN U) SIERRA & SILVERADO
| Component | Location | |
|---|---|---|
| A/C High Pressure Cut-Out Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Off Switch | On Right Side Of A/C Compressor | |
| Body Control Module (BCM) | On Lower Left Side Of Instrument Panel, Below Steering Column | |
| Camshaft Position (CMP) Sensor | Top Rear Center Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Right Rear Of Engine Block | |
| Cruise Control Module | Left Front Of Dash, In Engine Compartment | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| EGR Valve | Top Right Front Of Engine | |
| Engine Coolant Level Switch | In Coolant Reservoir | |
| Engine Coolant Temperature (ECT) Sensor | Near Engine Block, Below Exhaust Manifold | |
| Engine Oil Level Switch | In Right Side Of Oil Pan | |
| EVAP Canister Purge Solenoid | On Top Right Rear Of Engine | |
| EVAP Canister Vent Solenoid | At Front Right Side Of Fuel Tank | |
| EVAP Canister Purge Vacuum Switch | Right Rear Top Of Engine, Right Of Purge Solenoid | |
| Fuel Injectors | On Intake Manifold | |
| Fuel Pump Level Sensor | In Fuel Tank | |
| Fuel Tank Pressure Sensor | In Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Left Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 1, Sensor 2 | In Left Exhaust Pipe, After Catalytic Converter | |
| Bank 2, Sensor 1 | In Right Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 2, Sensor 2 | In Right Exhaust Pipe, After Catalytic Converter | |
| Heater & A/C Control Module | Center Of Instrument Panel, At Heater Control | |
| Idle Air Control (IAC) Valve | In Throttle Body Housing | |
| Ignition Coil | On Rocker Cover | |
| Intake Air Temperature (IAT) Sensor | Part Of MAF Sensor, On Air Induction Tube | |
| Knock Sensor | In Valley, Under Intake Manifold, Near Front Of Engine | |
| Manifold Absolute Pressure (MAP) Sensor | Top Rear Of Engine, On Intake Manifold | |
| Mass Airflow (MAF) Sensor | In Air Induction Tube, Near Air Cleaner Assembly | |
| Powertrain Control Module (PCM) | Near Left Front Inside Of Engine Compartment | |
| Secondary Air Injection Reaction Relay | In Underhood Bussed Electical Center | |
| Secondary Air Injection Reaction Solenoid | At Right Rear Of Engine Compartment | |
| Throttle Position (TP) Sensor | On Throttle Body | |
| Underhood Bussed Electical Center | At Left Side Of Engine Compartment, Near Battery | |
| Vehicle Speed Sensor Adapter (4WD) | On Left Side Of Transmission | |
| Vehicle Speed Sensor | In Extension Housing, On Left Side Of Transmission | |
COMPONENT LOCATIONS 4.8L (VIN V), 5.3L (VIN T) & 6.0L (VIN U) SIERRA & SILVERADO
COMPONENT LOCATIONS 5.0L (VIN M), 5.7L (VIN R) & 7.4L (VIN J) "C" & "K" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C Compressor Cycling Switch | On Top Of Accumulator, Right Rear Of Engine Compartment | |
| A/C High Pressure Cut-Out Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Off Switch | On Top Of A/C Compressor, In High Pressure Line | |
| Air Injection Reaction Relay | In Underhood Fuse/Relay Block | |
| Auxiliary Cooling Fan Relay | Left Rear Side Of Engine Compartment | |
| Camshaft Position (CMP) Sensor | Top Rear Center Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Right Front Of Engine Block, Near Crankshaft | |
| Cruise Control Module | Left Rear Side Of Engine Compartment, On Bulkhead | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| Distributor | Located Center Rear Of Engine | |
| EGR Valve | Top Of Engine | |
| Engine Coolant Temperature (ECT) Sensor | Top Right Front Of Engine, Near Thermostat Housing | |
| EVAP Canister Purge Solenoid | At Top Right Of Engine | |
| EVAP Canister Vent Solenoid | Near Master Cylinder, At Left Front Wheelwell | |
| EVAP Canister Purge Vacuum Switch | Right Rear Top Of Engine, Right Of Purge Solenoid | |
| Fuel Injectors | On Intake Manifold | |
| Fuel Pump Prime Connector | At Instrument Panel Harness, Near Instrument Panel Fuse Block | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | In Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Left Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 1, Sensor 2 | In Right Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 2, Sensor 1 (5.0L) | In Left Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 2, Sensor 1 (5.7L & 7.4L) | In Left Exhaust Pipe, After Catalytic Converter | |
| Bank 2, Sensor 2 | In Right Exhaust Pipe, After Catalytic Converter | |
| Heater & A/C Control Module | Center Of Instrument Panel, At Heater Control | |
| Idle Air Control (IAC) Valve | Rear Of Throttle Body | |
| Ignition Coil | Right Rear Of Engine | |
| Ignition Control Module | Right Rear Of Engine | |
| Intake Air Temperature (IAT) Sensor | On Air Intake Duct | |
| Knock Sensor | ||
| 5.0L & 5.7L | Right Front Of Engine Block, Below Exhaust Manifold, Forward Of Starter | |
| 7.4L | Left Rear Of Engine Mount, On Engine | |
| Manifold Absolute Pressure (MAP) Sensor | Top Center Of Intake Manifold, Near Fuel Injectors | |
| Mass Airflow (MAF) Sensor | On Air Intake Duct, Near Air Filter | |
| Throttle Position (TP) Sensor | On Side Of Throttle Body | |
| Transfer Case Relay | Right Rear Of Engine Compartment, Near Center Of Bulkhead | |
| Underhood Fuse/Relay Block | Left Rear Of Engine Compartment, On Wheelwell | |
| Vehicle Control Module (VCM) | In Engine Compartment, Near Master Cylinder, At Left Front Wheelwell | |
| Vehicle Speed Sensor | ||
| RWD | Left Rear Side Of Transmission | |
| Selectable 4WD | Left Rear Side Of Transfer Case | |
COMPONENT LOCATIONS 5.0L (VIN M), 5.7L (VIN R) & 7.4L (VIN J) "C" & "K" SERIES
COMPONENT LOCATIONS 5.0L (VIN M) & 5.7L (VIN R) "G" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Off Switch | In Low Pressure Refrigerant Line | |
| Camshaft Position (CMP) Sensor | Part Of Distributor, Rear Top Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Front Engine, Near Crankshaft | |
| Cruise Control Module | Front Of Engine Compartment, Near Left Fender | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| EGR Valve | Top Front Of Engine | |
| Engine Coolant Temperature (ECT) Sensor | Top Front Of Engine | |
| Engine Oil Pressure Gauge Sensor | Top Rear Of Engine | |
| EVAP Canister Purge Solenoid | Right Side Of Engine | |
| EVAP Canister Vent Solenoid | Right Side Of Engine | |
| Fuel Injectors | On Top Of Intake Manifold | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | In Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Exhaust Pipe, At Front Catalytic Converter | |
| Bank 1, Sensor 3 | In Exhaust Pipe, At Rear Catalytic Converter | |
| Bank 2, Sensor 1 | N Exhaust Pipe, At Front Catalytic Converter | |
| Bank 2, Sensor 2 | N Exhaust Pipe, At Rear Catalytic Converter | |
| Idle Air Control (IAC) Valve | Top Left Side Of Engine | |
| Ignition Coil | Top Right Of Engine | |
| Ignition Control Module | Top Right Side Of Engine | |
| Intake Air Temperature (IAT) Sensor | Part Of Air Intake Duct, Front Of Engine Compartment | |
| Knock Sensor | Top Rear Of Engine | |
| Manifold Absolute Pressure (MAP) Sensor | Top Right Side Of Engine | |
| Mass Airflow (MAF) Sensor | Part OF Air Intake Duct, Front Top Of Engine | |
| Throttle Position (TP) Sensor | Left Top Of Engine | |
| Underhood Fuse/Relay Block | In Engine Compartment, On Left Fender | |
| Vehicle Control Module (VCM) | In Engine Compartment, On Left Fender | |
| Vehicle Speed Sensor | Left Side Of Transmission | |
COMPONENT LOCATIONS 5.0L (VIN M) & 5.7L (VIN R) "G" SERIES
COMPONENT LOCATIONS 6.5L (VIN F) "C" & "K" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C Compressor Cycling Switch | On Top Right Of A/C Accumulator, Right Side Of Engine Compartment, On Bulkhead | |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Off Switch | Top Of Compressor, In High Pressure Refrigerant Line | |
| Camshaft Position (CMP) Sensor | Top Rear Center Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Right Front Of Engine Block, Near Crankshaft Pulley | |
| Cruise Control Module | Left Rear Of Engine Compartment, On Bulkhead | |
| Data Link Connector (DLC) | Below Steering Column, At Bottom Of Knee Bolster | |
| EGR Control Pressure/Baro Sensor | Top Of Engine Assembly | |
| Engine Coolant Temperature (ECT) Sensor | Lower Left Front Of Engine Block | |
| Glow Plug Controller | Left Rear Of Engine, Near Bulkhead | |
| Glow Plug Relay | Left Rear Of Engine, Near Bulkhead | |
| Heater & A/C Control Module | Center Of Instrument Panel, At Heater Control | |
| Intake Air Temperature (IAT) Sensor | Left Front Of Engine, Near Intake Manifold Opening | |
| Mass Airflow (MAF) Sensor | At Air Intake Duct, Near Air Filter, Right Of Engine | |
| Powertrain Control Module (PCM) | Under Right Side Of Instrument Panel, Above Blower Motor | |
| Transfer Case Relay | In Underhood Fuse/Relay Block | |
| Underhood Fuse/Relay Block | Left Rear Of Engine Compartment, On Wheelwell | |
| Vehicle Speed Sensor | ||
| RWD | Left Rear Side Of Transmission | |
| Selectable 4WD | Left Rear Side Of Transfer Case | |
| Wastegate Solenoid | Left Rear Top Of Engine, Above Valve Cover | |
| Water-In-Fuel Sensor | Rear Top Of Engine | |
COMPONENT LOCATIONS 6.5L (VIN F) "C" & "K" SERIES
COMPONENT LOCATIONS 6.5L (VIN F) "G" SERIES
| Component | Location |
|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor |
| A/C Low Pressure Cut-Off Switch | In Low Pressure Refrigerant Line |
| Accelerator Pedal Position Module | Attached To Accelerator Pedal |
| Boost Pressure Sensor | Top Of Engine |
| Crankshaft Position (CKP) Sensor | Lower Left Front Of Engine, Near Crankshaft Pulley |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel |
| Engine Coolant Temperature (ECT) Sensor | Top Rear Of Engine |
| Engine Oil Pressure Gauge Sensor | Top Front Of Engine |
| Engine Shutoff Solenoid | Top Right Side Of Engine |
| Exhaust Pressure Regulator Solenoid | Top Right Of Engine |
| Fuel Pump Relay | In Underhood Fuse/Relay Block |
| Fuel Solenoid | Part Of Fuel Solenoid Driver |
| Fuel Solenoid Driver | Top Right Side Of Engine |
| Glow Plug Relay | Top Right Side Of Engine |
| Ignition Timing Stepper Motor | Top Front Of Engine |
| Intake Air Temperature (IAT) Sensor | Top Right Side Of Engine |
| Optical Fuel Temperature Sensor | Top Of Engine |
| Powertrain Control Module (PCM) | Behind Center Of Instrument Panel |
| Underhood Fuse/Relay Block | In Engine Compartment, On Left Fender |
| Vehicle Speed Sensor | Left Side Of Transmission |
| Vehicle Speed Sensor Buffer | Below Left Side Of Instrument Panel, Near Steering Column |
| Wastegate Solenoid | Right Top Of Engine |
| Water-In-Fuel Sensor | Left Frame Rail, Near Center Of Vehicle |
COMPONENT LOCATIONS 6.5L (VIN F) "G" SERIES
COMPONENT LOCATIONS 6.5L (VIN F) "P" SERIES
| Component | Location |
|---|---|
| A/C Compressor Refrigerant Pressure Switch | Located By Body Builder |
| A/C Compressor Relay | On Right Side Of Driver's Island |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor |
| Accelerator Pedal Position Module | Attached To Accelerator Pedal |
| Battery Junction Block | On Forward Left Side Of Bulkhead |
| Boost Pressure Sensor | On Right Top Of Air Intake |
| Crankshaft Position (CKP) Sensor | Lower Right Front Of Engine, Near Harmonic Balancer |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel |
| Engine Coolant Temperature (ECT) Sensor | Upper Right Front Of Engine, On Right Side Of Coolant Outlet Tube |
| Engine Shutoff Solenoid | At Fuel Injection Pump, Near Front Of Intake Manifold |
| Fuel Pump Prime Connector | At Engine Harness Breakout, Above Battery Junction Block |
| Fuel Pump Relay | On Right Side Of Driver's Island |
| Fuel Solenoid | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Fuel Solenoid Driver | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Glow Plug Controller | At Rear Of Left Cylinder Head |
| Ignition Timing Stepper Motor | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Intake Air Temperature (IAT) Sensor | On Right Top Of Air Intake, Near Boost Pressure Sensor |
| Optical Fuel Temperature Sensor | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Powertrain Control Module (PCM) | On Left Side Of Driver's Island |
| Wastegate Solenoid | Above Rear Of Left Cylinder Head, Near Glow Plug Controller |
| Water-In-Fuel Sensor | Part Of Fuel/Water Separator (Filter), At Rear Of Intake Manifold |
COMPONENT LOCATIONS 6.5L (VIN F) "P" SERIES
COMPONENT LOCATIONS 6.5L (VIN Y EFI) "P" SERIES
| Component | Location |
|---|---|
| A/C Compressor Refrigerant Pressure Switch | Located By Body Builder |
| A/C Compressor Relay | In Engine Compartment, On Bulkhead, Under Battery Junction Block |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor |
| Accelerator Pedal Position Module | Attached To Accelerator Pedal |
| Battery Junction Block | On Forward Left Side Of Bulkhead |
| Crankshaft Position (CKP) Sensor | Lower Right Front Of Engine, Near Harmonic Balancer |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel, On Relay Bracket |
| Engine Coolant Temperature (ECT) Sensor | Upper Right Front Of Engine, On Right Side Of Coolant Outlet Tube |
| Engine Shutoff Solenoid | At Fuel Injection Pump, Near Front Of Intake Manifold |
| Fuel Pump Prime Connector | At Fuel Pump Relay Breakout, Under Battery Junction Block |
| Fuel Pump Relay | In Engine Compartment, On Bulkhead, Under Battery Junction Block |
| Fuel Solenoid | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Fuel Solenoid Driver | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Glow Plug Controller | At Rear Of Left Cylinder Head |
| Ignition Timing Stepper Motor | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Intake Air Temperature (IAT) Sensor | At Front Right Side, In Engine Air Induction System Elbow, Behind Remote Air Cleaner |
| Manifold Absolute Pressure (MAP) Sensor | Near Center Of Intake Manifold, Behind Air Intake |
| Optical Fuel Temperature Sensor | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Powertrain Control Module (PCM) | On Left Side Of Driver's Island, On Relay Bracket |
| Vehicle Speed Sensor (M/T) | On Left Side Of Transmission, Near Middle |
| Vehicle Speed Sensor Calibrator | On Left Side Of Driver's Island, Under Relay Bracket |
| Water-In-Fuel Sensor | Part Of Fuel/Water Separator (Filter), At Rear Of Intake Manifold |
COMPONENT LOCATIONS 6.5L (VIN Y EFI) "P" SERIES
COMPONENT LOCATIONS 6.5L (VIN Y MFI) "P" SERIES
| Component | Location |
|---|---|
| Barometric Pressure Sensor | On Top Of Intake Manifold, At Left Rear Side, Near Glow Plug Controller |
| Battery Junction Block | On Forward Left Side Of Bulkhead |
| Cold Advance Solenoid/Engine Coolant Temprature Switch | At Rear Lower Of Right Cylinder Head, Near Exhaust Manifold |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel, On Relay Bracket |
| Engine Speed Sensor | At Rear Of Intake Manifold, Near Fuel/Water Separator (Filter) |
| Fuel Injection Pump Cold Advance Solenoid | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Fuel Injection Pump Shutoff Solenoid | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Fuel Pump Prime Connector | At Fuel Pump Relay Breakout, Under Battery Junction Block |
| Fuel Pump Relay | In Engine Compartment, On Bulkhead, Under Battery Junction Block |
| Glow Plug Controller | At Rear Of Left Cylinder Head |
| Glow Plug Relay | Left Interior Bulkhead, On Relay Bracket |
| Idle Speed Control Actuator Solenoid | At Fuel Injection Pump, Near Top Front Of Intake Manifold |
| Throttle Position (TP) Sensor | At Right Front Of Intake Manifold |
| Vehicle Speed Sensor (M/T) | On Left Side Of Transmission, Near Middle |
| Vehicle Speed Sensor Calibrator | On Left Side Of Driver's Island, Under Relay Bracket |
| Water-In-Fuel Sensor | Part Of Fuel/Water Separator (Filter), At Rear Of Intake Manifold |
COMPONENT LOCATIONS 6.5L (VIN Y MFI) "P" SERIES
COMPONENT LOCATIONS 7.4L (VIN J) "G" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor Clutch Relay | In Underhood Fuse/Relay Block | |
| A/C High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Low Pressure Cut-Off Switch | In Low Pressure Refrigerant Line | |
| Camshaft Position (CMP) Sensor | Part Of Distributor, Rear Top Of Engine | |
| Crankshaft Position (CKP) Sensor | Lower Front Of Engine, Near Crankshaft | |
| Cruise Control Module | Front Of Engine Compartment, Near Left Fender | |
| Data Link Connector (DLC) | Under Left Side Of Instrument Panel | |
| EGR Valve | Right Side Of Engine | |
| Engine Coolant Temperature (ECT) Sensor | Top Front Of Engine | |
| Engine Oil Pressure Gauge Sensor | Top Rear Of Engine | |
| EVAP Canister Purge Solenoid | Right Side Of Engine | |
| EVAP Canister Vent Solenoid | Right Side Of Engine | |
| Fuel Pump Relay | In Underhood Fuse/Relay Block | |
| Fuel Tank Pressure Sensor | In Fuel Tank | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Exhaust Pipe, In Front Of Catalytic Converter | |
| Bank 1, Sensor 3 | In Exhaust Pipe, In Back Of Catalytic Converter | |
| Bank 2, Sensor 1 | In Exhaust Pipe, In Front Of Catalytic Converter | |
| Bank 2, Sensor 2 | In Exhaust Pipe, In Back Of Catalytic Converter | |
| Idle Air Control (IAC) Valve | Top Left Side Of Engine | |
| Ignition Coil | Top Right Of Engine | |
| Ignition Control Module | Top Right Side Of Engine | |
| Intake Air Temperature (IAT) Sensor | Part Of Air Intake Duct, Front Top Of Engine | |
| Knock Sensor | Left Side Of Engine & Right Side Of Engine | |
| Manifold Absolute Pressure (MAP) Sensor | Top Right Side Of Engine | |
| Mass Airflow (MAF) Sensor | Part Of Air Intake Duct | |
| Secondary Air Injection Reaction Pump Relay | In Underhood Fuse/Relay Block | |
| Throttle Position (TP) Sensor | Right Top Of Engine | |
| Underhood Fuse/Relay Block | In Engine Compartment, On Left Fender | |
| Vehicle Control Module (VCM) | In Engine Compartment, On Left Fender | |
| Vehicle Speed Sensor | Left Side Of Transmission | |
COMPONENT LOCATIONS 7.4L (VIN J) "G" SERIES
COMPONENT LOCATIONS 7.4L (VIN J) "P" SERIES
| Component | Location | |
|---|---|---|
| A/C Compressor High Pressure Cut-Off Switch | On Rear Of A/C Compressor | |
| A/C Compressor Refrigerant Pressure Switch | Located By Body Builder | |
| A/C Compressor Relay | On Right Side Of Driver's Island | |
| Battery Junction Block | On Forward Left Side Of Bulkhead | |
| Camshaft Position (CMP) Sensor | In Distributor | |
| Crankshaft Position (CKP) Sensor | At Lower Right Front Of Engine, Near Harmonic Balancer | |
| Cruise Control Module | On Radiator Support Bracket, Left & Behind VCM | |
| Data Link Connector (DLC) | Lower Left Side Of Instrument Panel | |
| Distributor | At Top Rear Of Engine | |
| EGR Valve | At Top Front Left Of Intake Manifold | |
| Engine Coolant Temperature (ECT) Sensor | At Top Front Of Engine, Near Thermostat Housing | |
| EVAP Canister Purge Solenoid | At Left Center Of Intake Manifold | |
| Fuel Control Relay | On Top Of Steering Column Support, Behind Steering Column | |
| Fuel Pump Module | At Top Center Of Fuel Tank | |
| Fuel Pump Prime Connector | In Engine Compartment, On Bulkhead, Under Battery Junction Block | |
| Fuel Pump Relay | On Right Side Of Driver's Island | |
| Heated Oxygen Sensors (HO2S) | ||
| Bank 1, Sensor 1 | In Left Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 1, Sensor 3 | In Left Exhaust Pipe, Behind Catalytic Converter | |
| Bank 2, Sensor 1 | In Right Exhaust Pipe, Forward Of Catalytic Converter | |
| Bank 2, Sensor 2 | In Right Exhaust Pipe, Behind Catalytic Converter | |
| Idle Air Control (IAC) Valve | At Right Center Of Intake Manifold | |
| Ignition Coil | At Top Rear Of Intake Manifold, Near Distributor | |
| Ignition Control Module | On Bracket, At Top Rear Of Intake Manifold, Near Ignition Coil | |
| Intake Air Temperature (IAT) Sensor | At Front Right Side, In Engine Air Induction System Elbow, Behind Remote Air Cleaner | |
| Knock Sensor | On Sides Of Engine Block, Below Exhaust Manifolds | |
| Manifold Absolute Pressure (MAP) Sensor | At Front Of Intake Manifold, Behind Thermostat | |
| Mass Airflow (MAF) Sensor | At Front Right Side, In Engine Air Induction System Elbow, Behind Remote Air Cleaner | |
| Throttle Position (TP) Sensor | At Right Center Of Intake Manifold, Near IAC Valve | |
| Vehicle Control Module (VCM) | Mounted On Top Of Radiator Support | |
COMPONENT LOCATIONS 7.4L (VIN J) "P" SERIES
See also:
• MODEL IDENTIFICATION
• DIAGNOSTIC AIDS
• FUEL EVAPORATION
• IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS
• TRANSMISSION
• INJECTOR COIL TEST (EXCEPT 2.2L & 3.4L)
• INJECTOR BALANCE TEST (EXCEPT 2.2L & 3.4L)
• INJECTOR COIL TEST - ECT NOT BETWEEN 50-95°F (2.2L)
• INJECTOR BALANCE TEST (2.2L & 3.4L)
• INJECTOR COIL TEST - ECT BETWEEN 50-95°F (2.2L)
• NORMAL GLOW PLUG CIRCUIT OPERATION
• WATER-IN-FUEL LIGHT DIAGNOSIS
• PCM OUTPUT DIAGNOSIS (2.2L)
• TORQUE CONVERTER LOCK-UP SIGNAL FROM PCM/VCM